D375a 3

SEBM008402
D375A-3
MACHINE MODEL SERIAL NUMBER
D375A-3 17001 and up
This shop manual may contain attachments and optional equipment that are not available in your
area. Please consult your local Komatsu distributor for those items you may require.
Materials and specifications are subject to change without notice.
D375A-3 mounts the SA6D170-2 engine.

For details of the engine, see the 6D170-2 Series Engine Shop Manual.
@ 1996KOMAlbU
All Rights Reserved
02-96(03)03601 oo-1
0
CONTENTS
No. of page
01 GENERAL . . . ..~........................................................................ 01-l
-.
i0 AND FUNCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IO-I
20 nSTING AND ADJUSTING . . . . . . . . . . . . . . . . . . . . . ..m........................ 20-I
30 DISASSEMBLY AND ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-I
40 MAINTENANCE STANDARD . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..m................ 40-I
2
z
90 OTHERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-l 0'
00-2
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The affected pages are indicated by the use of the
following marks. Itis requested that necessan/ actions
Mark Indication Action required
must be taken to these pages according to the list
0 Page to be newly added Add
0 Page to be replaced Replace
( 1 Page to be deleted Discard
Pages having no marks are not revised atthistime.
LIST OF REVISED PAGES
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0 30-170 0 30-227 @ 0 30-284 40- 13 90-13
0 30-171 0 30-228 @ 0 30-285 40- 14 90-15
0 30-172 0 30-229 @ 0 30-286 90-17
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SAFETY SAFETY NOTICE
SAFETY
SAFETY NOTICE
I
IMPORTANT SAFETY NOTICE
Proper service and repair is extremely important for safe machine operation. The
service and repair techniques recommended by Komatsu and described in this manual
are both effective and safe. Some of these techniques require the use of tools specially
designed by Komatsu for the specific purpose.
To prevent injury to workers, the symbol a. IS used to mark safety precautions in this
manual. The cautions accompanying these symbols should always be followed care-
fully. If any dangerous situation arises or may possibly arise, first consider safety, and
take the necessary actions to deal with the situation.
GENERAL PRECAUTIONS 6. Decide a place in the repair workshop to

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

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

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

wash parts. In particular, use only the mini-
mum of gasoline when washing electrical
parts.
00-4
FOREWORD GENERAL
FOREWORD
GENERAL
This shop manual has been prepared as an aid to improve the quality of repairs by giving the
serviceman an accurate understanding of the product and by showing him the correct way to perform
repairs and make judgements. Make sure you understand the contents of this manual and use it to full
effect at every opportunity.
This shop manual mainly contains the necessary technical information for operations performed in a
service workshop. For ease of understanding, the manual is divided into the following chapters; these
chapters are further divided into the each main group of components.
STRUCTURE AND FUNCTION

This section explains the structure and function of each component. It serves not only to give
an understanding of the structure, but also serves as reference material for troubleshooting.
TESTING AND ADJUSTING

This section explains checks to be made before and after performing repairs, as well as
adjustments to be made at completion of the checks and repairs.
Troubleshooting charts correlating “Problems” to “Causes” are also included in this section.
DISASSEMBLY AND ASSEMBLY

This section explains the order to be followed when removing, installing, disassembling or
assembling each component, as well as precautions to be taken for these operations.
MAINTENANCE STANDARD
This section gives the judgement standards when inspecting disassembled parts.
NOTICE
The specifications contained in this shop manual are subject to change at any
time and without any advance notice. Use the specifications given in the book
with the latest date.
00-5
FOREWORD HOW TO READ THE SHOP MANUAL
HOW TO READ THE SHOP MANUAL
VOLUMES REVISED EDITION MARK
Shop manuals are issued as a guide to carrying When a manual is revised, an edition mark
out repairs; They are divided as follows: (@@@....I is recorded on the bottom of the
Chassis volume: Issued for every machine model pages.
Engine volume: Issued for each engine series
Electrical volume: Each issued as one

Attachments volume: volume to cover all REVISIONS
I models
Revised pages are shown in the LIST OF RE-
These various volumes are designed to avoid VISED PAGES next to the CONTENTS page.
duplicating the same information. Therefore, to
deal with all repairs for any model , it is neces-
sary that chassis, engine, electrical and attach-
SYMBOLS
ment volumes be available.
So that the shop manual can be of ample prac-
DISTRIBUTION AND UPDATING tical use, important safety and quality portions
are marked with the following symbols.
Any additions, amendments or other changes
will be sent to KOMATSU distributors. Get the
most up-to-date information before you start any
work.
FILING METHOD
See the page number on the bottom of the Symbol item Remarks
page. File the pages in correct order.
Special safety precautions are
Following examples show how to read the
Safety necessary when performing
page number. A the work.
Example 1 (Chassis volume):
Special technical precautions
10 -3 or other precautions for pre-
Caution serving standards are neces-
*
Item number (IO. Structure sary when performing the
and Function) work.
Yz Consecutive page number for
Weight of parts of systems.
each item. Caution necessary when se-
Weight letting hoisting wire, or when
Example 2 (Engine volume): working posture is important,
etc.
12 - 5
Places that require special at-
Tightening
Unit number (1. Engine) tention for the tightening
torque torque during assembly.
Item number (2. Testing and
Adjusting)
‘L__ Consecutive page number for
each item.
Oil, water must be added, and the ca-

Additional pages: Additional pages are indi- pacity.
cated by a hyphen (-1 and number after the

Places where oil or water
page number. File as in the example. Drain must be drained, and quan-
Example: tity to be drained.
IO-4 12-203
IO-5 12-204
00-6
FOREWORD HOISTING INSTRUCTIONS
HOISTING INSTRUCTIONS
HOISTING
Slinging near the edge of the hook may
Heavy parts (25 kg or more) must be cause the rope to slip off the hook during
lifted with a hoist, etc. In the DISAS- hoisting, and a serious accident can re-
sult. Hooks have maximum strength at
every part weighing 25 kg or more is the middle portion.
indicated clearly with the symbol &
. If a part cannot be smoothly removed from

the machine by hoisting, the following checks
should be made:
I) Check for removal of all bolts fastening 100% 88% 79% 71% 41%
the part to the relative parts. SAD00479
2) Check for existence of another part caus- 3) Do not sling a heavy load with one rope
ing interference with the part to be re- alone, but sling with two or more ropes
moved. symmetrically wound onto the load.
Slinging with one rope may cause
turning of the load during hoisting,
untwisting of the rope, or slipping of
WIRE ROPES
the rope from its original winding
I) Use adequate ropes depending on the
position on the load, which can re-
weight of parts to be hoisted, referring to
sult in a dangerous accident.
the table below:
4) Do not sling a heavy load with ropes form-
Wire ropes
ing a wide hanging angle from the hook.
(Standard “Z” or “S” twist ropes
When hoisting a load with two or more
without galvanizing)
ropes, the force subjected to each rope
Rope diameter
mm
r Allowable
KN
load
tons
will increase with the hanging angles. The
table below shows the variation of allow-
able load KN (kg) when hoisting is made
10 9.8 1.0 with two ropes, each of which is allowed
11.2 13.7 1.4 to sling up to 9.8 KN (1000 kg) vertically,
at various hanging angles.
12.5 15.7 1.6
When two ropes sling a load vertically, up
14 21.6 2.2
to 19.6 KN (2000 kg) of total weight can
16 27.5 2.8 be suspended. This weight becomes 9.8
18 35.3 3.6 KN (1000 kg) when two ropes make a 120”
20 43.1 4.4 hanging angle. On the other hand, two

ropes are subjected to an excessive force
22.4 54.9 5.6
as large as 39.2 KN (4000 kg) if they sling
30 98.1 10.0
a 19.6 KN (2000 kg) load at a lifting angle
40 176.5 18.0
50 274.6 28.0
60 392.2 40.0
t The allowable load value is estimated to

be one-sixth or one-seventh of the break-
ing strength of the rope used.
I I I I I I
2) Sling wire ropes from the middle portion 120
30 60 90 150
of the hook. Lifting mole (degree) SAD00480
00-7
FOREWORD COATING MATERIALS
COATING MATERIALS
The recommended coating materials prescribed in Komatsu Shop Manuals are listed below.
Category <omatsu code Part No. O’ty Container Main aoplications, features
* Used to prevent rubber gaskets, rubber cushions,
LT-IA 790-l 29-9030 150 g Tube
and cork plugs from coming out
m Used in places requiring an immediately effec-
LT-16 790-129-9050 20 9 Plastic tive, strong adhesive. Used for plastics (except
(x2) container polyethylene, polypropylene, tetrafluoroethylene,
and vinyl chloride), rubber, metal, and non-metal.
- Features: Resistance to heat, chemicals
Plastic
LT-2 09940-00030 50 g - Used for anti-loosening and sealant purposes for
container
Adhesive bolts and plugs.
adhesive * Used as adhesive or sealant for metal, glass, plastic
790-129-9060
(Set of adhesive
1 Kg
LT-3 lardeninc Can
and hardengins
gent:
agent)
500 g
Plastic . Used as sealant for machined holes
LT-4 790-129-9040 250 g
container
* Features: Resistance to heat, chemicals
Loctite 646-50) 79A-129-9110 50 cc - * Used at joint portions subject to high tempera-
ture
- Used as adhesive or sealant for gaskets and
LG-1 790-129-9010 200 g Tube oackinos Of Dower train case. etc.
. Features: Resistance to heat
- Used as sealant for flange surfaces and bolts at
high temperature locations, used to prevent sei-
LG3 790-129-9070 1 Kg Can zure
* Used as sealant for heat resistant gasket for high
temperature locations such as engine precombustion
chamber, exhaust pipe
- Features: Resistance to water, oil
+ Used as sealant for flange surface, thread
790-129-9020 * Also possible to use as sealant for flanges with
LG-4 200 g Tube
Gasket sealani large clearance
* Used as sealant for mating surfaces of final drive
case, transmission case
* Used as sealant for various threads, pipe joints,
Plastic flanges
LG-5 790-129-9080 1 Kg - Used as sealant for tapered plugs, elbows, nip-
container
ales of hvdraulic piping_
. Features: Silicon based, resistance to heat, cold
LG-6 09940-00011 250 g Tube * Used as sealant for flange surface, thread
* Used as sealant for oil pan, final drive case, etc.
. Features: Silicon based, quick hardening type
LG-7 0992040150 150 g Tube * Used as sealant for flywheel housing, intake mani-
fold. oil Dan. thermostat housina. etc.
Rust oreven l Used as lubricant for sliding parts (to prevent
LM-G 09940-00051 60 g Can
tion lubricant squeaking)
Molybdenum * Used to prevent seizure or scuffing of the thread
disulphide Iu- LM-P 09940-00040 200 g Tube when press fitting or shrink fitting
bricant . Used as lubricant for linkage, bearings, etc.
SYG-350LI * General purpose type
SYG-400LI
Lithium grease G2-LI SYG-400Ll-A Various Various
SYG-16OLI
SYGA-IGOCNL
SSG2-400CA * Used for normal temperature, light load bearing
SYG2-350CA at places in contact with water or steam
GZ-CA SYG2-4OOCA-A Various Various
SYG2-160CA
SYGA-IGCNCA
Molybdenum * Used for places with heavy load
400 g
disulphide SYG2-400M 3ellows type
IOpercasf
arease
-
00-8
FOREWORD STANDARD TIGHTENING TORQUE
STANDARD TIGHTENING TORQUE
STANDARD TIGHTENING TORQUES OF BOLTS AND NUTS

The following charts give the standard tightening torques of bolts and nuts. Exceptions are given
in section of DISASSEMBLY AND ASSEMBLY.
1 Kgm = 9.806 Nm
Thread diameter Width

of bolt across flats
SAD00481 SAD00482
mm mm Nm kgm
6 10 13.2* 1.4 1.35f0.15

8 13 31.4k2.9 3.2f0.3
IO 17 65.7k6.8 6.7kO.7
12 19 112k9.8 11.5fl.O
14 22 177* 19 18.0f2.0
16 24 279*29 28.5f3
18 27 383*39 39+4
20 30 549 k 58 56f6
22 32 745+78 76f8
24 36 927f98 94.5f 10
27 41 1320f140 135+15
30 46 1720* 190 175f20
33 50 221Ok240 225+25
36 55 2750f290 280f30
39 60 3280f340 335+35
* This torque table does not apply to the bolts with which nylon packings or other
nonferrous metal washers are to be used, or which require tightening to otherwise
specified torque.
00-9
FOREWORD STANDARD TIGHTENING TORQUE
TIGHTENING TORQUE OF SPLIT FLANGE BOLTS

Use these torques for split flange bolts.
Thread diameter Width

Tightening torque
of bolt across flats I
mm mm Nm kgm
10 14 65.7k6.8 6.7f0.7
12 17 112k9.8 11.5*1
16 22 279*29 28.553
,Sealing surface
TIGHTENING TORQUE FOR FLARED NUTS
Use these torques for flared part of nut.
Thread diameter Width across flats

of nut part of nut part Tightening torque
mm mm Nm kgm
14 19 24.5k4.9 2.5kO.5
18 24 49k 19.6 5f2
22 27 78.5+ 19.6 8+2
24 32 137.3k29.4 14k3
30 36 176.5529.4 18k3
33 41 196.1 k49 2Ok5
36 46 245.2 + 49 25f5
42 55 294.2 zk49 3Ok5
00-l0
FOREWORD ELECTRIC WIRE CODE
ELECTRIC WIRE CODE
In the wiring diagrams, various colors and symbols are employed to indicate the thickness of wires.
This wire code table will help you understand WIRING DIAGRAMS.
Example: 5WB indicates a cable having a nominal number 5 and white coating with black stripe.
CLASSIFICATION BY THICKNESS
Applicable circuit
I\ Circuits1 I I I I I
Prior-
ity
1
FOREWORD CONVERSION TABLE
CONVERSION TABLE
METHOD OF USING THE CONVERSION TABLE

The Conversion Table in this section is provided to enable simple conversion of figures. For
details of the method of using the Conversion Table, see the example given below.
EXAMPLE
. Method of using the Conversion Table to convert from millimeters to inches
1. Convert 55 mm into inches.
(I) Locate the number 50 in the vertical column at the left side, take this as @, then draw a horizontal
line from @.
(2) Locate the number 5 in the row across the top, take this as @I, then draw a perpendicular line
down from @.
(3) Take the point where the two lines cross as 0. This point 0 gives the value when converting
from millimeters to inches. Therefore, 55 mm = 2.165 inches.
2. Convert 550 mm into inches.

(I) The number 550 does not appear in the table, so divide by 10 (move the decimal point one place
to the left) to convert it to 55 mm.
(2) Carry out the same procedure as above to convert 55 mm to 2.165 inches.
(3) The original value (550 mm) was divided by 10, so multiply 2.165 inches by 10 (move the decimal
point one place to the right) to return to the original value. This gives 550 mm = 21.65 inches.
Millimeters to inches 1 mm = 0.03937 in
0 1 2 3 4 5 ! 6 7 8 9
0 0.039 0.079 0.118 0.157 0.197; 0.236 0.276 0.315 0.354

0.394 0.433 0.472 0.512 0.551 0.591; 0.630 0.669 0.709 0.748
0.787 0.827 0.866 0.906 0.945 0.984; 1.024 1.063 1.102 1.142
1.181 1.220 1.260 1.299 1.339 1.378 i 1.417 1.457 1.496 1.536
1.575 1.614 1.654 1.693 1.732 1.772: 1.811 1.850 1.890 1.929
0. ;
@ .... . . . . . . .. . . . . .2.008
..1.969 . . .. . . . . . . .2.047
. . .._..... . . . . . .. ..I ..2.126
. .2.087 . .. . . . . . . ,#I 2.205 2.244 2.283 2.323
2.362 2.402 2.441 2.480 2.520 2.598 2.638 2.677 2.717
2.756 2.795 2.835 2.874 2.913 2.953 2.992 3.032 3.071 3.110
3.150 3.189 3.228 3.268 3.307 3.346 3.386 3.425 3.465 3.504
3.543 3.583 3.622 3.661 3.701 3.740 3.780 3.819 3.858 3.898
00-l 2
FOREWORD CONVERSIONTABLE
Millimeters to Inches
1 mm = 0.03937 in
0 0 0.039 0.079 0.118 0.157 0.197 0.236 0.276 0.315 0.354
10 0.394 0.433 0.472 0.512 0.551 0.591 0.630 0.669 0.709 0.748
20 0.787 0.827 0.866 0.906 0.945 0.984 1.024 1.063 1.102 1.142
30 1.181 1.220 1.260 1.299 1.339 1.378 1.417 1.457 1.496 1.536
40 1.575 1.614 1.654 1.693 1.732 1.772 1.811 1.850 1.890 1.929
50 1.969 2.008 2.047 2.087 2.126 2.165 2.205 2.244 2.283 2.323
60 2.362 2.402 2.441 2.480 2.520 2.559 2.598 2.638 2.677 2.717
70 2.756 2.795 2.835 2.874 2.913 2.953 2.992 3.032 3.071 3.110
80 3.150 3.189 3.228 3.268 3.307 3.346 3.386 3.425 3.465 3.504
90 3.543 3.583 3.622 3.661 3.701 3.740 3.780 3.819 3.858 3.898
Kilogram to Pound
1 kg = 2.2046 lb
0 1 2 3 4 5 6 7 8 9
0 0 2.20 4.41 6.61 8.82 11.02 13.23 15.43 17.64 19.84
10 22.05 24.25 26.46 28.66 30.86 33.07 35.27 37.48 39.68 41.89
20 44.09 46.30 48.50 50.71 51.91 55.12 57.32 59.53 61.73 63.93
30 66.14 68.34 70.55 72.75 74.96 77.16 79.37 81.57 83.78 85.98
40 88.18 90.39 92.59 94.80 97.00 99.21 101.41 103.62 105.82 108.03
50 110.23 112.44 114.64 116.85 119.05 121.25 123.46 125.66 127.87 130.07
60 132.28 134.48 136.69 138.89 141.10 143.30 145.51 147.71 149.91 152.12
70 154.32 156.53 158.73 160.94 163.14 165.35 167.55 169.76 171.96 174.17
80 176.37 178.57 180.78 182.98 185.19 187.39 189.60 191.80 194.01 196.21
90 198.42 200.62 202.83 205.03 207.24 209.44 211.64 213.85 216.05 218.26
00-13
Literto U.S. Gallon

I! = 0.2642 U.S. Gal
0 0 0.264 0.528 0.793 1.057 1.321 1.585 1.849 2.113 2.378
10 2.642 2.906 3.170 3.434 3.698 3.963 4.227 4.491 4.755 5.019
20 5.283 5.548 5.812 6.076 6:340 6.604 6.869 7.133 7.397 7.661
30 7.925 8.189 8.454 8.718 8.982 9.246 9.510 9.774 10.039 10.303
40 10.567 10.831 11.095 11.359 11.624 11.888 12.152 12.416 12.680 12.944
50 13.209 13.473 13.737 14.001 14.265 14.529 14.795 15.058 15.322 15.586
60 15.850 16.115 16.379 16.643 16.907 17.171 17.435 17.700 17.964 18.228
70 18.492 18.756 19.020 19.285 19.549 19.813 20.077 20.341 20.605 20.870
80 21.134 21.398 21.662 21.926 22.190 22.455 22.719 22.983 23.247 23.511
90 23.775 24.040 24.304 24.568 24.832 25.096 25.361 25.625 25.889 26.153
Liter to U.K. Gallon

le = 0.21997 U.K. Gal
0 0 0.220 0.440 0.660 0.880 1.100 1.320 1.540 1.760 1.980
10 2.200 2.420 2.640 2.860 3.080 3.300 3.520 3.740 3.950 4.179
20 4.399 4.619 4.839 5.059 5.279 5.499 5.719 5.939 6.159 6.379
30 6.599 6.819 7.039 7.259 7.479 7.969 7.919 8.139 8.359 8.579
40 8.799 9.019 9.239 9.459 9.679 9.899 10.119 10.339 10.559 10.778
50 10.998 11.281 11.438 11.658 11.878 12.098 12.318 12.528 12.758 12.978
60 13.198 13.418 13.638 13.858 14.078 14.298 14.518 14.738 14.958 15.178
70 15.398 15.618 15.838 16.058 16.278 16.498 16.718 16.938 17.158 17.378
80 17.598 17.818 18.037 18.257 18.477 18.697 18.917 19.137 19.357 19.577
90 19.797 20.017 20.237 20.457 20.677 20.897 21.117 21.337 21.557 21.777
00-14
kgmto ft.lb
1 kgm = 7.233ft.lb
0 1 2 3 4 5 6 7 8 9
0 0 7.2 14.5 21.7 28.9 36.2 43.4 50.6 57.9 65.1
10 72.3 79.6 86.8 94.0 101.3 108.5 115.7 123.0 130.2 137.4
20 144.7 151.9 159.1 166.4 173.6 180.8 188.1 195.3 202.5 209.8
30 217.0 224.2 231.5 238.7 245.9 253.2 260.4 267.6 274.9 282.1
40 289.3 296.6 303.8 311.0 318.3 325.5 332.7 340.0 347.2 354.4
50 361.7 368.9 376.1 383.4 390.6 397.8 405.1 412.3 419.5 426.8
60 434.0 441.2 448.5 455.7 462.9 470.2 477.4 484.6 491.8 499.1
70 506.3 513.5 520.8 528.0 535.2 542.5 549.7 556.9 564.2 571.4
80 578.6 585.9 593.1 600.3 607.6 614.8 622.0 629.3 636.5 643.7
90 651.0 658.2 665.4 672.7 679.9 687.1 694.4 701.6 708.8 716.1
100 723.3 730.5 737.8 745.0 752.2 759.5 766.7 773.9 781.2 788.4
110 795.6 802.9 810.1 817.3 824.6 831.8 839.0 846.3 853.5 860.7
120 868.0 875.2 882.4 889.7 896.9 904.1 911.4 918.6 925.8 933.1
130 940.3 947.5 954.8 962.0 969.2 976.5 983.7 990.9 998.2 1005.4
140 1012.6 1019.9 1027.1 1034.3 1041.5 048.8 1056.0 1063.2 1070.5 1077.7
150 1084.9 1092.2 1099.4 1106.6 1113.9 121.1 1128.3 1135.6 1142.8 1150.0
160 1157.3 1164.5 1171.7 1179.0 1186.2 193.4 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-l 5
kg/cm2 to lb/in2
1 kg/cm2 = 14.2233 lb/in2
0 1 2 3 4 5 6 7 8 9
0 0 14.2 28.4 42.7 56.9 71.1 85.3 99.6 113.8 128.0
10 142.2 156.5 170.7 184.9 199.1 213.4 227.6 241.8 256.0 270.2
20 284.5 298.7 312.9 327.1 341.4 355.6 369.8 384.0 398.3 412.5
30 426.7 440.9 455.1 469.4 483.6 497.8 512.0 526.3 540.5 554.7
40 568.9 583.2 597.4 611.6 625.8 640.1 654.3 668.5 682.7 696.9
50 711.2 725.4 739.6 753.8 768.1 782.3 796.5 810.7 825.0 839.2
60 853.4 867.6 881.8 896.1 910.3 924.5 938.7 953.0 967.2 981.4
70 995.6 1010 1024 1038 1053 1067 1081 1095 1109 1124
80 1138 1152 1166 1181 1195 1209 1223 1237 1252 1266
90 1280 1294 1309 1323 1337 1351 1365 1380 1394 1408
100 1422 1437 1451 1465 1479 1493 1508 1522 1536 1550
110 1565 1579 1593 1607 1621 1636 1650 1664 1678 1693
120 1707 1721 1735 1749 1764 1778 1792 1806 1821 1835
130 1849 1863 1877 1892 1906 1920 1934 1949 1963 1977
140 1991 2005 2020 2034 2048 2062 2077 2091 2105 2119
150 2134 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-l 6
FOREWORD CONVERSION TABLE
Temperature
Fahrenheit-Centigrade Conversion ;a simple way to convert a Fahrenheit temperature reading into a Centigrade tempera-
ture reading or vice versa is to enter the accompanying table in the center or boldface column of figures.
These figures refer to the temperature in either Fahrenheit or Centigrade degrees.
If it is desired to convert from Fahrenheit to Centigrade degrees, consider the center column as a table of Fahrenheit
temperatures and read the corresponding Centigrade temperature in the column at the left.
If it is desired to convert from Centigrade to Fahrenheit degrees, consider the center column as a table of Centigrade values,
and read the corresponding Fahrenheit temperature on the right.
1°C = 33.8”F
“C “F “C “F “C “F “C “F
-40.4 -40 -40.0 -11.7 11 51.8 7.8 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 48 118.4 28.3 83 181.4
-31.7 -25 -13.0 -10.0 14 57.2 9.4 49 120.2 28.9 84 183.2
-28.9 -20 -4.0 -9.4 15 59.0 10.0 50 122.0 29.4 85 185.0
-28.3 -19 -2.2 -8.9 16 60.8 10.6 51 123.8 30.0 86 186.8

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

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

-22.2 -8 17.6 -2.8 27 80.6 16.7 62 143.6 36.1 97 206.6
-21.7 -7 19.4 -2.2 28 82.4 17.2 63 145.4 36.7 98 208.4
-21.1 -6 21.2 -1.7 29 84.2 17.8 64 147.2 37.2 99 210.2
-20.6 -5 23.0 -1.1 30 86.0 18.3 65 149.0 37.8 100 212.0
-20.0 -4 24.8 -0.6 31 87.8 18.9 66 150.8 40.6 105 221.0

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

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

-13.9 7 44.6 5.6 42 107.6 25.0 77 170.6 71.1 160 320.0
-13.3 8 46.4 6.1 43 109.4 25.6 78 172.4 73.9 165 329.0
-12.8 9 48.2 6.7 44 111.2 26.1 79 174.2 76.7 170 338.0
-12.2 IO 50.0 7.2 45 113.0 26.7 80 176.0 79.4 175 347.0
00-17
ox GENERAL
Specification drawing .................................. Ol- 2

Specifications ............................................... Ol- 4
Weight table ................................................. Ol- 9
Table of fuel, coolant and lubricants.. ...... .01-l 1
01-l
GENERAL SPECIFICATION DRAWING
SPECIFICATION DRAWING
. SEMI U-TILTDOZER + GIANT RIPPER
Unit: mm
SDD01385
l U-TILTDOZER + GIANT RIPPER
3815 3450 rv,

r- 10695
SD001386
01-2
GENERAL SPECIFICATION DRAWING
l SEMI U-TILTDOZER + MULTI-SHANK RIPPER
Unit: mm
z-
rz
3615 3160 p_
I0040
SDD01387
. U-TILTDOZER + MULTI-SHANK RIPPER
P
3615 3160 c”,
10405
SDD01388
01-3
GENERAL SPECIFICATIONS
SPECIFICATIONS
Machine model D375A-3
Serial No. 17001 and up
Operating weight
I
l Bare tractor 49,000
l With above + semi U-dozer 59,540

kg
l With above + variable multi-shank rippe r 66,260
l With above + ROPS cab + air conditione r

67,500
+ seat belt + perforated side cover
Min. turning radius m 4.2
Gradeability deg 30
Stability (front, rear, left, right) deg 35
Forward 1st 0 - 3.8
Forward 2nd km/h 0 - 6.8
Forward 3rd 0 - 11.8
Reverse 1st 0 - 5.1
Reverse 2nd km/h 0 - 9.2
Reverse 3rd 0 - 15.8
Bare tractor 102.97 {I.051
With semi U-dozer 125.53 {I .28}
With semi U-dozer +

KPa 139.25 (I.421
variable multi-shank ripper
{kg/cm*}
With above + ROPS cab +
air conditioner + seat belt + 142.20 11.45)
perforated side cover
Bare tractor 5,770
With semi U-dozer 7,635
With semi U-dozer + variable mm

multi-shank ripper 10,040
With U-dozer + variable multi-shank

ripper 10,405
Bare tractor 3,230
With semi U-dozer mm 4,695
With U-dozer 5,140
To tip of exhaust pipe 4,045
To top of handrail at top of mm

intake duct 3,295
01-4
Machine
Serial
model
No.
l- 17001
D375A-3
and up
Track gauge 2,500

E
.-C Length of track on ground 3,815
2
a:
mm
Track shoe width 610
.-E
0 Min. ground clearance 620
-
Name SA6D170-2
Type 4-cycle, water-cooled, in-line, vertical type,

direct injection, with turbocharger, aftercooler
No. of cylinders - bore x stroke mm 6- 170 x 170
Piston displacement e {ccl 23.15 {23,1501
KW/rpm
Rated horsepower 39211,800 1525/1,8001
HP/rpmI
Vm/rpm
g Max. torque 2,618/l ,300 {267/l ,300I
2 :gm/rpm
._ E
F
Lu
b Max. speed at no load (rpm) 1,960
fz 2 Min. speed at no load (rpm) 700
8 Min. fuel consumption g/KW*h

is ratio [g/HP-h}
213 (1571
Starting motor 24V. 7.5 KW x 2
Alternator 24V, 50A
Battery 12V, 170Ah x 2
Radiator core type D type
3-element, single stage, single phase

Torque converter
(with lock up clutch)
Planetary gear type, multiple disc clutch,

Transmission hydraulically actuated, force-feed lubrication gear
pump, forward 3 speed, reverse 3 speed
Bevel gear shaft Spiral bevel gear, splash type lubrication
Wet type, multiple clutch disc, spring boosted,

Steering clutch hydraulically actuated (manual type),
interconnected with brake
Wet type, multiple clutch disc, spring boosted,

Steering brake hydraulically actuated (pedal operated,
manually operated), interconnected with clutch
Spur gear l-stage, planetary gear l-stage

Final drive
reduction gear, splash type lubrication
01-5
8 Suspension Rigid, balancing beam type
? Carrier roller 2 on each side

6%
2 Track roller 6 on each side
*
Assembly type, single grouser, 40 each side,
3 Track shoe
pitch: 280.0 mm, width: 610 mm
Power train + lubrication pump (tandem) Gear type (BALI12 + 160)
Scavenging pump (tandem) Gear type (BAR63 + 200)
PPC charge pump (tandem with hydraulic pump) Gear type (SAR(1)022)
MPa
Max. presssure 20.6 I2101
Ikg/cm21
j g Type Gear type , tandem (SAR(4)140 + (3)071)
zz Discharge (at engine speed 1800 rpm) k?/min 405

c
5 Type
;
‘0, For blade lift l-spool pilot spool type, with demand spool
31
; $! For blade tilt, ripper (Lo) 3-spool pilot spool type
!
? For ripper (Hi) 2-spool pilot spool type
Type Reciprocal, piston type
0~ Cylinder bore 150

2% Outside diameter of piston rod 90
L? ‘z: Piston stroke mm 1,505
u” +
c So) Max. distance between pins 2,650
.- ._-o
F 02 Min. distance between pins 1,145
Q
.o &
5 z~ Cylinder bore 225
I
z gz Outside diameter of piston rod 110
1 ‘gg Piston stroke mm 240
Ez Max. distance between pins 1,668
.-u
02 Min. distance between pins 1,428
Q
01-6
I
Cylinder bore Left cylinder: 225, right cylinder: 250

a
IJ t Outside diameter of piston rod
110
E% (both left and right)
$ Piston stroke (both left and right) mm 185
E= Max. distance between pins
1,665
;z (both left and right)
5 Min. distance between pins
1,480
(both left and right)
55 Cylinder bore 225

2; Outside diameter of piston rod 110
ig Piston stroke mm 495
E & Max. distance between pins 1,855
in 1,360
.g Min. distance between pins
5$ Cylinder bore 200

8: Outside diameter of piston rod 110
2~ Piston stroke mm 550
5 k Max. distance between pins 1,800
?i= 1,250
.g Min. distance between pins
Control valve assembled type

Hydraulic tank
(externally installed)
Hydraulic semi U-tiltdozer,

hydraulic U-tiltdozer
Blade support method Brace type
Max. blade lifting height

mm 1,660
(from ground level)
Max. blade lowering depth

mm 715
(from ground level)
Max. tilt mm 1,065
Blade cutting angle variation deg +5
Blade capacity m3 24.0 CSAE 18.5>
Blade width mm 4,695
Blade height mm 2,265
Blade cutting angle deg 55
01-7

f
Max. blade lifting height
mm 1,660
(from ground level)
Max. blade lowering depth

mm 715
(from ground level)
Max. tilt mm 1,165
Blade cutting angle variation deg +5
Blade capacity m3 26.3 CSAE 22.0>
Blade width mm 5,140
Blade height mm 2,265
Blade cutting angle deg 55
Max. tilt mm 1,150
Max. pitch angle deg 5
Max. pitch-back angle deg 5
Max. tilt mm 1,260
Max. pitch angle deg 5
Max. pitch-back angle deg 5
Max. digging depth mm 1,075
Max. lifting height mm 1,030
Ripping angle of point deg 45 (adjustable steplessly 32.5 - 55.5)
Max. width of beam mm 2,854
No. of
Shank positions 2
holes
Max. digging depth mm 1,435
Max. lifting height mm 1,060
Ripping angle of point deg 45 (adjustable steplessly 32.5 - 55.5)
Max. width of beam mm 1,367
No. of
Shank positions 3
holes
01-8
GENERAL WEIGHT TABLE
WEIGHT TABLE
a This weight table is a guide for use when transporting or handling components.
Unit: kg
Engine, damper assembly 2,955

l Engine assembly 2,725
l Damper assembly 160
l Engine mount parts 70
Radiator assembly 365

Oil cooler assembly 100
Fuel tank assembly (when full) 460 (1,350)
Power train unit
l Torque converter, PTO assembly 795

l Transmission assembly 1,000
l Transmission valve assembly 35
8 l Steering clutch, brake assembly 1,730

% l Steering valve assembly 25
Z
Final drive assembly (each side) 2,200

Main frame assembly 5,200
Track group assembly (each side) 6,990

l Track frame (each side) 1,940
9 Idler assembly (each side) 460
l Track roller assembly (single, each) 130
l Track roller assembly (double, each) 150
l Carrier roller assembly (each) 70
l Bogie assembly (each) 810
Track shoe assembly (610 mm width) 8,400

Pivot shaft assembly (each side) 210
Equalizer bar 490
Hydraulic tank assembly 370

l Main control valve (blade lift) 57
l Main control valve (blade tilt, ripper Lo) 36
01-9
GENERAL WEIGHT TABLE
Unit: kg
Blade lift cylinder assembly (each side) 260
Blade tilt cyinder assembly 295
Semi U-dozer assembly 10,540
l Blade 4,870
l Straight frame (left) 1,130
l Straight frame (right) 1,130
l Tilt cylinder assembly 295
Variable multi-shank ripper assembly 6,720
l Shank assembly (each) 470
l Ripper lift cylinder assembly (each) 345
l Ripper tilt cylinder assembly (each) 265
Variable giant ripper assembly 5,470
l Shank assembly (each) 650
l Ripper lift cylinder assembly (each) 345
l Ripper tilt cylinder assembly (each) 265
Radiator guard assembly (including cyilnder yoke) 1,750
l Radiator guard 1,320
l Blade lift cylinder assembly (each side) 260
Mask 50
Engine underguard 285
Power train underguard (front) 275
Power train underguard (rear) 250
Hood 75
Fender (left) 315
Fender (right) 355
ROPS mount assembly 660
ROPS assembly 665
Floor frame 220
Cab assembly 320
Operator’s seat 40
01-10
GENERAL TABLE OF FUEL, COOLANT AND LUBRICANTS
TABLE OF FUEL, COOLANT AND LUBRICANTS
RESERVOIR KIND OF -22 -4 14 32 50 68 86

FLUID
Engine oil pan
Power train case
~a~~~;~ach sideEngine oi,
Pivot shaft case (each side)
g
------I
Hydraulic
l
l
system
Bare tractor
with abave + tiltdozer
with abave + ripper
Idler (each)
Track roller (each)

I
Gear oil
8 Carrier roller (each)

Z
Fuel tank Diesel

fuel
Cooling system(including Coolant

reservoir tank)
* ASTM D975 No. 1
NOTE:
(I) When fuel sulphur content is less than 0.5 (2) When starting the engine in an atmospheric
%, change oil in the oil pan every periodic temperature of lower than O”C, be sure to
maintenance hours described in this manual. use engine oil of SAEIOW, SAEIOW-30 and
Change oil according to the following table SAE15W-40 even though an atmospheric
if fuel sulphur content is above 0.5 %. temperature goes up to 10°C more or less
in the day time.
(3) Use API classification CD as engine oil and
Change interval of oil if API classification CC, reduce the engine
Fuel sulphur content
in engine oil pan oil change interval to half.
0.5to 1.0% l/2 of regular interval (4) There is no problem if single grade oil is
mixed with multigrade oil (SAEIOW-30, 15W-
Above 1.0 % l/4 of regular interval 40), but be sure to add single grade oil that
matches the temperature in the table on the
left.
ASTM: American Society of Testing and Material (5) We recommend Komatsu genuine oil which
has been specifically formulated and ap-
SAE: Society of Automotive Engineers
proved for use in engine and hydraulic work
API: American Petroleum Institute
equipment applications.
Specified capacity: Total amount of oil including oil for components and oil in piping.
Refill capacity: Amount of oil needed to refill system during normal inspection and maintenance.
01-11
0
xo STRUCTURE AND FUNCTION
Engine control ............................................... IO-3 Work equipment hydraulic system

Power train .................................................... IO-4 diagram (dual tiltdozer) ....................... 1O-82
Overall drawing of power train unit.. ......... IO-6 Work equipment hydraulic circuit
Power train hydraulic piping diagram ....... IO-8 diagram ................................................. IO-83
Power train hydraulic system drawing .... IO-IO Hydraulic tank ............................................. IO-84
Power train hydraulic circuit diagram.. .... IO-I 1 PPC charge valve ........................................ IO-85
Damper, universal joint.. ............................ IO-12 Accumulator ................................................ IO-87
Torque converter, PTO ............................... IO-14 PPC lock valve.. ........................................... IO-88
Torque converter valve .............................. IO-20 PPC valve ..................................................... IO-90
Transmission control .................................. IO-29 Piston valve ............................................... IO-100
Transmission ............................................... IO-30 Quick drop valve ....................................... IO-101
Transmission control valve ....................... IO-36 Pin puller switch ....................................... IO-102
8 Lubrication relief valve.. ............................. IO-43 Pin puller solenoid valve ......................... IO-103
2 Scavenging pump strainer.. ....................... IO-44 Blade control Knob.. ................................. IO-105
z Power train pump strainer.. ....................... IO-45 Pitch, dual tilt solenoid valve .................. IO-106
Power train, lubrication oil filter.. ............. IO-46 Main control valve .................................... IO-108
Steering, brake control.. ............................. IO-48 Cylinder stay.. ............................................ IO-134
Transfer, bevel gear shaft, steering.. ........ IO-50 Blade.. ......................................................... IO-135
Steering control valve ................................ IO-54 Ripper ......................................................... IO-137
Final drive .................................................... IO-62 Cab mount ................................................. IO-139
Track frame.. ................................................ IO-66 Cab ............................................................. IO-140
Recoil spring.. .............................................. IO-68 Air conditioner .......................................... IO-142
Track roller bogie.. ...................................... IO-69 Actual electric wiring diagram ................ IO-144
Main frame .................................................. 1 O-70 Electric circuit diagram ............................ IO-146
Suspension .................................................. IO-72 Machine monitor system ......................... IO-150
Work equipment hydraulic piping Switch panel .............................................. IO-158
diagram ................................................. IO-74 Fuse box .................................................... IO-158
PPC control piping diagram ...................... IO-78 Engine start safety system ...................... IO-160
Work equipment control ............................ IO-79 APS ............................................................. IO-161
Work equipment hydraulic system Torque converter lock-up control
diagram (tiltdozer) ............................... 1O-80 system ................................................. IO-163
Work equipment hydraulic circuit
diagram ................................................. IO-81
10-l
STRUCTURE AND FUNCTION ENGINE CONTROL
ENGINE CONTROL
_
SLD01466
1. Decelerator pedal Outline

2. Fuel control lever l The engine speed is controlled by fuel con-
3. Clutch trol lever (2) or decelerator pedal (I).
4. Stopper
5. Rod
6. Fuel injection pump
Lever, pedal positions

0: STOP
0: LOW IDLING
0: HIGH IDLING
0: HIGH IDLING
0: LOW IDLING
1o-3
STRUCTURE AND FUNCTION POWER TRAIN
POWER TRAIN
I 2 3 7 8 9. 14
SBD01264
Outline
l The power generated by engine (I) has its The power entering transfer (14) has its
torsional vibration dampened by damper (21, speed reduced. Its speed is further reduced
and then passes through universal joint (31, by the bevel pinion and bevel gear of the
and is transmitted to torque converter (7). bevel gear shaft, and it is then divided at
The power from the engine is transmitted right angles to the left and right and trans-
through oil by torque converter (7) to the mitted to the respective steering clutches (9).
input shaft (turbine shaft) of transmission The power transmitted from the bevel gear
(8) in accordance with the change in the shaft to the final drive is used to steer the
load. machine by engaging or disengaging steer-
There is a lock-up clutch assembled to the ing clutch (9).
torque converter, and when the rotating The steering lever is operated to disen-
speed beyond the torque converter becomes gage the steering clutch on the side to which
higher, the lock-up clutch is engaged. When the machine is to be steered in order to
this happens, the drive case and turbine change the direction of travel. The size of
form one unit, so the power from the en- the turning radius is controlled by steering
gine is transmitted directly to the transmis- brake (IO) installed to the outside of the
sion input shaft. steering clutch.
Transmission (8) uses a combination of a Steering brake (IO) uses the same disc sys-
planetary gear system and hydraulic equip- tem that is used for the steering clutch.
ment to reduce the speed and shift the gears The power output from the steering clutch
(forward: 3 gears, reverse: 3 gears). It con- enters final drive (II), where it is reduced,
nects two sets of clutches selected with the and rotates sprocket (12).
gear shift lever according to the change in Final drive (15) is a double reduction type
the load, and transmits the power from the consisting of a single stage spur gear and
transmission to transfer (14) from the out- single stage planetary gear system.
put shaft. It rotates the sprocket to drive track shoe
(13) and move the machine.
1o-4
STRUCTURE AND FUNCTION POWER TRAIN
---_--___1
-11
\ I
SAD01265
1. Engine (S6D170-2) 9. Steering clutch

2. Damper 10. Steering brake
3. Universal joint 11. Final drive
4. Power train pump (BALI 12+160) 12. Sprocket
5. PTO 13. Track shoe
6. Hydraulic pump (SAR(4)140+(3)071+(1)022) 14. Transfer
7. Torque converter 15. Scavenging pump (BAR63+200)
8. Transmission
1o-5
STRUCTURE AND FUNCTION OVERALL DRAWiNG OF POWER TRAIN UNIT
OVERALL DRAWING OF POWER TRAIN UNIT
1O-6
STRUCTURE AND FUNCTION OVERALL DRAWING OF POWER TRAlN UNIT
Z
SED01267
1. PTO
2. Torque converter
3. Torque converter valve
4. Transmission control valve
5. Transmission
6. Steering clutch, brake
7. Steering control valve
8. Power train pump (BAL112+160)
9. Power train oil filter
10. Power train oil strainer
11. Scavenging pump (BAR63+200)
12. Power train oil tank
1o-7
STRUCTURE AND FUNCTION POWER TRAIN HYDRAULIC PIPING DIAGRAM
J IHGFE
P
SLD01268
1. Oil cooler A. Torque converter lock-up pressure pickup port

2. Power train lubrication oil filter B. Stator clutch pressure pickup port
3. Power train oil filter C. L.H. clutch pressure pickup port
4. Torque converter valve D. L.H. brake pressure pickup port
5. Transmission control valve E. R.H. brake pressure pickup port
6. Steering control valve F. R.H. clutch pressure pickup port
7. Oil tank G. Transmission Fl reducing pressure pickup port
8. Power train oil strainer H. Transmission modulating pressure pickup port
9. Power train pump (BALI 12+160) I. Torque converter outlet port pressure pickup port
10. Scavenging pump (BAR63+200) J. Torque converter inlet port pressure pickup port
11. Centralized pressure detection port
IO-8
STRUCTURE AND FUNCTION POWER TRAIN HYDRAULIC SYSTEM DRAWING
- r
I I
-
019503
POWER TRAIN HYDRAULIC CIRCUIT DRAWING

For details of this page, see Section 90.
T._?l
33...I i 31
t
t?
L.._.._..-..-.._.r
_c
II IT
Oil tank 20. Torque converter relief valve L.H. steering clutch
Power train oil strainer Set pressure : 0.85 MPa (8.7 kg/cm*) ::: Steerino case
Power train pump (BALIIP) Torque converter 42. TransmTssion lubrication valve
Power train oil filter 2 Oil cooler 43. Transmission lubrication
Set pressure : 0.14 MPa (1.4 kg/cm21 Steering clutch, brake lubrication PTO lubrication
- 5: Torque converter case :z, Scavenging pump (BAR63+200)
Oil filler port 25. Torque converter lock-up valve 46: Solenoid valve (for pin puller)
Power train lubrication pump (BALIGO) 26. Lock-up clutch modulating valve 47. Pin puller cylinder
Power train lubrication oil filter Set pressure : 1.3fO.l MPa U3fl kg/cm*)
Main relief valve 27. Torque converter lock-up solenoid valve
Set pressure : 2.69+0.1 MPa f27.4*1.0 kg/cm21 28. Torque converter lock-up clutch A. Transmission main relief pressure pickup port
Modulating relief valve 29. Stator clutch modulatin valve Transmission reducing pressure pickup port
Set pressure : 3.0’:’ MPa (31’: kg/cm?) Set pressure : 2.5ztO.l 1\8Pa f25fl.O kg/cm21 :: Torque converter stator clutch pressure pickup port
Ouick return valve 30. Stator clutch lubrication Torque converter relief pressure pickup port
Reducing valve 31. Stator clutch ? Torque converter regulator pressure pickup port
Set pressure : 2.1’: MPa (21’: kg/cm2) 32. Parking brake valve F: Torque converter lock-up pressure pickup port
Speed valve R.H. steering valve R.H. steering clutch pressure pickup port
1st clutch :z. R.H. brake valve :: R.H. steering brake pressure pickup port
2nd clutch 35: L.H. brake valve J. L.H. steering brake pressure pickup port
3rd clutch 36. L.H. steering valve K. L.H. steering clutch pressure pickup port
Directional valve 37. R.H. steering clutch
REVERSE clutch 38. R.H. steering brake
FORWARD clutch 39. L.H. steering brake
STRUCTURE AND FUNCTION DAMPER, UNIVERSAL JOINT
DAMPER, UNIVERSAL JOINT
! J-7.
\. f-\ / /A
ii
i \
8
SBDOl271
10-12
STRUCTURE AND FUNCTION DAMPER, UNIVERSAL JOINT
Outline
l The damper dampens the torsional vibra-
tion caused by the change in the engine
torque and the impact torque generated
when accelerating suddenly or when carry-
ing out heavy-duty digging. In this way it
acts to protect the torque converter,
transmission, and other parts of the power
train.
The damper uses a rubber coupling, so the
vibration can be absorbed by the internal
damping effect of the rubber and the wear
damping effect provided by the deforma-
tion, Furthermore, there are few component
parts.
Operation
. The power from the engine passes through
flywheel (2) and is transmitted to outer body
(3) and rubber coupling (8). The torsional
vibration of the engine is absorbed by the
rubber coupling, and the power is transmit-
ted to coupling (4) from the output shaft.
It then passes through universal joint (5),
and is transmitted to the torque converter
input shaft.
1. Output shaft
2. Engine flywheel
3. Outer body
4. Coupling
5. Universal joint
6. Flange
7. Cover
8. Rubber coupling
9. Breather
10. Oil level gauge tube
10-13
STRUCTURE AND FUNCTION TORQUE CONVERTER, PTO
TORQUE CONVERTER, PTO
SBDO1272
1. Coupling 14. Bearing cage 28. Scavenging pump gear

2. Seal cage 15. Retainer (63 teeth)
3. Input shaft [PTO drive 16. Shaft 29. Seal seat
gear (61 teeth)] 17. Transmission input shaft 30. Spacer
4. Front housing 18. Stator shaft boss 31. Cover
5. Idler gear (77 teeth) 19. Stator clutch housing 32. Hydraulic pump gear
6. Idler gear shaft 20. Return spring (57 teeth)
7. Clutch housing 21. Stator clutch plate 33. Power train pump gear
8. Drive case 22. Stator clutch disc (57 teeth)
9. Turbine 23. Stator clutch piston 34. Cover
IO. Rear housing 24. Turbine boss 35. Cover
11. Stator - 25. Lock-up clutch disc
12. Pump 26. Lock-up clutch plate A. Hydraulic pump mount
13. Stator shaft 27. Lock-up clutch piston B. Power train pump mount
C. Scavenging pump mount
10-14
15 18
/
30 29 28 27 26 25 24 23 22 21 20 19 18
x-x
33
34
Y-Y z-z
SED01273
10-15
STRUCTURE AND FUNCTION TORQUE CONVERTER,, PTO
Outline Structure
. The torque converter is a 3-element, single- . Pump (12) forms one unit with coupling (I),
stage, l-phase torque converter, and it forms shaft (31, clutch housing (71, and drive case
a single structure with the transmission. (81, and is rotated by the power from the
To improve the fuel consumption and ease engine.
of operation and to reduce consumption of l Turbine (9) forms one unit with turbine boss
the engine horsepower, a wet-type, multi- (24) and transmission input shaft (turbine
ple-disc clutch type torque converter lock- shaft) (171, and is rotated by oil from the
up device and a wet-type, double-disc stator pump.
clutch device are assembled inside it. l Stator (11) forms one unit with stator shaft
. When the machine is carrying out continu- (13) and stator shaft boss (181, and is locked
ous low-load dozing or grading operations, to rear housing (IO) by the stator clutch.
it is more efficient if the power of the en- . The lock-up clutch consists of three parts:
gine is transmitted directly to the transmis- clutch plate (26) (meshed with drive case
sion input shaft. (8)), clutch disc (25) (meshed turbine boss
To achieve this, a lock-up clutch actuated (24)), and clutch piston (27) (that slides in-
by hydraulic pressure is assembled inside side housing (71, which forms one unit with
the torque converter. the drive case).
When the torque converter is locked up l The stator clutch consists of three parts:
(the pump and turbine form one unit), the clutch disc (22) (meshed with boss (18) that
oil supplied from the torque converter relief is connected by a spline to stator shaft (13)),
valve does not stop, so the oil leaving the clutch plate (21) (supported by a pin to clutch
turbine from the pump is given unneeded housing (19) and rear housing (IO)), and
direction by the stator, and this resists the clutch piston (23) (that slides inside the g
rotation of the pump and turbine (the oil is rear housing). 8
churned). l The PTO consists of input shaft (3), idler &
To prevent this, a stator clutch similar to gear (51, scavenging pump drive gear (281,
the lock-up clutch is built in. This allows the hydraulic pump drive gear (33), and power
stator to rotate freely when the torque con- train pump drive gear (34).
verter is locked up. The oil then moves to-
gether with rotation of the pump and tur-
bine; it is discharged from the pump and
turbine with little resistance, and is returned
to the pump.
* The condition for the torque converter to
enter the lock-up range and torque converter
range are as follows.
. Lock-up range
When both of the following conditions are
fulfilled:
Torque converter output shaft speed:
Above 1,260 rpm
Transmission set pressure:
Above 2.0 MPa (20 kg/cm*}
l Torque converter range
When either of the following conditions are
fulfilled.
Torque converter output shaft speed:
Below 1,200 rpm
Transmission set pressure:
Below 1.5 MPa (15 kg/cm*)
.lO-16
Path of transmission of motive force I 3 7 i IO II 12 13 17

1. Lock-up clutch OFF, stator clutch ON
When the lock-up clutch is OFF, the con-
nection between drive case (8) and turbine
(9) is cut; and when the stator clutch is ON,
rear housing (IO) and stator shaft (13) are
connected, so stator (II) is locked and the
torque converter provides the normal func-
tions of a torque converter.
The power generated by the engine passes
through the damper and universal joint, and ~$3
is transmitted to coupling (I). Input shaft
(31, clutch housing (71, drive case (81, and
pump (12) rotate as one unit.
The motive force from the pump uses oil to
rotate turbine (9), and is transmitted to trans-
mission input shaft (171, which forms one
unit with the turbine.
Lock-up clutch Stator clutch
SEDO1275
2. Lock-up clutch ON, stator clutch OFF

When the lock-up clutch is ON, drive case
(8) and turbine (9) are connected to form
one unit; and when the stator clutch is OFF,
the connection between rear housing (IO)
and stator shaft (13) is cut, so stator (11)
follows the rotation of pump (12) and tur-
bine (9).
The power generated by the engine passes
through the damper and universal joint, and
is transmitted to coupling (I). Input shaft
(31, clutch housing (7), drive case (81, and
pump (12) rotate as one unit. In addition,
the drive case and turbine (9) are con-
nected by the clutch, so the oil is not used.
The motive force is transmitted directly to
the turbine and transmission input shaft (17).
Lock-u0 clutch Stator clutch
10-17
Flow of oil 9, IO, I! 1,7 ,A

l Oil set to within 0.9 MPa (9 kg/cm21 by the
torque converter relief valve flows from port
A, passes through the oil hole inside rear
housing (IO), and enters pump (12).
The pump is always being rotated by the
power from the engine, so the oil entering
the pump is given centrifugal force, and
enters turbine (9). The turbine is rotated by
the centrifugal force of the oil.
The turbine forms one unit with transmis-
sion input shaft (171, so the motive force
B
received by the turbine is transmitted to the
transmission.
The oil leaving the turbine is sent to stator
(11) and enters the pump again, but some
of the oil passes from the stator through
port B and is sent to the oil cooler.
Lock-up clutch Statar clutch
s9001279
lo-18
STRUCTURE AND FUNCTION TORQUE CONVERTER VALVE
TORQUE CONVERTER VALVE
A-A B-B c-c
Pl
P3 P
SBD0066 1
1. Valve body 16. Valve spring (Outer) 32. Valve seat

2. Torque converter relief 17. Valve spring (Inner) 33. Spring
valve 18. Stopper 34. Valve seat
3. Valve spring 19. Load piston 35. Cap
4. Valve spring 20. Cover
5. Main relief valve 21. Cover P. Stator clutch pressure
6. Cover 22. Valve spring pickup port
7. Piston 23. Valve body P2. Torque converter relief
8. Piston spring 24. Lock-up selector valve pressure pickup port
9. Piston 25. Piston P3. Lock-up clutch pres-
IO. Stator clutch modulating 26. Cover sure pickup port
valve Lock-up solenoid valve P8. Main relief pressure
11. Lock-up clutch modulat- assembly pickup port
ing valve 27. Cover PIO. Lock-up clutch initial
12. Cover 28. Coil pressure pickup port
13. Piston 29. Spring PI?. Stator clutch initial
14. Piston spring (Small) 30. Plunger pressure pickup port
15. Piston 31. Valve seat holder
1O-20
26
/
/
20
SD00662
Outline
l The torque converter valve is installed at 4. Torque converter lock-up solenoid valve
the top of the rear housing of the torque Solenoid valve receives an electrical signal
converter and consists of the following six from the lock-up controller and switches the
types of valves. pilot pressure to lock-up selector valve (24).
1. Main relief valve It operates lock-up selector valve (24) and
Main relief valve (5) sets the hydraulic pres- switches the two clutches ON e OFF.
sure to 2.6 - 2.8 MPa (26.4 - 28.9 kg/cm*} in 5. Stator clutch modulating valve
the transmission, steering clutch, brake and Modulating valve (IO) sets the clutch pres-
torque converter lock-up clutch, and stator sure to 2.5 MPa (25 kg/cm*) to protect the
clutch circuits. stator clutch from abnormally high pressure
2. Torque converter relief valve and acts to raise the pressure of oil from
Torque converter relief vale (2) sets the in- lock-up selector valve (24) gradually until it
let pressure of the torque converter to within reaches the set pressure.
0.87 MPa (8.7 kg/cm*) to protect the torque 6. Lock-up clutch modulating valve
converter from abnormally high pressure. Modulating valve (II) acts in the same way
3. Torque converter lock-up valve as stator clutch modulating valve (IO) and sets
Lock-up selector valve (24) acts to switch the clutch pressure to 1.3 MPa {I3 kg/cm*} to
the lock-up clutch and stator clutch ON t) protect the stator clutch from abnormally high
OFF. pressure.
10-21
Operation of main relief valve

. The oil from the power train pump passes
through the oil filter, and enters port A of
the main relief valve. It then passes through
orifice a and enters port B.
When the oil from the pump fills the circuit,
the pressure starts to rise.
l When the pressure in the circuit rises, the
oil entering port B pushes piston (9). The
reaction force compresses spring (4), moves
main relief valve (5) to the left in the direc-
tion of the arrow, and opens ports A and C.
When this happens, the oil from the pump
is relieved from port A to port C, and flows
port C to the torque converter.
The pressure in the circuit at this point is From pump SBDoO663
2.6 - 2.8 MPa i26.4 - 28.9 kg/cm21. To torque To oil tank

converter
Operation of torque converter relief valve

l The oil relieved from the main relief valve
flows into the torque converter from port C,
and at the same time passes through orifice
b and enters port D.
When the oil fills the torque converter, the
pressure starts to rise.
. If the pressure in the torque converter rises
abnormally high, the oil entering port D
pushes piston (9). The reaction force com-
presses spring (31, moves relief valve (2) to
the right in the direction of the arrow, and
opens ports C and E.
When this happens, the oil at port C is re-
lieved to port E, and is drained to the oil From pump SBO00664
tank. To torque To oil tank

converter
The pressure in the circuit at this point is
below 0.9 MPa (9 kg/cm2).
From pump SW300665
1o-22
Operation of torque converter lock-up valve, solenoid valve

l The torque converter lock-up valve supplies l The diagram shows the electrical circuit for
oil to switch the lock-up and stator clutch the torque converter lock-up system. (For
built into the torque converter ON H OFF. details, see the electrical circuit diagram.)
The lock-UP valve is actuated by the pilot When the starting switch is pressed-ON, the
pressure from the solenoid valve that is ac- relay inside the relay box is actuated. The
tuated when it receives an electrical signal electricity from the battery passes through
from the lock-up controller. the pilot lamp and acts as the power source
l When the lock-up switch on the mode se- for the lock-up controller.
lector panel at the front of the operator’s In this condition, if both the torque con-
compartment is pressed ON (the indicator verter output shaft speed detected by the
lamp inside the switch lights up), the auto- speed sensor is above 1,260 rpm, and the
lock-up system is actuated, and when the transmission modulating pressure detected
torque converter reaches the lock-up range, by the hydraulic sensor is above 2.0 MPa
the lock-up controller, which has received I20 kg/cm? (AND circuit), the lock-up con-
signals from the two sensors, connects the troller connects the pilot lamp and solenoid
solenoid to the ground and current flows. to the ground, and they light up and are
The hydraulic circuit is switched and pilot excited respectively.
pressure is sent to the lock-up valve to lock If either the torque converter output shaft
up the torque converter. speed is below 1,200 rpm or the modulat-
ing pressure is below 1.5 MPa (15 kg/cm*)
(OR circuit), the controller cuts the circuit
connecting the pilot lamp and solenoid to
the ground, and they go out or are deacti-
vated respectively.
In other words, when the torque converter
comes close to the stall range or tries to
shift gear, the machine changes to TORQUE
CONVERTER DRIVE, and when there is con-
tinuous light operation, the machine changes
to DIRECT DRIVE.
1 O-23
LOCK-UP SYSTEM
Battery relay
Lack-up controller
f-y ‘c Torque converter speed (t)
Transmission oil
Pressure sensor
Torque converter speed (-1
Lock-up Power source

Lock-up
solenoid
Lock-up GND
- n Lock-up valve
- f\ Lock-up valve Power source
1
Torque converter
speed sensor SAD01469
1 O-24
1. Travel in torque converter drivel
ivat
SSDO1285
When the machine is in the torque converter The oil from the pump flows ports P and N into
range, the solenoid valve is DEACTIVATED, so port L of the lock-up valve. When the pressure
valves (32) is pushed to the left in the direction of inside the circuit rises, piston (25) is pushed to
the arrow by the tension of spring (29). Ports N the left in the direction of the arrow, and the pis-
and P open. ton pushes out lock-up selector valve (24) to the
left.
When lock-up selector valve (24) moves to the sure of the stator clutch piston. When the pres-
left in the direction of the arrow, ports F and G sure in the circuit rises, the stator clutch is
and ports H and K close, and ports F and H and engaged.
ports G and J open. At the same time, the oil that is the back pres-
When this happens, the oil from the pump flows sure of the lock-up clutch piston is drained from
from port F to port H, and becomes the back port G to port J, and the lock-up clutch is disen-
pres gaged.
2. Travel in direct drive
SBDOl289
When the machine is in the direct drive range, Ports F and H and ports G and J close, and
the solenoid valve is EXCITED, so plunger (30) ports F and G and ports H and K open.
is pushed to the right in the direction of.the When this happens, the oil from the pump flows
arrow and valve (32) is moved. Port P close from port F to port G, and becomes the back
and ports N and M open. pressure of the lock-up clutch piston. When the
When this happens, oil from the pump stops at pressure in the circuit rises, the lock-up clutch
P. The high-pressure oil at port L is drained is engaged.
from port N to port M. At the same time, the oil that is the back pres-
When the pilot pressure at port L is lost, piston sure of the stator clutch piston is drained from
(25) and lock-up selector valve (24) are returned port H to port K, and the stator clutch is disen-
to the right in the direction of the arrow by the gaged.
tension of spring (22).
1 O-26
Operation of stator clutch, lock-up clutch modu-

lating valve
l The modulating valves are in the circuit be-
tween the lock-up selector valve and the
inlet ports of the two sets of clutches. When
the clutch is switched ON, the modulating
valve acts to raise the pressure on the pis-
ton gradually until it reaches the set pres-
sure so that the clutch is engaged smoothly,
thereby reducing any shock to the torque
converter or transmission.
* The following explanation of operation takes From PUMP To solenoid valve
the stator clutch as the example, but the

operation of the lock-up clutch is the same.
However, the oil flow to the clutch during
direct drive or torque converter drive is the
reverse.
1. Travel in direct drive

When the machine enters the direct drive
range, the oil at port L of lock-up selector
valve (24) returns to the solenoid valve and
is drained.
When this happens, lock-up selector valve
(24) is pushed to the right in the direction of
the arrow by the tension of spring (22). Ports
F and H close, and ports H and K open, and
the oil at port H is drained from port K.
When the hydraulic pressure at port H is
lost, modulating valve (IO) is returned to
the right in the direction of the arrow by the
tension of spring (16), and ports H and Q
SBDOl291
open fully. At this point, the actuating pres-
sure of the stator clutch is drained from
port H to port K, and the clutch is disen-
gaged.
1 O-27
2. Travel in torque converter drive

When the machine is in the torque converter From solenoid
From P”BP
valve_
drive range, the oil from the solenoid valve
enters port L of lock-up selector valve (24)
and moves the lock-up selector valve to the
left in the direction of the arrow. Ports F
and G, and ports H and K close, and ports F
and H open. A circuit is then formed from
port F through modulating valve (IO) to the
stator clutch. The oil from the pump flows
from port F to the stator clutch, and the
pressure in the circuit starts to rise.
As the hydraulic pressure in the circuit rises,
the oil passing through orifice d in modulat-
ing valve (IO) pushes piston (131, and the
reaction force moves the modulating valve
to the left in the direction of the arrow to
throttle ports Q and H.
Port Q is connected with port S that applies
back pressure to load piston (191, and moves
the load piston to the right in the direction
of the arrow to compress spring (16). The
tension of spring opens port Q and H. This
operation is repeated intermittently to in-
crease the load of spring (16). While this is
happening, the hydraulic pressure gradually
increases, and finally stops at the position
where ports Q and H are closed to complete
the rise in hydraulic pressure.
The hydraulic pressure at this point is 2.5 +
0.1 MPa (25 f 1 kg/cm*}. From PUUIO
From solenoid
valve
The hydraulic pressure of the lock-up clutch
is 1.3+:’ MPa 113’: kg/cm?.
10228
STRUCTURE AND FUNCTION TRANSMISSION CONTROL
TRANSMISSION CONTROL
* For details of the operation of the joystick
for the steering system, see STEERING,
BRAKE CONTROL section.
Lever positions
0: NEUTRAL
0: FORWARD
0: REVERSE
0: 1st
0: 2nd
8: 3rd
0: FREE
8: LOCK
SLD01296
Outline
l The transmission is controlled by joystick
(2).
1. Safety lever The joystick is used to shift between for-
2. Joystick (directional, gear shift) ward and reverse, and to shift gears.
3. Limit switch (for safety lever) l The transmission is equipped with a safety
4. Cable mechanism: if safety lever (I) is not placed
5. Transmission control valve at the LOCK position, limit switch (3) is not
actuated and the engine cannot be started.
1o-29
STRUCTURE AND FUNCTION TRANSMISSION
TRANSMISSION
SAD01297
019503
* For details of this page, see Section 90.
No. I No. 2 No. 3 No. 4 No. 5
1. Input shaft
2. Transmission valve
3. Front case
4. Rear case
5. Front cover
6. Sun gear for REVERSE (34 teeth)
7. Ring gear for FORWARD (91 teeth)
8. Pinion shaft
9. Planet pinion for REVERSE (25 teeth)
10. Ring gear for REVERSE (84 teeth)
11. Sun gear for FORWARD (41 teeth)
14. Pinion shaft
15. Ring gear for 3rd (91 teeth)
16. Planet pinion for 3rd (25 teeth)
17. Sun gear for 3rd (41 teeth)
18. Ring gear for 2nd (93 teeth)
19. Planet pinion for 2nd (23 teeth)
20. Pinion shaft
21. Sun gear for 2nd (47 teeth)
22. 1st clutch inner drum
23. 1st clutch piston
24. 1st clutch piston housing
25. Output shaft
26. Collar
27. Block
28. 1st clutch spring
29. Seal seat
30. Carrier for 2nd
31. Plate
32. Carrier for FORWARD, 3rd
33. Piston housing for FORWARD, 3rd
34. Carrier for REVERSE
35. Piston housing for REVERSE
36. REVERSE clutch piston
37. Clutch spring
38. Clutch plate
39. Clutch disc
40. Tie bolt
41. Carrier gear for REVERSE (91 teeth)
Outline
. The transmission is a forward 3 gear, re-
verse 3 gear transmission that consists of a
combination of a planetary gear system and
disc clutches.
. The transmission actuates the control valve
to use hydraulic pressure to fix two of the
clutches in the five sets of planetary gears
and disc clutches to select one rotating di-
rection and one gear speed.
l The clutches are locked as follows: No. 1
clutch for REVERSE, No. 2 clutch for FOR-
WARD, No. 3 clutch for 3rd, No. 4 clutch for
2nd and No. 5 clutch for 1st.
No. of plates and discs used
Clutch No. No. of plates No. of discs

I I
No. 1 clutch 5 5
No. 2 clutch 4
No. 3 clutch 2 z
No. 4 clutch 3 3
No. 5 clutch 4 5
Gear speed, clutch combination, reduction ratio
Gear speed Clutch combination (engaged)
FORWARD
1st No. 2 l No. 5
2nd No. 2 l No. 4
3rd No. 2 l No. 3
NEUTRAL No. 5
REVERSE
1st No. 1 l No. 5
2nd No. 1 l No. 4
3rd No. 1 l No. 3
1 O-32
Operation of disc clutch

l To lock ring gear (71, a disc clutch is used.
The clutch consists of piston (361, plates (381,
discs (391, pins (42) and piston return springs
(37).
The internal teeth of the disc engage with
the external teeth of the ring gear.
The teeth on the outside diameter of the
plate engage with pins (42) secured by hous- ‘1
ing (35).
Clutch engaged (locked)

l Oil from the control valve flows under pres-
sure through the port in housing (35) to the
back of piston (36). The piston presses plates
(38) and discs (39) together, and the result-
ing frictional force stops the rotation of discs
(391, so ring gear (7) meshing with the in- ‘\
ternal teeth of the disc is locked.
Clutch disengaged (free)

l When the supply of pressure oil from the
control valve is shut off, piston (36) is re-
turned to its original position by the force
of piston return spring (37). This relieves
the frictional force between plates (38) and
discs (39), making the ring gear (7) free.
Washer spring (43) installed between the
plates at the pin acts to speed up the return
of the piston when the clutch is disengaged,
and also to separate the plate and disc
cleanly to prevent continued rotation.
1o-33
OPERATION OF TRANSMISSION
FIRST FORWARD SPEED
\
31 30 SAD01302
. For FORWARD Ist, No. 2 clutch and No. 5 . Ring gear (13) is locked in position by No. 2
clutch are engaged. The motive force trans- clutch, so planet gear (12) rotates carrier
mitted from the torque converter to input (32), which is on the inside of ring gear (13).
shaft (I) is transmitted to output shaft (25). . No. 5 clutch is also engaged, so the No. 5
. No. 2 clutch is actuated by the hydraulic gear (221, sun gears (17) and (211, planet
pressure applied by the clutch piston and pinions, ring gears (i5) and (181, and No. 4
locks ring gear (13) in position. No. 5 clutch carrier (30) form one unit. In addition, car-
is actuated by hydraulic pressure applied rier (32) rotates as one unit with the gears
by the clutch piston and engages No. 5 gear of No. 3, 4 and 5 clutches to rotate output
(22) and No. 4 ring gear (18). shaft (25).
. The motive force from the torque converter Output shaft (25) rotates at the same speed
is transmitted to input shaft (1). The rota- as carrier (32).
tion of the input shaft is transmitted through
sun gear (II) to planet pinion (12).
1o-34
FIRST REVERSE SPEED

No. 1 No. 2 No. 3 No. 4 No. 6
SAD01303
. For REVERSE Ist, No. 1 clutch and No. 5 l Carrier (34) is locked in position by No. 1
clutch are engaged. The motive force trans- clutch, so the rotation of planet pinion (9)
mitted from the torque converter to input rotates ring gear (IO).
shaft (I) is transmitted to output shaft (25). Ring gear (IO) rotates in the opposite direc-
. No. 1 clutch is actuated by the hydraulic tion from the input shaft, and it rotates car-
pressure applied by the clutch piston and rier (32).
locks carrier (34) in position. No. 5 clutch is . No. 5 clutch is engaged, so the No. 5 gear
actuated by hydraulic pressure applied by (22), sun gears (17) and (21), planet pinions,
the clutch piston and engages No. 5 gear ring gears (15) and (18), and No. 4.carrier
(22) and No. 4 ring gear (18). (30) form one unit.
. The motive force from the torque converter In addition, carrier (32) rotates as one unit
is transmitted to the input shaft (I). The with the gears of No. 3, 4 and 5 clutches to
rotation of the input shaft is transmitted rotate output shaft (25).
through sun gear (6) to planet pinion (9).
1o-35
STRUCTURE AND FUNCTION TRANSMISSION CONTROL VALVE
TRANSMISSION CONTROL VALVE
w-w
Z
SAD01304
Set pressure
From power train pump

To speed valve G
‘3 3 To speed valve J D. To No. 2 (FORWARD)
clutch piston port
To No. 1 (REVERSE) clutch piston port
To No. 5 1st clutch piston port
6. From reducing valve B
H. To No. 4 2nd clutch piston port
J. From reducing valve C
K. To No. 3 3rd clutch piston port
1 O-36
1. Piston
2. Modulating valve
3. Modulating valve load piston
4. Modulating valve spring (outside)
5. Modulating valve spring (inside)
6. Quick return valve
7. Cover
8. Piston spring
9. Piston
10. Piston
11. Reducing valve
12. Stopper
13. Reducing valve spring
14. Stopper
15. Modulating valve spring (small)
16. Stopper
17. Piston
18. Directional selector valve
12’ II ‘IO 19. Speed selector valve
Y-Y
D E
K. J H \ G F
I!
x-x SAD01305
1o-37
Modulating valve
Outline
. The modulating valve consists of the modu-
lating valve and quick return valve, and acts
to modulate the pressure.
. When the transmission shift lever is oper-
ated to change the speed range, the clutch
is engaged by the piston, but if high pres-
sure is suddenly applied, the piston will en-
gage the clutch suddenly. This will cause
the machine to start moving suddenly and
will subject the machine to excessive shock.
To avoid this, the modulating valve is in-
stalled. When the transmission shift lever
is operated to shift the speed range, the
modulating valve allows the pressure on the
piston to rise slowly to the set pressure so
that the clutch can be engaged smoothly
and so that there will be no shock when
starting. This improves the durability of the
power train, and also gives a more comfort-
able ride.
. The diagram on the right shows the time
intervals and the rise in pressure when us-
ing the modulating valve.
For example, if the transmission is shifted
from Fl to F2, the oil from the pump passes
through the speed valve spool to the 2nd
clutch and fills the circuit up to the clutch
piston port.
The time taken to fill the circuit up to the
clutch piston port is called the FILLING TIME; MPa
Modulatine time
(ka/cm’)
the pressure is 0 - 0.3 MPa {O - 3 kg/cm2).
2.9 _ Fillins time Build-up time
The time taken from the point where the (30)
hydraulic pressure starts to rise (after the
2.6 _
oil fills the circuit up to the clutch piston ” (27)
pot-t) to the point where it reaches the set z 2.0 _
pressure is called the BUILD-UP TIME. % (20)
The total time for the filling time and build- :
up time is called the MODULATING TIME. 0
/i:1
0
0 0.5 1.0
(Sec. 1
Time
SAD01 307
1 O-38
From Pump
Operation
-4% 3
1. Immediately after shifting
When the transmission shift lever is oper-
ated and the clutch is engaged, the passage
from the pump to the clutch piston port is
opened and the oil flows to the clutch pis-
ton port.
When this happens, the passage between
port B and port D is restricted by orifice b,
so a difference in pressure is generated, and
b
quick return valve (6) is moved to the left by
the pressure at port B. This connects port E
and drain port F, and removes the back
pressure of load piston (3).
To clutch cylinder Drain 6 SAD0 1309
2. Pressure starting to rise, during rise A

When the oil sent under pressure from the
pump fills the circuit from port A to the
clutch piston port, the hydraulic pressure
starts to rise.
When this happens, the difference in pres-
sure on the two sides of orifice b of quick
return valve (6) is lost, and the quick return
valve is moved to the right to close the pas- b
sage between port E and drain port F.
The oil flows form orifice a of modulating
valve (2) to port C, and pushes piston (I).
Because of the reaction force, the modulat-
To clutch,cylinder SAD01311
ing valve compresses springs (4) and (5),
and moves to the right to drain the oil from
port A to port G.
At the same time, the oil flowing from ori- From Pump
fice e in quick return valve (6) through the
central port passes through orifice d and
enters port E. It becomes the back pressure,
of load piston (3), moves the load piston to
the left and compresses springs (4) and (5).
To clutch cylinder SAD01313
1o-39
3. During rise in oil pressure, completion of

From PurnP
rise
A G 2 5
As the pressure rises, the back pressure of \ @- I / /
load piston (3) increases. When the move-
ment of the load piston to the left increases,
modulating valve (2) closes the passage
between port A and port G because of the
tension of springs (4) and (5).
As the pressure at port C pushing piston (I)
increases, modulating valve (2) moves to
the right due to the reaction force, com-
presses springs (4) and (51, and opens the
passage between port A and port G.
By repeating this operation intermittently,
the load of springs (4) and (5) increases and
the pressure rises slowly. Finally, load pis-
ton (3) contacts the valve body and does
not move any further.
When this happens, modulating valve (2)
stops at the position where the passage from From Pump
port A to port G is closed, and the rise in
hydraulic pressure is completed.
The hydraulic pressure at this point is 2.6 -
2.8 126.4 - 28.4 kg/cm*). The oil from the
pump is relieved through the main relief
valve assembled to the torque converter as-
sembly.
There is a drill hole (0 0.85 mm) in the side
face of load piston (31, and in the range of
movement of the load piston where the hole
is open, oil is drained from this hole to port
G and the pressure rises. Therefore, the
pressure rises slowly and any shock when
shifting is reduced.
From Dump
To clutch
@9’
cylinder Drain
Drill hall
SAD01319
1O-40
Reducing valve From modulating valve
Outline
l The reducing valve is in the circuit between
the modulating valve and the 1st speed valve
spool. It reduces the pressure applied to the
1st clutch to 2.06’~.’ MPa (21’: kg/cm*).
The hydraulic pressure in the circuit as a
whole is set to 2.6 - 2.8 (26.4 - 28.4 kg/cm?
by the modulating valve.
To FR. 2nd. 3rd SPOOI To 1st spool

SAD01321
Operation
1. Valve OPEN From modulating valve
l The oil from the modulating valve flows 13

from port A. Some passes through port B I
and flows to the 1st valve spool, and at the
same time, passes through orifice a and
enters port D.
The oil also flows from port A through port
C, and flows to the 2nd and 3rd spools and
the directional spool.
. When the circuit up to the clutch that has
been shifted becomes filled with oil and the
pressure rises according to the operation of
the modulating valve, the oil passing
through orifice a of reducing valve (II)
pushes piston (12). The reaction force com- To FR. 2nd. 3rd SPOOI To 1st SPOOI
SAD01 323
presses spring (13) and moves reducing
valve (11) slowly to the left in accordance
with the rise in the hydraulic pressure, and
starts to throttle port B. From modulating valve
2. Valve CLOSED
. When the pressure in the whole circuit rises
further because of the action of the modu-
lating valve, reducing valve (11) moves fur-
ther to the left and closes the circuit from
the modulating valve, so the pressure in the
1st clutch circuit stops rising. The pressure
at this point is 2.06’~.’ MPa (21’02 kg/cm*). J-J-
To FR.Znd.3rd SPOOL To 1st spool

SAD01325
10-41
0
. If the pressure in the 1st clutch circuit drops

Fran reducing valve
because of leakage from the transmission Dart B
lubrication or seal ring, the reaction force of

the spring of reducing valve (11) opens the
circuit. This raises the pressure to the set
pressure of reducing valve (II) and main-
tains the set pressure.
Except for the 1st clutch circuit, the pres-
sure in all the circuits continues to rise to
the set pressure of the modulating valve.
* The 1st clutch is farthest from the control

valve, and the piping to the cylinder is
longer, so it takes a longer time for the oil
to fill the piping. 1st clutch Piston SAD01327
For this reason, even when the gear shift

lever is in neutral, oil still flows to the 1st
clutch.
Therefore, when moving the gear shift lever
from neutral to Fl, it is only necessary for
the oil from the pump to fill the FORWARD
clutch.
When the gear shift lever is moved from Fl
to F2, the FORWARD clutch is already filled
with oil, so the oil from the pump only needs
to fill the 2nd clutch. By using the oil in this
way, the time lag when shifting gear is re-
duced.
1 O-42
STRUCTURE AND FUNCTION LUBRICATION RELIEF VALVE
LUBRICATION RELIEF VALVE
l 2 3
ILU Lu
A-A
SBD01328
1. Lubrication oil pressure measurement plug Function

2. Lubrication relief spool l The lubrication relief valve is installed to
3. Valve body the right side face of the transmission, and
acts to prevent any dbnormal piessure in
the transmission lubricating oil’.
Cracking pressure: 0.26 MPa 12.7 kg/cm*}
1o-43
STRUCTURE AND FUNCTION SCAVENGING PUMP STRAINER
SCAVENGING PUMP STRAINER
1. Scavenging pump (BAR63+200)

2. Strainer
z-z SBD01329
A. Scavenging pump suction port
B. Scavenging pump delivery port
Outline
l The strainer is made of punched metal with
2-mm diameter holes.
1o-44
STRUCTURE AND FUNCTION POWER TRAIN PUMP STRAINER
POWER TRAIN PUMP STRAINER
-I=
1 -_I
SBDOI 330
1. Cover
2. Spring
3. Magnet
4. Screen
5. Case
A. From oil tank

B. To power train, lubrication pump
1o-45
STRUCTURE AND FUNCTION POWER TRAIN, LUBRICATING OIL FILTER
POWER TRAIN, LUBRICATING OIL FILTER
-z
SBD01331
1. Cover Performance
2. Element
Cracking 0.14{1.4)
3. Body Dressure MPa{kg/cm*l
4. Valve
Filter flow Umin I 273
5. Spring
Mesh size pm I 30
A. Inlet port
B. Outlet port
1O-116
STRUCTURE AND FUNCTION STEERING, BRAKE CONTROL
STEERING, BRAKE CONTROL
* For details of operation of the joystick for

the transmission system, see TRANSMIS-
SION CONTROL.
II IO
SLD01332
1O-48
STRUCTURE AND FUNCTION STEERING BRAKE CONTROL
Outline
Joystick (4) moves rods (I 1) and (8) to oper-
ate the steering clutch and brake. (The steer-
ing clutch and brake are interconnected.)
Brake pedal (I) moves rod (6) to operate
only the brake. In this case, the brake is
used for stopping the machine, so both the
left and right brakes are applied at the same
time.
If joystick (4) is moved slightly to the left,
the left steering clutch is partially disen-
gaged and the machine turns gradually to
the left.
If joystick (4) is moved fully to the left, the
left steering clutch is completely disengaged,
and in addition, the left steering brake is
applied, so the machine turns sharply to the
left.
Safety lever (2) is interconnected with park-
ing brake lever (91, and also acts as a park-
ing brake.
s: 1. Brake pedal
8
2. Safety lever
;;
3. Rod
(from joystick)
4. Jovstick Lever, pedal positions
(steering) 0: NEUTRAL
5. Limit switch 0: STRAIGHT TRAVEL FORWARD
6. Rod (from brake 0: STRAIGHT TRAVEL REVERSE
pedal) 0: LEFT CLUTCH DISENGAGED
7. Steering control 0: LEFT CLUTCH DISENGAGED,
valve LEFT BRAKE APPLIED
8. Rod (for left @: RIGHT CLUTCH DISENGAGED
steering) 0: RIGHT CLUTCH DISENGAGED,
9. Parking brake lever RIGHT BRAKE APPLIED
(from safety lever) 8: BRAKE RELEASED
10. Cable @: BRAKE APPLIED
11. Rod (for right @: FREE
steering) 0: LOCK
1o-49
STRUCTURE AND FUNCTION TRANSFER, BEVEL GEAR SHAFT. STEERING
TRANSFER, BEVEL GEAR SHAFT, STEERING
SE001333
B--l
1. Input shaft Function

2. Transmission l The power train unit can be broadly divided
3. Steering valve into the torque converter and transmission
4. Steering unit unit and the steering unit.
5. Breather Therefore, after the power train is removed
6. Torque converter speed sensor as a unit, it can be divided into the torque
converter and transmission unit and the
steering unit.
. The steering unit consists of the transfer,
bevel gear shaft, steering clutches, and steer-
ing brakes.
1O-50
STRUCTURE AND FUNCTION TRANSFER, BEVEL GEAR SHAFT, STEERING
TRANSFER, BEVEL PINION
li i0 9
B-0 SED01334
1. input shaft Outline

2. Drive shaft . The transfer and bevel pinion are installed
3. Drive gear (35 teeth) at the rear inside the steering case and re-
4. Rear cover ceive the motive force from the transmis-
5. support sion output shaft with input shaft (I). The
6. Torque converter speed sensor transfer consists of drive gear (3) and driven
7. Bearing cage gear (11). it reduces the speed of the mo-
8. Drum tive force from input shaft (I) and transmits
9. Cover it to bevel pinion (12).
10. Bearing cage Drive shaft (2) rotates drum (81, which sends
11. Driven gear (33 teeth) a pulse signal to torque converter speed
12. Bevel pinion sensor (6). This sends an electric signal for
the speed to the torque converter lock-up
controller.
10-51
1. Output shaft Outline

2. Sleeve l The steering clutches are wet, multiple-disc
3. Brake cage clutches with a spring booster. They are in-
4. Brake spring terconnected with the brakes and are hy-
5. Brake case draulically actuated by a steering valve that
6. Brake piston is actuated when the joystick is operated.
7. Torque pin A forced lubrication system is employed in
8. Spacer which the oil from the power train oil cooler
9. Brake plate (9 each) passes through the passage inside the steer-
IO. Brake disc (9 each) ing case, enters the housing and cage, and
11. Brake stopper is then sent to the discs and plates.
12. Brake hub
13. Pipe l The steering brakes are wet, multiple-disc
14. Bearing cage clutches with a spring booster. They are in-
15. Bevel shaft terconnected with the clutch and are hy-
16. Bevel gear shaft draulically actuated by a steering valve that
17. Bevel gear is actuated when the brake pedal and joy-
18. Bearing cage stick are operated.
19. Clutch hub A forced lubrication system is employed in
20. Clutch stopper which the oil from the power train oil cooler
21. Spacer passes through the passage inside the steer-
22. Clutch plate (9 each) ing case, enters the housing and cage, and
23. Clutch disc (9 each) is then sent to the discs and plates.
24. Torque pin The steering brakes are designed so that
g 25. Clutch piston when the engine has stopped, the back pres-
% 26. Clutch spring sure of the brake piston drops and the brakes
z 27. Clutch housing are applied without the brake pedal being
28. Clutch cage depressed. However, when the engine is
started again, the brake is released as the
hydraulic pressure inside the circuit rises,
so the parking brake lever must always be
locked.
1o-53
STRUCTURE AND FUNCTION STEERING CONTROL VALVE
STEERING CONTROL VALVE
Y
-I &Y’
2
Y-l
/
4
SAD01336
1o-54
27 26 25
T-----T\\
24 23 22 21
\ 20
x-x SAD01337
A. To right clutch
B. P port
C. To right brake
D. To left brake
E. Clutch valve drain
F. Brake valve drain
G. To left clutch
1. Right steering lever 11. Right brake valve 20. Roller (left steering)
2. Brake lever 12. Valve spring (clutch valve) 21. Guide (brake valve)
3. Left steering lever 13. Piston (clutch valve) 22. Modulating spring (brake valve)
4. Parking brake lever 14. Right clutch valve 23. Bolt (brake valve)
5. Body 15. Bolt (clutch valve) 24. Left clutch valve
6. Cover 16. Modulating spring 25. Left brake valve
7. Cover (clutch valve) 26. Piston (brake valve)
8. Parking brake valve 17. Guide (clutch valve) 27. Valve spring (brake valve)
9. Check valve 18. Roller (right steering)
IO. Roller (parking brake) 19. Roller (brake)
1o-55
Outline
. The steering control valve is in the circuit
between the power train pump (through the
main relief valve) and the pistons of the
steering clutch and brake. It consists of two
sets of steering valves and brake valves.
If the joystick (steering, directional) is moved
to the right or left, the steering clutch is
disengaged. If the joystick is moved further,
the brake is also applied.
It is possible to adjust between gradual and
sharp turning by the amount the joystick is
operated.
If the brake pedal is depressed, both the left
and right brakes are applied, and the ma-
chine will stop.
The above operations are carried out by
switching the steering control valve, which
is interconnected with the lever and pedal.
The steering control valve sends oil from
the power train pump to the steering clutch
and brake, and operates each disc clutch.
Valve control
. The steering control valve is operated by
left and right steering levers (I) and (31,
which are interconnected with the joystick,
and parking brake lever (4) and brake lever
(21, which are interconnected with the brake
pedal.
Left and right steering levers (I) and (3) use
a cam to interconnect the steering valve and
brake valve inside the the steering control
valve to carry out control.
lo-56
Operation
1. Joystick at neutral, brake pedal released
(Clutch engaged, brake released, parking brake OFF)
Joust ick Brake Pedal
Brake
Clutch
To main relief valve

Clutch
Brake
Parking brake OFF SAD01339
. When the joystick is at the NEUTRAL posi- the back pressure port of the clutch piston
tion and the brake pedal is released, levers returns from port C to drain port H, and the
(I), (2), and (3) are also at the NEUTRAL clutch is engaged by the tension of the clutch
position. The oil ports of each valve are spring.
opened or closed by the spring tension. . The rest of the oil pushes open check valve
The oil from the power train pump passes (91, enters port E of left and right brake
through the main relief valve and enters port valves (25) and (I I), and flows from port F
A of check valve (9). to the back pressure port of the brake pis-
Some of the oil entering port A flows to ton. When the oil pressure in the circuit rises,
port B of left and right steering valves (24) the piston moves to the left in the arrow
and (14), and stops there. Then, the oil from direction, compresses the brake spring, and
releases the brake.
1o-57
2. Joystick operated half way to left (left clutch disengaged, brake released, parking brake OFF)
utch
ake
oFb__
j
ON1
.I
B
8
Parkins brake OFF
z
SAD01340
When the joystick is operated half way to where it contacts bolt (23) of the brake valve,
the left, roller (20) of lever (3) pushes bolt the oil pressure beyond port C rises to the
(15) to the left in the arrow direction, and set pressure 2.5 + 0.1 MPa 125 rt 1 kg/cm21 of
compresses modulating spring (16). The re- the reducing valve and the clutch is com-
action moves steering valve (241 to the left pletely disengaged.
in the arrow direction. The oil pressure beyond port C is deter-
Then, port C and drain port H are closed, mined by the tension of modulating spring
and ports B and C are opened. (16), which changes the load according to
The oil from the power train pump enters the amount the joystick is moved.
port C from port B. Some of it flows to the Therefore, if the joystick is moved only
clutch piston port to form the back pres- slightly, the oil pressure beyond port C is
sure, and the rest passes through orifice b set low and the clutch is partially disen-
and enters port D. gaged. If the joystick is moved a greater
The oil entering port D pushes piston (131, distance, the oil pressure is set high and the
and the reaction compresses spring (16) clutch is completely disengaged.
and moves valve (24) to the right in the l Port J is connected to port C and reduces
arrow direction. This closes ports B and C, the operating force of lever (31, pushing bolt
so no oil goes beyond port C, and the oil (15) out to the left in the arrow direction.
pressure is maintained without rising any However, the oil pressure at port J (the
further. booster pressure) follows the oil pressure
If the joystick is operated further to the left, of port C, which changes in accordance with
the above operation is repeated, and when the change in the amount of joystick move-
roller (20) of lever (3) reaches the position ment, so the operating force of the joystick
also changes.
lo-58
4. Brake pedal depressed (clutch engaged, brake applied, parking brake OFF)
Brake pedal
Joystick at
neutral
H. Brake
H. Clutch
H. Clutch
25
H. Brake
I
\ “-
\
\‘I
Fl 11 93 OFF c-=Lf
Parkins brake OFF
SAD01342
. When the brake pedal is depressed, two roll-

ers (19) of lever (2) push left and right bolts
(23) to the left in the arrow direction, and
left and right brake valves (25) and (II) are
actuated in the same way as in Item 3.
Therefore, the oil pressure is set according
to the amount the brake pedal is operated,
and it is possible to adjust the braking force.
The left and right steering levers are not
operated, so the clutch is engaged.
1O-60
5. Parking brake ON (clutch engaged, brake applied, joystick at neutral, brake pedal released)
Joystick at Brake pedal

neutral
II. Brake
-l I
, , _. ~~~1~1~1~111,,/,,,,,,,,,,,,
_I f.......
F~~~~,,-,
1I-k1m.H. Clutch
I L
Clutch
Brake
Parking brake ON
SAD01343
. When the joystick safety lever is placed at F through port E, then passes through check
the LOCK position, roller (IO) of lever (4) valve (9) and parking brake valve (8) and is
pushes parking brake valve (8) to the left in drained. Parking brake valve (8) remains
the arrow direction. pushed in by lever (4) and roller (IO), so the
Check valve (9) is pushed by parking brake back pressure of the brake piston port con-
valve (81, and moves to the left in the arrow tinues to drop. As a result, the brake is fully
direction in the same way, so port A and applied and is held in this condition.
port E are closed. . Even if the engine is started again, check
The oil flowing to the brake piston port and valve (9) remains closed, so the brake is
forming the back pressure passes from port kept applied.
1O-61
FINAL DRIVE
STRUCTURE AND FUNCTION
FINAL DRIVE
--
-- _/-’
SED01344
1O-62
STRUCTURE AND FUNCTION FINAL DRIVE
A-A SED01345
1. Floating seal 8. Floating seal guard 15. No. 1 pinion (20 teeth)
2. Sun gear (16 teeth) 9. Cover 16. Final drive case
3. Carrier 10. Planetary pinion (26 teeth) 17. Bearing cage
4. Hub 11. Ring gear (68 teeth) 18. Boss
5. Cover 12. Cover 19. Shaft
6. Sprocket boss 13. No. 1 gear (79 teeth) 20. Wear guard
7. Sprocket teeth 14. No. 1 gear hub 21. Pivot shaft
1 O-63
STRUCTURE AND FUNCTION FINAL DRIVE
PATH OF POWER TRANSMISSION
SEC101346
. The power from the bevel gear and steering Then, the rotating force of sun gear (2) forms
clutch is transmitted to No. 1 pinion (15). It the rotating force of carrier (31, which sup-
then passes through No. 1 gear (131, which ports the planet pinion, and is transmitted
is meshed with the No. 1 pinion, and is to sprocket hub (4).
transmitted to sun gear (2) to rotate it. The direction of rotation of carrier (3) is the
The rotation of sun gear (2) is transmitted same as that of sun gear (2).
to planet pinion (IO), but ring gear (II), The rotating force transmitted to sprocket
which is meshed with the planet pinion, is hub (4) is transmitted to sprocket teeth (7).
fixed to cover (91, so the planet pinion ro-
tates on its own axis and moves around the
sun gear along the ring gear.
1 O-64
STRUCTURE AND FUNCTION TRACK FRAME
TRACK FRAME
SAD01347
Outline Track roller, bogie

. The track roller uses an X-shape bogie
mount to increase the ground contact area Track roller flange type and bogie
between the track shoe and ground surface
on rough surfaces, thereby increasing the
drawbar pull.
. The X-shape bogie is fitted with rubber pads Track roller S D D S D S
to absorb the shock from the ground sur-
face.
1O-66
STRUCTURE AND FUNCTION TRACK FRAME
I______--___
r-r----- _-___I --
i j
i___. I
A-A 8-B SAD01348
1. Idler
2. Recoil spring assembly
3. Carrier roller
4. Track frame
5. Sprocket
6. Sprocket guard
7. Track roller bogie
8. Track roller
9. Track roller support guard
10. Cap
11. Idler bogie
12. Guide
13. Stopper pin
1 O-67
STRUCTURE AND FUNCTION RECOIL SPRING
RECOIL SPRING
L-1
A-A
SKD01349
1. Yoke Outline
2. Nut . Recoil spring (4) is used to adjust the track
3. Retainer tension by pumping in or releasing grease
4. Recoil spring from lubricator (IO) to move rod (5) forward
5. Rod or backward. The recoil spring (4) also acts
6. Spring cylinder to dampen any sudden shock brought to
7. Retainer bear on the idler.
8. Piston
9. Grease chamber cylinder
10. Lubricator
(for pumping in and releasing grease)
11. Pin
10-68
STRUCTURE AND FUNCTION TRACK ROLLER BOGIE
TRACK ROLLER BOGIE
5 6 7 3 4 4
--------.
c
____-_-i-.
A-A
3 I I
! 4 !
ii___--..j ___ ,--q t__
\ I
__~__
SAD01350
1. Rubber mount Outline

2. Track roller . One track roller is mounted to each of inner
3. Inner bogie bogie (3) and outer bogie (4) to ensure that
4. Outer bogie the track roller and track shoe are always in
5. Cartridge pin contact.
6. Floating seal . Rubber mount (I) is used to absorb the ma-
7. Bushing chine vibration caused by contact with the
8. Plug ground.
9. Bogie mount cap
lo-69
STRUCTURE AND FUNCTION MAIN FRAME
MAIN FRAME
H4
A-A E-E F-F G-G H-H SBD01351
1. Main frame 6. Cage 11. Cap

2. Bracket 7. Clamp 12. Cushion
3. Cap 8. Seal 13. Bushing
4. Cushion 9. Cover 14. Flange
5. Plate 10. Coupling 15. Cushion spacer
1O-70
STRUCTURE AND FUNCTION SUSPENSION
SUSPENSION
!i
-__--
--
---‘_.I
I ‘2
SAD01352
1 O-72
STRUCTURE AND FUNCTION SUSPENSION
A-A
x2
A-A SAD01353
%I With blade tilt

%2 Without blade tilt
1. Equalizer bar 9. Seal rubber

2. Pivot shaft assembly 10. Bushing
3. Cover 11. Seal
4. Thrust plate 12. Bushing
5. Thrust plate 13. Side pin
6. Pivot shaft 14. Stopper rubber
7. Seal gauge 15. Center pin
8. Cover 16. Bushing
1o-73
STRUCTURE AND FUNCTION WORK EQUIPMENT HYDRAULIC PIPING DIAGRAM
WORK EQUIPMENT HYDRAULIC PIPING DIAGRAM

BLADE SYSTEM
lSEMI U + TILT
SLD01355
1. Blade tilt cylinder 6. Hydraulic tank

2. R.H. blade lift cylinder 7. Ripper Hi valve
3. Blade lift valve 8. Work equipment + PPC charge pump
4. Blade tilt, ripper Lo valve (SAR(4)140+(3)071+(1)022)
5. Hydraulic filter 9. L.H. blade lift cylinder
1o-74
l U-DOZER + DUAL TILT
SLD01356
1. Blade tilt cylinder 8. Hydraulic tank

2. R.H. blade lift cylinder 9. Ripper Hi valve
3. Pitch solenoid valve 10. Work equipment + PPC charge pump
4. Dual tilt solenoid valve (SAR(4)140+(3)071+(1)022)
5. Blade lift valve 11. L.H. blade lift cylinder
6. Blade tilt, ripper Lo valve 12. Blade pitch cylinder
7. Hydraulic filter
1o-75
RIPPER SYSTEM
l MULTIPLE SHANK RIPPER
SED01357
1. Ripper Hi valve
2. Ripper tilt cylinder
3. Ripper lift cylinder
lo-76
l GIANT RIPPER
3 k

2. Ripper Hi valve
5. Pin puller cylinder
(from power train hydraulic circuit)
6. Solenoid valve (for pin-puller)
1o-77
STRUCTURE AND FUNCTION PPC CONTROL PIPING DIAGRAMPPC CONTROL PIPING DIAGRAM
PPC CONTROL PIPING DIAGRAM

BLADE, RIPPER CONTROL
SLD01359
1. Blade lift valve 6. Blade control PPC valve

2. Blade tilt, ripper Lo valve 7. PPC lock valve
3. PPC charge valve 8. PPC charge pump (SAR(lj022)
4. Accumulator 9. Hydraulic pump (SAR(4)140+(3)071)
5. Ripper control PPC valve 10. Oil cooler (for PPC)
1 O-78
STRUCTURE AND FUNCTION WORK EQUIPMENT CONTROL
WORK EQUIPMENT CONTROL

l The diagram shows a machine equipped with pitch dozer and pin puller cylinder
SLD01360
Lever positions
Blade HOLD 0: Pitch selector switch ON 1. Work equipment safety lever
Blade LOWER 8: Dual tilt selector switch OFF 2. Blade control lever
Blade FLOAT 0: Dual tilt selector switch dN 3. Tilt/pitch selector switch
Blade RAISE @: Pin puller switch PUSH IN 4. Ripper control lever
Blade (left tilt/pitch) @: Pin puller switch PULL OUT 5. Pin puller switch
Blade (right tilt/pitch) 6. PPC lock valve
Ripper HOLD Outline
Ripper RAISE . The work equipment control employs a PPC
Ripper LOWER system which uses a PPC valve to move the
Ripper TILT IN spools of the control valve.
Ripper TILT BACK . Work equipment safety lever (I) is intercon-
FREE nected with PPC lock valve (61, and when it
LOCK is at the LOCK position, the flow of oil in
Pitch selector switch OFF the PPC circuit is stopped.
1o-79
;I; WORK EQUIPMENT HYDRAULIC SYSTEM DIAGRAM
zs TILTDOZER
019503
019503
WORK EQUIPMENT HYDRAULIC CIRCUIT DIAGRAM 1. Hydraulic tank

1A. Oil filler cap
2. Strainer
Ir For details of the pin puller cylinder, see POWER TRAIN HYDRAULIC CIRCUIT DIAGRAM. 3. PPC charge pump (SAR(1)022)
4. PPC charge valve
* For details of this page, see Section 90. Set pressure: 4.46 MPa (45.5 kg/en?)
5. Accumulator
6. Oil cooler (for PPC)
7. PPC lock valve
8. Blade control PPC valve
8A. For blade lift
89. For blade tilt
9. Ripper control PPC valve
9A. For ripper lift
99. For ripper tilt
IO. Hydraulic pump (SAR(4)140+(3)071)
11. Blade lift control valve
11A. Demand valve
119. Main relief valve
Set pressure: 20.6 MPa (210 kg/cm21
1 IC. Shuttle valve
11D. Check valve
1 IE. Check valve
1 IF. Blade lift valve
11G. Suction valve (for blade lift)
1 IH. Shuttle valve
12. Blade tilt, ripper Lo valve
12A. Main relief valve
Set pressure: 20.6 MPa (210 kg/cm*)
128. Check valve
12C. Blade tilt valve
12D. Check valve
12E. Ripper tilt valve
12F. Check valve
12G. Ripper lift valve
12H. Shuttle valve
13. Ripper Hi valve
13A. Check valve
139. Check valve
13C. Ripper lift (Hi) valve
13D. Ripper lift fixed differential pressure valve
13E. Ripper lift fixed differential pressure valve
13F. Shuttle valve
13G. Shuttle valve
13H. Suction valve (for ripper lift)
13J. Ripper tilt (Hi) valve
13K. Ripper tilt fixed differential pressure valve
13L. Ripper tilt fixed differential pressure valve
13M. Shuttle valve
13N. Shuttle valve
^...
14. uwx arop valve
15. R.H. blade lift cylinder
16. L.H. blade lift cylinder
17. Blade tilt cylinder
18. R.H. ripper tilt cylinder
19. R.H. ripper lift cylinder
20. L.H. ripper lift cylinder
21. L.H. ripper tilt cylinder
22. Hydraulic filter
Set pressure: 0.15 MPa (1.5 kg/cm?)
STRUCTURE AND FUNCTION WORK EQUIPMENT HYDRAULIC SYSTEM DIAGRAM
lo-82
STRUCTURE AND FUNCTION WORK EQUIPMENT HYDRAULIC CIRCUIT DIAGRAM
!
~ ri
T
.___________----_----------~
8
.______________--------------~
r-1 /
,.__________________..~
,a,= i I
1
9
I I
I I I
lo-83
STRUCTURE AND FUNCTION HYDRAULIC TANK
HYDRAULIC TANK
‘T SEC101363
1. Sight gauge Outline

2. Oil filler . The hydraulic tank has an assembled type
3. Valve (externally installed) main control valve and
4. Hydraulic filter a built-in hydraulic filter. The tank capacity
5. Baffle tube is 2302 and the amount of oil inside the tank
6. Blade tilt, ripper Lo valve is set at 1206.
7. Blade lift valve
PI. From large pump

A. To blade lift cylinder head
B. To blade lift cylinder bottom
P. From small pump
Al. To blade tilt cylinder bottom
Bl. To blade tilt cylinder head
A2. To ripper tilt cylinder bottom
B2. To ripper tilt cylinder head
A3. To ripper lift cylinder head
B3. To ripper lift cylinder bottom
T. From ripper Hi valve
1O-84
STRUCTURE AND FUNCTION PPC CHARGE VALVE
PPC CHARGE VALVE
C. To oil cooler
P. From PPC pump
P2. To PPC valve
T. To hydraulic tank
7’ A-A c-c
SAD01364
Unit: MPa {kg/cm21
1. Strainer Item Set value

2. Body
Cracking pressure MPa Ikg/cm? 3.76 W-6}
Relief
4. Valve valve Set pressure MPa {kg/cm3 4.46 {46.51
5. Spring Relief valve
Oil cooler
6. Sleeve b_pass va,ve Cracking pressure kPa {kg/cm? g; .!y
3.
7. Piston
Screw 1 Accumulator
Cracking pressure MPa {kg/cm*1 {~fi~,‘opd$
8. Accumulator check valve
9. Accumulator check valve Mesh size 24x110
Fm
IO. Oil cooler bypass valve Strainer
Filtering area cm2 62.2
1O-85
0
STRUCTURE AND FUNCTION PPC CHARGE VALVE
1. Adjustment screw
2. Lock nut
3. Sleeve
4. Main valve spring
5. Pilot piston
6. Main valve
l Set pressure: 4.46 MPa (45.5 kg/cm21

(At 44.5 e/min)
SYD00306
Outline
l The PPC charge valve acts to relieve the oil
sent from the pump when the PPC valve is
at NEUTRAL.
It also acts to set the pressure sent to the
PPC valve to the set pressure.
Operation
l Chamber A is connected to the pump circuit
and chamber C is connected to the tank drain
circuit. The oil passes through the orifice in
the main valve and fills chamber B.
0 A
sY000307
When the pressure in chamber A rises, and

the differential pressure [z//4 (D*- d*) x pres-
sure of chamber Al caused by the differ-
ence in the area of diameter D and d reaches
the pressure set by the main valve spring,
the main valve opens. The pressurized oil in
chamber A then escapes to chamber C, so
the pressure in chamber A drops.
/ \ \
d 6 D
SYD00308
1O-86
STRUCTURE AND FUNCTION ACCUMULATOR
ACCUMULATOR
FOR PPC VALVE
1. Gas plug
2. Shell
3. Poppet
4. Holder
5. Bladder
6. Oil port
Specifications:
Type of gas: Nitrogen
Gas volume: 300 cc
Max. actuation pressure: 3.1 MPa 132 kg/cm*}
Min. actuation pressure: 1.2 MPa {I2 kg/cm*}
Function
l The accumulator is installed between the
PPC charge pump and the PPC valve. Even
if the engine is started with the work equip-
ment still raised, the pressure of the nitro-
gen gas compressed inside the accumula-
tor sends the pilot pressure to the main con-
trol valve to actuate it and enable the work
equipment to move down under its own
weight.
Before actuation After actuation
Operation
l After the engine is stopped, when the PPC
valve is at neutral, chamber A inside the
bladder is compressed by the oil pressure
in chamber B.
. When the PPC valve is operated, the oil pres-
sure in chamber B goes below 2.9 MPa 130
kg/cm*}, and the pressure of the nitrogen
gas in chamber A expands the bladder, so
the oil in chamber B acts as the pilot pres-
sure and actuates the main control valve.
1O-87
STRUCTURE AND FUNCTION PPC LOCK VALVE
PPC LOCK VALVE
1. Lever
2. End cap
3. Ball
4. Seat
5. Body
SYDoO312
Outline
. The PPC lock valve is installed in the PPC
circuit between the PPC charge valve and
PPC valve. If the work equipment safety le-
ver is placed at the LOCK position, the PPC
lock valve is actuated together with the work
equipment safety lever. This stops the oil in
the PPC circuit and makes it impossible to
operate the work equipment.
1O-88
STRUCTURE AND FUNCTION PPC VALVE
PPC VALVE
FOR BLADE LIFT, TILT
SKD01435
P. From PPC charge valve port P2 (through

PPC lock valve)
PI. To blade lift valve (LOWER) port P3
P2. To blade lift valve (RAISE) port P4
P3. To blade tilt valve (left tilt) port PA1
P4. To blade tilt valve (right tilt) port PBI
10-90
STRUCTURE AND FUNCTION PPC VALUE
.8
SKD00535
1. Spool 6. Nut (for lever joint)

2. Metering spring 7. Joint
3. Centering spring 8. Plate
4. Pistion 9. Retainer
5. Disc 10. Body
1o-91
Operation
I) At neutral
(i) PPC value for blade lift
Ports PA and PB of the blade lift control
valve, and ports PI and P2 of the PPC valve
are connected to drain chamber D through
fine control hole f in spool (I).
SKD01437
(ii) PPC valve for blade tilt

Ports PA1 and PBI of the blade tilt control
valve, and ports P3 and P4 of the PPC valve
are connected to drain chamber D through
fine control hole f in spool (1).
SKD01439
1o-92
21 During fine control (neutral- fine control)

When piston (4) starts to be pushed by
disc (51, retainer (9) is pushed; spool (1)
is also pushed by metering spring (21,
and moves down.
When this happens, 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, so pilot
pressure oil from the charging pump
passes through fine control hole f and
goes from port PI to port PB.
When the pressure at port PI becomes
higher, spool (I) is pushed back and fine
control hole f is shut off from pump pres-
sure chamber PP.
At almost the same time, it is connected
to drain chamber D to release the pres-
sure at port PI.
When this happens, spool (I) moves up
or down so that the force of metering
spring (2) is balanced with pressure at
port PI.
The relationship in the position of the
spool (I) and body (IO) (fine control hole
f is at a point midway between drain
hole D and pump pressure chamber PP)
does not change until retainer (9) con-
tacts spool (I).
Therefore, metering spring (2) is com-
pressed proportionally to the amount of
movement of the control level, so the
pressure at port PI also rises in propor-
tion to the travel in the control lever.
In this way the control valve spool
moves to a position where the pressure
in chamber PB (the same as the pres-
sure at port PI) and the force of the
control valve spool return spring are
balanced.
1o-93
3) During fine control

(when control lever is returned)
When disc (5) starts to be returned, spool
(1) is pushed up to the force of centering
spring (3) and the pressure at port PI.
When this happens, fine control hole f
is connected to drain chamber D, and
the pressure oil at port PI is released.
If the pressure at port PI drops too far,
spool (I) is pushed down by metering
spring (21, and fine control hole f is shut
off from drain chamber D. At almost
the same time it is connected to pump
pressure chamber PP, and the pump
pressure is supplied until the pressure
at port PI recovers to a pressure that
corresponds to the lever position.
When the spool of the control valve re-
turns, oil in drain chamber D flows in
from fine control hole f’ in the valve on
the side that is not working.
The oil passes through port P2 and en-
ters chamber PA to fill the chamber with
Lift control
oil.
SKD01443
4) At full stroke
When disc (5) pushes down piston (4),
and retainer (9) pushes down spool (I),
fine control hole f is shut off from drain
chamber D, and is connected with pump
pressure chamber PP.
Therefore, the pilot pressure oil from the
charging pump passes through fine con-
trol hole f and flows to chamber PB from
port PI, and pushes the control valve
spool.
The oil returning from chamber PA from
port P2 through fine control hole f’ and
flows to drain chamber D.
-
SKD01445
1oi94
5) Blade operated to FLOAT

When piston (4) at port PI (LOWER side)
is pushed by disc (5) and moves down,
protrusion a of the piston contacts ba,lI
(11) during the downward stroke. (The
detent starts to be actuated.)
If piston (4) is pushed further, ball (11)
pushes up collar (121, which is being.
held by detent spring (13), and moves
to the outside, so the ball passes over
protrusion a of the piston. At this point,
piston (4’) at the opposite side is pushed
up by the spring (14).
As a result, the oil inside chamber F
flows through b and c and enters cham-
ber E, and piston (4’) follows disc (5).
Passage d is interconnected with port
PI, so it is under more or less the same
pressure as port PI.
Chamber E is normally interconnected
with drain chamber D, but when ball
(11) passes over protrusion a of the pis-
ton, passage d and chamber E (which
were shut off) are interconnected and
pressurized oil flows. At the same time, SKD01447
the control valve also moves to the
FLOAT position, so the blade circuit is
set to the FLOAT condition. The pressu-
rized oil inside chamber E pushes up
piston (4’), so even of the lever is re-
leased, it ‘is held at the FLOAT position.
6) Blade released from FLOAT

When disc (5) is returned from the
FLOAT position, it is pushed down by a
force greater than the pressure of the
oil in chamber E.
For this reason, chamber E is shut off
from passage d and is connected to the
drain chamber. Therefore, the oil pres-
sure inside chamber E is lost, and the
FLOAT, position is released.
1o-95
FOR RIPPER
C A
P4
SKD01448
P. From PPC charge valve port P2 (through

PPC lock valve)
PI. To ripper tilt valve (TILT BACK) port PB2
P2. To ripper tilt valve (TILT IN) port PA2
P3. To ripper Iif? valve (LOWER) port PA3
P4. To ripper lift valve (RAISE) port PB3
1 O-96
A-A B-B
D-D
E-E
SYD00314
1. Spool 7. Joint
2. Metering spring 8. Plate
3. Centering spring 9. Retainer
4. Piston IO. Body
5. Disc 11. Filter
6. Nut (for lever joint)
1o-97
Operation
1) At neutral
Ports PA2, PA3, PB2 and PB? of the ripper
control valve and ports PI, P2, P3, and P4 of
the PPC valve are connected to drain cham-
ber D through fine control hole f of spool
(I).
21 During fine control (neutral + fine control)

When piston (4) starts to be pushed by disc
(5), retainer (9) is pushed; spool (I) is also
pushed by metering spring (21, and moves
down.
When this happens, fine control hole f is SLD01450
shut off from drain chamber D, and at al-
most the same time, it is connected to pump
pressure chamber PP, so pilot pressure oil
from the charging pump passes through fine
control hole f and goes from port P2 to Port
PA2.
When the pressure at port P2 becomes
higher, spool (I) is pushed back and fine
control hole f is shut off from pump pres-
sure chamber PP.
At almost the same time, *it is connected to
drain chamber D to release the pressure at
port P2.
When this happens, spool (I) moves up or
down so that the force of metering spring
(2) is balanced with the pressure at port P2.
The relationship in the position of the spool
(I) and body (IO) (fine control hole f is at a
point midway between drain hole D and
pump pressure chamber PP) does not
change until retainer (9) contacts spool (I).
Therefore, metering spring (2) is compressed
proportionally to the amount of movement
of the control lever, so the pressure at port
P2 also rises in proportion to the travel in
the control lever.
In this way the control valve spool moves
to a position where the pressure in cham-
ber PA2 (the same as the pressure at port
P2) and the force of the control valve spool
return spring are balanced.
1O-98
During fine control

(when control lever is returned)
When disc (5) starts to be returned, spool
(I) is pushed up by the force of centering
spring (3) and the pressure at port P2.
When this happens, fine control hole f is
connected to drain chamber D and the pres-
sure oil at port P2 is released.
If the pressure at port P2 drops too far, spool
(I) is pushed down by metering spring (2),
and fine control hole f is shut off from drain
chamber D. At almost the same time, it is
connected to pump pressure chamber PP,
and the pump pressure is supplied until the
pressure at port P2 recovers to a pressure
that corresponds to the lever position.
When the spool of the control valve returns,
oil in drain chamber D flows in from fine
control hole f’ in the valve on the side that
is not working.
The oil passes through port PI and enters
chamber PBI to fill the chamber with oil.
SLD01454
At full stroke
When disc (5) pushes down piston (41, and
retainer (9) pushes down spool (I), fine con-
trol hole f is shut off from drain chamber D,
and is connected with pump pressure cham-
ber PP.
Therefore, the pilot pressure oil from the
charging pump passes through fine control
hole f and flows to chamber PA1 from port
P2, and pushes the control valve spool.
The oil returning from chamber PBl passes
from port PI through fine control hole f
and flows to drain chamber D.
SLD01456
1o-99
STRUCTURE AND FUNCTION PISTON VALVE
PISTON VALVE
(BLADE LIFT CYLINDER)
Outline
l The piston valve is installed on the piston
in the blade lift cylinder. When the piston
reaches its stroke end, the valve releases
the oil from the hydraulic pump to reduce
the oil pressure being exerted on the pis-
ton.
When the blade is tilted, the blade is sub-
ject to a tortional force owing to the uneven
position of the pistons in the two cylinders;
that is the piston one side is still moving
while the piston on the other side has
reached its stroke end.
The piston valves are installed to prevent
the tortional force from occurring. When
one of the pistons reaches its stroke end, its
piston valve opens to relieve the oil pres-
sure.
In addition the piston valve relieves the
shock which occurs when the piston comes
into contact with the cylinder head or the
bottom and serves to reduce the subsequent
surge pressure in the cylinder by letting the
oil escape from the cylinder before the pis-
ton reaches its stroke end.
Operation
1. Piston valve CLOSED
Pressurized oil from the hydraulic pump acts
on piston (2) and piston valve (3).
The piston valve (3) is pushed in the direc-
tion of the arrow until piston valve seat (4)
comes into snug contact with the tapered
section, thereby, this causing. the pressure
in the cylinder to rise and moving piston (2)
in the direction of the arrow.
‘4 SAD00206
2. Piston valve OPEN

Just before piston rod (I) reaches the end
1 3 2 6 Contact
of its stroke, the tip of valve (6) contacts the
cylinder bottom, so valve (6) and piston
valve (3) stop at that position and do not
move further. Only piston (2) moves fur-
ther.
When this happens, the oil at the cylinder
head, which was sealed by piston valve (3),
escapes from piston valve seats (4) and (51,
and the pressure inside the cylinder stops
rising. \
i 4 SAD00207
10-100
STRUCTURE AND FUNCTION QUICK DROP VALVE
QUICK DROP VALVE

(BLADE LIFT CYLINDER)
Structure
The quick drop valve consists of valve body (I),
spool (21, check valve (31, and spring (4).
The quick drop valve serves to increase the
blade lowering speed and to reduce the occur-
rence of vacuum when the blade is lowering,
thereby shortening the time lag before digging
is started.
The blade lowering speed, which is generally
determined by the pump discharge, can be
made faster with the quick drop valve.
1. Valve body
2. Spool
3. Check valve
4. Spring
Operation
1. Start of lowering
When the blade lever is operated to LOWER,
the oil from the control valve enters the
8 cylinder bottom through port A and pushes
s the piston. In the meantime, the oil in the
;; cylinder head is pushed out into the piston,
enters valve port B, and flows into the tank
from port C.
2. While lowering
Pressurized oil from the cylinder head flows
into port C through port B.
At this time, the oil flow is restricted by an
orifice a provided along the way, causing a
differential pressure between front and back
of orifice.
When the pressure of port B becomes
greater than the force of spring (4), it com-
presses the spring and moves spool (2) and
check valve (3) to the right.
When the spool and the check valve have
moved, the circuit of port B and A is opend,
part of the oil flowing from the cylinder head
to port C enters the passage port A, and
merged with the oil from the control valve,
and flows to the cylinder bottom.
Thus, the blade lowering speed increases in
accordance with the amount of oil that flows
to the bottom of the cylinder and reduces
the formation of vacuum at the bottom of SBD00739
the cylinder.
10-1-01
STRUCTURE AND FUNCTION PIN PULLER SWITCH
PIN PULLER SWITCH
@
1
Structure of circuit SED01393
Function 1. Connector
l The pin puller solenoid valve is controlled 2. Wire
by turning the pin puller switch ON/OFF. 3. Switch
This changes the oil circuit to the pin puller 4. Knob
cylinder and sets the shank mounting pin to
the PUSH IN or PULL OUT position.
10-102
STRUCTURE AND FUNCTION PIN PULLER SOLENOID VALVE
PIN PULLER SOLENOID VALVE
A fB
1
P T
1 2 5 6 ,‘I 8 9
\ I I /
SKDO0214
1. Plug A. To pin puller cylinder bottom

2. Spring B. To pin puller cylinder head
3. Spring retainer P. From power train pump
4. Valve body T. To steering case
5. Spool
6. Spring retainer
7. Spring
8. Push pin
9. Solenoid assembly
10-103
STRUCTURE AND FUNCTION PIN PULLER SOLENOID VALVE
Operation From Power train Pump Switch at

1. Pin puller switch at PUSH IN position
When the pin puller switch is set to the
PUSH IN position, no electric current flows
to solenoid (9) and it is deenergized.
Then, ports P and A and ports B and P of
spool (5) open, and the oil from the power 9
train pump flows from port P to port A, and
enters the bottom end of pin puller cylinder
(IO).
When the oil enters the bottom end of the
cylinder and the pressure in the circuit starts
to rise, the cylinder extends and pushes
shank mounting pin (11) into shank (12).
2. Pin puller switch at PULL OUT position From Power train Pump Switch at
When the pin puller switch is set to the
PULL OUT position, electricity flows to sole-
noid (9) and it is excited.
Then, the solenoid pushes out push pin (8)
and spool (5) moves to the left in the arrow
direction.
At this point, ports P and A and ports B and
T close, and ports P and B and ports A and
T open, so the oil from the power train pump
flows from port P to port B and enters the
head end of pin puller cylinder (IO).
When the oil enters the cylinder head end
and the pressure in the circuit rises, the cyl-
inder retracts and pulls shank mounting pin
(II) out of shank (12).
SLDO1395
10-104
STRUCTURE AND FUNCTION BLADE CONTROL KNOB
BLADE CONTROL KNOB

MACHINES EQUIPPED WITH DUAL TILT
Dual tilt Pitch
Structure of circuit
6
SBDO1283
1. Switch (pitch)
2. Switch (dual tilt) The blade lift, lower, left tilt, and right tilt
3. Cover are operated by moving the blade control
4. Cover knob to the front, rear, left, or right. In
5. Connector (male) addition, if the lever is moved to the left
6. Connector (male) and right while pressing switch (I) or (21,
the dual tilt or pitch operation can be car-
ried out.
Press switch (I) and operate the lever to
pitch the blade. Operate the lever to the left
for pitch back and to the right for pitch
dump.
Press switch (2) and operate the lever to
operate the dual tilt for the blade. Operate
the lever to the left for left dual tilt and to
the right for right dual tilt.
If switches (I) and (2) are both pressed at
the same time the blade is pitched. (Prior-
ity is given to the pitch operation.)
10-105
STRUCTURE AND FUNCTION PITCH, DUAL TILT SOLENOID VALVE
PITCH, DUAL TILT SOLENOID VALVE

MACHINES EQUIPPED WITH DUAL TILT
Pitch
,---,-_- -7
SBD01459
Function 1. Main spool assembly

. This valve is installed between the blade 2. Pilot solenoid assembly
tilt, pitch cylinder and the blade tilt, ripper 3. Connector
Lo valve. It acts to open or close the hy-
draulic circuit to the blade tilt or pitch cylin- A. To R.H. blade pitch (dual tilt) cylinder bottom
der according to the pitch or dual tilt switch B. To R.H. blade pitch (dual tilt) cylinder head
signal. Tl. To L.H. blade pitch (dual tilt) cylinder bottom
T2. To L.H. blade pitch (dual tilt) cylinder head
Pl,P2. From blade tilt control valve
P. From PPC charge valve
lo-106
PITCH, DUAL TILT SOLENOID VALVE
Operation
Pitch switch ON
. When pitch switch (I) is operated, electric-
ity flows to pitch solenoid valve (2) and it is
excited. When this happens, main spool (4)
opens the circuit between port Tl and B
and between A and PI, and the hydraulic
circuit is connected to the bottom end of
left pitch cylinder (5) and to the head end of
right pitch cylinder (6). As a result, both the
right pitch cylinder and left pitch cylinder
are retracted and the blade is pitched to the
rear.
Dual tilt switch ON

. When dual pitch switch (2) is operated, elec-
tricity flows to dual tilt solenoid valve (3)
and it is excited. When this happens, main
spool (4) opens the circuit between port T2
and B and between A and P2, and the hy-
draulic circuit is connected to the head end
of left tilt cylinder (5) and to the bottom end
of right tilt cylinder (6). As a result, the left
dual tilt cylinder is extended and the right
dual tilt cylinder is retracted to tilt the blade.
10-107
STRUCTURE AND FUNCTION MAIN CONTROL VALVE
MAIN CONTROL VALVE

BLADE LIFT VALVE
P2 Pl B PA ‘A
SAD01366
Outline PI. From large pump

. Demand valve (14) is assembled to the blade P2. From small pump
lift valve, and the oil from the two hydraulic A. To blade lift cylinder head
pumps is merged by check valve (4). B. To blade lift cylinder bottom
With the demand valve, the oil from the T. To hydraulic tank
large pump becomes the pilot pressure, and PA. From blade lift PPC valve port P2
at the same time, the oil from the ripper PB. From blade lift PPC valve port PI
circuit or the blade lift circuit through shut- PL. From ripper Lo valve
tle valve (18B) also becomes the pilot pres-
sure, so the oil from the two hydraulic
pumps is used efficiently.
lo-108
1’2 i i
A-A
D-D SAD01367
1. Check valve spring 9. Shuttle valve ball 17. Suction valve spring
2. Small pump circuit check valve 10. Shuttle valve seat (plug) 18. LOWER suction valve
3. Check valve 11. Retainer 19. Main relief, shuttle valve
4. Check valve spring 12. Return spring (for FLOAT) assembly
5. Valve body 13. Case 19A. Main relief valve
6. Return spring 14. Demand valve spring 19B. Shuttle valve
7. Blade lift valve 15. Demand valve
8. Shuttle valve seat (plug) 16. RAISE suction valve
10-109
MAIN RELIEF, SHUlTLE VALVE
PL
PO
A-A
10-110
STRUCTURE AND FUNCTION MAJN CONTROL VALVE
1. Valve body Outline

2. Piston . The main relief valve is in the circuit be-
3. Shuttle valve tween the hydraulic tank and the ripper cir-
4. Shuttle valve spring cuit and blade lift circuit through shuttle
5. Plug valve (3). The oil pressure in the blade lift
6. Valve seat circuit, that is, the large pump circuit, is set
7. Main relief valve poppet at 20.6 MPa 1210 kg/cm2).
8. Main relief valve spring . The shuttle valve is in the circuit between
9. Sleeve the demand valve through the main relief
10. Main relief pressure adjustment screw valve and the blade lift circuit and ripper
circuit. It selects the two circuits to apply
PL. From shuttle valve inside ripper valve the pilot pressure to the demand valve.
PB. From- shuttle valve inside blade lift valve In other words, it selects either the blade lift
PD.To demand valve pilot port circuit or the ripper circuit.
T. To hydraulic tank When the work equipment is not being used
(when the control lever is at neutral) the
shuttle valve connects the blade lift circuit
and the pilot port of the demand valve by
the tension of spring (4).
10-m
BLADE TILT, RIPPER LO VALVE
Pi1 Bi Pi2 PL
llll -
SAD01 369
P. From small pump PAI. To blade tilt PPC valve P3 (left tilt)
Al. To blade tilt cylinder bottom PA2. To ripper tilt PPC valve P2 (tilt in)
Bl. To blade tilt cylinder head PA3. To ripper lift PPC valve P3 (lower)
A2. To ripper tilt cylinder bottom (through ripper Hi valve PAI) PBI. To blade tilt PPC valve P4 (right tilt)
B2. To ripper tilt cylinder head (through ripper Hi valve PBI) PB2. TO ripper tilt PPC valve PI (tilt back)
A3. To ripper lift cylinder head (through ripper Hi valve PB2) PB3. To ripper lift PPC valve P4 (raise)
B3. To ripper lift cylinder bottom (through ripper Hi valve PAZ
CO. To demand valve
PL. To shuttle valve inside blade lift valve
10-112
I!’
A-A
c-c SAD01370
1. Blade tilt valve 9. Sleeve 18. Check valve spring

2. Ripper tilt valve 10. Main relief valve body 19. Valve seat
3. Ripper lift valve 11. Poppet spring 20. Shuttle valve seat (plug)
4. Valve body 12. Main relief valve poppet 21. Shuttle valve ball
5. Return spring 13. Valve seat 22. Shuttle valve seat
6. O-ring 14. Main relief valve spring
7. Case 15. Main relief valve
8. Main relief pressure 16. Valve seat
adjustment screw 17. Check valve
10-113
RIPPER HI VALVE
Bl-1 Bz-1 PB2

\ /
I
/ B-i D--i \ \
Al-l AZ-1 PA2
From small pump

Al-2 A2-2 PAI. From Lo valve tilt in
PBI. From Lo valve tilt back
PA2. From Lo valve ripper raise
PB2. From Lo valve ripper lower
Al-l. To L.H. tilt cylinder bottom
Bl-1. To L.H. tilt cylinder head
Al-2. To R.H. tilt cylinder bottom
Bl-2. To R.H. tilt cylinder head
A2-1. To L.H. lift cylinder bottom
82-l. To L.H. lift cylinder head
A2-2. To R.H. lift cylinder bottom
B2-2. To R.H. lift cylinder head
/W ‘W\
Bl-2 P Bz-2 SBD01371
10-114
I
\ t /3 /’
IO\
II’
D-D SBD01372
1. Valve body 11. Plug

2. Shuttle valve seat 12. Check valve spring
3. Shuttle valve ball 13. Check valve
4. Valve body 14. Valve return spring
5. Plug 15. Plug
6. Fixed differential pressure valve spring 16. Ripper lift Hi valve
7. Fixed differential pressure valve 17. Suction valve spring
8. Fixed differential pressure valve 18. Suction valve
9. Fixed differential pressure valve 19. Ripper tilt Hi valve
10. Fixed differential pressure valve
10-l15
IIIIi
lo-116
l When the blade lever is at the HOLD posi- When oil is drained
tion, the spool of the PPC valve directly con- . In the condition already explained, if the
nected to the control lever is not actuated; hydraulic pressure in the circuit rises, the
blade lift spool (5) closes the circuit from surface pressure (force pushing the demand
port B to ports C and D, and opens the valve to the left) on port L of demand valve
circuits of ports H and E and ports J and F; (I) becomes greater than the combined force
blade tilt spool (16) closes the circuit from [force pushing the demand valve to the
port B3 to ports C3 and D3. right) of the surface pressure bearing on
Therefore, the circuits for blade lift cylinder port M and tension of spring (21, it moves
(9) and blade tilt cylinder (17) become closed the demand valve to the left, opens the cir-
circuits, and the cylinders are held in the cuits between ports A and E, and ports R
same position. and F. The oil from the large and small
If the ripper lever is placed at the HOLD pumps is then relieved to ports E and F and
position, the spool of the PPC valve directly -is drained from port G to the hydraulic tank.
connected to the control lever does not Therefore, both the large and small pumps
move; ripper tilt spool (19) closes the circuit are put in an unload condition.
from port B4 to ports C4 and D4, and ripper
lift spool (21) closes the circuit from port B5
to ports C5 and D5. Therefore, the circuits
for ripper tilt cylinder (45) and ripper lift
cylinder (33) become closed circuits through
the two ripper valves, and the cylinders are
kept in the same position.
If the engine is started in this condition, the
oil from the large pump enters port A of the
blade lift valve. Some of the oil pushes open
check valve (3) and enters port B where it
stops. The rest of the oil passes through
orifice a of demand valve
(I!, and enters ports L and M. (The demand
valve is pushed to the right by the tension
of spring (21.1
The oil from the large pump flows to the
blade lift valve, but it also enters port Al of
the ripper Hi valve, pushes open the two
check valves (23) and (351, then enters ports
Bl and B2, and stops.
The oil from the small pump flows from
port A2 of the ripper Lo valve and blade tilt
valve to ports A3, A4, and A5. Some of the
oil pushes open check valves (15), (181, and
(201, then enters ports B3, B4, and B5, and
stops. The rest of the oil flows from port
A5, enters port R of the blade lift valve,
pushes open check valve (41, and flows to
port A, where it merges with the oil from
the large pump.
10-117
lo-118
. When the blade lever is moved fully to the

RAISE position, the spool of the PPC valve
directly connected to the control lever is ac-
tuated. When this happens, the pilot pres-
sure entering the PPC valve from the PPC
pump is sent to port PB of the blade lift
valve. This pilot pressure moves spool (5)
to the left to the end of its stroke, and fully
opens the circuits between ports B and C,
ports C and H, and ports D and F.
When this happens, the oil from the two
pumps passes from ports A and B and en-
ters port C. Some of the oil flows to the
head end of cylinder (9), and the rest flows
from ports H and H’, pushes shuttle valve
(8) to the right and opens it, flows to port K,
and enters ports N, 0, and P of shuttle valve
(IO). It then enters port Q of demand valve
(I) and becomes the pilot pressure.
At the same time, the oil from the pump
passes through orifice a of demand valve
(I), enters ports L and M, and becomes the
pilot pressure.
The oil at the bottom end of cylinder (9)
flows from port D to port F, and returns
from port G to the hydraulic tank. When the
hydraulic pressure in the circuit rises in this
way, spool (5) opens the circuit between
ports B and C fully, so the resistance of the
oil flowing from port B to port C is small,
and there is little pressure difference gener-
ated between port B and port C.
Therefore, no pressure difference is gener-
ated between port L and ports M and 0 of
the demand valve. The surface pressure act-
ing on the left and right of the demand valve
is equal, so the demand valve is moved to
the right by the tension of spring (2).
When this happens, the circuits between
ports A and E’, and ports R and F’ are closed,
and all the oil from both the large and small
pumps flows to the head end of the cylin-
der to increase the speed of movement of
the cylinder.
10-119
E
;
t
I- ll
\\ II H
I Ih--T=r
L
lL___+_q /
a
l When the blade lever is operated slightly to which corresponds to the movement of the
the RAISE position the spool of the PPC lever. If it is wide open, the flow of oil be-
valve directly connected to the control lever yond port C increases, the hydraulic pres-
is actuated. When this happens, the pilot sure rises, and the speed of movement be-
pressure entering the PPC valve from the comes faster.
PPC pump is sent to port PB of the blade lift If it is opened only slightly, the flow of oil
valve. This pilot pressure moves spool (5) beyond port C is throttled, so the oil flow is
slightly to the left to a point where the pilot reduced, the hydraulic pressure becomes
pressure and the force of the spring are in low, and the speed of movement is slow.
balance, and partially opens the circuit be- In other words, the hydraulic pressure and
tween ports B and C, ports C and H, and oil flow beyond port C is proportional, so
ports D and F. this provides operation of the blade that fol-
When this happens, the oil from the two lows the fine movements of the blade lever.
pumps passes from ports A and B, is throt-
tled by spool (51, and enters port C. Some When cylinder is at stroke end
of the oil flows to the head end of cylinder If cylinder (9) moves to the end of its stroke
(9), and the rest flows from ports H and H’, from the condition in Items 2 and 3, the
pushes shuttle valve (8) to the right and hydraulic pressure in the whole circuit rises.
opens it, flows to port K, and enters ports Therefore, the hydraulic pressure beyond
N, 0, and P of shuttle valve (IO). It then port C rises, and the oil entering the main
enters port Q of demand valve (I) and be- relief valve through shuttle valves (8) and
comes the pilot pressure. (IO) (that is, the oil at port P) pushes open
At the same time, the oil from the pump poppet (13) and is relieved to port T.
passes through orifice a of demand valve At this point, the circuit from port 0 to port
(I), enters ports L and M, and becomes the P is throttled by orifice c, so the supply of
pilot pressure. oil to port P is delayed. As a result, the
The oil at the bottom end of cylinder (9) hydraulic pressure of pilot port Q of demand
flows from port D to port F, and returns valve (I) drops, and the demand valve
from port G to the hydraulic tank. When the moves to the left.
hydraulic pressure in the circuit rises in this When this happens, the circuit between ports
way the situation is different from in Item 2: A and E’ and ports R and F’ are opened, and
spool (5) is throttling the circuit between the oil from the two pumps is relieved to
ports B and C, so the flow of oil from port B prevent the hydraulic pressure from rising
to port C is restricted, and a pressure differ- any further.
ence is generated between port B and port The hydraulic pressure at this point is 20.6
C. The hydraulic pressure in the circuit up MPa I210 kg/cm?.
to port B becomes higher.
Therefore, when the surface pressure act-
ing on port L of the demand valve becomes
greater than the combined force of the sur-
face pressure acting on port M, the surface
pressure (low pressure) acting on port 0,
and the tension of spring (21, the demand
valve is moved to the left.
ports A and E’ and ports R and F’ are
opened, and the oil from both the large and
small pumps is relieved to the hydraulic
tank. This suppresses the rise in the hy-
draulic pressure at ports A and B, and the
cylinder moves slowly.
As explained in the items above, the speed
of movement of the cylinder is determined
by the amount of opening of ports B and C,
10-121
I >>
I
. When the blade lever is moved to the LEFT

TILT position the spool of the PPC valve
pump is sent to port PA1 of the ripper Lo
down, opens the circuits of ports B3 and C3
and ports D3 and F3, and closes the circuit
of ports A2 and A3.
When this happens, the oil from the small
pump flows from port A2, pushes open
check valve (151, flows from port B3, and
enters port C3. It flows to the bottom end of
cylinder (171, and when the hydraulic pres-
sure in the circuit rises, it extends the cylin-
der.
At this point, the oil at the head end of the
cylinder returns from port D3 to port F3,
and is drained from port E3 to the hydraulic
tank.
The oil from the large pump enters port A
of the blade lift valve, and actuates demand
valve (I), is relieved from port A to E, and is
drained to the hydraulic tank.
When the blade tilt is operated, the circuit
between ports A2 and A3 is closed, so the
oil does not enter the ripper circuit, and it is
impossible to operate the ripper.
In other words, the blade tilt circuit is given
priority over the ripper circuit.
When cylinder is at stroke end

From the above condition, if cylinder (17) is
moved to the end of its stroke, the hydrau-
lic pressure in the whole circuit rises.
pump flows from port A2, and pushes open
main relief valve poppet (14). It is then re-
lieved to port E2, so the hydraulic pressure
does not rise any further.
The hydraulic pressure at this point is 20.6
MPa 1210 kg/cm21.
lo-123
I r
-
I#
L
P
1O-l 24
l When the ripper lever is moved to the TILT

IN position, the spool of the PPC valve di-
rectly connected to the control lever is actu-
ated. When this happens, the pilot pres-
down, opens the circuits between ports B4
and C4, ports D4 and F4, and ports A3 and
64, and closes the circuit between ports A3
and A4.
pump enters port A2 and A3. Some of the
oil pushes open check valve (181, flows from
port B4 into port C4, and the flows to port
G2 of the ripper Hi valve. The rest of the oil
passes through the groove in spool (191,
enters port G4, pushes shuttle valve (22)
down fully, then flows from port H5 to port
S of shuttle valve (IO).
The oil entering port S passes through ori-
fice b, and pushes piston (11). The reaction
moves shuttle valve (IO) to the left, closes
the circuit between ports N and 0, and opens
the circuit between ports S and 0.
The oil entering port 0 from port S then
passes through orifice c, and enters ports P
and 0. It becomes the pilot pressure of de-
mand valve (I), and moves the demand
valve to the right.
When this happens, the circuit between ports
A and E’ is closed, so the oil from the large
pump is not drained to the hydraulic tank.
The whole amount of the oil flows to port
Al of the ripper Hi valve.
lo-125
Y >> -
‘---f--j-J
. As explained in item 5, the oil from the large

pump enters Al of the ripper Hi valve,
pushes open check valves (23) and (351,
flows to ports Bl and B2, and stops.
port C4 of the ripper Lo valve and enters
port H2.
Some of the oil entering port H2 passes
through the passage inside valve (421, flows
to port l2, and pushes shuttle valve (44)
fully to the right. It then enters port 02,
pushes spool (36) up, and becomes the pi-
lot pressure.
The rest of the oil is throttled by orifice g
and enters port D2.
Some of the oil entering port D2 passes
to port 52, and pushes shuttle valve (41)
fully to the left. It then enters port N2, pushes
spool (36) down, and becomes the pilot pres-
sure.
The rest of the oil flows from port D2 to the
bottom end of ripper tilt cylinder (45).
When all the above hydraulic circuits are
filled with oil, the hydraulic pressure starts
to rise.
. From the condition previously explained, if
the hydraulic pressure continues to rise, the
oil at port H2 is throttled by orifice g and
enters port D2. Because of the resistance,
the hydraulic pressure at port H2 becomes
higher than the pressure beyond port D2.
Therefore, the hydraulic pressure at pilot
port 02 of spool (36) becomes higher than
the hydraulic pressure at port N2, so when
this pressure difference becomes greater
than the tension of spring (381, it pushes
spool (36) up.
ports B2 and D2, and ports C2 and Fl open,
the oil from the large pump flows from port
B2 to port D2, enters the bottom end of
ripper tilt cylinder (451, and merges with the
oil from the small pump to extend the cylin-
der.
Some of the oil at the head end of the cylin-
der returns from port C2 to port Fl, and is
drained to the hydraulic tank. The rest of
the oil flows from port C2, is throttled by
orifice f of valve (391, and returns to port
G2. It then flows from port D4 of the ripper
Lo valve, returns to port F4, and is drained
to the hydraulic tank.
lo-127
I I -
lo-128
. When the ripper lever is moved to the

LOWER position, the spool of the PPC valve
moves down, opens the circuits of ports B5
and C5, ports D5 and F5, and ports A4 and
G5 and closes the circuit of ports A4 and
A5.
pump enters ports A2, A3, and A4. Some of
the oil pushes open check valve (201, flows
from port B5 into port C5, and then flows to
port HI of the ripper Hi valve. The rest of
the oil passes through the groove in the
spool, enters port G5, pushes shuttle valve
(22) up fully, then flows from port H5 to
port S of shuttle valve (IO).
The oil entering port S passes through ori-
fice b, and pushes piston (11). The reaction
moves shuttle valve (IO) to the left, closes
the circuit between ports N and 0, and opens
the circuit between ports S and 0.
The oil entering port 0 from port S then
passes through orifice c, and enters ports P
and 0. It becomes the pilot pressure of
demand valve (I), and moves the demand
valve to the right.
A and E is closed, so the oil from the large
pump is not drained to the hydraulic tank.
The whole amount of the oil flows to port
Al of the ripper Hi valve.
lo-129
l As explained in Item 7, the oil from the large

pump enters port Al of the ripper Hi valve,
pushes open check valves (23) and (351,
flows to ports Bl and B2, and stops.
port C5 of the ripper Lo valve and enters
port HI.
Some of the oil entering port HI passes
to port Ml, and pushes shuttle valve (32)
fully to the left. It then enters port 01, pushes
spool (24) up, and becomes the pilot pres-
sure.
The rest of the oil is throttled by orifice e
and enters port Dl.
Some of the oil entering port Dl passes
to port Kl, and pushes shuttle valve (29)
fully to the right. It then enters port Nl,
pushes spool (24) down, and becomes the
pilot pressure.
The rest of the oil flows from port Dl to the
bottom end of ripper lift cylinder (33).
When all the above hydraulic circuits are
g filled with oil, the hydraulic pressure starts
% to rise.
z l From the condition previously explained, if
the hydraulic pressure continues to rise, the
oil at port HI is throttled by orifice e and
enters port Dl. Because of the resistance,
the hydraulic pressure at port HI becomes
higher than the pressure beyond port Dl.
Therefore, the hydraulic pressure at pilot
port 01 of spool (24) becomes higher than
the hydraulic pressure at port Nl, so when
this pressure difference becomes greater
than the tension of spring (251, it pushes
spool (24) up.
ports Bl and Dl and ports Cl and El open,
the oil from the large pump flows from port
Bl to port Dl, enters the bottom end of
ripper lift cylinder (331, and merges with the
oil from the small pump to extend the cylin-
der.
Some of the oil at the head end of the cylin-
der returns from port Cl to port El, and is
drained to the hydraulic tank. The rest of
the oil flows from port Cl, is throttled by
orifice d of valve (271, and returns to port
Gl. It then flows from port D5 of the ripper
Lo valve, returns to port E5, and is drained
to the hydraulic tank.
10-131
1 I
I II 3.
1O-l 32
. From the condition in items 7 and 8, if cylin-

der (33) is moved to the end of its stroke,
the hydraulic pressure in the whole circuit
rises.
When this happens, in the same way as in
Item 4, the oil from the small pump flows
from port A2 and pushes open main relief
valve poppet (14). It is then relieved to port
E2, so the hydraulic pressure does not rise
any further.
MPa (210 kg/cm2).
The oil passing through shuttle valves (22)
and (IO), and flowing from ports S and 0 to
port P also pushes open main relief valve
poppet (13), and is relieved to port T.
The circuit from port 0 to port P is throttled
by orifice c, so the supply of oil to port P is
delayed. As a result, the hydraulic pressure
at pilot port 0 of demand valve (I) also
drops, and the demand valve moves to the
left.
A and E’ opens, and the oil from the large
pump is relieved, so the hydraulic pressure
in the circuit of the large pump does not
rise any further.
MPa (210 kg/cm21.
When the hydraulic pressure in the whole
circuit is set at 20.6 MPa (210 kg/cm2), the
pressure difference on both sides of orifice
e of valve (30) (that is, the difference in pres-
sure between ports HI and Dl) disappears.
The pilot pressure at port 01 that is push-
ing spool (24) up becomes the same pres-
sure as the pressure at port Nl. When this
happens, spool (24) is pushed down by the
tension of spring (25) to a position where it
is in balance with the tension of spring (26).
At this point, the circuits between ports Bl
and Dl and ports Cl and El are closed.
The oil from the large pump goes as far as
port Bl, and stops. The oil at the head end
of cylinder (33) flows from port Cl, passes
through orifice d of valve (271, and returns
only to port Gl.
10-133
STRUCTURE AND FUNCTION CYLINDER STAY
CYLINDER STAY
SBD01380
1. Grease nipple
2. Yoke
3. Oil seal
4. Bushing
5. Bushing
6. Grease nipple
10-134
STRUCTURE AND FUNCTION BLADE
BLADE
SEMI U-DOZER
SED01381
Unit: mm
1. End bit
2. Cutting edge
~
3. Blade
4. Center pin
5. Center brace
6. Tilt cylinder
7. Straight frame
8. Trunnion
9. Brace
Max. digging depth of blade 715
Max. tilt of blade 1.065
10-135
STRUCTURE AND FUNCTION BLADE
U-DOZER
SED01382
Unit: mm
1. End bit Specifications
2. Cutting edge Distance between left and
3,904
3. Blade right frames
4. Center pin Length of frame 4,119
5. Center brace
Width of blade 5,140
6. Tilt cylinder
7. Straight frame Height of blade 2,195
8. Trunnion
Max. lifting height of blade 1,660
9. Pitch cylinder
Max. digging depth of blade 715
Max. tilt of blade 1,065
10-136
STRUCTURE AND FUNCTION RIPPER
RIPPER
MULTIPLE-SHANK RIPPER
SED01383
1. Bracket
Unit: mm
3. Ripper lift cylinder Specifications
4. Beam Length of beam 2,854
5. Shank
6. Ripper point No. of shanks
7. Protector Shank pitch (3 shanks) 1 1,320

8. Arm
Max. lifting height
1o-1 37
STRUCTURE AND FUNCTION RIPPER
GIANT RIPPER
SED01384
Unit: mm
1. Bracket Specifications
2. Ripper tilt cylinder Lenath of beam I 1,367

4. Beam
5. Shank
6. Pin puller cylinder
7. Protector
8. Ripper point Max. lifting height 1,060
I
9. Arm
1O-l 38
STRUCTURE AND FUNCTION CAB MOUNT
CAB MOUNT
1 A-A
SLD01396
1. Viscous mount (front) Outline

2. Viscous mount (rear) . Viscous mounts are installed at two places
3. support at the front and two places at the rear to
secure the floor frame and cab.
. An oil-filled viscous mount is used to ab-
sorb the vibration.
1o-1 39
0
STRUCTURE AND FUNCTION CAB
CAB
CAB ASSEMBLY
m Z
SKD00215
1. Front wiper
2. Front glass
3. Rear wiper
4. Door
10-140
STRUCTURE AND FUNCTION CAB
ROPS GUARD
SLD01397
1. ROPS guard Outline

. A ROPS guard is installed to protect the
operator if the machine should roll over.
10-141
0
STRUCTURE AND FUNCTION AIR CONDITIONER
AIR CONDITIONER PIPING
SLDOl398
1. Air conditioner compressor 9. Valve (hot water outlet)

2. Condenser IO. Hot water return piping
3. Window defroster 11. Valve (hot water inlet)
4. Side defroster 12. Refrigerant piping
5. Air conditioner unit 13. Receiver tank
6. Vent
7. Blower motor A. Fresh air
8. Hot water pickup piping B. Recirculated air
C. Hot air/cold air
lo-142
STRUCTURE AND FUNCTION ACTUAL ELECTRIC WIRING DIAGRAM
019503
Ir For details of this page, see Section 90.
46
22. Alternator
23. L.H. front lamp
24. Horn
25. Dual tilt switch
26. Blade pitch switch
27. Horn switch
28. Pin puller switch
29. Fuel level sensor
30. Transmission neutral
safety switch
31. Fuse box
32. Lockup controller
33. APS controller
34. Battery relay
35. Battery
36. Monitor panel
37. Starting switch
38. APS switch
39. Rear lamp switch
40. Front lamp switch
41. Lockup switch
42. Front lamp, working
1. Radiator water level sensor 8. Backup alarm 15. L.H. working lamp lamp relay
2. R.H. front lamp 9. Hydraulic oil temperature sensor 16. Engine speed sensor 43. Monitor alarm
3. Engine water temperature sensor 10. Transmission oil pressure sensor 17. Engine oil level sensor 44. Air conditioner relay
4. R.H. working lamp 11. Torque converter speed sensor 18. APS nozzle 45. Magnet relay (for air
5. ‘Blade pitch solenoid valve 12. L.H. rear lamp 19. Engine oil pressure sensor conditioner)
6. Dual tilt solenoid valve 13. Lockup solenoid valve 20. APS nozzle 46. Lockup lamp
7. R.H. rear lamp 14. Torque converter oil temperature sensor 21. Starting motor 47. Caution lamp
STRUCTURE AND FUNCTION ELECTRIC CIRCUIT DIAGRAM
lo-146
STRUCTURE AND FUNCTION ELECTRIC CIRCUIT DIAGRAM
10-147
ELECTRIC CIRCUIT DIAGRAM INSIDE CAB
G Ir For details of this page, see Section 90.
motor
Sizer lighter
box
I I,
Antella Rear
Radio - L. H.Wioer switc h front wiper switch R. H.Wioer switch Rear wlwr switch Front
law switch law wtch
T
r
Rear speaker Rear speaker Additional lamp
Pickup
Rear wiper motor SDDOl403
019503
STRUCTURE AND FUNCTION MACHINE MONITOR SYSTEM
MACHINE MONITOR SYSTEM
Monitor Dane1
Sensor sional
i-
Sensor
b
Lamp signal
II I I
II Buzzer signal
Buzzer
Caution lamp
Battery
SLO01472
. The machine monitor system uses sensors l The machine monitor system consists of the
installed at various parts of the machine to monitor panel, sensors, warning lamp, alarm
observe the machine condition. It processes buzzer and power source.
this information swiftly and displays it on The monitor panel and sensors are con-
the panel to keep the operator informed of nected with wiring harnesses, and the power
the machine condition. supply for the monitor panel is taken from
The information displayed on the panel can the battery.
be broadly divided into the following cat- If any abnormality occurs in the machine
egories. (detected by the sensors), the monitor and
1. The monitor group, which informs the op- warning lamp flash and the buzzer sounds
erator when there is any abnormality in the to protect the machine.
machine
2. The gauge group (coolant temperature,
torque converter oil temperature, fuel level),
which always displays the condition of the
machine.
10-150
MONITOR PANEL
SKU01473
1. Engine oil level 6. Battery charge 11. Hydraulic oil temperature

2. Radiator water level 7. Engine oil pressure 12. Engine preheating
3. Fuel level 8. Radiator water level 13. Service meter indicator
8 4. Torque converter oil tem- 9. Engine cooling water tem- 14. Service meter
% perature perature
G 5. Engine cooling water 10. Torque converter oil tem-
temperature perature
OUTLINE
l The monitor panel consists of the monitor 2) The CHECK items go out when the en-
portion, which gives out warning when any gine is started. (To judge if the engine
abnormality occurs in the machine, and the is running or not, the system checks if
gauge portion and service meter, which al- the engine oil pressure has risen or if
ways indicate the condition of the machine. the voltage from the alternator is more
The monitor and gauge portions each have than IOV.)
microcomputers that process the signals 3. CAUTION
from each sensor and display the results. The caution items are checked from the time
A liquid crystal display is used. the engine is started until the time the en-
For details of the items displayed on the gine is stopped.
monitor and gauge portions, see the table If there is any abnormality, the item flashes,
on the next page. and the warning lamp also flashes.
OPERATION If any item in CAUTION 2 flashes, the alarm
1. Power switched on (starting switch ON) buzzer also sounds.
I) All items on the gauge and monitor light * The monitor and warning lamps flash in an
up for 3 seconds. ON-OFF cycle of approx. 0.8 sec.
2) The warning lamps light up for 2 sec- * The flashing cycle of the monitor may
onds and the alarm buzzer sounds for 1 change slightly if the ambient temperature
second. is low (approx. -10°C or below), but this is
2. CHECK items not an abnormality.
I) After lighting up as explained in Section
1, if there is any abnormality in any
CHECK item, that item flashes.
10-151
. MONITOR PANEL DISPLAY
Display
Symbol Display item Display range Display method
category
43
SAD01479
Radiator water level Below low level
Displays when engine
stopped and starting switch
is ON
Display when normal: OFF
is
Display when abnormal:

CHECK Below low level Flashes
Engine oil level
SAD01480
Displays when engine is

stopped and starting switch
is ON
Engine oil pressure Below specified pressure
SAD01481
Flashes
Displays when starting switch
is ON and engine is running
CAUllON Battery charge When charge is defective
SAP00522 Flashes
CAUTION lamp flashes
Engine oil pressure Below 48.03 kPa IO.5 kg/cm’
SAD01481
e
SAD01479
Radiator water level Below low level
When at highest level

Displays
running
when starting
switch is ON and engine is
CAUTION :
al
SAD01482
Engine water temperature (108°C or above) on en
gine water temperature
gauge
Display
Flashes
CAUTION
when abnormal:
lamp flashes
Alarm buzzer sounds
When at highest leve
(130°C or above) OI
Torque converter oil
torque converter tern
temperature
SAD01483 perature gauge
Hydraulic oil temperature 108°C or above
SAD01484
luring cold weather, when sheet

Switch (preheating switch) on
Pilot
7x7 Preheating When preheating
switch panel is ON, it lights up
‘or approx. 12 seconds. After this,
t goes out to inform operator
SAD00708 :hat preheating is completed.
1O-l 52
Display
Symbol Display item Display range Display method
category
Red 108+2’C
a
102 ‘;T
SST
Engine water temperature ;ree 94%
83°C
SAD01462 Whit
70%
I
One place lights up to show

applicable level
Torque converter oil

Gauges temperature
SAD01463
All lamps light up below ap-

Fuel level plicable level
SAD01466
Red
[El1
Actuated when alternator is
Hourmeter From 0 to 99999 charged. Advances by 1 hour
for every hour.
Service SKD00631
meter
0
SKD00632
Service meter indicator Service meter
Lights up when service
meter is running
10-153
Sensors
l The signals from the sensors are input di-
rectly to the machine monitor panel.
With the contact type sensors, one side is
always connected to the chassis ground. For
all the sensors (except the engine oil pres-
sure sensor) the panel judges the signal to
be normal when the contacts are closed and
the signal wire is connected to the chassis
ground.
With the engine oil pressure sensor, the
panel judges the signal to be normal when
the contacts are open and the signal wire is
disconnected from the chassis ground.
Type of sensor I Sensor method When normal When abnormal
Engine oil level Contact ON OFF
Radiator water level Contact ON OFF
Hydraulic oil level Contact ON OFF

Engine oil pressure Contact OFF ON
Engine cooling water temperature Resistance - -
Torque converter oil temperature Resistance - - 8

- - g
Fuel level Resistance
;;
ENGINE OIL LEVEL SENSOR
SBDO1487
. The engine oil level sensor is installed to 1. Connector

the top of the left side face of the oil pan. 2. Bracket
When the oil goes below the specified level, 3. Float
float (3) goes down and turns switch (4) 4. Switch
OFF. The monitor panel display and warn-
ing lamp then flash and the alarm buzzer
sounds to warn of the abnormality.
10-154
RADIATOR WATER LEVEL SENSOR
2
ti
I 2 3 SEW00291
l The radiator water level sensor is installed 1. Float

to the radiator upper tank. When the cool- 2. Switch
ant goes below the specified level, float (I) 3. Connector
goes down and turns switch (2) OFF. The
monitor panel display and warning lamp
then flash and the alarm buzzer sounds to
warn of the abnormality.
8
8
5;
HYDRAULIC OIL TEMPERATURE SENSOR
SAD01 536
. The hydraulic oil temperature sensor is in- 1. Switch portion

stalled to the hydraulic pump inlet tube. It 2. Case
detects the temperature at switch (I), and 3. Wire
when the temperature goes above the speci- 4. Connector
fied temperature, the switch is turned OFF.
The monitor panel display and warning lamp
then flash and the alarm buzzer sounds to
warn of the abnormality.
10-155
ENGINE OIL PRESSURE SENSOR

I 234 5
@
SBDOl537
l This sensor is installed to the top rear at the 1. Plug
left side of the engine cylinder block. If the 2. Contact ring
engine oil pressure is above the specified 3. Contact
pressure, diaphragm (4) expands and the 4. Diaphragm
contact between contact (3) and contact ring 5. Spring
(2) separates to turn the circuit OFF. If the 6. Terminal
engine oil pressure drops below the speci-
fied pressure, the expansion of diaphragm
(4) becomes smaller, so the contact between
contact (3) and contact ring (2) closes and
turns the circuit ON. The monitor panel dis-
play and warning lamp then flash and the
alarm buzzer sounds to warn of the abnor-
mality.
ENGINE COOLING WATER TEMPERATURE SENSOR

TORQUE CONVERTER OIL TEMPERATURE SENSOR
Structure of
SBDOl538
. The engine cooling water temperature sen- . The torque converter oil temperature sen-
sor is installed to the water manifold pipe at sor is installed to the left side of the torque
the top rear on the right side of the engine. converter case, and acts in the same way as
Thermostat (3) detects the temperature and the engine cooling water temperature sen-
sends a signal to the monitor panel. On the sor.
monitor panel, when the signal reaches a 1. Connector
set range on the gauge display, the gauge 2. Plug
lights up. When it goes above the specified 3. Thermistor
temperature, the monitor panel display and
warning lamp flash to warn of the abnor-
mality.
lo-156
Fuel level sensor
A-A
38001539
1. Connector Function
2. Float l The fuel sensor is installed to the bottom
3. Arm right of the front face of the fuel tank.
4. Body Float (2) moves up and down according to
5. Spring the fuel level. This movement of the float is
6. Contact transmitted by arm (3) and actuates a vari-
7. Spacer able resistance. This sends a signal to the
monitor panel to indicate the remaining fuel
level. When the display on the monitor
panel reaches a certain level, a warning lamp
flashes.
10-157
STRUCTURE AND FUNCTION SWITCH PANEL. FUSE BOX
SWITCH PANEL
CAB SPECIFICATION MACHINE
l The switch panel contains switches to turn
ON/OFF the lock-up, front lamps, working
lamps, rear lamps, and APS.
1. Lock-up switch
2. Front lamp, working lamp switch
3. Rear lamp switch
4. APS switch
I’1 I\ SKD01281
NO-CAB SPECIFICATION MACHINE

. The switch panel contains switches to turn
ON/OFF the front lamps, working lamps, rear
lamps, APS, and lock-up mode, together with
the starting switch, caution lamps, and lock- ulr D P 0 0
up display lamp.
1. Lock-up switch
2. Front lamp, working lamp switch
3. Rear lamp switch
I 2 3 4 5 6 7
4. APS switch
5. Lock-up display lamp 8
SKD01478
6. Caution lamp z
7. Starting switch z
1. Lock-up display lamp

2. Warning lamp
3. Starting switch
I b Y JJ 1
SKD01427
FUSE BOX
. The fuse box consists of the fuses used to
protect the various types of electrical equip-
ment, the lock-up controller to actuate the
lock-up, and the APS controller, which actu-
ates the APS.
1. Fuse box
2. Fuse
3. Lock-up controller
4. APS controller
4
SLD01428
lo-158
STRUCTURE AND FUNCTION SWITCH PANEL l FUSE BOX
OPERATION OF LAMP SYSTEM

Front lamp system Front lamp switch
l When the front lamp switch is turned ON,
the front lamp switch contacts close and it
Battery 24V
is connected to the ground. Electricity from
the battery then passes through the fuse,
flows to the coil of the front lamp relay, and
Head lamp relay
closes the lamp relay.
When this happens, electricity from the bat-
tery passes through the fuse, enters the front
lamp relay, and flows to the front lamp to
light it up. Head lamp
At the same time, electricity also flows to
the monitor night lighting and working lamp
and lights them up.
Working lamp
A7 Monitor
illmination IamP
SAD01540
Rear lamp system

. When the rear lamp switch is turned ON,
electricity from the battery passes through
the fuse, flows to the rear lamp, and lights
it up.
b@ Rear lamp
SAD01541
10-159
STRUCTURE AND FUNCTION ENGINE START SAFETY SYSTEM
ENGINE START SAFETY SYSTEM
Monitor Dane1
SAD01542
1. Joystick assembly (directional, speed, steering) FUNCTION

2. Neutral detection limit switch l The engine starting circuit has the following
3. Safety lever safety mechanisms.
Neutral detection limit switch (2) is installed
to joystick assembly (I), and if safety lever
(3) is not at the LOCK position, the starting
circuit is not turned ON, so this prevents
the engine from starting.
lo-160
STRUCTURE AND FUNCTION APS
APS
* APS stands for Auto Priming system.
Hereafter referred to as “APS”.
Engine
r From fuel injection Pump
I Air intake manifold
Monitor panel ,
Nozzle
II
,’
Xi
,’
-____
,’
‘1 ,’
‘. ,’
‘\ I
_,
L i Glow plug :
‘\. \
II ------I
Q
I
Controller
SAD01 543
APS SYSTEM DIAGRAM

Start ina switch
Controller
Power
Glow 1
CN142
Terminal C
2l+
-0
P Starting snitch
Glow 2
Nozzle
CN143
GND
Water illmination lamp
Water temp.
sensor
0 v I A7
Starting mater
Preheat lamp
amp
Spare
SAD0 1544
lo-161
STRUCTURE AND FUNCTION APS
APS ACTUATION CHART

APS start APS stops completely
Flow of time - - - - - - J J J -----------
i
Glow Plug ’ ‘Starting mAor E!gine starts, intake
preheating turns air heated
Starting switch ON 1 START )
Preheating switch (panel) OFF ON OFF (manual)
Water temperature sensor Below specified temperature (20 “C) Above specified temperature
Glow plug OFF ON OFF

I
APS fuel injection nozzle I OFF I

I
ON
I OFF
Flashes
Lamp display OFF OFF OFF
(12osNec) (2 times/3 set)
(When abnormal) OFF ON
l The APS burns fuel inside the intake manifold to heat the intake air.
l The APS acts in the following order.
1. When the temperature of the engine cooling water is below the specified temperature, the
g
contacts of the APS water temperature sensor close and the water temperature sensor ON
%
signal is input to the controller.
Z
2. Under the above conditions, if the preheating switch is turned ON, the controller sends
electricity to the glow plug to heat it.
When the glow plug is being heated, the preheating pilot lamp lights up.
3. After the preheating time for the glow plug has passed, the lamp goes out.
When the pilot display goes out, it shows that the glow plug has been heated sufficiently to
actuate the APS.
4. After the preheating lamp goes out, if the starting switch is turned to the START position, the
APS fuel injection nozzle inside the intake manifold is switched ON/OFF (IO times/set) to inject
fuel.
5. When the engine cooling water temperature goes above the specified temperature, the APS
water temperature sensor contacts open, and the action of the glow plug and fuel injection
nozzle is stopped. The preheating lamp then flashes at IHz to indicate that the APS has
finished.
6. Turn the preheating switch OFF.
7. If the glow plug or APS nozzle system are short circuited with the ground, the lamp will light up
until the short circuit is canceled.
If the lamp does not go out when the preheating is completed (after 12 seconds have passed), or
the lamp goes out and then lights up again, stop the engine and check for any short circuit
with the ground.
8. If the preheating switch is turned ON when the temperature of the engine cooling water is
above the specified temperature, the lamp will light up for 12 seconds and then will flash. In
this case, the glow plug is not actuated.
lo-162
STRUCTURE AND FUNCTION TORQUE CONVERTER LOCK-UP CONTROL SYSTEM
TORQUE CONVERTER LOCK-UP CONTROL SYSTEM
ql Lock-up mode switch
Torque converter
output shaft
Transmission speed sensor
(20 Pulses/rev.)
SLD01470
TORQUE CONVERTER LOCK-UP CONTROL CIRCUIT DIAGRAM
Lock-UP controller
Torque converter
speed sensor
I\ 1
I I C Torque converter speed (+I
Transmission oil
Transmission oi Pressure sensor
Pressure sensor
Torque converter speed f-1
Lock-up Power source

Lock-un
switch
Lock-UP GND
Pilot lamn
Lock-up valve
a
C Lock-up valve Power source
3
Lock-up
solenoid 3
SAD01471
lo-163
Function
. The torque converter lock-up control sys-
tem user a controller and the signal from
two sensors to automatically lock up the
converter according to the load on the ma-
chine.
When the torque converter is locked up, the
display lamp at the front of the operator’s
compartment lights up.
. The lock-up controller receives torque con-
verter speed signals from the transmission
oil pressure sensor and torque converter
speed sensor. It connects and cuts the lock-
up solenoid and display lamp from the
ground to switch the lock-up ON/OFF.
The lock-up is switched ON-OFF if the sig-
nals from the two sensor fulfill the follow-
ing the conditions.
. Lock-up ON
When both of the following two conditions
are satisfied (AND circuit)
Torque converter output shaft speed: Above
1260 rpm
Transmission oil pressure: Above 2.0 MPa
(20 kg/cm*)
. Lock-up OFF
When either of the following two conditions
are satisfied (OR circuit)
Torque converter output shaft speed: Below
1,200 rpm
Transmission oil pressure: Below 1.5 MPa
{I 5 kg/cm*)
1O-l 64
0
TORQUE CONVERTER SPEED SENSOR
II
D
2
g*/::j
F
0
o 1
I i ‘3 SBD01545
1. Connector
2. Flange
3. Sensor
TRANSMISSION OIL PRESSURE SENSOR
SBDO1546
1. Plug
2. Diaphragm
3. Switch
4. Wire
5. Connector
lo-165
20 TESTING AND ADJUSTING
Standard value table for engine related parts.. . ..20 - 2 Adjusting joystick (Steering, directional, speed
Standard value table for chassis related parts.. ... .20- 3 control lever), parking brake lever linkage.. . ..20-3 3
Standard value table for machine monitor ....... 20-10 Adjusting brake pedal linkage ............................. 20-37
Table of tools for testing, adjusting, Adjusting work equipment control linkage ........ 20-38
and troubleshooting ...................................... 20-13 Measuring power train oil pressure ................... 20-39
Table of applicable T-adapter kits (Tool M) ...... 20-14 Measuring and adjusting work equipment
Measuring engine speed ...................................... 20-16 hydraulic pressure ......................................... 20-42
Measuring exhaust color.. .................................... 20-17 Testing and adjusting work equipment
Adjusting valve clearance .................................... 20-18 control circuit pressure ................................. 20-44
Measuring compression pressure.. ..................... 20-19 Measuring PPC valve output pressure ............... 20-45
Measuring blow-by pressure ............................... 20-20 Adjusting PPC valve.. ............................................ 20-46
Measuring engine oil pressure.. .......................... 20-21 Measuring ON-OFF solenoid valve
Testing and adjusting fuel injection timing.. ..... 20-22 output pressure .............................................. 20-47
Testing and adjusting alternator belt tension ... 20-24 Bleeding air from hydraulic cylinders ................ 20-48
Testing and adjusting belt tension for Releasing remaining pressure in
air conditioner compressor.. ......................... 20-24 hydraulic circuit .............................................. 20-48
Measuring exhaust temperature ......................... 20-25 Checking location of cause of hydraulic drift
Measuring air supply pressure of blade and ripper ........................................ 20-49
8 (Boost pressure) ............................................. Measuring leakage inside cylinder ..................... 20-50
20-26
8 Measuring torque converter stall speed ............ 20-27 Adjusting semi u-tiltdozer .................................... 20-51
z Measuring speed at torque converter stall + Adjusting clearance of idler.. ............................... 20-53
Hydraulic pump relief (Full stall) ................. 20-28 Simple procedure for testing brake
Adjusting fuel control linkage ............................. 20-29 performance .................................................... 20-54
Adjusting decelerator pedal ................................. 20-32 Troubleshooting ................................................... 20-101
* When using the standard value table to make judgement for testing and adjusting, and troubleshooting, the
following precautions are necessary.
1. The standard values in the table are the values for a new machine and are given as reference values for the time
when the machine is shipped from the factory. These values should be used as a guide when estimating wear
and tear after the machine is operated, and when carrying out repairs.
2. The permissible values given in the table are values estimated based on the results of various tests carried out
on the machines shipped from the factory, so they should be used together with the information on the repair
condition and other information such as the operating history of the machine when judging the condition of the
machine.
3. These standard values do not form a basis for judging claims.
g When carrying out testing, adjusting, or troubleshooting, park the machine on level ground and use the safety
pins and blocks to prevent the machine from moving.
g When carrying out work together with other workers, always use signals and do not let unauthorized people
near the machine.
a When checking the water level, always wait for the water to cool down. If the radiator cap is removed when
the water is still hot, the water will spurt out and cause burns.
g Be careful not to get caught in the fan, fan belt, or other rotating parts.
20-l
0
TESTING AND ADJUSTING STANDARD VALUE TABLE FOR ENGINE RELATED PARTS
STANDARD VALUE TABLE FOR ENGINE RELATED PARTS

I
Engine
I SAGD170-2
Item Measurement conditions Permissible value
High idling 1,960 r 50
Low idling 720 5 50

Engine speed vm
Rated speed 1,800 +. 50 1,800 2 50
(when mounted on
machine) I
Whole speed range

(ambient tempera-
Exhaust temperature ture: 20°C) “C Max. 650 Max. 700
(turbocharger inlet
port temperature)
Air supply pressure At rated output KPa Min. 146.6 Min. 133.3
mmHg1 {Min. l,lOO} {Min. 1,000)
At sudden acceleration Bosch Max. 6.0 Max. 8.0

Exhaust gas color
At high idling index
Max. 1.0 Max. 2.0
Intake valve 0.4 -

Valve clearance mm
Exhaust valve 1.0
(Normal temperature)
Oil temperature:
40 - 60°C
Compression pressure MPa
Engine speed: Max. 2.9 I301 Max. 2.1 {21J
q/cm?
210 - 250 rpm
(SAE30 oil)
(Water temperature: Op-

erating range) KPa Min. 3.4 Min. 6.9
Blowby pressure
At rated output nmKO} {Min. 3501 {Min. 700)
(SAE30 oil)
(Water temperature:
Operating range) Max. 0.39 14.0) Max. 0.20 12.01
;Ur&yo; output
MPa Max. 0.12 (I.21 Max. 0.07 fO.71

Oil pressure
kg/cm?
At rated output Max. 0.39 I4.0) Max. 0.18 11.81

(SAEIOW)
At low idling Max. 0.10 Il.0) Max. 0.07 {0.7}

(SAEIOW)
Whole speed range

Oil temperature “C 80 - 110 120
(inside oil pan)
Fuel injection timing B.T.D.C. (angle) 22 f 1 22 + 1
Alternator belt tension -

Deflection when pressed
with finger force of mm
Air conditioner com- approx. 58.8 N 16 kg}
pressor belt tension
20-2
0
TESTING AND ADJUSTING STANDARD VALUE TABLE FOR CHASSIS RELATED PARTS
STANDARD VALUE TABLE FOR CHASSIS RELATED PARTS

Cate- Standard Permissible
Item Measurement conditions Unit
gory value value
l Engine oil pressure:
Torque converter stall
Within operating range 1,500 f 50 1,430
speed
. Engine oil temperature:
Within operating range
. Power train oil temperature:
Torque converter stall + 70 - 80 “C
ilvork equipment relief . Hydraulic oil temperature: 1,300 + 50 1,160
speed 45 - 55 “C
l Speed range: F3
70 * 20 I 70 f 20
Center of lever
Fuel control lever
knob mm
-+ storl 40 2 20 I 40 2 20
Decelerator pedal Center of pedal 352 15 I 35& 15
132 5 I 13-c 5
Speed
13 t 5 I 132 5
l Engine stopped N + FORWARD 40* 15 I 402 15

l Center of lever
knob N + REVERSE 40* 15 I 402 15
Total travel I
l Engine at low
idling Until point
l Center of lever where clutch is
knob completely
disengaged
l Engine at low
Total travel I 752 10 I 75* 10
idling Positionuntilbrake
Brake pedal
l Center of pedal oil pressurebecomes mm 61 5 10 61 2 10
OMPa(0 k&m2 } I
l Engine at low
idling HOLD --f RAISE,
8Ok 15 802 15
LOWER
l Center of lever
knob
Blade lever l Hydraulic oil
temperature: 60-c 10 602 10
45 - 55°C
l Engineat low HOLD j RA,SE
idling 952 15 95* 15

l Center of lever LoWER
knob
?ipper lever
95? 15 95% 15
107.9 f 29.4
{I 1.0 f 3.0) 147.1 115.0)
83.4 r 29.4
Fuel control lever 18.5 2 3.0) 122.6 {12.5}
122.6 2 29.4
f12.5 rt 3.0) 161.8 i16.5)
Decelerator pedal
1st --f 2nd
l Engine stopped 2nd -+ 3rd

Speed l Center of lever
knob 3rd + 2nd
2nd --f 1st
l Engine stopped N -+ FORWARD

Directional . Center of lever
knob N + REVERSE
20-3
a
Cate Standard Permissible

goq value value
Until clutch is 29.4 + 9.8

Y completely dis- (3.0 2 1.0) 49.0 {51
.g l Engine stopped engaged
Steering l Center of lever
; knob Until machine
_) 34.3 2 9.8
turns when l3.5 * 1.01 58.8 (61
brake is applied
l Engine at low idling 460.9 2 98.1 608.0

Brake pedal
l Center of pedal (47.0 2 10.0) 162.0)
l Engine at low 1l9.6k9.8 {2.0~1 .O} 39.2 (41

idling
LOWER ’ i !9.4*9.8 {3.0+1 .O} 49.0 (5)
l Hydraulic oil
Blade lever temperature:
45 - 55°C
22.7 2 9.8
l Center Of lever HOLD _+ Left, 49.0 (51
(2.5 r 1.0)
knob right tilt
l Engine at low
HOLD --f RAISE, 19.6 2 9.8
idling (2.0 2 1.0) 39.2 {4)
LOWER
l Hydraulic oil
Ripper lever temperature:
45 - 55°C
Center of lever BOLD -+ TILT IN 19.6 2 9.8
l
(2.0 2 1.0) 39.2 (4)
knob TILT BACK
Torque converter relief 0.9 * 0.10 0.9 r 0.10

txessure (inlet DOIT) (92 I} (92 I)
Toraue converter outlet 0.54 + 0.15 0.54 +. 0.15
port’pressure 15.5 2 1.5) 15.5 f I.51 8
Lock-up clutch 1.3 2 0.15 1.3 f 0.15 %
Torque converter lock-up pressure I13.0 f I.51 (13.0 + I.51 ;;
pressure Stator clutch 2.5 + 0.2 2.5 2 0.2
pressure 125.0 2 2.0) (25.0 + 2.0}
Transmission main relief 2.7 2 0.20
pressure (27.5 2 2.0) Min. 2.4 {24.0}
Transmission modulating l Power train oil 2.7 + 0.20
pressure temperature: (27.5 2 2.0} Min. 2.4 (24.0)
70 - 80°C
Transmission reducing 2.2 * 0.15 2.2 f 0.15
l Engine at high
oressure 122.0 * I.51 (22.0 + 1.5}
idling
Transmission lubricating 0.20 f 0.05 0.20 2 0.05
pressure {2.0 2 0.5) 12.0 + 0.5)
Engine at low MPa 2.55 cr 0.20
126.0 2.0) Min. 2.4 124.0)
Steering clutch actuating idling <g/cm? /
pressure Engine at high 2.70 * 0.20
idling {27.5 2 2.0) Min. 2.4 {24.0}
Engine at low 2.55 ? 0.20

idling l26.0 5 2.01 Min. 2.4 {24.0}
Brake actuating pressure
g$;e at high 2.55 = 0.20
126.0 + 2.01 Min. 2.4 {24.0}
Entgne at low 2.55 = 0.20

Ripper pin-puller pressure 126.0 * 2.01 Min. 2.2 {22.0}
Blade lift relief pressure

19.6 -‘;” 19.6 -‘;”
Engine at low
Blade tilt relief pressure idling (all items)
l Hydraulic oil (200 $0) {200 :J}
temperature:
Ripper lift relief pressure 45 - 55°C 20.6 -‘;” 20.6 ;;”
Engine at high
idling (all items)
Ripper tilt relief pressure {210_+;0} {21o_+;c}
l Hydraulic oil 4.5 2 0.29

PPC valve relief pressure Engine at high
temperature: idling 146.0 5 3.0) Min. 3.9 I40.0)
45 - 55°C
20-4
a

gory value value
FORWARD 1st 8.921.0 <3.8+0.2> 8.921 .O <3.8+0.2>
FORWARD 2nd 0.6kO.6 <6.8+0.3> 0.6kO.6 <6.8~0.3>
FORWARD 3rd .1+0.3 .1+0.3 <11.8?0.6>
l Level road surface REVERSE 1st 5.OeO.8 <4.8?0.2> 5.OkO.8 <4.8+0.2>

l Engine at high
idling
REVERSE 2nd 3.3t0.4 <8.7+0.4> 3.3~0.4 <8.7+0.4>
l Engine water
temperature: Within
REVERSE 3rd ,.9+0.3 ..9+0.3 <14.7?0.7>
operating range sec.
rravel speed l Run-up distance: C km/h>
IO-30m FORWARD 1st 8.9kl.O <3.8+0.2> 8.921.0 <3.8~0.2>
l Measurement
distance: 20 m 0.6~0.6 <6.8?0.3>
FORWARD 2nd 0.6kO.6 <6.8+0.3>
FORWARD 3rd i.lkO.3 i.120.3


REVERSE 1st 4.120.7 <5.1+0.3> 4.120.7 <5.1+0.3>
REVERSE 2nd 7.8kO.4 <9.2+0.5> 7.8~0.4 <9.2*0.5>
REVERSE 3rd ..6~0.3 <15.8+0.8> ..6+0.3 
Work equipment
posture Engine
at low 10 - 15 26
idling
Engine
at high 3.5 - 4.5 6
idling
Blade (lift)
Engine
at low l-I.5 1 - 1.5
TYD00005 idling
!z
Hydraulic oil tern- 3
perature: 45 - 55°C
l Blade: No load s Engine
lGround level - Max. at high 1 - 1.5 1 - 1.5
idling
height
Sec.
Work equipment Engine
at low
posture
idling 10 - 15 17
Engine
at high 4-5 6
idling
Blade (tilt)
Engine
at low 8- 12 16
idling
TYD00006 z
z
Hydraulic oil tern- 2
perature: 45 - 55°C Engine
Blade: No load at high 3-4 5
Left tilt - Right tilt idling
20-5
0
Standard Permissible
value value
Work equipment Engine
posture _ at low 8- 12 15
E idling
I $ Engine
at high 2.5 - 3.5 5
idling
Ripper (lift)
TYD00007 Engine
oc at !ow 2-3 2-3
l Hydraulic oil tempera- w ldhng
ture: 45 - 55°C 3
l Lowest shank hole 2 Engine
l Ground level - Max. at high 2-3 2-3
height idling
i
Work equipment posture
12 - 18 24
4.5 - 5.5 7
Ripper (tilt) set
TYD00008 8-12 16
l Hydraulic oil temperature:
45 - 55°C
l Lowest shank hole 3-4 6
l Tilt in - Tilt back

Engine
45 - 55°C Max. 8 12
* Raise blade to maximum ~~11~~ 2
height, then lower blade and %
Blade measure time taken from z
point where blade contacts Engjne
ground to point where idler ;,th;;h Max. 1.8 2.0
B comes off ground
i * Hydraulic oil temperature: 45 - 55°C
I=
B Raise ripper to maximum height,
then lower ripper and measure time
Ripper taken from point where ripper con- Max. 1.0 1.5
tacts ground to point where sprocket
comes off ground
- Engine at high idling
Blade lift I 1 nrn/mi Max. 200/l 5 400/l 5

{h #
TYDOOOOl
45 - 55°C
l Engine stopped
l Hydraulic drift at center of
blade cutting edge when
raised 800 mm from ground
20-6
0

gory value value
-
c
3
r’ Max. 5015 8015

4
Blade tilt
TYD00002 Max. 5015 8015

45 - 55°C
l Measure extension of tilt
cylinder
Max. 5015 10015
PID00003
l Hydraulic oil temperature: 45 - 55°C
l Engine stopped
l Hydraulic drift at center of idler with
blade pushed against ground
Hydraulic drift nm/mir
of chassis
TYD00004 Max. 3015 6015

Hydraulic oil temperature:
45 - 55°C
Engine stopped
Hydraulic drift at center of
sprocket with .ripper pushed
against ground
Ripper lift BKDOb164 Max. 80/l 5 160/15

l Engine at high idling
45 - 55°C
l Engine stopped
. Raise ripper and set with tip
of point 500 mm from ground

Blade tilt 45 - 55°C Max. 3.0 12
l Extend piston rod fully and
Ripper lift disconnect hose at head end cc/mir Max. 3.6 12
l Engine at high idling
l Measure oil leakage during
Ripper tilt one minute relief Max. 3.2 12
20-7
0
TESTING AND ADJUSTING STANDARD VALUE TABLE FOR ELECTRICAL RELATED PARTS
STANDARD VALUE TABLE FOR ELECTRICAL RELATED PARTS

Classi- onnecto ispectior Vleasurement
Component Judgement table
ficatior 1 No. method condition
If the condition is as shown in the ) Turn starting

table below, it is normal switch OFF.
Torque converter Jleasure !) Disconnect
speed sensor CN-651 esistancc connector.
1) Measure at
sensor end.

!) Disconnect
connector.
Torque converter CN-653 vleasure
lock-up solenoid (male) esistancc

table below, it is normal switch ON.
‘ower source Measure !) InsertT-adapter.
Joltage voltage
I Between @ - @ I 20 - 3ov I
CN-622 If the condition is as shown in the I) Turn starting

Transmission 1 !) insert T-adapter.
Measure
oil pressure Start engine 20 - 3ov
voltage Between
sensor
O-0 Starting switch ON Max. IV
If the condition is as shown in the I) Turn starting z

!) Insert T-adapter.
CN-622 Vleasure
‘esistance
Torque con-
Jerter speed
sensor
If the condition is as shown in the I) Turn starting
Measure table below. it is normal switch ON.
voltage !) Insert T-adapter.
Between @ - @ 0.5 - 6.OV

Torque con- CN-622
verter lock-up
!) Turn lock-up
solenoid Engine at low idling switch ON.
Max. IV
Measure Between JoVstidaN $1 Insert T-adapter.
voltage B-0 ;~$$gt;$hidling 2. _ 3ov

Power sourc Measure 2) Insert T-adapter.
voltage voltage Between APS switch OFF Max. IV
CN412 @ -
CN413O APS switch ON 20 - 30V
CN-412
CN-413
If the condition is as shown in the ta-
ble below, it is normal 1) Turn starting
switch OFF.
Glow 1 signal Measure 2) Disconnect
I I
resistant Between connector.
CN412 @ - 0.8-1.3Q
CN413 @
20-8
0
TESTING AND ADJUSTING STANDARD VALUE TABLE FOR ELECTRICAL RELATED PARTS
Classi- :onnector ispection Measurement

Component Judgement table
ficatior No. method condition

table below, it is normal (AC range) switch OFF.
2) Disconnect
tieasure connector.
Glow 2 signal
I I
,esistance Between
CN412 @ - 0.8- 1.3 R
CN413 0
If the condition is as shown in the 1) Turn starting

CN-412 2) Disconnect
Measure
APS nozzle CN-413 connector.
resistance
1.5-2.5R
If the condition is as shown in the ta- 1) Turn starting

ble below, it is normal switch ON.
APS water 2) Insert T-adapter.
Measure
temperature Between Below 20°C Max. IV
voltage
sensor CN413 @
-0 20°C and above 7-l ov
-
CN-224 Measure 2) Disconnect
Pin-puller solenoid (male) resistance IBetween@-@ 1 40-80R ( connector.
Between 0, @ - chassis Min. 1 MQ

2) Disconnect
CN-SOL1 Measure connector.
Blade pitch solenoid resistance Between @ -@ 40-8052
(male)
Between 0, @ - chassis / Min. 1 MQ 1

CN-SOL2 Measure 2) Disconnect
Blade pitch solenoid (male) resistance Between @ -@ 40-80R connector.
Between 0, @ - chassis Min. 1 MQ
20-9
0
TESTING AND ADJUSTING STANDARD VALUE TABLE FOR MACHINE MONITOR
STANDARD VALUE TABLE FOR MACHINE MONITOR
Name of -IT :on- Inspect Measurement

sctor ion Judgement table
component No. method conditions
C Iheck, caution the condition is as shown in Tables 1 and 2, the monitor

Flortion buzzer anel is normal.
signal
able 1 (Check, caution portion) 1) Start engine.
-he H and L in the 2) Insert
Monitor auxiliary signal output
~~llrl
able above are the T-adapter.
ollowing voltages.
E 1 Engine oil
pressure signal
H: 3.5 - 30V
L: Approx. OV
H 2 Starting signal
Engine oil L ON
H: 3 - 30V lressure H H
L: Approx. OV CNI 0 H OFF
( Ince the starting
L ON
S signal is H, even if 3attery charge H H
i,t then changes to CNI @ H OFF
1-I the starting signa
I:s stored in memor)
i nside the monitor
F)anel as H until the
5starting switch is ‘able 2 (Buzzer sional) 1) Turn starting
t urned OFF. switch ON.
3L 3 Alternator 2) Insert T-
signal adapter or
H: 27.5 - 30V connect short g
L: Max. 5V connector. Z
G
Disconnect CN402
(coolant temperature
sensor) tf connect
short connector to
CN402
r 1) Turn starting
switch OFF,
insert dummy
resistance, or
measure
resistance of
sensor.
2) Turn starting
switch ON and
check display.
Coolant N-40. 3) Connect
temperature nale 17 socket.
108*2’C
102Z2’C
98’C
94’C
83’C
-L
Name of Con-
SY iecto Judgement table Measurement
ter jmponent No. conditions
-
I) Turn starting
switch OFF,
insert dummy
5 resistance, or
E measure
5
Power train oil :N-45 resistance of
temperature male sensor.
2) Turn starting
switch ON and
check display.
3) Connect T-
Approx. 1.8 kQ adapter.
:N-42
Fuel level
male
/
I
-Tfthe condition is as shown in the table 1) Turn starting

blelow, it is normal switch OFF.
2) Disconnect
Coolant temperature Oil temperature or When normal
coolant temperature connector.
sensor :N-40
(Coolant temperature male 1oo”c Approx. 3.8 kQ
gauge) I
Power train oil :N-45 9dT Approx 5 kQ
temperature sensor male I I
(Power train oil 35OC Approx. 29 kQ
temperature gauge) I I
20°C Approx. 52 kQ
I I
10°C Approx. 80 kQ
-
If the condition is as shown in the table I) Start engine.
blelow, it is normal
:N-40 Engine oil pressure 0.05
Engine oil pressure No continuity
sensor MPa IO.5 kg/cm? or above
GNC
Engine oil pressure below
Continuity
0.05 MPa lo.5 kg/cm*}
t
-
If the condition is as shown in the table 1) Turn starting
bielow, the sensor is normal switch OFF.
(r normal temperature: 25°C)
Fuel level sensor :N-42
(fuel gauge) male
I CN423 (male) 0 - 0
Full I Approx. 12 L2 or below
E
Empty 1 Approx. 85 - 110 Q
-
v\/hen engine is running (l/2 throttle or 1) Start engine.
alhove) + 28 f 2V
% If the battery is old, or after starting in
cold areas, the voltage may not rise for
Alternator
some time.
20-11
0
Sy: Name of Con- Measurement

lector Judgement table conditions
comDonent
-ter No.
below, the sensor is normal switch OFF.
2) Disconnect
N-452 Oil temperature 105°C or
Hydraulic oil temperature Continuity connector.
male) above Continuity
sensor I
Oil temperature below

No continuity
105°C No continuitv

below, it is normal switch OFF.
2) Disconnect
connector.
3) Drain oil then
Engine oil level sensor :N-404

V’ BLPOOOO2
Float
raised Max. 1 R remove
sensor.
male)
V’ BLPOOO03
Float
lowered
Min. 1 MR
20-12
0
TESTING AND ADJUSTING TOOLS FOR TESTING, ADJUSTING. AND TROUBLESHOOTING
TABLE OF TOOLS FOR TESTING, ADJUSTING,

AND TROUBLESHOOTING
Check or measurement iten ‘ymbol Part No. Part Name Remarks
799-203-8001 1 Multi-tachometer L : 60 - 2,OOOrpm

1 I
Digital display
Engine speed A 6210-81-4110 Adapter
H : 60 - 19,999rpm
2 799-203-890
1 Clamp set Kit Part No. : 799-203-9000
Water temperature, or1 tem-
oerature. exhaust temoerature B 799-101-1502 Digital temperature gauge - 99.9 - 1,299’C
2.5,5.9,39.2,58.8MPa
799-l 01-5002 Hydraulic tester Pressure9auge:{25,60,400,600kg/cm*}
1
790-261-I 203 Digital hydraulic tester Pressure gauge:$$~~m~I
2 799-401-2320 Hydraulic gauge l.OMPa UOkg/cm2)

790-261-1311 Both male and female 14 x 1.5
(female PT l/8)
Oil pressure c 3- 790-261-1321 Adapter Both male and female 18 x 1.5
(female PT l/8)
790-261-1360 Adapter Both male and female 18 x 1.5
(female PT l/8)
4 790-261-I 370 Nut 14 x 1.5 blind
07003-31419 Gasket For blind
1 795-502-I 590 Compression gauge 0 - 6.9MPa (0 - 70kg/cm3

Compression pressure D
2 795-502-I 350 Adapter (Kit Part No. : 795-502-1205)
8
z Blow-by pressure
z
Valve clearance
Exhaust color
Air supply pressure

(boost pressure)
Operating effort
Stroke, hydraulic drift
Work equipment speed

Measuring voltage, resist
ante value
For details of the applicable T-adapter assem-

Troubleshooting of wiring blies and adapters, see TABLE OF APPLICABLE
harness, sensor
T-ADAPTER KITS (TOOL M)
Measuring sprocket wear N 791-627-1111 Sprocket wear gauge Measurement of sprocket wear
Adjusting fuel injection timin! P 795-471-1200 Gauge assembly Dial gauge available commercially
20-l 3
0
TESTING AND ADJUSTING TABLE OF APPLICABLE T-ADAPTER KITS (TOOL M)
TABLE OF APPLICABLE T-ADAPTER KITS (TOOL M)

* For tools which do not have a set kit number, select a suitable adapter from the chart below.
(l/2)
D375A-3
Component T-adapter kit parts number
Applicable model oftool M
- 799-601-2500
799-601-7100799-601-7000
799-601-8000
799-601-7400
Number T-adapter part _

Name of T-adapter of pins number Component of T-adapter kit
Measurement box $!!&!$ - 799-601-2600 0 0 0 0 0
BEN00014
20-14
0
TESTING AND ADJUSTING TABLE OF APPLICABLE T-ADAPTER KITS (TOOL M)
W2)
D375A-3
Component T-adapter kit parts number
Applicable model oftool M
- 799-601-2500
799-601-7100
799-601-7000
769-601-6000
769-601-7400
- Component of T-adapter kit

I
Measurement bo>
BEU00020
EEY0002I
MS 14P 14 799-601-2910
REL 5P 5 799-601-7360
Relay adapter
REL 6P 6 799-60 I-7370
Short connector(X-type) - 799-601-7230 0 0 0
Extension cable - 799-601-2840 0
20-M
0
TESTING AND ADJUSTING MEASURING ENGINE SPEED
MEASURING ENGINE SPEED

a Be careful not to touch any hot parts when re-
moving or installing the measuring tools.
* Measure the engine speed under the following
conditions.
l Coolant temperature: Within operating range

. Hydraulic temperature: 45 - 55°C
. Power train oil temperature: 70 - 90°C
1. Install sensor @ of multitachometer A to speed

pick-up port (I), then connect tachometer A.
BLD00171
2. Start the engine and measure the engine speed
at high idling and low idling.
* When measuring items other than above,
see the measurement procedure for each
item.
* See the separate section for the measure-
ment procedure when measuring the torque
converter stall speed or torque converter stall
+ hydraulic pump relief (full stall) speed.
BLD00172
20-16
0
TESTING AND ADJUSTING MEASURING EXHAUST COLOR
MEASURING EXHAUST COLOR

. When measuring in the field where there is no
air or electric power supply, use Handy Smoke
Checker Gl; when recording formal data, use
Smoke Meter G2.
* Raise the coolant temperature to the operat-
ing range before measuring.
a Be careful not to touch any hot parts when re-
moving or installing the measuring tools.
1. Measuring with Handy Smoke Checker Gl.

1) Install filter paper to Handy Smoke Checker
Gl.
2) Insert the exhaust gas suction port into the
exhaust pipe, accelerate the engine suddenly,
and operate the handle of Handy Smoke
Checker Gl at the same time to collect the
exhaust gas on the filter paper.
3) Remove the filter paper and compare it with
the scale supplied to judge the condition.
2. Measuring with Smoke Meter 62
8
1) Insert-the probe @ of Smoke Meter 62 into BLDD0173
2
the outlet port of the exhaust pipe, and
;;
tighten the clip to secure it to the exhaust
pipe.
2) Connect the air hose and the socket of the
probe hose and accelerator switch to Smoke
Meter 62.
* Keep the pressure of the air supply be-
low 1.5 MPa (15 kg/cm* I.
3) Connect the power cord to the AC socket.
* When connecting the cord, check that
the power switch of Smoke Meter G2 is
OFF.
4) Loosen the cap nut of the suction pump,
and fit the filter paper. BLD00174
* Fit the filter paper securely so that the
exhaust gas cannot leak.
5) Turn the power switch of Smoke Meter 62
ON.
6) Accelerate the engine suddenly, and depress
the accelerator pedal of Smoke Meter 62 at
the same time to collect the exhaust gas
color on the filter.
7) Place the filter paper used to catch the ex-
haust gas color on top of at least 10 sheets
of unused filter paper inside the filter paper
holder, and read the value shown.
I TLD00140
20-17
0
TESTING AND ADJUSTING ADJUSTING VALVE CLEARANCE
ADJUSTING VALVE CLEARANCE

1. Remove the cylinder head cover.
For details, see REMOVAL OF CYLINDER HEAD
ASSEMBLY.
2. Rotate the crankshaft in the normal direction to

align the 1.6TOP line on vibration damper (1)
with pointer (2) to set the No. 1 cylinder at com-
pression top dead center. When rotating, check
the movement of the intake valves of the No.
6 cylinder.
* When the No. 1 cylinder is near the com- 1’
pression top dead center, the intake valves
of No. 6 cylinder move (overlap position with
exhaust valves)
3. When No. 1 cylinder is at compression top dead
center, adjust the valves marked 0. Next, rotate Valve arrangement
crankshaft one turn (360”) in the normal direction
and adjust the valve clearance of the valves
marked 0.
TDD00714
4. To adjust the valve clearance, insert feeler gauge
F between crosshead (5) and rocker arm (6), and
adjust with adjustment screw (3) until the clear-
ance is a sliding fit.
5. Tighten locknut (4) to hold adjustment screw (3)
in position.
w Locknut : 58.8 Nm {S kgm}
* After adjusting No. 1 cylinder at compression

top dead center, it is also possible to turn the
crankshaft 120” each time and adjust the clear-
ance of the valves of each cylinder according to
the firing order. BLD00176
I
. Firing order : 15-3-6-2-4
After tightening the locknut, check the valve clear-

ance again.
6. After adjusting, install the cylinder head cover.
For details, see INSTALLATION OF CYLINDER
HEAD ASSEMBLY.
n
BLD00177
20-l 8
0
TESTING AND ADJUSTING MEASURING COMPRESSION PRESSURE
MEASURING COMPRESSION PRESSURE

A When measuring the compression pressure, be
careful not to touch the exhaust manifold or get
caught in the fan belt or other rotating parts:
1. Adjust the valve clearance.

For details, see ADJUSTING VALVECLEARANCE.
2. Warm up the engine to raise the oil temperature
to 40 - 60°C.
3. Remove the fuel injection tube and inlet con-
nector, then remove nozzle holder assembly (I)
of the cylinder to be measured.
For details, see REMOVAL OF NOZZLE HOLDER , I
BLD00178
ASSEMBLY.
4. Install adapter D2 in the mount of the nozzle
holder assembly, then connect pressure gauge
Dl.
5. Set multitachometer A in position.
* For details, see MEASURING ENGINE SPEED.
6. Place the fuel control rod in the NO INJECTION
position (STOP position). Crank the engine with
the starting motor and measure the compres-
sion pressure.
* Measure the compression pressure at the point
where the pressure gauge indicator remains
steady.
t?
* When measuring the compression pressure, BLD00179
%
measure the engine speed to confirm that it is
z
within the specified range.
7. After measuring the compression pressure, in-
stall the nozzle holder assembly.
For details, see INSTALLATION OF NOZZLE
HOLDER ASSEMBLY.
20-19
a
TESTING AND ADJUSTING MEASURING BLOW-BY PRESSURE
MEASURING BLOW-BY PRESSURE

* Raise the coolant temperature to the operating
range before measuring.
1. Install blow-by checker El to the end of engine

breather hose (I), then connect gauge E2.
2. Run the engine at near rated output, and meas-

ure the blow-by pressure.
AWhen measuring, be careful not to touch any

hot parts or rotating parts.
I BiD00180
The blow-by should be measured with the en-
gine running at rated output. When measuring
in the field, a similar value can be obtained at
stall speed.
In this case, the blow-by value will be about
80% of the value at rated output.
Blow-by varies greatly according to the condi-
tion of the engine. Therefore, if the blow-by
value is considered abnormal, check for prob-
lems connected with defective blow-by, such as
excessive oil consumption, defective exhaust
gas color, and prematurely dirty or deterio-
rated oil.
TLD00021
20-20
0
TESTING AND ADJUSTING MEASURING ENGINE OIL PRESSURE
MEASURING ENGINE OIL PRESSURE

* Measure the engine oil pressure under the fol-
lowing conditions.
1. Remove engine oil pressure pick-up plug (1)

(PT1/8) from the main gallery, then install the
adapter and oil pressure gauge C2 (1.0 MPa {IO
kg/cm’)) from oil pressure gauge kit Cl.
2. Start the engine, and measure the oil pressure

at low idling and high id‘ling.
/ ci / /m/
BLD00182
TLD00025
20-21
0
TESTING AND ADJUSTING TESTING AND ADJUSTING FUEL INJECTION TIMING
TESTING AND ADJUSTING FUEL INJECTION TIMING

1. Remove the tube (front only) between the muf-
fler and muffler adiabatic plate (front only) air
cleaner Komaclone.
2. Remove the injection pump coupling cover.
3. Remove the head cover, disconnect spill tube
(1) and delivery tube (2) of the No. 1 piston,
then remove No. 1 nozzle holder assembly (3).
4. Align No. 1 cylinder with the compression top
dead center line (1:6).
* When doing this, check that the fuel injec-
tion timing line on the fuel injection pump is
near the line on the fuel injection pump body.
5. Set dial gauge P to the nozzle holder hole where
the nozzle holder assembly has been
removed. (See the diagram.)
6. Set the scale on dial gauge P to 0 when the
piston is at the top dead center.
* Rotate the crankshaft in the normal direc-
tion and in the reverse direction in turn to
align the top dead center.
+ Record the value indicated by the short indi-
cator on dial gauge P.
7. Rotate the crankshaft approx. 45” in the reverse
direction from the No. 1 cylinder TOP position.
8. Rotate the crankshaft again slowly in the nor-
mal direction and set to specified dimension “I?‘.
* Specified dimension ‘It?‘: 7.86 + 0.2 mm
(BTDC: 22”)
* Always rotate the crankshaft in the normal
direction to align the position.
* Continue to rotate in the normal direction,
and when the No. 1 cylinder reaches the
TOP (top dead center) position (the indicator
on the dial gauge rotates in reverse), check
that the dial gauge reading is 0 f 0.2 mm. If
it is not within 0 f 0.2 mm, carry out Steps 5
and 6 again.
9. Check that fuel injection timing line “a” on the

fuel injection pump is aligned with line “b” on
the coupling.
20-22
a
TESTING AND ADJUSTING TESTING AND ADJUSTING FUEL INJECTION TIMING
10. If the lines are not aligned, loosen bolt (4) in

the oblong hole, move the coupling to align the
lines, then tighten the bolt.
11. After adjusting, install the No. 1 nozzle holder

assembly.
For details, see INSTALLATION OF NOZZLE
HOLDER ASSEMBLY.
20-23
0
TESTING AND ADJUSTING ALTERNATOR BELT TENSION
TESTING AND ADJUSTING TESTING AND ADJUSTING BELTTENSION FOR AIR CONDITIONERCOMPRESSOR
TESTING AND ADJUSTING ALTERNATOR BELT TENSION

1.. Testing
. Measure deflection a of the belt when it is
pushed with a finger force of approx. 58.8 N
{approx. 6 kg1 at a point midway between
the alternator pulley and the drive pulley.
* Deflection a of V-belt (standard value):

10 - 15 mm
I BKD00188
2. Adjusting
1) Loosen alternator mount bolt (I).
2) Loosen locknut (2), then turn
adjustmentnut (3) to adjust the tension of
the belt.
3) After adjusting the belt tension to the stand-
ard value, tighten locknut (2), then tighten
alternator mount bolt (1).
TESTING AND ADJUSTING

BELT TENSION FOR AIR
:\
CONDITIONER COMPRESSOR
1. Testing
. Measure deflection b of the belt when it is
pushed with a finger force of approx. 58.8
I n
B
N {approx. 6 kg) at a point midway
between the compressor pulley and the b
engine drive pulley.
* Deflection b of V-belt (standard value):

15 - 18 mm
BKD00190
2. Adjusting
I) Loosen 4 compressor mount bolts (I).
2) Loosen locknut (2), then turn
adjustmentnut (3) to adjust the tension of
the belt.
3) After adjusting the belt tension to the
standard value, tighten locknut (21, then
tighten alternator mount bolt (I).
m Mount bolt:
24.5 = 4.9 Nm I2.5 2 0.5 kgm}
20-24
a
TESTING AND ADJUSTING MEASURING EXHAUST TEMPERATURE
MEASURING EXHAUST TEMPERATURE

AThe temperature sensor must be installed to the
exhaust manifold, so if the machine has been
operated, wait for the manifold temperature to
drop before installing the sensor.
* Raise the coolant temperature to the operating
range before measuring.
1. Remove the adiabatic plate at the rear end of
the chassis, then remove plug (I) from the ex-
haust manifold, and install temperature sensor
B2.
. Temperature sensor B2:
6215-11-8180 (cable length 610 mm) or
6215-11-8170 (cable length 490 mm)
2. Connect to digital temperature gauge Bl with

the wiring harness.
Measurement procedure
X-type connector (PPin)
1. When measuring the maximum value during
Temperature sensor
troubleshooting
Carry out actual work and measure the maxi-
mum value during operation.
* Use the PEAK mode (it can store the maxi- Harness
(799-201-I 110)
mum value in memory) of the temperature
gauge function.
Note:
The exhaust temperature varies greatly accord-
ing to the ambient temperature (temperature of
the engine intake air), so if any abnormal value
is obtained, carry out temperature compensa-
tion.
* Compensation = Measured value + 2 x (con-
verted ambient temperature - actual ambi-
ent temperature)
* The converted ambient temperature is
taken as 20°C.
2. When measuring periodically (during preventive
maintenance, etc.)
1) Raise the exhaust temperature by using full TLD0003P
I
stall (torque converter stall + hydraulic pump
relief).
(Standard value: Approx. 650°C).
2) In the above condition, cancel the hydraulic
relief, and carry out only torque converter
stall. (The temperature will start to go down.
If it goes up without going down, raise the
set temperature shown in @ of the right I I k’ 1 with torque converter
/‘I stal I
lil I
figure.)
,’ I
3) Note the stable temperature when the tem- /’ I
perature starts to go down. 1’
* If only torque converter
when measuring
stall is used
the exhaust tempera-
I Full
+
stall
ture, torque converter will overheat be- I

I
- BKD00676
fore a stable value is obtained.
20-25
a
TESTING AND ADJUSTING MEASURING AIR SUPPLY PRESSURE (BOOST PRESSURE)
MEASURING AIR SUPPLY PRESSURE (BOOST PRESSURE)

A when
Be careful not to touch any hot or rotating parts
measuring or when removing or install-
ing the measuring tools.
1. Remove air supply pressure measurement plug

(I) (PT1/8), then install the coupler inside oil
pressure gauge kit Cl.
2. Connect the oil pressure measurement hose to

the coupler and pressure gauge H.
Note: Operate the engine at midrange speed or

above, and use the self-seal portion of the
gauge to bleed the oil inside the hose.
. Insert the gauge about half way, repeat
the action to open the self-seal portion,
and bleed the oil.
* If there is oil inside the hose, the gauge

will not work, so always bleed the oil.
3. Carry out the torque converter stall operation at

high idling and read the gauge indicator. BLD00196
I
* The air supply pressure (boost pressure) should
be measured with the engine running at rated
output. However, when measuring in the field,
a similar value can be obtained by operating at
torque converter stall.
20-26
0
TESTING AND ADJUSTING MEASURING TORQUE CONVERTER STALL SPEED
MEASURING TORQUE CONVERTER STALL SPEED
* Measure the stall speed under the following con-

ditions.
Hydraulic oil temperature: Min. 50°C
a‘ Make sure that there is no one near the ma-

chine before starting measurements.
1. install multitachometer A.
For details, see MEASURING ENGINE SPEED.
2. Start the engine.
3. Depress the steering brake firmly and move
the gearshift lever to F3 or R3.
4. After depressing the decelerator pedal, move
the fuel control lever from low idling to FULL,
run the engine at high idling, and stall the torque
converter.
A Precautions when relieving the torque con-
verter
1) Depress the decelerator pedal before pull-
ing the fuel control lever to the FULL
position.
2) Release the decelerator pedal to run the
engine at high idling. However, for safety
reasons, always keep your right foot on
the decelerator pedal until the comple-
tion of the measurement operation.
5. If the torque converter oil temperature gauge

enters the red range, return the speed lever im-
med.iately to neutral, and lower the oil tempera-
ture.
6. Repeat Steps 2 - 4 three times.
7. Repeat Steps 2 - 4 to stall the torque converter.
8. Measure the engine speed the moment the
torque converter oil temperature gauge enters
the red range,
* After completion of the measurement, re-
turn the speed lever swiftly to neutral, and
run the engine at high idling to lower the oil
temperature.
(Reference)
. The stall speed differs between machines for Variations according to characteristics of
4)
the reasons given below, so the measurement torque converter
must be carried out extremely carefully. 5) Variations according to method of measur-
I) Variation’s according to engine serial number ing torque
2) Variations in engine output due to atmos-
pheric pressure and temperature
3) Variations in consumption torque of auxil-
iary equipment
20-27
0
MEASURING SPEED AT TORQUE CONVERTER STALL+
TESTING AND ADJUSTING HYDRAULIC PUMP RELIEF (FULL STALL)
MEASURING SPEED AT TORQUE CONVERTER STALL +

HYDRAULIC PUMP RELIEF (FULL STALL)
* Measure the stall speed under the following con-
ditions.
. Coolant temperature: Within operating range
Hydraulic oil temperature: Min. 50°C
a’ Make sure that there is no one near the ma-

chine before starting measurements.
1. Install multitachometer A.
For details, see MEASURING ENGINE SPEED.
2. Start the engine.
3. Depress the steering brake firmly and move the
gearshift lever to F3 or R3.
4. After depressing the decelerator pedal, move
the fuel control lever from low idling to FULL,
run the engine at high idling, and stall the torque
converter.
A 1) Precautions when stalling the torque converter

Depress the decelerator pedal before pulling
the fuel control lever to the FULL position.
2) Release the decelerator pedal to run the en-
gine at high idling. However, for safety rea-
sons, always keep your right foot on the
decelerator pedal until the completion of the
measurement operation.
5. If the torque converter oil temperature gauge
enters the red range, return the speed lever im-
mediately to neutral, and lower the oil tempera-
ture.
6. Repeat Steps 2 - 4 three times.
7. Repeat Steps 2 - 4 to stall the torque converter.
At the same time, operate the ripper lever to the
RAISE position to relieve the circuit. (Reference)
6. Measure the engine speed the moment the . The stall speed differs between machines
torque converter oil temperature gauge enters
for the reasons given below, so the meas-
the red range,
urement must be carried out extremely care-
* After completion of the measurement, re-
fully.
turn the speed lever swiftly to neutral, and
run the engine at high idling to lower the oil
1) Variations according to engine serial
number
temperature.
Note: If this measurement is carried out im-
2) Variations in engine output due to at-
mospheric pressure and temperature
mediately after measuring the torque
3) Variations in consumption torque of aux-
converter stall speed, the measurement
iliary equipment
can be carried out by performing Steps
4) Variations according to characteristics of
3) - 7) once.
torque converter
5) Variations according to method of meas-
uring torque
20-28
0
TESTING AND ADJUSTING ADJUSTING FUEL CONTROL LINKAGE
ADJUSTING FUEL CONTROL LINKAGE
-1
I
I-7-7
f
L27!
-!-
I
j
_
7=-v /
,-7
“r-
t--Y
A-A
BLD00341
1’1!
I11
‘I
:c., X
__
__---
X
BLD00342
20-29
0
1. Make the length between the pins of rod (I) the

value “a” given below, and connect fuel con-
trol lever (2).
* Dimension “a” : 353 mm
2. Set fuel control lever (2) at the idling position.

* Move the fuel control lever to the idling po-
sition. The point where clearance “b” of
idling stopper (3) is 0 mm is the idling posi-
tion.
3. Make the length between the pins of rods (4)

and (5) the values “c” and “d” given below, then
connect them.
* Dimension “c” : 288 mm
Dimension “d” : 570 mm
4. Move fuel control lever (2) approx. 100 mm to-

wards the FULL position, and put it lightly in
contact with bolt FULL stopper (6).
Ir There is no need to lock it with the locknut.
5. Make the length between the pins of rod (7) the

value “e” given below, and connect fuel control
lever (2). -
* Dimension “e” : 690 mm I C BLD00320
6. Put the fuel control lever in contact with the

idling notch, make the length between the pins
of rod (8) the value “f” given below, then con-
nect with the shortest hole (distance between
pins: 144 mm) of lever (9).
Ir Dimension “f” : 963 mm
\ d--- BL.D00321
A ,179.m
BLD00322
20-30
0
7. Adjust with the turnbuckle so that the length

between the pins of lever (IO) and rod (II) is
the value “g” given below, then connect.
j, Dimension “g” : Approx. 991 mm
8. Start the engine, move the fuel control lever to
the FULL position, and measure the high idling
speed.
* Engine high idling speed : 1,960 + 50 rpm
9. Return the fuel control lever to the idling posi-

tion, then move the fuel control lever gradually
to the FULL position, and when the high idling
speed is the speed at the point measured in
Step 8, lock FULL stopper bolt (6).
10. In the above condition, put fuel control lever (2)

in contact with FULL stopper bolt (61, and check
that governor lever (12) is in contact with the
governor FULL stopper.
Ir Check that loose spring (13) does not de
fleet more than 1 mm.
11. Turn back FULL stopper bolt (6) of fuel control

lever (2) 1.5 turns, and lock it in position.
* This is to give some margin at the
FULLposition. BLD00324
12. Start the engine, then gradually move fuel con

trol lever (2) to the STOP position, and stop the
engine. Check that governor lever (12) is in
contact with the STOP stopper, turn the stopper
bolt, then turn it back 2 turns and lock it in
position.
20-31
0
TESTING AND ADJUSTING ADJUSTING DECELERATOR PEDAL
ADJUSTING DECELERATOR PEDAL
A the
Lower the work equipment to the
joystick to the neutral position,
ground, set
then set the
safety lever to the LOCK position.
1. Install so that distance “a” between the pins of

rod (I) is the dimension given below.
2. Start the engine and set the fuel control lever to

the FULL position.
ELD00205
3. In this condition, depress decelerator pedal (2)
fully, then turn turnbuckle (3) to adjust to the
following speed.
* Speed when decelerator ped.al is fully de
pressed: 850 + 50 rpm
* Turn the turnbuckle as follows.
EXTEND turnbuckle to DECREASE speed
RETRACT turnbuckle to INCREASE speed
4. Adjust stopper bolt (4) so that decelerator pedal

(2) contacts stopper bolt (4) when the engine is
at high idling.
* High idling speed: 1,960 t 50 rpm
BLD00142
20-32
0
ADJUSTING JOYSTICK (STEERING, DIRECTIONAL, SPEED
TESTING AND ADJUSTING CONTROL LEVER), PARKING BRAKE LEVER LINKAGE

CONTROL LEVER), PARKING BRAKE LEVER LINKAGE
20-33
0
B-B
BLD00207
20-34
0
Tighten the locknuts of the rods and cables se- 4) When doing this, do not pull the valve
curely, and bend the cotter pins securely. lever more than the amount of play.
The transmission control valves are installed to Check that lever (13) is at right angles to
speed lever (7) and directional lever (6). Each the crankshaft (ground surface).
speed position and directional position is set by 5) Next, connect to lever yoke (14) at the
the detent inside the valve. control box end and floor frame inter-
mediate fulcrum lever (17) so that the
Adjusting directional control linkage length of rod (15) is 584 mm.
1) Remove the control lever knob, and set park- 6) Connect to fulcrum lever (17) and ful-
ing lever (2) to the LOCK position in order to crum lever (13) so that length “a” of rod
determine the neutral position for direction. (16) is 571 mm.
(If the parking lever linkage is not connected, 7) Connect so that length “c” of rod (34) is
raise parking lever (2) with a screwdriver. In 386 mm.
this condition, the machine will not move 8) Turn the turnbuckle of rod (16) to adjust
forward or in reverse.) so that the distance from the center of
2) Adjust rod (3) so that the position of the the top to the end face of handle (18) is
lever is 54 + 1 mm from the center of the 65 mm when joystick (1) is at the NEU-
lever box assembly mounting bolt (front). TRAL position.
* Distance “b” between pins of rod (3):
6Bmm 4. Overall adjustment
3) Set control valve (33) in the neutral position, Assemble the armrest cover again and
then connect directional push-pull cable (4). check the following.
4) Next, connect directional push-pull cable (4)
to lever (5) in the control box. 1) Operate the joystick (directional lever) to
8 the FORWARD position and check that
5) Adjust so that the clearance from handle (18)
i% the clearance from the handle is 90 mm.
G is 90 mm at the F position.
2) Rotate speed lever (knob) (1) and check
2. Adjusting speed linkage the speed display (on top of the armrest
I) Connect so that the length of rod (8) in the cover) to confirm that the display is cor-
control box is 93 - 94 mm. (If the armrest rect (shows 1st when in Ist, 2nd when
cover is not open, leave it as it is.) in 2nd, 3rd when in 3rd).
2) Place speed lever (control valve) (7) in 1st * If it is not correct, carry out fine ad-
and connect speed push-pull cable (9). Next, justment with turnbuckle (19) at the
connect speed push-pull cable (9) to lever top of speed push-pull cable (9).
(IO) in the control box. 3) Operate the lever to the left and right
and check that the travel is 85 +. 25 mm
3. Adjusting steering linkage both to the left and right. For machines
1) Connect rod (11) and rod (12) to the follow- equipped with a cab, also move the joy-
ing dimensions. stick to the FORWARD position and op-
Ir Standard length of rod (11): 377 mm erate it to turn left (the lever is oper-
* Standard length of rod (12): 380 mm ated diagonally to the front left) and
2) Pull both rod (11) and rod (12) towards the check that the clearance from the cab is
front of the machine lightly (less than 29.4 N approx. 50 mm. (Check that your hand
{3 kg)), and put lightly in contact with the does not hit the cab.)
clutch spool inside the steering valve.
3) In this condition, set the clearance at the
oblong hole in the yoke to 0, turn the
turnbuckle of rod (11) (nut welded), and ad-
just clearance “d” at the oblong hole to 0.1 -
0.2 mm.
20-35
0
TESTING AND ADJUSTING CONTROL LEVER). PARKING BRAKE LEVER LINKAGE
5. Adjusting parking brake

1) With parking lever (22) at the FREE position,
connect rod (24) and rod (25) so that the
dimensions to lever (23) of the control box
are as given below. (Distance from the floor
frame to the center of the knob: 424 mm)
* Rod (24): 106 mm
Rod (25): 95 mm
With the rods connected in this condition,
check that there is a clearance between le-
ver (27) and the floor frame.
2) With the parking lever at the LOCK position,
adjust with the turnbuckle of rods (24) or
(25) so that the clearance between the hole
of bracket (28) and lever (27) is the dimen-
sion given below.
* Clearance : 26 mm
Set again to the FREE position and check
that there is no change in the free height.
Then put adjustment bolt (29) (for fixing the
lock position) in contact with lever (27) and
tighten.
3) Next, set lever (30) at the brake valve end
and lever (2) at the control box end to the
LOCK position and connect push-pull cable
(31). (Be careful not to pull the brake valve
lever when connecting.)
After connecting, set parking lever (22) to
the LOCK RELEASE positions and check that
it moves properly.
4) After adjusting, set parking lever (22) to the
FREE position, and check that the steering,
directional, and speed can be operated cor-
rectly. Check also that the levers are re-
turned from the FORWARD and REVERSE
positions to the neutral position when park-
ing lever (22) is placed in the LOCK position.
Check also that the directional lever does
not move to the FORWARD and REVERSE
positions when it is locked.
5) With parking lever (22) at the LOCK position,
adjust at the oblong hole of the switch mount
bolt so that lever (2) pushes in the movable
portion of safety switch (32) by dimension
“h”.
* Dimension “h” : 2.8 mm
20-36
0
TESTING AND ADJUSTING ADJUSTING BRAKE PEDAL LINKAGE
ADJUSTING BRAKE PEDAL LINKAGE
BLD00208
* Tighten the locknuts of the rods and cables se-

curely, and bend the cotter pins securely.
1. Adjust height “b” of damper (2) so that the travel
of brake pedal (I) is dimension “a”.
* Brake pedal travel “a” : 79 mm
* Damper standard height “b” : 39 mm
2. Adjust the length of rod (3) to dimension “c”,

then install to lever (4).
It Dimension 2” : 1,487 mm
8
3. Adjust the length of rod (5) to dimension “d”, TLD00059
k%
then install to lever (6).
;;
Ir Dimension “d” : 174 mm
4. Push rod (3) towards the rear of the machine
lqqgil$
with a force of 9.8 - 19.6 N {I - 2 kg}, and put it
lightly in contact with the brake spool inside the
steering control valve. Then turn only joint (7)
and connect rod (3) and rod (5).
5 7 8 3
5. With brake pedal (1) at the brake RELEASED
position, adjust the length of the rod so that the
play of the brake pedal is 1 - 5 mm at the center
of the pedal.
* Turn joints (7) and (8) in the same direction
at the same time to adjust the length of the
rod.
6. With brake pedal (I) at the brake RELEASED

position, check that lever (6) contacts damper
(2).
20-37
0
TESTING AND ADJUSTING ADJUSTING WORK EQUIPMENT CONTROL LINKAGE
ADJUSTING WORK EQUIPMENT CONTROL LINKAGE
BLD00209
1. Set the length of rod (I) to dimension “a”, then

connect PPC lock valve (2) and work equipment
lock lever (3).
20-38
0
TESTING AND ADJUSTING MEASURING POWER TRAIN OIL PRESSURE
MEASURING POWER TRAIN OIL PRESSURE
AStop the machine on level ground, lower the

work equipment to the ground and apply the
parking brake.
When measuring the hydraulic pressure, remove
all the sand and dirt from around the nipple and
plug.
Raise the power train oil temperature to 70 -
80°C before measuring.
Refer to the diagram and table below to install
oil pressure gauge Cl to the nipple for the cir-
cuit to be measured.
Table of centralized pressure pick-up port positions

and gauges to use when measuring hydraulic pres-
sure
8i
I
r
Gauge
No. Measurement location
I MPa {ka/cm?
1. Transmission main relief pressure 5.9 Eon
1
I I
Torque converter inlet pressure 5
Torque converter outlet pressure 4
5. Stator clutch pressure (S/C) 5.9 #x1

I I
6. Transmission modulating pressure (T/M) 5.9 Eon
,, Transmission Fl (reducing)
(Fl) 5.9 160)
oressure
8. Left clutch actuating pressure (UC) 5.9 #XI
9. Left brake actuating pressur U-/w 5.9 I60~
10. Right clutch actuating pressure WC) 5.9 {so}
11. Right brake actuating pressure NUB) 5.9 @oI
1. Measuring torque converter inlet port and out-

let pressure
1) Install oil pressure gauge Cl to torque con
verter inlet pressure measurement nipple (2)
and outlet pressure measurement nipple (3).
2) Set the joystick to neutral, and measure the
torque converter inlet port pressure and out
let port pressure with the engine at low idling
and high idling.
2. Measuring transmission main relief pressure
I) When measuring the main relief pressure,
remove plug (I) at the top of the filter cover
at the bottom of the front right fender of the
operator’s cab, then install the quick coupler
and oil pressure gauge Cl.
20-39
0
2) With the joystick at the neutral position,

measure the main relief pressure with the
engine at low idling and high idling.
3. Measuring torque converter lock-up pressure
1) Select the lock-up mode.
2) Insert tool C [gauge: 2.5 MPa (25 kg/cm*)1
securely into nipple (4).
3) Start the engine, move the joystick to set
the direction to NEUTRAL and the speed to
IST, then gradually raise the engine speed.
Measure the oil pressure when the lock-up
takes effect (engine speed: above approx.
1300 rpm).
A When measuring the oil pressure, be ex-
tremely careful not to get caught in the
track or other rotating parts.
4. Measuring stator clutch pressure
I) Install oil pressure gauge Cl to stator clutch
inlet pressure measurement nipple (5).
2) Set the joystick at neutral and measure the
stator clutch pressure with the engine at low
idling and high idling.
5. Measuring transmission modulating pressure
(measuring clutch circuit pressure)
1) lnstall~il pressure gauge C5 to modulating
pressure measurement nipple (6). Combination of speed range and clutches :
u>
Note: It is also possible to measure the
No. 2 No. 3 No. 4 No. 5 ;;
modulating pressure at the central
(F) (3rd) (2nd) (1st)
ized pressure pickup port, but the
modulating time cannot be measured Fl 0 0
(the oil pressure pickup hose is long
and there is a time lag when meas F2 0 0
uring).
* Measure the hydraulic pressure when the F3 0 0
clutch is actuated with the engine at low
idling and high idling when the joystick is RI loI I I lo
lol
operated to all the positions given below.
2) Measure the modulating pressure at each
speed range with the joystick (directional le-
R2 loI I
ver) at NEUTRAL. R3 0 0
3) Place the joystick (speed lever) at Fl, and
measure the modulating pressure.
4) Place the joystick (speed lever) at F2, and
5) Place the joystick (speed lever) at F3, and
20-40
a
A When carrying out the following measurements,

place the joystick at 3RD, and depress the brake
Ir Check also that the oil pressure is 0
MPa (0 kg/cm*) when the steering
pedal securely. lever is operated fully to the inside
6) l With the engine running at low idling, and outside, or when the brake pedal
place the joystick at the FORWARD posi is depressed, or when the parking
tion and measure the modulating pres- brake lever is at the LOCK position.
sure.
l With the engine running at high idling,
stall the torque converter and measure
the modulating pressure.
7) l
With the engine running at low idling,
place the joystick at the REVERSE posi-
tion and measure the modulating pres-
sure.
l With the engine running at high idling,
stall the torque converter and measure
the modulating pressure.
A verter
Precautions when relieving the torque con-
. Depress the decelerator pedal before

pulling the fuel control lever to the FULL
position.
. Release the decelerator pedal and run
the engine at full throttle. However, for
safety reasons, always keep your right
foot on the decelerator pedal until the
completion of the measurement opera-
tion.
6. Measuring transmission modulating pressure
1) Insert tool C [gauge: 2.5 MPa I25 kg/cm*11
securely into nipple (7).
2) Start the engine, then gradually raise the
engine speed and measure the oil pressure.
* Place the joystick at NEUTRAL for direc-
tion and IST for speed.
7. Measuring steering clutch pressure
1) Install oil pressure gauge Cl to left nipple
(9) and right nipple (11) for measuring the
steering clutch pressure.
2) Place the joystick at NEUTRAL for direction,
then operate the steering fully to the inside
or outside, and measure the oil pressure with
the engine at low idling and high idling.
8. Measuring steering brake pressure
1) Install oil pressure gauge Cl to left nipple
(8) and right nipple (IO) for measuring the
steering brake oil pressure.
2) Place the joystick at NEUTRAL for both di-
rection and steering, and measure the oil
pressure with the engine at low idling and
high idling.
20-41
0
MEASURING AND ADJUSTING WORK EQUIPMENT
TESTING AND ADJUSTING HYDRAULIC PRESSURE

HYDRAULIC PRESSURE
A work
Stop the machine on level ground,
equipment to the ground, then
lower the
apply the
parking brake.
* When installing the hydraulic gauge, remove
all the sand and dirt from around the plug.
1. Measuring hydraulic pressure

1) Remove plug (I) (front pump) and plug (2)
(center pump) for measuring the work equip-
ment main relief pressure, and install oil
pressure gauge Cl [Gauge: 39.2 MPa (400
kg/cnQll.
* Front pump: Blade lift
* Center pump:
Blade tilt, ripper tilt, ripper lift
* PM-2 specification machines are
equipped with a quick coupler.
2) Operate the blade tilt cylinder to the end of
its stroke to relieve the circuit, and measure
the oil pressure with the engine at low idling
and high idling.
3) Relieve the blade lift cylinder circuit and
measure the oil pressure with the engine at
low idling and high idling.
* Block the blade lift cylinder circuit with a
blind plug when measuring.
TAD00110
20-42
0
TESTING AND ADJUSTING HYDRAULIC PRESSURE
2. Adjusting main relief pressure

1) Adjusting main relief pressure for front pump
(blade lift)
i) Remove cap nut (2) from main relief
valve (1).
w Cap nut:
34.3 + 4.9 Nm 13.5 2 0.5 kgml
ii) Loosen locknut (3) of main relief relief
valve (I), then turn adjustment screw (4)
to adjust.
* Turn the adjustment screw as fol-
I
lows. BLDOOZ 17
l To INCREASE pressure, turn
CLOCKWISE
. To DECREASE pressure, turn
COUNTERCLOCKWISE
* Amount of adjustment for one
turn of adjustment screw:
2.43 MPa 124.8 kg/cm2)
* After completion of adjustment,
check the main relief pressure again.
BLD00218
2) Adjusting main relief pressure for center

pump (blade tilt, ripper tilt, ripper lift)
i) Remove cap nut (2) from main relief
valve (I).
Qgg Cap nut:
34.3 t 4.9 Nm 13.5 z 0.5 kgml
ii) Loosen locknut (3) of main relief relief
valve (I), then turn adjustment screw (4)
to adjust.
Sr Turn the adjustment screw as fol-
lows.
l To INCREASE pressure, turn
CLOCKWISE
. To DECREASE pressure, turn
COUNTERCLOCKWISE
j, Amount of adjustment for one turn
of adjustment screw:
2.43 MPa l24.8 kg/cm?
* After completion of adjustment,
check the main relief pressure again.
BLDOOZT!
TESTING AND ADJUSTING WORK EQUIPMENT
TESTING AND ADJUSTING CONTROL CIRCUIT PRESSURE
TESTING AND ADJUSTING WORK EQUIPMENT

CONTROL CIRCUIT PRESSURE
1. Measuring
* Oil temperature when measuring: 45 - 55°C
A stop
Lower the work
the engine.
equipment to the ground and
Loosen the oil filler cap slowly
to release the pressure inside the hydraulic tank.
Then set the safety lock lever to the LOCK posi-
tion.
1) Remove the right cover of the operator’s
cab, then remove control pressure pickup
plug (I) (PT 3/8) and install oil pressure gauge BLD00221 ELD00222
Cl (5.9 MPa I60 kg/cm21).
2) Start the engine, then set the safety lever to
the FREE position, and measure with the
engine at high idling.
* When testing for internal leakage of the
equipment in the control circuit, use the
parts given below to shut off the circuit
for the following sections when measur-
ing the relief pressure.
No Section of hydraulic Component that can
r-I
. circuit shut off be checked
5 Control pump outlet
Control pump
Port I
PPC valve inlet port Blade control PPC
6 for blade control valve
Blade control Ripper control
mjort 1 ;;ppzrr control PPC PPC valve PPC valve
6 PPC charge valve PPC charge valve

f outlet port
* Use the following parts to shut off the

circuit.
Plug: 07040-I 1409
O-ring: 07002-10423 / 1 ,relief valve 1

L!l BKD00677
2. Adjusting
1) Loosen locknut (3) of PPC charge relief valve
(21, then turn adjustment screw (4) to adjust.
* Turn the adjustment screw as follows.
l To INCREASE pressure, turn CLOCK-
WISE
l To DECREASE pressure, turn
COUNTERCLOCKWISE
Ir Amount of adjustment for one turn of
adjustment screw: 0.76 MPa (7.8 kg/cm?
w Locknut :
63.7 2 9.8 Nm I6.5 = 1.0 kgml
* After completion of adjustment, repeat
-2
the procedure in Step 1 to check the pres-
TAD00076
sure again.
20-44
0
TESTING AND ADJUSTING MEASURING PPC VALVE OUTPUT PRESSURE
MEASURING PPC VALVE OUTPUT PRESSURE
* Oil temperature when measuring: 45 - 55°C

1. Disconnect the hose of the circuit to be meas-
ured (see diagram below).
2. Install adapter C3 between the elbow and hose.
3. Install oil pressure gauge Cl (5.9 MPa I60 kg/
cm*)) to adapter C3.
4. Run the engine at high idling, operate the con-
trol lever of the circuit to be measured, and
measure the oil pressure.
BLD00226
Ripper tilt
(T I LT BACK)
1 Blade lift (RAISE) 1PA Ripper lift (LOWER)
Blade tilt(LEFT)
BKD00676
20-45
0
TESTING AND ADJUSTING ADJUSTING PPC VALVE
ADJUSTING PPC VALVE

llade PPC valve
Ir If there is excessive play in the work equipment
lever, adjust as follows.
ALower the work equipment to the ground and
stop the engine. Then loosen the oil filler cap
slowly to release the pressure inside the hy-
draulic tank.
1. Remove the PPC valve.
2. Remove boot (I).
3. Loosen locknut (41, then screw in disc (3) to

adjust the play.
* Lever play:0.5 - 3 mm (at a point approx.
75 mm from tip of lever knob)
* When locknut (4) is tightened, the play of
the lever is slightly reduced, so allow for
this when adjusting.
4. Secure disc (3) in position and tighten locknut

(4) to the specified torque.
w Locknut : 112.8 + 14.7 Nm
Ill.5 2 1.5 kgm}
5. Install boot (I) with boot stopper (2).

TAD00091
Ripper PPC valve
BLD00228
20-46
0
TESTING AND ADJUSTlNG MEASURING ON-OFF SOLENOID VALVE OUTPUT PRESSURE
MEASURING ON-OFF SOLENOID VALVE OUTPUT

PRESSURE Pin-Duller solenoid valve outlet hoses
1. Measuring output pressure of pin-puller sole-

noid valve
Lower the shank to the ground when measuring
the output pressure of the pin-puller solenoid
valve.
1) Disconnect pin-puller solenoid valve outlet
hoses (I) and (2), then use adapter C3 in the
oil pressure gauge kit to install oil pressure
gauge Cl (5.9 MPa (60 kg/cm*)).
2) Start the engine, operate the pin-puller to
the PULL OUT and PUSH IN positions, and BLD00229
measure the output pressure of the pin-puller i fieasuring output pressure of pin-puller
.
solenoid valve. solenoid valve
l Oil pressure when operating pin puller
to PULL OUT (solenoid ON)
(Engine at low idling)
Head end: 2.55 f 0.2 MPa

{26 I 2 kg/cm21
Bottom end: 0 MPa IO kg/cm*}
l Oil pressure when operating pin puller

to PUSH IN (solenoid OFF)
(Engine at low idling)
BLD00230
Head end: 0 MPa IO kg/cm*}
Bottom end: 2.55 = 0.2 MPa

I26 z 2 kg/cm3
2. Measuring output pressure of blade pitch, dual ---“t f’ WC’

tilt solenoid valve
1) Disconnect power pitch solenoid valve out-
let hoses (1) and (21, then use adapter (3) in
the oil pressure gauge kit to install the oil
pressure gauge (39.2 MPa 1400 kg/cm21).
2) Start the engine, operate the pitch and meas-
ure the output pressure of pitch solenoid
valve (3).
.
-cs‘2
When pitch is operated (front, rear) (so- BLD00231
lenoid ON): Actuating pressure
. When pitch is not operated (front, rear)
(solenoid OFF): 0 MPa IO kg/cm*}
3) Operate the dual tilt and measure the output
pressure of dual tilt solenoid valve (4).
. When dual tilt is operated (front, rear)
(solenoid ON): Actuating pressure
. When dual tilt is not operated (front, rear)
(solenoid OFF): 0 MPa {O kg/cm*}
Actuating pressure measurement ports
Pitch back : T2
Pitch dump : Tl
Left dual tilt :A
Right dual tilt : B
20-47
0
BLEEDING AIR FROM HYDRAULIC CYLINDERS l RELEASING
TESTING AND ADJUSTING REMAINING PRESSURE IN HYDRAULIC CIRCUIT
BLEEDING AIR FROM

HYDRAULIC CYLINDERS
* After replacing or installing hydraulic cylinders
or hydraulic piping, bleed the air from the hy-
draulic cylinders as follows:
1. Start the engine and run at idling for about 5

minutes.
2. Run the engine at low idling, and raise and
lower the blade or ripper 4 - 5 times.
* Stop the piston rod about 100 mm from the
end of the stroke. Never operate it to the
relief position.
3. Run the engine at full throttle and repeat the
procedure in Step 2. Then run the engine at
low idling and operate the piston rod to the end
of the stroke to relieve the circuit. .
RELEASING REMAINING
PRESSURE IN HYDRAULIC
CIRCUIT
A This machine is equipped with an accumulator
(the accumulator may lose its effect if it is left
for a long time), but the remaining pressure in
the piping between the control valve and hy-
draulic cylinders cannot be released simply by
operating the control levers.
When removing this piping, pay careful atten-
tion to the following points.
1. Run the engine at low idling, lower the work
equipment to the ground, taking care not to
relieve the circuit at the end of the stroke, then
stop the engine.
Ir If the engine is stopped when the hydraulic
cylinder has been relieved at the end of the
stroke, wait for at least 5 or 10 minutes be-
fore starting the operation.
2. When removing the piping, loosen the piping
sleeve nut gradually to release the pressure re-
maining inside the piping. Wait for the oil to
stop spurting out before removing the piping.
20-48
0
CHECKING LOCATION OF CAUSE OF HYDRAULIC
TESTING AND ADJUSTING DRIFT OF BLADE AND RIPPER
CHECKING LOCATION OF
CAUSE OF HYDRAULIC DRIFT
Blade lift cylinder
OF BLADE AND RIPPER
* If hydraulic drift occurs in the blade and ripper
(cylinder), check as follows to see if the cause is
in the cylinder packing or in the control valve.
1. Inspection posture
1) Blade lift cylinder
. Push the blade against the ground to
raise the chassis.
* The piston has a valve so do not oper-
ate to the end of the stroke.
2) Blade tilt cylinder
I TAD00123
. Extend the tilt cylinder rod fully (maxi-

mum tilt), then push the blade against
Blade tilt cylinder
the ground to raise the chassis.
3) Ripper lift cylinder
. Push the ripper against the ground to
raise the rear of the chassis.
2. Inspection
1) Set the cylinder of the circuit to be checked
in the inspection posture, then stop the en-
gine.
Sr For details of the inspection posture, see
Items I) - 4).
8 2) Operate the control lever in the direction to
% extend the cylinder rod.
I TAD00124
z * For details of the inspection posture, see

Items I) - 4).
Ripper lift cylinder
3) Operate the control lever in the direction to
extend the cylinder rod.
. If the downward movement becomes
faster, the packing is defective.
. If there is no change, the control valve
is defective.
* If there is no more pressure in the accu-
mulator, run the engine for approx. IO
seconds to charge the accumulator be-
fore carrying out the operation.
TAD00125
Reference:
If the cause of the hydraulic drift is in the packing,
the speed of downward movement in the above balance will be made in proportion to this
operation will become faster for the following rea- at a certain pressure (this differs accord-
sons. ing to the amount of leakage). .
1) With the work equipment in the posture given 3) When the pressure becomes balanced, the
above, (holding pressure applied to the bottom speed of downward movement becomes
end), the oil will leak from the bottom end to slower. In this condition, if the lever is
the head end. However, the volume at the head operated as shown above, the circuit at
end is smaller than at the bottom end (by an the head end is connected to the drain
amount proportional to the area of the rod), so circuit (the bottom end is closed by a check
if the oil flows in from the bottom end, the valve), and the oil at the head end flows
internal pressure at the head end will rise. to the drain circuit to increase the speed
2) If the internal pressure at the head end rises, a of downward movement.
20-49
0
TESTING AND ADJUSTING MEASURING LEAKAGE INSIDE CYLINDER
MEASURING LEAKAGE INSIDE

CYLINDER
. If the hydraulic drift exceeds the standard value,
check if the cause of the hydraulic drift is in the
cylinder or in the control valve.
* Oil temperature when measuring : 45 - 55°C
1. Measurement posture
I) Blade tilt cylinder
. Fully extend the rod of the cylinder to
be measured, and lower the end of the
blade to the ground.
2) Ripper lift cylinder
. Remove the shank pin and extend the
lift cylinder fully.
* The blade lift cylinder has a built-in
piston valve, so measurement is im-
possible. Disconnect hose
End of stroke
2. Measuring
1) Disconnect the head piping, and block the
piping at the chassis end with a blind plug.
ABe careful not to disconnect the piping
at the bottom end.
2) Start the engine, run the engine at high y Relief pressure /
idling, and apply the relief pressure to the

TAD001 48
bottom end of the cylinder. L
3) Wait for 30 seconds, then measure the

amount of leakage over the next 1 minute.
20-50
0
TESTING AND ADJUSTING ADJUSTING SEMI U-TILTDOZER
ADJUSTING SEMI U-TILTDOZER

+ If the blade has been removed or disassembled,
adjust as follows.
1. Adjusting blade tilt

I) After installing the blade, adjust with handle
(I) so that dimension “a” is the following
dimension.
Ir Dimension “a” : 1,554 mm
2) Check the left and right tilt.
Amount of tilt Unit: mm

BKD00233
)
3) If the tilt is not the same on the left and right

sides, adjust with handle (I) as follows to
give the same tilt on both sides.
. B2 > Bl:Carry out fine adjustment to Rioht tilt
make dimension “a” shorter
. B2 c Bl:Carry
make
out fine adjustment
dimension “a” longer
to
13
t
02
Left tilt
BKD00679
20-51
0
TESTING AND ADJUSTING ADJUSTING SEMI U-TILTDOZER
2. Procedure for adjusting with shims when as-

sembling blade
1) After assembling the blade, use shims to
adjust the clearance at center portion (2) and
lift portion (3).
Shim adjustment Unit: mm
” -
BKD00235
Standard clearance1 Max. 1 mm 1Max. 1 mm

I I
Standard shim 4.0

4.5
thickness
2) Apply grease to the adjustment locations and

check that the parts rotate smoothly.
a Adjustment portions (21, (3):
Grease (G2-LI)
BKD00236
BKD00237
BKD00238
20-52
a
TESTING AND ADJUSTING ADJUSTING CLEARANCE OF IDLER
ADJUSTING CLEARANCE OF IDLER
* If the idler side guides, top and bottom guides,

and guide plate are worn, and the idler is at an
angle or there is play to the side, adjust as fol-
lows.
1. Adjusting in sideways direction

1) Drive the machine for 1 or 2 m on level
ground, then measure clearance “a” (left,
right, inside, outside: 4 places).
2) If clearance “a” is more than 3 mm, loosen
bolt (I) and adjust with shim (2) as follows.
+- Clearance on one side: 0.5 - 1.0 mm
* Do not loosen bolt (I) more than 3 turns.
* The maximum adjustment amount is 6
mm.
BLDOO
20-53
0
TESTING AND ADJUSTING SIMPLE PROCEDURE FOR TESTING BRAKE PERFORMANCE
SIMPLE PROCEDURE FOR

TESTING BRAKE
PERFORMANCE
* Carry out the measurement under the following
conditions.
. Coolant temperature: Within operating range
1. Stop the machine on a level surface and set the
blade and ripper to the travel posture.
2. Run the engine at low idling, depress the brake
pedal securely, then place the joystick at F2.
3. Depress the decelerator pedal and pull the fuel
control lever to the FULL position. I TAD001 35
4. Release the decelerator pedal gradually and raise

the engine speed to full throttle. Check that the
machine does not start to move. .
A When measuring, keep your right foot on
the decelerator pedal, and if the machine
starts to move, immediately depress the
pedal and return the joystick to the neutral
position.
Note:
Never carry out this test in Fl. If this test is
carried out in Fl, an excessive load will be
brought to bear on the brake.
20-54
0
TROUBLESHOOTING
Points to remember when troubleshooting ......................................................................................... 20-I 02
Sequence of events in troubleshooting ................................................................................................ 20-I 03
Points to remember when carrying out maintenance ......................................................................... 20-104

Checks before troubleshooting ............................................................................................................. 20-I 12
Type of connector and position of installation.. ................................................................................... 20-I 14

Connector arrangement diagram .......................................................................................................... 20-I 16
Connection table for connector pin numbers.. ..................................................................................... 20-I 18
Method of using troubleshooting charts ............................................................................................. 20-128
Troubleshooting of engine (S mode) .................................................................................................... 20-201
Troubleshooting hydraulic, mechanical system (H mode). ................................................................. 20-301
Troubleshooting of machine monitor system (M mode) .................................................................... 20-401
Troubleshooting of electrical system (E mode) ................................................................................... 20-501
20-101
TROUBLESHOOTING POINTS TO REMEMBER WHEN TROUBLESHOOTING
POINTS TO REMEMBER WHEN TROUBLESHOOTING
a Stop the machine in a level place, and check that the safety pin, blocks, and parking brake are securely fitted.
a When carrying out the operation with two or more workers, keep strictly to the agreed signals, and do not
allow any unauthorized person to come near.
g If the radiator cap is removed when the engine is hot, hot water may spurt out and cause burns, so wait for
the engine to cool down before starting troubleshooting.
a Be extremely careful not to touch any hot parts or to get caught in any rotating parts.
A When disconnecting wiring, always disconnect the negative (-) terminal of the battery first.
A. When removing the plug or cap from a location which is under pressure from oil, water, or air, always release
the internal pressure first. When installing measuring equipment, be sure to connect it properly.
The aim of troubleshooting is to pinpoint the basic cause of the failure, to carry out repairs swiftly, and to
prevent reoccurrence of the failure.
When carrying out troubleshooting, and important point is of course to understand the structure and function.
However, a short cut to effective troubleshooting is to ask the operator various questions to form some idea
of possible causes of the failure that would produce the reported symptoms.
1. When carrying out troubleshooting, do not hurry to disassemble the components.
If components are disassembled immediately any ternally, so check any item that is considered
failure occurs: to be necessary.
. Parts that have no connection with the fail- 4. Confirming failure
ure or other unnecessary parts will be disas- Confirm the extent of the failure yourself, and
sembled. judge whether to handle it as a real failure or as
8
. It will become impossible to find the cause a problem with the method of operation, etc.
%
of the failure. * When operating the machine to reenact the z
It will also cause a waste of manhours, parts, or troubleshooting symptoms, do not carry out
oil or grease, and at the same time, will also lose any investigation or measurement that may
the confidence of the user or operator. make the problem worse.
For this reason, when carrying out troubleshoot- 5. Troubleshooting
ing, it is necessary to carry out thorough prior Use the results of the investigation and inspec-
investigation and to carry out troubleshooting in tion in Items 2 - 4 to narrow down the causes of
accordance with the fixed procedure. failure, then use the troubleshooting flowchart to
2. Points to ask user or operator locate the position of the failure exactly.
1) Have any other problems occurred apart from * The basic procedure for troubleshooting is
the problem that has been reported? as follows.
2) Was there anything strange about the ma- 1) Start from the simple points.
chine before the failure occurred? 2) ,Start from the most likely points.
3) Did the failure occur suddenly, or were there 3) Investigate other related parts or infor-
problems with the machine condition before mation.
this? 6. Measures to remove root cause of failure
4) Under what conditions did the failure occur? Even if the failure is repaired, if the root cause of
5) Had any repairs been carried out before the the failure is not repaired, the same failure will
failure? occur again.
When were these repairs carried out? To prevent this, always investigate why the prob-
6) Has the same kind of failure occurred be- lem occurred. Then, remove the root cause.
fore?
3. Check before troubleshooting
1) Check for symptoms of any abnormality in
the machine.
2) Check the CHECKS BEFORE STARTING items.
3) Other inspection items.
4) Other maintenance items can be checked ex-
20-102
0
TROUBLESHOOTING SEQUENCE OF EVENTS IN TROUBLESHOOTING
SEQUENCE OF EVENTS IN TROUBLESHOOTING
Office, shop Jobsite

TEW00180 TEW00181
\
step 1
Examination, confirmation of symptoms
1) When a request for repairs is received, first

_------
ask the following points. Ring I Ring I
. -------
Name of customer 3
. Type, serial number of machine
. Details of jobsite, etc.
2) Ask questions to gain an outline of the prob-
lem.
. Condition of failure
. Work being carried out at the time of the TEW00182
failure
. Operating environment
. Past history, details of maintenance, etc.
J
step 2
TEWO0183
step 3
IPreparation of troubleshooting tools
I) Look at the table of troubleshooting tools in

the shop manual and prepare the necessary
tools.
. T-adapter
- Hydraulic pressure gauge kit, etc.
21 Look in the parts book and prepare the nec-
essary replacement parts.
2) See the Troubleshooting Section of the shop

manual, select a troubleshooting flowchart
that matches the symptoms, and carry out
Drive and operate the machine to confirm
Ask operator questions to confirm details of
Was there anything strange about the ma-

chine before the failure occurred?
Did the failure occur suddenly?
TROUBLESHOOTING POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE
POINTS TO REMEMBER 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 re-
pairs 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” (particularly gear oil and hydraulic oil).
1. POINTS TO REMEMBER WHEN HANDLING

ELECTRIC EQUIPMENT
1) Handling wiring harnesses and connectors

Wiring harnesses consist of wiring connecting
one component to another component, connec-
tors used for connecting and disconnecting one
wire from another wire, and protectors or tubes
used for protecting the wiring.
Compared with other electrical components fit-
ted in boxes or cases, wiring harnesses are more
likely to be affected by the direct effects of rain,
water, heat, or vibration. Furthermore, during
inspection and repair operations, they are fre-
quently removed and installed again, so they
are likely to suffer deformation or damage. For
this reason, it is necessary to be extremely care-
ful when handling wiring harnesses.
Main failures occurring in wiring harness

Defective contact of connectors (defective
contact between male and female)
Problems with defective contact are likely to
improper insertion
occur because the male connector is not
properly inserted into the female connector,
or because one or both of the connectors is
deformed or the position is not correctly
aligned, or because there is corrosion or
oxidization of the contact surfaces.
Defective crimping or soldering of connec-

tors
The pins of the male and female connectors
Crimped portion
are in contact at the crimped terminal or
soldered portion, but if there is excessive
force brought to bear on the wiring, the plat-
ing at the joint will peel and cause improper
connection or breakage.
I TEwoo193
20- 104
0
@ 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 crimping of
the connector may separate, or the solder-
ing may be damaged, or the wiring may be
broken.
@ High-pressure water entering connector

The connector is designed to make it diffi-
cult for water to enter (drip-proof structure),
but if high-pressure water is sprayed directly
on the connector, water may enter the con-
nector, depending on the direction of the
water jet. *
As already said, the connector is designed
to prevent water from entering, but at the
same time, if water does enter, it is difficult 3-
for it to be drained. Therefore, if water should
get into the connector, the pins will be short-
TEwoo195
circuited by the water, so if any water gets
in, immediately dry the connector or take
other appropriate action before passing elec-
tricity through it.
@ Oil or dirt stuck to connector

If oil or grease are stuck to the connector
and an oil film is formed on the mating sur-
face between the male and female pins, the
oil will not let the electricity pass, so there
will be defective contact.
If there is oil or grease stuck to the connec-
tor, wipe it off with a dry cloth or blow it dry
with compressed air and spray it with a con-
I TEWOO196
tact restorer.
Ir When wiping the mating portion of the
connector, be careful not to use exces-
sive force or deform the pins.
* If there is oil or water in the compressed
air, the contacts will become even dirtier,
so remove the oil and water from the
compressed air completely before clean-
ing with compressed air.
zo-105
0
Removing, installing, and drying connectors and

wiring harnesses
Disconnecting connectors
Hold the connectors when disconnecting.
When disconnecting the connectors, hold the
connectors and not the wires. For connec-
tors 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 con-
nectors apart.
* Never pull with one hand.
When removing from clips

When removing a connector from a clip, pull
the connector in a parallel direction to the
clip.
* If the connector is twisted up and down
or to the left or right, the housing may
break.
I TBW00485
0 Action to take after removing connectors

After removing any connector, cover it with
a vinyl bag to prevent any dust, dirt, oil, or
water from getting in the connector portion.
* If the machine is left disassembled for a
long time, it is particularly easy for im-
proper contact to occur, so always cover
the connector.
TEWOO198
20-106
0
0 Connecting connectors
0 Check the connector visuallv.
1) Check that there is no dii, dirt, or water
stuck to the connector pins (mating por-
tion).
2) Check that there is no deformation, de- Clicks into position
fective contact, corrosion, or damage to
the connector pins.
3) Check that there is no damage or break-
age 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. II TEWOOlSS
If any water has got inside the connec-
tor, warm the inside of the wiring with a
dryer, but be careful not to make it too
hot as this will cause short circuits.
* If there is any damage or breakage, re-
place the connector.
0 Fix the connector securely.

Align the position of the connector correctly,
then insert it securely.
For connectors with lock stopper, push in
the connector until the stopper clicks into
position.
Correct any protrusion of the boot and any

misalignment of the wiring harness
For connectors fitted with boots, correct any
protrusion of the boot. In addition, if the
wiring harness is misaligned, or the clamp
is out of position, adjust it to its correct po-
sition.
+ If the connector cannot be corrected eas-
ily, remove the clamp and adjust the
position.
0 If the connector clamp has been removed,

be sure to return it to its original position.
Check also that there are no loose clamps. I TBwoo487
20-107
0
l Drying wiring harness

If there is any oil or dirt on the wiring harness,
wipe it off with a dry cloth. Avoid washing it in
water or using steam. If the connector must be
washed in water, do not use high-pressure wa-
ter or steam directly on the wiring harness.
If water gets directly on the connector, do as

follows.
@ Disconnect the connector and wipe off the
water with a dry cloth.
* If the connector is blown dry with com-
pressed air, there is the risk that- oil in
the air may cause defective contact, so
remove all oil and water from the com-
pressed air before blowing with air.
Dry the inside of the connector 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
regulate the time that the hot air is used
in order not to make the connector or
related parts too hot, as this will cause
deformation or damage to the connec-
tor.
@ Carry out a continuity test on the connector.

After drying, leave the wiring harness dis-
connected and carry out a continuity test to
check for any short circuits between pins
caused by water.
* After completely drying the connector,
blow it with contact restorer and reas-
semble. T-adapter
20-108
0
3) Handling control box

The control box contains a microcomputer
and electronic control circuits. These control
all of the electronic circuits on the machine,
so be extremely careful when handling the
control box.
Do not open the cover of the control box
unless necessary.
TEWOO204
0 Do not place objects on top of the control

box.
0 Cover the control connectors with tape or a
vinyl bag.
Never touch the connector contacts with your
hand.
0 During rainy weather, do not leave the con-
trol box in a place where it is exposed to
rain.
Do not place the control box on oil, water,

or soil, or in any hot place, even for a short
time.
(Place it on a suitable dry stand).
a Precautions when carrying out arc welding
When carrying out arc welding on the body,
disconnect all wiring harness connectors con-
nected to the control box. Fit an arc welding
ground close to the welding point.
II TEWOO206
2. Points to remember when troubleshooting electric circuits

1) Always turn the power OFF before disconnecting or connect connectors.
2) Before carrying out troubleshooting, check that all the related connectors are properly inserted.
* Disconnect and connect the related connectors several times to check.
3) Always connect any disconnected connectors before going on to the next step.
* If the power is turned ON with the connectors still disconnected, unnecessary abnormality
displays will be generated.
4) When carrying out troubleshooting of circuits (measuring the voltage, resistance, continuity, or
current), move the related wiring and connectors several times and check that there is no
change in the reading of the tester.
Jr If there is any change, there is probably defective contact in that circuit.
20- 109
0
3. POINTS TO REMEMBER WHEN HANDLING

HYDRAULIC EQUIPMENT
With the increase in pressure and precision of hy-

draulic equipment, the most common cause of fail-
ure is dirt (foreign material) in the hydraulic circuit.
When adding hydraulic oil, or when disassembling
or assembling hydraulic equipment, it is necessary
to be particularly careful.
1) Be careful of the operating 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) 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. Disas-
sembly and main-tenance of hydraulic equip-
ment should be carried out in a specially pre-
pared dustproof workshop, and the performance
should be confirmed with special test equipment.
I - TEWOO207
3) 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 en-
tering. 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 leak-
ing 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.
TEW00208
4) Do not let any dirt or dust get in during refilling

operations.
Be careful not to let any dirt or dust get in when
refilling with hydraulic oil. Always keep the oil
filler and the area around it clean, and also use
clean pumps and oil containers. If an oil clean-
ing device is used, it is possible to filter out the
dirt that has collected during storage, so this is
an even more effective method.
20-110
0
5) Change hydraulic oil when the temperature is

high.
When hydraulic oil or other oil is warm, it flows
easily. In addition, the sludge can also be drained
out easily from the circuit together with the oil,
so it is best to change the oil when it is still
warm. When changing the oil, as much as pos-
sible of the old hydraulic oil must be drained
out. (Do not drain the oil from the hydraulic
tank; also drain the oil from the filter and from
the drain plug in the circuit.) If any old oil is left,
the contaminants and sludge in it will mix with
the new oil and will shorten the life of the hy-
draulic oil.
6) Flushing operations
After disassembling and assembling the equip-
ment, 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 sec-
ondary flushing is carried out with the specified
hydraulic oil.
Cleaning operations
After repairing the hydraulic equipment (pump,
control valve, etc.) or when running the ma-
chine, 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 re-
move, so it is an extremely effective device.
20-111
0
TROUBLESHOOTING CHECKS BEFORE TROUBLESHOOTING
CHECKS BEFORE TROUBLESHOOTING
item Judgement
Action
value
1. Check fuel level - Add fuel
2. Check for impurities in fuel - Clean, drain
3. Check hydraulic oil level - Add oil
4. Check oil level in damper case - Add oil
5. Check power train oil level - Add oil
6. Check engine oil level (engine oil pan level) - Add oil
7. Check coolant level -’ Add water
8. Check dust indicator for clogging - Clean or replace
9. Check travel of brake pedal - Adjust
10. Check for looseness, corrosion of battery terminal, wiring - Tighten or replace
11. Check for looseness, corrosion of alternator terminal, wiring - Tighten or replace
12. Check for looseness, corrosion of starting motor terminal, wiring - Tighten or replace
13. Check for abnormal noise, smell - Repair
14. Check for oil leakage - Repair
15. Carry out air bleeding - Bleed air
16. Check battery voltage (engine stopped) 20 - 3ov Replace

17. Check battery electrolyte level - Add or replace
18. Check for discolored, burnt, exposed wiring - Replace
19. Check for missing wiring clamps, hanging wiring - Repair
20. Check for water leaking on wiring (pay particularly careful - Disconnect connector
attention to water leaking on connectors or terminals) and dry
21. Check for water on wiring - Replace

Uter running fo
22. Check alternator voltage (engine running at l/2 throttle or above) everal minutes Replace
17.5 - 29.5 v
23. Check operating sound of battery relay (starting switch ON, OFF) - Replace
20-112
0
TROUBLESHOOTING TYPE OF CONNECTOR AND POSITION OF INSTALLATION
TYPE OF CONNECTOR AND POSITION OF INSTALLATION

* The Address column in this table shows the address in the connector pin allocation drawing (3-
dimensional drawing).
Con- Con- No.

Add-
iector nectar of Place of use
No. pins ress
Type
EN-3611 SWP 1 16 1Intermediate connector 1 N-4

EN-3751 X 1 4 1Caution lamp 1 F-7
Front lamp,
EN-376 - 6 E-5
working lamp relay
EN-391 - 4 Air conditioner relav A-5
CN-392 - 2 Blower motor A-6
Thermostat,
CN-393 - 4 A-7
dual oressure switch
water temperature _ CN-3941 - 1 3 Blower resistor ) E-5

CN-3951 - 1 4 1Blower switch I E-8
Air conditioner clutch relay
CN-403 - 1 Engine oil pressure sensor W-2

CN-404 X 1 Engine oil level sensor w-2
CN-405 X 2 Radiator water level sensor R-6
CN-411 SWP 14 Fuse box N3,Z-Z-E
CN-412 SWP 4 APS controller M-2
CN-413 SWP 6 APS controller L-l
CN-421 SWP 16 Intermediate connector N-5
Intermediate connector
CN-422 X 2 N-5
(fuel level gauge)
CN-4231 X I 2 /Fuel level gauge 1 M-7
CN-4311 X I 2 I Intermediate connector I Z-9
CN-451 SWP 14 Intermediate connector K-l,Y-3
Hydraulic oil
CN-452 X 1 z-9
temoerature sensor
CN-622 SWP 8 Lock-up controller M-2

Torque converter
Z-8
CN651 ’ 2 soeed sensor
TROUBLESHOOTING TYPE OF CONNECTOR AND POSITION OF INSTALLATION
Con- Con- No.

Add-
Place of use nectar nectar of Place of use
No. Type pins ress
Knob switch for dual tilt (Insidecab)

) CN-PO3I%%% ) 1 ) tfor Ditchj ) F-3 CN-1 Single pin
1 Additional lamp pickup -
CO”“eCfOr
CN-PO4 X 2 Intermediate connector T-8 CN-2 - 1 Rear soeaker (R) -
Dual tilt oil pressure CN-3 - 1 1Rear speaker (R) -

CN-PO5 X 2 switch F-7
CN-4 - 4 1Rear wioer motor -
CN-PO61 X 1 2 IDual tilt 1 F-6 CN-5 - 1 JRear speaker (L)

CN-SOL11 X 1 2 /Solenoid for oitch I T-8 CN-6 1 - 1 1 (Rear speaker (L)
CN-SOL21 X ISolenoid for dual tilt I T-8 CN-7 - 1 Additional lamp pickup -
Single pin 1 -
CN-8 COnneCtOr Room lamp
CN-9 - 6 Front wioer motor -
CN-10 I - ) 9 IRadio -
CN-11 I - I 6 I Left wiper switch -
ICN-12 1 - 1 6 IFront wioer switch -

CN-13 - 6 Right wiper switch -
CN-14 - 6 Rear wiper switch -
CN-15 - 2 Front lamp switch -
CN-16 - 2 Rear lamp switch -

4 Right wiper motor
CN-17 -
(intermediate connector) -
ICN-18 I - I -
ICN-19 ( - 4 (Wiring harness for washer/ -
Single pin 1 -
CN-20 connector ACC power source
Single pin 1
CN-21 connector Battery power source -
1
Single pin -
CN-22 connector Cigarette lighter
TROUBLESHOOTING CONNECTOR ARRANGEMENT DIAGRAM
20-116
a
019503
CN-243
CN-462
CN-24 I
CN-203
TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS

* The terms male and female refer to the pins, while the terms male housing and female housing
refer to the mating portion of the housing.
No.
of
T X type connector
pins Male (female housing) Female (male housing)
TEwoo222
1 3
azll
TEWO0223
TEW00225 TEW00226
20-118
0
No.
of
T- SWP type connector
3 6
TEWOO235
TEWOO237
12
0
0
0
0
-
m _I._::-
1 4 8 11 11 8 4 1
8
14
14 10 7 3
TEWO0239 TEW00240
4 1 1 b
5 8
16
9 2
BLW0036
13 16 BLFOCG37
20-119
a
No.
of
T M type connector
1 i
BLWoO38 BLFQOO39
3 2
,
3
S
Y
1
TEW00244
2 4
Es
4 2
TEWO0245
1 A 4 1
El 3’ ‘6
TEW00247 TEW00248
BLPOO041
zo- 120
0
No. S type connector

of
5 1
m 4’ ‘8
TEW00249 TEwoo250
1 6
8
!i?
s
10
a j io TEW00251
BLFUO042
1 6
12
5 12
BLPO0043 TEWO0254
16
7 16BLPQOO44 TEW00256
20-121
0
No.
of
T MIC connector
BLPO0046
BLPOO046 8
a5
7 z
1
13
8 1 8
13
I J BLPOMI49 BLPCOO50
17
17
1 1 BLPQOO51 BLPO3052
11
21
21
TEW00260
20- 122
0
No.
of
T- AMP040 type connector
4 8
8 4
l-l
t I
1
BLmOO53
12 6
i i
16 8
16
1 ‘9
BLpoOO57 TEwoo232
10
\ 3
20
1' il TEW00234
BLW005B
20-123
0
No.
of
T AMP070 type connector
7 1
1 7
6 4
BLPOOO59
12
8
BLPOom i3LFSQO62
20-124
0
No.
of
T L type connector
pins M.ale (female housing) Female (male housing)
En
q
2
Eli
20-125
0
No.
of
r Automobile connector
B BLPOO063
1
BLPOOO64
II i-----l I
-i
I
3
D
BLPOO065
4
I UIH
4 BLFOOO68
\4
,
BLPOOO69
1
I
4
ub4 ffz3
4
I
I I J
6 8
BLPOCO72
20-126
0
No.
of
T Relay connector
2 5
?
--_--- T
5
f-J [o
_______ J
7 3 6 5 6 3
BLFOOO73 BLK0074
6 5
5 2 1
BLFOOO75 BLFOOO76
zo- 127
0
TROUBLESHOOTING METHOD OF USING TROUBLESHOOTING CHARTS
METHOD OF USING TROUBLESHOOTING CHARTS

1. Catesorv of troubleshootins code number
Troubleshooting
Component
Code No.
s-00 Troubleshooting of engine related parts
H-00 Troubleshooting of hydraulic, mechanical system
M-00 Troubleshooting of machine monitor system
E-00 1 Troubleshooting of chassis electrical system
2. Method of using troubleshooting table for each troubleshooting mode
Troubleshooting code number and problem

The title of the troubleshooting chart gives the troubleshooting code and failure mode (prob-
lem with the machine).
General precautions
When carrying out troubleshooting for the failure mode (problem), precautions that apply to all
items are given at the top of the page and marked with Ir.
The precautions marked * are not given in the r], but must always be followed when
carrying out the check inside the II.
Distinguishing conditions
Even with the same failure mode (problem), the method of troubleshooting may differ accord-
ing to the model, component, or problem. In such cases, the failure mode (problem) is further
divided into sections marked with small letters (for example, a), b)), so go to the appropriate 8
section to carry out troubleshooting.
z
If the troubleshooting table is not divided into sections, start troubleshooting from the first E;
check item in the failure mode.
Method of following troubleshooting chart
Check or measure the item inside Fe, and according to the answer follow either
NO
the YES line or the NO line to go to the next -1. (Note: The number written at the top
right corner of the I-1 is an index number; it does not indicate the order to follow.)
Following the YES or NO lines according to the results of the check or measurement will
lead finally to the Cause column.
Check the cause and take the action given in the Remedy column on the right.
Below the I] there are the methods for inspection or measurement, and the judge-
ment values. If the judgement values below the n are correct or the answer to the
question inside the r\ is YES, follow the YES line; if the judgement value is not
correct, or the answer to the question is NO, follow the NO line.
Below the 1-1 is given the preparatory work needed for inspection and measurement,
and the judgement values. If this preparatory work is neglected, or the method of opera-
tion or handling is mistaken, there is danger that it may cause mistaken judgement, or the
equipment may be damaged. Therefore, before starting inspection or measurement,
always read the instructions carefully, and carry out the work in the correct order.
Troubleshooting tools
When carrying out the troubleshooting, prepare the necessary troubleshooting tools. For
details, see TOOLS FOR TESTING, ADJUSTING, AND TROUBLESHOOTING.
Installation position, pin number
A diagram or chart is given for the connector type, installation position, and connector pin
number connection. When carrying out troubleshooting, see this chart for details of the
connector pin number and location for inspection and measurement of the wiring connector
number appearing in the troubleshooting flow chart for each failure mode (problem).
20-128
0
<Example>
@ M-5 Abnormality in buzzer
@ * Before carrying out troubleshooting, check that all the related connectors are properly in-
serted.
* Always connect any disconnected connectors before going on to the next step.
Ir Of the Caution items, the buzzer does not sound if there is an abnormality in the battery
charge.
@ a) Caution item flashes but buzzer does not sound
Remedy
1 YES
Does buzzer sound Defective monitor panel Replace
when CNPZ Defective contact or
(female) (7) is disconnection in wiring
connected to
harness between fuse 3 -
chassis ground? Repair or
CN215 (2) - CN217
replace
* Connect CNP2 No (female) (I ), or between
(female) (7) to CN217 (female) (2) - CNP2
chassis ground. (female) (7)
* Turn starting
switch ON.
20-129
a
TROUBLESHOOTING OF ENGINE SYSTEM
(S MODE)
Method of using troubleshooting charts . . . . . . . . . . . . . . . . . . . . . .. . . . . . . .. . . . . .. . .. . . .. . .. . . . . . . .. . . . . . . .. . . . . . . .. . . . .. . . . . . . . . . . . . . . .. . 20-202

s- 1 Starting performance is poor (Starting always takes time). ................................................ .20-206
s- 2 Engine does not start ............................................................................................................... 20-207
1) Engine does not turn .......................................................................................................... 20-207
2) Engine turns but to exhaust gas comes out (Fuel is not being injected) ................... 20-208
3) Exhaust gas comes out but engine does not start (Fuel is being injected). ............... 20-209
s- 3 Engine does not pick up smoothly (Follow-up is poor). ...................................................... .20-210
s- 4 Engine stops during operations .............................................................................................. 20-211

s- 5 Engine does not rotate smoothly (hunting) ........................................................................... 20-212
S- 6 Engine lacks output (no power). .............................................................................................. 20-213
s- 7 Exhaust smoke is black (incomplete combustion) ............................................................... .20-214

S- 8 Oil consumption is excessive (or exhaust gas is blue). ....................................................... -20-215
s- 9 Oil becomes contaminated quickly ......................................................................................... 20-216
S-IO Fuel consumption is excessive ................................................................................................ 20-217
S-II Oil is in cooling water, or water spurts back, or water level goes down.. ........................ 20-218
8 s-12 Oil pressure lamp lights up (drop in oil pressure) ............................................................... -20-219
%
s-13 Oil level rises (water, fuel in oil) ............................................................................................. 20-220
z
s-14 Water temprautre becomes too high (overheating) ............................................................. .20-221
s-15 Abnormal noise is made .......................................................................................................... 20-222
S-16 Vibration is excessive ............................................................................................................... 20-223
20-201
0
METHOD OF USING TROUBLESHOOTING CHARTS
This troubleshooting chart is divided into three

sections: questions, check items, and troubleshoot-
ing. The questions and check items are used to
pinpoint high probability causes that can be located
from the failure symptoms or simple inspection with-
out using troubleshooting tools.
Next, troubleshooting tools or direct inspection
are used to check the high probability causes to
make final confirmation.
[Questions]
Sections @ + @I in the chart on the right corre-
spond to the items where answers can be ob-
tained from the user. The items in @I are items
that can be obtained from the user, depending
on the user’s level.
[Check items] / Causes /
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 @ 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].
20-202
0
The basic method of using the troubleshooting chart

is as follows.
Items listed for [Questions] and [Check items] that
have a relationship with the Cause items are marked
with 0, and of these, causes that have a high prob-
ability are marked with Q.
Check each of the [Questions] and [Check items] in
turn, taking note of the o or Q marks in the chart for
the horizontal lines of symptoms applicable to the
machine. The vertical column (Causes) that has the
highest number of applicable 0 or Q marks is the
most probable cause, so start troubleshooting for
that item to make final confirmation of the cause.
%I. For (Confirm recent repair history) in the

[Questions] Section, ask the user, and mark
the Cause column with n to use as reference
for locating the cause of the failure. How-
ever, do not use this when making calcula-
tions to narrow down the causes.
%2. Use the A in the Cause column as reference
for [Degree of use (Operated for long pe-
riod)] in the [Questions] section as reference.
As a rule, do not use it when calculating the
points for locating the cause, but it can be
included if- necessary to determine the order
for troubleshooting.
20-203
0
. 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 a causal relationship with this problem: [Exhaust gas gradually became black], [Power
gradually became weaker], and [Dust indicator is red].
If we look from these three symptoms to find the causes, we find that there is a relationship with 5
causes. Let us explain here the method of using this causal relationship to pinpoint the most probable
cause.
s-7 Exhaust gas is black

(incomplete combustion)
Gerleral causes why exhaust gas is black.
Insufficient intake of air.
Improper condition of fuel injection.
Excessive injection of fuel.
20-204
a
-T3 Clarify the relationship between the three

Step
symptoms in the [Questions1 and [Check items1

section and the 5 Cause items in the vertical
l
column.
fl
Three symptoms
Steo 2
Add up the total of Oand Omarked where the

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

relationship is with [Clogged air cleaner
element]. Follow this column down to the
troubleshooting area and carry out the
troubleshooting item marked 0. The Remedy is
given as [Clean], so carry out cleaning, and the
exhaust gas color should return to normal.
20-205
TROUBLESHOOTING S-l
S-l’ Starting performance is poor

(Starting always takes time)
General causes why exhaust smoke comes out but engine takes time to start
. Defective electrical system
. Insufficient supply of fuel
. Insufficient intake of air
. Improper selection of fuel
(At ambient temperature of 10°C or below, use JIS No. 3 or JIS
Special No. 3)
t Battery charging rate.
I I I I I
100% 90% 80% 75% 70%
20°C 1 1.28 1 1.26 1 1.24 1 1.23 1 1.22
0°C 1.29 1.27 1.25 1.24 1.23
-10°C 1.30 1.28 1.26 1.25 1.24
A battery can be used if the specific gravity shows 70%

higher charging rate as per the above table.
In cold weather, 75% or higher charging rate is requir -ed.
Legend
0 : Possible causes (iudaina from Questions and check items)
0 : Most probable ca&siju~ging from Questionsand Check items)
A : Possible causes due to length of use (used for a long period)
l : Items to confirm the cause
Blow-by gas is excessive 0

Match marks on fuel injection pump are out of alignment 0
Mud is stuck to fuel tank cap 0
E
‘u When engine is cranked with starting motor
g_.
1) LIttIe fuel comes out even when injection pump sleeve
,t is loosened I I I I I I I I I I loII I I
Speed does not change when operation of cert;...

is stopped
When check is made using dial gauge method, injection
timing is found to be incorrect
When control rack is pushed, it is found to be heavy or does
not return
1 When fuel cap is inspected directly, it is found to be cIc,,__ a
8.: c c c g $ z se Z.L c
Smg$sqqqq,=qQJm
Remedy p 0 PPPP-CIQ~
wawa~$gG ’
P,“GGG cc~~ce
20-206
0
TROUBLESHOOTING s-2
S-2 Engine does not start

1) Engine does not turn
I Causes /
General causes why engine does not turn
. Internal parts of engine seized
Ir If internal parts of the engine are
seized, carry out troubleshooting for
“Engine stops during operations”.
. Failure in power train
. Defective electrical system
Legend
0: Possible causes (judging from Questions and check items)
0 : Most probable causes (judgingfrom Questionsand Check items)
n : Possible causes due to length of use (used for a long period) i
l : Items to confirm the cause. I 8
Confirm recent repair history I
Degree of use of machine Operated for long period I
When starting switch is turned to

START, pinion moves out, but
When starting switch is turned to START, pinion does not

move out I
When starting switch is turned to ON, there is no clicking sound
Battery terminal is loose
When battery is checked, battery electrolyte is found to be low
Specific gravity of electrolyte, voltage of battery is low
For the followingconditions1) - 4). turn the startingswitch OFF,

conntxtthe cord, and carry out troubleshootingat ON
1) When terminal B and terminal C of starting switch are j

connected, engine starts ‘Z
H
75
2) Even when terminal B and terminal C of starting motor
(magnet switch) are connected, engine does not start
3) When terminal B and terminal C of starting motor

(magnet switch) are connected, engine starts
4) There is no 24V between battew relay terminal M and
l- -
\Lki.
Nhen ring gear is inspected directly tooth surface is found
1
IRemedy
I
I’ I
20-207
0
TROUBLESHOOTING s-2
2) Engine turns but no exhaust smoke comes out

(Fuel is not being injected)
General causes why engine turns but no exhaust smoke comes out
. Supply of fuel impossible
. Supply of fuel is extremely small
. Improper selection of fuel (particularly in winter)
* Fuel selection standard

I Causes
I
AMBIENT TEMPERATURE
KIND OF
FLUID -22 ;; J$?;
-30 -zl -?I “0’ ?8 8
* In winter, if Class 3 oil is not available, you

may use mixture of Class 2 diesel fuel and
kerosene at the rate of 1 : 1.
Legend
0 : Most probable causes (judging from Questionsand Check items)
n : Possible causes due to length of use (used for a long period)
l : Items to confirm the cause.
1 Confirm recent repair history
Degree of use of machine Operated for long period

E
.g Exhaust smoke suddenly stops coming out (when starting again)
m”
Replacementof filters has not beencarriedout accordingto OperationManual
d
There is leakage from fuel piping
Mud is stuck to fuel tank cap
When fuel filter is drained, fuel does not come out
When engine is cranked with starting motor,

E 1) Injection pump coupling does not turn
.r
% 2) No fuel comes out even when fuel filter air bleed plug is loosened
9)
2 3) No fuel spurts out even when injection tube sleeve nut is loosenec
1 Rust and water are found when fuel tank is drained
Inspect injection pump directly

p
‘i: When control rack is pushed, it is found to be heavy, or does not return
8
x Inspect feed pump directly
3
When fuel filter, strainer are inspected directly, they are found to be clogged
‘:
e
c When feed pump strainer is inspected directly, it is found to be clogged
When fuel cap is inspected directly, it is found to be clogged

I
Remedy
20-208
0
TROUBLESHOOTING s-2
3) Exhaust smoke comes out but engine

does not start
(Fuel is being injected)
General causes why exhaust smoke comes

out but engine does not start
. Lack of rotating force due to defective
electrical system
. Improper selection of fuel
Possible causes (judging f Questions and check items)
20-209
TROUBLESHOOTING s-3
S-3 Engine does not pick up smoothly (follow-up is poor)

General causes why engine does not pick up smoothly
. Improper condition of fuel injection
. Improper fuel used
Legend
: Possible causes (judging from Questions and check items)
starting engine, temperature of some cylinders is low
20-210
0
TROUBLESHOOTING s-4
S-4 Engine stops during operations

Ir Check that the fuel tank level gauge
shows that there is still fuel remaining.
General causes why engine stops during op-
erations
l Seized parts inside engine
l Overheating
* If there is overheating and the en-
gine stops, carry out troubleshoot-
ing for overheating.
Legend
0 : Possible causes (judging from Questions and check items)
0 : Most probable causes (judgingfrom Questions and Check items)
A : Possible causes due to length of use (used for a long period)
0 : Items to confirm the cause.
1 Confirm recent repair history I I I I I I I
Condition when
engine stopped
Replacement
of filtershasnotbeencarriedoutaccording
to OperationManual 00
Non-specified fuel is being used 000 0
When feed pump is operated, operation is too light or too heavy 0000
oes not rotate
Rust and water are found when fuel tank is drained 00

Metal particles are found when oil is drained 00 00
it is found to be abnormal
it is found to be abnormal
TROUBLESHOOTING S-5
S-5 Engine does not rotate smoothly (hunting)

General causes why engine does not rotate
Causes I
smoothly
. Air in fuel system
. Defective governor mechanism
Legend
0 : Most probable causes (judgingfrom Questionsand Chedcitems)
A: Possible causes due to length of use (used for a long period)
_a : Items to confirm the cause.
Condition of hunting
ter, stramer are lnspecte

TROUBLESHOOTING S-6
S-6 Engine lacks output (no power)

* Measure the engine speed and judge if
the cause is in the engine or in the chas-
sis.
General causes why engine lacks output
. insufficient supply of fuel
. Improper fuel used
(if non-specified fuel is used, output
drops)
. Lack of output due to overheating
* If there is overheating and insufficient
output, carry out troubleshooting for
overheating.
TROUBLESHOOTING s-7
S-7 Exhaust smoke is black

(incomplete combustion)
General causes why exhaust smoke is black
. Excessive injection of fuel
ions and check items)

&ions and Check items)
(used for a long period)
Color of exhaust gas
20-214
0
TROUBLESHOOTING S-8
S-8 Oil consumption is excessive (or exhaust smoke is blue)

Ir Do not run the engine at idling for more
than 20 minutes continuously. (Both low
and high idling)
General causes why oil consumption is ex-
cessive
l Abnormal combustion of oil
. External leakage of oil
l Wear of lubrication system
Causes
Legend
Amount of blow-by gas is Excessive 00 0 0

Area around engine is dirty with oil
0000
i
I There is oil in engine cooling water Q
When exhaust pipe is removed, inside is found to be dirty with oil 0 0.
E
C
When turbocharger air supply pipe is removed, inside is
0
+Y? found to be dirty with oil
6 Oil level in PTO chamber (torque converter case) rises

I I I I I I I I I I Kl I 1
Clamps for intake system are loose I lo1
1 When intake manifold is removed, dust is found inside I I I I I I I 1-1~~1.1

I I
I When intake manifold is removed, inside is found to be dirty with oil I I I I I I I I I I I I
TROUBLESHOOTING s-9
S-9 Oil becomes contaminated quickly

General causes why oil becomes contaminated
quickly
. Intake of exhaust gas due to internal wear
l Clogging of lubrication passage
. Improper fuel
. Improper oil used
l Operation under excessive load
Legend
ount of blow-by
20-216
0
TROUBLESHOOTING S-IO
S-IO Fuel consumption is excessive

General causes why fuel consumption is ex-
cessive
. Leakage of fuel
. Excessive injection of fuel
I Causes /
Possible causes from Questions and check items)

from Questions and Check items)
1 Confirm recent repair historv
1 Degree of use of machine 1 Operated for long period
More than for other machines of same model

Condition of fuel
Gradually increased
consumption
8 Suddenly increased
8 / Exhaust smoke Black

z; color White
Seal on iniection Dump has come off
There is irregular combustion
When exhaust manifold is touched immediately after

00
Match mark on injection pump is misaligned 0

There is external leakage of fuel from engine 0
Engine oil level rises and smells of diesel fuel 0 00
Engine low idling speed is high 0 0
TROUBLESHOOTING S-II
S-11 Oil is in cooling water, or water spurts back, or water level goes
down
General causes why oil is in cooling water
. Internal leakage in lubrication system
. Internal leakage in cooling system
/ Causes I
Legena
Confirm recent repair history
z
.P Degree of use of machine Operated for long period IAl 1 iAl I
20-218
0
TROUBLESHOOTING s-12
S-12 Oil pressure caution lamp lights up (drop in oil pressure)

General causes why oil pressure lamp lights up
. Leakage, clogging, wear of lubricating system
. Defective oil pressure control
. Improper oil used (improper viscosity)
. Deterioration of oil due to overheating
* Standard for engine oil selection

I AMBIENT TEMPERATURE
KIND OF
FLUID -22
-30 -‘PO 32
0 50
10 g 86
30 l%J
Engine oil
Legend
-
: Most probable causes (judgingfrom Questionsand Check items)
: Possible causes due to length of use (used for a long period)
There is catching of relief valve or regulator valve, spring or

S-13 Oil level rises (water, fuel in oil)

* If there is oil in the cooling water, carry out
troubleshooting for “Oil is in cooling water”.
General causes why oil level rises
. Water in oil
. Fuel in oil (diluted, and smells of diesel fuel) Causes
. Entry of oil from other component
Possible causes (judging from Questions and check items)

Most probable causes (judging from Questions and Check items)
Possible causes due to length of use (used for a long period)
items to confirm the cause.
1 Pressure-tiahtness test of oil cooler shows there is leakage
I--~
Pressure-tiohtness test of cylinder head shows there is leakage
When compression pressure is measured, it is found to be low
Remove water pump and inspect directly
Remove head cover and inspect directly
Remove injection pump and inspect directly
Remove oil pan and check directly 1 1.101
20-220
0
s-14 Water temperature becomes too high Causes

(overheating)
Gel?eral causes why water temperature becomes too high
. Lack of cooling air (deformation, damage of fan)
. Drop in heat dissipation efficiency
. Defective cooling circulation system
j, Carry out troubleshooting for chassis.
Legend
0 : Mastprobable causes (judgingfrom Questionsand Check items)
4) : items to confirm the cause.
Confirm recent repair history
Degree of use of machine Operated for long period
E Suddenly overheated
.P Condition of overheating
5 Always tends to overheat
s
c) Rises quickly
Water temperature gauge
Does not go down
Fan belt whines under sudden load
Cloudy white oil is floating on cooling water
Cooling water flows out from overflow hose
Excessive air bubbles inside radiator, water spurts back
Engine oil level has risen, oil is cloudy white

E There is play when fan pulley is rotated
.%
% Radiator shroud, inside of underguard are clogged with dirt or mud
o
6 When light bulb is held behind radiator, no light passes through
Water is leaking because of cracks in hose or loose clamps
When belt tension is inspected, it is found to be loose
Temperature difference between top and bottom radiator

0
tanks is excessive
Temperature difference between top and bottom radiator

0
tanks is slight
When water filler port is inspected, core is found to be clogged

z
._
When function test is carried out on thermostat, it does not
‘d
2 open even at cracking temperature
2
When water temperature is measured, it is found to be normal
2
e
c When oil cooler is inspected directly, it is found to be clogged
When measurement is made with radiator cap tester, set

pressure is found to be low
Remove oil pan and inspect directly
Check fan belt, pulley directly
Remedy
20-221
0
S-15 Abnormal noise is made Causes
* Judge if the noise is an internal noise or

an external noise.
General causes why abnormal noise is made
. Abnormality due to defective parts
. Abnormal combustion
l Air sucked in from intake system
Legend
0: Most probable causes (judging from Questions and Check items)
Condition of abnormal noise
Color of exhaust gas
When turbocharger is rotated by hand, it is found to be heavy
Remove gear cover and inspect directly
.-? Speed does not change when operation of certain cylinders is stopped
s
2 When control rack is pushed, it is found to be heavy, or does not return
1 Injection pump test shows that injection amount is incorrect
o
z Fan is deformed, belt is loose
;
When valve clearance is checked. it is found to be outside standard value
Remove cvlinder head cover and inspect directlv
1 When muffler is removed, abnormal noise disaooears
20-222
0
TROUBLESHOOTING S-16
S-16 Vibration is excessive

IrIf there is abnormal noise together with
the vibration, carry out troubleshooting
for “Abnormal noise is made”.
General causes why vibration is excessive
. Defective parts (abnormal wear, break-
age)
. Improper alignment
l Abnormal combustion
I Causes /
Legend
0 : Most probable causes (judgingfrom Questions and Check items)
I I Confirm recent repair history I I I I I I I
I Degree of use of machine I Operatedforlongperiod 1~1~1~1 I 1
Suddenly increased 0
Condition of vibration
Gradually increased 000
Non-specified oil is being used 00
’ Metal particles are found in oil filter ai0
Metal particles are found when oil is drained 00
Oil pressure is low at low idlina 00
[ Vibration occurs at mid-range speed I I lol I I

Vibration follows engine speed 00
%
m
6
Exhaust smoke is black 00
Seal on injection pump has come off 0
Remove oil pan and inspect directly 0

.-P Remove side cover and inspect directly 0
6-
z inspect directly for loose engine mounting bolts or cushion 0
4 Remove front cover and inspect directly 0
4
e Remove head cover and inspect directly 0
F
Injection pump test shows that injection amount is incorrect 0
20-223
0
TROUBLESHOOTING OF
HYDRAULIC AND MECHANICAL SYSTEMS
(H MODE)
TABLE OF FAILURE MODES AND CAUSES (HYDRAULIC AND MECHANICAL SYSTEMS)..........20-302
H -1 Machine lacks power (lacks drawbar pull) .............................................................................. 20-304
H -2 Machine does not move (2nd, 3rd, engine running) ............................................................. 20-306
H -3 Machine does not move in any speed range ......................................................................... 20-308
H -4 Machine travels only ‘in one direction (forward or in reverse) ............................................. 20-310
H -5 Time lag is excessive when shifting gear or changing direction ......................................... 20-311
H -6 Machine does not turn (can travel in straight line). ............................................................... 20-312
H -7 Machine turns only in one direction (left or right)

[joystick (steering, directional, speed lever) operated1 ................................................. 20-313
H -8 Machine turns too far.. .............................................................................................................. 20-314
H -9 Brakes do not work.. ................................................................................................................... 20-315
H -10 Torque converter lock-up does not work ................................................................................ 20-315
H -11 Power train oil overheats.. ........................................................................................................ 20-316
H -101 All work equipment speeds are slow ...................................................................................... 20-318
H -102 Work equipment does not move ............................................................................................. 20-320

z?
H -103 Blade lift speed is slow or lacks power ................................................................................... 20-321
z
z H -104 Blade tilt speed is slow or lacks power.. ................................................................................. 20-321
H -105 Ripper lift speed is slow or lacks power ................................................................................. 20-322
H -106 Ripper tilt speed is slow or lacks power ................................................................................. 20-322
H -107 Excessive hydraulic drift of blade lift ...................................................................................... 20-323
H -108 Excessive hydraulic drift of blade tilt ...................................................................................... 20-323
H -109 Excessive hydraulic drift of ripper ........................................................................................... 20-324
H -110 Pin-puller cylinder does not work ............................................................................................ 20-324
H -111 Blade pitch does not work ........................................................................................................ 20-325
H -112 Abnormal noise from around hydraulic pump.. ..................................................................... 20-325
20-301
0
TROUBLESHOOTING TABLE OF FAILURE MODES AND CAUSES
TABLE OF FAILURE MODES AND CAUSES

(HYDRAULIC AND MECHANICAL SYSTEMS)
r
- - - -
Hydraulic system
- - - 1
Parts causing failure
T- -
Power train
- - - -
T
s I”
7
E 3 z &
2
t I” 5
3 T 2
z &
9 r E
u
.E
9 E P 2 s
i% 8 b
?u ii s
.5
F
1 s E ‘v,
E 0 .o
ii
5 5 E z
F
_c
z z .E
E 2 5 t 7
& 2 .E F
xa ! t,
2 I= 3 s d .E ii a u
Failure mode
- - L
- -
a0
3
t2
2
m s I-
F g
-
2:
1
-
F
Gi
-
f
-
Machine lacks power (lacks drawbar pull) - - - - 0 0 0 0 0 - - - -
Machine does not move (2nd, 3rd, engine running) - - - - 0 0 0 0 0 - - - -
Machine
Machine
does
travels
not move
only
in any speed
in one direction
range
(forward or
- - - - 0
- 0
- 0
- 0 0 - - - -
s
‘E
in reverse)
Time lag is excessive when shifting gear or
- - - - - -- - - - - - -
changing direction
- - - -
0
-
0 0
- -0 - - - -
G
3 Machine does not turn (can travel in straight line) - - - - - 0 0 - - - - - -
2 Machine turns only in one direction (left or right)
0 0
(steerinn, directional, speed lever ooerated)
- - - - - - - - - - -
1 Machine turns too far - - - - - 0 0 - - - - - -
1 Brakes do not work - - - - - 0 0 - - - - -
Torque converter lock-up does not work - - - - 0 - 5 - - -
Power train oil overheats
-0 0
- 0
- 0 - - -
All work equipment speeds are slow T 7 5 5 - - - - - - 5 - -
Work equipment does not move T
- 5 - - - - - - - 5 - -
Blade lift speed is slow or lacks power - - - 5 - - - - - - - - -
Blade tilt speed is slow or lacks power - - - 5 - - - - - - - - -
Riooer lift soeed is slow or lacks Dower - - - 5 - - - - - - - - -
- - - 5 - - - - - - - -
- - - - - - - - - - - - 7
- - - - - - - - - - - - 7
- - - - - - - - - - - - s
Pin-puller cylinder does not work - - - - - - - - - - - - -
Blade pitch does not work - - - - - - - - - - - -
Abnormal noise from around hydraulic pump.
- - - - - - - - - - 3 - -
20-302
0
Hydraulic system Mechanical system

- -
Lla Ives
-
%
%
%
9
z
.g
53 2
E 3 ‘3
3 u
L ‘5
n
3 F 5P .B
3
T z 6 Ai
0 & .-2 5
2
2 B
u E
2 & 5 E 5 t
4 1
u
.fs F .F c s %
5 : 3
s-0
z s 5i 3 Q m
z
6 5 52
z .-
2 t: 2 ;;
3 8 =t &
C
a .c
z
z
:: z 8 9 .g
z 5 = P
5
ii a,
‘Z
-0 .-E
u:
.z i?i
.t 2 ‘F
g
? ?
+i
0
‘C
d E s 7 P 5
d s 8
3 al
g F 5 W
5 cn
a
E m -E + ii
-
v) -I
- - - - - - - - -
- - - - - - 0 0 5 - - 0
- - -
-I- 1
- - - - - - 0 0 5 - - - - -
-I- 2
- - - - - - 0 0 5 - - - - -
H- 3
0 0 0 H- 4
- - - - - - - - - - - - - - -
0 0 0 H- 5
- - - - - - - - - - - - -
- - - - - - 0
- 0 - - - - - - -
H- 6
0 0 0 H- 7
- - - - - - - - - - - - -
- - - - - - 0 0 - - - - - - -
H- 6
- - - - - - 0
- 0 - - - - - -
H- 9
- - - - - - - 0
- - - - -
H- 10
- - - - 0 0 - - - 0
- H- 11
0 - - - - - 3 E G - - - - G G H-101
0
- - - - - - - - - - - - - -
- - - - - - - - - - - - - - _5
- - - - - - - - - - - - - - L
- - - - - - - - - - - - - - L
- - - - - - - - - - - - - - L
- - - - - - - - - - - - - -
- c - - - - - - - - - - - - -
- c
- - - - - - - - - - - -
- - 1 z - - - - - - - - -
- - - - 1 i - - - - - - - - -
- - - - - - - - - -
20-303
0
TROUBLESHOOTING H-l
H-l Machine lacks power (lacks drawbar pull)

* Check power train oil level before carrying out troubleshooting.
6 Low
YES IS enginespeed
- normal at F3
5 stall?
YES Is steering clutch, - Stall speed: High

- brake oil - Min. 1430 rpm
pressure normal? - High idling stall speed:
Does brake drag? - Min. 1160 rpm
t See Table 1
NO
.x See Note 1. normal?
I
I’ - Engine
. ...
at high
H
ranng 1
YES Is modulating
rJO
* Oil pressure:
pressure normal?
Ii * Inlet pressure: 0.9 * 0.1 MPa
w {9 t 1 kg/cm3
2 * Outlet pressure: 0.54 + 0.15 MPa
- - Oil pressure:
Min. 2.4 MPa (5.5 z 1.5 kg/cm3
Is transmission
L main relief _ (24 kg/cm3 NO
* Engine at high
NO pressure normal?
idling
* Oil pressure: -
. Is free length of
YES
>
Min.2.4 MPa spring of main 8
(24 kg/cm? relief valve %
* Engine at high NO normal?
z
. Does spool move
smoothly?
- NO
- Free length of
spring: 120.3 mm
Note 1 : Set the machine on level ground, run the

engine at low idling, shift the joystick to F2,
and check if the machine moves (travels).
Table 1 Unit : MPa Ika/cm3
Oil pressure
Conditions
Clutch Brake
Joystick (steering, directional,

speed) not operated T Engine speed
High idling
Low idling
0 {0} (left, right)
0 IO) (left, right)
Min. 2.4 (24) (left, right)
Min. 2.4 (241 (left, right)
Steering
Engine speed
to left
Joystick (steer-
ing, directional,
speed) operated Highidling{ 1 Left: Min.2.4124)
Right: Min 2.4 1241 Right: 0 {o}
Steering
Engine speed
to right
Left: 0 101 Left: Min. 2.4 1241
Low idling
20-304
0
TROUBLESHOOTING H-l
Cause Remedy
3rake dragging -
See H-9)
Defective engine
See ENGINE volume -
S-mode)
;epair or
Defect inside transmission
:place
Defective steering clutch -

bee H-6)
Defect inside torque lepair or

converter eplace
Defective transmission tepair or

valve eplace
Defective power train

replace
pump
Defective spring, spool leplace or

catching, or clogging with epair, clean
dirt
20-305
TROUBLESHOOTING H-2
H-2 Machine does not move (Znd, 3rd, engine running)

* Power train oil temperature: 70 - 80X
YE YES
Does brake drag
YE
pressure normal?
0 -Oil pressure:
2 Min. 2.4 MPa
Is transmission 1
I24 kg/cm?)
main relief NO
YE enter gear normally h - Engine at high
pressure normal? idling
and is adjustment I
of linkage normal?
* Oil pressure: YES
% See TESTING Min. 2.4 MPa
AND ADJUSTING {24 kg/cm?)
1 * Engine at high N
idling * Does spool mow
- Free length of
spring: 120.3 mm 0
20-306
0
TROUBLESHOOTING H-2
Cause Remedy
Brake dragging (see H-9) -
7 YES iepair or
Defect inside transmission
eplace
YES Issteering clutch
- 011pressure
6
- normal?
Is inlet and outlet , Defective steering clutch -
oil pressure of NO (see H-6)
- % See Table 1
torque converter
normal?
Defect inside torque lepair or
*Engine at high
NO converter eplace
idling
* Oil pressure:
* Inlet pressure: 0.9 t 0.1 MPa
8 + 1 kg/cm3
- Outlet pressure: 0.54 t 0.15 MPa
(5.5 + 1.5 kg/cm? Defective transmission lepair or
valve eplace

leplace
pump
Defective spring, spool

teplace or
catching, or clogging witt
epair, clean
dirt
Defective adjustment of
idjust
speed lever linkage
parking brake linkage idjust
(see TESTING AND
ADJUSTING)
Table 1 Unit : MPa {kg/cm2}
Oil pressure
Conditions
I Clutch I Brake
Joystick (steering, directional, High idling 0 {O} (left, right) Min. 2.4 (24) (left, right)
Engine speed
speed) not operated Low idling 0 (01 (left, right) Min. 2.4 (241 (left, right)
Left: Min 2.4 1241 Left: 0 IO)

High idling
Steering Right: 0 {OI Right: Min. 2.4 (241
Engine speed
to left Left: Min 2.4 {24} Left: 0 101
Low idling
Joystick (steer- Right: 0 {O} Right: Min. 2.4 {24)
ing, directional,
speed) operated
Steering
Engine speed
to right
Right: Min 2.4 1241
20-307
0
TROUBLESHOOTING H-3
H-3 Machine does not move in any speed range

YES
pressure normal?
NO
normal? - Engine at high
- Engine at high
idling
idling ‘I
-H
Is 1transmission - Oil pressure: I
YE.S - Inlet pressure: NO
r mz sin relief
0.9 + 0.1 MPa (9 + 1 kg/cm?
prl assure normal?
-Outlet pressure: 0.54 2 0.15 MPa i5.5 - 1.5 kg/cm?
Yf
1
% See TESTING * Free length of
AND ADJUSTING spring: 120.3 mm
Is brake oil
pressure normal?
10
.x See Table 1
L
r40
Table 1 Unit : MPa {ka/cm2
Oil pressure (left, right)

Conditions
Clutch Brake
High idling 0 (01 Min. 2.4 {24}

Brake pedal released Engine speed
Low idling 0 101 Min. 2.4 1241
Brake pedal depressed Engine speed High idling 0 IO) 0 101

Low idling 0 101 0 (01
20-308
0
TROUBLESHOOTING H-3
Cause Remedy
Defect inside steering

YES _ clutch, or defect inside
lepair or
6 transmission eplace
Is steering clutch
oil pressure as
Defective steering clutch
shown in Table 7 YES
_ seal, or defective steering leplace
2?
valve
- Is adjustment of
- steering linkage -
NO normal?
idjust
linkage
I See TESTING No
AND ADJUSTING.
Defective transmission 3epair or

valve eolace
Defect inside torque 3epair or

converter ‘eplace

Ieplace
pump
Xeplace or
‘epair, clean
/ ;;g: adjustment of
idjust
r brake (see l-I-9

-
Table 2 Unit : MPa {kg/cm2)
Oil pressure
Conditions
Clutch Brake
Joystick (steering, directional, High idling 0 (0) (left, right) Min. 2.4 {241 (left, right)
Engine speed
speed) not operated Low idling 0 101 (left, right) Min. 2.4 I241 (left, right)
Left: Min 2.4 {24) Left: 0 {O}

High idling
Steering Right: 0 IO} Right: Min. 2.4 (24)
Engine speed
to left Left: Min 2.4 I241 Left: 0 101
Low idling
Joystick (steer- Right: 0 IO} Right: Min. 2.4 {24}
ing, directional,
speed) operated Left: 0 {O) Left: Min. 2.4 {24}
High idling
Steering
Right: Min 2.4 124) Right: 0 {o}
Engine speed
to right Left: 0 10) Left: Min. 2.4 {24)
Low idling
Right: Min 2.4 {24) Right: 0 {o}
20-309
0
TROUBLESHOOTING H-4
H-4 Machine travels only in one direction (forward or in reverse)

* Conditions: Oil pressure normal (Min. 2.7 MPa I28 kg/cm21)
* If the machine travels normally in 1st - 3rd in the direction where travel is normal (forward or
reverse).
F
Remedy
Clutch slipping in
1 YES Repair or
direction where travel is
replace
Is adjustment of not normal (F or R)
speed lever
linkage normal?
Adjust
speed lever linkage
% See TESTING No
AND ADJUSTING.
20-310
0
TROUBLESHOOTING H-5
H-5 Time lag is excessive when shifting gear or changing direction

* Joystick (steering, directional, speed) operated
Cause Remedy
Defective brake (see H-9) -
Defective transmission
ES valve Repair or
* Defective operation of reolace
spool
Does brake drag?
YEiS
main relief
pressure normal? Defective power train
.X SeeNote 1.
2 pump
. Oil pressure:
4
valve normal?
Is adjustment of Min. 2.4 MPa h Defective main relief
speed lever i24 kg/cm3 Replace or
valve spring, clogging
No linkage normal? . Engine at high clean
with dirt
idling * Free length of
-X See TESTING spring: 120.3 mm
AND ADJUSTING Defective adjustment of
i Adjust
NO linkage
Note 1 : Use the blade and ripper to raise the chassis,

then run the engine at low idling, shift the joy-
stick to F3 or R3, and check if the track rotates.
20-311
0
TROUBLESHOOTING H-6
H-6 Machine does not turn (can travel in straight line)

Cause Remedy
YES See H-9 -
YES Seizure of clutch disc and

Is clutch Replace
plate
disengaged?
2
3%See 1). 4 YES Defective seal of clutch

Is clutch, brake Replace
- oil pressure piston
YES Does valve spool
NO normal?
- move smoothly? -
3
I See Table 1.
- (clutch)
Defective operation of Repair or
Is adjustment of P -NO clutch valve spool replace
- steering linkage -
NO normal?
.XSee TCCTlhlC
ILUIIl.U
_
~ Adjust
AND ADJUSTING. NO linkage
-X
1) Travel in Fl or RI with the engine at low idling, then
operate the joystick to the left or right steering in the
range that steering clutch is slightly disengaged
(approx. half stroke) and check that the machine stops
or turns slowly.
Table 1 Unit : MPa {ka/cm2
Oil pressure
Conditions
Clutch Brake
Joystick (steering, directional, High idling 0 {O} (left, right) Min. 2.4 (241 (left, right)
Engine speed
speed) not operated Low idling 0 IO) (left, right) Min. 2.4 {241 (left, right)
Left: Min 2.4 (24) Left: 0 (0)

High idling
Right: 0 {OI Right: Min. 2.4 {24)
Steering
Engine speed
to left Left: Min 2.4 {24} Left: 0 IO}
Low idling
Joystick (steer- Right: 0 10) Right: Min. 2.4 {241
ing, directional,
speed) operated Left: 0 10) Left: Min. 2.4 1241
High idling
Right: Min 2.4 {24) Right: 0 {O}
Steering
Engine speed
to right Left: 0 {O} Left: Min. 2.4 {24)
Low idling
Right: Min 2.4 1241 Right: 0 {o]
20-312
0
TROUBLESHOOTING H-7
H-7 Machine turns only in one direction (left or right)

[joystick (steering, directional, speed lever) operated]
Cause Remedy
3 YES Wear, scuffing of brake

Replace
Is oil pressure of disc, plate
YES clutch on
opposite side
normal? Slippage of clutch on Repair or
-
2
I See Table 1.
NO opposite side replace
Is clutch, brake oil
YES pressure
Norman
on
Defective sealing of clutch
side where turning 4 YES Repair or
is impossible? chamber replace
l- or defective seal ring
Does valve spool
7 % See Table 1.
Is adjustment of NO move smoothly?
Defective operation of
steering linkage - Repair or
clutch or brake valve
normal? NO replace
spool
% See TESTING
AND ADJUSTING.
Defective linkage Adjust
NO
Table 1 _
llnit _ : MPn
. _ fka/nm21
..._._..-,
Oil pressure
Conditions
Clutch Brake
Joystick(steering, directional, High idling 0 (0) (left, right) Min. 2.4 (241 (left, right)
Engine speed
speed) not operated Low idling 0 101 (left, right) Min. 2.4 {24) (left, right)
Left: Min 2.4 124) Left: 0 IO}

High idling
Steering Right: 0 (01 Right: Min. 2.4 124)
Engine speed
to left Left: Min 2.4 124) Left: 0 (0)
Low idling
Joystick (steer- Right: 0 (0) Right: Min. 2.4 {24}
ing, directional,
speed) operated Left: 0 IO} Left: Min. 2.4 (241
High idling
Right: Min 2.4 {241 Right: 0 {o}
Steering
Engine speed
to right Left: 0 101 Left: Min. 2.4 124)
Low idling
20-3 13
0
TROUBLESHOOTING H-8
H-8 Machine turns too far
Cause Remedy
1 YES
-
See H-9
Is clutch
disengaged?
See H-6 -
$ See 1).
1) Travel in Fl or RI with the engine at low idling, then

operate the joystick to the left or right steering in the
range that steering clutch is slightly disengaged
(approx. half stroke) and check that the machine stops
or turns slowly.
20-314
0
TROUBLESHOOTING H-S, H-10
H-9 Brakes do not work

Cause Remedy
* Check power train oil level before carrying out
troubleshooting.
YES
Wear of brake disc, plate
2
YES Is clutch, brake

- oil pressure
3 YES Defective sealing of clutch
normal? Replace
piston
Does valve spool
1 zc See Table 1. - move smoothly? -
NO (brake) Defective operation of
Is adjustment of Correct or
brake valve or clutch replace
brake linkage - NO valve spool
normal?
I See TESTING Defective adjustment of Adjust

AND ADJUSTING. NO brake linkage
Table 1 Unit : MPa {kg/cm21

Oil pressure (left, right)
Conditions
Clutch Brake
High idling 0 101 Min. 2.4 {24}

Brake pedal released Engine speed
Low idling 0 IO) Min. 2.4 (24)
High idling 0 {OI 0 (01

Brake pedal depressed Engine speed
Low idling 0 101 0 {OI
H-10 Torque converter lock-up does not work Remedy

* Conditions: When the lock-up solenoid is working normally.
M If it is defective, go to E-Sl.
2 YES qeplace or
Defective lock-up clutch repair
Defect inside torque

qepair
a. .
converter
1 when measuring
Is torque : 70 - 80°C
converter lock-up - Speed range: F3 4 YES Defective lock-up qeplace or
- Stall speed (selector) valve vepair
1
oil pressure
normal?
: Min. ,430 rpmYES Is operation of
lock-uo solenoid
* Oil temperature 3 Jspool normal?]
Spool scuffing Replace or
when measuring
NO repair
: 70 - 80°C Is main relief
- Engine at high _
pressure
idling NO normal? 5
- Oil pressure _ - Is free length of YES Defective power train
Replace
: 1.3+0.15MPa I spring of main pump
*Oil temperature
{I3 + 1.5 kg/cm7 relief valve
when measuring -
: 70 - 80°C
* Engine at high
idling
NO normal?
. Does spool
move smoothly?
NO
1 Defective spring, spool
catching, or clogging with
dirt
Replace or
repair, clean
*Oil pressure . Free length of
: Min. 2.4 MPa spring: 120.3 mm
{24 kg/cm?
20-315
0
TROUBLESHOOTING H-l 1
H-II Power train oil overheats

[I(
4
YE Is engine speed
normal at F3
stall? YES
1
Does brake drag? - Stall speed: 5
L
Min. 1430 rpm
Ioes machine
rtop when
.X See Note 1.
hIO :operation in Item
11is carried out?
I
Is transmission
Yf
main relief
pressure normal?
~
NO
- Oil pressure:
Min. 2.4 MPa
2 7
(24 kg/cm7
4-l - Engine at high - YES

- Is free length of 3
Is power train oil
idling spring of main
NO temperature
relief valve
sensor normal?
1 I normal?
* Does stool move
- Remove oil I
temperature
smoothly?
* Free lenath of
I NO
sensor. spring: GO.3 mm
- Check resistance
value.
1%See Table 1) IO
Note 1 : Use the blade and ripper to raise the chassis, Table 1
run the engine at low idling, then shift the joy-
Ambient
stick to F3 or R3 and check that the track moves. When normal
temperature
130°C Approx. 1.8 kQ

I I
120°C Approx. 2.3 kR
I I
90°C Approx. 3.8 kQ
I I
50°C Approx. 17 kQ
20-316
0
TROUBLESHOOTING H-II
Cause Remedy
3rake dragging (see H-9)

See ENGINE volume -
S-mode)
3efective cooling system -
Slippage of transmission
6 YES Autch, increase in engine Replace, adjust
Dutput, or slippage of
Is inlet and outlet steering clutch
- pressure of torque -
convener normal?
Defect inside torque 3epair or
- Engine at high Eonverter ,eplace
NO
idling
- Oil pressure:
* Inlet pressure:
0.9 I 0.10 MPa 19 2 1 kg/cm?
* Outlet pressure:
0.54 + 0.15 MPa 15.5 t 1.5 kg/cm? 3epair or
Slippage of brake disc
.eplace

pump, air entering qeplace,
through joint in suction :ighten
:ircuit
Defective spring, spool

3epair or
satching, or clogging with
.eplace, clean
jirt
Defective power train oil

temperature sensor -
lsee M-mode)
20-317
0
TROUBLESHOOTING H-101
H-101 All work equipment speeds are slow

Ir Check oil level in hydraulic tank before carrying out troubleshooting.
4 YES
Doescondition
YES becomenormalwhen
YE
- front pump normal -
at end of ripper tilt
stroke? 5 YES
2 Doescondiion
+ Oil pressure:
becomenormalwhen
Is relief pressure of Min.20.6 ‘i MPa _ reliefpressureof main -
YES main relief valve for NO reliefvalvefor front
I21 0 ““, kg/cm3
- center pump pumpisadjusted?
* Engine at high
normal at end of
blade tilt stroke?
idling. * Oil pressure: - NO
Min.20.6 ‘J MPa . Engine at high idling.
* Oil pressure: % Pressure adjustment: One turn
6 YES 1210 +‘; kg/cm3 changes by 2.43 Mpa 124.8 kg/cm?
Min.20.6 ‘i MPa
Doescondition
1 {210 “i kg/cm?
becomenormalwhen
* Engine at high - reliefpressureof main -
Is PPC charge idling. N 0 reliefvalvefor center
pump relief
pumpis adjusted?
pressure (basic
pressure) normal? - Oil pressure: NO
Min.20.6 ‘l MPa *Engine at high idling.
. Oil pressure: f Pressure adjustment: One turn
(210 ““, kg/cm’)
Min. 3.9 MPa YE changes by 2.43 Mpa 124.8 kg/cm3
(40 kg/cm’)
*Engine at high 7
idling Does condition
become normal
- when PPCcharge - YES
NO relief valve is
adjusted?
Block portion A in
* Oil pressure: diagram below.
Min. 3.9 MPa Does oil pressure g YES
140 kg/cm3 NO
become normal?
Is any foreign
- Engine at high
. Oil pressure: material found in
idling
Min. 3.9 MPa NO strainer inside PPC
140 kg/cm? charge valve?
* Engine at high
NO
idling
% Fit an adapter to
portion A and
install an oil
pressure gauge.
Blade PPC valve Ripper PPC valve
Saftv lock lever
- To Oil cooler
L_!_l relief valve

TOO00680
20-3 18
0
1 Defective hydraulic pump

drive portion
Reparr or
( replace
main relief valve for front Adjust
pump
Defective main relief

Replace
valve for front pump
main relief valve for Adjust
center pump
Defective valve for center Rep,ace

pump
Adjust
PPC charge relief valve
Internal leakage in PPC

Replace
valve
Defective PPC charge

Replace
pump
r PPC charge Replace
20-319
0
H-102 Work equipment does not move

* Check oil level in power train before carrying out troubleshooting.
Cause Remedy
3 YES
Defective hydraulic pump 3eplace
YES-FH-
, 2 assembly 1sreplaced?
Defective hydraulic pump Xepair or
I I I
NO drive portion ‘eplace
YEiS Is relief pressure
normal?
l-l
I
Idjust
nain relief valve
1
Defective main relief

*Engine at high Xeplace
- Oil pressure: - Engine at high idling. valve
idling. -
Min.20.6 ‘A MPa % Pressure adjustment:
{210 “i kg/cm?) One turn changes by
- Oil pressure:
Min. 3.9 MPa 5 .-
2.43 Mea -.-
124.8 kalcm? Defective PPC charge
ieplace
1IS anvforeign 1 YES pump
H
f40 kg/cm?
- Engine at high material fo;nd in
idling FJO strainer inside PPC
charge valve?
Defective PPC charge 3eplace
NO valve
20-320
0
TROUBLESHOOTING H-103, H-104
H-103 Blade lift speed is slow or lacks power

* If the hydraulic drift of the blade is normal.
* Check oil level in hydraulic tank before carrying out troubleshooting.
* Check if the blade has been modified.
3 YES Defective suction valve at

Replace
Doescondition blade RAISE end
YES become normalif
- suctionvalvefor blade-
_ 2 RAISE (blade cylinder Defective operation of
head end) is replaced? Correct or
Is output blade lift control valve
replace
YES pressure of PPC _ * Blade lifting speed: NO spool
valve for blade Max. 6 sec.
1
p RAISE normal? -Engine at high
Can cylinder be
. Oil pressure:
idling. Defective operation of 1Correct or
extended and _ PPC valve
Min. 3.9 MPa NO replace
retracted
smoothly? I40 kg/cm?
- . Engine at high
idling
Air in circuit Bleed air
NO
H-104 Blade tilt speed is slow or lacks power

* If the hydraulic drift of the tilt is normal.
-Lr Check oil level in hydraulic tank before carrying out troubleshooting.
Defective operation of
2 YES Correct or
blade tilt control valve
replace
spool
Defective operation of Correct or

~~ PPC valve replace

NO
20-32 1
0
H-105 Ripper lift speed is slow or lacks power

* If the hydraulic drift of the ripper is normal.
* Check oil level in hydraulic tank before carrying out troubleshooting.
* Check if the ripper has been modified. -

3 YES
suction valve at ripper replace
Doescondition II RAISE end
YES becOme nO”-d If
- suctionvalvefcr -
2 ripperRAISE in ripper Defective operation of Correct or
Is output pressure Lc
~~ valveis replaced? ~ ripper lift control valve replace
YES of PPC valve at - * Ripper lifting NO spool
ripper RAISE end speed: Max. 5 sec.
1
F normal?
Can cylinder be
, - Engineat high idling.
extended and * Oil pressure: Defective operation of Correct or
retracted - Min. 3.9 MPa NO PPC valve replace
smoothly? I40 kg/cm3
NO
H-106 Ripper tilt speed is slow or lacks power

Ir If the hydraulic drift of the tilt is normal.
Ir Check oil level in hydraulic tank before carrying out troubleshooting.
Ir Check if the ripper has been modified.
Cause Remedy
2 YES Defective operation of Correct or

ripper tilt control valve replace
spool

~~ PPC valve replace

NO
20-322
0
H-107 Excessive hydraulic drift of blade lift

j, Check that there is no leakage of oil in the work equipment circuit.
Cause Remedy
Excessive leakage inside

1 YES valve
Replace
- Internal leakage in
Is hydraulic drift
blade lift valve
normal when blind
plug is fitted at
cylinder head end? Excessive leakage inside
cylinder Replace
* Stop engine. NO - Defective piston seal
. Downward movement:
Max. 400mm/15 minutes
A aFitblind
blocks under the blade, disconnect
plug, then remove the block.
the hose at the head end, fit
H-108 Excessive hydraulic drift of blade tilt

* Check that there is no leakage of oil in the work equipment circuit.
Cause Remedy

valve
1 YES
- nternal leakage in blade Replace
Is leakage normal tilt valve
when cylinder is _ - Defective suction valve
relieved at end of
stroke?
cylinder Reolace
- Extend tilt NO - Defective piston seal
cylinder fully and
remove hose
from head end.
- Run engine at
high idling and
relieve circuit at
end where
cylinder is
extended.
- Oil leakage:
Max. 12 cclmin.
20-323
0
TROUBLESHOOTING H-109, H-l IO
H-109 Excessive hydraulic drift of ripper

* Check that there is no leakage of oil in the work equipment circuit.
I Cause Remedy

1 YES
valve, or defective suction Replace
Is leakage normal valve
when cylinder is
. ._
Replace
- Run engine at
high idling and
relieve circuit at
end where cylinder
is extended.
* Oil leakage:
Max. 12 cclmin.
H-l 10 Pin-puller cylinder does not work

* When operation of pin-puller solenoid is normal. (If it is abnormal, see E-2.)
* When power train oil pressure is normal.
I Cause
1 YES Defective pin-puller Repair or

Is output cylinder replace
pressure of pin-
puller solenoid
valve normal? Defective pin-puller
Replace
NO solenoid valve
* Min. 2.2 MPa
122 kg/cm7
20-324
0
H-III Blade pitch does not work
Cause Remedy
1 YES Defective blade pitch Correct or

Is output cylinder replace
pressure of blade _
pitch solenoid
valve normal? Defective blade pitch
Replace
solenoid valve
* See TESTING No
AND ADJUSTING.
H-112 Abnormal noise from around hydraulic pump

8
% * Check oil level in hydraulic tank before carrying - out troubleshooting.
s
Cause Remedy
Defective seal
YES * Loose piping clamp Tighten
* Damaged O-ring
22
Is air being
H
I--
sucked in by
pump suction
circuit?
YES
Clogged strainer
Defective hydraulic pump

Clean
Replace
IL Operate for a short time Check again

oil is drained?
and watch for any change [according to
NC in symptoms change in
symptoms)
Improper oil Replace

N0
20-325
TROUBLESHOOTING OF
MACHINE MONITOR SYSTEM
(M MODE)
Table of failure modes and causes (machine monitor system). ...................................................... .20-402
Related electrical circuit diagram for M Mode, E Mode .................................................................... 20-404
M- 1 When starting switch is turned ON, no display is given on monitor panel ...................... 20-406
M- 2 When starting switch is turned ON, monitor panel lamps all light up
but do not go out.. .................................................................................................................... 20-406
M- 3 When starting switch is turned ON (engine stopped), CHECK items flash ....................... 20-407
a) G (Radiator water level) flashes.. ................................................................................... .20-407
I1smns
b) b& (Engine oil level) flashes ......................................... ..................................................... 20-407
M- 4 When starting switch is turned ON (engine started), CAUTION items flash

(battery charge, engine oil pressure do not light up). ........................................................ .20-408
a) Alternator system ............................................................................................................... 20-408
b) Engine oil pressure sensor system.. ................................................................................. 20-409
M- 5 When starting switch is turned ON and engine is started, caution item flashes
(When there is no abnormality in CHECK items or in engine) ........................................... .20-410
a) g, (Battery charge) flashes ............................................................................................... 20-410
b) @ (Engine oil pressure) flashes.. .................................................................................... .20-410
IIQ0IIO
c) 2. (Radiator water level) flashes.. ................................................................................... .20-411
d) 21, (Coolant temperature) flashes.. ................................................................................... 20-411
e) a (Power train oil temperature) flashes.. ...................................................................... .20-412
1‘000111
f) PI (Hydraulic oil temperature) flashes ........................................................................... .20-412
1111111
M- 6 Abnormality in &a (Preheating) ............................................................................................ 20-413
M- 7 Abnormality in buzzer.. ............................................................................................................. 20-414
a) Caution item flashes but buzzer does not sound.. ......................................................... .20-414
b) Monitor display is normal but buzzer sounds ................................................................ .20-414
M- 8 Abnormality in warning lamp .................................................................................................. 20-415
a) Caution item flashes but warning lamp does not light up ........................................... .20-415
b) Monitor display is normal but warning lamp lights up ................................................ .20-415
M- 9 Abnormality in gauge ............................................................................................................... 20-416
a) Abnormality in engine coolant temperature gauge.. ..................................................... .20-416
b) Abnormality in torque converter (power train) oil temperature gauge.. ..................... 20-416
c) Abnormality in fuel level gauge ........................................................................................ 20-417
M-10 Service meter does not move after engine is started.. ........................................................ .20-418
M-l 1 Monitor panel lighting does not light up (front lamp, working lamp are normal). .......... 20-419
20-401
0
TABLE OF FAILURE MODES AND CAUSES

(MACHINE MONITOR SYSTEM)
Sensors
Parts causing failure
Failure mode
11 1Monitor panel llghtlng does not light up

I I I I I
20-402
a
0 M- 6
0 M- 7
,O M- 8
0 M- 9
0 M-10
0 M-II
20-403
0
TROUBLESHOOTING RELATED ELECTRICAL CIRCUIT DIAGRAM FOR M MODE, E MODE
RELATED ELECTRICAL CIRCUIT DIAGRAM FOR M MODE, E MODE
Hydraulic oil For dual tilt dozer

temperature 452 Back-up alarm snecifications -----_-_-_
limit pitch r----- 1
Rishtfear (X2)
Torque converter
oil temperature
sensor
1
L 224 Pin puller
Radiator water 405 (X2) solenoid
451
fSWP14) 1
[1
I 201 I
Back-up
Air conditioner
Left head compressor clutch
A
Ensine water 402
temperature (X2)
sensor
Engine oil
pressure sensor I
Engine
level
oil
sensor
404
(X1)
I III III 361
Left workins
lamp 70W 221
Fuse
Battery (NSZOOXZ) L_GJ”i

Battery relay Avsr.*5 y
KiOOAX2)
ED000345
20-404
0
TROUBLESHOOTING RELATED ELECTRICAL CIRCUIT DIAGRAM FOR M MODE, E MODE
Head lamp.
worki ne
I amo re I ay
Head lamp,
working
lamp switch
Rear lamp
switch
Far __-__-__-__-__-__
dual tilt dozer specifications
for dual tilt I

Pitch
Knob switch
for dual til t
I I I Tilt
I
Horn SW itch
Pin pul ler

switch
switch
BDD00346
20-405
0
TROUBLESHOOTING M-l, M-2
M-l When starting switch is turned ON, no display is given on

monitor panel
When the battery and battery relay are normal.
When fuse 15 is normal.
(If fuse 15 is blown, check for a short circuit with the chassis ground in the wiring harness between
CNI (1) - CN214 (2) - CN361 (14) - CN.411 (1) -fuse 15.)
Before carrying out troubleshooting, check that all the related connectors are properly inserted.
Always connect any disconnected connectors before going on to the next step.
Cause Remedy
2 YES Defective monitor panel

(monitor module)
YES Does problem
1 appear again?
Is voltage k System has been reset -
between CNI -Turn starting NO
(female) (1) and - switch ON.
(2) normal? Defective contact or
disconnection in wiring
* 20 - 30 v
harness between fuse 15 - Repair or replace
. Turn starting NO CN411 (1) - CN361 (14) -
switch ON.
CN214 (2) - CNl (female)
* Disconnect CNI
(1)
and connect T-
adapter to
female.
M-2 When starting switch is turned ON, monitor panel lamps all light
up but do not go out
Cause Remedy
Defective monitor panel

3eplace
(monitor module)
M-l, M-2. Related electrical circuit diagram
CNl
Monitor Panel (04012) CN214 CN361 CN41 1
(SWPl 6) (SWP 16) (SWP14) FIrsa
15
10A
CN215 CN42 1
(SWPl 6) (SWPl 6)
Battery relay
BKD00681
20-406
0
TROUBLESHOOTING M-3
M-3 When starting switch is turned ON (engine stopped), CHECK

items flash
* Before carrying out troubleshooting, check that all the related connectors are properly inserted.
* Always con’nect any disconnected connectors before going on to the next step.
a) 0 - (Radiator water level) flashes Remedy

SAP00519
* Check that radiator water level is normal before
carrying out troubleshooting.
Y== IDefective radiator water t(
(:heck sensor
see STANDARD
I\/ALUE TABLE),
.eplace
YES Defective monitor pane

Replace
(monitor module)
YE
I
(female) (5) and Defective contact, or
* Connect short harness between CN405 r\fter inspection,
connector to (female) (1) - CNZOI (1) - CF repair or replace
* Disconnect CNl.
CN405 (female). 101 (2) - CN421 (3) - CN214
between CN405 *Turn starting
. Turn starting h (5) - CNl (female) (5)
(female) (2) and switch OFF.
switch ON
. Disconnect
After inspection,
CN405.
repair or replace
-Turn starting
switch OFF. ground
* Max.lR
Monitor bane1
zQ) M-3. a) Related electrical circuit diagram
Nl I I
z CNlOl
y;;;yti:nb;;er CR405 (x2) X’
. .._. fSWP16)
__... ._
I \
n
/Q&rrJ I\/ Radiator water level
, ,
-d7 I
BKD00682
b) 6 (Engine oil level) flashes Cause Remedy

0
SAP00523
* Check that engine oil level is normal before car-
rying out troubleshooting. Defective engine oil level Check sensor
,* sensor system or (see STANDARL
defective chassis ground VALUE TABLE),
Does engine oil replace
level monitor
lamp go out when _
CN404 (female) (1) 2 YES Defective monitor panel
Replace
is connected to Is resistance (monitor module)
chassis ground? between CNl
* Disconnect - (female) (6) and - Defective contact, or
CN404. NO chassis ground disconnection in wiring After
normal?
. Turn starting harness between CN404 inspection,
switch ON. - Disconnect CNI. NO (female) (1) - CNlOl (16) -
-Turn starting switch CN421 (5) - CN214 (6) -
OFF. CNl (female) (6)
- Max.lR
Monitor Panel
M-3. b) Related electrical circuit diagram CNl
(04012)
CNlOl CN421 CN214
Enoin
level
oil
sensor
%” (SWPl 6) (SWPI fi) (SWPI 6)
h-u I )(16-5)( H I’ Enain oil level
BKD00663 u 20-407
0
TROUBLESHOOTING M-4
M-4 When starting switch is turned ON (engine started), CAUTION

items flash (battery charge, engine oil pressure do not light up)
Ir Always connect any disconnected connectors before going on to the next step.
* Check both the alternator system and engine oil pressure system.
Ir Check that fuse (15A) is normal before carrying out troubleshooting.
a) Alternator system
Cause Remedy

Replace
Is voltage (monitor module)
YES between CNI (4)
and chassis Short circuit in wiring
1
harness between CNl
II Repair or
(female) (4) - CN214 (4) -
NO replace
Disconnect CNl. CN421 (11) - CNlOl (9) -
alternator 13and alternator R
- Disconnect I
terminal R. Defective alternator Replace
NO
. Turn starting
switch ON.
* Max. 1 V
M-4. a) Related electrical circuit diagram
Monitor Panel CNl CN214 CN421 CNlOl

l(O4012) (SWPl6) (SWP 1 6) (SWP 1 6)
Alternator
Battery
4-
charge
I I +
(MIC5)
BK000664
20-408
0
TROUBLESHOOTING M-4
b) Engine oil pressure sensor system
* When engine oil pressure is normal.
Cause Remedy

Replace
(monitor module)
Is resistance
YES between CNl Defective contact, or
- (female) (8) and disconnection in wiring
1
- chassis normal? harness between CNl Repair or
Is resistance
between engine oil (female) (8) - CN214 (7) - replace
. Max. 1R NO
Pressure Se”Sor - s Turn starting CN421 (4) - CNlOl (15) -
terminal CN403 and sensor terminal CN403
switch OFF.
chassis normal?
* Disconnect CNl
- Max. 1 R Defective engine oil
pressure sensor Replace
-Turn starting
NO
switch OFF.
. Disconnect sensor
wiring harness CN403
M-4. b) Related electrical circuit diagram
CNl
Monitor Panel (0401.2) CN214 CN42 1 CNlOl
(SWP 16) (SWPl L.i) (SWP 16) Enoin oil
I Pressure sensor
CN403
Engin oil A
” -7
-Th
Pressure
LL-I
I
BKD00665
20-409
0
TROUBLESHOOTING M
M-5 When starting switch is turned ON and engine is started, caution

items flash (When there is no abnormality in CHECK items or in
engine)
Sr Check that fuse (15A) is normal before carrying out troubleshooting.
al I- +
SAP00522
(Battery charge) flashes
YES Defective monitor panel

Replace
(monitor module)
I
1
Defective contact or
harness between Repair or
alternator terminal NO alternator terminal R - fuse replace

15 - CNlOl (9) - CN421 (11) -
CN214(4)- CNl (femalejf4)
throttle or above.
-2O-30V
- Start engine. I Defective alternator Replace
NO
- Run at half
throttle or above.
Monitor Panel CNl CN214 CN421 CNlOl

I(O4012) (SWPIG) (SWP 16) (SWPl 6)
Fuss Alternator
Battery n-1 R
charge 1 15A ]
I I
BKD00664
b1 (Engine oil pressure) flashes

Cause Remedy
SAP00520
-Lr Check that engine oil pressure is normal before
Check sensor
YES Defective engine oil (see STANDARC
1 pressure sensor system VALUE TABLE),
Does display go
out when CN403 -
isdisconnected? p - Replace
Is resistance (monitor module)
_ between CNl
* Disconnect - (female) (8) and - Contact of chassis ground
CN403. NO chassis ground with wiring harness
-normal? Repair or
- Start engine. between CN403 - CNlOl
NO replace
* Min. 1 MR (15) - CN421 (4) - CN214
- Disconnect CNI. (7) - CNI (female) (8)
*Turn starting
switch OFF.
* Disconnect CN403.

cN1 CN214
Monitor Panel (04012) CN421 CNlOl
(SWPI 6) (SWPI 6) (SWPl 6) Ensin oil
Pressure sensor
CN403
c
Pressure
I
20-4 10 BKD00665
0
TROUBLESHOOTING M-5
Cl
bo -
SAP00519
(Radiator water level) flashes
Ir Check that radiator water level is normal before

Cause
See M-3 a) -
(Coolant temperature) flashes

Cause Remedy
SAP00527
C heck sensor
Defective coolant (Z;ee STANDARC
2 YES
temperature sensor V ALUE TABLE),
Does display 90 out system rf?place
YEB when short
- connector is
1 connected to CN402
1 (female)? Defective monitor panel ’ Freplace
Is indicator of (monitor module)
coolant *Connect short NO
temperature gauge - connector to
in red zone? CN402 (female).
- -Start engine.
*Start engine. Defective monitor panel
Fleplace
(monitor module)
NO
M-5. d) Related electrical circuit diagram
Ensin water
temperature sensor
BKD00666
20-411
TROUBLESHOOTING M-5
el (Power train oil temperature) flashes

Cause Remedy
lhecksensor
YES Defective power train oil see STANDARt
temperature sensor lALUE TABLE),
‘eplace

Is indicator of xeplace
NO :monitor module)
power train oil - Connect short
temperature gauge connector to
in red zone? CN453 (female).
* Start engine.
- Start engine. Defective monitor panel
[monitor module) qeplace
NO
M-5. e) Related electrical circuit diagram
_ . _ DaneI
Mnnitor __ _ CN2 CN214 CN421
1 (040081 (SWPIG) (SWPI 6) CN45 1 (SWPl4) CN453 (X2) Torque converter oil
temperature sensor
Torque converter
oil temperature ?.+I
I
BKD00667
(Hydraulic oil temperature) flashes

BKD00282 Cause Remedy
Checksensor
Defective hydraulic oil
(see STANDARC
temperature sensor
‘.‘ALUE TABLE),
system
replace

Replace
chassis ground? (monitor module)
* Disconnect (female) (8) and Defective contact, or

CN452 and
connect (female) u Repair or
harness between CNl
(1) to chassis replace
* Max. 1R NO (female) (8) - CN214 (8) -
ground.
* Disconnect CNl. CN421 (8) - CN451 (3) -
* Start engine.
- Ground CN452 to CN452 (female) (1)
chassis.
-Turn starting
switch OFF.
M-5. f) Related electrical circuit diagram
Monitor Dane1 CNl CN214 CN42 1 CN45 I

I(04008) (SWPI 6) (SWP16) (SWPl4) Hydraulic oil
temperature sensor
Hydraulic oil
temperature
BKD00688
20-412
0
TROUBLESHOOTING M-6
M-6 Abnormality in (Preheating)

SAP00526
* When the APS is working normally. (If there is any abnormality in the operation of the APS, carry
out troubleshooting for E-2 first.)
Cause Remedy
a) Preheating monitor lamp does not light up
YES Defective monitor panei

ieplace
(monitor module)
Defective contact, or
tepair or
harness between CN413
ground normal? eplace
(female) (4) - CN361 (8) -
-13-3ov between CN413 CN214 (5) - CN2 (female)
-Turn starting
switch ON. Go to E mode (E-2a)
* Turn APS switch (Abnormality in APS
- 13-3ov NO
ON. power source system)
* Turn starting
*Water
switch ON.
temperature:
* Turn APS switch
Max. 20°C
ON.
*Water
temperature:
Max. 20°C
Defective contact of +24
b) Preheating monitor lamp stays lighted up
with wiring harness
cr) sepair or
between CN413 (fernall
eplace
Is voltage (4) - CN361 (8) - CN214 1
YES between CN413 - CN2 (female) (5)
z
(4) and (1)
1 normal? Go to E mode (E-2b)
(Abnormality in APS -
Does display go *13-3ov NO system)
out when CN2 is - . Turn starting switch ON.
disconnected? . Turn APS switch ON.
* Water temperature: Max. 20°C
. Disconnect CN2.
. Turn starting Defective monitor panel
switch ON. [monitor module)
* Turn APS switch
ON.
-Water
temperature:
Max. 20°C
M-6. Related electrical circuit diagram
CN413 CN361 CN214 CN2 Monitor Panel

nr= L”llll”l ICI I...,._^\
(SWP 16) (SWPl 6) (04008)] Monitor module
Preheat ine _ Preheating

lamp sianal
GND
I-
BKD00689
20-413
0
TROUBLESHOOTING M-7
M-7 Abnormality in buzzer

* Of the Caution items, the buzzer does not sound if there is an abnormality in the battery charge.
a) Caution item flashes but buzzer does not sound or

buzzer does not sound for 1 sec. when starting
switch is turned ON (engine stopped)
, YES Defective monitor panel

Replace
1 (monitor module)
Does buzzer sound
when CN2 (female) _
(8) is connected to disconnection in wiring
chassis ground? harness between fuse 13 -
CN411 (3) - CN361 (2) - Repair or
* Connect CN2 NO CN215 (2) - CN217 (female) replace
(female) (8) to (I), or between CN217
chassis ground. (female) (2) - CN2 (female)
. Turn starting (8). or defective buzzer
switch ON.
b) Monitor display is normal but buzzer sounds Cause Remedy

Replace
(monitor module)
Does buzzer stop
when CN2 is Short circuit with chassis
disconnected? ground in wiring harness
between CN2 (female) (8) 8e$~~eor
NO and CN217 (female) (2). or
* Disconnect CN2.
* Turn starting defective buzzer
switch ON.
I
CN215 CN361 CN411

(SWP16) (SWP16) (SWP14)
C\217 (X2)
Monitor Panel
Buzzer
ICN2
(04008)
Jution buzz1 1 1
Battery relay
BKD00690
20-414
0
TROUBLESHOOTING M-8
M-8 Abnormality in warning lamp

j, Always connect any disconnected connectors before going on to the next step.
a) Caution item flashes but warning lamp does not

flash, or when starting switch is turned ON (engine
stopped), warning lamp does not light up for 1
second.
*
11 Replace
(monitor module)
Does warning lamp
light up when CN2
(female) (7) is
connected to
chassis ground? harness between fuse 13 -
CN411 (3) - CN361 (2) - CN Repair or
- Connect CN2
NO 215 (2) - CN375 (female) (1). replace
(female) (7) to or between CN375 (female)
chassis ground. (2) - CN2 (female) (7). or
* Turn starting defective warning lamp
switch ON.
b) Monitor display is normal but warning lamp lights up

Cause Remedy
8
-
%
z
Replace
Does warning (monitor module)
lamp go out
when CN2 is Short circuit with chassis
disconnected? ground in wiring harness
Repair or
between CN2 (female) (7)
+ Disconnect CN2. No replace
and CN375 (female) (2). or
-Turn starting defective warning lamp
switch ON.
CN215 CN361 CN41 1

(SWP 16) (SWPI 6) (swPl4)
CN375 (X4)
Monitor Panel
ICN2
(04006)
Battery relay
BKD00691
20-415
0
TROUBLESHOOTING M-9
M-9 Abnormality in gauge

* Before carrying out troubleshooting, check that all the related
connectors are properly inserted.
* Always connect any disconnected connectors before going on
to the next step.
a) Abnormality in engine coolant temperature gauge

Check sensor
Defective engine coolant
1 YES (see STANDARI
_ temperature sensor
When short connector VALUE TABLE),
system
is connected to CN replace
402, does 9auge
indicator move to end _ Defective contact or
of high temperature disconnection in wiring
range, does caution
lamp flash, and does harness between CN402
buzzer sound? (female) (1) - CNlOl (13) - IRepair or
NO CN421 (1) - CN214 (9) - replace
* Connect short
CN2 (female) (1). or
connector to
between CN402 (female)
CN402 (female).
(2) - chassis ground
*Turn starting
switch ON.
CN2 CN214 CN42l

Monitor Panel Ensin water
I (04008) (SWPl6) (SWPl6) CNlOl (SWPl6) CN402 (X2)
temperature sensor
Ensin water
temperature
I I
7A- BKD00686
If the condition is as shown below, it is normal. Engin water

Connector temperature sensor
BKD00692
Remedy
b) Abnormality in power train (torque converter) oil
temperature gauge
Check sensor
c
YES [see STANDARC
(torque converter) oil
VALUE TABLE),
When short connector temperature sensor system
is connected to replace
CN453, does gauge
indicator move to end
of high temperature
range, does caution disconnection in wiring
lamp flash, and does harness between CN453
buner sound? (female)(l)-CN451 cl)- Repair or
--I
- Connect short CN421 (7) - CN214 (IO) - replace
connector to CN2 (female) (2). or
CN453. between CN453 (female) (2)
* Turn starting - CN451 (2) - chassis ground
switch ON.

Monitor Panel CN2 CN214 CN42 I
1 (040081 (SWPI 6) (SWPI 61 CN451 (SWP14) CN453 (X2) Torque converter oi I
temperature sensor
Toraue converter
oil temperature lo- l- I \T
I 2 2
I- c-
77+7-u-.-J I \ I
If the condition is as shown below, it is normal. BKD00667
20-4 16
0
TROUBLESHOOTING M-9
c) Abnormality in fuel level gauge

Cause Remedy
(1) Fuel level gauge always shows FULL
F= Check sensor
2 YES Defective fuel level
(see STANDARD
YES Does fuel gauge sensor system VALUE TABLE),
go below EMPTY
mark when CN423 Short circuit with chassis
1 ground in wiring harness
p is disconnected? Repair or
Does fuel gauge ~ 3 between CN423 (female) (1 replace
* Disconnect NO - CN422 (1) - CN421 (6) - CN
go below EMPTY
- CN423. 214 (11) - CN2 (female) (3)
mark whien CN2
* Turn starting
is removed?
switch ON.
- Remove CN2.
. Turn starting
(monitor module)
switch ON. NO
-Wait for approx.
1 minute.
(2) Fuel level gauge always shows E or below

Remedy
Zhecksensor
Defective fuel level see STANDARI
sensor system /ALUE TABLE),
Does fuel gauge @J
YES above FULL mark Defective contact or
- when short disconnection in wiring
connector is
z 1 connected to CN423?
(female) (1) - CN422 (1) - qepair or
Does fuel gauge go * Connect short .eplace
*NO CN421 (6)- CN214 (II)-
above FULL mark connector to
when CN2 pins (3) - - CN2 (female) (3), or
CN423. between CN423 (female) (2)
(4) are short
circuited? * Turn starting - CN422 (2) -chassis ground
switch ON.
* Short circuit CN2
pins (3). (4). Defective monitor panel
<eplace
*Turn stairting NO (monitor module)
switch ON.
* Wait for approx.
1 minute.
M-9. c) Related electrical circuit diagram
Monitor Panel CN2 CN214 CE(42 1

Fuel level sensor
CN422 (X2) CN423 (X2)
Fuel level
Preheat GND
TKD00717
TOP (FULLI
Bottom(EMPTY1
Fuel level sensor TKD00694
20-417
0
TROUBLESHOOTING M-10
M-10 Service meter does not move after engine is started

Ir Always connect any disconnected connectors before going on to the next step.
1 YES -
See M-5 a)
Does charge
abnormality
display flash?
Defective monitor panel Replace
* Start engine. NO
Monitor Panel CNl CN214 CN42 1 CNlOl

(SWP 16) (SWPl 6)
FUSS
Alternator
r\ I
BKD00684
20-418
0
TROUBLESHOOTING M-l 1
M-II Monitor panel lighting does not light up (front lamp, working
lamp are normal)
Jr Check the lamp visually to check that the bulb is not blown. (If it is blown, replace the lamp.)
Jc Always connect any disconnected connectors before going on to the next step.
* When fuse 14 is normal.
Cause Remedy

Replace
(monitor module)
Is voltage between
CNSOZ (1). CN4 (1)
, CN5 (1) -chassis YES harness between CNS02 Repair or
(female) (I), CN4 (female) replace
(I), CN5 (female) (1) -
-2O-30V Is resistance CN215 (male) (3). (5)
-Turn starting
switch ON. Defective contact or
. Turn front lamp, disconnection in wiring
working lamp * Max. 1.D harness between CNS02 Repair or
switch ON. *Turn starting (female) (2). CN4 (female) replace
switch OFF. (2). CN5 (female) (2) -
- Disconnect CN215 (male) (12)
CNS02.CN4, and CN5.
8
z
5 M-l 1. Related electrical circuit diagram
Head. lam!.
uorklne lamp switch
Workino lame
BKO00695
20-419
0
TROUBLESHOOTING OF ELECTRICAL SYSTEM
(E MODE)
Electrical circuit diagram for starting and APS system .................................................................... .20-502
Electrical circuit diagram for inside operator’s cab.. .......................................................................... 20-503
E- 1 Engine does not start ............................................................................................................... 20-504
E- 2 Defective operation of APS ...................................................................................................... 20-506
a) Preheating monitor lamp does not light up during preheating ................................... .20-506
b) Preheating monitor lamp stays lighted up after preheating is completed.. ................ 20-506
c) Preheating monitor lamp flashes after preheating is completed ................................. .20-507
d) Preheating monitor lamp lights up when engine is started

(starting switch at START) after preheating is completed ............................................ .20-507
e) APS is not actuated when water temperature is below 20°C.. ..................................... .20-508
f) APS is actuated when water temperature is above 20°C.. ............................................ .20-510
g) APS is actuated when water temperature is below 20°C

but APS switch is not turned ON ...................................................................................... 20-510
E- 3 Defective operation of back-up alarm ..................................................................................... 20-511
a) Back-up alarm does not sound ......................................................................................... 20-511
zz b) Back-up alarm does not stop sounding ........................................................................... 20-511
%
;; E- 4 Lamps do not light up .............................................................................................................. 20-512
a) Front lamps ......................................................................................................................... 20-512
b) Working lamps .................................................................................................................... 20-512
c) Rear lamps (ripper lamp) ................................................................................................... 20-514
E- 5 Wiper does not work ................................................................................................................ 20-516
E- 6 No washer fluid is sprayed out ............................................................................................... 20-518
E- 7 Air conditioner has no effect ................................................................................................... 20-520
a) No air comes out ................................................................................................................ 20-520
b) Does not become cool ....................................................................................................... 20-524
E- 8 Pin-puller cylinder does not work (only machines equipped with giant ripper). .............. 20-528
E- 9 Blade pitch does not work (dual tiltdozer specification). ..................................................... .20-530
E-10 Blade dual tilt does not work (dual tiltdozer specification) ................................................. .20-532
E-l 1 Torque converter lock-up does not work
(torque converter lock-up display lamp does not light up) ................................................. .20-534
E-12 Torque converter lock-up is not cancelled
(torque converter lock-up display lamp stays lighted up). ................................................. .20-536
a) Lock-up display lamp does not go out.. .......................................................................... .20-536
b) Lock-up display lamp lights up but lock-up is not actuated ......................................... .20-536
20-50 1
a
TROUBLESHOOTING ELECTRICAL CIRCUIT DIAGRAM FOR STARTING AND APS SYSTEM
ELECTRICAL CIRCUIT DIAGRAM FOR STARTING AND APS SYSTEM
AEX4OB 161
APS switch
Starting switch
qqppd- 213
Battery (NS200X2)
214
lSWP16)
Start ine
limit switch
APS water
temperature
sensor
APS controller TDD00696
20-502
0
TROUBLESHOOTING ELECTRICAL CIRCUIT DIAGRAM FOR INSIDE OPERATOR’S CAB
ELECTRICAL CIRCUIT DIAGRAM FOR INSIDE OPERATOR’S CAB
Left wiper
Washer wiring
harness
Room lamp
I Rear Wiper
I Antenna
Left wiper
Rear speaker (R. H.
Front wiper Additional

lamp pick-up
CN-1
0 Earth
0 Front wiper
cN-9 motor
Right wiper
Siaer lighter
Rear wiper
switch Additional
I lamp pick-up
w m
CN-7
Right wiper
Front lamp
Rear lamp
ACC Power sourse CN-204 “;

Battery Power sourse CN-21 Q ’ TDD00697
20-503
a
TROUBLESHOOTING E-l
E-l Engine does not start

When an abnormality occurs and the system returns to normal when the connector has been
disconnected and a T-adapter inserted, or when the T-adapter has been disconnected and the
connector connected, the system has been reset.
Always turn the starting switch OFF before disconnecting the connector
YES
or connecting the T-adapter (or socket).
5
Before carrying out troubleshooting, check that all the
related connectors are properly inserted. Is voltage
YES_ between CN152 _
Always connect any disconnected connectors before (3) and chassis
going on the next step. 4 normal?
Carry out troubleshoot- Is voltage
YES_ between CN152 _ *20-30V
ing with the safety lever (1) and chassis
* Turn starting NO
3 switch ON.
at the LOCK position, the normal?
parking brake lever at the Is resistance
-2O-30V
LOCK position, and the YES_~~~~~~~~~d - -Turn starting
NO
joystick at the neutral switch ON.
(3) normal?
position.
2 * Max. 1R
Is sound heard . Disconnect
YES_ from battery relay _ CN214 and turn NO
when battery relay starting switch ON.
is turned OFF?
YES
*Turn starting
switch ON oOFF
L battery relay
NO terminal BR and 9 YES
chassis normal? _ Is resistance
between CN214
*20-30V
NO (female) (13) and
. Turn starting
(14) normal?
switch ON.
NO
- Max. 1.Q
- Disconnect
CN214 and turn
starting switch ON.
I
NO
E-l. Related electrical circuit diagram

Battery relay
Battery
START o~-~~~
B BR RI R2 C ACC
Start in@ switch
x- BKD00698
20-504
0
TROUBLESHOOTING E-l
Cause Remedy
7 YES
Go to S mode (S-2)
Defective alternator leplace

~
harness between CN152 lepair or
f 20 - 30 v I
NO (female) (3) - CNS08 (10) - eplace
-Turn starting CNIOI (6) - CN103 (1).
switch ON. - CN104 (1)
Defective neutral safety
leplace
switch
lepair or
eplace
Defective starting switch

leplace
(between B - C)
Defective battery relay leplace
repair or
eplace
(male) (14) - CN421 (14) -
battery relay terminal BR
Defective starting switch

leplace
(between B - BR)
:harge or
Drop in battery capacity
eplace
20-505
0
TROUBLESHOOTING E-2
E-2 Defective operation of APS

al Preheating monitor lamp does not light up during preheating
* Carry out troubleshooting for M-6 a) first.
* When an abnormality occurs and the system returns to normal when the connector has been
Only when the water temperature is below the specified temperature (below 20°C).
Always turn the starting switch OFF before disconnecting the
connector or connecting the T-adapter (or socket). Cause Remedy
Before carrying out troubleshooting, check that all the related
Always connect any disconnected connectors before going on
the next step. 3 YES
Defective APS controller qeplace
Is voltage
YES
-
_
Does APS work
nOrmally when frOnt
lamp switch and
YES
-
between CN412
(1) and chassis
normal?
-2O-30V
-Turn starting
H NO
(female) (3) CN215 (3) - CF
381 (7) - CN412 (female) (I)
Repair or
COnneCtOr
are switch ON.
1 interchanaed?
-Turn APS switch ON.
* Turn starting
Defective APS switch
Does front lamp switch ON. NO
liaht UD? - -Turn front lamp
- ’ 11 ;Gt;it;Jii;ead
* Turn starting Defective contact, or
1
switch ON.
*When battery harness between starting Repair or
NO switch terminal BR and
relay, front lamp
are normal CN213 (female) (2)
b) Preheating monitor lamp stays lighted up after preheating is completed

* When an abnormality occurs and the system returns to normal when the connector has
been disconnected and a T-adapter inserted, or when the T-adapter has been discon-
nected and the connector connected, the system has been reset.
Always turn the starting switch OFF before disconnecting the
connector or connecting the T-adapter (or socket). Cause Remedy
Always connect any disconnected connectors before going on
the next step. Defective APS controller Replace
Wiring harness between

CN412 (female) (2) - CNIOI
(1) -CN102 (female) (1). or
Repair or
between CN412 (female) (3) -
*Min. 1 M R NO veplace
CNlOl (II)-CN102Vemale)
* Turn starting (4) short circuiting with
(male) (1). (4) switch OFF.
chassis ground
* Disconnect
CN102 and CN412. Wiring harness between
*Turn starting CN102 (male) (I) - glow plug Repair or
glow plugs 1 and switch OFF. 1, or CN102 (male) (4) -glow replace
NO plug 2 short circuiting with
* Disconnect CN102.
chassis ground
.0.8-1.3R
*Turn starting Defective glow plug 1 or Repair or
switch OFF. NO glow plug 2 (plug which replace
* Remove glow plug.
20-506
0
TROUBLESHOOTING E-2
Preheating monitor lamp flashes after preheating is completed

When an abnormality occurs and the system returns to normal when the connector has been
Always turn the starting switch OFF before disconnecting the connector or connecting the T-
adapter (or socket).
Before carrying out troubleshooting, check that all the related connectors are properly inserted.
Always connect any disconnected connectors before going on the next step.
*
2 YES
Defective APS controller Replace
Is voltage between
YEz CN413 (2) and Defective contact. or
1 chassis normal? disconnection in wiring
Isvoltagebetween harness between APS water Repair or replace
APSwater NO
. Max. 1 V temperature sensor terminal
temperature SellSOr -
terminal and chassis - Turn starting and CN413 (female) (2)
IlOrIWl? witch ON.
- Turn APS switch ON.
- Max. 1 V Defective Aps water
Replace
- Turn starting NO temperature sensor
switch ON.
- Turn APS switch
ON.
-.
;; d) Preheating monitor lamp lights up when engine is started (starting switch at START) after
preheating is completed
Always turn the starting switch OFF before disconnecting the connector or connecting the T-
Always connect any disconnected connectors before going
on the next step.
Replace
Is resistance between
YES CN412(female)(4)
and CN102(female)
(2) normal? Wiring harness between
2
CN412 (female) (4) CNlOl Repair or replace
Is resistance NO (7) - CN102 (female) (2) shor
* Min. 1 MD
YES betweenCN102 _
-Turn starting
(male) (2). (3) - switch OFF.
1 chassis normal?
- Disconnect CN102
- Min. 1 MR and CN412. Wiring harness between
eachAPSnozzle _ -Turn starting CN102 (male) (2). (3) - APS tepair or replace
terminaland chassis NO
switch OFF. nozzle terminal short
- Disconnect APS nozzle
terminal and CN102.
- Min. 1 MD
-Turn starting Defective AF’S nozzle 3eplace
NO
switch OFF.
- Disconnect APS
nozzle terminal.
20-507
0
TROUBLESHOOTING E-2
el APS is not actuated when water temperature is below 20°C

* Always turn the starting switch OFF before disconnecting the connector or connecting the T-
* Always connect any disconnected connectors before going on the next step.
YES
I
5
Is resistance
YES between glow plug
terminal I, 2 and
chassis normal?
4-
-0.8-1.3R
YES Is resistancebetween
-Turn starting switch
_ CN412 Vemale) (4) _
and CN413 (female) OFF.
NO
(1) normal? - Disconnect glow
- plug terminal.
P 3 -1.5-25R
Is resistanca -Turn starting switch
YI . betweenCN102 _ OFF.
(male) (2) and (3) - DisconnectCN412 No
normal? and CN413.
2
- I.5 - 2.5 R
Is resistance of I
YlIS -Turn startina switch
both ends of APS OFF. ” I
nozzle normal? - DisconnectCNI02. NO
l---l
I I
1 *3-5R
*Turn starting switch
OFF.
CN413 (31 and (I)
IO
- Disconnect APS
nozzle terminal.
-Disconnect CN103
and CNIO4.
-2o-3Ov 1,
i 1 between CN413
-Turn starting
switch to START. ““1~~n’;;;;~? 1
*MaxID NO
*Turn starting switch
OFF.
- Disconnect CN413
and CNIOI.
20-508
0
TROUBLESHOOTING E-2
Cause Remedy
7. YFS
.-_
Defective APS controller Replace
Is resistance
YES betweenCN412 _
Defectfveamtxtor
(female) (2), (3) and
disconnectionin wiring hame~
6 chassis normal? Repair or
I I bstwaen CN412 &na!e) (2) -
NO CNlOl(l)-CN102(female)(l), replace
between CN102 or between CN412 @-nab) (31
(male) (l), (4) and CNIOI (II)-CNlO26emale)(4
Defec&eaxtact,or
-0.8-1.342 diinnecti~ in tiring hames
Repair or
*Turn starting I xtween CN102 (male) (1) and
NO reolace
switch OFF. glowplug l,orbeb%eenCN10
- Disconnect Imale)(4) and glow plug 2
CN102.
Iefective glow plug 1 or
yaw plug 2 Replace
Mxtivecontactor
&connection in tiring hames
Mween CN412 (female) (4) - Repair or
:NlOl t7)-CN1026emaks) (2). replace
xbetween CN413M?ak?) (1)
:N101(8)-CN1026emale) (3)
IafeWecontector
Repair or
dkconnectionin wiringhames
replace
Etwaen CNlO2 Vemaie) (2), (3
sndAPS nozzleterminal
Replace
(part where
Defective APS nozzle
resistance value
is abnormal)
Iefective contact, or
5sconnection in wiring
Repair or
iarness between CN413
replace
female) (3) - CN361
male) (10).
Hxtivecontact,or
kconnection in witirg hames Repair or
xztv.een CN413 knale) (1) - replace
zhassis
20-509
TROUBLESHOOTING E-2
fl APS is actuated when water temperature is above 20°C

cause
2 YES
DefectiveAFS amtroller ?eplace
Isresistance
YES teweenCN413
Wiling harness between
r (female) (2) and
CN413 (female) (2) - CNlOl(121
1 Ichasianoml? 11
-water temperature sensor Gpair or replace
NO terminalshoftdrcuitingwith
. Min. 1 MQ
*Turn startingwitch chassisground
OFF.
~DisxnlnectcN413
*Min. 1 MQ
Cefectivewatertemperature
*Turn stating witch Repbce
sensor (internalshort circuit)
OFF.
* Cisconwctwter
temperature sensor
terminal
cl) APS is actuated when water temperature is below 20°C but APS switch is not turned ON
2 YES
lMe&e APScontroller Rep!ace
YES lsvoltagewn
- CN412Il)and Contact of power source
chassisno-l? wiring harness (+24Vl with
1
wiring harness between Repairor replace
Isresistance NO CN213 (female) (3) - CN215 t7) -
.Max_lV
bebwenCN213 -Disconnect CN213 CN361(7) - CN412 (female)(1)
(male) (2) and (3) and CN412.
normal? -Tumstartingwitch
ON.
*Max.lR
. DsconnectCN213. EefectiveAFSswitch(intemal
~TumAFSswitchON. in shalt circuit)
*Tumstartingswitch ‘-_
OFF.
20-510
0
TROUBLESHOOTING E-3
E-3 Defective operation of back-up alarm

J, Before carrying out troubleshooting, check that all the related connectors are properly inserted.
Ir Always connect any disconnected connectors before going on the next step.
a) Back-up alarm does not sound
Defectivebackup alarm @IaCe

1
ls~ltagebetween Defectivecontact or
cN244eemaid(1) _ disconnectionin wiring
YES wiring
+52peplace
and chassis harnessbetween CN244
2 WlWSS
nom-A? (female)(1) CN431 (1) CN451
(IO) - CN251 M-rale) (3)
!svokagebetwean
~Tumstartingswitch - CN251 Band
ON. NO chassisnormal? 3 YES Defectiveback-upalarm switch
Fieplace
-Joystick R (reverse) (internaldisconnection)
*20-3ov p lsvoitagebstween
. Turn sating switch N; CNZl(l)and
ON. chassisnormal? Defectivecontact or
disconnectionin widng hames Replacewiring
.Joystfdc R (reverse)
NO betweanfuselO-CN411(6)- harness
*2O-3Ov *Turnstartingswitch
CN451(6) - CN251 @xnale) (1)
ON.
.26- 3Ov
b) Back-up alarm does not stop sounding 1 Cause Remedy
Defective back-up alarm

YES switch (internal short Replace
1 circuit)
Does alarm stop
when CN251 is -
2 ti
YES Defective back-up alarm
disconnected? Replace
Is voltage between
CN251 (female) (3),
*Turn starting Power in wiring
short
NO CN244 (female) (I)
switch ON. harness between CN244
and chassis normal? Repair or
(female) (1) - CN431 (1)
NO CN451 (10) - CN251 replace
. Turn starting
switch OFF. (female) (3)
* Disconnect
CN244 and CN251.
. Turn starting switch
ON.
* Max. 1 V
E-3. Related electrical circuit diagram

CR41 1 (SWP14) Fuse
10
Back-up alarm CN45 1
limit switch 10A
(SWP14)
I ,
EKD00699
TROUBLESHOOTING E-4
E-4 Lamps do not light up

Ir When battery is normal.
* Check that fuse 14 is normal before carrying out troubleshooting.
a) Front lamps
YE CN203 (female) (1)

or CN204 (female)
(1) -chassis normal?
-2O-30V 10
*Turn starting
switch ON.
1
-Turn front lamp and 5 YES
working lamp switch ON.
Is voltage
panel lamp light YE between CN216
4 (female) (3) and
chassis normal?
*Turn starting YE CN216 (female) (2),
switch ON. * 20 - 30 v
CN376 (female) (3) -
chassis normal? * Turn starting
switch ON.
Is resistance of relay *20-30V * Turn front lamp and
connector CN376 for working lamp switch ON.
*Turn starting
front lamps and
h switch ON.
JO
-Turn starting
switch OFF.
* Disconnect
CN376.
Table 1
t CN376 (male) 1 Resistance value 1 Remarks I
Between (I) and (2) 1 290 2 29 fi 1 Connect (+) pole of tester to (1) and (-) pole of tester to (2)
Between (3) and (5) 1 Max. 1 Q
1 Between (3) and (6) 1 Min. 1 MR I
b) Working lamps
cause
2 YES Defective working lamp, or

Iepair or replace
Is voltage between defective contact of ground
YE ; CN221 (female) (1)
and chassis
1 normal? disconnection in wiring
harness between CN221 lepair or replace
NO (female) (1) and CN361
Doesfront lamp *20-3ov
. Turn starting (female) (3)
switch ON.
. Turn front lamp and
-Turn starting switch working lamp switch ON.
ON. Go to M-.I1 a)
*Turn front lamp JO
and working lamp
switch ON.
20-512
0
TROUBLESHOOTING E-4
Cause
Remedy
1
Repair or
(female) (I) or CN204 (female
replace
(I) - CN202 (I) - CN201 (2) -
CNIOI (3) - CN361(5) - CNPIE
(5) - CN376 (female) (5)
Repair or
replace
Repair or
replace
(female) (3) - CN216 (female)
(21,CN215 (male) (6)
Defective front lamp, Repair or

working lamp switch replace
Defecfb contact or
Repair or
harness between fuse 14 - CF
replace
411 (male) (2) - CN361 (6) - Cb
215 (6) - CN376 (female) (3)
Defective front lamp, Repair or

working lamp relay replace
E-4. a), b) Related electrical circuit diagram Head lamp.

working lamp switch
Monitor Panel
Liuht ina
signal
1
GND
IIll 1
Liohtino
sional
1CN361 CN215 1 1 1 t--l31 2 GND
Left
head lamp CN41 1
(SWP14) Fuse
II
EKD00695
20-513
0
TROUBLESHOOTING E-4
c) Rear lamps (ripper lamp)
Cause Remedy
Rear lamp which does not

YES (epair or
light up is defective, or there
eplace
is defective contact in wiring
YE
~ Defectivecontact or
disconnectionin wiring
2 harness between CN223 lepair or
I
* 20 - 3ov (female) (1) fCN243 (female) eplace
NO
* Turn starting (1)) - (CN431 (2)) - CN361 (1) -
(3) and chassis switch ON. CN215(1)- CN211 (female) (3)
-Turn rear lamp
switch ON.
-Turn starting
switch ON.
between CN211 Defective rear lamp leplace
* 20 - 3ov
(2) and chassis switch
*Turn rear lamp
switch ON.
* Turn starting disconnection in wiring
switch ON. lepair or
NO eplace
CN411 (3) - CN361 (2) - CN
215 (2) - CN211 (female) (2)
E-4. c) Related electrical circuit diagram
Left rear CN361 CN215 CN21 1

lamp (SWP 16) fSWPi3) fKES4) Rear lamp’
switch
3
3
Battery relay
BKD00700
20-514
0
TROUBLESHOOTING E-5
E-5 Wiper does not work

* When the battery is normal.
* Before carrying out troubleshooting, check that the fuse for each wiper is normal.
Does it work if
YE
4 d
YES switch is
interchanged with
another wiper
switch?
-Turn starting
switch ON.
-Turn wiper NO
where wiper doas
switch ON.
% When other
-Turn starting wipers are normal.
YE switch ON.
Do other wipers
-Turn washer
work? NO
switch ON.
t
Note 1) 2 % When washers
* Turn starting are normal.
YE between starting switch ON.
switch terminal B - Turn wiper switch
ON.
Note 1) 1 .X When other
-Turn starting wtpers are normal.
make a noise when switch ON. z
- Remove terminal ;5
IO
B.
- Turn starting
switch ON+OFF.
Note I) If the lamps (front lamps, rear lamps) or horn circuit are normal, it is
possible to check instead if the lamps light up normally or if the horn
sounds normally.
Note 2) This troubleshooting flowchart uses the left wiper as an example. For
the other wipers, the connectors corresponding to CNII are as shown
in the table below.
Wiper Left wiper Front wiper Right wiper Rear wiper

Connector No. in cab [ CNII 1 CN12 1 CN13 1 CN14
20-5 16
0
TROUBLESHOOTING E-5
Cause Remedy
YES
1 Defective wiper motor Replace
Note 2) fi\
I
Check connector
directly in front of
Defective wiper arm
NO
connector terminal
1 (male) (2) and (3) (for

front wiper: (5) and (2)
for rear wiper: (1) and
10)
-Max. 10R
)
NO
Note 2)
harness between CNll
Repair or
replace
(female) (1) at cab end
-Turn starting and CN18 (female) (2)
switch OFF.
Replace
Repair or
replace
Defectivecontact or
disconnectionin tiring hames Repair or
between battery relay M and replace
fuse box terminal Bat cab end
!I Defective starting switch Replace
Defective battery relay Replace
20-5 17
0
TROUBLESHOOTING E-6
E-6 No washer fluid is sprayed out

* When the battery is normal.
* Before carrying out troubleshooting, check that the fuse for each wiper is normal.
YES
1 YES
Dosswasher
motorrotate? (Can 5
a rotatingsound be
Does wiper work
heardimmmotor7)
YES at place where
- no washer fluid -
*Turn starting
switch ON. 4 comes out?
*Turn washer * Turn starting
switch (wiper YES Do other switch ON.
switch) ON. - washerswork - *Turn wiper
normally? NO
switch ON.
Note I)
3 - EWhenother
Is there continuity *Turn starting
wipers are normal.
YES between starting switch ON.
switch terminal B . Turn washer
switch ON. NO
and BR?
Note 1) 2
.X When other
Is sound of battery *Turn starting washers are normal.
relay heard when _ switch ON.
NO starting switch is
. Remove terminal NO
turned OFF7
B.
* Turn starting
switch+ ON
NO
Note 1) If the lamps (front lamps, rear lamps) or horn circuit are normal, it is possible to
check instead if the lamps light up normally or if the horn sounds normally.
For left rasher CN367.

For rioht washer CN363
For front washer CN361
For rear rasher CN364
Washer CR*** Fuse box
M_
For left Washer Cab end CNll
For right rasher Cab end CN13
For front washer Cab end CN12
I I L For rear washer Cob end CN14
Wiper switch TDD00703

20-51.8
0
TROUBLESHOOTING E-6
Cause Remedy
1
Lack of water, clogged
Rc?pair or
nozzle, or defective water
re place
piping
8 YES
Defective washer motor RIsplace
II
YES Is washer motor
- properly
7
~- grounded?
Is voltage RIapair or
between CN360 NO reiplace
at cab end and
chassis normal? Note 2)
Does it work if switch RIepair or
.20-30V disconnection in wiring
is interchanged with re!place
*Turn starting NO harness between CN360 at
anotherwasher
witch Wiper
switch ON. cabend-CNll atcabend
switch)? * Turn washer
switch ON.
*Turn starting Defective washer switch RN
eplace
switch ON. IO (wiper switch)
*Turn washer
switch ON.
Note 2)
.x When other
switches are normal. disconnection in wiring
Repair or
hamass between CNl l(2)a t rrtplace
cab end -fuse at cab end
Dafactivecontactor
disconnectionin wiring Repair or
hamess b&veen battery relq ,- re3place
fuseboxterminaIBatcabenc i
~Defective starting switch Replace
Defective battery relay R;eplace
Note 2) This troubleshooting flowchart uses the left washer as an example. For
the other washers, the connectors corresponding to CNI 1 in the cab are
as shown in the table below.
Wiper Left wiper ( Front wiper 1 Right wiper 1 Rear wiper

Connector No. in cab 1 CNII ) CN12 ) CN13 1 CN14
20-519
0
TROUBLESHOOTING E-7
E-7 Air conditioner has no effect

* When battery and battery relay are normal.
* Check that fuse (FB2) No. 3 is normal before carrying out troubleshooting.
a) No air comes out

(ES
5
Is continuity
YEz between CN395 .
(4) (female) and
4 chassis normal?
Is continuity
* Max. 1 R
. between blower _
* Turn starting
switch terminals as VO
switch OFF.
3 shown in Table 1
. Turn starting
switch OFF.
(3) and chassis NO
- Disconnect
CN395.
Is resrstance
* Turn starting
(male) (I) and (3) F
switch ON.
-240t40~r
between CN391
* Turn starting
(1). (2) and chassis
switch OFF.
- Disconnect
CN391.
* Turn starting I
switch ON. NO
Table 1
20-520
0
TROUBLESHOOTING E-7
Remedy
6 YES - -
c Go to A on next
Is voltage
- between CN391 -
(4) and chassis
Defective air conditioner
relay
Redace
-Turn starting NO
switch ON.
* Blower switch:
Any position
disconnection in wiring Repair or
harness between CN395 replace
(4) and chassis
j/ Defective blower switch
i / zr air conditioner 1Replace
Repair or
replace
20-521
0
TROUBLESHOOTING E-7
11 YES
Is continuity
YES_ between CN394 _
(I) and CN395
10 (2) normal?
Is continuity * Max. 1 R NO
YE?. between CN394 _ . Turn starting
(3) and chassis switch OFF.
9 normal? * Disconnect
Is resistance CN394 and CN395
YE between CN394 * Max. 1 R
- (male) (2) and Cl), - * Turn starting
or between (2) and NO
switch OFF.
a (3) normal
- Disconnect
- Between (2) and CN394.
(1): 1 + O.lR
motor rotate? - Between (2) and NO
7 (3): 3 * 0.3 R
-Turn starting switch OFF.
. Turn starting * Disconnect CN394.
A between CN392 I.
switch ON.
(1) and chassis * Blower switch:
Any position
*20-30V
* Turn starting
switch ON.
- Blower switch:
Any position
except OFF
20-522
a
TROUBLESHOOTING E-7
Cause Remedy
Go to b) -
Repair or
harness between CN394 replace
(female) (1) and CN395
(female) (2)
Repair or
I harness between CN394
replace
(female) (4)
Defective blower resistor Replace
Defective blower motor Replace
Repair or
replace
(female) (4)
20-523
TROUBLESHOOTING E-7
bl Does not become cool
YES
5
Is continuity
YE S between CN397
- (2) (female) and -
CN398 (3) (female)
A
normal?
- Max. 1 R
YE between CN397 * Turn starting
switch OFF. NO
(male) (3) and (2)
- Max. 1D
YE -Turn air
between CN397
conditioner NO
switch ON.
2 * Disconnect
Is continuity - Max. 1 R CN397.
YES between CN397 -Turn starting
(male) (3) and (I) switch OFF. IO 8
1 normal? %
z
Is voltage - Max. 1 R
between CN397 -Turn air
(3) and chassis conditioner
IO
normal? switch ON.
* Disconnect
*20-30V CN397.
- Turn starting I
switch ON. NO
20-524
0
TROUBLESHOOTING E-7
Cause Remedy
7 YES -
Go to B on next
jIs
YES between CN398
tepair or
eplace
(female) (3)
Defective magnet relay

-Turn starting NO
cwitrh OFF
tepair or
harness between CN397 eplace
(male) (2) and CN398
(female) (I)

switch
Xepair or
eplace
(male) (1) and CN396
(female) (2)

Replace
switch
Iepair or
harness between fuse 15.
.eplace
CN411 (1) - CN361 (16) -
CN215 (14) - CN398 (2)
20-525
0
TROUBLESHOOTING E-7
12 YES
Is voltage
YES between CN351 _
(1) and chassis
normal?
_ 11 .20-30V NO
Is voltage *Turn dual
YES between CN393 _ pressure switch
(4) and chassis ON.
normal? . Turn thermostat
10 switch ON.
- *20-30V See Note 1).
Is voltage *Turn dual
YES_ between CN393 _ pressure switch
(1) and chassis ON. NO
normal? . Turn thermostat
9 switch ON.
.20-30V
See Note 1).
Is voltage . Turn starting
YEs between CN391 _ switchON.
(4) and chassis . Blower switch: NO
normal? Any position
8 except OFF.
~* *20-30V -Turn air conditioner
Is voltage *Turn starting switch ON.
between CN398 _ switch ON.
B- (2) and chassis * Blower switch: NO
ground normal? Any position
except OFF.
* 20 - 3ov *Turn air conditioner
*Turn starting
switch ON.
switch ON.
NO
Note 1) Dual-pressure switch ON-OFF switching pressure

Pressure in refrigerant circuit:
High-pressure side
OFF at 2.6 MPa I27 kg/cm? (when increasing)
ON at 2.1 MPa (21 kg/cm21 (when decreasing)
Low-pressure side
OFF at 0.21 MPa f2.1 kg/cm21 (when decreasing)
ON at 0.23 MPa (2.35 kg/cm21 (when increasing)
l Thermostat switch ON-OFF switching temperature
Evaporator discharge temperature:
OFF at above 1°C (when increasing)
ON at below 4.5X (when decreasing)
20-526
0
TROUBLESHOOTING E-7
Remedy
lepair or
eplace
I
disconnection in wirina
harness between CN393 Xepair or
(female) (4) - CN215 (13) - ‘eplace
CN361 (15) - CNIOI (5) -
CN351 (female) (I)
Defective dual pressure

Replace
switch
3epair or
.eplace
(female) (I 1
Defective magnet relay Replace
7epair or
harness between fuse I5 -
.eplace
CN411 (I) CN361 (16) -
CN215 (14) - CN398 (2)
20-527
0
TROUBLESHOOTING E-8
E-8 Pin-puller cylinder does not work (only machines equipped with
giant ripper)
* Check that fuse 15 is normal.
Cause
Iefective contact, or
7arnes.s between CN224 eplace wiring
Is resistance
1 YES :female) (2) and chassis harness, or
between CN224 ground, or defective C orrect
YES (male)(1)and (2L actuation of solenoid

between (1). (2) and Jalve (spool)
chassis as shown in
1 Table I? Defective solenoid R;eplace
NO
Is voltage . Disconnect Disconnection in wiring
between CN224 _ CN246. harness or short circuit
(1) and chassis - Turn starting with wiring harness
YES lepair or
normal? switch OFF. 3 between CN264 (female) eplace
(4) - CN421 (12) - CN224
.20-30V Is voltage (female) (1)
*Turn starting _ between CN263 _
switch ON. NO (2) and chassis 4 YES Defective pin-puller
Fleplace
. Turn pin-puller ground normal? _ Is voltage switch
switch ON. between CN263
.20-30V Defective contact, or
NO (female) (1) and
* Turn starting disconnection in wiring
chassis normal?
switch ON. harness between fuse 15 - Fteplace
-Turn pin-puller NO CN411 (1) - CN361 (14) -
-2O-30V
switch ON. * Turn starting CN264 (3)
switch ON.
- Disconnect
CN263.
Table 1
Between (1) - (2) ) 40 - 80 R
Between (l),(2) - chassi 4 Min. 1 MQ
CN264 CN42 I CN224

Pin Puller (X6) (SWP 16) (X2) Pin Puller
switch J, I\ 1 solenoid valve ~
BKD00705
20-528
0
TROUBLESHOOTING E-9
E-9 Blade pitch does not work (dual tiltdozer specification)

* Before carrying out troubleshooting, check that fuse 1 is normal.
‘ES
YE )
1
1 Does blade pitch 1 4 NO
* 20 - 30 v
. Start engine.
when CNPOl (male) YE between CNP03 s Turn blade pitch
and CNP03 (female)
(female) (1) and switch ON.
* Operate blade tilt
. Connect CNPOl 3 (operate slightly)
*20-30V Note 1)
(male) and CNPOB Isvoltage between * Start engine.
(female). I YES CNPOB(female) 11). * Turn blade pitch
- Start engine. CNPOG(female) (I) - IO
switch ON.
- Turn blade pitch chassis normal?
- Operate blade tilt
switch ON. 2-
(operate slightly)
- Operate blade Is resistance -2O-30V
Note 1)
tilt. _ between CNSOLl _ -Turn starting
NO (female) (1) and switch ON.
(2) normal?
*40-80R I
* Turn starting 0
I
switch OFF. NO
* If the operation becomes normal when CNP05 and CNPOG are interchanged, the blade tilt PPC oil
pressure switch on the opposite side is defective.
Note 1) Operate enough to be able to detect the blade tilt PPC oil pressure signal.
20-530
0
TROUBLESHOOTING E-9
Remedy
qeplace
qepair or
,eplace
Repair or
replace
Repair or
replace
Repair or
replace
I CN36 I
I n,.In 4 ‘)
CN153
MWP6)
PO4
(X2)
Blade pitch
Left blade
tilt
PO6 (X21
Right blade
tilt
Dual tilt oil

Pressure switch
(blade tilt oil pressure signal)
BKD00706
20-531
0
TROUBLESHOOTING E-10
E-10 Blade dual tilt does not work (dual tiltdozer specification)
Cause Remedy
YES
Defective dual tilt switch Replace
4 YEI disconnection in wiring Repair or
harness between CNSOLP replace
(female) (2) and chassis
CNPO? (male) and
CNPOB (female) are (female) (I) and Defective contact, or
chassis normal? diinneotion in wiring harness Repair or
3 between CNFW (male)-CN361 replace
- Connect CNPOP
(12xN153(5xNPO4(2)-
(male) and Is resistance - Start engine. auSDl2 &Me) (1)
CNP03 (female). between CNSOLZ -Turn dual tilt
* Start engine. NO (male) (1) and (2)
I
switch ON.
Does blade pitch *Turn dual tilt normal?
4 - Operate blade tilt
work normally? switch ON. (operate slightly)
* Operate blade * 40 - 80 R
Note I)
tilt. * Turn starting
* Connect CNPOl switch ON. Defective solenoid valve
Replace
(male) and IO for dual tilt
CNP03 (female).
. Start engine.
- Turn blade pitch
switch ON. Go to E-9
IO
- Operate blade
tilt.
Note I) Operate enough to be able to detect the blade tilt PPC oil pressure signal.
Knob switch
for dual til
Pitch
CN4 11
(SWP14) FUSFi
Dual tilt oil

Dressure switch
(blade tilt oil Pressure signal)
BKD00706
20-532
0
TROUBLESHOOTING E-l 1
E-II Torque converter lock-up does not work (torque converter lock-up
display lamp does not light up)
YES
YEiS betvveenCN622
(female) (8) and (7)
as shown in Table 17
*Turn starting
switch OFF.
* Disconnect
CN622.
YE:
normal? I
*I-lOV(AC
3 range)
* Start engine.
YEiS between CN622 . Engine at high
idling
(female) (2) and
* Turn lock-up
switch ON. NO
l Max. 1 R
Turn starting 10
2 i
l
switch OFF.
I
YE 1 Is resistance I
between CN652
between CN622 CN622. NO (male) (1) and (2)
* Start engine. normal?
. Joystick
(direction): * Max. 1 D
.20-30V Neutral * Turn starting switch OFF.
*Turn starting * Disconnect CN622.
switch ON. * Start engine.
between CN218 -Joystick (direction): Neutral
(female) (3) and
NO
* Min. 1 MD
- Turn starting
switch OFF.
*Turn lock-up
switch OFF.
NO
20-534
0
TROUBLESHOOTING E-II
Cause Remedy
7 YES Defective lock-up

eplace
controller
disconnection in wiring epair or
harness between CN375 tplace
Is voltage NO (female) (4) - CN215 (IO).
* Start engine.
between CN622 CN421 (16)
- *Joystick
(8) and (7) as
(direction):
shown in Table 2?
Neutral
* Start engine. *Turn lock-up
-Joystick switch ON.
(direction):
YES
Neutral Defective lock-up solenois eplace
- Turn lock-up NO I
1 switch ON. ) I~~eC;;~ Defective contact, or
harness between CN622 epair or
(female) (8). (7) - CN153 splace
* Turn starting NO
switch OFF. (female) (2). (3) - CN653
+ Disconnect (female) (1). (2)
CN653.
*Turn lock-up
switch ON.
a VFS harness between CNSSl epair or
(female) (l), (8) - CNSOG splace
Is voltage
between CN651 (1). (4) - CN457 (5). (4) -
CN651 (female) (2). (1)
- (1) and (2)
normal?
Defective torque :eplace
* 0.5 - 3.0 v (AC NO converter speed sensor
range)
* Start engine. Defective contact, or
* Engine at high idling disconnection in wiring
*Turn lock-up switch ON. harness between CN652
(female) (1) - CN153 (1) - lepair or
CN662 (female) (2), or eplace
between CN652 (female)
(2) - CN451 (14) -chassis
ground
Defective transmission o lepair or

pressure switch eplace
CN411 (7) - CN421 (15) -
tepair of
W-215 (male) (9) CN218
eplace
(female) (2), or between
CN622 (female) (4) -
CN421 (13) - CN215 (8) -
CN218 (female) (3)
Defective lock-up switch seplace
20-535
0
TROUBLESHOOTING E-12
E-12 Torque converter lock-up is not cancelled (torque converter lock-

up display lamp stays lighted up)
* Check that the torque converter lock-up lamp is normal (not blown).
* Carry out troubleshooting with the torque converter lock-up switch OFF.
a) Lock-up display lamp does not go out

cause Remedy
1 YES Defective lock-up leplace

I controller
Is resistance
between CN622 Wiring harness between
(male) (7) and CN622 (female) (7) -
chassis normal? CN153 (3) - CN653
(female) (2). or between
I (epair or
- Min. 1 MD CN622 (female) (7) -
-Turn starting NO CN421 (16) - CN215 (10) -
switch OFF.- CN375 (female) (4) short
- Disconnect circuiting with chassis
CN622. ground
: b) Lock-up display lamp lights up but lock-up is not actuated
2 YES Defective oil pressure

Is voltage between system (go to H-10)
Yt CN622 (8) and (7)
as shown in Table
l? Defective lock-up
leolace
NO controller
- Start engine.
1 - Joystick (direction):
Neutral.
between CN622 * Lock-up switch:
(female) (8) and ON
* Short circuit between Defective contact, or
CN622 (2) and (5). disconnection in wiring
.40-8OR 3 YES harness between CN622
lepair or
. Turn starting (female) (8) - CN153 (2) -
eplace
switch OFF. Is resistance CN653 (female) (1). or
- Disconnect between CN653 between CN653 (female)
CN622. hIO (male) (1) and (2) (2) - CN153 (3)
normal?
Defective lock-up solenoil leplace
-4O-80R
* Disconnect CN653.
Table 1
20-536
0
30 DISASSEMBLY AND ASSEMBLY
Method of using manual ........................... .30- 5 FUEL TANK

Precautions when carrying out Removal ................................................... .30-45
operation ................................................... Installation ................................................ 30-45
30- 7
Special RADIATOR
tool list .......................................... ..30-11
Removal .................................................... 30-46
Sketches of special tools ........................... .30-18 Installation ................................................ 30-47
STARTING MOTOR RADIATOR, GUARD
Removal ................................................... .30-22 Removal .................................................. 30- 48
Installation ............................................... .30-22 Installation .............................................. 30- 50
ALTERNATOR ENGINE
Removal ................................................... .30-23 Removal .................................................. 30- 51
Installation ................................................ 30-23 Installation .............................................. 30- 56
ENGINE OIL COOLER DAMPER
Removal .................................................... 30-24 Removal .................................................. 30- 57
g Installation ............................................... .30-25 Installation .............................................. 30- 60
z
FUEL INJECTION PUMP Disassembly ........................................... 30- 62
z
Removal .................................................... 30-26 Assembly ................................................. 30- 63
Installation ............................................... .30-26 POWER TRAIN UNIT
WATER PUMP Removal .................................................. 30- 65
Removal ................................................... .30-27 Installation .............................................. 30- 69
Installation ............................................... .30-27 Disconnection ......................................... 30- 70
Connection .............................................. 30- 75
THERMOSTAT
Removal .................................................... 30-28 PTO
Installation ............................................... .30-28 Disassembly . . . . . . . .. . . . . .. . . . . . . . .. . .. . . .. . .. . . . .. . . .. 30- 77
Assembly . .. . . . . . . . .. . . . . . .. . . . . . . . . .. .. . . . .. . . . . . . .. . . . . 30- 81
TURBOCHARGER
Removal .................................................... 30-29 TORQUE CONVERTER
Installation ............................................... .30-30 Disassembly . . . . . . . .. .. . . . . .. . . . . . . . . .. . . . . . .. . . . . . .. .. 30- 85
Assembly . .. . . . . . . . .. . . . . . .. . . . . . . . . .. . . . . . .. . . . . . . .. . . . . 30- 90
AFTERCOOLER CORE
Removal .................................................... 30-31 TORQFLOW TRANSMISSION
Installation ............................................... .30-32 Disassembly . . . . . . .. . . . . .. .. . . . . . . .. . . . . . . . .. . . . . .. .. . . 30- 96
Assembly . . . . . . . . .. .. . . . . . .. . . . . . . .. .. . . . . . .. . . . . . .. . . . . . 30-I 12
NOZZLE HOLDER
Removal .................................................... 30-33 STEERING CASE
Installation ................................................ 30-33 Disassembly . . . .. . . .. . . . .. . . . . . . .. . . . . . . . .. . . . . . .. . . . . . 30-129
Assembly . . . . .. . . . . . . .. .. . . . . . .. . . . . . . . . . .. . . . . .. . . . . .. . . 30-137
ENGINE FRONT SEAL
Removal .................................................... 30-34 POWER TRAIN, LUBRICATION PUMP
Installation ................................................ 30-34 Removal .. . . . . .. . .. . . . .. .. . . . . . .. . . . . . . .. . .. . . .. . . . . . . .. . . 30-147
Installation .. . . . . . .. .. . . . . .. .. . . . . . . .. . . . . .. .. . . . . .. . . . . . 30-147
ENGINE REAR SEAL
Removal .................................................... 30-36
Installation ................................................ 30-36 SCAVENGING PUMP
Removal . ..._............................................. 30-148
CYLINDER HEAD Installation . . .. . . . .. .. . . . . .. . . . . . . . . .. . . . . . . .. . . . . . .. .. . . 30-148
Removal .................................................... 30-38
Installation ............................................... .30-43
30-l
0
TORQUE CONVERTER OIL COOLER Overall disassembly of track shoe.. ........ 30-222
Removal .................................................. 30-149 Overall assembly ...................................... .30-227
Installation .............................................. 30-149
Press-fitting jig dimension table
for link press .......................................... 30-241
Removal .................................................. 30-150
Installation ............................................... 30-150 ONE LINK
Disassembly .......................................... .30-151 Field disassembly ................................. .30-242
Assembly ............................................... .30-l 53 Field assembly ...................................... .30-244
TRANSMISSION CONTROL VALVE MASTER LINK

Removal .................................................. 30-I 54 Field disassembly ................................. .30-246
Installation ............................................. .30-154 Field assembly ...................................... .30-248
Disassembly .......................................... .30-155 PIVOT SHAFT
Assembly ............................................... .30-156 Removal .............................. .l.................. 30-251
TRANSMISSION LUBRICATION VALVE Installation ............................................. .30-251
Removal ................................................. .30-157 EQUALIZER BAR
Installation .............................................. 30-157 Removal ................................................. -30-252
Disassembly .......................................... .30-157 Installation .............................................. 30-255
Assembly ............................................... .30-157
EQUALIZER BAR BUSHING
STEERING CONTROL VALVE Disassembly .......................................... .30-256
Removal ................................................. .30-158 Assembly ............................................... .30-257
Installation ............................................. .30-158
SEGMENT TOOTH
Disassembly .......................................... .30-160
Removal .................................................. ,30-258
Assembly ................................................ 30-162
Installation ............................................. .30-258
FINAL DRIVE
HYDRAULIC TANK
Removal ................................................. .30-165
Removal ................................................. -30-259
Installation ............................................. -30-165
Installation ............................................. .30-261
Disassembly ........................................... 30-166
Assembly ................................................ 30-172 WORK EQUIPMENT, PPC PUMP
Removal ................................................. -30-262
TRACK FRAME
Installation ............................................. .30-262
Removal .................................................. 30-181
Installation .............................................. 30-183 HYDRAULIC COOLER 8
Removal ................................................. -30-263 g
IDLER
Installation ............................................. .30-263
Removal ................................................. .30-184
Installation ............................................. .30-184 BLADE LIFT VALVE
Disassembly ........................................... 30-185 Removal ................................................. -30-264
Assembly ............................................... .30-187 Installation ............................................. .30-265
Disassembly .......................................... .30-266
RECOIL SPRING
Assembly ................................................ 30-267
Removal .................................................. 30-189
Installation .............................................. 30-194 BLADE TILT, RIPPER LO VALVE
Disassembly ........................................... 30-195 Removal ................................................. .30-268
Assembly ................................................ 30-196 Installation ............................................. .30-269
Disassembly .......................................... .30-270
TRACK ROLLER
Assembly ............................................... .30-270
Removal ................................................. .30-197
Installation .............................................. 30-198 RIPPER HI VALVE
Disassembly ........................................... 30-199 Removal ................................................. .30-272
Assembly ................................................ 30-200 Installation .............................................. 30-272
Disassembly .......................................... .30-274
BOGIE
Assembly ............................................... .30-274
Removal ................................................. .30-202
Installation .............................................. 30-203 PPC CHARGE VALVE
Disassembly .......................................... .30-204 Removal .................................................. 30-277
Assembly .................................. . ............. 30-208 Installation .............................................. 30-277
Disassembly .......................................... .30-278
CARRIER ROLLER
Assembly ............................................... .30-278
Removal ................................................. -30-213
Installation ............................................. .30-213 BRADE PPC VALVE
Disassembly .......................................... .30-214 Removal .................................................. 30-279
Assembly ............................................... .30-216 Installation .............................................. 30-280
Disassembly .......................................... .30-281
TRACK SHOE
Assembly ............................................... .30-282
Removal .................................................. 30-219
Installation ............................................. .30-221 RIPPER PPC VALVE
Removal ................................................. .30-284
Installation ............................................. .30-285
30-2
0
Disassembly .......................................... .30-286 HOOD
Assembly ................................................ 30-287 Removal . . .. . .. . . . . . . .. . .. . . . . . .. . . . . . .. . . . . .. . . . . . .. . . . . . 30-328
BRADE LIFT CYLINDER Installation . . . . . . .. .. . . . . .. . .. . . . . .. . . . . . .. . . . . . .. . . . .. . . 30-328
Removal .................................................. 30-288
Installation ............................................. .30-288
BRADE TILT CYLINDER
Removal .................................................. 30-289
Installation .............................................. 30-289
RIPPER LIFT CYLINDER
Removal ................................................. .30-290
Installation ............................................. .30-290
RIPPER TILT CYLINDER
Removal ................................................. .30-29 1
Installation ............................................. .30-291
HYDRAULIC CYLINDER
Disassembly .......................................... .30-292
Assembly ............................................... .30-295
RIPPER PIN-PULLER
Removal .................................................. 30-298
Installation ............................................. .30-298
Disassembly .......................................... .30-299
Assembly ................................................ 30-300
BLADE
Removal ................................................. .30-302
Installation ............................................. .30-303
Disassembly .......................................... .30-304
Assembly ................................................ 30-306
GIANT RIPPER
Disassembly .......................................... -30-308
s: Assembly ............................................... .30-310
z
ROPS GUARD
z
Removal .................................................. 30-312
Installation .............................................. 30-312
OPERATOR’S CAB
Removal ................................................. .30-313
Installation .............................................. 30-313
FLOOR FRAME
Removal ................................................. .30-314
Installation ............................................. .30-318
DASH BOARD
Removal ................................................. .30-320
Installation ............................................. .30-32 1
MONITOR
Removal ................................................. .30-322
Installation ............................................. .30-322
TORQUE CONVERTER LOCK-UP CONTROLLER
Removal .................................................. 30-323
Installation .............................................. 30-323
APS CONTROLLER
Removal .................................................. 30-324
Installation ............................................. .30-324
AIR CONDITIONER COMPRESSOR
Removal ................................................. .30-325
Installation ............................................. .30-326
AIR CONDITIONER CONDENSER
Removal .................................................. 30-327
Installation ............................................. .30-327
30-3
0
DISASSEMBLY AND ASSEMBLY METHOD OF USING MANUAL
METHOD OF USING MANUAL

1. When removing or installing unit assemblies
@ 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.
@ 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)
................................................................Precautions related to safety when

REMOVAL OF 0000 ASSEMBLY . . . . . .. . . . Title of operation
A
1. x x x x (I) . . .. . .. .. . .. . . .. . .. . .. . .. . . . . . . .. . . . . .. . .. . . .. Step in operation
carrying out the operation
* . . . . . .. . . . . . .. . . .. . . .. . . . . .. . .. . . . .. . . . . . .. . . . .. .. . . . . .. . . .. Technique or important point to remember when

removing x x x x (1).
2. n fI n A(2) . .. . . . .. . . . . .. . . . . . .. . . . . . . . .. . . .. . .. . . . . . .. m ..........Indicates that a technique is listed for use
during installation
3. 0 13 fl r3 assembly (3)
: . . .. . . . . . . . . .. . . . . . .. . . . . .. . . . .. . . . . . .. . . . . . .. . . . . .. .. . .. . .. .See Lubricant and Coolant Table
INSTALLATION OF 0000 ASSEMBLY . . Title of operation

l Carry out installation in the reverse order to removal.
m . .. . . . .. . . . . . . .. . . . . .. . .. . ..._................................. Technique used during installation
* . . . . . . .. . . . . .. . . . . . .. . . . .. .. . . . .. . . . . .. . .. . . .. .. . .. . .. . . .. . . Technique or important point to remember when
installing (2).
l Adding water, oil .. .. . . . .. . . . . . .. . . . .. . . .. . .. .. . . .. Step in operation
t . . . . . . . .. . . .. . . . . . . .. . . . .. .. . . . .. . . . . .. . .. . .. . . . . . .. .. . . .. . . Point to remember when adding water or oil
. . . . . .. . . . . . .. . . . . .. . . . .. . . . . . .. . . . . .. . . . . . .. . .. . . .. . . . . .. Quantity when filling with oil and water
2. General precautions when carrying out installation or removal (disassembly or assembly) of

units are given together as PRECAUTIONS WHEN CARRYING OUT OPERATION, so be sure to
follow these precautions when carrying out the operation.
3. Listing of special tools

CiJ For details of the description, part number, and quantity of any tools (Al, etc.) that appear
in the operation procedure, see the SPECIAL TOOLS LIST given in this manual.
4. General tightening torque table (when using torque wrench)

Sr In the case of metric nut and bolts for which there is no special instruction, tighten to the torque
given in the table below.
Thread diameter Width across flats
mm mm Nm kgm
6 10 13.2k1.4 1.35io.15
8 13 31.412.9 3.220.3
10 17 65.7r6.8 6.720.6
12 19 11229.8 11.5il.O
14 22 177+19 18.Ok2.0
16 24 279k29 28.523
18 27 383239 39-c4
20 30 549rt58 56-c6
22 32 745+78 7628
24 36 927+98 94.5&10
27 41 1320-c140 135*15
30 46 1720+190 175220
33 50 221Ok240 225+25
36 55 2750*290 280230
39 60 328Ok340 335&35 8
%
z
5. Table of tightening torques for flared nuts
* In the case of flared nuts for which there is no special
instruction, tighten to the torque given in the table
below.
Thread diameter Width across flats Tightening torque
mm mm Nm kgm
14 19 24.5k4.9 2.5~~0.5
18 24 49219.6 521
22 27 78.5k19.6 8rl
24 32 137.3+29:4 14i3
30 36 176.5k29.4 18k3
33 41 196.1-c49 2025
36 46 245.2*49 25+5
42 55 294.2-e49 30+5
6. Table of tightening torques for split flange bolts

* In the case of split flange bolts for which there is no special instruction, tighten to the torque given
in the table below.
Thread diameter Width across flats Tightening torque
mm mm Nm kgm
14 14 65.7k6.8 6.720.7
18 17 112k9.8 11.5+1
22 22 279529 28.523
30-6
0
PRECAUTIONS WHEN CARRYING OUT OPERATION

[When carrying out removal or installation (disassembly or assembly) of units, be sure to follow the
general precautions given below when carrying out the operation.]
1. Precautions when carrying out removal work
. If the coolant contains antifreeze, dispose of it correctly.
. After disconnecting hoses or tubes, cover them or fit blind plugs to prevent dirt or dust from
entering.
. When draining oil, prepare a container of adequate size to catch the oil.
. Confirm the match marks showing the installation position, and make match marks in the neces-
sary places before removal to prevent any mistake when assembling.
. To prevent any excessive force from being applied to the wiring, always hold the connectors when
disconnecting the connectors. Do not pull the wires.
. Fit wires and hoses with tags to show their installation position to prevent any mistake when
installing.
. Check the number and thickness of the shims, and keep in a safe place.
. When raising components, be sure to use lifting equipment of ample strength.
. When using forcing screws to remove any components, tighten the forcing screws uniformly in
turn.
. Before removing any unit, clean the surrounding area and fit a cover to prevent any dust or dirt
from entering after removal.
* Precautions when handling piping during disassembly
Fit the following blind plugs into the piping after disconnecting it during disassembly operations.
1) Hoses and tubes using sleeve nuts
Nominal number Plug Sleeve nut (elbow end) Use the two items below as a set
02 07376-50210 07221-2021O(Nut), 07222-0021O(Plug)
03 07376-50315 07221-20315(Nut), 07222-00312(Plug)
04 07376-50422 07221-20422(Nut), 07222-00414(Plug)
05 07376-50522 07221-20522(Nut), 07222-00515(Plug)
06 07376-50628 07221_20628(Nut), 07222-00616(Plug)
10 07376-51034 07221-21034(Nut), 07222-01018(Plug)
12 07376-51234 07221-21234(Nut), 07222-01219(Plug)
2) Split flange type hoses and tubes
Nominal number Flange (hose end) Sleeve head (tube end) Split flange
04 07379-00400 07378-I 0400 07371-30400
05 07379-00500 07378-I 0500 0737 I-30500
3) If the part is not under hydraulic pressure, the following corks can be used.
30-7
0
2. Precautions when carrying out installation work

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 anti-friction compound (LM-PI.
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 in fully, and
align the direction of the hook.
When tightening split flanges, tighten uniformly in turn to prevent excessive tightening on one
side.
When operating the hydraulic cylinders for the first time after reassembling cylinders, pumps and
other hydraulic equipment removed for repair, always bleed the air as follows:
1. Start the engine and run at low idling.
2. Operate the work equipment control lever to operate the hydraulic cylinder 4 - 5 times,
stopping 100 mm from the end of its stroke. z
3. Next, operate the hydraulic cylinder 3 -4 times to the end of its stroke. z
4. After doing this, run the engine at normal speed. z
Jr When using the machine for the first time after repair or long storage, follow the same
procedure.
Precautions when completing the operation

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 hydraulic equipment has 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 parts.
30-8
0
DISASSEMBLY AND ASSEMBLY SPECIAL TOOL LIST
SPECIAL TOOL LIST

Tools with part number 790T-000-0000 cannot be supplied (they are items to be locally
manufactured).
New/remodel: N .. . . . . .. . Tools with new part numbers, newly developed for this model
R . . .. . .. . . Tools with upgraded part numbers, remodeled from items already available
for other models
Blank ..Tools already available for other models, used without any modification
Tools marked 0 in the Sketch column are tools introduced in special sketches (See SKETCHES OF
SPECIAL TOOLS).
L
Component symbol Part No. Part Name g gi g Nature of work, remarks

-v)
c
1 795-902-I 410 Sleeve 1 .$ Installationof front seal (for maintenance)
m
2 795-902-I 420 Sleeve 1 z Installation of rear seal (for maintenance)
Engine -tj
790-451-1000 Remover 1 .g
assembly 2
3 Puller (294kN{30ton}) 1 7 Pulling out pin of radiator,
790-101-2102 guard assembly
?
790-101-1102 Pump 1 2
+
Torque con- Disassembly, assembly of
verter assembly torque converter assembly
Disassembly, assembly of
transmission assembly
Removal, installation of
No. 5 clutch piston
Assembly of No. 3 ring gear

and No. 4 carrier
TORQFLOW
transmission
assembly
Assembly of No. 2, No. 3 carrier

and No. 1 ring gear
i Checking actuation of piston
I I I I*
1
1 Removal, installation of
1 790-337-1001 Lifting tool $
final drive assembly
= .!
Pulling out sprocket bearing

Final drive
assembly
Press fitting of sprocket

bearing
Installation of floating seal
30-11
0
Component Symbol Part No. Part Name xf $1 g Nature of work, remarks

FU-J
I
Pulling out center hub
t 791-580-3500 1 installer III I I2

Final drive 6 I 79o-lo1-21o2 I Puller(294kN0OtonHI I I I Ig Press fitting center hub
assembly -c
790-101-1102 Pump 1
2
790-431-1230 Remover & installer 1 ;
Pulling out, press of fitting
7 790-101-2102 Puller (294kNQO ton)) 1 g
planetary gear shaft
790-101-1102 Pump 1
Assembly of No. 1 pinion
Press fitting of bushing
>;
Idler assembly 01643-31645 Washer 1 E
E
790-101-2102 Puller (294kN00 ton}) 1
I,”z
B
790-101-1102 Pump 1 .E
n
2 791-515-1520 Installer 1 Installation of floating seal
3 1 791-685-8310 1 Push tool III I I Press fitting of floating seal collar
4 791-601-1000 Oil pump 1 Fillina with oil
5 791-515-1520 Installer 1 $2 Installation of floating seal

Carrier roller if
6 791-685-8330 Push tool 1 I: Press fitting of floating seal collar
assembly ;:
0
7 791-630-1270 Wrench 1 Removal, installation of round nut
8 I 79lT-630-1230 I Plate II I ‘loI Press fitting of bushing
Track roller Installation of floating seal

assembly Press fitting of floating seal collar
Filling with oil
12 01017-31220 Bolt 3 Pulling out cage

2
Q
1 791-630-1700 Remover & installe- 1 N E
2 l l Frame 1 %
791-685-9510 %
Bogie
3 . 791-685-9520 l Frame 1 z
assembly o Pulling out shaft assembly
30-12
0
TOOL LIST
T
Component
T
Symbol Part No. Nature of work, remarks
(Pulling out shaft assembly)

1:3-
Bogie
g L
assembly
z
z
14 790-201-2280 1 Plate III I Pulling out collar
15 1 791-630-1730 1 Push tool 111 I Press fitting of collar
Press fitting of bushing of ring

167
and cage
I 790-101-5341 1 Plate Ill I

17 I 790-101-5221 I Grip Ill I Press fitting of ring
01010-51225 Bolt 1
18 791-630-1780 Installer 1 N Installation of floating seal
11 1 791-630-1700 1Remover & installer1 1 1 (
I21 l 791-685-9510 . Frame III I
Press fitting of shaft assembly
6 . 791-685-9550 l Nut 3
7 l 791-685-9560 l Bolt 4
181 791-630-1510
l l Shaft I21 I
30-13
0
Component symbol Part No. Part Name Nature of work, remarks
9 l 791-630-1520 l Nut 2
L I
10 l 04530-I 2030 l Eyebolt 1
11 l 791-126-0150 l Adapter 1
Bogie 13 [Press fitting of shaft assembly)

assembly
18 l 01010-51025 l Bolt 9 5
2
19 l 01643-51032 l Washer 8 .-2
n
20 790-101-4300 Cylinded147OkN{15Oton~ 1
21 790-101-1102 Pump 1
22 79lT-630-1580 Bracket 1 0
I I I I
23 79lT-630-1590 Stand 2 0
24 01017-52010 Bolt 4
Filling with oil
Disassembly of yoke and

-ecoil spring case
Recoil spring
assembly
2 790-101-1600 Cylinder@6 kNf7Oton)) 1 Z Disassembly, assembly of
2 recoil spring assembly
790-101-1102 Pump 1 I I
/ 791-635-3160 1 Extension III I IE
791-650-1300 Remover 1
l 791-735-1123 l Sleeve 1
- 790-434-1050 l Screw 1
I I I I
Pulling out center pin
Equalizer bar
I
assembly
1 79lT-650-2410 Bracket ‘NO’ Assembly Part No.

:
(Not available for supply):
2 79lT-650-2420 Bracket lN0
79lT-650-2400
Pulling out, press fitting of side
bushing
30-l 4
0
L
$ 0
Component Symbol Part No. Part Name $ ii
5
Y
Nature of work, remarks
- tn
4ssembly Part No. (Not available
for supply): 791T-650-2400
‘ullina out, grass frttina of side bushina
Assembly Part No.

(Not available for supply):
791T-650-2300
Pivot shaft
assembly Press fitting of pivot shaft seal
Removal of small plug
Cleaning of pin
Knocking in pin plug
Filling with oil and checking

air tightness
Knockino in pin PIUQ

Track shoe
Replacing of link seal
assembly
Disassembly, assembly of
track shoe
12 l 791-685-9540 l Rod 1
13 l 791-632-1140 . Adapter 1
14 l 791-680-5520 l Guide 1
15 ’ 01010-51030 l Bolt 1
16 l 791-632-1150 . Pusher 1
30-15
0
Component symbol Part No. Part Name i!;r Nature of work, remarks
-
17 l 791-685-9620 l Extension
-
18 l 791-632-1180 l Adapter
-
19 l 79 I-680-5543 l Adapter
-
20 l 791-632-1170 l Guide
-
21 l 791-680-5551 l Guide
-
(Disassembly, assembly of
Track shoe
7 22 l 79 l-680-9630 l Adapter track shoe)
-
assembly
23 l 791-632-1160 . Guide
-
24 195-32-l 620 Bolt
-
25 790-101-4300 Cyiinder(147OkN{15n
-
2E 790-101-1102 Pump
-
27 790-101-4200 Cylinder
Q94kNDOton):
-
26 791-680-1630 Spacer
1 790-502-l 003 Cvlinder reoair stand Disassembly, assembly of hydraulic cylinder
790-201-1702 Push tool kit

.-P
. 790-201-1841 l Push tool Blade lift cylinder
f 2
3 %
Blade tilt cylinder z
5;
l 790-201-1861 l Push tool Ripper lift cylinder z
Ripper tilt cylinder %
F
l 790-201-1721 l Push tool Pin-puller cylinder g
l 790-101-5021 l Grio All cylinders
l 01010-50816 l Bolt All cylinders
Hydraulic 790-201-1500 Push tool kit

cylinder l 790-201-1650 . Plate Blade lift cylinder
assembly
Blade tilt cylinder
. 790-201-1670 l Plate Ripper lift cylinder
Ripper tilt cylinder
l 790-201-1530 l Plate Pin-puller cylinder
l 790-101-5021 * Grip All cylinders
~01010-50816 p Bolt All cylinders
790-720-1000 Expander All cylinders
796-720-1680 Ring
Blade lift cylinder
07281-01589 Clamp
796-720-1720 Ring Blade tilt cylinder

Ripper lift cylinder
07281-02429 Clamp
30-16
0
Component Symbol Part No. Part Name Nature of work, remarks
Hydraulic
cylinder U
assembly 790-l 02-2302 Wrench z
or 1 z: Removal, installation of pin-

6
.I? puller cylinder round head
790-330-I 100 Multi-wrench 0
I I I I , 1
790-101-1102 I Pump III I I I

:
799-703-l 200 Service tool kit 1 _=
Related to :B
X 799-703-l 100 Vacuum pump 1 gz Charging with freon gas
air conditioner
799-703-1400 1 Gas leak detector III I l-7
30-17
0
DISASSEMBLY AND ASSEMBLY SKETCHES OF SPECIAL TOOLS
SKETCHES OF SPECIAL TOOLS

Note: Komatsu cannot accept any responsibility for special tools manufactured according to these
sketches.
L8 Plate
2-14DRILLS
CDD01245
1 791T-6304230 n
L13-22, L19-22 Bracket
23 DRILL
2 PLACES
A-A
CDD01246
HEAT TREATMENT MATERIAL
---- SEE DWG
02 BOSS SS400B I 1.76 $40 PART NAME QTY

BRACKET ----
01 PLATE SS4OOP 1 0.17 tl6
SYM. PART NAME MATERIAL QTY/SET "I;;? REMARKES 791T-630-1580 n
30-18
0
DISASSEMBLY AND ASSEMBLY SKETCHES OF SPECIAL TOOLS
P2 Plate
CDD01251
HEAT TREATMENT MATERIAL
---- SS4OOP
PART NAME OTY
PLATE
791T-650-2340 'A
30-21
0
DISASSEMBLY AND ASSEMBLY STARTING MOTOR
REMOVAL OF STARTING
MOTOR ASSEMBLY
A’ Disconnect the cable from the negative H ter-
minal of the battery.
1. Open engine right side cover (I) and remove
side cover (2).
2. Remove side covers (31, then remove side cover
stay.
3 CED01240
3. Disconnect 3 starting motor wires (41, top start-

ing motor connector (CN-104) (51, and bottom
starting motor connector (CN-103) (6).
4. Remove 3 mounting bolts, then remove top

starting motor assembly (7).
5. Remove 3 mounting bolts, then remove bottom
starting motor assembly (8).
1242
INSTALLATION OF STARTING
MOTOR ASSEMBLY
l Carry out installation in the reverse order to
removal.
30-22
0
DISASSEMBLY AND ASSEMBLY ALTERNATOR
REMOVAL OF ALTERNATOR
ASSEMBLY I
Ah-Drsconnect the cable from the negative (-1 ter-
side cover (2).
stay.
i CED01240
3. Disconnect alternator wiring (4) and (5).
4. Loosen locknut (61, then turn adjustment nut

(7), and remove V-belt (8). m
5. Remove mounting bolts (9) and (IO), then re-
move alternator assembly (II).
INSTALLATION OF
ALTERNATOR ASSEMBLY
. Carry out installation in the reverse order to
removal.
m
* After installing the V-belt, adjust the belt
tension.
For details, see TESTING AND ADJUSTING,
Testing and adjusting alternator belt tension.
30-23
0
DISASSEMBLY AND ASSEMBLY ENGINE OIL COOLER
REMOVAL OF ENGINE OIL

COOLER ASSEMBLY
1. Drain coolant.
side cover.
stay.
3 CED01240
4. Remove adiabatic covers (41, (51, and (6), then

remove brackets (7).
I CED01252
5. Remove hose clamp (8), wiring clamp (81, and

bracket (IO).
6. Remove turbocharger lubrication outlet tube

(II).
7. Remove water connector, then remove 2 water
pipe mounting bolts (13).
30-24
0
DISASSEMBLY AND ASSEMBLY ENGINE OIL COOLER
8. Remove oil cooler assembly (14).
INSTALLATION OF ENGINE
OIL COOLER ASSEMBLY
removal.
. Refilling with water
Add water to the specified level, and run the
engine to circulate the water through the
system. Then check the water level again.
30-25
0
DISASSEMBLY AND ASSEMBLY FUEL INJECTION PUMP
REMOVAL OF FUEL INJECTION

PUMP ASSEMBLY
1. Open engine left side cover (I) and remove side
cover (2).
stay.
3. Close fuel supply valve.
4. Remove bracket (4) and oil level gauge (5).

5. Disconnect fuel control rod (6).
6. Disconnect 4 fuel hoses (7).
7. Remove lubrication tubes (8) and (9). 3’
CED01332
8. Remove boost compensator tube (IO).
9. Disconnect 6 delivery tubes (II).
IO. Remove coupling cover (12).
11. Loosen mounting bolts (13) at drive shaft and
remove 4 pump mounting bolts (14).
12. Remove fuel injection pump assembly (15) to-
gether with coupling. m
& kg Fuel injection pump assembly : 30 kg
INSTALLATION OF FUEL
INJECTION PUMP ASSEMBLY
removal.
a
+ Adjust the injection timing.
Adjusting fuel injection timing.
* Bleed the air from the fuel circuit.
30-26
0
DISASSEMBLY AND ASSEMBLY WATER PUMP
REMOVAL OF WATER PUMP

ASSEMBLY
1. Drain coolant.
2. Open engine right side cover (1) and remove
side cover (2).
stay.
3 CED01240
4. Remove torque converter oil cooler connectors

(4) and (5).
5. Remove water tube (6).
6. Remove water pump assembly (7).
INSTALLATION OF WATER
PUMP
removal.
engine to circulate the water through the sys-
tem. Then check the water level again.
30-27
0
DISASSEMBLY AND ASSEMBLY THERMOSTAT
REMOVAL OF THERMOSTAT
ASSEMBLY
1. Drain coolant.
2. ‘Open engine left cover (I) and remove side
cover (2).
I CED01336
3. Disconnect radiator inlet hose (2).

4. Disconnect aeration hose (3).
5. Remove cover (4).

6. Remove 2 thermostats (5).
INSTALLATION OF
THERMOSTAT ASSEMBLY
removal.
a
w Radiator inlet hose clamp :
882 + 98 Ncm I90 f 10 kgcm1
m
w Aeration hose clamp :
333.2 + 49 Ncm I34 + 5 kgcm}
30-28
0
DISASSEMBLY AND ASSEMBLY TURBOCHARGER
REMOVAL OF
TURBOCHARGER ASSEMBLY
cover (2).
CED01339
2. Open engine left side cover (3) and remove

cover (4).
CED01340
3. Remove adiabatic covers (51, (61, and (7).
4. Remove intake connector (8).
30-29
0
DISASSEMBLY AND ASSEMBLY TURBOCHARGER
5. Disconnect hose (9) and move air cleaner as-

sembly (IO) towards rear.
* Remove all the mounting bolts at the left,
right, and rear of the air cleaner assembly
mounting bracket.
6. Remove lubrication inlet hose (11) and outlet

tube (12).
7. Lift off turbocharger assembly (13). a
A kg Turbocharger assembly : 30 kg
INSTALLATION OF
TURBOCHARGER ASSEMBLY
removal.
a
m Turbocharger assembly mounting bolt:
66.15 f 7.35 Nm (6.75 f 0.75 kgml
30-30
0
DISASSEMBLY AND ASSEMBLY AFTERCOOLER CORE
REMOVAL OF AFTERCOOLER
CORE ASSEMBLY
1. Drain coolant.
2. Remove hood assembly.
For details, see REMOVAL OF HOOD ASSEM-
BLY.
3. Remove left side covers (I), then remove side
cover stay.
I CED01933
4. Remove hose (2) and 3 air cleaner assembly

mounting bolts (3).
5. Remove air cleaner assembly mounting bands
(4) and bracket (5).
6. Lift off air cleaner assembly (60.
elkg Air cleaner assembly : 45 kg
7. Remove bracket and intake connector (8).

8. Remove delivery tube (9). m
CED01348
I
30-31
0
DISASSEMBLY AND ASSEMBLY AFTERCOOLER CORE
9. Disconnect corrosion resistor hoses (IO) and

clamps (II).
10. Remove cover (12). m
11. Remove 4 mounting bolts of front water tubes
(13).
12. Remove rear water tube (14).
13. Remove aftercooler core assembly (15).
* Disconnect the front water tube and
aftercooler with a bar, then lift up the
aftercooler from the front and remove it.
E?lkg Aftercooler core assembly : 30 kg
INSTALLATION OF
AFTERCOOLER CORE
ASSEMBLY
removal.
w Delivery tube sleeve nut:

l Nozzle holder end:
22.05 + 2.45 Nm 12.25 f 0.25 kgm1
l Fuel injection pump end:
112.7 f4.9 Nm 111.5 + 0.5 kgm}
CED01351
w Cover mounting bolt:

32.5 k 2.45 Nm 13.25 f 0.25 kgm1
30-32
0
DISASSEMBLY AND ASSEMBLY NOZZLE HOLDER
REMOVAL OF NOZZLE
HOLDER ASSEMBLY
A minal
Disconnect the cable
of the battery.
from the negative (-1 ter-

BLY.
* Only when removing the No. 5 and No. 6
nozzle holder assemblies.
2. Open engine left side cover (I 1 and remove side
cover (2).
3. Remove side covers (3), then remove side cover
CED01332
stay.
4. Disconnect delivery tube (4) and spill hose (5).
5. Remove intake connector (6).

+ Only when removing the No. 4 nozzle holder
assembly.
6. Remove pipe (7) and cover (8).
7. Remove cylinder head cover (9).
8. Remove holder (IO), then remove nozzle holder
assembly (11). m
i CED01352
INSTALLATION OF NOZZLE
HOLDER ASSEMBLY
removal.
m
w Delivery tube sleeve nut:
lNozzle holder end:
22.05 + 2.45 Nm f2.25 e 0.25 kgm}
11
Fuel injection pump end:
uI
l
”
112.7 = 4.9 Nm Ill.5 t 0.5 kgm}

CEDO
m
* Assemble with the nozzle holder match mark
facing the front of the engine.,
w Holder mounting bolt :

26.95 z 2.45 Nm (2.75 = 0.25 kgm}
30-33
0
DISASSEMBLY AND ASSEMBLY ENGINE FRONT SEAL
REMOVAL OF ENGINE FRONT

SEAL
1. Remove radiator guard assembly.
For details, see REMOVAL OF RADIATOR
GUARD ASSEMBLY.
2. Remove crankshaft pulley (I). a
\ - CEO01512
3. Remove front seal (2).
CDD01513
FRONT SEAL
removal.
m
* Align the dowel pin when installing the
crankshaft pulley.
* Tighten the mounting bolts in the order
shown in the diagram on the right.
w Crankshaft pulley mounting bolt:
1st step: 73.5 2 19.6 Nmf7.5 2 2 kgm1 CDD01514
2nd step: 245 2 19.6 NmI25 f 2 kgm)

3rd step: 637 2 19.6 Nmi65 t 2 kgm1
pJ
. Procedure for assembling standard seal
* Fill the lip portion with approx. 5 CC of
lithium grease (G2-LI).
* Press fit front seal (2) to front cover (3).
* After press fitting, check mounting dimen-
sion a.
Front seal mounting dimension a :
66 mm (standard)
CED01515
30-34
0
DISASSEMBLY AND ASSEMBLY ENGINE FRONT SEAL
. Assembly procedure for seal with sleeve (for

maintenance)
I) Using tool Al, guide bolt 0, and nut 0,
press fit sleeve (4) to crankshaft (5).
* Tighten 3 nuts @ uniformly.
* Press fit until tool Al contacts the end
face of the crankshaft.
Ir After press fitting, check that mounting
dimension b of the sleeve is the speci-
fied dimension.
Sleeve mounting dimension b:
68 * 0.1 mm CED01516
2) Press fit front seal (6) to front cover (3).

* Fill the lip portion with approx. 5 cc of
lithium grease (G2-LI).
* After press fitting, check mounting di-
mension c. 3
Front seal mounting dimension c:
66 mm (standard)
I ’ CED01517
30-35
0
DISASSEMBLY AND ASSEMBLY ENGINE REAR SEAL
REMOVAL OF ENGINE REAR

SEAL
1. Remove damper assembly.
For details, see REMOVAL OF DAMPER ASSEM-
BLY.
2. Remove 1 mounting bolt of flywheel (I), and
install guide bolt 0.
3. Using lifting tool 0, sling flywheel (I), then
remove remaining mounting bolts. m
4. Move flywheel (I) out and lift off.
A The flywheel pilot is shallow and it may come
off suddenly, so be careful not to get your fin-
gers caught. m
II&lkg Flywheel : 45 kg
5. Remove rear seal (2).
I,
II \\
CED01519
REAR SEAL
Coat the thread and seat surface of the fly-

wheel mounting bolts with anti-friction com-
pound (LM-P).
Secure the flywheel and housing with stop-
per 0, then tighten the mounting bolts.
Tighten the flywheel mounting bolts in the
order shown in the diagram on the right.
w Flywheel mounting bolt:
CED01520
1st step: 73.5 k 19.6 Nm17.5 * 2 kgm1
2nd step: 245 f 19.6 NmI25 * 2 kgm1
3rd step: 637 k 19.6 NmI65 f 2 kgm1
CDD01521
30-36
0
DISASSEMBLY AND ASSEMBLY ENGINE REAR SEAL
Ir After installing the flywheel, use dial gauge

@ to measure the radial and face runout of
the flywheel.
. Face runout: Max. 0.15 mm
. Radial runout: Max. 0.20 mm
pJ
l Procedure for assembling standard seal
* Press fit the rear seal until it contacts the
flywheel housing.
l Assembly procedure for seal with sleeve (for !522

maintenance)
1) Using tool A2, guide bolt 0, and nut 8,
press fit sleeve (3) to crankshaft (4).
+ Tighten 2 nuts @ uniformly.
* Press fit until tool A2 contacts the crank-
shaft.
* After press fitting, check that mounting
dimension a of sleeve is the specified
dimension.
Sleeve mounting dimension a:
27zlmm
2) Press fit rear seal (5) until it contacts fly-
wheel housing (6).
6--._
CED01773
30-37
0
DISASSEMBLY AND ASSEMBLY CYLINDER HEAD
REMOVAL OF CYLINDER HEAD

ASSEMBLY
& Disconnect the cable from the negative (-) ter-
1. Drain coolant.
BLY.
side cover stay.
i CED01775
4. Remove engine left side covers (2), then re-

move side cover stay.
I 2 CED01776

mounting bolts (4).
7. Lift off air cleaner assembly (7).
f?lkg Air cleaner assembly : 45 kg
30-38
0
8. Remove bracket (8) and intake connector (9).

9. Remove delivery tube (IO). m
CED01356
10. Disconnect hose (II), then lower fuel filter as-

sembly (12).
11. Disconnect hose (13) and 2 clamps, and move
corrosion resistor (14) towards front of chassis.
12. Disconnect wiring connectors (CN-102) (15) and
clamps (16).
13. Remove boost compensator tube (17).
14. Remove rear water tube (18).
“*+ CED01358
15. Lift off aftercooler assembly (19).

Ir Disconnect the front water tube and
aftercooler assembly with a bar. m
rel
kg Aftercooler assembly : 80 kg
B-i=Vl.
kc\ \ -.. . . ..__.
--c--c____
16. Remove pipe (20).
7 1 %$5
CED01359
1
17. Remove adiabatic covers (211, (Xi’), and (231,

and water drain tube (24).
18. Lift off muffler assembly (25).
rE3kg Muffler assembly : 90 kg
19. Disconnect turbocharger lubrication inlet hose

(26) and outlet tube (27).
20. Lift off turbocharger and I exhaust manifold as-

sembly (28). a
elkg Turbocharger, exhaust manifold assembly:

60 kg
30-40
0
21. Remove APS water temperature sensor con-

nector (CN-106) (29) and engine water tempera-
ture sensor connector (CN-402) (30).
22. Remove brackets (31) and (32).
23. Disconnect heater hose (33).
b !\,\
CEO01364

25. Remove spill hose (35) and eye joint (36).
26. Remove cylinder head cover (37). a
Remove rocker arm assembly (38). m

Ir Loosen the locknut, then loosen the adjust-
ment screw 2 or 3 turns.
- CED01366
28. Remove crosshead (39) and push rod (40).

m
29. Remove holder (41). then remove nozzle holder
assembly (42).
30-41
0
CYLINDER HEAD
30. Remove pin (431, then use bar to move water

manifold (44).
31. Remove mounting bolts, then remove rocker
arm housing (45). m
32. Using eyebolts @remove cylinder head as-

sembly (46). a
Cylinder head assembly : 40 kg
/I I I-1
CEO01369
30-42
0
INSTALLATION OF CYLINDER
HEAD ASSEMBLY I

removal.
a
m Delivery tube sleeve nut:
lNozzle holder end:
22.05 2 2.45 Nm (2.25 2 0.25 kgm)
lFuel injection pump end:
112.7 + 4.9 Nm Ill.5 2 0.5 kgm}
m
* Tighten the mounting bolts in the order
CDD01370
shown on the right.
m Aftercooler assembly mounting bolt :

66.15 t7.35 Nm j6.75 = 0.75 kgm1
m
* Tighten the mounting bolts as shown on
the right.
m Turbocharger, exhaust manifold
assembly mounting bolt:
110.35 f 12.25 Nm Ill.25 f 1.25 kgm1
m
m Cylinder head cover mounting bolt:
31.85 2 2.45 Nm (3.25 f 0.25 kgm}
I CDD01371
Clean the oil holes of the mounting bolts
before installing.
Check that the ball of the adjustment screw
is fitted properly into the socket of the push
rod.
Adjust the valve clearance.
Testing and adjusting valve clearance.
w Rocker arm assembly mounting bolt :

98 z 4.9 Nm {IO + 0.5 kgm}
m Locknut : 67.62 2 9.8 Nm I6.9 + 1 kgm}
* Adjust the crosshead as follows.

1) Loosen the locknut and turn back the
adjustment screw.
2) Press down lightly with a finger on the
top of the crosshead and screw in the
adjustment screw.
30-43
0
3) When the adjustment screw contacts the

valve stem, tighten it a further 20”.
4) Tighten the locknut to hold the adjust-
ment screw in position.
w Locknut :
58.8 z 5.88 Nm {S + 0.6 kgm}
m
Ir Assemble so that the nozzle holder match
marks are facing the front of the engine.
m
26.95 f 2.45 Nm 12.75 2 0.25 kgm1
I CEO01 372
w Rocker arm housing mounting bolt :

98 + 4.9 Nm {IO = 0.5 kgm}
m
* Check that there is no dirt or dust on the
cylinder head mounting surface or inside
the cylinder.
* Check that the grommet does not come out
when installing the gasket.
* Tighten the cylinder head mounting bolts in
the order shown in the diagram on the right.
& Mounting bolt :
Anti-friction compound (LM-P)
w Cylinder head mounting bolt
186.2 + 4.9 NmU9 + 0.5 kgm1 Make marks on

cvlinder head and bolt
bolt and head, then tighten bolt
*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.
Tighten bolt SO’:!5’
0B003028
Make mark with punch
OBD02984
30-44
0
DISASSEMBLY AND ASSEMBLY FUEL TANK
REMOVAL OF FUEL TANK

ASSEMBLY
ADisconnect the cable from the negative (-) ter-
1. Remove covers (1) and (2).
2. Disconnect wiring connector (CN-422) (3).

3. Close fuel supply valve and disconnect fuel sup-
ply hose (4).
4. Disconnect brackets (5) and (6).
5. Disconnect fuel return hose (7) and hose clamp

(8).
CEDO
6. Lift off fuel tank assembly (9).
& kg Fuel tank assembly :

Approx. 500 kg (when empty)
Approx. 1350 kg (when full)
INSTALLATION OF FUEL TANK

ASSEMBLY
removal.
DISASSEMBLY AND ASSEMBLY RADIATOR
REMOVAL OF RADIATOR
ASSEMBLY
&ADisconnect the cable from the negative (-1 ter-
1. Drain coolant.
2. Disconnect front lamp connector (CN-202) (I 1.
3. Using eyebolt 0, lift off radiator top cover (2).
kg
rE?l Radiator top cover : 70 kg
4. Disconnect radiator inlet hose (3) and aeration

hose (4). m
5. Disconnect ground wiring (CN-GND4)(5).
6. Disconnect wiring clamp (6) (4 places), and move
wiring towards left side of radiator.
7. Disconnect sub tank hose (7).

8. Disconnect radiator water level sensor connec-
tor (CN-405) (8).
9. Remove wind breaker plate (9).
IO. Using lifting tool, sling radiator assembly, then
remove top mount bolts (IO) (left and right: 2
each).
/ CED01737
11. Remove 2 covers (II).

12. Open guard (12).
30-46
0
DISASSEMBLY AND ASSEMBLY RADIATOR
13. Remove wind breaker plate (13).
14. Disconnect radiator outlet tube (14).

15. Remove bottom mount bolts (15).
16. Lift off radiator assembly (16).

Ir Be careful not to damage the core when
lifting the radiator off.
el kg Radiator assembly : 370 kg
INSTALLATION OF RADIATOR
ASSEMBLY
removal.
m
m Radiator inlet hose clamp :
882 f 98 Ncm I90 f IO kgcm1
w hose clamp :
Aeration
333.2 + 49 Ncm I34 * 5 kgcm}
l Refilling with water
30-47
0
DISASSEMBLY AND ASSEMBLY RADIATOR GUARD
REMOVAL OF RADIATOR
GUARD ASSEMBLY
1. Remove cap (I) of blade lift cylinder. m
Ir Check the number and thickness of the
shims, and keep in a safe place.
AStart engine and retract the piston rod fully,
and tie the piston rod with wire to prevent it
from coming out.
2. Disconnect hose (2).

A Release the remaining pressure from the hy-
draulic circuit.
Releasing remaining pressure from hydrau-
lic circuit.
* Fit a blind plug to prevent dirt from enter-
ing the piping.
3. Sling blade lift cylinder assembly (31, then fit

cylinder lock tool and secure to radiator guard.
4. Drain coolant.
BLY.
I \ CED021
96
6. Disconnect radiator inlet hose (4). m

* Disconnect the hose at the radiator end and
move it towards the engine.
7. Disconnect aeration hose (5). m
* Disconnect the hose at the radiator end, then
remove the clamps (2 places) and move it to-
wards the engine.
8. Disconnect air conditioner hoses (6) 1141
* Loosen the sleeve nut slightly and release
the air conditioner gas (R134a) completely
before disconnecting the hoses.
* Fit blind plugs to prevent dirt or moisture I
from entering the hoses.
30-48
0
9. Open engine underguard.

IO. Remove right undercover of radiator guard, then
remove radiator outlet tube (13). m
* Loosen the clamp at the hose portion, then
remove the tube.
12. Loosen tension of tension pulley (81, and re-

move fan belt (9).
* Using a chain block, pull the tension pulley
securely in the direction shown in the dia-
gram on the right to loosen the belt ten-
sion.
CEDO 1746
13. Sling radiator and guard assembly and remove

lock bolt, then using tool A3, push rear pin (IO)
to inside radiator guard and remove.
14. Remove lock plate, then using tool A3, pull front
pin (11) to outside radiator guard and remove.
Ii \ ‘A3
CED0174; CEO01750
15. Lift off radiator guard assembly (12).

* 8e extremely careful not to damage the wir-
ing and piping when removing.
&I kg Radiator guard assembly : 1750 kg
INSTALLATION OF RADIATOR
GUARD ASSEMBLY
removal.
a
* Standard shim thickness : 4 mm
/sJ
882 + 98 Ncm (90 +. 10 kgcm1
a
333.2 + 49 Ncm t34 + 5 kgcm1
m
* I nstall the hoses without twisting or interfer-
ence.
* When installing the air conditioner circuit
hoses, be extremely careful not to let any
dirt, dust, or moisture get inside the hoses.
* Check that there is an O-ring at the piping
connection for the air conditioner hose, then
tighten the hose.
T----
Coat the O-ring thoroughly with compres-
-_-_
sor oil (Showa Shell Suniso 4G or 5G).
w Air conditioner hose (top) :
22.05 t 2.45 Nm I2.25 +. 0.25 kgm1
w Air conditioner hose (bottom) : O-ring
13.23 2 1.47 Nm il.35 t 0.15 kgm1

DBD02985
@7J
w Radiator outlet hose clamp :
882 I 98 Ncm I90 z IO kgcml
l Charging with air conditioner gas
Using tool X, charge the air conditioner circuit
with air conditioner gas (R134a).
30-50
0
DISASSEMBLY AND ASSEMBLY ENGINE
REMOVAL OF ENGINE
ASSEMBLY
A Disconnect the cable from the negative (-1 ter-
1. Drain coolant.
BLY.
side cover stay.
I CED01775
4. Remove engine left side cover (21, then remove

side cover stay.
‘2 CED01776

mounting bolts (4).
C?lkg Air cleaner assembly : 45 kg
' CED01778
30-5 1
0
8. Disconnect ground wiring (8).

9. Disconnect starting motor wiring (9).
10. Close heater valve and disconnect heater hoses
(IO) and (II), then remove clamp and move
towards rear of engine.
11. Remove torque converter oil cooler connector

(12).
12. Disconnect radiator outlet tube (13).
13. Disconnect covers (14) and (15).

14. Disconnect air conditioner hoses (16), (171, and
(18). p-J
* Fit blind plugs to prevent dirt or moisture
Ir Disconnect all the clamps for hoses (16) and
(17).

16. Disconnect fuel supply hose (20).
30-52
0
17. Disconnect fuel return hose (21) and spill hose

(22).
18. Disconnect fuel control rod (23).
20. Disconnect radiator inlet hose (25).

21. Disconnect aeration hose (26).
22. Remove fan net (27).

23. Loosen tension of tension pulley (28) and re-
move fan belt (29).
* Using a chain block, pull the tension pulley
securely in the direction shown in the dia-
gram on the right to loosen the belt ten-
sion.
CED01795 CED01785
24. Remove right covers (30) and (31).

25. Remove left covers (32) and (33).
26. Remove air intake port (34).
27. Disconnect deceleration rod (35).

28. Disconnect 2 in-line servo valve hoses (36).
29. Disconnect wiring connectors (CN-SIO) (37) and
(CN-Sl 1) (38).
CED01788 CEO01789
30. Disconnect engine speed sensor connector (CN-

SM5) (39).
31. Lift off bracket assembly (40).
elkg Bracket assembly : 100 kg
CED01790 CED01791
32. Remove damper case oil level gauge (41).

33. Remove bracket (42).
34. Sling universal joint (431, then remove mount-

ing bolts and remove. /KJ
Universal joint : 45 kg
CED01792
30-54
0
35. Remove front mount bolt (44) and rear mount

bolt (45). a
36. Raise engine assembly (47) slowly and remove
right rear mount cap (46).
l+l kg Engine assembly : 3000 kg
4i 45 CED01793
37. Move engine assembly (47) towards front of

chassis and operate chain block to raise front of
engine and put engine assembly at an angle.
38. Move engine assembly (47) so that front and
rear of engine do not interfere with chassis com-
ponents, then turn at 90” to chassis and remove
engine assembly (47).
* Be careful not to damage the wiring and the
hoses when removing.
30-55
0
ASSEMBLY
removal. I
m-
* install the hoses without twisting or inter-
-_-_ -_
ference.
* When installing the air conditioner circuit
dirt, dust, or moisture get inside the hoses. q--
* Check that there is an O-ring at the piping 0-rino

OBDO2985
tighten the hose.
w Air conditioner piping

I
Thread size Tightening torque
16 X 1.5 13.23 k 1.47 Nm

(I.35 f. 0.15 kam1
22 x 1.5 22.05 f 2.45 Nm

(2.25 f 0.25 kgm1
24 X 1.5 31.85 & 2.45 Nm

(3.25 f 0.25 kgm1

882 t 98 Ncm I90 f 10 kgcm1
m
333.2 2 49 Ncm I34 + 5 kgcm1
m
w Universal joint mounting bolt :
176.4 + 19.6 Nm {I8 +12 kgm1
m
m Engine mount bolt :
926.1 + 102.9 Nm I94.5 2 1 kgml
30-56
0
DISASSEMBLY AND ASSEMBLY DAMPER
REMOVAL OF DAMPER
ASSEMBLY
a Disconnect the cable from the negative (-1 ter-
BLY.
mounting bolts (2).
r+ kg Air cleaner assembly : 45 kg

6. Disconnect starting motor wiring (7).
7. Close heater valve and disconnect heater hoses
(8) and (91, then remove clamp and move to-
wards rear of engine.
8. Disconnect fuel control rod (IO).

10. Remove right covers (12) and (13).

11. Remove left covers (14) and (1%.
12. Remove air intake port (16).
13. Disconnect deceleration rod (17).

14. Disconnect 2 in-line servo valve hose (18).
15. Disconnect wiring connectors (CN-SIO) (19) and
(CN-Sll) (20).
CED01853
16. Disconnect engine speed sensor connector (CN-

SM5) (21).
17. Disconnect air conditioner hoses (22) and (23).
m
Sr Fit blind plugs to prevent dirt or moisture
18. Lift off bracket (24).
&I kg Bracket assembly : 100 kg CED01854 CEO01855
19. Remove damper case oil level gauge (25).

30-58
0
21. Open power train underguard (front).

22. Sling universal joint (27), and remove mount-
ing bolts, then remove. m
kg
C&j Universal joint : 45 kg
CEDOI 856
23. Remove drain plug and drain oil from damper

case.
- : Damper case : Approx. 2.1 I?
24. Remove holder (28) and coupling (29). m

25. Remove retainer (30).
CED01857 CEO01858
26. Using eyebolt 0, sling damper cover (31), then

using forcing screw and remove. m
ASet guide bolt @ (e =200mm) in position so
that the damper cover does not come out
suddenly.
&I kg Damper cover : 75 kg
27. Using eyebolt 0, remove damper assembly (32).
ASet guide bolt @ (1 =200mm) in position so

that the damper assembly does not come CED01859 CED01860
out suddenly.
&I kg Damper assembly : 70 kg
28. Remove bearing (33) from flywheel. m
CED01861
30-59
0
INSTALLATION OF DAMPER
ASSEMBLY
removal.
a
Ir Install the hoses without twisting or inter-
ference.
Ir When installing the air conditioner circuit
dirt, dust, or moisture get inside the hoses.
Ir Check that there is an O-ring at the piping
tighten the hose.
w Air conditioner piping
Thread size Tightening torque
16 X 1.5 13.23 f 1.47 Nm

(1.35 f 0.15 kgm} - _dg+~~
22 x 1.5 22.05 + 2.45 Nm

(2.25 2 0.25 kgm1
24 X 1.5 31.85 f 2.45 Nm 0-rine

(3.25 f 0.25 kgm)
DBD02985
Universal joint mounting bolt :

176.4 t 19.6 Nm I18 + 2 kgm1
Holder mounting bolt thread :

Thread tightener (LT-2)
Holder mounting bolt :

276.85 2 31.85 Nm 128.25 f 3.25 kgm1
Using guide bolt @ (! =200mm), set the

damper cover in position.
Using guide bolt @I (&200mm), set the

damper assembly in position.
Fill 50% of the hatched portion in the dia-

gram on the right with grease (G2-LI)
(approx. 11 g).
30-60
0
. Refilling with oil (damper case)

Sr Add oil through oil filler to the specified level.
30-6 1
0
DISASSEMBLY OF DAMPER
ASSEMBLY
Disassembly of damper assembly
1. Set damper assembly to block 0.
2. Remove mounting nuts (I), then using forcing
screws 0, remove flange (2).
2
CED01798 CED01799
3. Remove shaft (3).

4. Remove rubber (4).
5. Using forcing screws 0, remove flange (5) from
body (6).
CED01800
6. Remove seal (7) from flanges (2) and (5).
CED01802
Disassembly of damper cover

assembly
7. Remove bearing (8) and oil seal (9) from cover
(IO).
8. Remove oil seal (11) from retainer (12).
CED01804
CED01803
30-62
0
ASSEMBLY OF DAMPER
ASSEMBLY
Assembly of damper assembly
1. install seal (7) to flanges (2) and (5).
Ir Install the seal with the lip facing the inside
as shown in the diagram.
CED01805
2. Align the bolt holes with body (6), then install

flange (5).
& Flange mating surface :
Gasket sealant (LG-4)
* Check that there are no dents, rust, oil or
grease, or water on the mating surface, then
coat both the flange and body surfaces with
gasket sealant.
CEDO1807
3. Set flange and body assembly to block 0, then

shaft (3) in position. Shaft
4. Assemble rubber (4).
-k When assembling the rubber, coat the whole
surface of the rubber, the outside circum-
ference of the shaft, and the inside circum-
ference of the body with grease (G2-LI).
* After assembling the rubber, fill approx. 30%
(approx. 190 g) of the space between the
shaft and body (16 places) with grease (G2-
learance
LI).
5. Install flange (2). CED01808 DBD02988
& Flange surface :

mating
* Check that there are no dents, rust, oil or
grease, or water on the mating surface, then
coat both the flange and body surfaces with
gasket sealant.
6. Set bolt in position and tighten mounting nuts
(I).
I CEDOlBlO
30-63
0
Assembly of damper cover assembly

7. Using push tool 0, press fit oil seal (11) to
retainer (12).
& Oil seal press-fitting surface :

Gasket sealant (LG-1 I
* Coat the inside surface of the retainer thinly
with gasket sealant and wipe off any seal-
ant that is forced out.
& Lip of oil seal : Grease (G2-LII
8. Using push tool 0, press fit bearing (8) to cover

(10).
CEO01812
9. Using push tool 0, press fit oil seal (9) to cover

(IO).
& Oil seal press fitting surface :
* Coat the inside surface of the cover thinly
with gasket sealant and wipe off any seal-
ant that is forced out.
& Lip of oil seal : Grease (G2-LI)
I CED01813
30-64
0
DISASSEMBLY AND ASSEMBLY POWER TRAIN UNIT
REMOVAL OF POWER TRAIN

UNIT ASSEMBLY
1. Drain oil from hydraulic tank and power train
case.
- : Hydraulic tank : Approx. 120 t
- : Power train case : Approx. 150 i?
2. Remove floor frame assembly.

For details, see REMOVAL OF FLOOR FRAME
ASSEMBLY.
3. Remove fuel tank assembly.
For details, see REMOVAL OF FUEL TANK AS-
SEMBLY.
4. Disconnect 2 in-line servo valve hoses (1).
5. Remove 2 clamps (2) of work equipment and
PPC pump inlet tube coupling.
* Move the coupling towards the power line
unit end, then disconnect the tube.
6. Disconnect PPC drain hose (3).
* Disconnect at the pump inlet tube end and
move towards right side of the chassis.
7. Disconnect 2 PPC oil cooler hoses (41, then dis-
connect clamps (2 places).
8 * Keep the two hoses together, pass them
iii around the outside of the oil level gauge,
5; and move them towards the right side of
the chassis.
8. Disconnect work equipment and PPC pump out-
let hoses (5).
Ir Disconnect at the pump end.
9. Disconnect wiring connector (CN-241) (61, then
disconnect clamps (2 places).
I 4 CED01524
10. Disconnect hydraulic oil temperature sensor

connector (CN-452) (7) and lock-up solenoid con-
nector (CN-653) (81, then disconnect clamp (1
place).
11. Disconnect torque converter oil temperature
sensor (CN-453) (9).
12. Disconnect torque converter oil cooler hose (IO).
30-65
0
13. Disconnect steering control rod (1 I). a

j, Disconnect at the power train unit end.
14. Remove bracket (12) together with rod.
15. Disconnect transmission 1st oil pressure switch
connector (CN-SO71 (131, then disconnect clamp
(1 place).
16. Disconnect transmission FORWARD detection

limit switch connector (CN-S12) (14), backup
alarm limit switch connector (CN-251) (151, and
transmission oil pressure switch connector (CN-
652) (16).
CEDO 1527
I
17. Disconnect right rear lamp connector ((IN-2431
(17), then disconnect clamps at top of frame (3
places) and bottom of frame (I place).
18. Remove frame (18).
19. Disconnect torque converter oil cooler hose (191,

then disconnect bracket at frame end. CEDOl528
j, Move the hose towards front of the chassis.
20. Disconnect ripper Lo valve hose (20), then dis-
connect bracket (1 place) on steering case.
* Move the hose towards the power train unit
end.
21. Disconnect 2 pin-puller solenoid hoses (21), then
disconnect clamp.
* Disconnect the hoses at the steering case
end and move towards the ripper end.
22. Disconnect torque converter speed sensor con-
nector (CN-651) (22), then disconnect clamps (3
places).
* Move all the wiring around the power train
unit together to the front left of the chassis.
30-66
0
23. Disconnect clamp (23), then disconnect clamp

(24) and remove bracket.
* Move the hose towards right side of the chas-
sis.
24. Disconnect universal joint (25) at torque con-

verter end. m
* After disconnecting, move towards the
damper end.
25. Remove cover (261, then using eyebolt, pull out

left and right drive shafts (27). m
* If the shaft will not come out, set a jack on
the ground and push the shoe grouser up,
then move the sprocket to the front or rear
to a position where the shaft will come out,
and remove the shaft.
* Pull the shaft out to a position where it con-
tacts the sprocket.
CED01532 CED0153:
26. Remove right floor frame rear mount (28).

* The rear right mount of the floor frame will
cause interference when the power train unit
is raised, so remove it at this point.
30-67
0
27. Remove left floor frame mount (29) and right

floor frame mount (30).
+ The front mount of the power train unit is
tightened together with the front mount of
the floor frame.
Left floor frame mount : 35 kg
Right floor frame mount : 30 kg
28. Remove left and right rear mount caps (31).

a
29. Loosen left and right rear coupling clamps

(32).
m
+ Move the clamp towards the main frame,
then open the jaw of the coupling, and move
it towards the main frame.
30. Lift off power train unit assembly (33). m

It Check that all the wiring and piping has been
disconnected before removing the power
train unit assembly.
A kg Power train unit assembly : 4200 kg
A
CED01533
30-68
0
INSTALLATION OF POWER
TRAIN UNIT ASSEMBLY
removal.
m
+ Connect steering control rod (1 I) and bracket
(12) so that the position of the levers is as
shown in the diagram on the right.
1121
w Universal joint mounting bolt :
176.4 z 19.6 Nm I18 t 2 kgml
m
* If the shaft will not go in, set a jack on the
ground and push the shoe grouser up, then
move the sprocket to the front or rear to a
position where the shaft will mesh, and as-
semble the shaft.
m
m Rear mount cap mounting bolt :
367.5 + 61.25 Nm (43.75 + 6.25 kgm}
m Rear coupling clamp mounting nut :

6.85 + 1.96 Nm IO.7 = 0.2 kgml
m
* When installing the power train unit assem-
bly, pay attention to the mating surface of
the coupling, and be careful not to damage
the seal of the rear mount coupling.
. Refilling with oil (power train case, hydraulic

tank)
Add engine oil through oil filler to the specified
level.
Run the engine to circulate the oil through the
system. Then check the oil level again.
G Power train case : Approx. 150 L?
Hydraulic tank : Approx. 120 e
30-69
0
DISCONNECTION OF POWER
TRAIN UNIT ASSEMBLY
1. Drain oil.
Before setting power train unit assembly in po-
sition, drain oil from oil pan.
2. Raise power train unit assembly (I) and set on
block (1).
* Set blocks under the front of the oil pan,
transmission rear case, and steering case.
CED01662
3. Remove brake rod (2). a

4. Remove parking brake cable (3) m
* Measure the dimension of the mounting
bracket.
5. Remove control cable and bracket assembly (4).
a
* Disconnect the directional control cable and
speed control cable together with the levers
at the control valve end.
CEO01663
6. Disconnect 10 pressure detection hoses (51, and

remove together with centralized pressure de-
tection bracket (6).
* Before removing the pressure detection
hoses, mark them with tags to prevent any
mistake when installing.
CED01684
7. Remove oil level gauge (7).

8. Remove oil filler pipe (8).
II CED01666
30-70
0
9. Lift off filter assembly (9) together with bracket.
A kg Filter assembly : 120 kg
10. Lift off strainer assembly (IO) together with suc-

tion tube.
& kg Strainer assembly : 50 kg
CED01687
11. Lift off power train and lubrication pump as-

sembly (11).
Power train, lubrication pump assembly:

50 kg
12. Lift off scavenging pump assembly (12).
Scavenging pump assembly : 40 kg
13. Lift off front mount (13).
Front mount : 150 kg
CED01691
14. Remove work equipment and PPC pump outlet

hose.
15. Lift off work equipment and PPC pump assem-
bly (14) together with inlet tube.
kg
rF?l Work equipment, PPC pump assembly :
65 kg
16. Disconnect steering control rods (15) at control

valve end, and remove together with lever as-
sembly (16). m
17. Remove block under oil pan, and sling oil pan
(17).
18. Remove mounting bolts, then remove oil pan
(17).
* In addition to the mounting bolts at the front,
rear, left, and right, there are also bolts in
the four holes at the bottom of the oil pan.
el kg Oil pan : 110 kg
19. Remove cage (18) together with torque converter

speed sensor. m
20. Remove case (19).
CED01695 CED0169t
30-72
0
DISASSEMBLY AND ASSEMBLY POWER TRAlN UNIT
21. Remove shaft (20).
22. Set block @ under PTO.

23. Sling steering case assembly (211, and remove
block under steering case.
CED01696
24. Remove mounting bolts, then remove steering

case assembly (21). m
&I kg Steering case assembly : 1,750 kg
CED01699
25. Stand PTO, torque converter, and transmission

assembly (22) upright with PTO at top, and set
on block 0.
CED01700
30-73
0
26. Remove coupling (23).

27. Remove retainer (24). m
* Check the number and thickness of the
CEO01723
CED01724
28. Remove snap ring (251, then remove spacer (26).
29. Using eyebolt, lift off PTO assembly (27). m
l+l kg PTO assembly : 290 kg
:ED01726
30. Lift off torque converter assembly (28).
& kg Torque converter assembly : 550 kg
CEO01727
30-74
0
CONNECTION OF POWER
TRAIN UNIT ASSEMBLY
. Carry out connection in the reverse order to
disconnection.
Bend the cotter pin securely.
Adjust the installation dimensions of the

bracket to the dimensions measured when
removing.
Bend the cotter pin securely.
Adjust the limit switch and lever of the di-

rectional control linkage as follows. (Lever
(29) and limit switch(30) are double-typed
in the vertical direction.)
1) Set lever (29) to the N position, then
insert.
2) Set to a height where the roller of top
and bottom limit switch (30) contacts
the top and bottom groove in lever (291,
then tighten lever (29) temporarily.
3) Move lever (29) to the F and R posi-
tions, check that the rollers are pushed
in securely (at F: top limit switch; at R:
bottom limit switch), then tighten lever
(29) fully.
/I CED01728
Bend the cotter pin securely. 18
Check that the tip of shaft (20) is fitted se-

curely in drum (31) of cage (18).
m
* Check that shaft (20) is fitted securely in
boss (32) of the tip of the transmission in-
put shaft.
\
32 CED01730
30-75
0
m Steering case mounting bolt :

276.85 + 31.85 Nm I28.25 f 3.25 kgm) 24
m
* Adjust the shim of the retainer portion as
follows. ----------~-
_____-------
1) Without fitting a shim, install retainer
(24) and tighten the 6 mounting bolts to
the following torque.
& Oil seal : Grease (G2-LB
w Mounting bolt : 9.8 Nm 11 kgm}
2) Using clearance gauge, measure clear-

ance a between retainer (24) and PTO
housing (33).
j, Measure clearance a at 4 places (A, A
B, C, D) around the circumference, 9 0 Q OJ
0
and calculate the average value.
3) Select shim thickness.
l Shim thickness = a+to5 mm 0 0
* Shim thickness: 0.15, 0.2, 0.5 mm
4) Assemble selected shim thickness, then
tighten mounting bolts of retainer (24)
to specified tightening torque. / O Q O YB
w Mounting bolt :
66.15 t 7.35 Nm I6.75 z 0.75 kgm1
I CDDO1732
+ Check the number and thickness of

the shims to confirm that the shim
thickness is the same on the left and
I Forcing tap hole
right.
Shim ,,Shim
Ir Assemble the shims as shown in the ‘\
diagram on the right so that the forc-
ing tap holes of the retainer are not
blocked.
m
* Coat the P portion of the PTO input shaft
with anti-friction compound (LM-PI and the
spline with grease (G2-LI).
Forcing tap hole DAD02989
Solined portion
30-76
0
DISASSEMBLY AND ASSEMBLY PTO
DISASSEMBLY OF PTO
ASSEMBLY
1. PTO lubrication tube
Sling PTO assembly and remove lubrication tube
(1).
* Remove the 3 lubrication tubes on the op-
posite side also, set the torque converter
end at the bottom, then lower.
I-
2. Hydraulic, PPC pump gear assembly
I) Using forcing screws 0, pull out cover as-
sembly (2) and to lift off.
2) Using puller 0, remove gear assembly (3)
from cover (4).
I/ CED01257 4 CED01258
3) Using puller 0, remove bearings (5) and (6)

from gear (7).
6’ CED01260
3. Power train pump gear assembly

1) Using forcing screw 0, pull out cover as-
sembly (8) and lift off.
2) Using puller, remove gear assembly (10)
from cover (9).
CED01261 ( CED01262
30-77
0
3) Using puller 0, remove bearings (11) and

(12) from gear (13).
CED01264
4) Turn over PTO case and remove cover (14).
4. Scavenging pump gear

Remove snap ring (I 5) from bottom of PTO case,
then remove gear (16).
CED01265 CEO01266
5. Idler gear assembly

I) Remove plate (17).
CED01267 CED01266
2) Turn over PTO case, then using forcing

screw 0, remove shaft assembly (18).
* The bearing outer race and gear assem-
bly will come off from the bottom of the
PTO case, so set wooden blocks in posi-
tion and be careful not to damage the
parts.
3) Remove plugs (191, then using forcing screw,
push out bearing inner race (20).
* After removing the bearing, install the
plugs. 20’
CED012691 CED01270
30-78
0
4) Remove bearing outer races (21) and (22)

from gear (23).
I 22
I CED01271
6. PTO case
1) Remove race assembly (24) together with
bearing outer race (25).
g
CED01.272
%
z
2) Remove bearing inner races (26) and (27)

from race (28).
CED01273
3) Remove bearing outer race (29).

4) Remove sleeve (30).
‘-3 CED01274
30-79
0
PTO
7. Bearing
Remove snap ring (311, then remove bearing
(32).
CED017.75
30-80
0
ASSEMBLY OF PTO
ASSEMBLY
* Clean all parts, and check for dirt or damage.
* Check the snap ring is fitted securely in the
groove.
1. Bearing
1) Using push tool, press fit bearing (32) to
case.
* Put drops (approx. 6 cc) of engine oil
(SAEIOW-CD or SAE30-CD) on the bear-
ing and rotate about IO times.
2) Install snap ring (31).
CED01275
2. PTO case
I) Install sleeve (30) to case.
Ir Install the sleeve with the chamfered in-
side circumference facing down.
* Expand-fit the sleeve.
2) Using push tool, press fit bearing outer race
(29).
I
CED01274
3) Using push tool, press fit bearing inner races

(27) and (26) to race (28).
27
CED01273
4) Install race assembly (24).
& Internal surface of race :

5) Using push tool, press fit bearing outer race
(25).
+ Put drops (approx. 6 cc) of engine oil
(SAEIOW-CD or SAEBO-CD) on the bear-
ing and rotate about 10 times.
CED01272
30-81
0
3. Idler gear
1) Using push tool 0, press fit bearing outer
races (22) and (21) to gear (23). 23 21
*
22
CED01276 CED01277
2) Using push tool 0, press fit bearing inner

race (20) to shaft.
3) Fit O-ring and install shaft assembly (18).
' CED01.2761 CED017.79
4) Turn over PTO case and install gear assem-

bly (33).
5) Press fit bearing spacer (34) and bearing
inner race (35).
CED01280 CEDOl261
6) Install plate (17).
& Mounting bolt :

Thread tightener (LT-21
w Mounting bolt :
110.35 + 12.25 Nm 111.25 d 0.25 kgm1
4. Scavenging pump gear

1) Install gear (16).
& Spline portion : Grease (G2-LI)
CED01266 CED01267
30-82
0
2) Install snap ring (15) from bottom of PTO

case.
‘1
5. Power train pump gear assemblv
1) Fit O-ring and install cover (i4).
2) Using push tool 0, install bearings (11) and

(12) to gear (13).
CEO01262 CEO01264
3) Using push tool @, press fit gear assembly

(IO) to cover (9).
& Gear spline portion : Grease (G2-LI)

44 Fit O-ring, then raise cover assembly (8) and
install to case.
* If the cover assembly is stiff and does
not enter the case easily, tap the sur-
rounding area uniformly with a plastic
hammer to install.
(SAEIOW-CD or SAE30-CD) on the bear- Y CED01283 CEO01284
6. Hydraulic, PPC pump gear assembly

1) Using push tool 0, press fit bearings (5)
and (6) to gear (7).
CED01285 CED01260
30-83
0
2) Using push tool @, press fit gear assembly

(3) to cover (4).
+ Install with the bearing end face and gear
end face (which form a level surface)
facing the cover.
& Gear spline portion : Grease (G2-LI)
3) Fit O-ring, then raise cover assembly (2) and
install to case.
* If the cover assembly is stiff and does
not enter the case easily, tap the sur-
rounding area uniformly with a plastic
hammer to install. CED01.286 CED01287
7. Lubrication tube
Sling PTO assembly and install lubrication tube
(I).
* Install the 3 lubrication tubes on the oppo-
site side also.
30-84
0
DISASSEMBLY AND ASSEMBLY TORQUE CONVERTER
DISASSEMBLY OF TORQUE
CONVERTER ASSEMBLY
. Preparatory work
Set torque converter assembly (56) to tool C.
CED01288
1. Torque converter valve assembly

Remove torque converter valve assembly (1).
2. Draining oil
Remove 2 drain plugs (2) and drain oil from
pump case.
* After draining oil, tighten the plug.
3. Lock-up clutch, drive case assembly
I) Leave 2 mounting bolts (3) in position, set
input shaft at top, then remove remaining
mounting bolts.
8
g CED01289 CED0129C
z
2) Using eyebolt 0, remove lock-up clutch and

drive case assembly (4).
3) Disassemble lock-up clutch and drive case
assembly as follows.
i) Remove 2 seal rings (5).
ii) Using forcing screws 0, remove input
shaft (6).
CED01291 CED01292
iii) Remove snap ring (71, then remove plate

(8).
iv) Set clutch housing at bottom, then us-
ing forcing screws 0, remove turbine
(9).
CED01293 CED01294
I
30-85
0
v) Set clutch housing at top, then using

eyebolts 0, remove housing and piston
assembly (IO).
* When the assembly is removed, the
piston will fall out, so support it by
hand when removing.
vi) Remove piston (11) from housing (12).
Ii
CEO01295 CED01.296
vii) Remove seal ring (13) from piston.

viii)Remove seal ring (14) from housing.
CED01297 CED01298
ix) Using push tool 0, remove bearing (15)

from housing.
CED01299
x) Remove 2 discs (16) and 1 plate (17)

from drive case (18).
* After removing the discs and plates,
keep them in a flat place to prevent
them from becoming distorted.
CED01300
30-86
0
4. Stator assembly
1) Remove snap ring (19), then remove stator
assembly (20).
2) Disassemble stator assembly as follows.
i) Remove snap ring (21), then remove race
(22) from stator (23):
‘23
CED01301 CED01302
ii) Remove snap ring (24) from stator (23).
23
CED01303
5. Pump assembly
1) Remove snap ring (25).
2) Remove pump assembly (26).
3) Disassemble pump assembly as follows.
i) Remove retainer (27).
ii) Remove bearing and guide assembly
(28) from pump (29).
29
CED01305
iii) Remove bearing outer race (30) from

guide (31).
6. Stator clutch housing
Set stator clutch housing at top and remove
stator clutch housing (32).
CED01306 CED01307
TORQUE CONVERTER
7. Spring
Remove spring (33).
8. Springs, discs, plate
Remove springs (341, 2 discs (351, and 1 plate
(36).
* After removing the discs and plates, keep
them in a flat place to prevent them from
becoming distorted.
9. Pin
Remove pin (37). 34 33 35 36 j7
CED01308 CED01309
10. Inner gear

Remove snap ring (38), then remove inner gear
(39).
11. Piston
1) Remove piston (40) from case (41).
CED01310 CED01311
2) Remove seal ring (42) from piston.

3) Remove seal ring (43) from case.
CED01312 CED01313
12. Stator shaft assembly

1) Tap stator shaft assembly (44) with a plastic
hammer, and remove from case (45).
2) Disassemble stator shaft assembly as fol-
lows.
i) Using push tool @, remove shaft assem-
bly (46) from stator shaft assembly.
CEDOt31!
30-88
0
ii) Remove snap ring (471, then remove

bearing inner race (481, bushing (491, and
seal ring (50) from shaft.
iii) Remove seal ring (51) from stator shaft
(52).
iv) Remove snap ring (531, then remove
plate (54).
50 47 48 53 54 51
CED01316 CED01317
VI Using push tool 0, remove bearing (55).
55
CED01318
30-89
0
ASSEMBLY OF TORQUE
CONVERTER ASSEMBLY
Ir Clean all parts, and check for dirt or damage.
* Check that the snap ring is fitted securely in the
groove.
. Preparatory work
Set case (41) to tool C.
1. Stator shaft assembly

I) Assemble stator shaft assembly as follows.
i) Using push tool, press fit bearing (55) to
stator shaft (52).
* Put drops (approx. 6 cc) of engine
oil (SAEIOW-CD or SAE30-CD) on the
bearing and rotate about 10 times.
ii) Install plate (54) and secure with snap
ring (53).
iii) Install seal ring (51).
* After installing the seal ring, coat
with grease (G2-LI) to secure it to CEO01320 CED01317
the shaft.
iv) Install seal ring (50) to shaft.

* After installing the seal ring, coat
with grease (G2-LI) to secure it to
the shaft.
v) Using push tool @, press fit bushing (49).
* Be careful not to deform the bush-
ing when press fitting.
50 47 48
CE0013.21
CED01316
vi) Using push tool @I, press fit bearing in-

ner race (48).
vii) Install snap ring (471, and secure bear-
ing inner race.
CED01322 I CED01323
30-90
0
2) Tap stator shaft (52) with a plastic hammer

and press fit bearing portion to case.
3) Set shaft (46) to stator shaft, then using push
tool, press fit bearing portion.
4) Turn over case and tighten mounting bolts
of shaft from case end.
6 Mounting bolt :
w Mounting bolt :
66.15 + 7.35 Nm (6.75 + 0.75 kgm}
I CED01324 46 CED01325
2. Piston
1) Install seal ring (43) to case.
& Outer circumference of seal ring :
Grease (G2-LI)
* Be careful to assemble the seal ring fac-
ing in the direction shown in the dia-
gram on the right.
2) Install seal ring (42) to piston.
Grease (G2-LI)
* Be careful to assemble the seal ring fac- CED01313 CED01312
ing in the direction shown in the dia-
gram on the right.
FL DBD02991
3) Install piston (40) to case (41).
& Contact surface of seal ring :

Grease (G2-LB
3. Inner gear
install inner gear (39) and secure with snap ring
(38).
CEDOl311 CED01310
4. Pin
Install pin (37).
5. Plate, discs, springs
Install 1 plate (36), 2 discs (351, and springs
(34).
6. Spring
Install spring (33).
CE001309 CED01308
7. Stator clutch housing

Install stator clutch housing (32). 32
/
* Check that the springs are fitted securely in
the holes in the housing and piston.
& Mounting bolt : Thread tightener (LT-2)
w Mounting bolt :
110.35 + 12.25 Nm III.25 + 1.25 kgml
8. Pump assembly
I) Assemble pump assembly as follows.
i) Using push tool, press fit bearing outer
CED01307 CED01306
race (30) to guide (31).
ii) Set bearing and guide assembly (28) to
28 27’
pump (29), then tap with a plastic ham- \ /
mer and press fit bearing portion.
iii) Install retainer (27).
& Mounting bolt :
w Mounting bolt :
66.15 L 7.35 Nm 16.75 + 0.75 kgml
2) Install pump assembly (26). 29
* When installing the pump, be careful not CED01305
to damage the seal ring assembled to
the shaft.
9. Stator assembly
I) Assemble stator assembly as follows.
i) Install snap ring (24) to stator (23).
I i3
CED01303
30-92
0
ii) Assemble race (22) to stator (231, and

secure with snap ring (21).
2) Install stator assembly (20) to stator shaft, I
and secure with snap ring (19).
23
CED0130: CED01301
10. Lock-up clutch, drive case assembly

I) Assemble lock-up clutch and drive case as-
sembly as follows.
i) Set turbine (9) to block 0, and set drive
case (18) to turbine.
CED01327 ii CED01328
ii) Install 2 discs (16) and 1 plate (17).
CED01300
iii) Install seal ring (14) to housing.

Grease (G2-LI)
88
0 8
Q
iv) Install seal ring (13) to piston.

Grease (G2-LB
13
CED01298 CED01297
30-93
0
v) Install piston (11) to housing (12).
a Contact surfaceof seal ring :

Grease (G2-LII
* When installing, be careful not to
damage the seal ring.
vi) Using dyebolts 0, install housing and
piston assembly (IO).
* Support the piston assembly by hand
to prevent it from falling out when
installing.
1t
& Mounting bolt : CED01296 CED01295

w Mounting bolt :
110.35~12.25 Nm{11.25t1.25 kgm}
vii) Using push tool, press fit bearing (15).
viii)lnstall plate (8), and secure with snap
ring (7).
ix) Install input shaft (6).
& Mounting bolt :
m Mounting bolt : CED01329 s CED01330
277.0~31.9 NmI28.25=3.25 kgm)
x) install 2 seal rings (5).
2) Using eyebolt 0, install lock-up clutch and
drive case assembly (4).
Ir Align the positions of the turbine oil
groove (X mark) and drain plug (2) when
installing.
.X.
2
CED01331
3) Tighten mounting bolts (3).

* Check that drain plug (2) is tightened.
m Mounting bolt :
53.9 + 4.9 Nm 15.5 f 0.5 kgm}
m Drain plug :
11.25 z 1.45 Nm {I.15 I 0.15 kgm)
CED01290 / 1 CED0'28g
30-94
0
11. Torque converter valve assembly

Install torque converter valve assembly (I)
* Tighten the mounting bolts uniformly in turn
and be careful not to tighten them unevenly.
w Mounting bolt :
49.0 =4.9 Nm I5.0 + 0.5 kgml
30-95
0
DISASSEMBLY AND ASSEMBLY TORQFLOW TRANSMISSION
DISASSEMBLY OF TORQFLOW
TRANSMISSION ASSEMBLY
1. Preparatory work
Set transmission assembly (I) to tool Dl.
CED02206
2. Control valve assembly

1) Remove tube.
2) Remove cover (21, then remove sleeve on
inside.
3) Remove cover (3).
4) Remove control valve assembly (4) together

with seat.
Ir Remove the 4 mounting bolts marked
%. Do not remove any other bolts.
CED01374
3. Lubrication valve assembly

Remove lubrication valve assembly (5).
CED01375
30-96
0
4. Front case
1) Set input shaft at top and stand transmis-
sion assembly upright.
2) Using eyebolts, remove front case (6).
CED01376
5. Input shaft, No. 1 carrier assembly

11 Remove 17 tie bolts (7).
21 Using forcing screws 0, disconnect input
shaft and No. 1 carrier assembly (8).
* Tighten the forcing screws uniformly and
be careful not to cause gouging of the
input shaft and No. 1 carrier assembly.
g
is
;;
3) Using eyebolt 0, remove input shaft and
No. 1 carrier assembly (8).
4) Turn over input shaft and No. 1 carrier as-
sembly, and remove seal ring (9).
CED01380
5) Disassemble input shaft and No. 1 carrier

assembly as follows.
i) Remove snap ring (IO), then remove No.
2 sun gear (I 1).
ii) Remove spacer and bearing assembly
(12).
CED01381 CED01382
30-97
0
ii) Using push tool, remove ball bearings

(13) and (14) from spacer (15).
I4
CEO01383
iv) Remove No. 1 sun gear (16).

v) Remove spacer (17).
CED01384 CED01385
vi) Using eyebolt 0, sling housing and No.

1 carrier assembly (18) and set on block.
+ Lower the tip of the input shaft to
the ground and separate the hous-
ing and No. 1 carrier assembly from
the block by approx. 20 mm.
vii) Remove snap ring (19).
viii)Tap housing with plastic hammer so that
housing and No. 1 carrier assembly (20)
falls on top of the block, then remove
input shaft assembly (21).
CED01387
ix) Using press, remove ball bearing (22)

from input shaft (23).
I CED01388
30-98
0
x) Remove snap ring (24) from housing and

xi) Set housing and No. 1 carrier assembly
on block, then using push tool 0, re-
move housing (25) from No. 1 carrier
assembly (26).
26 25
CEDOl389 CED01390
xii) Remove snap ring (27) from housing

(25).
xiii)Turn over housing and set on block, then
remove seal ring (146).
CED01391 CED01392
xiv)Using push tool 0, remove ball bearing

(28) from housing.
xv) Remove spacer (29) from No. 1 carrier
assembly (26).
CED01393 CED01394
xvi)Turn over No. 1 carrier assembly, and

remove snap ring (301, then remove col-
lar (31).
xvii)Turn over No. 1 carrier assembly, re-
move shaft (33) partially from carrier
(321, take out balls (341, then remove
shaft (33).
+ Be careful not to lose the balls and
keep them in a safe place.
CED01396
CED01395
xvii)Remove gear (34) and thrust washer (35)

from carrier.
xix)Remove needle bearing (36) from gear
(34).
CED01397
6. No. 1 discs, plates, springs

1) Remove 12 springs (37).
2) Remove 6 discs (381, 6 springs (401, and 5 38 .40
plates (39) in turn, then remove guide plate.
them in a flat place to prevent them from 39-
-17
becoming distorted.
CED01398
7. No. 1 clutch ring gear

Remove No. 1 clutch ring gear (41).
8. No. 1 housing
1) Using eyebolts 0, remove No. 1 housing
assembly (42).
:Fi-101400
30-100
0
2) Disassemble No. 1 housing assembly as fol-

lows. 11
i) Remove piston (43) from housing (44).
CED01401
ii) Remove seal ring (45) from piston (43).

iii) Remove seal ring (46) from housing (44).
CED01403

1) Remove 12 springs (47).
2) Remove 6 discs (48), 5 plates (491, and 6
springs (50) in turn.
becoming distorted.
3) Remove 17 sleeves (51).
CED01405
4) Remove seal ring (52) from No. 2 and No. 3

carriers.
5) Remove 6 torque pins (53).
6) Remove 12 guide pins (54).
IO. No. 1 ring gear, No. 2, No. 3 carrier assembly

1) Using eyebolts @, lift off No. 1 ring gear,
and No. 2 and No. 3 carrier assembly (55).
CEDO 1407
2) Disassemble No. 1 ring gear, No. 2 and No.

3 carrier assembly as follows.
i) Remove seal rings (57) and (58).
ii) Remove ring (59).
CED01408
iii) Remove shaft (61) partially from carrier

(60), take out balls (62), then remove
shaft (61).
Ir Be careful not to lose the balls and
I CED01409
30-102
0
iv) Remove gear (63) and thrust washer (64)

from carrier.
v) Remove needle bearing (65) from gear (63).
Ir No. 2, No. 3 carrier (60) and No. 1 ring
gear (66) are secured by embedding in-
side the ring, so they cannot be disas-
e
61
sembled further.
0
‘62 ‘63 ‘63

CED01410
11. No. 2 ring gear

Remove No. 2 ring gear (67).
CED01411
12. No. 2, No. 3 housing assembly

1) Using eyebolts 0, remove No. 2 and No. 3
housing assembly (68) together with top and /till
bottom pistons.
Ir Tie with wire to prevent the bottom pis-
ton from falling out.
CED01412
2) Disassemble No. 2 and No. 3 housing as-

sembly as follows.
i) Remove pistons (69) and (70) from hous-
ing (71).
CED01413
30- 103
0

iii) Remove seal ring (73) from piston (70). 70
73
69
D
72
CED01414
E
CED0141!
iv) Remove seal rings (74) and (75) from

housing (71).
II\ ‘t
CED01416

1) Remove guide plate, then remove 12 springs
(76).
2) Remove 4 discs (771, 4 springs (791, and 3
plates (78) in turn.
becoming distorted.
" ' " ' CEDO1417
14. No. 3, No. 4 clutch plate

Using eyebolts 8, remove plate (80).
CED01418
30-104
0

I) Remove 3 discs (811, 3 springs (831, and 2
plates (82) in turn, then remove guide plate
(147).
becoming distorted.
2) Remove 6 torque pins (84).
16. No. 4 housing assembly

1) Using eyebolts 0, remove housing assem-
bly (85) together with piston.
I CED01420
2) Disassemble No. 4 housing assembly as fol-

lows.
i) Remove piston (86) from housing (87).
86 07
CED01421
- i

iii) Remove seal ring (89) from housing (87).
87
86
89
1F
88
CED01422
iis! k
CED0142:3
I
30- 105
0
17. No. 3 ring gear, No. 4 carrier, No. 5 clutch as-

semblv
1) Tu;n over tool Dl, and set transmission fac-
ing to side.
2) Remove plate (90).
3) Remove snap ring (91), then remove plate
(92).
Dl
CED0142' !I CED01425
4) Remove snap ring (93), then remove spacer

(94).
CED01426
5) Set No. 4 carrier at top and stand transmis-

sion upright.
6) Using eyebolts @I, sling No. 3 ring gear, No.
4 carrier, and No. 5 clutch assembly (95),
then tap bottom of output shaft with a cop-
per hammer to remove.
421
7) Disassemble No. 3 ring gear, No. 4 carrier,

and No. 5 clutch assembly as follows.
i) Remove 2 seal rings (56) from housing.
ii) Remove seal ring (118) from output
shaft.
CED01458 CED01459
30-106
0
iii) Remove snap ring (96), then remove No.

3 sun gear (97).
iv) Remove collar and bearing assembly
(98).
97 CED01428
VI Using push tool, remove ball bearing

(99) from collar (100).
I CED01430
vi) Using eyebolts 0, remove No. 3 ring

gear and No. 4 carrier assembly (101)
together with No. 4 sun gear.
vii) Remove No. 4 sun gear (102) from No. 3
ring gear and No. 4 carrier assembly
(101).
CED0143' CED01432
viii)Turn over No. 3 ring gear and No. 4

carrier assembly, and remove hub (103). r-----F
ix) Remove seal rings (104) and (105) from
hub (103).
CED01433 CED01434
30- 107
0
x) Remove snap ring (1061, then remove

collar (107) from No. 3 ring gear and 107 I06
108 107
xi) Remove seal ring (108) from collar (107).
I
I41 CED01436
CED01435
II
xii) Remove shaft (110) partially from car-

rier (IOS), take out balls (I’ll), then re-
move shaft (110).
* Be careful not to lose the balls and
xiii)Remove gear (112) and thrust washer
(113) from carrier.
xiv)Remove needle bearing (114) from gear II0 II3 II4 II3
(112).
B/h 0 #& 0
CED01437 III ll! CED01438
xv) Turn over carrier (IOS), and remove snap

I!! IO! II!
ring (115).
xvi)Turn over carrier, then using push tool,
remove ball bearing (116).
* No. 3 ring gear (117) and No. 4 car-
rier (109) are secured by embedding
inside the ring, so they cannot be
disassembled further.
CED01439 1 / CED0'440
xvii)Set output end of output shaft at top,

then set output shaft and housing as-
sembly (118) on top of block.
xviii)Using forcing screws, disconnect out-
put shaft and housing assembly (1181,
and lift off with eyebolts 0.
* Tighten the forcing screws uniformly
and disconnect the output shaft and
housing assembly.
CED01441
30-108
0
xix)Remove 6 discs (1191, 6 springs (120),

and 5 plates (121) from housing (122) in
turn.
CED01441
CED01443
xx) Set output shaft and housing assembly

to press, then using push tool 0, re-
move housing assembly (123) from out-
put shaft assembly (124).
* Set block @ under the housing as-
sembly to prevent the housing as-
sembly from falling out.
xxi)Set housing assembly (123) to press,
then using tool D2, compress spring and
remove snap ring (125).
* Operate the press slowly and push
down the spring uniformly.
xxii)Remove retainer (126) and spring (127)
from housing (128).
l2i
CED01445 CED01446
xxiii)Remove piston (129) from housing.

xxiv)Remove seal ring (130) from piston (129).
CED01447 CED01448
TORQFLOW TRANSMISSION
xxv)Remove seal ring (131) from housing

(128).
miRemove snap ring (132) from housing.
dUsing push tool, remove ball bearing
(133) from housing.
CED01450
tiRemove snap ring (1341, then remove

needle bearing (135) from output shaft
,
(124).
xxix)Turn over output shaft, remove snap ring
(1361, then remove roller bearing ( 137)
from output shaft. 124
CED01452
19. Rear case assembly

1) Remove collar (138) from rear case (’139).
2) Remove seal ring (140) from collar (138).
CED01454
30-110
0
TORQFLOW TRANSMISSION
3) Turn over rear case, and remove snap ring

(141), then remove ball bearing (142).
I
0
30-111
0
ASSEMBLY OF TORQFLOW
TRANSMISSION ASSEMBLY
J, Clean and dry all parts (particularly oil holes),
and check for dirt or damage. Coat the sliding
surfaces of all parts with engine oil before in-
stalling.
Ir Coat each spline portion with grease (G2-LI).
1. Preparatory work
Set rear case (139) to tool Dl.
CEDC 11460
I
2. Rear case assembly

1) Install seal ring (149) to collar (138).
+ Align the direction of installation of the
seal ring with the diagram on the right.
& Seal ring : Grease (G2-LI)
\
138
CED01461
2) Turn over rear case (1391, and install collar

(138).
+ Be careful not to get the seal ring caught.
3. Output shaft assembly

I) Using push tool, press fit needle bearing
(135) to output shaft (124), and secure with
snap ring (134).
2) Using push tool, press fit ball bearing (142)
to output shaft.
CEO01462
30-112
0
3) Install spacer (941, and secure with snap ring

90
(93).
93
& Mounting bolt :
Thread tightener ILT-2)
C&KJ Mounting bolt :

66.15 + 7.35 Nm 16.75 f 0.75 kgm}
5) Install seal ring (118).
6) Turn over rear case (1391, set output shaft

assembly (124) in position, then using push
tool, press fit bearing portion.
8) Install plate (92) and secure with snap ring

(91).
\ CEO01465
4. No. 3 ring gear, No. 4 carrier, No. 5 clutch as-

sembly
I) Assemble No. 3 ring gear, No. 4 carrier, and
No. 5 clutch assembly as follows.
. When No. 3 ring gear and No. 4 carrier
are supplied as individual parts:
Using tool D3, compress ring (1431, set
No. 3 ring gear (117) on top of No. 4
carrier (1091, then tap No. 3 ring gear
(117) with a plastic hammer to assem-
ble.
* Check that the ring is fitted securely CED01466 CEO01467
in the groove.
30-113
0
i) Using push tool, press fit ball bearing

(116) to carrier (1091, then secure with
snap ring (115). II! ,115
IO!
CED01468
ii) Turn over carrier.

iii) Assemble needle bearing (114) to gear
(1121, then fit thrust washers (113) to
both ends and set to carrier.
iv) Fit ball (111) and install shaft (110) to
carrier.
-k Check that the gear rotates smoothly.
III I12 CED01438 CEO01469
VI Install seal ring (108) to collar (107).

vi) Align collar (107) with dowel pin and
instali to No. 3 ring gear and No. 4 car-
rier assembly (IOI), then secure with
snap ring (106).
* Knock in the dowel pin portion with
a plastic hammer until there is no
clearance at the mating surface.
CEO01435
vii) Install seal rings (105) and (104) to hub

(103).
6 Seal ring : Grease (G2-LI)
viiijlnstall hub (103) to No. 3 ring gear and

* Be careful not to get the seal ring
caught.
CED014: CED01470
30-114
0
ix) Using eyebolts @ install housing (122)

to No. 3 ring gear and No. 4 carrier as-
sembly.
CEO01471
XI install 6 discs (1191, 6 springs (1211, and

5 plates (120) in turn.
* Align the notches in the oil grooves
on the outside circumference of the
discs.
CED01472
15” CED01443
xi) Using push tool, press fit ball bearing

(133) to housing (1281, then secure with
snap ring (132).
I28 CED01473
xii) Install seal ring (131) to housing.

* Align the direction of installation of
the seal ring with the diagram on
the right.
6 Seal ring : Grease (G2-LI)
CED01474
30-115
0
xiiijlnstall seal ring (130) to piston (129).

* Align the direction of installation of
the seal ring with the diagram on
the right.
xiv)lnstall piston (129) to housing (128).

* Be careful not to get the seal ring
caught.
128
CED01475 CED01476
xv) Set spring (127) and retainer (126) to

housing.
Ir Set the 3 springs as shown in the
127 126125
diagram on the right.
xvi)Set housing assembly (123) to press, and
using tool D2, compress spring, then
install snap ring (125).
* Installed load of spring:
2175.6 N I222 kg)
1 CED01477 / 1 '25 CEDO'445
xvii) Using eyebolts @, install housing assem-

bly (123).
& Mounting bolt :
m Mounting bolt :
176.4 z 19.6 Nm {I8 z 2 kgm}
xviiiilnstall 2 seal rings (56) to housing.
& Seal ring : Grease (G2-LII
CED01478
2) Turn over rear case (139) and No. 3 ring

gear, No. 4 carrier, and No. 5 clutch assem-
bly (95).
3) Using eyebolts @, set No. 3 ring gear, No. 4
carrier, and No. 5 clutch assembly (95) to
rear case and output shaft.
Sr Be careful not to get the seal ring caught.
CEDOl479
30-116
0
4) Using push tool @I, press fit bearing portion

of No. 3 ring gear, No. 4 carrier, and No. 5
clutch assembly (95) to output shaft.
I CED01480
5. No. 4 sun gear

Install No. 4 sun gear (102).
6. No. 3 sun gear

1) Using push tool, press fit ball bearing (99)
to collar (100).
CED01482
2) Install collar and bearing assembly (98).

* Install with the flanged side of the collar
at the top.
3) Install No. 3 sun gear (97) and secure with
snap ring (96).
I CED01483
30-117
0

I) Install seal ring (89) to housing (87).
87
* Align the direction of installation of the I 86
a
seal ring with the diagram on the.right.
2)
&
&&
Seal ring : Grease (G2-LI)
Install seal ring (88) to piston (86).

* Align the direction of installation
Seal ring : Grease (G2-LI)

of the
89
[i,
d \
88
CED01423 CED01422
3) Install piston (86) to housing (87).

* Be careful not to get the seal ring caught.
86 87
CED01421
4) Using eyebolts @, align No. 4 housing as-

sembly (85) with dowel pin and install.
Sr Knock in the dowel pin portion with a
plastic hammer until there is no clear-
ance at the mating surface.
I CED01420

I) Install 6 torque pins (84). 81
Ir Length of torque pin : 162 mm
2) Fit guide plate (147) and install 3 discs (811,
3 springs (831, and 2 plates (82) in turn.
* Align the notches in the oil grooves on
the outside circumference of the discs.
83
147 CED01419
30-118
0
9. No. 3, No. 4 clutch plate

Using eyeboits @I, align plate (80) with dowel
pin and install.
* Knock in the dowel pin portion with a plas-
tic hammer until there is no clearance at the
mating surface.
CEDOl418

1) Install 4 discs (771, 4 springs (79). and 3
2) Install 12 guide pins (54).
* Length of guide pin : 360 mm
3) Fit 12 springs (76) and install guide plate.
Ir Free length of spring : 97 mm
11. No. 1 ring gear, No. 2, No. 3 housing assembly

1) Install seal rings (74) and (75) to housing
(71).
* Align the direction of installation of the
6 Seal ring : Grease (G2-LII
CED01416
2) Install seal ring (73) to piston (70).

* Align the direction of installation of the 73 70

seal ring with the diagram on the right. E
CED0141! CED01414
30-119
0
4) Install pistons (70) and (69) to housing (71).

Ir Tie piston (70) with thin wire to prevent
it from falling out when the housing is
raised.
CED01413
5) Align housing assembly (68) with dowel pin

and install.
+ Knock in the dowel pin portion with a
12. No. 2 ring gear

Install ring gear (67).
CED01486
13. No. 1 ring gear, No. 2, No. 3 carrier assembly

1) Assemble No. 1 ring gear, No. 2 and No. 3 66
carrier assembly as follows.
. 144
When No. 1 ring gear and No. 2, 3 car- -
rier are supplied as individual parts:
1
Using tool D4, compress ring (1441, set 0
No. 1 ring gear (66) on top of No. 2, 3
carrier (601, then tap No. 1 ring gear (66) D4
with a plastic hammer to assemble.
4
* Check that the ring is fitted securely
in the groove. 60 41 -L
CED01487 CEDOl488
30-120
0
i) Assemble needle bearing (65) to gear

(631, then fit thrust washers (64) to both
ends and set to carrier (60).
92 63 ‘63 CED01489
ii) Fit ball (62) and install shaft (61) to car-

rier.
* Check that the gear rotates smoothly.
I CED01490
iii) Install ring (59) to carrier.

* Check that the ring is fitted securely
in the groove.
iv) Install seal rings (58) and (57) to carrier.

* Center seal ring (58) with the carrier
and secure in position with grease
(G2-LI).
/ 5a
CED01408
2) Using eyebolts @, install No. 1 ring gear,

No. 2 and No. 3 carrier assembly (55).
w CED01407
30-121
0
31 Using push tool @, press fit bearing portion

of No. 1 ring gear, No. 2 and No. 3 carrier
assembly (55).
14. No. 2 discs, plates, sprmgs

1) Install 6 torque pins (53).
* Length of torque pin : 199 mm
2) Install seal ring (52) to No. 2 and No. 3 car-
riers.
3) Install 17 sleeves (51).
Ir Install the sleeves with the slits at the

bottom to the bolt holes marked X.
DBD02992
30-122
0
4) Install 12 springs (47).

* Free length of spring : 70 mm
5) Install 6 discs (48), 6 springs (50), and 5

1) Install seal ring (46) to housing (44).
-k Align the direction of installation of the 43
seal ring with the diagram on the right. 46 44
&
D
6 Seal ring : Grease IG2-LI) 45
m
CED01403 CED01402
3) Install piston (43) to housing (44).

I. CEDOl401
4) Using eyebolts 0, align housing (42) with

dowel pin and install.
Sr Check that the spring is fitted securely
in the hole of the housing.
Ir Knock in the dowel pin portion with a
CEDOf400
30- 123
0
16. No. 1 clutch ring gear

Install No. 1 clutch ring gear (41).

1) Fit guide plate and install 12 springs (37).
+ Free length of spring : 66 mm 40
2) Install 6 discs (381, 6 springs (401, and 5
+ Align the notches in the oil grooves on
-37
CED01398
18. Input shaft, No. 1 carrier assembly

1) Assemble input shaft and No. 1 carrier as-
sembly as follows.
i) Assemble needle bearing (36) to gear
(341, then fit thrust washers (35) to both
sides and set to carrier (32).
ii) Fit ball (34) and install shaft (33) to car-

rier.
iii) Install collar (31) to carrier and secure
with snap ring (30).
31 33
CED01495 CED01395
30-124
0
iv) Using push tool @, press fit ball bearing

(28) to plate (251, and secure with snap
ring (27).
CED01496 CED01497
/I
v) Turn over plate and install seal ring (146).

Ir Center the seal ring with the plate
(G2-LI).
vi) Install spacer (29) to No. 1 carrier as-
sembly (26).
CED01392 CED01394
vii) Set plate (25) to No. 1 carrier (26), then

using push tool @, press fit bearing por-
tion and secure with snap ring (24).
25 26
CED01498 CED01499
viii)Using press, install ball bearing (22) to

input shaft assembly (23).
ix) Set housing and No. 1 carrier assembly
(20) to block.
x) Using eyebolt 0, install input shaft as-
sembly (18) to housing and No. 1 carrier
assembly.
30-125
0
xi) install snap ring (19).
CED01502
xii) Set input shaft and No. 1 carrier assem-

bly facing to side, then install spacer
(17).
xiii)lnstall No. 1 sun gear (16).
CED01385 ( CEO01384
xiv)Using push tool, press fit ball bearings

(13) and (14) to spacer (15).
Ii
CEDOl383
xv) Install spacer and bearing assembly (12).

* Install the small-diameter bearing
facing the No. 1 sun gear.
xvi)lnstall No. 2 sun gear (11) and secure
with snap ring (IO).
CED01382 CEt-101381
30-126
0
xvii)lnstall seal ring (9) to No. 1 carrier.

* Center the seal ring with the carrier
(G2-LI).
2) Turn over input shaft and No. 1 carrier as-
sembly (81, then using eyebolt 0, set to No.
1 housing.
Sr Be careful not to get the seal ring caught.
+ Check that the tip of the input shaft does
not interfere with the output shaft bear-
ing, and lower carefully.
CEO01380
3) Tighten 4 tie bolts (12) uniformly on diago-

nally opposite sides.
4) Tighten remaining tie bolts (12).
w Tie bolt :
259.7 + 14.7 Nm 126.5 z 1.5 kgm1
CEO01503
19. Air check

Using tool D5, check piston stroke of each clutch.
* Air pressure : 49 - 58.8 Pa {5 - 6 kg/cm*}
* Standard stroke of piston (mm)
CED01504
20. Front case

Fit O-ring, then using eyebolts, install front case
(6).
* Check that the front case does not interfere
with other parts, and lower gradually.
21. Output shaft bearing

I) Set output shaft at top and stand transmis-
sion assembly upright.
2) Using push tool, press fit roller bearing (137)
to output shaft and secure with snap ring
(136).
* Be careful not to hit or damage the bear-
ing cage or roller.
Use a push tool of a size which pushes
only the outer race.
CED01505
22. Lubrication valve assembly

Install lubrication valve assembly (5).
CEO01375
23. Control valve assembly

1) Install control valve assembly (4) together
with seat.
w Mounting bolt :
49.0 + 4.9 Nm 15.0 = 0.5 kgm}
CED01374
2) Install cover (3).

* Remove plugs (145) and check that the
pin of the linkage on the inside of the
cover is meshed with the yoke of the
control valve spool.
After checking, install plugs (145).
3) Fit O-ring and install sleeve, then install
cover (2).
4) Install tube.
30-128
0
DISASSEMBLY AND ASSEMBLY STEERING CASE
DISASSEMBLY OF STEERING
CASE ASSEMBLY
1. Steering control valve assembly
I) Remove steering control valve assembly (1).
+I kg Steering control valve assembly :

25 kg
2) Remove seat (2).
2. Clutch, brake assembly
11 Using eyebolt, sling clutch and brake as-
sembly, remove mounting bolts, then re- I
move clutch and brake assembly (3). 2

* Remove the clutch and brake assembly CED01541 CED01542
on the opposite side in the same way.

* When pulling out the clutch and brake
assembly, be careful not to damage the
discs and plates.
2) Disconnect clutch and brake assembly as
follows.
i) Remove plate (4), then remove collar (5).
ii) Remove plate (6).
CED01543
iii) Using forcing screws 0, remove sleeve

(7).
iv) Using puller 0, pull out bearing inner
race (8) from sleeve.
CED01544 CED01545
VI Turn over clutch and brake assembly,

then using eyebolts 0, disconnect clutch
assembly (9) and brake assembly (IO).
CED01546
30-129
0
3) Disassemble clutch assembly as follows.

i) Remove stopper (II). II
ii) Remove discs (12), springs (13), and
CEO01548
CED01547
iii) Remove torque pins (15).

iv) Using eyebolts, remove clutch hub (16).
v) Using forcing screws 0, remove plate
(17).
I7
CED01549 CED01550
vi) Remove outer race (18) from plate.

vii) Remove bearing and cage assembly (19).
CED01551 CED01552
viii)Remove plate (21) and nut (22) from cage

(20).
ix) Remove bearing inner race (23), spacers
(24) and (25), and bearing outer race (26).
22
CEDO 1554
30-130
0
21 CED01553
x) Using eyebolts, remove clutch cage (27).

xi) Remove seal ring (28) from clutch cage.
xii) Remove piston (29).
xiii)Remove seal ring (30) from piston.
CED01555 CED01556
xiv)Remove bearing outer race (31) from

clutch cage.
xv) Remove belleville spring (32).
CEO01557 CED01558
II
xvi)Using eyebolts 8, remove brake hub

(33).
xvii)Remove bearing (34) from brake hub.
CED01559 CEO01560
30-131
0
4) Disassemble brake assembly as follows.

i) Remove stopper (35).
ii) Remove discs (361, springs (37), and
CED01561 CED01562
iii) Using eyebolts 0, remove brake cage

(39).
iv) Remove bearing outer race (40) and seal
ring (41) from brake cage.
4i
CED01564
v) Remove torque pins (42).

vi) Remove piston (43).
vii) Remove seal ring (44) from piston.
CED01565
II CED01566
viii)Remove belleville spring (45).
CED01567
30-132
0
3. Shafts
Remove left and right shafts (46).
4. Lubrication tubes
Remove lubrication tubes (47).
46
CED01568 CED01569
5. Pipes
1) Remove left and right pipes (48).
2) Remove pipe (49).
I ia CED01570 CED01571
6. Transfer, gear housing assembly

1) Fit guide bolt 0, raise with eyebolts @, and
remove housing assembly (50).
2) Disassemble transfer gear housing assem-
bly as follows.
i) Set transfer gear housing assembly on
block.
ii) Remove lubrication tube (51).
iii) Remove cage and bearing assembly (52).
I CED01572 CED01580
iv) Using push tool, remove bearing (53).

v) Remove drive gear (54).
CED01581 CED01582
30-133
0
vi) Using puller @, remove bearing inner I I
race (55) on both sides.

vii) Remove lubrication tube (56).
CED015831 I CED01584
viii)Using eyebolts 0, remove pinion hous-

ing assembly (57).
* Check the number and thickness of
the shims, and keep in a safe place.
ix) Using forcing screws, remove cover (58).
x) Remove holder (59).
57 CED0158E
xi) Push pinion shaft with press and remove

pinion gear (60).
xii) Remove holder, then using puller 0, re-
move bearing inner race (61) from pin-
ion gear (60).
xiii)Remove cage and bearing assembly (62).
CED01587 CED01588
xiv)Remove collar (63) from gear (64).

xv) Using push tool 0, remove bearing
outer races (65) and (69), bearing inner
races (66) and (671, and collar (68).
67 66 65
64
CEO01589 CE-001590
30-134
0
xvi)Remove bearing (70) from case.

xvii)Remove bearing (71) from case.
CED01591
7. Right cage
1) Turn-over so that right side of steering case
is at top.
2) Remove cage and bearing assembly (72).
3) Remove bearing outer race from cage and
bearing assembly.
4) Using eyebolts @, remove cage (73).
0
5: CED01574
Q, CED01573
;;
8. Bevel gear, shaft assembly

1) Using eyebolt, remove bevel gear and shaft
assembly.
2) Disassemble bevel gear and shaft assembly
as follows.
i) Pull out reamer bolt and remove bevel
gear (75) from shaft (76).
CED01575 CEDOl576
ii) Using puller 0, remove bearing inner

races (77) and (78) from shaft.
9. Left cage
1) Turn over so that left side of steering case
is at top, then remove cage and bearing
assembly (79).
CED01577 CEDOl578
30-135
0
2) Remove bearing outer race (80) from cage

and bearing assembly.
CEDOl579
30- 136
0
ASSEMBLY OF STEERING
CASE ASSEMBLY
Clean all parts, and check for dirt or damage.
Coat the rotating surfaces of the bearings with
engine oil and rotate several times before in-
stalling.
Coat the sliding surfaces of all parts with en-
gine oil before installing.
Check that the snap ring is fitted securely in the
groove.
Left cage
I) Using push tool, press fit bearing outer race
(80).
2) Assemble shims and install cage and bear-
ing assembly (79).
m Cage, bearing assembly mounting
bolt : 176.4 + 19.6 Nm {I8 = 2 kgm1
CED01592 CED01578
2. Bevel gear, shaft assemblv

1) Assemble bevel gear and shaft assembly as
follows.
i) Using push tool @, press fit bearing in-
ner races (78) and (77).
ii) Set bevel gear (75) to shaft (76) and
tighten reamer bolt.
w Reamer bolt :
274.4 = 29.4 Nm I28 + 3 kgml
CED01593 CED01576
r
2) Using eyebolts, install bevel gear and shaft
assembly (74).
3. Right cage
1) Using eyebolts @, install cage (73).
CED01575 CED01574
30-137
0
2) Assemble shims and install cage and bear-

ing assembly (72).
w Cage, bearing assembly mounting

bolt : 176.4 + 19.6 Nm {I8 + 2 kgm1
4. Adjusting preload
Adjust shim thickness at cage to adjust rotating
force of bevel gear shaft.
* Rotate the bevel gear 2 or 3 times then put
a push-pull scale in contact with the tip of
CED01573 CED01594
the tooth.
Ir Rotating force (when bevel gear is not
meshed): 4.9 - 5.88 N IO.5 - 0.6 kg}
(Rotating torque:
23.52 - 28.42 Nm (2.4 - 2.9 kgm1)
5. Transfer, gear housing assembly

1) Assemble transfer and gear housing assem-
W as follows.
i) Using push tool @, press fit bearing (71)
at transfer gear end to case.
ii) Using push tool 0, press fit bearing (70)
at pinion end to case.
CED01595
I
iii) Using push tool, press fit bearing outer
race (69) to cage.
iv) Assemble bearing inner races (67) and
(661, and collar (68).
v) Using push tool, press fit bearing outer
race (65).
CEO01597 CED01598
I”
vi) Using push tool @, press fit inner race

(61) to pinion gear (60).
vii) Install holder.

276.85+31.85 Nm I28.25t3.25 kgm}
viii)lnstall gear (64) and collar (63) to pinion

gear.
CED01599 CED01600
30-138
0
ix) Using push tool @I, press fit cage and

bearing assembly (62).
x) Install holder (59).
276.85231.85 Nm I28.25~3.25 kgml
I I I
59
CEDOIGO CED01566
xi) Tighten mounting bolts of cover (58) in

order shown in diagram on right to
specified torque, and assemble cover
(58) temporarily.
w Mounting bolt : 49 Nm I5 kgml
xii) Check that clearance a between cover

and cage is value given below.
* Clearance a : 0.48 2 0.27 mm
* Check that the bearing has been
completely press fitted and has a
variation around the whole circum- CED01602
ference of less than 0.05 mm. Check
also that the bearing is not at an
angle.
xiii)Tighten mounting bolts of cover (58)
fully in order shown in diagram on right.
m Mounting bolt :
66.15k7.35 Nm (6.75~0.75 kgm)
xiv)Assemble shims to pinion housing as-

sembly (57), then using eyebolts @I, in-
stall.
xv) Install lubrication tube (56).
58
5: CED01565 CED01564
xvi)Using push tool @, press fit bearing in-

ner race (55) to both sides of drive gear.
xvii) Set drive gear (54) to case.
CED01562
xvii) Using push tool 0, press fit bearing (53).

xiv)lnstall bearing cage assembly (52) to
case.
xv) Install lubrication tube (51) together with
block.
CED01605 CED01560
2) Fit guide bolt @to steering case, then using

eyebolts @, install transfer and gear hous-
ing assembly (50).
w Mounting bolt :
276.85231.85 Nm I28.25~3.25 kgm}
6. Lubrication tube
Install lubrication tube (47j.
CED01572 CED01569
7. Adjusting tooth contact, backlash

I) Adjusting backlash
Testing
Put the probe of dial gauge @ at right an-
gles in contact with the tip of the bevel gear
teeth. Hold the bevel pinion in position,
P
and read the measurement when the bevel
gear is moved forward and backward.
* Standard value for backlash :
0.3 - 0.4 mm
CED01606
30-140
0
Ir Measure at a minimum of three points

When backlash is small
on diagonally opposite sides.
Adjusting
If the result of the inspection shows that the
correct backlash is not being obtained, ad- \ -
just as follows.
i) If backlash is too small:
Adjust the shim thickness at the. bevel
l3+
pinion end to move the bevel pinion in
direction A, or adjust the shim thickness
at the bearing cage of the bevel gear
shaft to move the bevel gear in direc- / DBD02993
tion B.
ii) If backlash is too large:
Adjust the shim thickness at the bevel
When backlash is large
pinion end to move the bevel pinion in
direction A (the opposite direction from
A above), or adjust the shim thickness Q
at the bearing cage of the bevel gear
shaft to move the bevel gear in direc-
tion B (the opposite direction from B
a hove).
BC
Ir When adjusting the shim thickness at
the bearing cage of the bevel gear shaft,
s: do not change the preload of the bear-
8 ing. Adjust by moving shims between 7 nRnn7ood
z the bearing cage and the bevel pinion.
Always keep the same total thickness of
shims.
Dedendum (root of tooth)
\ Addendumctip of tooth)
2) Adjusting tooth contact
Testing
i) Coat the tooth face of the bevel pinion
lightly with red lead (miniurn). Rotate
the bevel gear in both the forward and
reverse directions, and inspect the pat-
tern left on the teeth.
ii) The standard tooth contact should be as
follows: Small end
(from small end of pinion) I DBD02995
a) Width of tooth contact: 30 - 75%
b) Center of tooth contact: 25 - 50%
c) Position of tooth contact: 25 - 50%
It must be within the standard value
when preload is given to the taper roller
bearing which is supporting the bevel
gear, and only the bevel pinion is
meshed, with no load.
The tooth contact should be in the center
of the tooth height and there should be
no strong contact at the root of the teeth.
The contact should be in about the same
position when the gear is rotated in for-
ward or reverse.
30-141
0
Adjustment
If the result of the inspection shows that the
correct tooth contact is not being obtained,
adjust again as follows.
i) If bevel pinion is too far from center line
of bevel gear.
Contact is at the small end of the con-
vex tooth face of the bevel gear and at
the big end of the concave tooth face.
[Correct the tooth contact as follows.1
Adjust the thickness of the shims at the
bevel pinion to move the bevel pinion
in direction A.
Or adjust the thickness of the shims at
the bearing cage of the bevel gear shaft
to move the bevel gear in direction B,
then check the tooth contact pattern and
backlash again.
ii) If bevel pinion is too close to center line
of bevel gear.
Contact is at the big end of the convex
tooth face of the bevel gear and the
small end of the concave tooth face.
[Correct the tooth contact as follows.1
Adjust the thickness of the shims at the A
DBCCOW
bevel pinion to move the bevel pinion
in direction A (the opposite direction
from A above).
Or adjust the thickness of the shims at
the bearing cage of the bevel gear shaft
to move the bevel gear in direction B
(the opposite direction from B above),
then check the tooth contact pattern and
backlash again.
* When adjusting the movement in or out
of the bevel gear, do not change the
preload of the bearing. Adjust by mov-
ing shims between the bearing cage and
the bevel pinion. Always keep the same
40
total thickness of shims. CED01571 CED01570
8. Pipes
1) Install pipe (49).
2) Install left and right pipes (48).
9. Clutch, brake assembly

1) Assemble brake assembly as follows.
i) Install belleville spring (45).
* Put the belleville springs back to back
when installing.
ii) Install seal ring (44) to piston (43).
CED01613 CED01566
30-142
0
iii) Install piston (43)

iv) Install torque pins (42).
VI Using push tool, install seal ring (41)
and bearing outer race (40) to brake
cage.
CEDOl565
vi) Using eyebolts 0, install brake cage (39).

m Mounting bolt :
110.25~12.25 Nm {11.25=1.25 kgml
vii) Install plates (381, springs (37), and discs

(36).
+ Check that there is no dirt or dam-
age on the mating face of the disc
and plate, then coat thinly with en-
gine oil and assemble.
JJ
CED01563
II CED01562
_I
-l
viiijlnstall stopper (35).

w Mounting bolt :
276.85=31.85 Nm {28.25=3.25 kgm}
2) Assemble clutch assembly as follows.

i) Using push tool, install bearing (34) to
brake hub.
CEDOl561
II CED01560
I I
ii) Using eyebolts 8, install brake hub (33)
to clutch housing. 32
iii) Install belleville spring (32).
t Put the belleville springs back to back
when installing.
CED01559 CED01556
30- 143
0
iv) Install outer race (31) to clutch cage.

v) Install seal ring (30) to piston.
vi) Install piston (29). 30 29
CEDOl557 CED01556
vii) Install seal ring (28) to clutch cage.

viii)Using eyebolt, install clutch cage (27) to
housing.
2i ia CEDOl614
ix) Install bearing inner race (261, spacers

(25) and (241, and bearing inner race (23)
to cage (20).
x) Tighten nut (22) and install plate (21).
* Using a push tool, hold the cage
down with a press, and use a hook
wrench to tighten the nut.
23. is CED01554
21 CED01553
30-144
0
xi) install bearing and cage assembly (19).

xii) Using push tool, install outer race (18)
to plate.
CEO01552 CED01551
xiii) Install plate (17).

w Mounting bolt :
110.25t12.25 Nm {11.25+1.2 gm}
xiv)Set guide bolt to housing.

xv) Using eyebolt, install clutch hub (16).
* Check that the rotation of the hous-
ing is less than 3 kg and that it ro-
tates smoothly.
xvi)lnstall torque pins (15).
CED01615 CEDOl549
xvii) Install plates (141, springs (131, and discs

(12) in turn.
* Check that there is no dirt or dam-
age on the mating face of the disc
and plate, then coat thinly with en-
gine oil, and assemble.
xvii)lnstall stopper (II).
w Mounting bolt :
276.85~31.85 Nm (28.25~3.25 kgm}
CED01548 CEO01547
3) Connect clutch and brake assembly as fol-

lows.
i) Using eyebolts 0, install brake assem-
bly (IO) to clutch assembly (9).
ii) Using push tool @, press fit bearing in-
ner race (8) to sleeve.
CED01616 CED01617
30-145
0
iii) Set sleeve (7) to clutch and brake as-

sembly.
CED01618
iv) Install plate (6).

w Mounting bolt :
110.25+12.25 Nm 111.25+1.25 kgm}
v) Fit collar (5) and install plate (4).

4) Using eyebolt, install clutch and brake as-
sembly (3).
w Mounting bolt :
276.85~31.85 Nm I28.2523.25 kgm}
CED01543
10. Shafts
Install left and right shafts (46).
Ir If the bevel gear is locked in position and it
is difficult to insert the shaft, release the
steering brake before inserting.
Remove plugs (81), then remove mounting
bolt (82), screw the mounting bolt into the
plug hole to compress the clutch spring and
release the brake.
* After finishing the work,install bolt(82) and
plug(81). 48
CED01568 CEDOl619

1) nstall seat (2).
2) Raise steering control valve assembly (I)
and install.
w Mounting bolt :
49 t 4.9 Nm 15 = 0.5 kgm)
81
I CED01620
30-146
0
DISASSEMBLY AND ASSEMBLY POWER TRAIN, LUBRICATION PUMP
REMOVAL OF POWER TRAIN,

LUBRICATION PUMP
ASSEMBLY
1. Remove power train underguard (front).
&I kg Power train underguard (front) : 280 kg
2. Remove cover (I).
‘I CEO01755
3. Disconnect tube (2).

4. Lift off power train and lubrication pump as-
sembly (3).
A kg Power train, lubrication pump assembly:

50 kg
g
iii
z
INSTALLATION OF POWER
TRAIN, LUBRICATION PUMP
ASSEMBLY
. Ca,rry out installation in the reverse order to
removal.
30-147
0
DISASSEMBLY AND ASSEMBLY SCAVENGING PUMP
REMOVAL OF SCAVENGING
PUMP ASSEMBLY
1. Remove power train underguard (front).
kg
LF?l Power train underguard (front): 280 kg
2. Disconnect inlet tube (I).

* Oil will leak out from inside the piping, so
prepare a container to catch the oil.
3. Disconnect outlet tube (2).
4. Remove scavenging pump assembly (3).
INSTALLATION OF
SCAVENGING PUMP
ASSEMBLY
removal.
. Refilling with oil (power train case)
Add oil through oil filler to the specified level,
and run the engine to circulate the oil through
the system. Then check the oil level again.
30-148
0
DISASSEMBLY AND ASSEMBLY TORQUE CONVERTER OIL COOLER
REMOVAL OF TORQUE
CONVERTER OIL COOLER
1. Remove engine underguard.
& kg Engine underguard : 290 kg
2. Drain coolant.
side cover (2).
4. Remove side covers (3), then remove side cover
stay.
5. Remove water tubes (4) and (5). i CED01240
6. Disconnect oil inlet hose (6) and outlet hose (7).
7. Sling torque converter oil cooler assembly (81,
remove mounting bolts, then lower assembly
to remove.
&I kg Torque converter oil cooler assembly :

110 kg
INSTALLATION OF TORQUE
CONVERTER OIL COOLER
removal.
30-l 49
0
DISASSEMBLY AND ASSEMBLY TORQUE CONVERTER VALVE
REMOVAL OF TORQUE
CONVERTER VALVE
ASSEMBLY
ASSEMBLY.
2. Disconnect lock-up solenoid connector (CN-653)
(I).
3. Disconnect pressure detection hoses (21, (31, and
(4).
* Before removing the pressure detection
hoses, mark them with tags to prevent any
4. Remove torque converter valve assembly (5).
Torque converter valve assembly :

35 kg
CONVERTER VALVE
ASSEMBLY
removal.
a
w Torque converter valve assembly
mounting bolt :
49.0 + 4.9 Nm (5.0 + 0.5 kgml
30- 150
0
DISASSEMBLY OF TORQUE CONVERTER VALVE ASSEMBLY
CDD02150
30-l 51
0
1. Disassembly of lock-up valve

1) Remove solenoid valve (I).
2) Remove cover (21, then remove spring (3).
3) Remove cover (4), then remove piston (5).
4) Pull out spool (6).
2. Disassembly of torque converter relief valve

2) Remove cover (91, then remove valve (IO),
spring (II), and valve (12).
3. Disassembly of main relief valve

2) Remove cover (16), then remove valve (171,
spring (18), and valve (19).
4. Disassembly of stator clutch modulating valve

1) Remove cover (211, then remove piston (22)
and spring (23).
2) Remove ring (24) from body.
3) Remove cover (251, then remove valve (26),
5. Disassembly of lock-up clutch modulating valve

1) Remove cover (3Oj, then remove piston (31)
and spring (32).
2) Remove ring (33) from body.
3) Remove cover (341, then remove valve (351,
spring (361, and valve (37).
5) Remove spool (39) and shim (40) from spool
(38).
30-152
0
ASSEMBLY OF TORQUE
CONVERTER VALVE
ASSEMBLY
+ Clean all parts, and check for dirt or damage.
* When assembling valves (37) and (351, (28) and
(26), (19) and (171, and (12) and (IO), assemble
as shown in the diagram so that the end with
the hole in the center of the valve is on the
inside of the spool.
1. Assembly of lock-up clutch modulating valve
1) Set shim (40) to spool (39) and assemble to
spool (38).
* Standard shim thickness : 2.0 mm
2) Assemble spool (38).
3) Assemble valve (371, spring (361, and valve
(35) to spool, then fit O-ring and install cover
(34).
4) Assemble ring (33) to body.
5) Assemble spring (32).
6) Assemble piston (31) to cover (30), then fit
O-ring and install cover.
2. Assembly of stator clutch modulating valve
I) Assemble spool (29).
g
2) Assemble valve (281, spring (271, and valve
% CED02152
z
(25).
3) Assemble ring (24) to body.
4) Assemble spring (23).
5) Assemble piston (22) to cover (211, then fit
O-ring and install cover.
3. Assembly of main relief valve
2) Assemble valve (19), spring (181, and valve
(16).
3) Assemble spring (15L then fit O-ring and
install cover (14).
4. Assembly of torque converter relief valve
1) Assemble spool (13).
2) Assemble valve (121, spring (II), and valve
(IO) to spool, then fit O-ring and install cover
(9).
3) Assemble spring (8), then fit O-ring and in-
stall cover (7).
5. Assembly of lock-up valve
1) Assemble spooi (6).
2) Assemble piston (5) to cover (41, then fit O-
ring and install cover.
3) Assemble spring (31, then fit O-ring and in-
stall cover (2).
4) Fit O-ring and install solenoid valve (I).
30-153
0
DISASSEMBLY AND ASSEMBLY TRANSMISSION CONTROL VALVE
REMOVAL OF TRANSMISSION
CONTROL VALVE ASSEMBLY
ASSEMBLY.
2. Remove cover (I), then remove sleeve.
3. Remove cover (2). m
4. Lift off transmission control valve assembly (3).

m
* Remove the 4 mounting bolts marked x
Do not remove any other bolts.
II+ kg Transmission control valve assembly :

35 kg
CED01770
INSTALLATION OF
TRANSMISSION CONTROL
VALVE ASSEMBLY
removal.
If
* When installing the cover, remove plugs (4)
and check that levers (6) at the cover end
are securely meshed with yokes (5) of the
directional valve and speed valve. I
I
i’ ‘5 CED01771
After installing the cover, install plugs (4).
a
w Transmission control valve assembly
mounting bolt :
49.0 + 4.9 Nm I5.0 2 0.5 kgml
30-154
0
DISASSEMBLY OF TRANSMISSION CONTROL VALVE

ASSEMBLY
CDD02153
I. Disassembly of modulating valve, quick return

valve, reducing valve
I) Remove snap ring (6), then remove retainer
(7), shim (8), spring (9), valves (5) and (4),
2) Remove snap ring (IO), then remove stop-
per (11) and spool (12).
3) Remove snap ring (13), then remove stop-
per (14), valve (15), spring (16), valve (171,
spool (18), shims (19) and (20), and springs
(21) and (22).
4) Remove cover (I), then remove valve (23).
2. Disassembly of directional valve, speed valve

1) Remove spool (24).
2) Remove spool (25).
30-155
0
ASSEMBLY OF TRANSMISSION CONTROL VALVE ASSEMBLY
COD02153

1. Assembly of directional valve, speed valve

I) Install spool (24).
2) Install spool (25).
2. Assembly of modulating valve, quick return

valve, reducing valve
1) Assemble valve (23) and install cover (I).
2) Fit springs (22) and (21), shims (20) and (19),
and spool (181, then fit valve (171, spring
(16), and valve (151, and secure with stop-
per (14) and snap ring (13).
* Standard shim thickness (19) : 0.5 mm
+ Standard shim thickness (20) : 2.0 mm
3) Fit spool (12) and secure with stopper (II)
and snap ring (IO).
4) Fit valve (21, spring (3), and valves (4) and
(5), then fit spring (9) and shim (8) and se-
cure with stopper (7) and snap ring (6).
30-156
0
TRANSMISSION LUBRICATION VALVE
REMOVAL OF TRANSMISSION
LUBRICATION VALVE
ASSEMBLY
For details, see REMOVAL FLOOR FRAME AS-
SEMBLY.
2. Remove transmission lubrication valve assem-
bly (1).
INSTALLATION OF
TRANSMISSION LUBRICATION
VALVE ASSEMBLY
removal.
DISASSEMBLY OF
!
VALVE ASSEMBLY
1. Remove plug (2) from body (1).
2. Remove spring (31, then remove spool (4).
CEO01 797
ASSEMBLY OF
VALVE ASSEMBLY
1. Assemble spool (4) to body (I), and install spring
(3).
2. Install plug (2).
30-l 57
0
DISASSEMBLY AND ASSEMBLY STEERING CONTROL VALVE
REMOVAL OF STEERING
1. Remove fuel tank assembly.
For details, see REMOVAL OF FUEL TANK AS-
SEMBLY.
2. Remove brake rod (I).
3. Disconnect steering control rod (2). H
4. Disconnect parking brake cable (3). &
Ir Measure the dimension of the mounting
bracket portion.
6. Remove steering control valve assembly (5).

114
&I kg Steering control valve assembly : 25 kg
INSTALLATION OF STEERING
removal.
m
* Bend the cotter pin securely.
m
Jr Bend the cotter pin securely.
m
* Adjust the installed dimension at the bracket
portion to the dimension measured when
removing.
* Bend the cotter pin securely.
114
w Steering control valve assembly
mounting bolt :
49.0 2 4.9 Nm j5.0 2 0.5 kgml
30-158
0
DISASSEMBLY OF STEERING
1. Parking brake control assembly
Remove parking brake control assembly (1).
2. Steering control assembly

Remove steering control assembly (1).
3. Parking brake valve

1) Remove body (3), then remove piston (4).
2) Remove spring (5), then remove valve (6).
4. Valve cover
1) Remove nuts (7) and (8).
2) Remove cover (9).
5. Clutch valve
1) Remove plug (IO), then remove spring (II).
2) Push in valve from mounting face end of
cover, and remove piston (12), valve (13),
and shaft assembly (14).
3) Disassemble shaft assembly as follows.
i) Remove nut (15), then remove guide
(16).
ii) Remove shim (17) from guide (16).
iii) Remove spring (18) and guide (19) from
bolt (20).
4) Remove cylinder (21).
6. Brake valve
1) Remove plug (22), then remove spring (23).
2) Push valve in from mounting face end of
cover, and remove piston (24), valve (25),
and shaft assembly (26).
i) Remove nut (27), then remove guide
(28).
ii) Remove shim (29) from guide (28).
iii) Remove spring (30) and guide (31) from
bolt (32).
4) Remove cylinder (33).
30-160
0
CDD02154
30-161
0
ASSEMBLY OF STEERING
* Clean all parts, and check for dirt or dam- 4. Parking brake valve
age. Coat the sliding surfaces of all parts 1) Assemble valve (6) and install spring (5).
with engine oil before installing. 2) Assemble piston (41, then fit O-ring and
install body (3).
1. Brake valve 5. Steering control assembly
I) Install cylinder (33) to valve body (34). Install steering control assembly (2).
2) Assemble shaft assembly as follows.
w Mounting bolt :
i) Assemble guide (31) and spring (30)
49.0 + 4.9 Nm I5.0 I 0.5 kgm1
to bolt (32).
ii) Assemble shim (29) to guide (28) and
6. Parking brake control assembly
install to bolt (32).
Install parking brake control assembly (I).
* Shim thickness : 0.5 mm
iii) Install nut (27). w Mounting bolt :
49.0 = 4.9 Nm 15.0 z 0.5 kgm1
w Nut :
13.25 + 1.45 Nm Il.35 2 0.15 kgml
3) Insert shaft (261, valve (251, and piston

(24) into body (34) from plug mounting
surface end.
4) Fit spring (23). then fit O-ring and install
plug (22).
w Plug : 68.6 + 9.8 Nm I7 + 1 kgm1
2. Clutch valve
1) Install cylinder (21).
2) Assemble shaft assembly as follows.
i) Assemble guide (19).and spring (18)
to bolt (20).
ii) Assemble shim (17) to guide (16) and
install to bolt (20).
Ir Shim thickness : 0.5 mm
iii) Install nut (15).
w Nut :
13.25 + 1.45 Nm Il.35 + 0.15 kgm}
3) Insert shaft (141, valve (131, and piston

(12) into body (34) from plug mounting
surface end.
4) Fit spring (II), then fit O-ring and install
plug (IO).
w Plug : 68.6 2 9.8 Nm 17 = 1 kgm)
3. Valve cover
1) Install cover (9).
2) Install nuts (8) and (7).
& Nut : Thread tightener (LT-2)
w Nut :
13.25 + 1.45 Nm Il.35 f 0.15 kgm1
30-162
0
io
30-163
0
DISASSEMBLY AND ASSEMBLY FINAL DRIVE
REMOVAL OF FINAL DRIVE

ASSEMBLY
1. Remove track shoe assembly.
For details, see REMOVAL OF TRACK SHOE AS-
SEMBLY.
2. Raise chassis with jack or ripper and set stand
@ under frame.
3. Remove covers (I) and (2).
4. Remove cover (31, then using eyebolt, pull out
drive shaft (4). &l
* If the shaft will not come out, set a jack
the ground and push the shoe grouser up,
then move the sprocket to the front or rear
to a position where the shaft will come out,
and remove the shaft.
* Pull the shaft out to a position where it con-
tacts the sprocket.
5. Remove 3 bolts of final drive and install tool Jl.
6. Sling final drive assembly (5) and remove
mounting bolts, then lift off. m
& kg Final drive assembly : 2300 kg
INSTALLATION OF FINAL
8
zi DRIVE ASSEMBLY CED01815 CED01816
z l Carry out installation in the reverse order to

removal.
a
* If the shaft will not go in, set a jack on the
ground and push the shoe grouser up, then
move the sprocket to the front or rear to a
position where the shaft will go in, and in-
stall the shaft.
m
& Final drive assembly mounting bolt :

w Final drive assembly mounting bolt :

CED01817
1720 = 190 Nm I175 t 20 kgm}
. Refilling with oil (final drive case)

Add oil through oil filler to the specified level.
%# Final drive case : 65 f? (SAE30CD)
30-165
0
DISASSEMBLY OF FINAL
DRIVE ASSEMBLY
1. Draining oil 1
Remove drain plug and drain oil from final drive
case.
- : Final drive case : Approx. 65 !I
2. Sprocket
I) Set final drive assembly to block (height:
approx. 50 mm).
2) Remove sprocket (I). I\ \ /
CED01621
3. Cover
Using eyebolts 0, remove cover (2).
CED01622
4. Hub
I) Remove plate (3).
2) Using eyebolts 0, lift off hub (4).
CEDOt621 CED01624
5. Sprocket hub assembly

I) Remove holder (5).
CED01625
30- 166
0
2) Using tool 52, disconnect sprocket hub as-

sembly (6) and bearing (7) portion.
3) Using eyebolts 0, remove sprocket hub as-
sembly (6).
CED0162f CED01627
' - CEDO
4) Remove bearing inner race (8) from sprocket

hub assembly.
CED01629
5) Turn over sprocket- hub assembly, then re-

move floating seal cover (9) and bearing
outer races (IO) and (II).
6) Remove floating seal (12) from floating seal
cover.
Ir Keep the floating seal in a safe place to
protect it from damage.
I CED01630
30-167
6. Wear guard
Lift off wear guard (13).
7. Cover assembly
1) Using eyebolts 0, lift off cover assembly
(14).
CEDO 1631
2) Disassemble cover assembly as follows.

i) Remove floating seal cover (15).
ii) Remove floating seal (16) from floating
seal cover.
* Keep the floating seal in a safe place
to protect it from damage.
CED01632 CED01633
iii) Remove spacer (17) and bearing inner

race (18).
CED01634
iv) Remove plate, then remove ring gear

(19).
8. Carrier assembly
1) Using eyebolts 0, remove carrier assembly
PO).
CED01635
30-168
0
FINAL DRIVE
2) Disassemble carrier assembly as follows.

i) Set carrier assembly on block (height:
approx. 100mm).
ii) Remove holder (21).
iii) Using tool 57, remove planetary gear
shaft (22).
CED01638
iv) Remove planetary gear (231, bearing in-

ner races (24A) and (24B), and spacer
(240.
CED01639
VI Remove bearing outer race (24D).
24D .CED01640
9. Sun gear
I) Remove plate (25), button (261, and sun gear
(27).
CED01641
30-l 69
0
10. Hub, shaft assembly

1) Remove plate (28).
31
CED01642
2) Using tool 55, pull out hub assembly (29) 7

and bearing inner race (30) from shaft as- 1
sembly (31).
31 29
1 CED01643 CED01644
3) Disassemble hub assembly as follows.

i) Remove gear (32) from hub (33).
ii) Remove hub (33) from boss (34). I 33
iii) Using puller, remove bearing outer race
(35) from boss (34).
34
( CED01645 CED01646
4) Using eyebolts 8, pull out shaft assembly

(31) from case.
i) Remove collar (36).
ii) Remove bearing inner race (37) and col-
lar (38).
31
CED01647 CED01648
30-170
0
11. Cage assembly

1) Using eyebolts 0, remove cage assembly
(39).
2) Remove shims (40).
t Check the number and thickness of the
CEO01649 CED01650
3) Disassemble cage assembly as follows.

i) Using puller @, remove bearing outer 42
race (41).
ii) Remove oil seals (42) and (43). I
CED01652
12. Gear assemblv

1) Remove gear assembly (44).
2) Using puller @, remove bearing inner races
(45) and (46).
CED0165?
13. Outer race, oil seals

1) Using puller @, remove bearing outer race
(48).
2) Remove oil seals (49) and (50) from case.
CED01655 CED01656
ASSEMBLY OF FINAL DRIVE

1. Oil seals, bearing outer race
1) Using push tools @ and 0, install oil seals
(50) and (49).
-Lr Install the bottom oil seal with the side
receiving the pressure at the bottom;
install the top oil seal with the side re-
ceiving the pressure at the top.
& Oil seal press-fitting surface :

Gasket sealant (LG-I)
Sr Coat the inside surface of the case thinly
with gasket sealant and wipe off any
sealant that is pushed out.
CEO01656
2) Using push tool 0, press fit bearing outer

race (48).
2. Gear assembly
1) Using push tool @I, press fit bearing inner
races (46) and (45) to gear.
2) Set tool 58 to case and install gear assem-
bly (44).
* Do not remove tool 58 until the cage is
installed.
45
CED01660
30-172
0
3. Cage assembly
I) Assemble cage assembly as follows.
i) Using push tools @I and 0, install oil
seals (43) and (42).
* Install the bottom oil seal with the
side receiving the pressure at the
bottom; install the top oil seal with
the side receiving the pressure. at the
top.
6 Oil seal press-fitting surface :

CED01662
1
Gasket sealant (LG-I)
+ Coat the inside surface of the case
thinly with gasket sealant and wipe
off any sealant that is pushed out.
ii) Using push tool 0, press fit bearing

outer race (41).
I CED01664
2) Using eyeboltsa, set cage assembly (39) to

case and tighten 6 mounting bolts.
w Mounting bolt : 14.7 Nm Il.5 kgm}
Ir Rotate the gear and tighten uniformly,

then remove tool 58.
3) Using thickness gauge (16) as shown in

the diagram on the right, measure clear-
ance a and b between cage A and case B. Q
A
P0
4) Select shim thickness c to be inserted from
the table below.
5) Assemble shim selected in Step 4), then
tighten cage mounting bolts.
m Mounting bolt :
227.3 & 80.85 Nm (23.25 z 8.25 kgm)
CED01666
CED01667
J
4.6 ( 5.0 1 1 ( 1 ( 2 1 2.6
30-174
0
4. Hub, shaft assembly

I) Assemble shaft assembly as follows.
i) Install collar (38).
ii) Using push tool 0, press fit bearing in-
ner race (37).
iii) Install collar (36).
CEO01646 CED01666
2) Using eyebolts 8, install shaft assembly (31)

to case.
3) Assemble hub assembly as follows.
i) Using push tool, press fit bearing outer
race (35) to boss (34).
34
CED01647 CEDOl646
ii) Set boss (34) to hub (33).

4) Set shaft assembly (31) and hub assembly
(29) in position, then using tool J6, press fit
bearing (30) portion.
CED01669 CED01670
5) Tighten mounting bolts of hub assembly

(291.
m Mounting bolt :
276.85 z 31.85 Nm 128.25 + 3.25 kgml
6 Mounting bolt :
m Mounting bolt :
548.8 +: 58.8 Nm I56 + 6 kgm)
7) Install gear (32).
m Mounting bolt : 31
CED01671
539 2 49 Nm I55 + 5 kgml I
30-175
0
5. Sun gear
1) Install sun gear (27) to hub assembly.
2) Install button (26) and plate (25).
CED01641
6. Carrier assembly Distinguishing mark for bearing

1) Assemble carrier assembly as follows. (for example:MZ-1LB)
* The planetary gear bearing forms a set, Distinouishino mark for bearing
(for examPle:MZ-12BI
so align the distinguishing marks on the
inner race, outer race, and spacer when
assembling.
Oistinsuishino msrk for spacer

(for example:MZ-12)
DBD02998
i) Install ring and spacer to planetary gear,

then using push tool @I, press fit top
and bottom bearing outer races (24D).
ii) Assemble spacer (240 and bearing in-

ner races (24B) and (24A) to planetary
gear (231, then set to carrier.
240 2ic 2iA CEDOI 639
30-176
0
iii) Using tool 57, press fit planetary gear

shaft (22).
* Align the shaft with the position of
the bearing and spacer hole, and
press fit gradually.
iv) Install holder (21).
m Mounting bolt :
548.8 I 58.8 Nm I56 t 6 kgm}
Ir After tightening the bolts, check that
the gear rotates smoothly.
2) Using eyebolts 0, install carrier assembly

(20).
7. Cover assembly
I) Assemble cover assembly as follows.
i) Fit ring gear (19) and install plate.
* Install the plate with the chamfered
side at the top.
CED01635
ii) Using tool 53, press fit bearing inner

race (18).
iii) Install spacer (17).
18 CED01675 CED01676
iv) Using tool 54, press fit floating seal (16)

to floating seal cover.
* Remove all oil and grease from the
O-ring and O-ring contact surface,
and dry before installing.
* After installing the floating seal,
check that the angle of the seal is
less than 1 mm.
CED01677
30- 177
0
v) install floating seal cover (15).

Ir Fit a cork plug in the forcing tap.
I CED01676
Install so that the cut-out portion of

the floating gasket sealant cover is
facing the bottom as shown in the
diagram on the right.
DBD02999
I
2) Using eyebolts 0, lift off cover assembly

(14).
8. Wear guard
Raise wear guard (13) and install.
9. Sprocket hub assembly

I) Using tool 54, install floating seal (12) to
floating seal cover.
* Remove all oil and grease from the O-
ring and O-ring contact surface, and dry
before installing.
Ir After installing the floating seal, check
that the angle of the seal is less than 1
mm. J4
30-178
0
2) Using push tool, press fit bearing outer races

(11) and (IO).
3) Install floating seal cover (9).
CED01630
4) Set bearing (8) to sprocket hub assembly.
CED01629
5) Using eyebolts 0, sling sprocket hub as-

sembly (6) and set to cover.
* Check that there is dirt on the sliding
surface of the floating seal, then coat
thinly with engine oil.
CED0162 CED0168
6) Using tool 53, press fit bearing (7) portion.

+ Rotate the sprocket hub assembly when
press fitting.
7 6
CED02180
30-179
0
7) Install holder (5).
& Mounting bolt :

w Mounting bolt :
276.85 + 31.85 Nm 128.25 + 3.25 kgml
10. Hub
I) Using eyebolts@, raise hub (4) and install.
CED01624 CED0162:
11. Cover
Using eyebolts 0, install cover (2).
CED01622
12. Sprocket
Install sprocket (I ).
& Mounting bolt : Thread tightener (LT-2)
w Mounting bolt :
1813 + 98 Nm I185 + 10 kgm1
13. Refilling with oil
Tighten drain plug and add engine oil through
oil filler to the specified level.
Q Final drive case : Approx. 65 e
* After installing the final drive assembly to

the chassis, check again that the oil is at the
/ CED01621
specified level.
30- 180
0
DISASSEMBLY AND ASSEMBLY TRACK FRAME
REMOVAL OF TRACK FRAME

ASSEMBLY
SEMBLY.
2. Raise chassis with jack or ripper, then set sup-
port @ under frame to keep rear of chassis off
ground.
3. Set hydraulic jack @ to center of equalizer bar,
and raise front of chassis.
4. Sling track frame assembly.
1 CEDOlBIB

CEDOla20
7. Remove bushing (3).

8. Using eyebolts 0, pull out pin (4). a
* It is difficult to remove the pin if the centers
of the equalizer bar hole and track frame
hole are not aligned, so adjust the height of
the track frame before removing.
9. Remove cover (5) together with cushion (6).

a
CEO01823 CED01824
30-l 81
0
IO. Remove mounting bolts, and disconnect cover

(7) from track frame.
CDD01906
11. Remove cover (8). Right track frame

Left track frame IO
* With the right track frame, disconnect 4
blade tilt cylinder hoses from the cover. 8
12. Remove seal (9) together with washer (IO). m 9
* Right track frame only.
13. Remove washer (111, then remove spacer (12).
DAD03001
14. Lift off track frame assembly (13). m

* Oil will flow out from the pivot case, so
catch it in an oil container.
- : Pivot case : 16 e
rel
kg Track frame assembly : 7000 kg
I r CED01627
30-182
0
INSTALLATION OF TRACK

removal.
Gil
& Inside surface of bushing :

-Grease (G2-LI)
Before installing the pin, adjust the height
of the track frame and align the center of
the equalizer bar hole and track frame hole.
Set the pin with the grease hole facing the
outside of the machine.
Fit pin (4) and bushing (31, install cover (21,

then install the cover and cushion.
After removing the grease from the press-

fitting surface of the seal, coat with gasket
sealant (LG-6).
Be careful not to install with the seal dis-
placed in the direction of twisting.
Be careful not to install the track frame with I4

seal (14) displaced in the direction of twist-
ing.
. Refilling with oil (pivot case)
Pivot case : 16 @I(SAE30)
30-183
0
DISASSEMBLY AND ASSEMBLY IDLER
REMOVAL OF IDLER
ASSEMBLY
SEMBLY.
2. Remove scraper (I).
* Remove the inside scraper also.
Ir Remove the inside cover also.
4. Sling idler assembly and remove idler cap (3).
m
* For both the left and right idler assemblies,
there is a a ball assembled to the left idler
cap, so keep it in a safe place and be careful
not to lose it.
5. Lift off idler assembly (4).
&I kg Idler assembly : 640 kg
INSTALLATION OF IDLER
ASSEMBLY
removal.
CEO01829
m
* For both the left and right idler assemblies,
install with the oil filler plug facing the left
side of the machine.
* Tighten the idler cap mounting bolts in the
following order.
Tightening order:
1) 2 boltsata
2) 2 bolts at b
3) .2 bolts at a
4) Tighten all bolts to specified torque.
& Mounting bolt :

Thread tightener (LT-21
COD01830
w Mounting bolt :
1641.5 L 171.5 Nm 1167.5 f 17.5 kgm}
* After tightening the idler cap mounting bolts,

check that clearance c between the bottom
of the idler cap and the yoke is 0.
30- 184
0
DISASSEMBLY OF IDLER
ASSEMBLY
1. Remove oil filler plug and drain oil.
- : Idler : 1.45 - 1.7 r!.
2. Set idler assembly @ on block (1).

3. Remove mounting bolts, then using forcing
screws 0, remove seal guide (2) together with
retainer (3).
CEDOl831
4. Turn over idler assembly.

5. Remove mounting bolts, then using eyebolts
0, remove shaft (4) together with retainer.
6. Using puller 0, remove seal guide (5) and re-
tainer (6).
7. Remove seal guides (2) and (5) from retainers
(3) and (6).
CED01832 CED01833
CED01834
I
8. Remove floating seal (7) from seal guides (2) 7
and (5). 8
D
Jr Keep the floating seal in a safe place to
9. Remove floating seal (8) from seal guides (3)
and (6).
* Keep the floating seal in a safe place to
2.5
CED01835 CED01838
30- 185
0
9. Remove bushings (9) from idler (10).
CED01837
30-186
0
ASSEMBLY OF IDLER
ASSEMBLY
1. Set bushing (9) and tool Ll to idler (IO), and
press fit bushing (9).
* First, center the bushing with a plastic ham-
mer, then press fit with a puller.
* Press fit so that press-fitting dimension a
from the end face of the idler to the top
surface of the bushing is the dimension
given below.
Press-fitting dimension a : 15 2 1 mm
l
‘9 CED01838 ’
2. Using tool L2, install floating seal (8) to retain-

ers (3) and (6).
3. Fit O-ring and install retainer (3) to idler.
CEDD01840
CED01839
4. Using eyebolts 0, set idler (IO) to shaft (4).

* Set block (height: approx. 140 mm! under
the idler.
5. Turn over idler assembly.
Ir Tie with wire to prevent the shaft from fall-
ing out.
6. Fit O-ring and install retainer (6) to idler.
I’ CED01841 CED01842
7. Using tool L2, install floating seal (7) to seal

guides (2) and (5).
8. Install O-rings to seal guides (2) and (5).
CED01843
30-187
0
9. Set seal guide (2) to shaft, then using tool L3,

press fit seal guide (2).
* Seal guide press-fitting force :
68.6 - 98 kN I7 - IO ton}
CED01844
* Press fit the seal guide so that press-fitting

dimension b from the end face of the shaft
to the top surface of the seal guide is the
dimension given below.
. Press-fitting dimension b : 102 t 0.2 mm
* Turn over the idler assembly and repeat the
same procedure to press fit the seal guide
on the opposite side.
CEO01845
10. Using tool L4, fill with oil to specified level,

then tighten oil filler plug.
-) To vacuum tank
G Idler : 1.45 - 1.7 e (SAE140)

m Oil filler plug : 206 t 49 Nm I21 + 5 kgm} - To oil PUMP
= DAD03002
DISASSEMBLY AND ASSEMBLY RECOIL SPRING
REMOVAL OF RECOIL SPRING

ASSEMBLY
SEMBLY.
a To prevent danger, never stand in front of
the idler yoke assembly.
2. Drain oil from recoil cylinder chamber using oil
pump.
‘-
- : Recoil cylinder chamber : Approx. 50 I?
3. Using eyebolt 0, remove cover (1).
r&l kg Cover : 40 kg

5. Lift off trunnion (3).
Trunnion : 75 kg
6. Remove covers (4). m

* Remove both the inside and outside covers.
7. Using tool Ml, remove pins (5). 1121

* Remove both the inside and outside pins.
30-189
8. Lift off idler and recoil spring assembly (6). a

* Using a lever block, keep the assembly hori-
zontal, and be careful not to damage the oil
seal at the track frame end.
A kg Idler, recoil spring assembly : 3350 kg
9. Disconnect recoil cylinder assembly (8) from

idler yoke assembly (7) as follows. a
1) Put idler yoke assembly (7) in contact with
ground, then raise recoil cylinder assembly
(8).
* When doing this, check that there is no
damage to the weld of recoil cylinder
assembly (7).
* Wrap cloth around the chrome plated
bushing to protect it.
CED01995
2) Loosen idler yoke mounting bolts (9) gradu-

ally in turn on diagonally opposite sides.
pJ
A To prevent danger,
of the idler yoke
never stand in front
assembly or behind
the recoil cylinder assembly.
A The recoil spring inside the recoil cylin-
der is applying a pushing force of
approx. 500 kN (approx. 51 tons) on the
idler yoke, so be careful not to loosen
the mounting bolts suddenly. Loosen
the mounting bolts gradually until clear- OBDO3003
ance a between the flange of the recoil
cylinder and idler yoke is 8 - 12 mm.
3) When the bolts are loosened, the torque
will suddenly drop. Check that the installed
load of the recoil spring is not applying any
pushing force on the mounting bolts, then
remove all bolts.
* If the torque increases (the installed load
of the recoil spring is applied) during
the loosening operation, stop the loos-
ening operation and disassemble as fol-
lows.
CED01997
30-190
0
A If the torque does not drop during Steps

2) and 3) described above, and the
torque when the bolts are loosened re-
mains large, there is probably damage
to recoil spring set bolt (IO), or nut (11)
at the tip of the shaft has fallen off, so
there is danger that the idler yoke as-
sembly may fly off to the front. For this
reason, disassemble as follows.
A When disconnecting the idler yoke as-
sembly and recoil cylinder assembly, do
not stand in front of the idler yoke as-
sembly or behind the recoil cylinder as-
sembly until safety has been confirmed
and the recoil spring assembly has been
removed.
i) Prepare the following parts.
. Bolt @ (x6): 791-730-1110
. Nut @ (x6): 01580-12722
l Washer @ (x6):
01643-32780 (use again)
ii) Remove 6 bolts marked %, then in-
stall bolts 0, nuts 0, and washers
0.
Ir Check that dimension L is less
than 360 mm. I CKD01063
+ Screw in bolts @ until they con-

tact the bottom of the yoke
thread.
iii) Remove remaining 12 bolts (those
not marked 0%).
iv) Hold bolts @ with a wrench to pre-
vent them from turning, and loosen
2 nuts @ simultaneously on diago-
nally opposite sides.
* Be careful not to let the load bear
on only one bolt.
v) When recoil spring is fully extended
and torque has completely dropped
DKD02952
in loosening direction of nut 0, re-
move bolt 0.
I
* When clearance b is approx. 230
mm, the spring is fully extended.
\ 4,111
CED01999
I
30-191
0
10. Remove ring (12).
CEDOZOOO
11. Pump in grease through lubricator (131, and re-

move cylinder (14) and piston assembly. m
CED02001
12. Disassemble piston assembly as follows.

16 I8 17
i) Remove wear ring (16) from piston.
ii) Remove snap ring (171, then remove pack-
ing (18).
4?!lm-d CED02002
13. Remove recoil spring assembly (19).
Recoil spring assembly : 550 kg
CED02003
30-192
0
14. Remove holder (20) from recoil spring assem-

bly.
CED02004
30- 193
0
INSTALLATION OF RECOIL
SPRING ASSEMBLY
removal.
m
m Cover mounting bolt :
277 + 32 Nm I28.25 + 3.25 kgml
Before installing the pin, align the center of

the hole in the track frame and the dowel
pin at the recoil cylinder end with a bar.
Using a lever block, keep horizontal and be

careful not to damage the oil seal at the
track frame end when installing.
Adjust the clearance.
Adjusting clearance of idler.
If the recoil spring set bolt is broken or the

nut at the tip of the shaft has fallen off, see
ASSEMBLY OF RECOIL SPRING ASSEMBLY
when assembling.
& Idler yoke assembly mounting bolt :

w Idler yoke assembly mounting bolt :

1641.5 L 171.5 Nm 1167.5 + 17.5 kgm}
m
Jr To prevent air from accumulating inside the
cylinder, fill with grease as follows.
i) Fill the inside of the cylinder with approx.
1.3 I? of grease.
ii) Set with the cylinder drain hole facing
up, then loosen the lubricator.
iii) Push the piston until it contacts the stop-
per. This will push out the air and any
extra grease.
30- 194
0
DISASSEMBLY OF RECOIL
SPRING ASSEMBLY
1
1. Remove recoil spring assembly (I) with tool
4 The spring is under high installed load, so

be careful to set it correctly.
* Installed load of spring:
Approx. 500 kN {approx. 50 ton}
I
CED02010
2. Apply hydraulic pressure slowly to compress

spring, then remove lock plate (2) and remove
nut (3).
3. Release hydraulic pressure gradually and relieve
tension of spring.
g
CED02011
z
z
4. Remove rear pilot (5), spacer (6), bolt (71, and

front pilot (8) from spring (4.
2 CED02012
30- 195
0
ASSEMBLY OF RECOIL SPRING

ASSEMBLY
1. Assemble front pilot (81, bolt (71, spacer (61, and
rear pilot (5) to spring (4), then set in tool M2.
2 CED02012
A The spring is under high

be careful to set all parts
installed load, so
correctly.
CED02010
2. Apply hydraulic pressure slowly to compress

spring, and set so that installed length of spring
is specified value.
+ Installed length a of spring : 1230.5 mm
* Installed load of spring :
Approx. 500 kN {approx. 51 ton1
I CED02013
3. Fit nut (31, then install lock plate (2).

* Make clearance b of 0 - 1 mm between the
nut and lock plate to prevent the nut from
protruding from the end face of bolt (7).
* Bring lock plate (2) and bolt (7) into tight
contact, and secure in position.
Bring into
6 Lock plate mounting bolt : tight contact
4. Gradually release hydraulic pressure to com-

2 3 7
pletely relieve tension of spring, then remove
DBD03004
recoil spring assembly (I) from tool M2. I
30-196
0
DISASSEMBLY AND ASSEMBLY TRACK ROLLERR
REMOVAL OF TRACK ROLLER

ASSEMBLY
1. Loosen track shoe tension.
SEMBLY.
2. Remove guard (I). a
* Only when removing the last track roller
assembly.
I CED01876
3. Operate blade and ripper to raise chassis to a

point where track roller assembly is separated
from track shoe.
4. Set steel plate @ on top of track shoe, operate
blade and ripper, and lower chassis until track
roller assembly contacts steel plate.
+ When operating the blade and ripper, run
the engine at low idling and operate slowly.
g
ii?
I CED01877
‘5
5. Remove mounting bolts and put track roller as-

sembly (2) on steel board 0. a
UJ CED01878
6. Operate blade and ripper, and raise chassis to a

position where track roller assembly (2) sepa-
rates from bogie.
7. Using a bar, pull track roller assembly (2) on
top of steel plate to outside of machine.
&I kg Track roller assembly :

130 kg. (single flange)
150 kg. (double flange)
2 CEO01879
DISASSEMBLY AND ASSEMBLY TRACK ROLLER
ROLLER ASSEMBLY
removal.
rzil
-a Guard mounting bolt
1325 + 145 Nm I135 + 15 kgm1
m
* The single flange track roller assembly and
double flange track roller assembly are in-
stalled in different positions, so check the S DD S D S
positions when installing.
COD01880
l S: Single flange
l D: Double flange
* Install the track roller assembly with the oil
filler plug facing the outside of the machine.
* After fitting the track roller assembly tem-
porarily, align the position of dowel pin (3).
w Track roller assembly mounting bolt :
1325 + 145 Nm I135 + 15 kgm)
30-198
0
DISASSEMBLY OF TRACK
ROLLER ASSEMBLY
- : Track roller : 1.4 - 1.5 L
2. Set track roller assembly (1) on block 0.

3. Remove mounting bolts, then using forcing
screws 0, remove seal guide (2) together with
retainer (3).
4. Turn over track roller assembly.
5. Remove mounting bolts, then using eyebolts
CED02015 CED02016
0, remove shaft (4) together with retainer.
6. Using press, remove seal guide (5) together with

retainer (6) from shaft.
7. Remove seal guides (2) and (5) from retainers
(3) and (6).
Fz
z CED07.017 cD002011
8. Remove floating seal (7) from seal guides (2)

and (5).
* Keep the floating seal in a safe place to
9. Remove floating seal (8) from retainers (3) and
(6).
Ir Keep the floating seal in a safe place to
CED02019 CED02020
IO. Remove bushing (9) from roller (IO).
I
CEDO202'
30- 199
0
ASSEMBLY OF TRACK ROLLER

ASSEMBLY
1. Set roller (IO) to press, then using tool L8, press
fit bushing (9).
* First, center the bushing with a plastic ham-
mer, then press fit with a press.
* Press fit so that press-fitting dimension a
from the end face of the roller to the top
surface of the bushing is the dimension
given below.
. Press-fitting dimension a: 15 + 1 mm
DBD03i05 1 CED02023
2. Set shaft (4) to roller.
3. Using tool L9, install floating seal (8) to retain-

ers (3) and (6).
4. Fit O-ring and install retainers (3) and (6) to
roller.
CED02024 CED02025

guides (2) and (5).
6. Fit O-ring, then using tool LIO, press fit seal
3
9
guide (2) to shaft.
+ Seal guide press-fitting force : 7 ./
49 - 78.4 kN 15 - 8 ton1
I
I
CED02027
* Press fit the seal guide so that press-fitting

dimension b from the end face of the shaft
to the top surface of the seal guide is the
dimension given below.
. Press-fitting dimension b : 84 = 0.2 mm
a CED02028
30-200
0
7. Using tool Lll, fill with oil to specified level,

then tighten oil filler plug.
G Track roller : 1.4 - 1.5 .t (SAE140)
w Oil filler plug :

206 t 49 Nm I21 z 5 kgm}
I CDD02024
30-201
0
DISASSEMBLY AND ASSEMBLY RBOGIE
REMOVAL OF BOGIE
ASSEMBLY
SEMBLY.
2. Operate blade and ripper to raise chassis to a
point where track roller assembly is separated
from track link.
A Set a block between the track roller and the
track link to prevent the chassis from com-
ing down.
3. Remove guard (1). m
I CED01873
* Only when removing the last track roller
assembly.
4. Align with height of track link and set block @

on outside of track shoe.
5. Set steel plate @ on top of track shoe and block
0.
6. Operate blade and ripper, and lower chassis
until bogie assembly (2) contacts steel plate 0.
* When operating the blade and ripper, run
the engine at low idling and operate slowly.
7. Remove mounting bolts and put bogie assem-
bly (2) on steel board 0. m
6. Operate blade and ripper, and raise chassis to a I I ,
I
position bogie assembly can be pulled out. CED01982
A Set a block between the track roller and the

track link to prevent the chassis from com-
ing down.
9. Raise bogie assembly (2) together with guard,
place on top of steel plate 0, and pull to outsid
m
10. After removing, separate bogie assembly and
guard.
elkg Bogie assembly: 700 kg
Guard: 130 kg
30-202
0
DISASSEMBLY AND ASSEMBLY BOGIE
INSTALLATION OF BOGIE
ASSEMBLY
m
m Guard mounting bolt : 1325 2 145 Nm
{I35 t 15 kgm1
& Bogie assembly mounting bolt:

w Bogie assembly mounting bolt:
1641.5 f 171.5 Nm 1167.5 2 17.5 kgm}
* Fit lever block @ between the guard of bogie

assembly (2) and the guard of the bogie assem- I
bly on the opposite side, then slide bogie as-
sembly (2) on top of the steel plate to set it to
the mounting position.
CED01875
30-203
0
DISASSEMBLY OF BOGIE
ASSEMBLY
1. Track roller assembly
Turn over bogie assembly (I), and lift off 2 track
roller assemblies (3).
-k When removing the track roller, check the
0,
D
mounting position and direction of mount-

ing of the single flange @ and double flange
@ roller and cap.
-
‘I CED01947
2. Installation of fixture
Turn over bogie assembly, then use tools L13 -
L17 - L13-19to secure bogie assembly.
* Install the washer between the fixture and
the bogie.
3. Collar
1) Remove pin (3).
* Hit the pin from the end where the col-
lar has an arrow mark, and remove from
the opposite side.
2) Remove collar (4).
CED01949
CED01950
30-204
3) Remove floating seal (5) from collar.
w CEO01951
4. Cage
1) Using tool L12, remove cage (6) and spacer
(7).
* Catch the oil in an oil container.
LIZ CED01952
2) Remove 2 floating seals (8) from both sides

of cage.
CED01953 CED01954
5. Pulling out pin assembly

1) Set bogie assembly to tool L13.
Ir The pin assembly is removed from the
cage installation side, so set the bogie
assembly correctly in the direction for
removal.
* For details of the method of setting tool
L13, see SETTING CHART FOR PIN AS-
SEMBLY REMOVAL TOOLS.
2) Pull out pin assembly (9) from bogie as-
sembly (I).
Ir Pin assembly removal pressure : I CED01955
519.4 - 1107.4 kN (53 - 113 ton1
30-205
3) Lift off pin assembly (9).
9
\ (IF \
+ - CED01956
6. DisassemblY of pin assembly

1) Remove spacer (IO) and ring (11) from pin
assembly.
of ring.
CED01958
3) Remove spacer (13) and ring (14) from pin

assembly.
of ring.
13
5) Remove floating seal (16) and spacer (17)

from pin assembly.
6) Using hydraulic press 0 and push tool 0,
pull out collar (19) from shaft (18).
* Collar removal pressure :
58.8 - 154.84 kN 16 - 15.8 ton}
-I c
CED01961 CED01962
30-206
0
7. Disconnection of bogie
Remove tools L13-17 - L13-19, disconnect inner
bogie (20) and outer bogie (21).
* SETTING CHART FOR PIN ASSEMBLY RE-

MOVAL TOOL L13-1
CED01964
30-207
0
ASSEMBLY OF BOGIE
ASSEMBLY
1. Securing bogie
Assemble outer bogie (21) and inner bogie (301,
and secure with tools LIS-17 - L19-19.
+ Install the washer between the fixture and
the bogie.
* After securing the tools, check that the pin
mounting holes of the inner bogie and outer
bogie are correctly centered.
1
- z-7- CED01965
2. Assembly of pin assembly

* When assembling each floating seal, coat
the mating surface of the seal thinly with oil
l-k@
(EO-30).
I) Using hydraulic press @ and tool L13-16,
‘64=-l
!!ik
press fit shaft (18) to collar (IS).
* Before press fitting the shaft, center the shaft
with the collar.
Ll3-16
* Collar press-fitting pressure : I!
58.8 - 154.84 kN I6 - 15.8 ton1
* Check that stepped difference a between-the
CED01966 CED01967
end face of the shaft and collar is the di-
mension given below.
. Stepped difference a: 1.0 2 0.48 mm
2) Using LlS-14, press fitting floating seal (16)
to collar (19).
* Remove all oil and grease from the O-
ring and O-ring contact surface, and dry
before installing. L I!-14
* After installing the floating seal, check
that the angle of the seal is less than 1
mm.
* Check that the protrusion of the sliding
surface of the floating seal from the col- I6 I!
lar is 5 - 7 mm. s,i
CEDOl966 CED01961
3) Install spacer (17).
4) Using tool LIS-14, install floating seal (15)
to both ends of ring (14).
* Follow the precautions marked Ir for
Step 2).
5) Install ring (14) and spacer (13) to shaft.
I4
CED01969
30-208
0
6) Using tool L19-14, install floating.seal (12)

to both sides of ring (11). 12 L I!-14
* Follow the precautions marked * for c
Y
Step 2). IO
7) Install ring (II) and spacer (IO) to shaft.
II
II
8
CED01970 CED01957
8) Using tool L19-14, press fit floating seal (8)

to both ends of cage (6).
+ Follow the precautions marked * for
Step 2).
9) Install cage (6) and spacer (7) to shaft.
IO) Using tool L19-14, install floating seal (5) to

collar (4). 5
CED01971
L I!-14
u CED01972
Ir Follow the precautions marked * for

Step 2).
11) Install collar (4) to shaft.
0
@?I
4
CED01973 CED01974
* Align the arrow mark on the shaft with

the arrow mark on the collar.
* Align the arrow marks on the shaft and
collar with the center of the cage bolt
hole.
CED01983
30-209
0
12) Install pin (3).

* Align with the direction of the arrow
mark on the collar, and knock the pin in.
CED0.21
3. Press fitting of pin assembly

1) Raise pin assembly (9) and set to bogie as-
sembly (I).
* Set the pin assembly with the arrow
marks on the cage and collar facing di-
rectly up.
I I CED01975
2) Using tool L19, press fit pin assembly (9) to

bogie assembly (I).
+ For details of the method of setting tool
L19, see SETTING CHART FOR PIN AS-
SEMBLY PRESS-FITTING TOOLS.
& Outer circumference of pin assembly :
Anti-friction compound
(Three Bond 1809B or equivalent)
+ Pin assembly press-fitting force :

519.4 - 1107.4 kN (53 - 113 ton1
+ After press fitting the pin assembly par- CEDOl 976
tially, use guide bolt @ to align the po-
sition of the cage bolt hole.
* Press fit until the cage flange is in tight
contact.
To protect the thrust bushing until the
cage flange is in tight contact, press fit
at a maximum force of 1274 kN II30
ton}.
* to protect the flange after the cage flange
is in tight contact, push in with a maxi-
mum force of 1862 kN {I90 ton}.
30-210
0
4. Removal of fixture
Remove tools L19-17 - L19-19 from bogie as-
sembly.
-‘----- CED01978
5. Refilling with oil

Using tool L20, add oil to specified
tighten oil filler plug.
level and To vac~ua tank 1
Bogie assembly : 230 - 250 cc (SAE140) To oil DUMP
Q
* To settle the floating seal in position, fill

with oil, then move the inner bogie and outer
bogie up and down 5 times.
DAD03006
6. Track roller assembly

Raise 2 track roller assemblies (2) and install to
bogie assembly (1).
Ir Check the mounting position and direction
of mounting of the track roller single flange
@ and double flange @J roller and cap.
1 CED01947
30-211
a
j, SETTING CHART FOR PIN ASSEMB.LY PRESS-

FITTING TOOL L19-1
I Y-24
I!-23
CEDOl981
30-212
0
DISASSEMBLY AND ASSEMBLY CARRIER ROLLER
REMOVAL OF CARRIER
ROLLER ASSEMBLY
SEMBLY.
2. Using hydraulic jack (I), push up track shoe.
3. Lift off carrier roller assembly (I). a
r+ kg Carrier roller assembly : 70 kg
DBD03007
INSTALLATION OF CARRIER
ROLLER ASSEMBLY
removal.
a
* Make a clearance between the carrier roller
and the support as shown on the right.
a Carrier roller assembly mounting bolt :

w Carrier roller assembly mounting bolt :
744.8 f 83.3 Nm (76 2 8.5 kgm}
30-213
0
DISASSEMBLY OF CARRIER
ROLLER ASSEMBLY
* Rotate the shaft when draining the oil.
- : Carrier roller : Approx. 0.7 Q
2. Set carrier roller assembly (1) on block 0.

3. Remove mounting bolts, then remove cover (2).
4. Remove ring (3).
DEWXE3
5. Using tool L7, remove nut (4).

6. Using puller 0, remove press-fitting portion of
seal guide, then using eyebolts (2), remove bear-
ing (5) together with roller (6).
CED01669 DEW0261
7. Remove bearing outer race (7) from roller.

8. Using puller 0, remove seal guide (8) together
with bearing inner race (9).
9. Remove floating seal (IO) from seal guide (8).
8 10
I Mm7266
30-214
0
10. Using push tool 0, remove seal guide (II).
11. Remove floating seal (12) from seal guide (II). 11 12
30-215
0
ASSEMBLY OF CARRIER
ROLLER ASSEMBLY
Ir Clean all parts, and check for dirt or damage.
1. Using push tool 0, press fit bearing inner race
(9).
2. Using push tool @, press fit bearing outer race
(7).
3. Set roller (6) and bearing inner race (5) to shaft.
4. Using push tool 0, press fit bearing inner race
(5) to shaft.
* When press fitting the bearing inner race,
rotate the roller and press fit to a point
where the rotation of the roller becomes
slightly heavier.
5. Using tool L7, tighten nut (4).

w Nut : 98 Nm {IO kgm)
* After tightening the nut, if the nut hole and
shaft hole are not aligned, turn the nut back
to align.
6. Install ring (3).
7. Fit O-ring, and install cover (2).

+ Tighten the oil filler plug temporarily.
30-216
0
8. Turn over roller (61, and add oil betv\ieen shaft

and roller.
‘% Carrier roller assembly : 700 - 800 cc

(SAE140)
6
9. Using tool L5, install floating seal (IO) to seal

guide (8).
10. Fit O-ring, then align with dowel pin and install
seal guide (8).
8. i5
CEDOlB70

guide (11).
CED0187
1
CEDO 1872
12. Using tool L6, press fit seal guide (II).

* Press fit the seal guide to a point where
dimension a from the end face of the shaft
to the top surface of the seal guide is 158.75
f 0.2 mm.
DECO0277
30-217
0
13. Using tool L4, apply standard pressure to roller

oil filler port, and check for leakage of air from
seal.
* Standard pressure : 0.1 MPa 11 kg/cm*}
Ir Method of checking
Hold the standard pressure for 10 seconds
and check that the gauge indicator does not
go down.
DCCOJ278
14. After checking for air leakage, check again that

the oil added in Step 8 is at the specified level.
* Method of checking oil level
Remove the oil plug, set the carrier roller
assembly at approx. IO” and check the oil
level.
15. Tighten oil filler plug.

a Plug : 205.9 + 49.0 Nm I21 + 5 kgm1
30-218
0
DISASSEMBLY AND ASSEMBLY TRACK SHOE
REMOVAL OF TRACK SHOE

ASSEMBLY
CHECKING BEFORE REMOVAL OF TRACK SHOE
ASSEMBLY
a In some cases, it may be extremely dangerous
to remove the track shoe assembly. To prevent
danger, carry out the following checks before
removing the track shoe assembly.
g Never loosen the lubricator more than one turn.
. Loosen lubricator (I) at the adiustment cylin-
der, release the grease, then move the ma-
chine backwards and forwards a short distance,
and check that the track tension is relieved.
* If the shoe tension is relieved, go to REMOVAL
OF TRACK SHOE ASSEMBLY (NORMAL).
. If the above procedure does not relieve the track
tension and the track shoe assembly remains
tense, there may be an abnormality inside the
track frame (the recoil spring case is broken,
the recoil spring set bolt is broken, or the nut at
the end of shaft has fallen off).
* If the shoe tension is not relieved, go to RE-
MOVAL OF TRACK SHOE ASSEMBLY (WHEN
THERE IS ABNORMALITY INSIDE TRACK
FRAME).
z?
%
5;
REMOVAL OF TRACK SHOE ASSEMBLY (NORMAL)

Ir If CHECKING BEFORE REMOVAL OF TRACK
SHOE ASSEMBLY shows that there is no ab-
normality, do as follows.
1. Set master link in position.
* Set a block (height: approx. 400 mm) so
that the master link is approx. 600 mm from
the ground at the front.
2. Relieve track shoe tension. m
A Never loosen lubricator (I) more than one
turn.
* If the track is not relieved’ by loosening the
lubricator,,move the machine backwards and
forwards.
3. Remove track shoe (2). m
CED02035
30-219
0
4. Remove connection portion of master link (3).
CEO02036
5. Raise tip of master link, move machine towards

rear slowly, and lay out track shoe assembly
(4).
Ir Length of track : Approx. 12.5 m
ATO prevent danger, never stand in front of the
idler yoke assembly.
CED02037
REMOVAL OF TRACK SHOE ASSEMBLY

(WHEN THERE IS ABNORMALITY INSIDE TRACK
FRAME)
* When CHECKING BEFORE REMOVAL OF TRACK
SHOE ASSEMBLY shows any abnormality, do
as follows.
Ajf there is any abnormality inside the track
frame, there is danger that the track shoe as-
sembly may spring back when it is removed or
that the idler may spring out when the track
shoe assembly is removed. This may lead to
serious injury, so remove the track shoe as-
sembly as follows.
1. Remove work equipment assembly.
For details, see REMOVAL OF WORK EQUIP-
MENT ASSEMBLY.
2. Loosen lubricator (I), then move machine back-
wards and forwards to remove grease.
A Never loosen lubricator (I) more than one
turn.
* Check that all the grease has been removed.
30-220
0
3. Drive slowly forward to put track shoe at idler

end in contact with large block @ or a wall (if
another large bulldozer of the same capacity as
the machine being repaired is available, put in
contact with the blade). Stop machine when
recoil spring bends and slack is formed in track
shoe assembly, then apply brake.
When doing this, set so that master link.is be-
tween idler and front carrier roller.
For safety reasons, fit a lever block between
carrier roller support and link.
4. Remove shoe (51, then disconnect master link I CEO02038
(6).
5. Move machine towards rear slowly and lay out
track shoe assembly.
g To prevent danger, never stand in front of the
idler yoke assembly.
SHOE ASSEMBLY
g removal.
Z m
Z * For details of the track shoe tension, see
STANDARD VALUE TABLE, Testing and ad-
justing of track shoe tension.
m
+ Tighten the master link shoe mounting bolts
in the order shown in the diagram on the
right.
& Shoe mounting bolt :
Seizure prevention compound

(Maruzen Molymax No. 2 or equivalent)
w Shoe mounting bolt :
DLlxm28
1st step : 686 t 68.6 Nm I70 = 7 kgm1
2nd step: Tighten a further 180 z IO”
30-221
0
DISASSEMBLY AND ASSEMBLY OVERALL DISASSEMBLY OF TRACK SHOE
OVERALL DISASSEMBLY OF
TRACK SHOE
* This section describes only the procedure for
the lubricated track.
1. Shoe (master link portion)

Set the track assembly on a flat floor with the
shoe facing up, then remove the shoe bolt at
the master link, and remove the shoe.
* Do not use an impact wrench when loosen-
ing the master link bolt.
2. Disassembly into l/4 parts
Because of the weight of the track assembly, if I DLDCO283
the l/2 assembly is too large and there are prob-
lems with disassembly and assembly work, di-
vide into l/4 assemblies.
3. Shoe (regular link portion)
Raise the track assembly and set it on the floor
with the shoe facing up, then use a shoe bolt
impact wrench to remove the shoes.
* When moving the track assembly, be care-
ful not to damage the master link portion.
* If a gas cutter has to be used to remove the
shoe nut, to prevent deterioration of the seal
due to the heat, keep the temperature of the
seal portion below 8O”C, and take action to
prevent welding spatter from entering the
gap between the links.
4. Draining oil
Before disassembling the link assembly, drain
the oil from inside the pin and take precautions Burrs Chamfer
so that the link press does not become dirty

with oil.
* Before disassembling, if it is judged that it
is necessary to rebuild the track as a dry
type track, the following work need not be
carried out.
1) Set the link assembly on a flat floor with the
large plug side facing up, then chamfer the
burrs on the end face of the pin with a
grinder.
+ If the track is disassembled with burrs
still at the end face of the pin, the pin
press-fitting hole of the link will be
scratched, and this will cause leakage
from the pin press-fitting portion after
rebuilding.
2) Using a drill (al0 mm), make a hole in the
large plug, then remove the large plug.
* If any dirt or deteriorated oil is stuck to
the pin hole, drill through with a longer
drill to remove it. When doing this, be
careful not to damage the oil hole.
I DLlXJ286
30-222
0
3) After removing the large plug, use a baby

grinder (angle of grinder tip: 45” - 609, and
chamfer the pin hole so that the plug is not
damaged when the plug is knocked in.
4) Turn over the link assembly so that the small
plug side is facing up, remove the burrs at
the end face of the pin with a grinder, then
use tool RI to knock the small plug to the
inside.
* If the small plug hole is blocked with
burrs, grind with a grinder until the hole
can be seen completely.
5) Using a drill ($310 mm), chamfer the small
plug hole.
6) Blow with compressed air to remove the
metal particles when draining the oil inside
the pin or removing the burrs, then wash
the link assembly with high-pressure water
or steam.
CED01882
5. Disassembly of link
1) Set the link assembly on a link press, then
hit with a hammer so that the bushing and
jaw are in tight contact.
* If the link tread and outside diameter of
the bushing are worn, adjust the height
of the shoe or guide plate, and center
the disassembly jig with the pin and
bushing center to prevent damage to the
link hole when disassembling.
Ir If the centering is not carried out prop- Left disassembly jis Right disassembly jis
Jaw
erly, the link hole may be damaged, the OLD02924
pin may break, or the bushing may crack

during disassembly.
2) Operate the left cylinder and remove the
left link and pin and bushing press-fitting
portion at’the same time.
Check the removal force of the pin and
bushing, and use this value as reference
to judge if it is possible to obtain the
necessary pin and bushing press-fitting
force when turning and reassembling.
Do not push the disassembly jig inside
more than is necessary as the spacer
may break.
DLD00290
3) Return the left cylinder, then operate the

right cylinder and remove the right link and
pin and bushing press-fitting portion at the
same time.
4) Return the right cylinder, remove the left
and right links, pins, bushings, and spacers,
then feed the following set for one link as-
sembly into the jaw.
To decide if the seal can be used again,
carry out inspection when the seal is
still installed to the link, so do not re-
move the seal from the link.
If oil is remaining, this can be used as a
guideline for reuse of the seal, so mark
such links or seals.
If the end face of the bushing and seal
surface are damaged, it will cause oil
leakage, so be extremely careful when
handling.
6. Inspection
Check the following items to determine if the
part can be reused as a lubricated track or as a
grease-filled track. Carry out a comprehensive DLDCQSZ
check to determine if the link assembly can be

rebuilt as a lubricated track or as a grease-filled
track.
* When making judgments about reuse of
parts, see “Guidance for Reusable Parts, Un-
dercarriage, Lubricated Track”.
1) Check the pins, bushings, links, and spacers
visually for damage, and carry out a color
check or use a flaw detector to check parts
that are suspected of being damaged. Any
part that is cracked must not be used again,
so scrap it.
2) Check the external appearance of the seal
and the end face of the bushing visually to
determine if they can be used again.
* If only the bushing is replaced with a new
part, the worn or damaged part of the seal
lip will contact the end face of the bushing
directly, so it may not be able to carry out
its sealing function. For this reason, al-
ways replace the seal
together with the bushing, or rebuild as a
grease-filled track.
30-224
3) Using calipers, measure spacer thickness a

and overall length b of the sliding portion
of the bushing and spacer. Check if it is
possible to obtain the specified seal mount-
ing dimension when reassembling.
* If the amount of wear of the spacer and
bushing is greater than the specified
amount, the assembly precision of the
b
seal portion cannot be guaranteed, so
replace with new parts, or rebuild as a
grease-filled track.
4) Using a micrometer, cylinder gauge, and

calipers, measure the outside diameter of
the pin and the inside diameter of the bush-
ing at the worn portion, and judge if the
parts can be used again.
* If the amount of wear is greater than
the specified amount, there will be play
during travel, and it will also cause oil
leakage, so replace with new parts or
rebuild as a grease-filled track.
-k For details of the dimensions when mak-
ing judgment, see MAINTENANCE
STANDARDS.
5) Using a micrometer and cylinder gauge,

measure the outside diameter of the pin and
bushing press-fitting portion, and the inside
diameter of the pin and bushing press-fit-
ting portion of the link to determine if the
permitted interference can be obtained.
However, when rebuilding as a lubricated
track, check that the standard interference
for the pin and link can be obtained.
Ir If the permitted interference can not be
obtained, replace with new parts or re-
place with an oversize part.
+ For details of the dimensions when mak-
ing judgment, see MAINTENANCE
STANDARDS.
* Precautions for storage

I) To prevent rust of the counterbore portion
of the link, leave the seal installed to the
link and be careful not to damage the seal
lip during storage.
2) Coat the pin and bushing press-fitting por-
tion, shoe mating surface, and master link
mating surface of the link with rust preven-
tion oil to prevent rust.
3) Coat the whole circumference of the pins,
bushings, and spacers with rust prevention
oil to prevent rust, and be particularly care- DLIXO297
L
ful not to damage the end face of the bush-
ing during storage.
30-226
0
DISASSEMBLY AND ASSEMBLY OVERALL ASSEMBLY
OVERALL ASSEMBLY
1. When rebuilding as lubricated track
Load rina Seal rins
1. Preparatory work \ I
I) ‘Washing seal assembly

. Machines fitted with F3 type seals
Remove the seal assembly from the link,
then separate into the seal ring and load
ring, and clean the parts.
* The seal ring and load ring deteriorate
easily when brought into contact with
cleaning agent (trichlene, etc.), so wash
the parts quickly. After cleaning, wipe DE003026
the parts with a clean cloth to remove

all the cleaning agent.
. Machines fitted with W7 type seals
For seals that are to be reused, leave the
seal installed to the link, and do not wash it.
2) When reusing the pin, chamfer the corner

of the end face smooth with a grinder. Use
a grinder to remove any protruding parts
stuck to the press-fitting portion.
* If the corner of the end face has become
sharp due to wear, there will be scuffing
at the press-fitting portion and this will
cause oil leakage.
3) Make a mark on the end face at the small

plug end to show the direction of the side
hole (hole in the radial direction) in the pin
Make make to indicate
when assembling.
* When reusing the pin, assemble in the
same direction as when the part is new
(side hole on the link tread side).
30-227
0
4) If the link, pin, bushing, or spacer are dirty,

wash them. Remove any protruding parts
stuck to the link and bushing with a grinder.
* These parts easily rust, so wash them
immediately before assembly.
* Use tool R2 to wash the pin hole.
* Do not polish or carry out any other
treatment of the end face of the bushing
as this will cause oil leakage.
5) Use tool R3 to knock the large plug into the
pin.
i) Insert the plug into the guide hole H CED01883
through the plug insertion window.
ii) Push the bar by hand and insert the plug
as far as possible.
iii) Push the plug with the bar and push the
guide itself against the pin.
iv) Knock in the bar with a hammer.
Ir Dimension a to knock in from end
face of pin: 11 I 2 mm
* If there is no more place to chamfer
at the pin hole because of wear, use
a baby grinder (angle of grinder tip:
45” - SO’) to carry out chamfering.
* Coat the outside circumference of the
plug with GO90 and knock in the DAD03009
smaller diameter part first.
6) Installation of seal assembly
. Machines fitted with F3 type seal
Clean the link counterbore, then use tool R6 Remove all oi I and
grease from portions
to push the seal in fully to the bottom. marked bv bold line I
* If there is oil stuck to the link counterbore
.Rc’
and seal assembly, the seal will rotate and Direct ion
of insertion
its sealing performance will drop, so do not
coat with oil. In addition, be careful not to
let oil get into the counterbore portion of
the seal when pushing in.
. Machines fitted with W7 type seal
When reusing the link and replacing the seal
R6
with a new part, clean the link counterbore, DAD03010
then push the seal in fully to the bottom.
* If there is oil stuck to the link counterbore
and seal assembly, the seal will rotate and
its sealing performance will drop, so do not
Remove all oil and sreese
coat with oil. In addition, be careful not to from the shaded area
let oil get into the counterbore portion of
the seal when pushing in.
DLD02932
30-228
0
71 In order to keep the protrusion of the pin

and bushing constant and the installation
dimensions of the seal within the specified
value during assembly, adjust the press-fit-
ting jig dimensions of the link press.
For details of the standard dimensions,
see PRESS-FITTING JIG DIMENSION
TABLE FOR LINK PRESS.
To leave a small space for the pin when
assembling, ensure that the dimension
(dimension a’) is greater than dimen-
sion a at the pin pushing portion of the DLD00306
left press-fitting jig.
When assembling in order @ press fit
ting left link, @ press fitting right link,
provide the extra space for the pin on
the right press-fitting jig.
If the end face of the pin (portion P) or
the side face of the link (portions 0, R)
are worn, add the amount of wear to
the standard dimension when adjusting
the dimension of the press-fitting jig so
that the amount of protrusion of the left
and right pin and bushing is uniform.
DLDOOS7
1
8) Adjust the relief pressure of the link press
to make sure that the pushing force of the
press does not exceed the specified value.
* If the pushing force is too strong, exces-
sive force will be brought to bear on the
spacer, and it will be pushed against the
bushing. This will cause the spacer to
break or will cause abnormal wear be-
tween the spacer and bushing end face.
+ If the interference at the press-fitting
portion is different from when the part
i
is new, as when reusing a pin or bush-
ing, measure several of the press-fitting
portions, and use the table below to de-
termine the set pushing force according
to the average interference.
* Pushing force for pin, bushing:1,666 kN
I170 ton}
Pushing force = 1.8 x average press-fit-
ting force
(Adjust the relief pressure of the link
press and set the pushing force.)
30-229
0
2. Assembly of link
I) Use a clean brush to coat the area between
the pin and bushing with oil (GOgO), set in
position, then set in front of the jaw of the
link press.
+ When reusing (turning) the bushing, set
the worn surface on the outside circum-
ference of the bushing facing the shoe
mounting surface of the link (facing up
on the link press).
DLD3039
2) Set the left and right bushing end master

link with the shoe mounting surface facing
up, then press fit to the bushing.
* When doing this, use the pin end mas-
ter link as a support.
* Press-fitting force for bushing:
196 -343 kN {20 - 35 ton1
3) Using a shoe bolt hole pitch gauge, press fit

until the distance between the shoe bolt
holes of the left and right link is the speci-
fied value.
* Use compressed air to remove all metal
particles from burrs caused by press fit-
ting the bushing.
4) Turn over the master link, and check that

the left and right master links have been
press fitted in parallel.
30-230
0
5) Measure the amount of protrusion of the

left and right bushings with a depth gauge.
Ir Adjust the press-fitting jig for the link
press so that the protrusion of the left
and right bushings is uniform.
6) Feed the master link portion, then set the

pin and bushing in position.
When reusing the pin, assemble so that
the side hole is on the link tread side in
the same way as when the part is new.
If the parts are not assembled facing the
specified direction, the strength may
drop, so mark the direction of the side
hole clearly on the end face to prevent
any mistake during assembly.
* Align the large plugs so that they are on
the left side facing the link press when DLD0292
assembling.
7) To prevent oil from leaking out from scuff

marks on the pin press-fitting portion, coat
the pin press-fitting hole in the link and the
outside diameter of the pin press-fitting por-
tion with gasket sealant (198-32-19890).
Coat whole circumference) /
DLD02926
8) Set the right link in position and install the

spacer to the pin.
* Check that there is no dirt or dust stuck
to the seal surface and bushing end face,
then use a clean cloth or brush to coat
with oil (GOgO).
Ir Wipe the spacer with a clean cloth, then
install it.
30-231
0
9) Using the right jig as the receiving end and

the left jig as the pushing end, press fit the
pin and bushing at the same time.
* The seal may come off the link due to
the play when press fitting, so press fit
smoothly. If the seal comes off the link,
stop the press-fitting operation and fit
the seal correctly on the link, then start
the press-fitting operation again.
* Press-fitting force for pin, bushing:
784 - 1,078 kN {SO - 110 ton1
DLD00316
IO) Using a fine adjustment spacer, press fit so Fine adjustment

SPSCC!r
that the end face of the pin is in tight con-
tact with the bottom of the receiving jig.
* Adjust the depth of the hole in the re-
ceiving jig so that the protrusion of the
left and right pins is uniform.
11) Set the left link in position and install the

spacer to the pin.
* Coat with oil in the same way as when
installing the right link.
I DLW0318
12) Using the left jig as the receiving end and

the right jig as the pushing end, press fit
the left link.
When press fitting, be careful that the
left and right seal and spacer do not
come out of position.
Provide enough space on the left jig so
that the end face of the pin does not
contact the bottom of the jig.
Press-fitting force for link:
784 - 1,078 kN (80 - 110 ton}
DLD00319
30-232
0
13) Press fit the link, spacer, and bushing so

Sma I I
that they are each in tight contact. at er
* It is impossible to check from outside if
they are in tight contact, so control the
hydraulic force of the link press and set
the relief pressure to a constant value.
Then apply hydraulic force and push in
until this pressure is reached.
For details of the setting for the relief
pressure, see “Preparatory work”.
* Check that adjacent links swivel freely
in relation to each other. DLD02928
14) After assembling each link, use a dial gauge
and pinch bar to measure the end play from
the link previously assembled, to check that
the link is assembled within the specified
value.
+ If the end play does not come within 0 -
0.13 mm even when applying the push-
ing force until the relief valve is actu-
ated, raise the relief pressure setting
gradually to adjust.
* Adjust the relief pressure setting care-
fully and be sure not to raise the push-
ing force of the link press higher than
necessary.
Using a shoe bolt hole pitch gauge, check
that the distance between the shoe bolt
holes is within the standard value.
+ If the distance between the shoe bolt
holes is greater than the specified value,
disassemble and check for any abnor-
mality, then press fit again.
* If the distance between the shoe bolt
holes is smaller than the specified value,
and the shoe cannot be installed, the
wear of the spacer or bushing end face
is probably greater than the repair limit,
so disassemble and replace with a new
part.
+ If the end play is too large, the sealing
performance will drop, so set the end
play to a small value.
16) After assembling each link, use tool R4 to
remove the air from inside the pin, and check
the sealing performance.
* Hold the space inside the pin at a
vacuum of 86.7 - 93.3kPa (650 - 700
mmHg1 for 5 seconds and check that
there is no change in pressure.
If the pressure changes, disassemble and
check the seal for any abnormality, then
assemble again.
CED01886
30-233
0
17) Assemble the pin end master link as the

final link.
Ir Check that the left and right master links
are press fitted in parallel.
3. Filling with oil

After completion of assembly of the link assem-
bly, add oil through the pin hole.
1) Using tool R4, remove the air inside the pin
from the small plug hole, set to a vacuum
of 86.7 - 93.3 kPa (650 - 700 mmHg1, then fill
with oil (GO901 until the pressure is 196.1 -
294.2 kPa (2 - 3 kg/cm?.
In cold or extremely cold areas, instead
of G090, fill with Komatsu genuine oil
(150-09-19270 or 195-32-61990) which
I CED01887
has excellent low-temperature qualities.
Be careful not to raise the oil pressure
too high as this will have an adverse
effect on the seal.
To determine the oil amount, set the
small plug end at the top (stand the link
assembly on its side), leave for 30 min-
utes, then fill with oil so that depth L of
4- L
Oil level
the space at the pin hole is within the

specified value below. GO90
Dimension L: 40 - 70 mm -Pin
-Laroe PIUD
OLD02929
2) After completion of filling with oil, use tool

R5 to knock in the small plug to the speci-
fied position.
* Coat the outside circumference of the
small plug with G090.
-f The depth to knock in the plug is as
follows.
Depth from end face: 7.5 + 1 mm
30-234
0

Set the link assembly on the bed, then use a
shoe bolt impact wrench and torque wrench to
install the shoe.
w Shoe bolt (regular link):
Initial torque: 1,372 + 137.2 Nm
I140 + 14 kgm}
Tightening angle: 120 f IO”
5. Connecting to make l/2 assembly

Set two completely assembled portions of track
on a flat surface in a straight line with the shoes
facing up. Pull master link (I) at the pin end to
master link (2) at the bushing end, and set at
the mating surfaces. Then put shoe (3) on top,
check that shoe bolt (4) goes in easily by hand,
and connect the two parts with the master bolt. n n
& Shoe bolt:
Anti-friction compound (LM-PI
s: QGFJ Shoe bolt (regular link):
% Initial torque: 686 + 68.6 Nm DLCXXW7
z {70 + 7 kgm}
Tightening angle: 180 + IO”
+ When tightening, tighten in the order @ -

@*
DLDX328
+ Do not use an impact wrench for the master

link.
30-235
2. When rebuilding as grease-filled .track I
1. Preparatory work
I) Washing seal assembly
. Machines fitted with F3 type seals
Remove the seal assembly from the link,
then separate into the seal ring and load
ring, and clean the parts.
+ The seal ring and load ring deteriorate
easily when brought into contact with
cleaning agent, so wash the parts
quickly. After cleaning, wipe the parts
with a clean cloth to remove all the
cleaning agent.
. Machines fitted with W7 type seals

For seals that are to be reused, leave the
seal installed to the link, and do not wash it.
2) When reusing the pin, chamfer the corner

of the end face smooth with a grinder so
that press fitting can be carried out
smoothly.
3) Make a mark on the end face at the small

plug end to show the direction of the side
hole (hole in the radial direction) in the pin
Make make to indicate
when assembling.
* When reusing the pin, assemble in the
same direction as when the part is new
(side hole on the link tread side).
30-236
0
4) Use tools R3 and R5 to knock the large plug

and small plug into the pin.
i) Insert the plug into the guide hole R3
through the plug insertion window.
(Coat the plug with oil.)
ii) Push the bar by hand and insert the plug
as far as possible.
iii) Push the plug with the bar and push the
guide itself against the pin.
iv) Knock in the bar with a hammer. a
* Dimension a to knock in from end
Pin
face of pin: DAD03009
Small pin: 7.5 * 1 mm

Large pin: 11 +. 2 mm
* If the plug was not removed from
the pin during disassembly, it can Remove all oil and
crease from portions
be used again as it is. marked by bold line
5) Clean any part where outside diameter of

the pin, front face of the spacer, or end face Direction
of insertion
or inside diameter of the bushing are dirty.
Coat the outside diameter of the pin and C I
6)
the front face of the spacer with grease.
7) Installation of seal assembly
. Machines fitted with F3 type seal
g Clean the link counterbore, then use tool R6
R6
% to push the seal in fully to the bottom. DAD03010
z * If there is grease stuck to the link

counterbore and seal assembly, the seal
will rotate and its sealing performance
will drop, so do not coat with grease.
. Machines fitted with W7 type seal
When reusing the link and replacing the seal
with a new part, clean the link counterbore,
then push the seal in fully to the bottom.
* If there is grease stuck to the link
counterbore and seal assembly, the seal
will rotate and its sealing performance
will drop, so do not coat with grease.
8) In order to keep the protrusion of the pin
DLD02932
and bushing constant and the installation
dimensions of the seal within the specified
value during assembly, adjust the press-fit-
ting jig dimensions of the link press.
+ For details of the standard dimensions,
see PRESS-FITTING JIG DIMENSION
TABLE FOR LINK PRESS.
* If the end face of the pin (portion P) or
the side face of the link (portions Q, R)
are worn, add the amount of wear to
the standard dimension when adjusting
the dimension of the press-fitting jig so
that the amount of protrusion of the
left and right pin and bushing is uni-
L-4 k
form. C C DLD00306
30-237
0
2. Assemblv of link
I) Coat the area between the pin and bushing
with lithium grease (G2-Lb, set in position,
then set in front of the jaw of the link press.
* When reusing (turning) the bushing, set
the worn surface on the outside circum-
ference of the bushing facing the shoe
mounting surface of the link (facing up
on the link press).
2) Set the left and right bushing end master

link with the shoe mounting surface facing
up, then press fit to the bushing.
* When doing this, use the pin end mas-
ter link as a support.
* Press-fitting force for bushing:
196 - 343 kN I20 - 35 ton1
3) Using a shoe bolt hole pitch gauge, press fit

until the distance between the shoe bolt
holes of the left and right link is the speci-
fied value.
j, Use compressed air to remove all metal
particles from burrs caused by press fit-
ting the bushing.
4) Turn over the master link, and check that

the left and right master links have been
press fitted in parallel.
5) Measure the amount of protrusion of the

left and right bushings with a depth gauge.
* Adjust the press-fitting jig for the link
press so that the protrusion of the left
and right bushings is uniform.
30-238
0
6) Feed the master link portion, then set the

pin and bushing in position.
* When reusing the pin, assemble so that
the side hole is on the link tread side in
the same way as when the part is new.
If the parts are not assembled facing the
specified direction, the strength may
drop, so mark the direction of the side
hole clearly on the end face to prevent
any mistake during assembly.
* If the outside diameter of the pin is worn,
assemble so that the face that is not DLD00329
worn is on the pulling side. However,

in this case also assemble so that the
side hole faces the tread surface of the
link.
7) Set the left and right links in position, then
operate the left and right pushing jigs to
press fit the pin and bushing at the same
time.
* The seal may come off the link due to
the play when press fitting, so press fit
smoothly. If the seal comes off the link,
stop the press-fitting operation and fit
the seal correctly on the link, then start
the press-fitting operation again. DLD00330
Ir Pushing force for pin, bushing: 1,666 kN

(170 ton1
Pushing force = 1.8 x average press-fit-
ting force
(Adjust the relief pressure of the link
press and set the pushing force.)
8) Using a shoe bolt hole pitch gauge, meas-
ure the distance between the shoe bolt holes
and stop press fitting when it is within the
standard value.
9) Assemble the pin end master link as the
final link.
Ir Check that the left and right master links
are press fitted in parallel. DLCC0311

Set the link assembly on the bed, then use a
shoe bolt impact wrench and torque wrench to
install the shoe.
w Shoe bolt (regular link):
Initial torque: 1,372 = 137.2 Nm
{I40 t 14 kgm1
Tightening angle: 120 2 IO”
DLDOO284
4. Connecting to make l/2 assembly

facing up. Pull master link (1) at the pin end to
the mating surfaces. Then put shoe (3) on top,
check that shoe bolt (4) goes in easily by hand,
and connect the two parts with the master bolt.
& Shoe bolt:
w Shoe bolt (master link):
Initial torque: 686 + 68.6 Nm DLlxnl327
I70 2 7 kgm}
Tightening angle: 180 = IO”
Ir When tightening, tighten in the order @ -

0.
* Do not use an impact wrench for the master

link.
DLDO0298
30-240
0
DISASSEMBLY AND ASSEMBLY PRESS-FITTING JIG DIMENSION TABLE FOR LINK PRESST
PRESS-FITTING JIG DIMENSION

TABLE FOR- LINK PRESS
DLDO0331
Unit: mm
Jig dimension
a b C
4.5 2.0 53.6
30-241
0
DISASSEMBLY AND ASSEMBLY FIELD DISASSEMBLY OF ONE LINK
FIELD DISASSEMBLY OF ONE

LINK I
1. Install tool R7-2 to link (1) with R7-24, then in-
stall tool R7-3 with R7-4.
* It is also possible to use a shoe bolt for tool
R7-24.
R7:3 d7-4 CDD01889
2. Assemble tools R7-25 and R7-5 - R7-11, then

raise whole assembly and set on shoe.
R7:ll R7-7
CDD01890
3. Insert tool R7-12 from cylinder end, and install

with 2 tools R7-8.
R7-8 R7-12 R7-0

CDD01891
4. Set tools R7-13 - R7-16 in position, then con-

nect tool R7-26 and apply hydraulic pressure to
pull out pin (2).
2‘ R7-I3
CDD01892
30-242
0
DISASSEMBLY AND ASSEMBLY FIELD DISASSEMBLY OF ONE LINK
* When the cylinder reaches the end of its

stroke, insert tool R7-17, and repeat the op-
eration.
5. Set tools R7-27 and R7-28 to center of roller

tread of link to be disassembled, connect tool
R7-26, then apply hydraulic pressure to open
link 5 - 6 mm.
H7-28
I CED01694
6. Repeat Steps 1 - 4 and pull out other pin (3) on

opposite side.
CDD01695
7. Repeat Step 5 and remove link (4).
I-
I CED01696
30-243
DISASSEMBLY AND ASSEMBLY FIELD ASSEMBLY OF ONE LINK
FIELD ASSEMBLY OF ONE

LINK
Presscor remover)
1. Assemble link sub-assembly as follows.
1) Set tool R7-18 to end face of link (5) at bush- +
ing end, then press fit bushing (6).
* Bushing press-fitting force :
196 - 294 kN (20 - 35 ton1
/ /////
' DAD03011
2) Set tool R7-19 to end face of link at pin end, PressIor remover)
then press fit pin (7). +
* Set with the side hole in the pin facing
7
the link tread. - Side hole
* Pin press-fitting force : 588 - 735 kN
{60 - 75 ton1 \o
Tread side R7-19

/ //I//
/’ DAD03012
2. Set link sub-assembly (8) on link to be con-

nected.
i7---kT CDPO1899
3. Set link (9) on opposite side and support with

tool R7-20.
CD001900
30-244
0
DISASSEMBLY AND ASSEMBLY FIELD ASSEMBLY OF ONE LINK
4. Set tools R7-25, R7-5 - R7-12 and R7-17 to link

in same way as when disassembling.
5. Use tools R7-19 and R7-21 for press fitting pin
end, and tools R7-22, R7-18, and R7-21 for press R7-21 R 7-22
fitting bushing end, and press fit in turn.
Ir Press fit the pin end first, and when the
bushing meshes with the link, remove tool
R7-20 installed in Step 3, then press fit the
bushing end.
Ir Pin press-fitting force : 588 - 735 kN
I60 - 75 ton1
* Bushing press-fitting force : 196 - 294 kN
I20 - 35 ton1
R7-21 R7-I!
CDDOl901
6. Use tools R7-27 and R7-28 in same way as when

disassembling, and push open link (IO) at end
to be connected.
7. Set link (11) to be connected to link (IO), con-

R7-2f1 Q
nect with tool R7-23, then remove tools R7-27
and R7-28.
R 7-23
II
COD01903
8. Set tools R7-2 - R7-12 in same way as when

disassembling, then press fit pin (12) to link.
& Pin press-fitting hole in link:
Gasket sealant (198-32-19890)

Set with the side hole in the pin facing the
link tread.
Pin press-fitting force : 1176 - 1470 kN
I120 - 150 ton1
When the cylinder reaches the end of its
stroke, insert tool R7-17 and R7-14 - R7-16,
and repeat the operation.
30-245
0
DISASSEMBLY AND ASSEMBLY MASTER LINK
DISASSEMBLY OF MASTER
LINK
* For details of the method of using tool R7, see
FIELD DISASSEMBLY OF ONE LINK.
1. Removal of track assembly
Remove the track assembly from the track frame.
SEMBLY.
2. Separation of track
Disconnect all master link portions, and divide
into four parts.
3. Removal of master link

Master pin type
1) Gas cutting of regular link
Gas cut the portion marked WW, and re-
move m .
Special tool to use: Gas cutter
Bushing <
\L c
DLD02940
2) Removal of regular link

Push pin (1) in the direction of the arrow
with a press, remove from link (2), then re-
move pin (I) and link (3) at the same time
from bushing (4).
= DBDOO346
. Master link type

1) Gas cutting, removal of master link at bush-
ing end
Gas cut the portion marked WW, remove
a, then move master links (5) and (6) up
or down to remove them. Push pins (8) and
(9) press fitted to regular link (7) with a press
in the direction of the arrows to remove
them.
l Special tool to use: 1. Gas cutter
2. Tool R7.
= DBD0034;
30-246
0
2) Removal of master link at pin end

Gas cut the portion marked VW, remove
@ , push pin (IO) with a press in the di-
rection of the arrow and remove from link
(II), then remove pin (IO) and link (12) at
the same time from bushing (13).
l Special tool to use: 1. Gas cutter
2. Tool R7
DBD003.W
30-247
0
ASSEMBLY OF MASTER LINK

j, For details of the method of using tool R7, see
FIELD DISASSEMBLY OF ONE LINK.
1
1. Assembly of link at bushing end
1) Using a press, press fit master link (I) at the
bushing end to bushing (2).
+ When press fitting the left and right
master links, be extremely careful to
keep them parallel.
* Be careful not to scratch or damage the 2
mating surface of the master link and
the end face of the bushing.
Unit: mm
Installation of link at bushing end

1) Push open the central part of the link tread
with tool R7 as shown in the diagram. (Open
5mm
approx. 10 mm at the tip of the link.)
5mm
CEDOI 905
2) Set spacer (3) and seal assembly (4) at the

counterbore of the link at the connection.
30-248
0
3) Align the pin hole and bushing hole, and

connect with guide pin 0.
I DLD02942
4) Press fit pin (5) with tool R7, and install

master link (1) at the bushing end.
& Pin press-fitting hole in link:
Gasket sealant (198-32-198901
I
* Set with the side hole in the pin facing
the link tread.
+
Press fit
DLD0.2943
5) Install the shoe to the link at the connec-

tion.
6) After knocking in large plug (6) with tool R3,

fill with oil using tool R4, then knock in small
plug (7) with tool R5.
Ir When press fitting the left and right mas-
ter links, be extremely careful to keep
the left and right links parallel. (Bush-
ing end and pin end)
+ Be careful not to scratch or damage the 6
mating surface of the master link and DBDGQ354
the end face of the bushing.

+ End play at connection (play in thrust
direction of links on both sides of pin):
0 - 0.13 mm
+ Be extremely careful not to get mud or
dust on the tap hole mating face of the
master link, bushing end face, spacer,
or seal.
30-249
0
3. Assembly of link at pin end

1) Set spacer (3) and seal assembly (4) in the
counterbore of the master link.
2) Pass pin (9) through bushing (81, set pin

master link (IO) from the left and right,
then press fit with tool R7.
3) After knocking in large plug (I I) with tool

R3, fill with oil using tool R4, then knock in
small plug (12) with tool R5.
9 11
DEW0355
_. _ .. . .. I
Connectmg master unK poruon
facing up. Pull master link (13) at the pin end to
the mating surfaces. Then put the shoe on top,
and check that the shoe bolt goes in easily by
hand.
& Shoe bolt:
m Shoe bolt (master link):
14
Initial torque: 686 z 68.6 Nm DEW0356
I70 I 6 kgm1
Tightening angle: 180 2 IO”
30-250
0
DISASSEMBLY AND ASSEMBLY PIVOT SHAFT
REMOVAL OF PIVOT SHAFT

ASSEMBLY
1. Remove track frame assembly.
For details, see REMOVAL OF TRACK FRAME
ASSEMBLY.
2. Sling pivot shaft assembly (1) and remove
mounting bolts, then using forcing screw 0,
pull out pivot shaft assembly. m
iI+ kg Pivot shaft assembly : 210 kg
- CED02111
3. Remove seal (2), then remove cover (3). m
CED02191
INSTALLATION OF PIVOT
SHAFT ASSEMBLY
removal.
m’
a Pivot shaft press-fitting surface :
a
+ Using tool P, press fit seal (3) to the pivot
shaft. CED02192
& Seal press-fitting surface :

* Check that press-fitting dimension a of the
seal from the end face of the shaft is the
specified dimension.
. Press-fitting dimension a : 540 I 0.2 mm
30-Z 1
0
DISASSEMBLY AND ASSEMBLY EQUALIZER BAR
REMOVAL OF EQUALIZER BAR

1. Remove engine underguard and power train Left track frame Right track frame
underguard (front). 3
Engine underguard : 290 kg 1

A kg
Power train underguard (front) : 280 kg

* With the right track frame, disconnect 4
blade tilt cylinder hoses from the cover.
* The front of the machine is raised using the
blade, so install a blind plug securely in the
hose at the tilt cylinder end. I I DAD03013 DAD03014
3. Remove seal (2) together with washer i3I.m

+ Right track frame only.
4. Remove washer (41, then remove spacer (5).
* Oil will flow out from the pivot case, so
catch it in an oil container.
- : Pivot case : 16 r?
5. Set hydraulic jack @ (490 kN I50 ton)) under

radiator guard.
0.

8. Remove bushing (8).

9. Using eyebolt 0, remove side pin (9). m
Ir It is difficult to remove the pin if the centers
of the equalizer bar hole. and track frame
hole are not aligned, so use hydraulic jack
0 to adjust the height at the equalizer bar
end before removing.
I
I CEO01913
30-252
10. Remove cover (IO) together with cushion (11).

m
+ Repeat Steps 6 to 10 to remove the side pin
on the opposite side.
11. Operate hydraulic jack @ slowly and lower chas-
sis to point where equalizer bar contacts left
and right track frames.
IO
CED01916
12. Disconnect lubrication tube (12).

13. Remove 2 lock plates (13).
i--:
i
------.._---\__A
I !
g
ifi / CED01917
7
T +“’
- \__/-
,,,,,
13
CDD01918
z
14. Using tool Nl, remove center pin (14). m I

+ It is difficult to remove the pin if the centers
of the equalizer bar hole and main frame
hole are not aligned, so use hydraulic jack
@ to adjust the height at the main frame
end before removing.
CD001919
15. Operate blade and raise front of chassis, and

set stand @ under radiator guard.
I CD001920
30-253
0
16. Raise equalizer bar (151, move it past main frame

and track frame, and remove.
4L After removing the equalizer bar, do not
lower the chassis.
I3 kg Equalizer bar assembly : 500 kg
30-254
0
INSTALLATION OF EQUALIZER
BAR
removal.
q
After removing the grease from the press-
fitting surface of the seal, coat with gasket
sealant (LG-6).
* Be careful not to install with the seal dis-
placed in the direction of twisting.
& Inside surface of bushing : Grease(GZ-LII

+ Before installing the pin, operate hydraulic
jack, @ to adjust the height of the main frame
and align the center of the equalizer bar
hole and track frame hole.
* Set the pin with the grease hole facing the
outside of the machine.
@
Ir Fit pin (9) and bushing (8), install cover (71,
then install the cover and cushion.
a
m Lock plate mounting bolt : 549 + 59 Nm
{56 + 6 kgml
a
6 Equalizer bar bushing and main frame
bushing : Grease (G2-LB
* Before installing the pin, operate the crane
to align the center of the main frame hole
and the equalizer bar hole.
. Refilling with oil (pivot case)
I& Pivot case : 16 I? (SAE301
30-255
0
DISASSEMBLY AND ASSEMBLY EQUALIZER BAR BUSHING
DISASSEMBLY OF EQUALIZER
BAR BUSHING
1. Center bushing
Remove center bushing (I).
CDD01922
2. Side bushing
1) Remove seal (2).
2) Remove snap ring (3).
CDD01923 CDD01924
3) Set tool N2 in position and remove side

bushing (4) from equalizer bar (5).
I CED01925
30-256
0
DISASSEMBLY AND ASSEMBLY EQUALIZER BAR BUSHING
ASSEMBLY OF EQUALIZER
BAR BUSHING
1. Side bushing
1) Set side bushing (4) and tool N2 in posi-
tion, then press fit side bushing (4) to equal-
izer bar (5).
& Outer circumference of bushing :

Anti-friction compound (,LM-P)
* Align the direction of installation of the side
bushing as shown in the diagram on the
right.
i) Make split surface (mating surface) a of
CED01926
outer bushing horizontal.
ii) Set inner bushing and outer bushing
grease hole b at an angle.
* Side bushing press-fitting force :
34.3 - 73.5 kN I3.5 - 7.5 ton}
CDD01927

* After installing the snap ring, fill front
and rear portion c of side bushing with
grease (G2-LI).
& Amount of grease to fill side

bushing: 0.3 .4
3) Using press, press fit seal (2).
* Seal press-fitting force : 9.8 - 29.4 kN
(1 - 3 ton1
* Press fit so that the mouthpiece of the
3 CDD01928 CDD01929
seal does not extend from the end face
of the equalizer bar.
& Lip of oil seal : Grease (G2-LII
2. Center bushing
Using press, press fit bushing (I).
& Outer circumference of center bushing :

+ Center bushing press-fitting force :
49 - 186.2 kN 195 - 19 ton}
I CDD01930
30-257
0
DISASSEMBLY AND ASSEMBLY SEGMENT TOOTH
REMOVAL OF SEGMENT
TOOTH
1. Set segment tooth to position where it can be
removed (midway between shoe and track
frame), then stop machine.
3. Remove mounting bolts, then remove segment

tooth (3).
* Before removing all the mounting bolts, in-
sert bar @) into a mounting bolt hole at the
top, move the segment tooth to the outside,
and remove.
kg
rE?l Segment tooth : 35 kg
INSTALLATION OF SEGMENT
TOOTH
removal.
a
& Seat surface of segment tooth mount-
ing nut : Anti-friction compound (LM-PI
m Segment tooth mounting nut :

1813 2 98 Nm {I85 f 10 kgm1
30-258
0
DISASSEMBLY AND ASSEMBLY HYDRAULIC TANK
REMOVAL OF HYDRAULIC
TANK ASSEMBLY
stop the engine. Release the remaining pres-
sure in the hydraulic piping. For details, see
TESTING AND ADJUSTING, Releasing remain-
ing pressure from hydraulic circuit. Then loosen
the oil filler cap slowly to release the pressure
inside the hydraulic tank.
1. Drain oil from hydraulic tank.
& Hydraulic tank : 230 4!

I CED01984
2. Remove operator’s cab right cover (I).

I
3. Disconnect PPC charge valve (2) from hydraulic

tank.
* Move the PPC charge valve towards the floor
frame.
g
%
;;
5. Disconnect 2 PPC hoses (4) and 3 main hoses

(5) from blade lift valve.
Sr The PPC hoses are distinguished by color
bands. m
I .
”
CFDO2031
6. Open hydraulic tank front cover (6), and discon-

nect hoses (7) and (8) from blade lift valve.
* Move the disconnected hoses towards the
operator’s cab.
\ ,.
CED0.2043
30-259
0
7. Disconnect 6 PPC hoses (9), 4 rear main hoses

(IO), and 4 front main hoses and tubes (I I)
from blade tilt and ripper Lo valve.
* The PPC hoses are distinguished by color
bands. a
8. Disconnect return hose (12) and suction tube
(13) from hydraulic tank.
v9 -
I CED02032
9. Remove hydraulic tank front cover (14) and dis-

connect return hose (15).
I CED02033
10. Lift off hydraulic tank assembly (16). m
& kg Hydraulic tank assembly : 380 kg
30-260
0
INSTALLATION OF HYDRAULIC
TANK ASSEMBLY
removal.
pc-i-jm
* The connecting position of the PPC hoses is
distinguished by the band color at the quick
coupler portion, so check the colors ,when
installing.
Band
I DBD03015
Transoarent
m Hydraulic tank mounting bolt : +
(From operator’s cad)
151.9 = 24.5 Nm {I55 f 2.5 kgml
Refilling with oil (hydraulic tank)

Bleeding air +
Bleed the air from the piping. Red/White DA00301 6
Bleeding air from hydraulic cylinder.
Distinauishins operator’s cad)
Brown ‘From
color bands
Black/Blue Black
+++
Yellow Green
White DAD0301 7
30-261
0
DISASSEMBLY AND ASSEMBLY WORK EQUIPMENT, PPC PUMP
EQUIPMENT, PPC PUMP

ASSEMBLY
the oil filler cap slowly to release the pres-
sure inside the hydraulic tank.
g Disconnect the cable from the negative (-1 ter-
- : Hydraulic tank : 230 e

ASSEMBLY.
3. Disconnect hydraulic oil temperature sensor
connector (CN-452)(l).
4. Disconnect 2 hoses (2).
5. Disconnect 4 delivery hoses (3).
6. Disconnect suction tube (4). m
* Remove 2 clamps, then move the coupling
towards the pump, and disconnect.
7. Sling work equipment pump assembly (51, and
remove mounting bolts, then remove.
&I kg Work equipment, PPC pump assembly:

45 kg
INSTALLATION OF WORK
EQUIPMENT, PPC PUMP
ASSEMBLY
removal.
m
w Suction tube clamp bolt:2695 t 2.45 Nm
(2.75 +. 0.25 kgml
. Refilling with oil (hydraulic tank)
30-262
0
DISASSEMBLY AND ASSEMBLY HYDRAULIC COOLER
REMOVAL OF HYDRAULIC
COOLER ASSEMBLY
dh Lower the work equipment to the ground and
1. Remove engine undercover.
elkg Engine undercover : 290 kg

cover (2).
3. Disconnect inlet hose (3), and remove 2 top
mounting bolts.
* Remove from the top of the engine.
4. Disconnect outlet hose (4).
5. Remove 2 bottom mounting bolts, then remove
hydraulic cooler assembly (5).
* Remove from the bottom of the engine.
g
g
z
INSTALLATION OF HYDRAULIC
COOLER ASSEMBLY
removal.

30-263
0
DISASSEMBLY AND ASSEMBLY BLADE LIFT VALVE
REMOVAL OF BLADE LIFT

VALVE ASSEMBLY
a Lower the work equipment to the ground and
- : Hydraulic tank : 230 .r?

I
I
CEDOl964
3. Disconnect 2 PPC hoses (2) and 3 main hoses

(3).
bands. m
4. Open hydraulic tank front cover (4) and discon-

nect hoses (5) and (6).
CED01966
I
5. Sling blade lift valve (71, and remove mounting

bolts, then lift off.
& kg Blade lift valve assembly : 60 kg
I v CED01967
30-264
0
INSTALLATION OF BLADE LIFT

VALVE ASSEMBLY
removal.
a
coupler portion, so check the colors when
installing.
. Band
DBD03015
. Bleeding air Distinguishing Transparent

color bands
Bleed the air from the piping. ram oDerator‘s cad)
7
Red/White DAD03016
30-265
0
DISASSEMBLY OF BLADE
LIFT VALVE ASSEMBLY
CED02155
1. Disassembly of main spool assembly 3. Disassembly of main relief, shuttle valve as-
1) Remove case (I), then remove bolt (2). sembly
* Loosen the bolt with the spool as- Remove main relief and shuttle valve as-
sembled inside the body. sembly (18).
2) Remove washer (31, retainer (4), spring * If the adjustment screw of the main re-
(51, spacer (6), and retainer (7). lief valve is turned, the set pressure will
3) Remove case (81, then remove spring change, so do not disassemble unless
(9) and retainer (IO). necessary.
4) Remove case (I I), then remove spool 4. Disassembly of suction valve assembly
(12). Remove plug (241, then remove spring (25)
Ir If the result of disassembly shows and valve (26).
that there is any abnormality in the 5. Disassembly of check valve assembly
spool or body, replace the whole Remove plug (271, then remove spring (28)
assembly. and valve (29).
2. Disassembly of demand valve assembly 6. Disassembly of shuttle valve assembly
1) Remove case (131, then remove spring Remove plug (301, then remove ball (31).
(14).
2) Remove case (151, then remove spool
(16) and seal (17).
30-266
0
ASSEMBLY OF BLADE LIFT

VALVE ASSEMBLY
* Clean all parts, and check for dirt or dam- If the main relief valve was disassembled,
age. Coat the sliding surfaces of all parts carry out adjustments after installing the
with engine oil before installing. valve assembly to the chassis. For details,
1. Assembly of shuttle valve assembly see TESTING AND ADJUSTING, Measuring
Assemble ball (31), then fit O-ring and in- and adjusting work equipment hydraulic
stall plug (30). pressure.
5. Assembly of demand valve assembly
m Plug : 34.3 z 4.9 Nm {3.5 r 0.5 kgm)
1) Assemble seal (17) and spool (161, then
2. Assembly of check valve assembly fit O-ring and install case (15).
Assemble valve (29) and spring (281, then fit
m Mounting bolt : 186.2 + 9.8 Nm
O-ring and install plug (27).
{I9 z 1 kgm}
m Plug : 367.5 + 24.5 Nm 137.5 a 2.5 kgm1 2) Assemble spring (14) and install case
3. Assembly of suction valve assembly (13).
Assemble valve (26) and spring (25), then fit w Mounting bolt : 186.2 f 9.8 Nm
O-ring and install plug (24). {I9 z 1 kgm}
w Plug : 514.5 t 24.5 Nm 152.5 = 2.5 kgm) 6. Assembly of main spool assembly
I) Assemble spool (12), then fit O-ring and
4. Assembly of main relief, shuttle valve as-
install case (II).
sembly
2) Assemble retainer (IO) and spring (9),
Fit O-ring and install main relief and shuttle then fit O-ring and install case (8).
valve assembly (18).
3) Assemble retainer (7), spacer (6), spring
* Tighten the mounting bolts in the order (51, retainer (4), and washer (31, and in-
@ - 0. stall bolt (2).
s:
% w Mounting bolt : w Mounting bolt :
;;
1st step 34.3 2 4.9 Nm (3.5 f 0.5 kgm} 110.25 2 12.25 Nm ill.25 +. 1.25 kgm1
2nd step 66.15 = 7.35 Nm I6.75 = 0.75 kgm1 Ir Tighten the bolt with the spool as-
sembled inside the body.
4) Fit O-ring and install case (I).
COD02156
30-267
0
DISASSEMBLY AND ASSEMBLY BLADE TILT, RIPPER LO VALVE
REMOVAL OF BLADE TILT,

RIPPER LO VALVE ASSEMBLY
- : Hydraulic tank : 230 r?

CEDOI 984
2. Remove operator’s cab right cover (1).
3. Disconnect PPC charge valve (2) from hydraulic

tank.
* Move the PPC charge valve towards the floor
frame.
5. Disconnect 6 PPC hoses (41, 4 rear main hoses

(51, and 4 front main hoses and tubes (6I.m
+ The PPC hoses are distinguished by color
bands.
6. Lift off blade tilt and ripper Lo valve assembly

(7).
& kg Blade tilt, ripper Lo vaive assembly :

40 kg
30-268
0
INSTALLATION OF BLADE TILT,

RIPPER LO VALVE ASSEMBLY
removal.
m
installing.
Band
Add oil through oil filler to the specified level. DBDOJOt 5
. Bleeding air Distinguishin@ Transparent

color bands
Bleed the air from the piping. (From ooerator’s cad)
+
Red/White DAD0301 6
30-269
0
DISASSEMBLY OF BLADE ASSEMBLY OF BLADE TILT,

TILT, RIPPER LO VALVE RIPPER LO VALVE
ASSEMBLY ASSEMBLY
1. Disassembly of spool assembly * Clean all parts, and check for dirt or dam-
1) Remove case (I). age. Coat the sliding surfaces of all parts
2) Remove case (2). with engine oil before installing.
3) Remove bolt (31, then remove washer 1. Assembly of shuttle valve assembly
(4), retainer (51, spring (61, spacers (7) 1) Assemble ball (20) and seat (19) to plug
and (81, and retainer (9). (18).
Ir When loosening the bolt, always 2) Fit O-ring and install plug (18).
loosen with the spool assembled in- m Plug : 34.3 + 4.9 Nm
side the valve. (3.5 I 0.5 kgm1
4) Pull out spool (IO) from body (II). 2. Assembly of check valve assembly
* If the result of disassembly shows 1) Assemble valve (17) and spring (16).
that there is any abnormality in the 2) Fit O-ring and assemble seat (151, then
spool or body, replace the whole install bar (14) and tighten bolt (13).
assembly. 3. Assembly of main relief valve assembly
2. Main relief valve assembly Fit O-ring and install main relief valve as-
Remove main relief valve assembly (12). sembly (12).
* If the adjustment screw is turned, the
set pressure will change, so do not dis- w Main relief valve assembly :
assemble unless necessary. 83.3 + 14.7 Nm i8.5 f 1.5 kgm1
Disassembly of check’valve assembly Ir If the main relief valve was disassem-
3.
Remove mounting bolts (131, then remove bled, carry out adjustments after install-
bar (141, seat (15). spring (161, and valve ing the valve assembly to the chassis.
For details, see TESTING AND ADJUST- g
(17). z
Disassembly of shuttle valve assembly ING, Measuring and adjusting work
4. z
Remove plug (181, then remove seat (19) equipment hydraulic pressure.
and ball (20). 4. Assembly of spool assembly
1) Assemble spool (IO) to body (II).
2) Set retainer (91, spacers (8) and (71,
spring (6), retainer (5), and washer (4) in
position, then tighten bolt (3).
* Tighten the bolt with the spool as-
sembled inside the body.
w Mounting bolt : 34.3 z 4.9 Nm
13.5 2 0.5 kgml
3) Fit O-ring and install case (2).
4) Fit O-ring and install case (I).
30-270
0
I3
CED0215'
30-271
0
DISASSEMBLY AND ASSEMBLY RIPPER HI VALVE
REMOVAL OF RIPPER HI
VALVE ASSEMBLY
a Lower the work equipment
stop the engine.
to the ground and
Release the remaining pres-
- : Hydraulic tank : 230 e
3. Disconnect wiring clamp (3) and remove cover

(4).
4. Disconnect bracket (5) of fuel drain hose from

valve.
5. Disconnect 4 left hoses (6).
6. Disconnect 4 right hoses (7). CED02049
7. Disconnect 3 top hoses (8).
8. Disconnect 3 front hoses (9).
9. Lift off ripper Hi valve assembly (IO).
& kg Ripper Hi valve assembly : 90 kg
INSTALLATION OF RIPPER HI
VALVE ASSEMBLY
removal.

. Bleeding air
Bleed the air from the piping.
30-272
0
DISASSEMBLY OF RIPPER HI ASSEMBLY OF RIPPER HI

VALVE ASSEMBLY VALVE ASSEMBLY
1. Remove blocks (I) and (2). * Clean all parts, and check for dirt or dam-
2. Remove plug (31, then remove ball (4). age. Coat the sliding surfaces of all parts
3. Disassembly of fixed pressure difference with engine oil before installing.
valve assembly 1. Assemble valve (231, spring (221, and seat
1) Remove plug (51, then remove retainer (211, then fit O-ring and install plug (20).
(61, spring (71, and retainer (8). w Plug : 514.5 z 24.5 Nm
2) Pull out spool (9). I52.5 I 2.5 kgml
* When loosening the plug, always 2. Assemble check valve (19) and spring (181,
loosen with the spool assembled in- then fit O-ring and install plug (17).
side the valve.
4. Disassembly of ripper lift Hi valve assembly w Plug : 127.4 f 19.6 Nm I13 f 2 kgm}
1) Remove plug (IO), then remove spring 3. Assembly of ripper lift Hi valve assembly
(11) and retainer (12). 1) Assemble spool (16).
2) Remove plug (131, then remove spring 2) Set retainer (15) and spring (14) to spool,
(14) and retainer (15). then fit O-ring and install plug (13).
3) Pull out spool (16). w Plug : 66.15 = 7.35 Nm
* When loosening the plug, always I6.75 z 0.75 kgml
loosen with the spool assembled in- 3) Set retainer (12) and spring (II) to spool,
side the valve. then fit O-ring and install plug (IO).
5. Disassembly of ripper tilt Hi valve assembly
m Plug : 66.15 + 7.35 Nm
Disassemble in same way as for disassem-
16.75 + 0.75 kgml
bly of ripper lift Hi valve.
Ir When tightening the plug, always
6. Remove plug (171, then remove spring (18)
tighten with the spool assembled
and check valve (19).
inside the valve.
7. Remove plug (201, then remove seat (21),
4. Assembly of ripper tilt Hi valve assembly
spring (221, and valve (23).
Assemble in same way as for assembly of
ripper lift Hi valve assembly.
5. Assembly of constant pressure difference
valve assembly
2) Set retainer (8), spring (71, and retainer
(6) to spool, and install plug (5).
* When tightening the plug, always tighten
with the spool assembled inside the
valve.
6. Assemble ball (41, then fit O-ring and install
plug (31..
w Plug : 34.3 t 4.9 Nm 13.5 + 0.5 kgm}
7. Fit O-ring and install blocks (2) and (I).
30-274
0
CED02158
30-275
0
DISASSEMBLY AND ASSEMBLY PPC CHARGE VALVE
REMOVAL OF PPC CHARGE

VALVE ASSEMBLY
A Lower the work equipment
stop the engine.
to the ground and
2. CED01984
Remove hoses (21, (3), (41, and (5).
3. Remove PPC charge valve assembly (6).
INSTALLATION OF PPC
CHARGE VALVE ASSEMBLY
removal.
30-277
0
DISASSEMBLY AND ASSEMBLY PPC CHARGE VALVE
DISASSEMBLY OF PPC
CHARGE VALVE ASSEMBLY
1. Remove accumulator (2) from valve body (I).
2. Remove relief valve (3) from valve body (I).
3. Remove plug (41, then remove strainer (5).
4. Remove plug (61, then remove spring (7) and
poppet (8).
5. Remove plug (91, then remove spring (IO) and
poppet (I I).
6. Remove plugs (12) and (13).
ASSEMBLY OF PPC CHARGE

VALVE ASSEMBLY
1. Install plugs (13) and (12).
2. Assemble poppet (11) and spring (IO) to valve
body (I), and install plug (9).
* Check the free length of the spring when
installing.
Free length of spring : 25.3 mm
3. Assemble poppet (8) and spring (7) to valve
body (I), and install plug (6). CDDOZl59
Ir Check the free length of the spring when
installing.
Free length of spring : 20.6 mm
4. Install strainer (5), then install plug (4).
+ After tightening the strainer to the torque
given below, caulk at 2 places around the
circumference.
w Strainer : 7.35 + 0.49 Nm
(0.75 2 0.05 kgm}
5. Tighten relief valve (3) to valve body (I).
w Relief valve : 5.39 + 4.9 Nm
j5.5 + 0.5 kgm}
6. Install accumulator (2) to valve body (I).
SO-278
0
DISASSEMBLY AND ASSEMBLY BLADE PPC VALVE
REMOVAL OF BLADE PPC

VALVE ASSEMBLY
stoo the engine. Release the remaining pres-
sure in the-hydraulic piping. For details, see
CEDOl984
2. Remove right console (2).

j, Disconnect the wiring connectors (CN262
and CN263) inside the console.
3. Loosen lock bolt of lever (3), then pull out lever
together with boot.
4. Remove brackets (4).
CED02056 CED0205i
5. Disconnect hose (5). 8

6. Disconnect 4 PPC hoses (6). x2
-)r The PPC hoses are distinguished by color
bands.
7. Remove mounting bolts, rotate blade PPC valve

assembly (7) .90” as shown in diagram, then (
tighten mounting bolts temporarily.
8. Disconnect hose (8). m
CED02059 1 ) CED02060
30-279
0
9. Remove blade PPC valve assembly (7). m
INSTALLATION OF BLADE PPC

VALVE ASSEMBLY
removal.
m
w Hose mounting bolt (A bolt) :
39.2 + 4.9 Nm I4 t 0.5 kgm}
m
Band
DBD03015
installing.
m
w Hose mounting bolt (B bolt) :
29.4 + 4.9 Nm I3 2 0.5 kgm}
m
Front of machine
Ir Install the PPC valve in the direction shown
in the diagram on the right. (The diagram
on the right shows the PPC valve as seen
from below.)
. DBD03018
Bleeding air
30-280
0
DISASSEMBLY OF BLADE PPC

VALVE ASSEMBLY
1. Remove nut (I), then remove disc (2) and-boot
(3).
2. Remove joint (4), then remove plate (5).
3. Remove seal (6) and collar (7).
4. Remove body (8).
5. Remove plate (9).
6. Remove orifice (IO).
7. Remove blade tilt valve.
I) Remove pistons (11) and (12), retainer (13),
springs (14) and (15), and shim (16).
* Check the mounting position (hydraulic
port) of spring (14), mark with tags, and
keep in a safe place.
2) Pull out valve (17) from body (18).
8. Remove blade LOWER valve.
I) Remove piston (19), spacer (20), spring (211,
collar (22), ball (23), retainer (241, shim (251,
piston (26), retainer (271, springs (28) and
t29), and shim (30).
port) of spring (28), mark with tags, and
g 9. Remove blade RAISE valve.
z I) Remove piston (32), spring (33), piston (34),
z retainer (351, springs (36) and (371, and shim
(38).
port) of spring (361, mark with tags, and
CEDOZl60
30-281
0
ASSEMBLY OF BLADE PPC

VALVE ASSEMBLY
1. Install blade RAISE valve.
1) Assemble valve (39) to body (18).
2) Assemble shim (38) and spring (37) to valve
(39).
* When installing spring (371, install with
the small end face of the seat coil sur-
face (inside diameter) on the side of shim
(38).
3) Assemble spring (361, retainer (35), piston
(34). spring (331, and piston (32).
* When ksembling. piston (341, coat the
outside circumference of the piston and
the inside circumference of the body
hole with grease (G2-LI).
* When assembling piston (321, coat the IO
inside circumference of the body hole
with grease grease (G2-LI).
2. Install blade LOWER valve.
(31). 22-g .32
* When installing spring (291, install with #
fk!? .33
26-0 &-34
(30).
27e -v. 7335
3) Assemble spring (281, retainer (27), piston 0
(36), shim (25), retainer (24), ball (231, collar
(22), spring (211, spacer (20). and piston (19).
* When assembling piston (26). coat the
the inside circumference of the body
hole with grease (G2-LI).
* When assembling piston (19), coat the
with grease grease (G2-LI). 18
3. Install blade tilt valve.
CEDO~2160
(17).
Ir When installing spring (151, install with
(16).
30-282
0
3) Assemble spring (14), retainer (13), and pis-

tons (12) and (II).
When assembling piston (121, coat the
the inside circumference of the body hole
with grease (G2-LI).
When assembling piston (II), coat the
with grease grease (G2-LI).
4. Install orifice (IO).
m Orifice : 11.8 + 14.7 Nm Il.2 + 1.5 kgml
5. Fit O-ring and install plate (9).

6. Fit O-ring and install body (8).
7. Fit O-ring to collar (7) and assemble to body (81,
then install seal (6).
8. Install plate (5).
w Mounting bolt : 11.8 + 14.7 Nm
Il.2 f 1.5 kgm)
Install joint (4).
When installing the joint, coat the female
thread of body (8) with thread tightener (LT-
2).
w Joint : 44.1 2 4.9 Nm I3.5 t 0.5 kgm}
Coat the sliding portion of the joint with
grease (G2-LI).
10. Assemble boot (3) and disc (21, then tighten
with nut (I).
Coat the contact surface portion of disk (2)
and pistons (321, (191, and (II) with grease
(G2-LI).
w Nut : 112.7 2 14.7 Nm
III.5 z 1.5 kgm}
After installing the disc, adjust the height of
the disc.
Adjusting PPC valve.
30-283
0
DISASSEMBLY AND ASSEMBLY RIPPER PPC VALVE
REMOVAL OF RIPPER PPC

VALVE ASSEMBLY
A stop
Lower the work
the engine.
equipment to the ground and
1. Remove operator’s cab right cover (1).
CED01964

+ Disconnect the wiring connectors ((IN-262
and CN-263) inside the console.
3. Loosen lock bolt of lever (31, then pull out lever
together with boot.
4. Disconnect 3 oil pressure switch connectors (CN-

S03, CN-S04, CN-S05) (4).
5. Disconnect 2 hoses (5).
6. Disconnect 4 PPC hoses (6). HX2
bands.
CEO02064 CED0206E
I J-
7. Remove ripper PPC valve assembly (7). 113
30-284
0
INSTALLATION OF RIPPER PPC

VALVE ASSEMBLY
removal.
m
w Hose mounting bolt (A bolt) :
29.4 2 4.9 Nm I3 + 0.5 kgml
@q Hose mounting bolt (B bolt) :
39.2 + 4.9 Nm (4 + 0.5’kgmI
Band
DBD03015
m B bolt
coupler portion, so check the colors when Front of machine
installing.
1
m Brown
g
A bolt' Black
z . DBD03019
Bleeding air
z Bleed the air from the piping.
30-285
0
DISASSEMBLY OF RIPPER PPC

VALVE ASSEMBLY
1. Remove nut (I), then remove disc (3) and boot
(3).
lP-----’
2. Remove joint (41, then remove plate (5).
3. Remove seal (6) and collar (7).
4. Pull out piston (81, and remove retainer (9),

springs (IO) and (II), and shim (12).
* Spring (IO) consists of a set of 2 springs
each of 2 types with different installed loads,
so check the mounting position (hydraulic
port), and mark with tags to prevent any
5. Pull out valve (13) from body (14).
Pl--- 8
30-286
0
ASSEMBLY .OF RIPPER PPC

VALVE ASSEMBLY
1. Assemble valve (13) to body (14).
2. Assemble
(13).
shim (12) and spring (II) to valve
lzk-----’
Ir When installing spring (II), install with the
small end face of the seat coil surface (in-
side diameter) on the side of shim (12).
3. Assemble spring (IO), retainer (91, and piston
(8).
With spring (IO), springs with a different
number of coils are used at the hydraulic
ports given below, so be careful when in-
stalling.
Total number of coils

Port position for spring
The position of each port is stamped on the 8

bottom of the valve body. %-
& Piston : Grease (G2-LI) -9
0
M
When assembling piston (81, coat the out- +----IO
ti
side circumference of the piston and the in-
side circumference of the body hole with
grease (G2-LI).
4. Fit O-ring to collar (7) and assemble to body
(14), then install seal (6).
5. Install plate (5).
m Mounting bolt : 13.72 = 1.96 Nm
Il.4 = 0.2 kgm}
6. Install joint (4).
& Sliding portion of joint : Grease (G2-LI)
& Joint : Thread tightener (LT-21

w Joint : 14.3 t 5 Nm 14.5 z 0.5 kgm1
* Always keep strictly to the tightening torque

for the joint.
7. Assemble boot (3) and disc (21, and tighten with
nut (I).
w Nut : 112.7 2 14.7 Nm Ill.5 i 1.5 kgm1
* After assembling the disc, adjust the height

of the disc.
Adjusting PPC valve.
30-287
0
DISASSEMBLY AND ASSEMBLY BLADE LIFT CYLINDER
REMOVAL OF BLADE LIFT

CYLINDER ASSEMBLY
A Lower the work equipment to the ground com-
pletely and stop the engine.
1. Sling bottom end of cylinder assembly, and re-
move cap (I). a
AStart the engine, retract the piston rod fully,
then tie the piston rod with wire to prevent
it from falling out.
A Release the remaining
draulic circuit.
pressure in the hy-
For details, see TESTING
AND ADJUSTING, Releasing remaining pres-
sure in hydraulic circuit.
* Fit blind plugs to prevent dirt or dust from
entering the piping.
3. Sling cylinder assembly horizontally and remove
handrail (3).
4. Remove cap (41, then lift off blade lift cylinder
assembly (5). 1121
&I kg Blade lift cylinder assembly : 270 kg
INSTALLATION OF BLADE LIFT

CYLINDER ASSEMBLY
removal.
m
+ Standard shim thickness : 4 mm
& Yoke : Grease (G2-LI)

system. Then check the oil level again. I \ CED02046
. Bleeding air
30-288
0
DISASSEMBLY AND ASSEMBLY BLADE TILT CYLINDER
REMOVAL OF BLADE TILT

CYLINDER ASSEMBLY
&bLower the work equipment to the ground com-
1. Remove mounting bolts and lower cover (1) on
top of frame.
2. Sling cylinder assembly, and remove lock plate,
then remove pin (2). a
g Start the engine, retract the piston rod fully,
3. Disconnect hoses (3).
g Release the remaining pressure in the hy-
draulic circuit. For details, see TESTING
4. Remove lock plate, then remove pin (41, and lift
off blade tilt cylinder assembly (5). m
+ When lifting off, be careful not to damage
the hoses at the bottom end.
&I kg Blade tilt cylinder assembly : 310 kg
g
8 48
z
INSTALLATION OF BLADE TILT

CYLINDER ASSEMBLY
removal.
mm
& Pin : Grease (G2-LI)

. Bleeding air
30-289
0
DISASSEMBLY AND ASSEMBLY RIPPER LIFT CYLINDER
REMOVAL OF RIPPER LIFT

CYLINDER ASSEMBLY
A Lower the work equipment to the ground com-
then remove pin (I). a
AStart the engine, retract the piston rod fully,
draulic circuit.
pressure in the hy-
AND ADJUSTING, Releasing remaining
pressure in hydraulic circuit.
3. Remove lock plate, then remove pin (3), and lift
off ripper lift cylinder assembly (4). m
r+ kg Ripper lift cylinder assembly : 350 kg
; ! CED02053
INSTALLATION OF RIPPER LIFT

CYLINDER ASSEMBLY
removal.
Iz7-j IfI
. Bleeding air
30-290
0
DISASSEMBLY AND ASSEMBLY RIPPER TILT CYLINDER
REMOVAL OF RIPPER TILT

CYLINDER ASSEMBLY
a Lower the work equipment to the ground com-
then remove pin (I). a
A Start the engine, retract the piston rod fully,
draulic circuit.
pressure in the hy-
3. Remove lock plate, then remove pin (3), and lift
off ripper tilt cylinder assembly (4). a
&I kg Ripper tilt cylinder assembly : 270 kg
INSTALLATION OF RIPPER LIFT

CYLINDER ASSEMBLY
removal.
01
. Bleeding air
30-291
0
DISASSEMBLY AND ASSEMBLY HYDRAULIC CYLINDER
DISASSEMBLY OF HYDRAULIC
CYLINDER ASSEMBLY
1. Cylinder tube
Remove cylinder tube.
2. Quick drop valve assemblv
* Blade-lift cylinder only.
1) Remove quick drop valve assembly (I).
2) Disassemble quick drop valve assembly as

follows.
i) Remove elbow (2).
ii) Remove spring (31, washer (4), and
valves (5) and (6). and pull out collar (7).
I CED02079
3. Piston rod assembly

1) Set cylinder assembly (8) to tool Ul.
2) Remove head assembly (9).
3) Pull out piston rod assembly (IO).
Ir Put an oil container under the cylinder
catch the oil.
I CED02080
4. Piston assembly
I) Set piston rod assembly (IO) to tool Ul.
Ul
CED02081
30-292
0
2) Remove spacer (11).

3) Remove piston assembly (12).
4) Remove backup rings (13) and (14), and O- II I2
ring (15).
5) Remove retainer (16).
13 I4
CED02082 CED02083
6) Disassemble piston assembly as follows.

i) Remove wear ring (17).
ii) Remove piston ring (18).
I Ii i7 CED02084
5. Head assembly Blade lift 3lade tilt.

1) Remove head assembly (19) from piston rod. ripper Iift.tilt
DBD0302( DBD03021
2) Disassemble head assembly as follows. Blade t i It.

i) Remove O-ring (20) and backup ring (21). ripper Iift.tilt
I==----
I DBD0302 2 DBD03023
30-293
0
ii) Remove snap ring (22), then remove seal Blade lift Blade tilt.
(23). riDPer Iift.tilt
iii) Remove packing (24), then remove bush- 24

ing (25).
DBD03024 DBD03025
30-294
0
ASSEMBLY OF HYDRAULIC
CYLINDER ASSEMBLY
* Coat the sliding surfaces of all parts with en-
gine oil before installing. Be careful not to dam-
age the packings, dust seals, and O-rings when
installing.
1. Head assembly
1) Assemble head assembly as follows.
DBD03024
I
i) Using tool U2, press fit bushing (25) to

head.
ii) Install packing (24).
iii) Using tool U3, press fit seal (23).
iv) Install snap ring (22).
CED02091 CED02092
V) Install backup ring (21) and O-ring (20). Blade ti It.

ripper lift.tilt
08003022/ ( DBD03023
2) Install head assembly (19) to piston rod.
DBD03020 1 1 DBD03021
30-295
0
2. Piston assembly
1) Assemble piston assembly as follows.
i) Using tool U4, expand piston ring (18).
* Set the piston ring on the expander
and turn the handle 8 - 10 times to
expand the ring.
ii) Remove piston ring (18) from tool U4,
then install to piston.
iii) Set tool U5 in position and compress
piston ring (18).
iv) Install wear ring (17) to piston.
CEO02093 CED02094I
Ii i7 CED02084
2) Install retainer (16).

3) Install O-ring (15) and backup rings (14) and
(13).
* Coat the O-ring and backup ring portion
with grease, and secure the backup ring
to prevent it from opening.
4) Install piston assembly (12).
5) Assemble spacer (II) and tighten mounting
bolts.
& Mounting bolt : Thread tightener
(LT-2)
CED02083 CED02082
m Mounting bolt : _I_
Blade lift : 66.5 = 7.5 Nm

16.75 z 0.75 kgml
Blade lift, ripper lift, ripper tilt :
176.5 t 19.5 Nm I18 + 2 kgml

1) Set cylinder (8) to tool Ul.
I
-
Ul
\
I CED02095
30-296
0
2) Assemble piston rod (10) to cylinder (8).

Jr Coat the seal portion of the piston with
grease.
* Push in the piston rod fully.
3) Push head assembly to cylinder and tighten
mounting bolts.
* Coat the backup ring with grease.
4. Quick drop valve assemblv

* Bladelift cylinder only.
I) Assemble quick drop valve assembly as fol-
lows.
i) Assemble collar (7), and install valves
(6) and (5), washer (4). and spring (3).
ii) Install elbow (2).
F2
CED02079
kii
z
2) Install quick drop valve assembly (I).
5. Cylinder tube
Install cylinder tube.
CDD02078
30-297
0
DISASSEMBLY AND ASSEMBLY RIPPER PIN-PULLER CYLINDER
REMOVAL OF RIPPER PIN-

PULLER CYLINDER
A Lower the work equipment
stop the engine.
to the ground and
1. Disconnect 2 hoses (I).
2. Remove plate (2). m
3. Remove ripper pin-puller cylinder assembly (3). ,
CEDOZlI:
INSTALLATION OF RIPPER PIN-

PULLER CYLINDER
removal.
If
* Install the plate slightly open so that the
piston rod of the ripper pin-puller cylinder
can bend in relation to the pin.
30-298
0
DISASSEMBLY OF RIPPER PIN-

PULLER CYLINDER ASSEMBLY
I. Cylinder assembly
I) Set pin-puller cylinder assembly (1) to tool
Ul.
2) Using tool U6, loosen cylinder head assem-
bly (2).
3) Remove piston rod (3) together with cylin-
der head assembly (2).
* Put an oil container under the cylinder
to catch the oil.
2. Cylinder head assembly

I) Remove cylinder head assembly (2) from
piston rod (3).
CDD02194
2) Remove O-ring (5) and backup ring (6).

3) Remove O-ring (7).
4) Remove snap ring (81, then remove dust
seal (9).
5) Remove rod packing (IO), then remove bush-
ing (11).
CED02184
I

Remove piston ring (12) from piston rod (3).
30-299
0
ASSEMBLY OF RIPPER PIN-

PULLER CYLINDER ASSEMBLY
U5
* Coat the sliding surfaces of all parts with en-
gine oil before installing. Be careful not to dam-
age the packings, dust seals, and O-rings when Q
0 l2
installing.

1) Using tool U4, expand piston ring (12).
1; Set the piston ring on the expander and
turn the handle 8 - 10 times to expand ~
the ring.
CED02186 CDD0'2187
2) Remove piston ring (12) from tool, then in-
stall to piston rod (3).
3) Using tool U5, compress piston ring (13).
CED02185
2. Cylinder head assembly

1) Using tool U2, press fit bushing (11) to cyl-
inder head (4).
-u2
CDD02188
2) Using tool U3, press fit dust seal (9) to cyl-

inder head (4).
30-300
0
3) Install snap ring (8) and rod packing (’10).

4) Install O-ring (7).
5) Install backup ring (6) and O-ring (4).
CED02184
6) Install cylinder head assembly (2) to piston

rod (3).
CDD02194
3. Cylinder assembly
li Set cylinder to tool Ul and support with
block 0.
2) Install piston rod (3) together with cylinder
head assembly (2).
Ir Coat the seal portion of the piston with
grease.
+ Coat the backup ring with grease.
Ir Push in the piston fully.
3) Using tool U6, tighten cylinder head assem-
bly (2).
m Cylinder head assembly :
441 2 44.1 Nm I45 + 4.5 kgm}
30-301
0
DISASSEMBLY AND ASSEMBLY BLADE
REMOVAL OF BLADE
ASSEMBLY
ALower the work equipment to the ground in a
horizontal place, and set blocks @ securely un-
der the left and right straight frames.
1. Remove cap (I) of lift cylinder. m
Ir Check the number and thickness of the
I DLW0381
2. Sling lift cylinder assembly (2), then start en-

gine and retract piston rod fully, fit cylinder
lock tool and secure to radiator guard.
Ir Tie the piston rod with wire to prevent it
from coming out.
. Repeat the same procedure to disconnect
the blade from the cylinder on the opposite
side.
ARelease the remaining pressure from the hy-
draulic circuit.
For details, see TESTING AND ADJUSTING, Re-
I CEDOZO I44
leasing remaining pressure from hydraulic cir- L
cuit.
Then loosen the oil filler cap slowly to release
the pressure inside the hydraulic tank.
\ CED0.2118
3. Remove left and right covers (3).

Ir Fit blind plugs to prevent dirt or dust from
5. Remove left and right trunnion caps (5).
6. Remove blade assembly. a
* Start the engine, drive the machine slowly
in reverse, and disconnect the blade assem-
bly from the trunnion.
30-302
0
INSTALLATION OF BLADE
ASSEMBLY
removal.
@!r Adjust the shims

For details, see TLSTING AND ADJUSTING,
Adjusting semi-U tiltdozer.
m
* Adjust with block @ so that height b and width
c of the left and right straight frames are the
dimensions given below.
. Height b of trunnion portion :
Approx. 863 mm
. Brace width c : Approx. 3484 mm
.
I
30-303
0
DISASSEMBLY OF BLADE
ASSEMBLY
APut blocks @ and stands @ under the left and
right straight frames and the bottom of the
blade, and set the blade securely in a stable
position.
1. Remove right frame covers (I) and (2).

2. Disconnect tilt cylinder hoses (3).
CED02120
3. Sling tilt cylinder assembly (4), and remove lock

plate, then remove pin (5).
4. Remove lock plate, remove pin (61, then lift off
tilt cylinder assembly (4).
r+lkg Tilt cylinder assembly : 380 kg
5. Set block @ under right center brace (7) and

remove mounting bolts of cap (8) at center frame
end.
Ir There are shims installed at the cap portion,
so check the number and thickness of the
30-304
0
6. Sling right straight frame (9) and disconnect

right center brace (7).
7. Remove lock plate, remove pin (IO), then lift off
right straight frame (9).
&I kg Straight frame : 1150 kg
I CEDO2124
8. Sling tilt brace (1 I), and remove lock plate, then

remove pin (12).
9. Remove lock plate, remove pin (13), then lift off
tilt brace (11).
elkg Tilt brace : 200 kg
IO. Repeat Steps 5 to 7 above to disconnect left

center brace, and remove left straight frame
(14).
::
g
z
I lj
CEO02125
11. Sling center brace (151, remove mounting bolts,

and disconnect cap (16), then lift off left and
right center braces (16) and (7).
* There are shims installed at the cap portion,
so check the number and thickness of the
A kg Center brace : 220 kg
I5 7 CED02126
12. Raise blade (171, then tip blade over.
&I kg Blade : 4900 kg

ASSEMBLY OF BLADE
ASSEMBLY
* Check the number and thickness of shims re-
moved from each part during disassembly, and
assemble them in the place from which they
are removed.
* If the shims are adjusted, see TESTING AND
ADJUSTING, Adjusting semi-U tiltdozer for de-
tails.
1. Raise blade (171, and insert block and stand
under blade to set blade securely in a stable
position.
&I kg Blade : 4900 kg
2. Raise center brace (15) and assemble shims,

then tighten mounting bolts of cap (16).
Ir Set a block under the center brace to match
the height of the straight frame.
el kg Center brace : 220 kg
J, Install center brace (7) on the opposite side

in the same way.
i CED02126
3. Raise right straight frame (91, then install pin

(IO) and secure with lock plate.
el kg Straight frame : 1150 kg
4. Sling right straight frame (91, and set spherical

portion of right center brace (7) to right straight
frame (9).
CED02124
5. Assemble shims to cap (8) of right center brace

(71, and tighten mounting bolts.
30-306
0
6. Raise tilt cylinder assembly (4), then install pin

(6) and secure with lock plate.
elkg Tilt cylinder assembly : 380 kg
7. Install pin (5) and secure with lock plate.
8. Connect tilt cylinder hoses (3).

9. Install right frame covers (2) and (I).
8
%
z
10. Repeat procedure in Steps 3 to 5 above to in-
stall left straight frame (14) and connect to left
center brace.
11. Raise tilt brace (II), then install pin (13) and
secure with lock plate.
el kg Tilt brace : 200 kg
12. Install pin (12) and secure with lock plate.
CED02125
13. Greasing
After completion of assembly, grease all parts
thoroughly in’diagram on right.
a Each portion of work equipment :

Grease (G2-LI)
.\ w”
CED02127
30-307
0
DISASSEMBLY AND ASSEMBLY GIANT RIPPER
DISASSEMBLY OF GIANT
RIPPER ASSEMBLY
1. Mount machine on block @ and lower blade to
ground.
2.
A Lock the brake securely.
Sling shank, then operate pin-puller switch and
pull out shank pin.
3. Raise ripper fully, and lower shank (I) to re-
move.
I+l kg Shank : 470 kg
4. Set stand @ under arm and beam.

5. Sling lift cylinder assembly and remove pin (2).
* Start the engine, retract the piston rod fully,
and lower on top of the arm.
6. Sling tilt cylinder assembly and remove pin (3).
Jr Start the engine, retract the piston rod fully,
and lower on top of the lift cylinder.
A Release the remaining pressure from the hy-
draulic circuit.
Releasing remaining pressure from hydrau-
lic circuit.
CED02130 CED02131
7. Disconnect 4 lift cylinder hoses (41, 4 tilt cylin-

der hoses (51, and 2 pin-puller cylinder hoses
6).
8. Sling tilt cylinder assembly (71, then remove

pin (8) and lift off lift cylinder assembly (7).
&I kg Tilt cylinder assembly’: 270 kg
I CED02133
30-308
0
9. Sling lift cylinder assembly (91, theri remove

pin (IO) and lift off Mt cylinder assembly (9).
elkg Lift cylinder assembly : 350 kg
CED02134
10. Sling beam (I I), then remove left and right pins
(12) and lift off beam (II).
elkg Beam : 2000 kg
CED02135
11. Sling arm (131, then remove left and right pins
(14) and lift off arm (13).
elkg Arm : 1000 kg
30-309
0
ASSEMBLY OF GIANT RIPPER

ASSEMBLY
1. Raise arm (13) and set in mounting position,
then fit left and right pins (14) and secure with
lock plate.
&I kg Arm : 1000 kg
Ir Set a stand under the arm.
2. Raise beam (1 I) and set in mounting position,

then fit left and right pins and secure with lock
plate.
&+Ikg Beam : 2000 kg
Ir Set a stand under the beam.
3. Raise lift cylinder assembly (9) and set in mount-

ing position, then fit pin (IO) and secure with
lock plate.
Lift cylinder assembly : 350 kg
CED02134
4. Raise tilt cylinder assembly (7) and set in mount-

ing position, then fit pin (8) and secure with
lock plate.
Eel kg Tilt cylinder assembly : 270 kg
CED02133
30-310
0
5. Connect 2 pin-puller cylinder hoses (61, 4 tilt

cylinder hoses (5). and 4 lift cylinder hoses (4).
,. ,
' CED07132
6. Sling tilt cylinder assembly, start engine, ex-

tend piston rod and align with pin hole, then
install pin (3) and secure with lock plate.
7. Sling lift cylinder assembly, start engine, ex-
tend piston rod and align with pin hole, then
install pin (2) and secure with lock plate.
8. Mount machine on block @ and lower blade to
ground.
9.
A Lock the brake securely.
Operate ripper and raise slightly to remove stand
8 0.
s IO. Raise ripper fully, pass wire through shank
holder, then raise shank (1) slowly, align with
CED02131 CED0213l
E;
pin hole, and operate pin-puller switch to insert
shank pin.
11. Raise blade and lower machine from block 0.
12. Bleed air from cylinder.
Bleed air from hydraulic cylinder.
1
CED021291 CED0212
30-311
0
DISASSEMBLY AND ASSEMBLY ROPS GUARD
REMOVAL OF ROPS GUARD

1. Sling ROPS guard (I) and remove 12 mounting
bolts (2). m
2. Lift off ROPS guard (1).
I3 kg ROPS guard : 700 kg
-h
CED0207:
INSTALLATION OF ROPS
GUARD
removal.
j?zJ
m ROPS guard mounting bolt :
1715 + 196 Nm I175 t 20 kgm}
CED02073
30-312
0
DISASSEMBLY AND ASSEMBLY OPERATOR’S CAB
REMOVAL OF OPERATOR’S
CAB ASSEMBLY
A~minal
Disconnect the cable
of the battery.
1. Remove ROPS guard.

For details, see REMOVAL OF ROPS GUARD.
2. Open operator’s cab left cover (1).
3. Disconnect wiring connectors (CN-19) (2) and
(CN-20, CN-21) (3).
* Pull out wiring from inside the operator’s
cab.
4. Disconnect 4 washer hoses (4). m
Ir Pull out the hoses from inside the opera- CEO02074 CEt-102075
tor’s cab.
5. Remove steps (51, then remove covers (6).
6. Remove panels (71, (8). and (9).
7. Remove 19 mounting bolts, then lift off opera-
tor’s cab assembly (IO).
&I kg Operator’s cab assembly : 150 kg
INSTALLATION OF
OPERATOR’S CAB ASSEMBLY
removal.
a
Ir Match the color bands when connecting the
washer hoses.
/ I I I
CED02077
DISASSEMBLY AND ASSEMBLY FLOOR FRAME
REMOVAL OF FLOOR FRAME

ASSEMBLY
1. Remove operator’s cab assembly.
For details, see REMOVAL OF OPERATOR’S CAB
ASSEMBLY.
3. Remove covers (31, (41, (51, and (61, and suction

port (7).
4. Remove step cover (8).
5. Lift off operator’s seat (9).

* Remove the seat together with the under-
cover.
elkg Operator’s seat : 40 kg
6. Remove air conditioner element (IO).

7. Disconnect 2 air conditioner hoses (I 1). a
Loosen the sleeve nut slightly and release
Disconnect at the air conditioner end, re-
move all clamps from the floor frame, then
move the hoses towards the engine.
Fit blind plugs to prevent dirt or moisture
Be careful not to damage or drop the O-
rings.
8. Disconnect 2 heater hoses (12).
t Close the heater valve at the engine end.
9. Remove air conditioner duct (13).
Ir The ground connection (CN-206) is also tight-
ened with the air conditioner duct mounting
bolts.
CED02091 CED02099 1
30-314
0
10. Remove 4 operator’s seat side covers (14).
11. Disconnect blade PPC hoses (15), (16), (171, (18),

and (19). m
* Keep the hoses together and move them
towards the floor frame.
12. Disconnect ripper PPC hoses (20), (21), (22), (23),
and (24). m
* Keep the hoses together and move them
towards the floor frame.
13. Disconnect PPC hose (25).
F=fk?q\m
CED02101
14. Disconnect clamps (26) (3 places) for wiring

harness and washer tank hose.
-Ir Of the 3 clamps, the clamp at the top is also
used to tighten the ground connection (SX-
8).
15. Disconnect wiring connectors (CN-421)(27), (CN-
SO8)(28), (CN-361)(29), and (CN-S06H30).
16. Disconnect harness clamps (31) (2 places).
17. Disconnect directional control cable (321, speed

control cable (331, and parking brake cable (34)
at lever end, then remove from bracket.
Sr Before disconnecting, check the mounting
dimensions of the cable. m
I/ I!/ / = CED02104
30-3 15
0
18. Disconnect fuel control linkage (35) at rear of

chassis.
19. Disconnect brake pedal linkage (36) at turnbuckle
portion. m
+ Before disconnecting, check the mounting
dimension of the brake rod.
Ir The turnbuckle has a reverse thread.
20. Disconnect steering linkage (37) at rear of chas-

sis.
* After disconnecting, secure the steering rod
to the floor frame with rope.

* Disconnect wiring connectors (CN-262, CN-
263) inside the console.
* Remove the lever boot from the console,
then remove the console.
22. Remove left handrail (391, then remove left con-
sole (40).
* Remove the lever boot from the console,
then remove the console.
23. Remove rear mount bolts (41) (left and right: 4

bolts each). a
30-3 16
0

25. Remove 4 left front mount bolts (43).
26. Remove 2 right front mount bolts (44).
-rv I/ CED02109
27. Lift off floor frame assembly (47). m
r&lkg Floor frame assembly : 500 kg
* Use a chain block to adjust the balance to

the front, rear, left, and right, and lift off
slowly.
* After removing the floor frame assembly,
remove the spacer on the right front floor
mount.
30-317
0
INSTALLATION OF FLOOR
FRAME ASSEMBLY
removal.
a
* Install the hoses without twisting or inter-
ference.
* Install the air conditioner circuit hoses care-
fully to prevent dirt, dust, or water from
getting inside the hoses.
O-ring
* Check that there are O-rings at the piping
connection of the air conditioner hoses be-
DBD02985
fore installing.
Coat the O-rings thoroughly with compres-
sor oil (Shell Suniso 4G or 5G).
w Tighten the air conditioner gas pip-
ing to the following tightening tor-
ques.
Thread size Tightening torque Nm {kgrnj
16 x 1.5 13.23k1.47 Nm {1.35+0.15 kgm)
Band
22 x 1.5 22.05k2.45 Nm (2.25kO.25 kgm}
DBD03015
24x 1.5 31.8522.45 Nm (3.35kO.25 kgm)
~~ti~$,tI(rece’ver 5.39k1.47 Nm {0.55?0.15 kgm)
Distinauishins (From operator's cad)

M6 bolt (com- Brown
9.821.96 Nm (1.0~0.2 kgm} color bands
pressor portion) Black/Blue Black
+++
Adjust the directional, speed control, and

parking brake linkage.
For details, see TESTING AND ADJUSTING

Adjusting joystick (steering, directional, gear
shift lever) parking brake linkage. ttt
Yellow Green
White DAD03017
Adjust the brake pedal linkage.
Adjusting brake pedal linkage.
Distinouishina Transparent
m Brake pedal linkage turnbuckle : color bands

(From ouerator's cad)
45.56 + 12.25 Nm (4.76 2 1.25 kgm1
+
Red/White DAD03016
30-318
0
m Rear mount bolt : 338.1 2 39.2 Nm

I34.5 z 4 kgm1
mm
w Front mount bolt : 338.1 = 39.2 Nm
(34.5 +. 4 kgml
a
* Before setting the floor frame assembly at
the mounting position, set spacers on top
of the right front floor mount.
DISASSEMBLY AND ASSEMBLY DASHBOARD
REMOVAL OF DASHBOARD
ASSEMBLY
1. Remove operator’s cab assembly.
For details, see REMOVAL OF OPERATOR’S CAB
ASSEMBLY.
2. Remove suction port (I) and covers (2) and (3).
3. Remove air conditioner element (4).

4. Disconnect 2 air conditioner hoses (5). m
Loosen the sleeve nut slightly and release
Disconnect at the air conditioner end, re-
move all clamps from the floor frame, then
move the hoses towards the engine.
Fit blind plugs to prevent dirt or moisture
Be careful not to damage or drop the O-
rings.
5. Disconnect 2 heater hoses (6).

* Close the heater valve at the engine end.
6. Remove air conditioner duct (7).

* The ground connection (CN-206) is also
tightened with the air conditioner duct
mounting bolts.
7. Disconnect wiring connectors (CN-215)(8), (CN-

S13)(9), and KN-214HlO).
8. Lift off dashboard assembly (II).
r+ kg Dashboard assembly :, 130 kg
30-320
0
DISASSEMBLY AND ASSEMBLY DASHBOARD
INSTALLATION OF
r
DASHBOARD ASSEMBLY
e
removal.
pJ
T----
* Install the hoses without twisting or inter-
-_-- _ - _ ----
ference.
fully to prevent dirt, dust, or water’ from
O-ring
connection of the air conditioner hoses be- DBD02985
fore installing.
w Tighten the air conditioner gas piping to
the following tightening torques.
Thread size Tightening torque Nm {kgmI
16 x 1.5 13.2321.47 Nm {I .35+0.15 kgm}
22 x 1.5 22.0522.45 Nm 12.25kO.25 kgm)
E r 24x 1.5 31.8522.45 Nm (3.35kO.25 kgm1
. Charging with air conditioner gas

with air conditioner gas (R134aL
30-321
0
DISASSEMBLY AND ASSEMBLY MONITOR PANEL
REMOVAL OF MONITOR
PANEL ASSEMBLY
ADisconnect the cable from the negative H ter-
1. Remove mounting bolts, then open monitor
panel assembly (I).
2. Disconnect connectors (CN-1, CN-2, CN-3, CN-
4, CN-5, CN-SOI, CN-S02) (2).
3. Remove monitor panel assembly (I).
- DEW1118
INSTALLATION OF MONITOR
PANEL ASSEMBLY
removal.
30-322
0
DISASSEMBLY AND ASSEMBLY TORQUE CONVERTER LOCK-UPCONTROLLER
REMOVAL OF TORQUE
CONVERTER LOCK-UP
CONTROLLER ASSEMBLY
a -~ Disconnect the cable from the negative
H ter-
1. Open operator’s cab left cover (I).
CED02145
3. Disconnect control connector (CN-622) (3).

4. Remove torque converter lock-up controller as-
sembly (4).
3 4 CEO02147
CONVERTER LOCK-UP
CONTROLLER ASSEMBLY
removal.
30-323
0
DISASSEMBLY AND ASSEMBLY APS CONTROLLER
REMOVAL OF APS
CONTROLLER ASSEMBLY
1. Open operator’s cab left cover (1).
2146
3. Disconnect controller connectors (CN-412 and

CN-413) (3).
4. Remove APS controller assembly (4).
CEDO21
INSTALLATION OF APS
CONTROLLER ASSEMBLY
l Carry out installation in the ‘reverse order to
removal.
30-324
0
DISASSEMBLY AND ASSEMBLY AIR CONDITIONER COMPRESSOR
REMOVAL OF AIR
ASSEMBLY
cover (2).
2. Remove side cover (31, then remove side cover
stay.
3
CEDOI
3. Disconnect air conditioner compressor clutch

connector (CN-351) (4).
4. Disconnect 2 compressor hoses (5). m
+ Loosen the sleeve nut slightly and release
Ir Be careful not to damage or drop the O-
rings..
5. Loosen 4 mount bolts (6). m

6. Loosen locknut, and remove adjustment bolt
(71, then remove belt from pulley. a
7. Remove 4 mount bolts (61, then remove air con-
ditioner compressor assembly (8).
30-325
0
DISASSEMBLY AND ASSEMBLY AIR CONDITIONER COMPRESSOR
INSTALLATION OF AIR
ASSEMBLY
removal.
a
Ir Install the air conditioner circuit hoses care-
fore installing.
m Air conditioner hose mounting bolt :
10 + 2 Nm Il.0 2 0.2 kgm1
m
QGFJ Mount bolt : 24.5 + 4.9 Nm
12.5 t 0.5 kgm1
m
* Adjust the belt tension.
Testing and adjusting tension of air condi-
tioner compressor belt.
30-326
0
DISASSEMBLY AND ASSEMBLY AIR CONDITIONER CONDENSER
REMOVAL OF AIR
CONDITIONER CONDENSER
ASSEMBLY
cover (2).
2. Open side cover (3).
side cover (5).
5. Disconnect hoses (7). m
the air conditioner gas (R134a) completely 3’
CED02139
* Be careful not to damage or drop the O-
rings.
6. Remove air conditioner condenser assembly (8)
from right side of chassis.
CED02140
INSTALLATION OF AIR
CONDITIONER CONDENSER
ASSEMBLY
removal.
m
fore installing.
w Air conditioner hose sleeve nut :

Top : 22.05 f 2.45 Nm i2.25 2 0.25 kgm}
Bottom : 13.25 t 1.47 Nm Il.35 f 0.15 kgm}
DISASSEMBLY AND ASSEMBLY HOOD
REMOVAL OF HOOD
ASSEMBLY
A-minal
Drsconnect the cable
of the battery.
1. Remove exhaust pipe (1).

2. Disconnect front lamp connector (CN-202) (2).
3. Using eyebolt 0, lift off radiator top cover (3).
A kg Radiator top cover : 70 kg

cover (5).
CED01752
5. Open engine left side cover (6) and remove

cover (7).
CED01753
6. Lift off hood assembly (8).
elkg Hood assembly : 105 kg
INSTALLATION OF HOOD
ASSEMBLY
removal.
I CED01754
30-328
0
40 MAINTENANCE STANDARD
Engine mount ............................................... .40- 2

Torque converter.. ........................................ .40- 4
Torque converter valve ............................... 40- 6
Transmission ................................................ .40- 8
Transmission control valve.. ....................... 40-10
Power train + lubrication pump ................. 40-12
Scavenging pump ........................................ .40-13
Transfer, bevel pinion.. ................................ 40-14
Bevel gear shaft, steering clutch, brake .... 40-15
Seering control valve.. ................................. 40-18
Final drive ..................................................... .40-20
Main frame ................................................... .40-22
Track frame ................................................... .40-24
Recoil spring ................................................. .40-25
Idler.. ............................................................... 40-26
Track roller bogie ......................................... .40-28
Track roller.. .................................................. .40-30
Carrier roller ................................................. .40-32
Track shoe.. ................................................... .40-34
Equalizer bar.. ............................................... .40-36
Pivot shaft ...................................................... 40-38
Work equipment + PPC charge pump ....... 40-40
Work equipment control valve ................... 40-42
PPC valve ...................................................... .40-46
PPC charge valve ......................................... .40-49
Work equipment valve ................................ 40-50
Quick drop valve .......................................... .40-54
Clinder stay .................................................... 40-55
Blade.. ......... . .................................................. .40-56
Ripper equipment.. ....................................... .40-62
40-l
MAINTENANCE STANDARD ENGINE MOUNT
ENGINE MOUNT
B-0 SBD01222
Unit: mm
No. Check item Criteria Remedy
Standard Tolerance Standard Clearance

size Shaft Hole clearance limit
, Clearance between bracket
and cushion
+0.018 +0.030 -0.018 -
70 0.1
-0.012 0 0.042 Replace
Standard size Repair limit

2 Free height of mount
rubber 105 103
40-Z
MAINTENANCE STANDARD DAMPER, UNIVERSAL JOINT
DAMPER, UNIVERSAL JOINT =Cb
----I
i_;
i A-A
SBD01223
Unit: mm
No Check item Remedy

Clearance between size Shaft Hole clearance limit
1 flywheel housing and
cover +0.024 +0.080 0.024 -
647.7 0.2
+0.105 0 0.185
Clearance between
2 flywheel and damper
Standard size Repair limit Replace

Outside diameter of
3 coupling oil seal contact 0
surface ‘I0 -0.035
109.9
Outside diameter of output 0

4 “0 -0.035 109.9
shaft oil seal contact surface
Xmension of coupling
5 48fO.l 47.7
Detween bearing and holder
I I
40-3
MAINTENANCE STANDARD TORQUE CONVERTER
66.15*7.35Nm
(6.75*0.75kpm)
66.15*7.35Nm
(6.75*0.75ksm)
m 110.35*12.25Nm
(11.25*1.25km)
A-A
SBD01224
40-4
Unit: mm
No Check item I Criteria Remedy
Standard size Tolerance Repair limit

Outside diameter of
1 coupling oil seal contact 0
125 124.8
surface -0.063 Repair hard
chrome
Inside diameter of retainer +0.46 plating or
2 190 190.5
seal ring contact surface 0 replace
Inside diameter of sleeve +0.035

3 110 120.2
seal ring contact surface 0
Standard clearance Clearance limit

Backlash between PTO
drive gear and scavenging
0.250 - 0.420 -
pump drive gear
Backlash between PTO -

5 0.204 - 0.516
drive gear and driven gear

Wear of stator shaft seal
6
ring Width : 5.95 Width : 5.35
Height: 6.50 Height: 5.85
Thickness of disk 5.4 5.0
7 Thickness of plate 5.0 4.5
Replace
Thickness of overall
15.8 14.5
assembly
Thickness of disk I 5.4 I 5.1
8 Thickness of plate 5.0 4.5
Thickness of overall
15.8 14.7
assembly
Free Installed Installed Free Installed

9 Stator clutch spring length length load length load
54.1 37.0 125.5 N 56.9 106.9 N

(12.8 kg} 110.9 kg}
40-5
MAINTENANCE STANDARD TORQUE CONVERTER VALVE
/’
Llo o-u&-
8 3
Y
4
E-E SAD01225
40-6
MAINTENANCE STANDARD TORQUE CONVERTER VALVE
Unit: mm

Clearance between main
’ relief valve and valve body
-
40 -0.035 +0.016 0.035 0.08
-0.045 0 0.061
valve and valv

Replace
120.3 101.5 1455.3 N 116.7 1382.6 N

1146.5 kg} il41.1 kg)
7 Torque converter relief 116.92 90.8 550.4 N 113.41 523.2 N

valve spring i56.16 kg} 153.35 kg}
8 Stator clutch modulating 103.5 95.2 151.9 N 144.4 N

valve spring (15.5 100.4
kg} 114.7 kg}
g Lock-up clutch modulating 158.6 N 150.7 N

valve spring (outer) 141.4 88.7 137.16
I16.18 kg} Il5.37 kg}
1o Lock-up clutch modulating - -

valve spring (inner) 80.5 80.5 78.09
11 Lock-up valve spring 110.07 100.0 29.4 N 27.9 N

13.0 kg} 106.8 12.85 kg}
40-7
MAINTENANCE STANDARD TRANSMISSION
TRANSMISSION
14 17 18 17 I! 19 20 I! 20 4 / I5
300* 14.7Nm
(26.5*1.5kon) 1 5 IO li 2 12 7 8 3 II Y 13 16
SAD01226
40-8
Unit: mm
No Check item Criteria Remedy
~~
1 No. 1 clutch spring (x 12)
No. 2 clutch spring (x 12) 70.0 60.3 218.7 N 68.0 196.1 N

2
122.3 kg} (20.0 kg}
No. 3, 4 clutch spring (x 12) 97.0 82.4 149.1 N 95.0 127.5 N

3
(15.2 kg] (13.0 kg}
No. 5 clutch spring (x 3) 7.75 6.75 3422.5 N - 3079.3 N

4
{349 kg} 1314 kg}

Overall assembled thick-
5
ness of No. 1 clutch 54.6 +0.33 49.0

6 50.3 +0.33 45.0
ness of No. 2 clutch
Overall assembled thick- 36.4 50.26 [Ti


8 27.3 f0.22 24.0

50.0 +0.33 45.2 Replace
ness of No. 5 clutch I I
Thickness of clutch disc

4.8 kO.1 4.0
(No. 1 - 4 clutch) I I I
Thickness of clutch disc

5.0 kO.1 4.2
(No. 5 clutch)
Thickness of clutch plate

4.3 kO.1
(No. 1 - 4 clutch) I I
13
Thickness of clutch plate
(No. 5 clutch) I 4.0
I
fO.l
I
3.8
I
-0.01
14 Wear of seal ring on Width : 3.0 Width : -0.03 Width : 2.6
transmission input shaft Thickness: 3.5 Thickness: k0.15 Thickness: 3.3
15 Wear of seal ring on Width : 4.5 Width : 3::; Width : 4.1

transmission output shaft Thickness: 5.8 Thickness: ke.1 Thickness: 5.6
401
16 Wear of seal ring on No. 5 Width : 5.0 Width : -0.03 Width : 4.6
clutch Thickness: 6.0 Thickness: k0.15 Thickness: 5.8

Backlash between No. 1, 2
17 sun gear and planet pinion
0.13 - 0.40 -
Backlash between No. 1

planet pinion and ring 0.13 - 0.40 -
18
gear inner teeth
Backlash between No. 2, 3,
4 planet pinion and ring 0.14 - 0.40 -
gear inner teeth
Backlash between No..3! 4 -

0.13 - 0.37
sun gear and planet prnron
Clearance between bearing -

0.16 - 1.59
2nd thrust washer
40-9
MAINTENANCE STANDARD TRANSMISSION CONTROL VALVE
TRANSMISSION CONTROL VALVE
4- A-A
C0
c0
\
-3
0 n 00 n
0 n0 c0 ‘7
SAD01227
40-10
MAINTENANCE STANDARD TRANSMISSION CONTROL VALVE
Unit: mm

Clearance between modu- size Shaft Hole clearance limit
1 lating valve and valve
body -0.035 +0.016 0.035 -
35 0.08
-0.045 0 0.061
2 Clearance between modu-

lating valve and piston
-
3 Clearance between quick 19 -0.035 +0.013 0.035 0.08
return valve and valve body -0.045 0 0.058
-
4 Clearance between reduc- 28 -0.035 +0.013 0.035 0.08
mg valve and valve body -0.045 0 0.058
-
5 Clearance between reduc- 15 -0.020 +0.018 0.020 0.07
rng valve and piston -0.030 0 0.048 Replace
-
6 Clearance between direc- 28 -0.035 +0.013 0.035 0.08
tronal valve and valve body -0.045 0 0.058
7 Clearance between speed

/ 28 1 $j;;; 1 +;.‘I3 / “‘““,“.,, j 0.08 /
valve and valve body

8 Modulating valve spring length length load length load
(outer)
76.1 58.0 319.7 N 80.1 304.0 N
132.6 kg} (31.0 kg}
g Modulating valve spring 53.3 53.3 - 51.7 -

(Inner)
IO Reducing valve spring 68.0 50.5 366.8 N 66.0 349.1 N

137.4 kg} i35.6 kg}
40-11
MAINTENANCE STANDARD POWER TRAIN + LUBRICATION PUMP
POWER TRAIN + LUBRICATION PUMP

BALlI + 160
Unit: mm
No. Check item Criteria
Side clearance
0.060 - 0.145
Driving depth of pin
Spline shaft rotation

5.9 Nm (0.6 kgm}
torque
Rotating Discharge
Type discharge discharge
speed pressure
Delivery amount amount
2.9 MPa
Oil: EOlO-CD BAL 112 2,200 rpm I3o kg,cm2I 227 0nin 210 e/min -
Oil temperature:
45 - 55°C 2.9 MPa
SAL 160 2,200 rpm 296 e/min
(30 kg/cm*} 321 e’min
MAINTENANCE STANDARD SCAVENGING PUMP
SCAVENGING PUMP
BAR63 + 200
J
SBDO1261
Unit: mm
, Spline shaft rotation -

torque I I
Rotating Discharge
speed pressure
Delivery amount amount -
-
Oil: EOIO-CD
Oil temperature:
45 - 55°C
40-13
MAINTENANCE STANDARD TRANSFER, BEVEL PINION
TRANSFER, BEVEL PINION
-
SED01229
Unit: mm

Adjust or
1 Backlash of transfer gear
0.24 - 0.63 0.75 replace

Thickness of collar be-
2 tween transfer gear and Replace
bearing 24 23.6
3 Standard shim thickness Adjust

2.0
for bearing cage mount
40-14
BEVEL GEAR SHAFT, STEERING CLUTCH, BRAKE
Sr For details of this
MAINTENANCE STANDARD BEVEL GEAR SHAFT. STEERING CLUTCH. BRAKE
Unit: mm
Distortion of brake, clutch
clutch disc and brake hub
seal ring contact surface
Interference between bevel
taper roller bearing

MAINTENANCE STANDARD STEERING CONTROL VALVE
STEERING CONTROL VALVE
SAD01231
40-18
MAINTENANCE STANDARD STEERING CONTROL VALVE
Unit: mm

Clearance between clutch, size Shaft Hole clearance limit
brake valve and valve
body -0.020 +0.013 0.020 -
19 0.06
-0.030 0 0.043
Clearance between clutch,
2 brake valve sleeve and -0.034 +0.013 0.034 -
18.35 0.08
guide -0.043 0 0.056
Clearance between clutch,
brake valve sleeve and 16 -0.034 +O.Oll 0.034 -
3 0.07
guide -0.043 0 0.054
Clearance between clutch, -0.03 +0.015 0.030 -

4 brake valve and piston 9 -0.04 0 0.055 0.08
Clearance between parking -0.016 +0.043 0.016 -

5 brake valve and body 16 -0.034 0 0.077 0.10
Replace

Clutch modulating spring length length load length load
92.77 N 88.3 N
59 38 57.3
I9.46 kg} i9.0 kg1
66.69 N 63.35 N
Brake modulating spring 60.1 38 58.3
I (6.80 kg} I6.46 kg}
I I I I I I
8 Clutch valve return spring 1 77.2 j 39.5 1 gTk;) / 74.9 j zl
Brake valve return spring 62.4 40.5 148.1 N 60.5 141.2 N

9
115.1 kg} I14.4 kg}
IO Parking brake valve spring 1.67 N 1.57 N

28 15 27.2
IO.17 kg} iO.16 kg)
40-19
MAINTENANCE STANDARD FINAL DRIVE
FINAL DRIVE
II
m152*24.5Nm
(15.5*2.5km)1
m_
277.5*31.9Nm
(28.25*3.25km)
m 1814.2*98.lNm
(185*IOkm)
i2
SED01232
40-20
MAINTENANCE STANDARD FINAL DRIVE
Unit: mm

I Backlash between No. 1 I
’ 1 pinion and No. 1 gear 1 0.25 - 0.99
Backlash between sun

0.22 - 0.81 1.5
: 2 gear and planet pinion I I I
0.3
z Backlash between planet

0.25 - 0.81
3 pinion and ring gear

Outside diameter of No. 1
4 pinion oil seal contact
115.0 114.9 Replace
surface
Thickness of thrust collar

5 of inner body roller 25.14 24.9
bearing
Thickness of thrust collar
6 of No. 1 gear boss roller 10.0 9.5
bearing
7 Thickness of thrust collar

of cover and shaft 20.0 18.5
8 Thickness of plate and

22.25 20.5
thrust collar

g Clearance between pinion
shaft and carrier
-0.035 +0.072 0.072 -
100 0.1
-0.054 +0.037 0.126
I I I I
Standard shim thickness
10 for No. 1 pinion bearing 2
cage
Dimension of end face of
11 final drive cover and end Adjust
7-L
face of bearing
,2 Clearance of floating seal

2.6 - 3.6
guard
40-21
MAINTENANCE STANDARD MAIN FRAME
MAIN FRAME
l--E
k-F
c-c
B-B D-D
H4
A-A
E-E F-F G-G H-H SEID01233
40-22
MAINTENANCE STANDARD MAIN FRAME
Unit: mm

, Interference between
steering case and bushing
+O.lOS +0’.052 0.004 -
275 Min. 0
+0.056 0 0.108
Clearance between -
2 frame and final drivesteering 332 -0.018
-0.075 +0.057
0 0.018
0.132 0.2
cage
Clearance between bracket +0.046 -0.018 -

3 and cushion 70 -0.018
-0.012 0 0.058 0.1
Clearance between ripper

0.064 -
4 beam mount pin and 120 -0.036
-0.090 +0.166
+0.028 0.256 1.5
bushing
Clearance between ripper
-0.036 +0.287 0.236 -
5 cylinder mount pin and 100 -0.090 +0.200 0.377 1.5
bushing Replace
Clearance between radiator
-0.030 +0.371 0.299 -
6 guard mount pin and 80 -0.076 +0.269 0.447 1.5
bushinq
Clearance between radiator
-0.036 +0.369 0.303 -
7 guard mount pin and 90 -0.090 +0.267 0.459 1.0
bushinq
Clearance between equal- -0.036 +0.243 0.137 -
8 izer bar shaft and bushing 120 -0.090 +O.lOl 0.333 0.5

Protrusion of rubber at end
9 face of seal
1 0.5
1o Free height of front mount

58 56
rubber
Free of rear mount

,1 height 105 103
rubber
44.1 - 117.6 KN i4.5 - 12 ton1
force for
13 Press-fitting ripper 58.8 - 171.6 KN 16 - 17.5 ton}
cylinder mount bushing
Press-fitting force for

14 radiator guard mount 98.0 - 181.4 KN {IO - 18.5 ton} Adjust
bushing
Press-fitting force for
15 radiator guard mount 58.8 - 137.3 KN 16 - 14 ton)
bushing
16 Press-fitting force for

31.4 - 105.9 KN 13.2 - 10.8 ton1
equalizer bar shaft bushing
40-23
MAINTENANCE STANDARD TRACK FRAME
TRACK FRAME
*103Nm 277*32Nm
10.5kam) (28.25*3.25km)
Unit: mm
Item I Reoair limit I

Deformation of track frame Curvature 7 (for length of 3,000)
1 Repair or
outer pipe Twisting 3 (for level length of 300) replace
Dents (oioe oortion) 12

size clearance limit
-._-.-.._- between
Clearance --_ inner Shaft Hole
Replace
2
pipe and adju stment
-
cylinder protrusron 60 -0.15 +0.3 0.15 2.0
-0.35 0 0.65

Clearance between idler
3 Adjust
bogie and guide 0 - 0.5 3.0
40-24
MAINTENANCE STANDARD RECOIL SPRING
RECOIL SPRING
SAD01235
Unit: mm

, Recoil spring length length load length load
499.7 KN 458.5 KN
1,461 1,230.5 1,440
I50,994 kg1 146,790 kg}
Standard Tolerance Standard Clearance Replace

Clearance between inner size Shaft Hole clearance limit
2 cylinder and outer cylinder
of outer cylinder bushing -0.058 +0.317 0.118 -
380 0.8
-0.228 +0.060 0.545
3 Clearance between adjust- -0.600

135
ment cylinder and bushing -1 .ooo
Press-fitting force for outer
4 cylinder bushing (outer 49.0 - 109.8 KN {5.0 - 11.2 ton)
cylinder side)
5 cylinder bushing (inner 91.2 - 322.6 KN I9.3 - 32.9 ton} Adjust
cylinder side)
Clearance between recoil
6 spring mount nut and lock o- 1.0
plate
40-25
MAINTENANCE STANDARD IDLER
-__-__-__f
-__________A __-__-__-__ _ -
,
-__-___
j-7
r-------
j/i i_______Jj
:I Ir-----: j
7
1 I #,
I i
I) A ky I
I/\\ h
1
SAD01236
40-26
MAINTENANCE STANDARD IDLER
Unit: mm
B -
s No Check item Remedy
z
1 Outside diameter of idler
protrusion 960.0 -
Outside diameter of idler

2 915.0 890.0
tread
3 Width of idler protrusion 136.0 119.0

Rebuild or
replace
4 Width of idler tread 79.0 87.5
5 Overall width of idler 294.0 -
6 Width of shaft flange 242.0 -

I I
7 Clearance between shaft Replace
and bushing bushing
155 -0.350 +0.220 0.244 -
1.5
-0.413 -0.106 0.633
Clearance between shaft -

8
and seal guide
1
Standard clearance Clearance limit Replace
Play in axial direction of
9
shaft 0.47 - 0.83 1.5
40-27
MAINTENANCE STANDARD TRACK ROLLER BOGIE
TRACK ROLLER BOGIE
iii i I
,,\=~c---------------_
~-__--_-__-__---- ___
---------~!_,_______--_--------
-__-__-__ ‘_--_.._..__..
~~
IO 7 II 7 12 8 7 13 7
A-A SAD01 237
40-28
MAINTENANCE STANDARD TRACK ROLLER BOGIE
Unit: mm

size Hole clearance limit
, Clearance between shaft Shaft
and bushing
-
95 -0.160 +0.151 0.185 0.8
-0.195 +0.025 0.346
Clearance between collar

-
2 fitted)
and outer bogie (press- 153 +0.150
+O.llO +0.040
0 -0.150-0.07 -

-
3 fitted)
and outer bogie (press- 155 +0.043
+0.003 +0.040
0 -0.043
-0.037 - Replace
-
4 and inner bogie
fitted) (press- 154 +0.210
+0.170 +0.040
0 -0.210
-0.130 -
Clearance between shaft -0.160 -0.237 -0.042 -

and collar (press-fitted) 1 g5 1 -0.195 1 -0.272 1 -0.112 I -
5l
6 Clearance between shaft

and collar (press-fitted)
7 Clearance of collar 1.8 f 0.33

I
8 Press-fitting force for

4.9 - 30.4 KN IO.5 - 3.1 ton)
bushing
g Press-fitting force for

1.5 - 3.3 KN IO.15 - 0.34 ton}
washer
10 Press-fitting force for collar 58.8 - 154.9 KN 16 - 15.8 ton1
force for outer

I1 Press-fitting 170.6 - 366.7 KN I17.4 - 37.4 ton}
bogie
12 Press-fitting force for inner 345.2 - 653.1 KN 135.2 - 66.6 ton}

bogie

0 - 94.1 KN IO - 9.6 ton1
I3 bogie
40-29
MAINTENANCE STANDARD TRACK ROLLER
TRACK ROLLER
;----------- _-__-__-__-__-__-__--_---------------~
I I
SAD01238
40-30
MAINTENANCE STANDARD TRACK ROLLER
Unit: mm
I I I
I
, Outside diameter of flange
(outside) 310 -
2 Outside
(inside)
diameter of flange
300
I -
3 Outside diameter of track 270 228
roller tread
-
Rebuild or
I
4 Overall width of track replace
358
roller I
5 Width of track roller tread
82 91
(single flange)
6 Width of track roller tread 82 103

(double flange)
7 Width of flange (single

29 20
flange) I
8 Width of flange (outside of
29 20
double flange)

l3 Play in axial direction of
shaft 0.48 - 0.86 1.5
Press-fitting force for seal Adjust

107.9 - 156.9 KN {II - 16 ton)
I4 guide
40-3 1
MAINTENANCE STANDARD CARRIER ROLLER
CARRIER ROLLER
I
A 3
L--
I
--I
_t
”----I
~
===..I
__ I
SBD01239
40-32
MAINTENANCE STANDARD CARRIER ROLLER
Unit: mm
Check item Criteria Remedy
I Standard size I Reoair limit I

1 Outside diameter of flange
242 -
I
2 Outside diameter of carrier

210 185
roller tread
Rebuild or
replace
Width of carrier roller
3 79 90
tread
4 Width of flange 23 12
Standard Tolerance . Standard Interference

size Shaft Hole interference limit
5 Clearance between shaft
and support
-
86 -0.2
0 +0.350
0 0 0.550 -

6 Interference between shaft Replace
and seal guide
+0.245 +0.035 0.150 -
90
+0.185 0 0.245 -

7 Play in axial direction of
shaft 0.01 - 0.22 0.3
40-33
MAINTENANCE STANDARD TRACK SHOE
TRACK SHOE
0 9 SAD01240
40-34
MAINTENANCE STANDARD TRACK SHOE
Unit: mm
Fz
z Standard size Repair limit
5; 1 Link pitch Turn or
280.3 - replace
Weld lug,
2 Grouser height
93.0 30.0 rebuild or
replace
163.0 Rebuild or
3 Link height 181.0
replace
4 Outside diameter of 90.0 (normal loading) Turn or

98.5 replace
bushing 92.5 (hard loading)
bushing and link

MAINTENANCE STANDARD EQUALIZER
EQUALIZER
Ii f9
_A___
IL__Jy”
--_m&_
I\ ._i’___-__-__
/ I___\ ~~-____-_-------
k--T: 1
j
I , (5-l;
SAD01241
40-36
MAINTENANCE STANDARD EQUALIZER BAR
A-A SAD01242
Unit: mm
-
NC Check item
Tolerance
Criteria
1 Remedy
Standard Standard Clearance

Clearance between center
1
pin and bushing
-0.036 +0.243 0.137 -
120 0.5
-0.090 +O.lOl 0.333
Clearance between side pin -0.048 +0.015 0.033 -

2 95 1.0
and bushing -0.078 -0.015 0.093
Replace
Clearance between side pin 0.2 - bushing
-0.1 +0.3
3 and spherical surface of 108 1.0
-0.3 +O.l 0.6
bushing
Standard Tolerance Standard nterference

size Shaft Hole interference limit
Interference between side
4
pin boss and bushing
160 +0.045 -0.028 0.055 - -
+0.027 -0.068 0.113
-
Press-fitting force for side
5 92.2 - 226.5 KN 19.4 - 23.1 ton1
pin bushing
Press-fitting force for center -

6 49.0 - 186.3 KN I5 - 19 ton1
pin bushing
-
Press-fitting force for side
7 34.3 - 73.5 KN (3.5 - 7.5 ton}
pin bushing
-
40-37
MAINTENANCE STANDARD PIVOT SHAFT
PIVOT SHAFT
----_---_____-_---------
_____-----_-________----
__-__-__----.
243
% 1: Left pivot shaft (without blade tilt)

% 2: Right pivot shaft (with blade tilt)
40-38
MAINTENANCE STANDARD PIVOT SHAFT
Unit: mm
I I I
No
I Check item Criteria Remedy
Standard Tolerance Standard Interference

, interference between size Shaft Hole interference limit
thrust washer and seal
+0.213 -0.180 0.278 -
230 +0.098 -0.226 0.439 -
2 Interference between thrust

/ 165 1 $;,“; / 2:;;: 1 “‘7g4 1 - 1 Rep’ace
washer and seal
Interference between +0.096 -0.115 0.165 -

3 shaft and seal pivot 213 +0.050 -0.187 0.283 -

4 Clearance between pivot
shaft and bushing
175 -0.145 +0.125 0.230 - 1.0 Replace
-0.208 +0.085 0.333 bushing
Clearance between pivot -0.170 +0.146 0.270 -

5 210 1.0
shaft and bushing -0.242 +O.lOO 0.338
40-39
MAINTENANCE STANDARD WORK EQUIPMENT + PPC CHAGE PUMP
WORK EQUIPMENT + PPC CHAGE PUMP

SAR(4)140 + (31071 + (I)022
.-
L ,-=m
III I Y il___lr
I
Id
J
40-40
MAINTENANCE STANDARD WORK EQUIPMENT s PPC CHAGE PUMP
Unit: mm
Type Standard clearance Clearance limit
SAR(4)-140 0.11 - 0.16 0.19
1 Side clearance
8
kz -
r; SAR(4)-140 0.060 - 0.140
Clearance between plain

2 bearing inside diameter and
gear shaft outside diameter
Type Standard size Tolerance Repair limit
0 -
SAR(4)-140 21
-0.5
3 Driving depth of pin

0 -
SAR(3)-071 14
-0.5
0 -
SAR( 1 I-022 10
I -0.5 I
Spiine shaft rotation

4 16.7 - 26.5 Nm II.7 - 2.7 kgm)
torque
Rotating Discharge
speed pressure
amount amount
Delivery
SAR(4)-140 2,200 rpm ,2?,\6,g~cp~zI 287 e/min 266 e/min
- Oil: EOIO-CD -
Oil temperature:
SAR(3)-071 ( 2,200 rpm 1$$$$P~q/ 137 JYmin 1 125 Cumin 1
45 - 55°C
SAR(lI-022 1 2,200 rpm 1,,$\zJi21 / 43 e/min 1 39 e/min /
40-41
0
MAINTENANCE STANDARD WORK EQUIPMENT CONTROL VALVE
WORK EQUIPMENT CONTROL VALVE

l BLADE LIFT VALVE
w &7.8*24.5Nm
(37.5 k2.5 Iam)
A-A B-B
SAD01245
40-42
l MAIN RELIEF, SHUTTLE VALVE

f
S6001246
Unit: mm
g No. Check item Criteria Remedy

%
z Standard size Repair limit

1 Spool return spring length length load length load
431.5 N _ 345.2 N
69.9 63
I44 kg1 135.2 kg}
400.1 N 319.7 N
2 Spool return spring 80.69 76.5
i40.8 kg} - 132.6 kg}
Spool return spring 588.4 N _ 470.7 N

43.82 32.5
3 (For FLOAT) I60 kg1 {48 kg1
Replace
8.14 N 6.47 N
9 Shuttle valve spring 42.7 38.6
IO.83 kg} IO.66 kg}
,. Height of main relief

8 (1 turn of screw adjusts by 2.4 MPa i24.8 kg/cm*}) Adjust
pressure adjustment screw
40-43
l BLADE TILT. RIPPER LOW VALVE

24.9Nm
:O.Likam)
m 34.3*4.9Nm
(3.5*0.5kPm)
SAD01247
Unit: mm
Free Installed Installed Free installed

1 Spool return spring length length load length load
2 Check valve spring 1 28.0 1 18.0 1 {o”.;”kNgl 1 26.0 1 $2 rgl 1 Replace
Main relief valve spring 24.2 18.3 31.4 N 23.0 25.1 N

3
13.2 kg} 12.56 kg}
Main relief valve poppet 258.9 N 206.9 N

4 41.1 32.6 39.4
spring 126.4 kg1 i21.1 kg}
Height of main relief Adjust

5 8 (I turn of screw adjusts by 2.4 MPa 124.8 kg/cm*})
pressure adjustment screw
40-44
. RIPPER HIGH VALVE

n-i-l
n
LLU LUI
A-A B-0
514.9*24.5Nm
(52.5*2.5kpm)
c-c D-D SBD01248

Unit: mm
~~
1 Hi valve return spring
24.1 N Replace
2 Check valve spring 32.6 27.0 30.2 N 31.5
13.08 kg} 12.46 kg1
135.3 N
4 Constant differential pres- 57.4 33.5 169.7 N 52.6
sure valve spring {17.3 kg} 113.8 kg1
40-45
MAINTENANCE STANDARD PPC VALUE
PPC VALVE
l FOR BLADE LIFT, BLADE TILT
m 112.7t14.7Nm
/ (11.5t1.5kgm)
14.4+1.9Nm
(1.47i0.2kgm)
-6.3722.45Nm
(0.65+0.25kgm)
w 7.36?1.47Nm
(0.75t0.15kgm)
40-46
MAINTENANCE STANDARD PPC VALVE
Unit: mm
NO Check item Criteria Remedy

Free installed Installed Free Installed
1 Centering spring (for PI) lengthX0.D. length load length load
71.4 N 57.1 N
33.8X15.5 31.9
17.28 kg} - i5.82 kg}
-
Metering spring (for PI, P2) 27.23X8.14 24.9 16.7 N 13.7 N
2
{I.7 kg} - II.4 kg1
Replace
Centering spring (for P2) 50.35x15.5 31.9 62.8 N - 50.0 N spring if
3
16.4 kg} 15.1 kg1 damaged or
deformed
31.9 80.81 N 64.63 N
4 Centering spring (for P3, P4) 50.05X15.5
18.24 kg} - j6.59 kg}
24.9 16.7 N 13.7 N

5 Metering spring (for P3, P4) 26.53X8.15
Il.7 kg} - il.4 kg1
-
159.36 N _ 127.5 N
6 Detent spring (for PI) 20.39x19.5 13.1
116.25 kg} {13 kg}
38.44 N 30.79 N
7 Detent spring (for P2) 45.36X7.5 26
I3.92 kg} - 13.14 kg}
40-47
MAINTENANCE STANDARD PPC VALVE
l FOR RIPPER LIFT, RIPPER TILT
.m 44.1*4.9Nm
(4.5*0.5kPm)
‘2
SAD01249
Unit: mm
Free installed installed Free Installed

I Centering spring (for ~3, ~4) lengthX0.D. length load length load
55.9 N 45.1 N Replace

50.4x15.5 34 spring if
i5.7 kg1 - 14.6 kg}
damaged or
16.7 N 13.7 N deformed
2 Metering spring 26.6X7.5 24.9
(1.7 kg} - Il.4 kg}
3 Centering spring (for PI, P2) 50.1X15.5

1 1 34 / ;::k;I 1 -
40-48
MAINTENANCE STANDARD PPC CHARGE VALVE
PPC CHARGE VALVE

A_
-------------~-------------_-_-_______
_I
2 2
A-A B-0 c-c SAD01250
Unit: mm
Check item Criteria
Clearance between relief

valve and spool
3 Relief valve spring
Oil cooler bypass valve 37.3 N 35.3 N

4
spring 26.3 19.1 i3.8 kg1 25.4 13.6 kg}
Accumulator check valve 20.6 19.1 1.96 N 1.77 N

5 spring 20.0
IO.2 kg} IO.18 kg}
40-49
MAINTENANCE STANDARD WORK EQUIPMENT CYLINDER
WORK EQUIPMENT CYLINDER

l BLADE LIFT CYLINDER
SAD01251
l BLADE TILT CYLINDER
SAD01252
l PIN PULLER CYLINDER
7 1 8
441+44Nm
SBD00462
(45.0*4.5kgm)
40-50
Unit: mm
Criteria
Thickness of standard
Blade 4.0 Adjust
4 shim between tip of
LIFT
piston rod and cap

Clearance between clearance limit
size Shaft Hole
c piston rod support
3 shaft and bushing Blade -0.200 +0.200 0.200 -
TILT 75 0.500 1.0
-0.300 0
Clearance between
6 ;‘&d~e$=&“ppofl Blade 75 -0.200 +0.174 0.300 - 1.0 Replace
TILT -0.300 +O.lOO 0.474
g
7 E$a$EZZZ~c~iZZJ Fz,,, 29 -0.100 +I .300 1.3 - -

-0.200 +I .200 1.5
cap
Clearance between
6 cylinder bottom support Pin 26 -1.1 fO.l 1.0 - -
puller -1.2 1.3
shaft and boss
40-51
l RIPPER LIFT CYLINDER
1323.8* 147.lNm
SBD01253
l RIPPER TILT CYLINDER
40-52
Unit: mm
Clearance
1 between piston
rod and bushing
Clearance between
2 piston rod support
shaft and bushing
-
-0.036 +0.207 0.156 -
Clearance between p$fe’ 100 1.0
-0.090 +0.120 0.297
cylinder bottom
3
support shaft and -0.036 +0.207 0.156 -
bushing Ripper 100 +0.120 0.297 1.0
TILT -0.090
40-53
MAINTENANCE STANDARD QUICK DROP VALVE
QUICK DROP VALVE

. FOR BLADE LIFT CYLINDER
Unit: mm
No. Check item

MAINTENANCE STANDARD CYLINDER STAY
CYLINDER STAY
SBD01255
Unit: mm
I
Clearance between cylin- size Shaft Hole clearance limit
1
der yoke and bushing
150 -0.085 +0.063 0.085 -
0.5
-0.148 0 0.211
Clearance between cylin- 115 -0.072 +0.054 0.072 -

2 0.5
der yoke and bushing -0.126 0 0.180
Clearance between lift
105 -0.120 +0.035 0.120 -
cylinder support shaft and 0.5
-0.207 0 0.242
- bushing
40-55
MAINTENANCE STANDARD BLADE
BLADE
. SEM-U DOZER
A,
\
12 7
A-A B-0 c-c D-D
4
E-E F-F
I I5
2
H-H G-G I-1 K-K
SED01256
40-56
Unit: mm
Clearance between brace
brace and cap spherical
Clearance between joint
in and bracket
spherical surface and

. U-DOZER
13
II
i2
A-A c-c
‘7
D-D E-E
G-G F-F H-H J-J

SED01257
40-58
Unit: mm
No, Check item Criteria Remedy

Clearance between brace size Shaft Hole clearance limit
1 pin and brace
-0.2 +0.3 0.3 -
75 2
-0.3 +O.l 0.6

2
pin and bracket / 75 1 1::: 1 :::: 1 Oe3;6 1 2 j ~~~~~~~
Clearance between brace -0.2 +0.3 0.2 -

3 pin and bracket 75 -0.3 0 0.6 1
Clearance between brace -0.2 +0.2 0.2 -

4 pin and bushing 75 -0.3 0 0.5 1

brace and spherical 170 -0.2 +0.3 0.2 - 1 Adjust shim
cap
-0.3 0 0.6 or replace
surface
and bracket 200 -0.7 +O.l 1.0 3

Clearance between joint -0.2 +0.3 0.3 - I
Clearance between frame

7 100 1 2:; / +;.3 / 0.3;* j 3 /
pin and joint
Clearance between frame

8
pin and bracket
Clearance between straight

9 160
frame joint bushings / o.3;4 / ’ I
Clearance between trunnion -0.5 +0.5 0.5 -

IO and spherical surface 200 -1.0 0 1.5 8
cap
Clearance between joint -0.2 +0.3 0.3 -

11 and bracket 200 -0.7 +O.l 1.0 3
Clearance between blade -0.3 +0.3 0.3 -

12 pin and joint 100 -0.5 0 0.8 3
Clearance between blade -0.3 +0.5 0.5 -

13 2
pin and bracket 100 -0.5 +0.2 1.0

14
link pin and blade bracket
Clearance between center -0.3 +0.5 0.5 -

15 link pin and center link 125 -0.5 +0.2 1.0 2
Clearance between center -0.2 +0.3 0.3 -

16 link and blade bracket 280 -0.4 +O.l 0.7 2

brace spherical surface and 170 -0.2 +0.3 0.2 - 1 Adjust shim
17
-0.3 0 0.6 or replace
cap
40-59
. CUTTING EDGE, END BIT
m 2226.1 *264.8Nm
@27*27kpm)
D 2226.1 *264.8Nm
[227*27kom)
-- -- -- - - -
SDD01258
Unit: mm

1 Height of end bit outside
478 380
Replace
2 Width of end bit 734 600
3 Height of end bit inside 393 300
Replace
4 Height of cutting edge 406 335 (264 after turned)
or turn
40-60
MAINTENANCE STANDARD RIPPER EQUIPMENT
RIPPER EQUIPMENT
. VARIABLE MULTIPLE SHANK RIPPER
A-A
E-E F-F
SED01259
40-62
.
Unit: mm

-
size clearance limit
Clearance between bushing
1
and bracket and arm mount
0.161 -
pin 120 0.298 1.5
-
Clearance between bush-
0.161 -
2 ing and beam and arm 120 0.298 1.5
mount pin
Clearance between cylin-
0.156 -
3 der mount pin and bush- 100 0.207 1.5
ing Replace
:
4 Clearance between shank
and mount pin 82 +0.3

5 Wear of point
420 255
6 Wear of protector 155 115
:40-63
l GIANT RIPPER
E3
c-c
A-A
E-E F-F
SED01260
40-64
Unit: mm
1

Clearance between bushing.
and bracket and arm mount
-0.036 +0.208 0.161 -
pin 120 1.5
-0.090 +0.125 0.298
Clearance between bush-
-0.036 +0.208 0.161 -
ing and beam and arm 120 1.5
-0.090 +0.125 0.298
mount pin
Clearance between cylin-
-0.036 +0.207
3 der mount pin and bush- 100
-0.090 +0.120 Replace
ing
Standard size Tolerance
4 Clearance between shank
and mount pin 82 f0.3
Standard size Reoair limit

5 Wear of point
6 Wear of protector
40-65
90 OTHERS
Power train hydraulic system Actual electric wiring diagram (10-144) . . . 90-37
drawing (IO-IO) . . .. . . . . . .. . . . . . . . .. .. . . . . .. . . . . . . . . .. 90- 3 Actual electric wiring diagram (10-145) . . . 90-39
Power train hydraulic circuit drawing Actual electric circuit diagram
(IO-II) . . . . . . . .. . . . . . . .. . . . . . . .. . . . . . . . .. . . . . . .. . . . . . . .. . . . . . go- 5 Chassis electric circuit diagram (l/2)
Transmission (IO-311 . . . . . . . . .. . . . . . . . .. . . . . . .. . . . . . . . . 90- 7 (10-146) . . . . . . . . . .. . . . . . . .. .. . . . . .. .. . . . . . . .. . . . . . . . . .. . . . . 90-41
Bevel geaar shaft, steering clutch, Chassis electric circuit diagram (2/2)
brake (IO-521 . .. . . . . . . .. . . . . . . . .. . . . . . . .. . . . . . .. . . . . . . . . 90- 9 (10-147) . . . . .. . .. . . . . . . .. . . . . . . .. . . . . . . . . . .. . . . . . . .. . . . . . . . 90-43
Work equipment hydraulic system Electric circuit diagram inside cab
diagram (Tilt dozer) (10-80) .. . . . . . .. . . . . . . . .. 90-I 1 (10-148) . .. .. . . . . . . . .. . . . . . . . . .. . . . . . . . .. . . . . . .. . .. . . . . . . . . 90-45
Work equipment hydraulic circuit Connector arrengement diagram
diagram (IO-811 . . . . . .. . . . . . . .. . . . . . .. . . . . . . .. . . . . . . .. 90-13 (20-I 16) .. . . . . . . . .. . . . . . . . . .. . . . . . . . . .. . . . . . . . .. . . . . . .. .. .. 90-47
Work equipment hydraulic system Connector arrengement diagram
g diagram(Dual tilt dozer) (IO-821 . . .. . . . . . . . 90-15 (20-I 17) . . . . . . . .. . . . . . . .. . . . . . . . . .. . . . . . . . . .. . . . . . .. . .. . . . . 90-49
% Work equipment hydraulic system Bevel gear shaft, steering clutch, brake
z diagram (Dual tilt dozer)(lO-83) .. . . . . . . . .. 90-17 (40-16) . . . . . .. . .. . . . . . . . .. . . . . . .. . . . . . . . . . .. . . . . . .. . . . . . . . .. 90-51
Main control valve
1. Blade lever at HOLD, ripper lever
at HOLD (10-116) .. . . . . . . . .. . . . .. . . . . . . . . .. . . . . . 90-19 * This section has been enlarged to make it
2. Blade lever at RAISE (blade easier to read; the page number in ( )
operating at high speed)(lO-118) . . . . 90-21 shows the original page.
3. Blade lever at RAISE
(blade operating at low speed)
(10-120) .. . . . . . . . . .. . . . . .. . . . . . .. .. . . . . .. . . . . . . .. . . . . . 90-23
4. Blade lever at LEFT TILT(lO-122) . . . . 90-25
5. Ripper lever at TILT IN (ripper Lo
valve, shuttle valve actuated)
(10-124) . . . .. .. . . . .. .. . . . . .. .. . . . . . .. . . . . . . . .. . . . . . . .. 90-27
6. Ripper lever at TILT IN
(ripper Hi valve actuated)
(10-126) . . . . .. . . . . .. .. . . . . . . .. . . . . . . .. . . . . . . .. . . . . . . .. 90-29
7. Ripper level at LOWER (ripper Lo
valve, shuttle valve actuated)
(10-128) .. . . . . . . . . .. . . . . . .. . . . . . . .. . . . . . .. . . . . . . . . . .. . 90-31
8. Blade lever at HOLD, ripper lever
at LOWER (ripper Hi valve
actuated) (10-130) . . . . . . . . .. . . . . . .. . . . . . . . . . .. . 90-33
9. Ripper lever at LOWER
(cylinder at stroke end)(lO-132) . . . . . 90-35
90-l
a
POWER TRAIN HYDRAULIC SYSTEM DRAWING
(Engine started, joystick at neutral, gear shift lever at 1st)
38
2nd
m
I6
3rd
m
t
I 41 SBD01474
(10-10)
90-3
POWER TRAIN HYDRAULIC CIRCUIT DRAWING
r
I I Nv7 I
_.
4
r
4r
--- I-
i __A
j
r- -
16 3rd
IL -II
I! F
41
t
SAD01475
1. Oil tank 17. Directional valve 34. R.H. brake valve A. Transmission main relief pressure pickup port
2. Power train oil strainer 18. REVERSE clutch 35. L.H. brake valve B. Transmission reducing pressure pickup port
3. Power train pump (BALI121 19. FORWARD clutch 36. L.H. steering valve C. Torque converter stator clutch pressure pickup port
4. Power train oil filter 20.Torque converter relief valve 37. R.H. steering clutch D. Torque converter relief pressure pickup port
Set pressure : 0.14 MPa Il.4 kg/cm21 Set pressure : 0.85 MPa I8.7 kg/cm? 38. R.H. steering brake E. Torque converter regulator pressure pickup port
5. - 21.Torque converter 39. L.H. steering brake F. Torque converter lock-up pressure pickup port
6. Oil filler port 22. Oil cooler 40. L.H. steering clutch G. R.H. steering clutch pressure pickup port
7. Power train lubrication pump (BALIGO) 23. Steering clutch, brake lubrication 41. Steering case H. R.H. steering brake pressure pickup port
8. Power train lubrication oil filter 24.Torque converter case 42.Transmission lubrication valve J. L.H. steering brake pressure pickup port
9. Main relief valve 25. Torque converter lock-up valve 43.Transmission lubrication K. L.H. steering clutch pressure pickup port
Set pressure : 2.69*0.1 MPa {27.4+1.0 kg/cm21 26. Lock-up clutch modulating valve 44. PTO lubrication
10. Modulating relief valve Set pressure : 1.3kO.l MPa {13+1 kg/cm*} 45. Scavenging pump (BAR63+200)
Set pressure : 3.0$2MPa {31$ kg/cm? 27.Torque converter lock-up solenoid valve 46. Solenoid valve (for pin puller)
ll.Quick return valve 28.Torque converter lock-up clutch 47. Pin puller cylinder
12. Reducing valve 29. Stator clutch modulating valve
Set pressure : 2.1:2 MPa I21’,2 kg/cm? Set pressure : 2.5kO.l MPa {25+1.0 kg/cm?
13. Speed valve 30. Stator clutch lubrication
14.lst clutch 31. Stator clutch
15.2nd clutch 32. Parking brake valve
16.3rd clutch 33. R.H. steering valve
(10-11)
90-5
TRANSMISSION
No. 1 No. 2 No. 3 No. 4 No. 5
1. Input shaft
2. Transmission valve
3. Front case
4. Rear case
5. Front cover
6. Sun gear for REVERSE (34 teeth)
8. Pinion shaft
10. Ring gear for REVERSE (84 teeth)
11. Sun gear for FORWARD (41 teeth)
14. Pinion shaft
15. Ring gear for 3rd (91 teeth)
16. Planet pinion for 3rd (25 teeth)
17. Sun gear for 3rd (41 teeth)
18. Ring gear for 2nd (93 teeth)
19. Planet pinion for 2nd (23 teeth)
20. Pinion shaft
21. Sun gear for 2nd (47 teeth)
22. 1st clutch inner drum
23. 1st clutch piston
24. 1st clutch piston housing
25. Output shaft
26. Collar
27. Block
28. 1st clutch spring
29. Seal seat
30. Carrier for 2nd
31. Plate
32. Carrier for FORWARD, 3rd
33. Piston housing for FORWARD, 3rd
34. Carrier for REVERSE
35. Piston housing for REVERSE
36. REVERSE clutch piston
37. Clutch spring
38. Clutch plate
39. Clutch disc
40. Tie bolt
41. Carrier gear for REVERSE (91 teeth)
41 40 39 38 37 36 35 34 33 32 31 30 29 28 27
A-A SAD01298
(10-31)
90-7
BEVEL GEAR SHAFT, STEERING CLUCH, BRAKE
A-A SED01335
(1O-52)
90-9
WORK EQUIPMENT HYDRAULIC SYSTEM DIAGRAM
TILTDOZER
!B I
1r
I II I ‘IU I
m m
(10-80)
90-11
WORK EQUIPMENT HYDRAULIC CIRCUIT DIAGRAM
* For details of the pin puller cylinder, see POWER TRAIN HYDRAULIC CIRCUIT DIAGRAM.
1. Hydraulic tank
IA. Oil filler cap
2. Strainer
3. PPC charge pump (SAR(1)022)
4. PPC charge valve
Set pressure: 4.46 MPa 145.5 kg/cmz}
5. Accumulator
7. PPC lock valve
8. Blade control PPC valve
8A. For blade lift
88. For blade tilt
9. Ripper control PPC valve
9A. For ripper lift
9B. For ripper tilt
10. Hydraulic pump (SAR(4)140+(3)071)
1 IA. Demand valve
IIB. Main relief valve
Set pressure: 20.6 MPa I210 kg/cm21
1 IC. Shuttle valve
11 D. Check valve
11 E. Check valve
11 F. Blade lift valve
IIG. Suction valve (for blade lift)
IIH. Shuttle valve
12. Blade tilt, ripper Lo valve
12A. Main relief valve
Set pressure: 20.6 MPa I210 kg/cm*}
12B. Check valve
12D. Check valve
12F. Check valve
12H. Shuttle valve
I5 14 13. Ripper Hi valve
13A. Check valve
T
i 77 13B. Check valve
__ 13C. Ripper lift (Hi) valve
13F. Shuttle valve
13G. Shuttle valve
13M.Shuttle valve
I J 13N. Shuttle valve
I
14. Quick drop valve
17. Blade tilt cylinder
18. R.H. ripper tilt cylinder
Set pressure: 0.15 MPa il.5 kg/cm?
SAD01362
(10-81)
90-13
WORK EQUIPMENT HYDRAULIC SYSTEM DIAGRAM
DUAL TILTDOZER
ir
1
I I
I I I
I I I r-
f
f
- f
f
I’ il
I’
I r-
I m I
I I
t/i
XI
T
I
II I
(10-82)
90-15
WORK EQUIPMENT HYDRAULIC CIRCUIT DIAGRAM 1. Hydraulic tank
Ir For details of the pin puller cylinder, see POWER TRAIN HYDRAULIC CIRCUIT DIAGRAM. IA. Oil filler cap
2. Strainer
3. PPC charge pump (SAR(l)OZZ)
4. PPC charge valve
Set pressure: 4.46 MPa 145.5 kg/cm*>
IA 5. Accumulator
17
AT________________--
i_i 6LJ 7.
a.
PPC lock valve
Blade control PPC valve
8A. For blade lift
____ I___-_-_-___-_-_-_-_-2 -%Hl 88. For blade tilt
I !-------&-$-
I_______1______---~:~:~I
Lc i
i
I-------------------_------i
-----------------------------:
___--------------------------+
_______-_-_------------------4
--c
l--my
jry-q j “- p4~~!-----____--------------~
‘--t-------_----’
! j I
I 9.
10.
Ripper
9A.
9B.
Hydraulic
control
For ripper
For ripper
pump
PPC valve
lift
tilt
(SAR(4)140+(3)071)
1 IA. Demand valve
1 IB. Main relief valve
Set pressure: 20.6 MPa {ZIO kg/cm2}
1 IC. Shuttle valve
11 D. Check valve
1 IE. Check valve
IIF. Blade lift valve
11G. Suction valve (for blade lift)
l2Ei
_---- 11 H. Shuttle valve
_------_ 12. Blade tilt, ripper Lo valve
_-_- 12A. Main relief valve

31 AZ Set pressure: 20.6 MPa 1210 kg/cm*}
128. Check valve
12D. Check valve
I
-2’
II
12F. Check valve
12H. Shuttle valve
13. Ripper Hi valve
13A. Check valve
13B. Check valve
13C. Ripper lift (Hi) valve
13F. Shuttle valve
13G. Shuttle valve
Ix---
L___ ldM.Shuttle valve

Al -: 13N.Shuttle valve
13N. Ripper lift fixed differential pressure valve
14. Quick drop valve
17. Pitch selector solenoid valve
18. Dual tilt selector solenoid valve
I I 19. Blade tilt cylinder
II I 20. Blade pitch cylinder
24 21. R.H. ripper tilt cylinder
SAD01458
Set pressure: 0.15 MPa II.5 kg/cm21
(10-83)
90-17
Operation
1. Blade lever at HOLD, ripper lever at HOLD
1 R F' ‘I
SBD01373
(1046)
90-19
2. Blade lever at RAISE (blade operating at high speed)
, , I
< < _
I I
Ii-l-d r-
SBD01374
(10-118)
90-21
3. Blade lever at RAISE (blade operating at low speed)
I r
c-7
- II-
i i -
(10-120)
90-23
4. Blade lever at LEFT TILT
r
1
r I
E3
\ ‘S PA1 I I
r
r
J
ttll r
.
< A -
-
<
WI-9VY
M
I
I I m
//, ,
////,,:,::::
11/1/,/,/,,,
/11,,,,,,,,,
SBDOl376
(10-122)
90-25
5. Ripper lever at TILT IN (ripper Lo valve, shuttle valve actuated)
I-
::::
11/1,,//,,
5::::
SBD01377
(10-124)
90-27
6. Ripper lever at TILT IN (ripper Hi valve actuated)
<
< -
r
I
44 b2
SBD01378
(10-126)
90-29
7. Ripper level at LOWER (ripper Lo valve, shuttle valve actuated)
t.TH3
1/,, ::
:::::::,::::
5::: I
SBD01379
(10-128)
90-3 1
8. Blade lever at HOLD, ripper lever at LOWER (ripper Hi valve actuated)
I r I I
r r
.a
I
I
II
1
f
k!d3
.I,: :: 5:::
:::::::,::::
SBD01464
(10-130)
90-33
9. Ripper lever at LOWER (cylinder at stroke end)
r r-
r
p.
C- ,CI 27 r
0'
SBD01467
(10432)
90-35
ACTUAL ELECTRIC WIRING DIAGRAM
SLDO1476
(10-144)
90-37
ACTUAL ELECTRIC WIRING DIAGRAM
1.Radiator water level sensor

2.R.H. front lamp
3.Engine water temperature sensor
4.R.H. working lamp
5.Blade pitch solenoid valve
6.Dual tilt solenoid valve
7.R.H. rear lamp
8.Backup alarm
9.Hydraulic oil temperature sensor
10. Transmission oil pressure sensor
Il. Torque converter speed sensor
12. L.H. rear lamp
13. Lockup solenoid valve
14. Torque converter oil temperature
sensor
15. L.H. working lamp
16. Engine speed sensor
17. Engine oil level sensor
18. APS nozzle
19. Engine oil pressure sensor
20. APS nozzle
21. Starting motor
22. Alternator
23. L.H. front lamp
24. Horn
25. Dual tilt switch
26. Blade pitch switch
27. Horn switch
28. Pin puller switch
29. Fuel level sensor
30. Transmission neutral
safety switch
31. Fuse box
32. Lockup controller
33. APS controller
34. Battery relay
35. Battery
36. Monitor panel
37. Starting switch
38. APS switch
39. Rear lamp switch
40. Front lamp switch
41. Lockup switch
42. Front lamp, working lamp
relay
43. Monitor alarm
44. Air conditioner relay
45. Magnet relay (for air
conditioner)
46. Lockup lamp
47. Caution lamp
(10-145)
90-39
ELECTRIC CIRCUIT DIAGRAM INSIDE CAB
0t or Right Wiper motor

Frot Wiper motor
Siaer lighter
Additional
I amp
I I I I
Earth
box
CN-
I6
Front wiper switch R. H. Wiper switch Rear wiper switch Front Rear
lamu switch lamp switch
i c
_ _
_ -
CN-I 9
CN-4 2
UTz
dd
f&-T?F CN-3
La
CN-2
CN-1
Cab room lamp Rear speaker Rear speaker Additional lamp

(L. H. ) (R. H. ) pickup
Rear wiper motor
SDD01403
(10-148)
90-45
CN-1
\
CN-2
CN-? \ d CN-4
CN-262
I CN-263
CN-423
111 CN-162
To monitbr
\’ \ \// , I CNI 153
CN-45 1
BI .D00135
(20-116)
90-47
0
CN-24 1
\
CN-22 1
(20-117)
90-49
0
BEVEL GEAR SHAFT, STEERING CLUTCH, BRAKE
(40-l 6)
90-5 1
a
Komatsu America international Company
440 North Fairwav Drive I 1
Vernon Hills, IL 66061-8112 U.S.A.
Attn: Technical Publications PROPOSAL FOR MANUAL REVlslON
Fax No. (847) 970-4186
FOR INTERNAL USE ONLY -- No. PMR
2 NAME OF COMPANY: LOCATION:
: PHONE NO:
:
S DEPARTMENT: DATE:
E
R NAME:
MANUAL NAME:
MANUAL NO:
MACHINE MODEL:
S/N IF APPLICABLE:
PAGE NO:
PROBLEM:
Attach photo or sketch.

If more space is needed, use another sheet.
1 FOR INTERNAL USE ONLY

CORRECTIVE ACTION:
PFMRl 081696

D375a 3

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SEBM008402

D375A-3 17001 and up

D375A-3 mounts the SA6D170-2 engine.

20 nSTING AND ADJUSTING . . . . . . . . . . . . . . . . . . . . . ..m........................ 20-I

30 DISASSEMBLY AND ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-I

40 MAINTENANCE STANDARD . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..m................ 40-I

0 Page to be newly added Add

0 Page to be replaced Replace

( 1 Page to be deleted Discard

Pages having no marks are not revised atthistime.

LIST OF REVISED PAGES

Revision Revision Revision Revision

oo- 1 IO-13 IO- 57 IO-102 IO-145

20- 23 @ 20-127 @ 20-407 @ 0 30-14 @ 0 30- 71

0 30-128 0 30-185 @ 0 30-242 0 30-299 @ 40-29

GENERAL PRECAUTIONS 6. Decide a place in the repair workshop to

2. When carrying out any operation, always PREPARATIONS FOR WORK

16. When removing components, be careful not

18. As a general rule, do not use gasoline to

STRUCTURE AND FUNCTION

TESTING AND ADJUSTING

DISASSEMBLY AND ASSEMBLY

HOW TO READ THE SHOP MANUAL

VOLUMES REVISED EDITION MARK

Electrical volume: Each issued as one

Oil, water must be added, and the ca-

cated by a hyphen (-1 and number after the

. If a part cannot be smoothly removed from

20 43.1 4.4 hanging angle. On the other hand, two

t The allowable load value is estimated to

STANDARD TIGHTENING TORQUE

STANDARD TIGHTENING TORQUES OF BOLTS AND NUTS

Thread diameter Width

6 10 13.2* 1.4 1.35f0.15

TIGHTENING TORQUE OF SPLIT FLANGE BOLTS

Thread diameter Width

TIGHTENING TORQUE FOR FLARED NUTS

Use these torques for flared part of nut.

Thread diameter Width across flats

18 24 49k 19.6 5f2

22 27 78.5+ 19.6 8+2

33 41 196.1 k49 2Ok5

42 55 294.2 zk49 3Ok5

ELECTRIC WIRE CODE

METHOD OF USING THE CONVERSION TABLE

2. Convert 550 mm into inches.

Millimeters to inches 1 mm = 0.03937 in

0 0.039 0.079 0.118 0.157 0.197; 0.236 0.276 0.315 0.354

0 0 0.039 0.079 0.118 0.157 0.197 0.236 0.276 0.315 0.354

0 0 2.20 4.41 6.61 8.82 11.02 13.23 15.43 17.64 19.84

Literto U.S. Gallon

0 0 0.264 0.528 0.793 1.057 1.321 1.585 1.849 2.113 2.378

Liter to U.K. Gallon

0 0 0.220 0.440 0.660 0.880 1.100 1.320 1.540 1.760 1.980

0 0 7.2 14.5 21.7 28.9 36.2 43.4 50.6 57.9 65.1

0 0 14.2 28.4 42.7 56.9 71.1 85.3 99.6 113.8 128.0

-40.4 -40 -40.0 -11.7 11 51.8 7.8 46 114.8 27.2 81 117.8

-28.3 -19 -2.2 -8.9 16 60.8 10.6 51 123.8 30.0 86 186.8

-25.6 -14 6.8 -6.1 21 69.8 13.3 56 132.8 32.8 91 195.8

-22.8 -9 15.8 -3.3 26 78.8 16.1 61 141.8 35.6 96 204.8

-20.0 -4 24.8 -0.6 31 87.8 18.9 66 150.8 40.6 105 221.0

-17.2 1 33.8 2.2 36 96.8 21.7 71 159.8 54.4 130 266.0

-14.4 6 42.8 5.0 41 105.8 24.4 76 168.8 68.3 155 311.0