VEBM460104 WA380-3 With-Diagrams 09-06 PDF
VEBM460104 WA380-3 With-Diagrams 09-06 PDF
VEBM460104 WA380-3 With-Diagrams 09-06 PDF
Shop Manual
WA380-3
Wheel Loader
Serial Number
WA380H20051 and up
© 2000
All Rights Reserved
Printed in Europe 03/2000
CONTENTS
No. of page
01 GENERAL ......................................................................... 01-1
00-2
SAFETY SAFETY NOTICE
SAFETY
SAFETY NOTICE
Proper service and repair is extremely important for safe machine operation. Some of the
described service and repair techniques require the use of tools specially designed by
Komatsu for the specific purpose.
To prevent injury to workers, the symbol is used to mark safety precautions in this
manual. The cautions accompanying these symbols must always be followed carefully. If any
dangerous situation arises or may possibly arise, first consider safety, and take the neces-
sary actions to deal with the situation.
GENERAL PRECAUTIONS
Mistakes in operation are extremely dangerous. Read the OPERATION AND MAINTENANCE MANUAL
carefully BEFORE operating the machine!
Always follow the safety rules valid in your country carefully!
1. Before carrying out any greasing or repairs, Always keep the work area clean and make
read all the precautions given on the decals sure that there is no dirt or oil on the floor.
which are fixed to the machine. Never smoke while working.
Smoke only in the areas provided for smoking.
2. When carrying out any operation, always wear
safety shoes and helmet. Do not wear loose
work clothes, or clothes with buttons missing.
PREPARATIONS FOR WORK
• Always wear safety glasses when hitting parts
with a hammer.
7. Before adding oil or making any repairs, park
• Always wear safety glasses when grinding
the machine on hard, level ground, and block
parts with a grinder, etc.
the wheels or tracks to prevent the machine
3. If welding repairs are needed, always have a from moving.
trained, experienced welder carry out the work.
8. Before starting work, lower blade, ripper, bucket
When carrying out welding work, always wear
or any other work equipment to the ground and
welding gloves, apron, glasses, cap and other
install the safety bar on the frame. If this is not
clothes suited for welding work.
possible, insert the safety pin or use blocks to
4. When carrying out any operation with two or prevent the work equipment from falling. In ad-
more workers, always agree on the operating dition, be sure to lock all the control levers and
procedure before starting. Always inform your hang warning signs on them.
fellow workers before starting any step of the
9. When disassembling or assembling, support the
operation. Before starting work, hang UNDER
machine with blocks, jacks or stands before
REPAIR signs on the controls in the operator's
starting work.
compartment.
10. Remove all mud and oil from the steps or other
5. Keep all tools in good condition and learn the
places used to get on and off the machine.
correct way to use them.
Always use the handrails, ladders or steps when
6. Decide a place in the repair workshop to keep getting on or off the machine. Never jump on or
tools and removed parts. Always keep the tools off the machine. If it is impossible to use the
and parts in their correct places. handrails, ladders or steps, use a stand to pro-
vide safe footing.
00-3
SAFETY SAFETY NOTICE
11. When measuring hydraulic pressure, check that 17. When removing components, be careful not to
the measuring tool is correctly assembled be- break or damage the wiring. Damaged wiring
fore taking any measurements. may cause electrical fires.
12. When removing the oil filler cap, drain plug or 18. When removing piping, stop the fuel or oil from
hydraulic pressure measuring plugs, loosen them spilling out. If any fuel or oil drips onto the floor,
slowly to prevent the oil from spurting out. wipe it up immediately. Fuel or oil on the floor
Before disconnecting or removing components can cause you to slip, or can even start fires.
of the oil, water or air circuits, first remove the
19. As a general rule, do not use gasoline to wash
pressure completely from the circuit.
parts. In particular, use only the minimum of
13. The water and oil in the circuits are hot when gasoline when washing electrical parts. Do not
the engine is stopped, so be careful not to get smoke!
burned.
20. Be sure to assemble all parts again in their
Wait for the oil and water to cool before carry-
original places.
ing out any work on the oil or water circuits.
Replace any damaged parts with new parts.
14. Before starting work, remove the leads from • When installing hoses and wires, be sure
the battery. Always remove the lead from the that they will not be damaged by contact with
negative (–) terminal first. other parts when the machine is being oper-
15. When raising heavy components, use a hoist or ated.
crane. 21. When installing high pressure hoses, make sure
Check that the wire rope, chains and hooks are that they are not twisted. Damaged tubes are
free from damage. dangerous, so be extremely careful when in-
Always use lifting equipment which has ample stalling tubes for high pressure circuits. Also,
capacity. check that connecting parts are correctly in-
Install the lifting equipment at the correct places. stalled.
Use a hoist or crane and operate slowly to
22. When aligning two holes, never insert your fin-
prevent the component from hitting any other
gers or hand. Be careful not to get your fingers
part. Do not work with any part still raised by
caught in a hole.
the hoist or crane.
16. When removing covers which are under internal 23. When assembling or installing parts, always use
pressure or under pressure from a spring, al- the specified tightening torques. When installing
ways leave two bolts in position on opposite protective parts such as guards, or parts which
sides. Slowly release the pressure, then slowly vibrate violently or rotate at high speed, be
loosen the bolts to remove. particularly careful to check that they are in-
stalled correctly.
00-4
F O R EW OR D GENERAL
F O R EW OR D
GENERAL
This shop manual has been prepared as an aid to improve the quality of repairs by giving the service personnel
an accurate understanding of the product and by showing them 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.
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
F O R EW OR D HOW TO READ THE SHOP MANUAL
12 - 5
Unit number (1. Engine)
Item number (2. Testing and
Adjusting)
Consecutive page number for
each item.
00-6
F O R EW OR D HOISTING INSTRUCTIONS
HOISTING INSTRUCTIONS
HOISTING
Slinging near the edge of the hook may cause
Heavy parts (25 kg or more) must be lifted the rope to slip off the hook during hoisting,
with a hoist, etc. In the DISASSEMBLY and a serious accident can result. Hooks
AND ASSEMBLY section, every part have maximum strength at the middle portion.
weighing 25 kg or more is indicated clearly
with the symbol
2000
1900
1700
2000
1400
« The allowable load value is estimated to be
1000
one-sixth or one-seventh of the breaking
1000
strength of the rope used. 500
00-7
00-8
01 GENERAL
Up to SN WA380H20500:
Dimensions and weights ................................. 01- 3
Dimensions and weights High-Lift .................. 01- 4
Specifications ................................................. 01- 5
Weight table ................................................... 01- 8
List of lubricant and water ............................. 01- 9
SN WA380H20501 and up:
Dimensions and weights ................................. 01-10
Specifications ................................................. 01-11
Weight table ...................................................01-14
List of lubricant and water ............................. 01-15
Outlines of service .......................................... 01-16
General view of controls and gauges ............01-20
Torque list .................................................... 01-22
01-1
Blank for technical reason
01-2
GENERAL DIMENSIONS, WEIGHTS AND OPERATING DATA
Buckets
* This dimensions refer Special bucket sizes: The 3,0/3,3 m3 standard buckets
to machines with 23.5R25SPT7LD. 2,8 m3- HD bucket shown in the table can be supplied
4,5 m3 - light material bucket with bold on cutting edge.
* Machines without extra counterweight
01-3
GENERAL DIMENSIONS, WEIGHTS AND OPERATING DATA
WA380-3H High-Lift
Up to SN WA380H20500
e Digging depth mm 26 26
U:\DTP\BA380gb\ABMES.TBL
U:\DTP\BA380gb\Schaufel.TBL
01-4
GENERAL SPECIFICATIONS
SPECIFICATIONS Up to SN WA380H20500
Gradeability (deg) 25
01-5
GENERAL SPECIFICATIONS
Alternator 24 V 50 A
Battery 12 V 134 Ah x 2
Transmission
hydraulically actuated, modulation type
Tire 23.5-25-16PR
01-6
GENERAL SPECIFICATIONS
01-7
GENERAL WEIGHT TABLE
This weight table is a guide for use when transporting or handling components.
Unit: kg
H20001 H20001
Serial No. Serial No.
- H20500 - H20500
01-8
GENERAL LIST OF LUBRICANT AND WATER
CCMC D4
42
Transmission Engine oil EO EO 10 or, if not available, - SAE 10W
(40**)
API CD
Hydraulic oil HYD HYD 0530 HVLP, HVLP D -35° to 50° C ISO VG 46 *)
CCMC D4
or engine oil EO EO 10 or, if not available, -35° to 40° C SAE 10W
Hydraulic system, 190
API CD
steering, brakes (138 **)
HEES
or hydraulic oil ISO VG 46
BIO-E-HYD 0530 (to VDMA fluid -35° to 50° C
BIO-E-HYD
technology)
U:\DTP\BA380gb\FÜLL-BI.TBL 02.97
01-9
GENERAL DIMENSIONS, WEIGHTS AND OPERATING DATA
d
a
c
H*
b
f F*
e W A_ACT
*
E
D* B
C* A
Buckets
* This dimensions refer Special bucket sizes: The standard buckets shown in the
to machines with 23.5R25SPT7LD. 3,0 m3- HD bucket table can be supplied with bold on
4,5 m3 - light material bucket cutting edge.
** Machines without extra counterweight
01-10
GENERAL SPECIFICATIONS
H20501 and up
Serial No.
Gradeability (deg) 25
01-11
GENERAL SPECIFICATIONS
Alternator 24 V 50 A
Battery 12 V 143 Ah x 2
Transmission
hydraulically actuated, modulation type
Tire 23.5-25-16PR
01-12
GENERAL SPECIFICATIONS
01-13
GENERAL WEIGHT TABLE
This weight table is a guide for use when transporting or handling components.
Unit: kg
01-14
GENERAL LIST OF LUBRICANT AND WATER
CCMC D4
42
Transmission Engine oil EO EO 10 or, if not available, - SAE 10W
(40**)
API CD
Hydraulic oil HYD HYD 0530 HVLP, HVLP D -35° to 50° C ISO VG 46 *)
CCMC D4
or engine oil EO EO 10 or, if not available, -35° to 40° C SAE 10W
Hydraulic system, 190
API CD
steering, brakes (138 **)
HEES
or hydraulic oil ISO VG 46
BIO-E-HYD 0530 (to VDMA fluid -35° to 50° C
BIO-E-HYD
technology)
Long-life coolant with
anti-frost and rust Anti-frost and rust
Cooling system SP-C 53
prevention prevention
SP-C
CFPP class B up to 0°C
CFPP class D up to -10°C
Fuel tank Diesel fuel DIN-EN 590 287
CFPP class E up to -15°C
CFPP class F up to -20°C
U:\DTP\BA380gb\380gb_mc\FÜLL-BI.TBL 05.97
01-15
GENERAL LIST OF LUBRICANT AND WATER
**)Axle oils (AXO) - The selection of the oils depends on the equipment of the axle:
For reasons of harmonization, engine oil in accordance API CD/SAE 30 may be used in the standard
axle instead of axle oil. Any noises from the brakes do not affect the life.
The use of not recommended axle oils may cause unnormal noises from the differential.
01-16
GENERAL OUTLINES OF SERVICE
Oil
• Oil is used in the engine and work equipment under extremely severe conditions (high temperature,
high pressure), and it deteriorates with use.
Always use oil that matches the grade and temperature given in the Operation and Maintenance Manu-
al. Even if the oil is not dirty, always replace the oil after the specified interval.
• Oil can be compared to blood in the human body, so always be careful when handling it to prevent any
impurities (water, metal particles, dirt, etc.) from penetrating.
The majority of problems with machines are caused by the entry of such impurities.
Take particular care not to let any impurities penetrate when storing or adding oil.
• If the oil in the work equipment is not clear, there is probably water or air getting into the circuit. In such
cases, please contact your Komatsu distributor.
• When changing the oil, always replace the related filters at the same time.
• We recommend to have an analysis of the oil made periodically to check the condition of the machine.
Those who wish to use this service, are requested to their Komatsu distributor.
FUEL
• The fuel pump is a precision instrument; if fuel containing water or dirt is used, it cannot work properly.
• Be extremely careful not to let impurities penetrate when storing or adding fuel.
• Always use the fuel specified in the Operation and Maintenance Manual.
Fuel may congeal depending on the temperature (particularly at low temperatures below -15 °C), so
change to a fue matching this temperature.
• To prevent the moisture in the air from condensing and forming water inside the fuel tank, always fill the
fuel tank after completing the day's work.
• Before starting the engine, or when 10 minutes have passed after adding fuel, drain the sediment and
water from the fuel tank.
• If the engine runs out of fuel, or if the filters have been replaced, it is necessary to bleed the air from
the circuit.
• If the fuel sulphur content is between 0.5 and 1.0 %, the oil change interval must be 1/2 normal.
If the fuel sulphur content is more 1.0 %, the oil change interval must be 1/4 normal.
01-17
GENERAL OUTLINES OF SERVICE
COOLANT
• River water contains large amounts of calcium and other impurities, so if it is used, scale will stick to
the engine and radiator causing a defective heat exchange and overheating.
• When using anti-freeze, always observe the precautions given in the Operation and Maintenance
Manual.
• Komatsu machines are supplied with Komatsu original anti-freeze in the coolant when the machine is
shipped.
This anti-freeze prevents corrosion in the cooling system.
The anti-freeze can be used continuously for two years or 4000 hours. Therefore, it can be used as it is
even in hot areas.
• Anti- freeze is flammable, so be extremely careful not to expose it to open flame or fire.
• If the engine overheats, wait for the engine to cool before adding coolant.
• If the coolant level is low, it will cause overheating and corrosion due to the air in the coolant.
GREASE
• Grease is used to prevent twisting and noise at the joints.
• The nipples not included in the maintenance section are nipples for overhaul, so they need not be
lubricated.
If any part becomes stiff after being used for a long time, add grease.
• Always wipe off all of the old grease that is pushed out when greasing. Be particularly careful to wipe
off the old grease in places where sand or dirt in the grease would cause the rotating parts to wear.
• When keeping barrels for a long period, lay down the barrel on its side so that the filler port is at the
side (to prevent moisture from being sucked in).
If barrels have to be stored outside, cover them with a waterproof sheet or take other measures to
protect them.
• To prevent any change in quality during long term storage, be sure to use in the order of 'first in - first
out' (use the oldest oil or fuel first).
01-18
GENERAL OUTLINES OF SERVICE
• The use of biodegradable hydraulic oils and lubricants - on the basis of synthetic esters - for Komatsu
machines is permitted. For information on the products cleared for use and best suited for your application
contact our authorized service workshops.
• Maintenance work at the electric system includes: (1) check fan belt tension, (2) check damage or
wear to the fan belt and (3) check battery fluid level.
• Never install any electric components other than those specified by Komatsu.
• Be careful to keep the electric system free of water when washing the machine or when it is raining.
• When working on the seashore, carefully clean the electric system to prevent corrosion.
• The optional power source must never be connected to the fuse, starter switch, or battery relay.
01-19
GENERAL GENERAL VIEW OF CONTROLS AND GAUGES
35
35 Pilot lamp for rear working lamp 42
36 Transmission cut-off selector pilot lamp MANUAL 36
37 Parking brake pilot lamp 46
41
38 Central warning lamp
39 Speedometer
40 Transmission shift indicator
41 ALS Electronic 40 39 38 37 470_264j
42 Auto-greasing switch
43 Hold signal
MAIN MONITOR
44 Emergency steering operating monitor
45 Work mode selector switch / SN: WA380H20987 and up
46 Autoshift transmission pilot switch /
SN: WA380H20951 and up
50 Fuel gauge
51 Engine cooling water temperature gauge
52 Torque converter oil temperature gauge
57 Service meter
58 Air cleaner clogging warning pilot lamp
59 Charge monitor
60 Brake oil pressure warning pilot lamp
61 Engine oil pressure warning lamp
62 Engine oil level warning pilot lamp
63 Engine water level warning lamp MAINTENANCE MONITOR
01-20
GENERAL GENERAL VIEW OF CONTROLS AND GAUGES
MAINTENANCE MONITOR
01-21
GENERAL TORQUE LIST
TORQUE LIST
Unless otherwise specified, tighten the metric bolts and nuts
to the torque shown in the table. The tightening torque is
determined by the width across flats of the nut and bolt.
If it is necessary to replace any nut or bolt, always use a
Komatsu genuine part of the same size as the part that
was replaced.
NOTE
When tightening panels or other parts having tightening fixtures made of plastic, be careful not to use
excessive tightening torque: doing so will damage the plastic parts.
01-22
10 STRUCTURE AND FUNCTION
Power train ....................................................... 10-3 Work equipment hydraulic system diagrams . 10-202
Power train system ........................................... 10-4 Work equipment lever linkage ....................... 10-212
Torque converter, transmission piping ...............10-6 Hydraulic tank ............................................... 10-213
Transmission hydraulic circuit diagram ............. 10-7 Oil filter bypass valve ..................................... 10-214
Torque converter ...............................................10-9 PPC valve ..................................................... 10-215
Torque converter oil filter ................................. 10-11 Operation of PPC valve ................................. 10-220
Transmission ................................................... 10-21 PPC relief valve ............................................. 10-223
Transmission control valve ............................... 10-41 Accumulator (for PPC valve) ......................... 10-224
Upper valve ..................................................... 10-42 Main control valve (up to H20383) ................. 10-225
Transmission solenoid valve ............................ 10-44 Relief valve (up to H20383) ........................... 10-229
Pilot reducing valve ......................................... 10-45 Safety valve with suction (up to H20383) ...... 10-230
Main relief valve .............................................. 10-46 Suction valve (up to H20383) ........................ 10-231
Torque converter outlet port valve .................... 10-47 Main control valve (from H20384 up to H20836) . 10-232
Priority valve ................................................... 10-48 Safety valve with suction (H20384 and up) .... 10-234
Directional selector valve ................................. 10-49 Anticavitation valve (H20384 and up) ............ 10-235
H-L selector valve and range selector valve ..... 10-50 Safety valve (H20384 and up) ....................... 10-235
Emergency manual spool ................................ 10-52 Main control valve (H20837 and up) .............. 10-236
Electronic control modulation valve (ECMV) .... 10-53 Operation of cut-off valve (up to H20383) ..... 10-238
Pilot oil filter ....................................................10-56 Work equipment valve operation ................... 10-240
Accumulator valve ........................................... 10-57 Hydraulic safety system (up to H20836) ....... 10-246
Flow control valve ............................................ 10-59 Hydr. safety system location (up to H20836) 10-247
Check valve..................................................... 10-60 Hydraulic safety valve (up to H20836) .......... 10-248
Drive shaft ...................................................... 10-81 Work equipment linkage ............................... 10-261
Axle ................................................................. 10-82 Bucket .......................................................... 10-263
Differential ...................................................... 10-84 Bucket positioner and boom kick-out ............ 10-264
Final drive ....................................................... 10-91 Wiring diagrams (up to H20500) .................. 10-273
Axle mount, center hinge pin ........................... 10-92 Wiring diagrams (from H20501 up to 20836) 10-281
Steering piping .............................................. 10-111 Wiring diagrams (from H20837 up to 20986) 10-282
Steering control, orbit roll .............................. 10-112 Wiring diagrams (H20987 and up) ................ 10-283
Orbit roll valve ................................................ 10-113 Machine monitor system ............................... 10-291
Steering valve................................................ 10-114 Transmission auto-shift control system .......... 10-298
Overload relief vavle ...................................... 10-115 Transmission controller ................................. 10-303
Steering relief valve ....................................... 10-117 ALS ............................................................... 10-321
Operation of demand valve ............................ 10-118 Sensors ........................................................ 10-341
Brake piping ................................................. 10-151 Engine starting circuit ................................... 10-346
Park brake and foot brake circuits ................ 10-152 Engine stop circuit ........................................ 10-347
Brake valve ................................................... 10-153 Preheating circuit .......................................... 10-348
Accumulator charge valve ............................. 10-158 Electric transmission ..................................... 10-361
Accumulator for brake system ...................... 10-162 Combination switch ....................................... 10-362
Brake circuit diagram.................................... 10-164 Kick-down, hold switch .................................. 10-364
Brake ............................................................ 10-176 Kick-down electric circuit diagram ................ 10-365
Parking brake control .................................... 10-178 Transmission cut-off function ........................ 10-370
Parking brake ............................................... 10-179 Parking brake: Transmission neutralizer ....... 10-371
Parking brake valve ....................................... 10-180 Air conditioner .............................................. 10-451
Hydraulic piping ............................................ 10-201
10-1
2
Blank for technical reason
10-2
STRUCTURE AND FUNCTION POWER TRAIN
POWER TRAIN
Outline
• The motive force from engine (3) passes through • The motive force from the output shaft of the
the engine flywheel and is transmitted to torque transmission passes through center drive shaft
converter (2), which is connected to the input (6), front drive shaft (5) and rear drive shaft (7),
shaft of transmission (1). and is then transmitted to front axle (4) and rear
• The transmission has six hydraulically actuated axle (8) to drive the wheels.
clutches, and these provide four speed ranges
for both FORWARD and REVERSE. The trans-
mission speed ranges can be selected manu-
ally.
10-3
STRUCTURE AND FUNCTION POWER TRAIN SYSTEM
10-4
STRUCTURE AND FUNCTION POWER TRAIN SYSTEM
10-5
STRUCTURE AND FUNCTION TORQUE CONVERTER, TRANSMISSION PIPING
10-6
STRUCTURE AND FUNCTION TRANSMISSION HYDRAULIC CIRCUIT DIAGRAM
10-7
STRUCTURE AND FUNCTION TRANSMISSION HYDRAULIC CIRCUIT DIAGRAM
10-8
STRUCTURE AND FUNCTION TORQUE CONVERTER
TORQUE CONVERTER
10-9
STRUCTURE AND FUNCTION TORQUE CONVERTER
Flow of oil
• The oil supplied from the torque converter charg-
ing pump enters inlet port A, passes through
the oil passage of stator shaft (8), and flows to
pump (5).
The oil is given centrifugal force by pump (5),
enters turbine (2), and transmits the energy of
the oil to the turbine. Turbine (2) is fixed to
transmission input shaft (11), so the motive force
is transmitted to the transmission input shaft.
The oil from turbine (2) is sent to stator (3), and
enters the pump again. However, part of the oil
is sent from the stator through outlet port B to
the cooler.
10-10
STRUCTURE AND FUNCTION TORQUE CONVERTER OIL FILTER
Specifications
Filter mesh size: 10 microns
Filtering area: 8900 cm2
Relief pressure: 0.34 MPa (3.5 bar)
Operation
• The oil from the torque converter charging pump
enters filter inlet port A. It is filtered from the
outside of element (2) to the inside, and flows
to outlet port B.
10-11
10-12
STRUCTURE AND FUNCTION TRANSMISSION
TRANSMISSION
10-21
STRUCTURE AND FUNCTION TRANSMISSION
Outline
• The transmission is installed behind the torque • The transmission uses the combination of the
converter. The motive force from the torque con- forward or reverse clutches and the four speed
verter passes through the transmission input clutches to shift to F1 – 4 or R1 – 4, and trans-
shaft and enters the transmission. mits the motive force from the input shaft to the
output shaft.
10-22
STRUCTURE AND FUNCTION TRANSMISSION
10-23
STRUCTURE AND FUNCTION TRANSMISSION
10-24
STRUCTURE AND FUNCTION TRANSMISSION
Operation of clutch
When operated
• The oil sent from the transmission valve passes
through the oil passage inside shaft (1), and
goes to the rear face of piston (6) to actuate the
piston.
• When piston (6) is actuated, separator plate (2)
is pressed against clutch disc (3) and forms
shaft (1) and clutch gear (4) into one unit to
transmit the motive force.
• Oil is drained from oil drain hole (5) at this time,
but this does not affect clutch operation since
less oil is drained than supplied.
10-25
STRUCTURE AND FUNCTION TRANSMISSION
FORWARD 1ST
Operation
• In forward 1st, forward clutch (8) and 1st clutch • Since the 1st clutch is engaged, the motive
(20) are engaged. The motive force from the force transmitted to 1st and 3rd cylinder gear
torque converter transmitted to input shaft (9) is (32) is transmitted from 1st gear (25) via the 1st
transmitted to output shaft (14). clutch to 2nd and 4th cylinder gear (33), then
• The clutch discs of forward clutch (8) and 1st transmitted to output shaft (14) via 2nd and 4th
clutch (20) are held by the hydraulic pressure shaft (17), idler gear (31) and output gear (34).
applied to the piston.
• The motive force from the torque converter is
transmitted from input shaft (9) via forward clutch
(8) to forward gear (23), then transmitted to 1st
and 3rd cylinder gear (32).
10-26
STRUCTURE AND FUNKTION TRANSMISSION
FORWARD 2ND
Operation
• In forward 2nd, forward clutch (8) and 2nd clutch transmitted to the 2nd gear is transmitted
(18) are engaged. The motive force from the from 2nd and 4th cylinder gear (33) via the
torque converter transmitted to input shaft (9) is 2nd clutch to output shaft (14) via 4th shaft
transmitted to output shaft (14). (17), idler gear (31) and output gear (34).
• The clutch discs of forward clutch (8) and 2nd
clutch (18) are held by the hydraulic pressure
applied to the clutch piston.
• The motive force from the torque converter is
transmitted from input shaft (9) via forward clutch
(8) to forward gear (23), then transmitted via
1st and 3rd cylinder gear (32), 1st and 3rd shaft
(19), and idler gear (29) to 2nd gear (26). Since
the 2nd clutch (18) is engaged, the motive force
10-27
STRUCTURE AND FUNCTION TRANSMISSION
FORWARD 3RD
Operation
• In forward 3rd, forward clutch (8) and 3rd clutch • Since 3rd clutch (11) is engaged, the motive
(11) are engaged. The motive force from the force transmitted to 1st and 3rd cylinder gear
torque converter transmitted to input shaft (9) is (32) is transmitted from 3rd gear (27) via the
transmitted to output shaft (14). 3rd clutch, then to output shaft (14) via 2nd and
• The clutch discs of forward clutch (8) and 3rd 4th shaft (17), idler gear (31) and output gear
clutch (11) are held by the hydraulic pressure (34).
applied to the clutch piston.
• The motive force from the torque converter is
transmitted from input shaft (9) via forward clutch
(8) to forward gear (23), then to 1st and 3rd
cylinder gear (32).
10-28
STRUCTURE AND FUNCTION TRANSMISSION
FORWARD 4TH
Operation
• In forward 4th, forward clutch (8) and 4th clutch • Since the 4th clutch is engaged, the motive
(12) are engaged. The motive force from the force transmitted to the 4th gear is transmitted
torque converter transmitted to input shaft (9) is from 2nd and 4th cylinder gear (33) via the 4th
transmitted to output shaft (14). clutch, then to output shaft (14) via 2nd and 4th
• The clutch discs of forward clutch (8) and 4th shaft (17), idler gear (31) and output gear (34).
clutch (12) are held by the hydraulic pressure
applied to the clutch piston.
• The motive force from the torque converter is
transmitted from input shaft (9) via forward clutch
(8) to forward gear (23), then transmitted via
1st and 3rd cylinder gear (32) to 4th gear (28).
10-29
TRANSMISSION
REVERSE 1ST
Operation
• In reverse 1st, reverse clutch (7) and 1st clutch cylinder gear (32) via idler gear (29) and 1st
(20) are engaged. The motive force from the and 3rd shaft (19). Since the 1st clutch is en-
torque converter transmitted to input shaft (9) is gaged, the motive force transmitted to 1st and
transmitted to output shaft (14). 3rd cylinder gear (32) is transmitted from 1st
• The clutch discs of reverse clutch (7) and 1st gear (25) via the 1st clutch to 2nd and 4th
clutch (20) are held by the hydraulic pressure cylinder gear (33), then transmitted to output
applied to the piston. shaft (14) via the 2nd and 4th shaft, idler gear
• The motive force from the torque converter is (31) and output gear (34).
transmitted from input shaft (9) via reverse clutch
(7) to reverse gear (24). The direction of rota-
tion is reversed by idler gear (21), and the mo-
tive force is then transmitted to 1st and 3rd
10-30
STRUCTURE AND FUNCTION TRANSMISSION CONTROL
1. Upper valve b. Clutch oil pressure measure- f. Measurement port for torque
2. Lower valve ment port converter outlet port oil pres-
3. Solenoid valve c. Measurement port for torque sure
4. Electronic modulation valve converter inlet port oil pressure g. To oil cooler
5. Emergency manual spool d. Priority pressure measurement h. Parking brake oil pressure
a. Main oil pressure measure- port measurement port
ment port e. Pilot pressure measurement i. From pump
port
Outline
• The oil from the pump passes through the flow • The transmission controller senses the travel
valve and torque converter oil filter, enters the speed and the engine speed when the machine
transmission, and is divided into the pilot circuit is traveling. It actuates the proportional solenoid
and clutch actuation circuit. The priority valve valve according to the command current from
adjusts the delivery pressure of the pump and the transmission controller to control the oil flow
ensures the pilot pressure and oil pressure used and oil pressure. This allows the clutch to en-
to release the parking brake. gage smoothly and reduces the shock when
• The pressure of the oil flowing to the clutch cir- shifting gear.
cuit is regulated by the electronic modulation In addition, when the machine is traveling, the
valve. The transmission is automatically shifted clutch pressure is kept constant.
to the optimum speed range, and the appropri- The pressure of the oil flowing to the pilot valve
ate clutch is actuated. is regulated by the pilot reducing valve, and ac-
In addition, the oil relieved by the main relief tuates the directional and range spools as the
valve is supplied to the torque converter. solenoid valves are switched ON or OFF.
• When the directional and range spools are
switched, the oil, whose pressure regulated by
the modulation valve, is supplied to the selected
clutch to provide the necessary speed range.
10-41
STRUCTURE AND FUNCTION TRANSMISSION CONTROL
UPPER VALVE
10-42
STRUCTURE AND FUNCTION TRANSMISSION CONTROL
LOWER VALVE
10-43
STRUCTURE AND FUNCTION TRANSMISSION CONTROL
Function
• When the gear shift lever is operated to move
in forward or reverse, electric signals are sent
to four solenoid valves mounted on the trans-
mission valve, activating the FORWARD/RE-
VERSE, H-L or range spool, according to the
combination of solenoid valves which are opened
and closed.
Operation
1. Solenoid valve OFF
The oil from pilot reducing valve (1) flows to
ports a and b of H-L selector spool (2) and
range selector spool (3). The oil at a and b is
blocked by solenoid valves (4) and (5), so se-
lector spools (2) and (3) are moved to the right
in the direction of arrow.
As a result, the oil from the pump flows to the
2nd clutch.
2. Solenoid valve ON
When the speed lever is operated, the drain
ports of solenoid valves (4) and (5) open. The
oil at ports a and b of selector spools (2) and
(3) flows from ports c and d to the drain circuit.
Therefore, the pressure in the circuits at ports a
and b drops, and the spools are moved to the
left in the direction of the arrow by return springs
(6) and (7).
As a result, the oil at port e flows to the 4th
clutch and switches from 2nd to 4th.
F-1 ¡ ¡
F-2 ¡
F-3 ¡ ¡
F-4 ¡ ¡ ¡
N
R-1 ¡ ¡
R-2 ¡
R-3 ¡ ¡
R-4 ¡ ¡ ¡
10-44
STRUCTURE AND FUNCTION TRANSMISSION CONTROL
Function
• The pilot reducing valve controls the pressure
used to actuate the directional selector spool,
H-L selector spool, range selector spool, and
parking brake spool.
Operation
• The oil from the pump enters port a, passes
through port b of pilot reducing spool (1), enters
spools (2) and (3) in the lower valve, and fills
the pilot circuit.
The oil at port b passes through the orifice and
flows to port c.
10-45
STRUCTURE AND FUNCTION TRANSMISSION CONTROL
Function
• The main relief valve regulates the pressure of
the oil flowing to the clutch circuit and distrib-
utes the oil flow between the clutch circuit and
the torque converter.
Operation
1. The oil from the pump passes through the pri-
ority valve, then through ports A and B of until
the main relief valve (1) specified pressure is
reached, and flows to the modulation valve.
10-46
STRUCTURE AND FUNCTION TRANSMISSION CONTROL
Function
• The torque converter outlet port valve is installed
in the outlet line of the torque converter and
adjusts the maximum pressure of the torque
converter.
Operation
• The oil at port a passes through the orifice in
spool (1) and flows to port c.
10-47
STRUCTURE AND FUNCTION TRANSMISSION CONTROL
PRIORITY VALVE
Function
• The priority valve regulates the pump's discharge
pressure and provides the pilot oil pressure and
parking brake release oil pressure.
• If the pressure in the circuit reaches a level
above the measured oil pressure, the priority
valve acts as a relief valve, releasing the pres-
sure to protect the hydraulic circuitry.
Operation
1. The oil from the pump enters port a and sepa-
rates into the oil flowing to parking brake valve
(1), priority valve (2) and the pilot circuit.
10-48
STRUCTURE AND FUNCTION TRANSMISSION CONTROL
Operation
1. When at neutral
• Solenoid valves (4) and (5) are OFF and the
drain port is closed. The oil from the pilot circuit
passes through the oil hole in the emergency
manual spool and fills ports a and b of the
directional spool.
• In this condition, P1 + spring force (1) = P2 +
spring force (2), so the balance is maintained.
Therefore, the oil at port c does not go to the
FORWARD or REVERSE clutch.
2. When at FORWARD
• When the directional lever is placed at the FOR-
WARD position, solenoid valve (4) is switched
ON and drain port d opens. The oil which is
filling port a is drained, so P1 + spring force (1)
< P2 + spring force (2). When this happens, the
directional spool moves to the left, and the oil at
port c flows to port e and is supplied to the
FORWARD clutch.
10-49
STRUCTURE AND FUNCTION TRANSMISSION CONTROL
Operation
1. 2nd speed
• When solenoid valves (1) and (2) are OFF, the
drain port is closed. The oil P1 from the pilot
circuit overcomes the force of the H-L selector
spool (4) and range selector spool (5) springs
(3) and moves spools (4) and (5) to the left.
The oil in the clutch circuit passes from H-L
selector spool (4) port a through range selector
spool (5) port b and is supplied to the 2nd clutch.
10-50
STRUCTURE AND FUNCTION TRANSMISSION CONTROL
10-51
STRUCTURE AND FUNCTION TRANSMISSION CONTROL
Function
• Should the electric system malfunction and the
forward/reverse solenoid valves cannot be ac-
tuated, the emergency manual spool actuates
the forward and reverse clutches manually.
Operation
1. When the emergency manual spool is at neu-
tral (during normal operation)
• The oil from the pilot valve passes through
emergency manual spool (1), enters the lower
valve directional spool (2) ports "a" and "b" and
is sealed by forward solenoid valve (4) and re-
verse solenoid valve (3).
10-52
STRUCTURE AND FUNCTION TRANSMISSION CONTROL
Structure of ECMV
• The ECMV (Electronic Control Modulation Valve)
consists of a proportional solenoid valve and the
ECMV spool.
Operation of ECMV
The ECMV is controlled by the command current
sent from the transmission controller to the propor-
tional solenoid. The relationship between the clutch
pressure and the command current for the propor-
tional solenoid in the ECMV is as shown in the
diagram on the right.
10-53
STRUCTURE AND FUNCTION TRANSMISSION CONTROL
10-54
STRUCTURE AND FUNCTION TRANSMISSION CONTROL
4. Adjusting pressure
When the electric current flows to proportional
solenoid (1), a propulsion force proportional to
the current is generated. This propulsion force
of shaft (2) of solenoid (1) is adjusted by the oil
pressure at the clutch port applied to spool (3)
so that it is in balance with the reaction force.
In other words, the clutch pressure is controlled
by controlling the command current sent to so-
lenoid (1).
Method of engaging
(i) Disconnect all connectors to the transmission
control valve.
(ii) Remove the manual selector lock plate, then
push in or pull out the spool.
FORWARD: Pull out
REVERSE: Push in
(iii) Push in the adjustment screw of the proportional
solenoid valve to the end.
Speed range when engaged: 2nd
10-55
STRUCTURE AND FUNCTION TRANSMISSION CONTROL
A. Inlet port
B. Outlet port
Outline
• The pilot oil filter is mounted on the transmission
lower valve, and filters dirt from the oil flowing to
the pilot circuit.
10-56
STRUCTURE AND FUNCTION TRANSMISSION CONTROL
ACCUMULATOR VALVE
10-57
STRUCTURE AND FUNCTION TRANSMISSION CONTROL
Operation
1. Shifting down when digging (kick-down F2 à
F1)
When the transmission is in F2, oil pressure is
stored in the 2nd clutch accumulator.
When the kick-down is operated, the F1 clutch
is engaged, but the oil pressure in the accumu-
lator is maintained for the 2nd clutch until the
torque is transmitted to the 1st clutch. In this
way, it is possible to shift gear smoothly without
losing the torque.
10-58
STRUCTURE AND FUNCTION TRANSMISSION CONTROL
Outline
• The oil from the pump is distributed to the clutch
lubricating circuit with the transmission valve
circuit.
• When the engine speed is low and the pump's
oil discharge is low, the oil is sent with priority to
the transmission valve circuit, increasing the
clutch oil pressure response.
Operation
• The oil from the pump passes from port b
through orifice d and enters the transmission
valve from port a.
• When the oil from the pump reaches a level
above the specified oil pressure, spool (1) moves
to the right, and the oil flows from port c to the
clutch lubricating circuit.
10-59
STRUCTURE AND FUNCTION TRANSMISSION CONTROL
CHECK VALVE
Outline
• The check valve is mounted on the fitting sur-
face of the transmission valve (lower valve) and
transmission case.
• A check valve is provided in the forward/reverse
valve's drain circuit, stabilizing shifting perform-
ance when shifting between forward and re-
verse.
1. Directional spool
2. Check valve
10-60
STRUCTURE AND FUNCTION DRIVE SHAFT
DRIVE SHAFT
Outline
• The motive force from the engine passes • The drive shaft has the following purpose in
through the torque converter and the transmis- addition to simply transmitting the power.
sion. Some of it is transmitted from rear drive The drive shaft has a universal joint and sliding
shaft (4) to the rear axle, while the rest goes joint to enable it to respond to changes in the
from center drive shaft (3) through flange bear- angle and length. This enables the drive shaft
ing (2) and front drive shaft (1) to the front axle. to transmit the motive force when the machine
is articulated and to protect the components
from damage from shock when the machine is
being operated or shock from the road surface
when the machine is traveling.
10-81
STRUCTURE AND FUNCTION AXLE
AXLE
FRONT AXLE
10-82
STRUCTURE AND FUNCTION AXLE
REAR AXLE
10-83
STRUCTURE AND FUNCTION DIFFERENTIAL
DIFFERENTIAL (TPD)
FRONT DIFFERENTIAL
10-84
STRUCTURE AND FUNCTION DIFFERENTIAL
REAR DIFFERENTIAL
10-85
STRUCTURE AND FUNCTION DIFFERENTIAL
Outline
• The motive force from the engine is transmitted
to the front and rear axles via the torque con-
verter, the transmission and the propeller shaft.
• In the axle, the motive force is transmitted from
pinion gear (1) to bevel gear (5), shifted 90°
and reduced, and transmitted to sun gear shaft
(2) via differential (4).
• The motive force of the sun gear is further re-
duced by planetary gear-type final drive, and
transmitted to the axle shaft and wheel.
When turning
• When turning, the rotating speed of the left and
right wheels is different, so pinion gear (4) and
side gear (3) in the differential assembly rotate
according to the difference between the rotating
speed of the left and right wheels. The motive
force of carrier (6) is then transmitted to the sun
gear shafts (2).
10-86
STRUCTURE AND FUNCTION DIFFERENTIAL
Function
• Because of the nature of their work, 4-wheel-
drive loaders have to work in places where the
road surface is bad. In such places, if the tires
slip, the ability to work as a loader is reduced,
and also the life of the tire is reduced. The
torque proportioning differential is installed to
overcome this problem.
• In structure it resembles the differential of an
automobile, but differential pinion gear (3) has
an odd number of teeth. Because of the differ-
ence in the resistance from the road surface,
the position of meshing of pinion gear (3) and
side gear (4) changes, and this changes the
Torque proportioning differential
traction of the left and right tires.
Operation
When traveling straight (equal resistance from road
surface to left and right tires)
• If the resistance from the road surface to the
left and right wheels is the same, the distance
between pinion gear (2) and meshing point “a”
of left side gear (1) is the same as the distance
between pinion gear (2) and meshing point “b”
of right side gear (3).
• Therefore the left side traction TL and the right
side traction TR are balanced.
10-87
STRUCTURE AND FUNCTION DIFFERENTIAL
Function
Operation
• The locking effect depends on the internal friction of
the differential. It is produced by two multi-disc
brakes, which are arranged symmetrically in the
differential cage. With a conventional differential
one wheel can be stopped or slowed down without
any difficulty when the vehicle is jacked up, the
engine running and a gear engaged. The other
wheel will then revolve correspondingly faster. With
the selflocking differential this process is rendered
more difficult due to the multi-disc brakes, in fact it
will become increasingly more difficult with increas-
ing torque.
10-88
STRUCTURE AND FUNCTION FINAL DRIVE
FINAL DRIVE
Outline
• As the final function the final drive operates to
reduce the rotative speed of the motive force
from the engine and increases the driving force.
• Ring gear (4) is press-fitted in the axle housing
and fixed in place by a pin.
• The motive force transmitted from the differen-
tial to the sun gear shaft (5) is reduced using a
planetary gear mechanism, increasing the driv-
ing force.
The increased driving force is transmitted to the
tires via planetary gear (2) and axle shaft (3).
10-89
STRUCTURE AND FUNCTION AXLE MOUNT, CENTER HINGE PIN
1. Front axle
2. Rear axle
3. Front frame
4. Rear frame
5. Upper hinge pin
6. Lower hinge pin
10-90
STRUCTURE AND FUNCTION AXLE MOUNT, CENTER HINGE PIN
10-91
10-92
STRUCTURE AND FUNCTION STEERING PIPING
STEERING PIPING
1. Steering cylinder
2. Steering valve
3. Hydraulic tank
4. Hydraulic pump
5. Oil cooler
10-111
STRUCTURE AND FUNCTION STEERING COLUMN, ORBIT ROLL
Outline
• The orbit-roll steering is fully hydraulically operated. • When the steering wheel is turned, the orbit-
There is no mechanical steering connection be- roll passes oil to the steering demand valve.
tween the front and rear machine frame. The steer- The amount of oil is proportional to the turning
ing action is achieved through pipes, hoses and the of the steering wheel. The steering demand
steering cylinders. valve is moved to the left or right depending
on the turned direction of the steering wheel.
10-112
STRUCTURE AND FUNCTION STEERING COLUMN, ORBIT ROLL
10-113
STRUCTURE AND FUNCTION STEERING VALVE
STEERING VALVE
10-114
STRUCTURE AND FUNCTION STEERING VALVE
1. Poppet
2. Relief valve poppet
3. Check valve poppet
4. Pilot poppet
5. Spring
Function
• The overload relief valve is installed to the steer-
ing valve. It has the following two functions:
When the steering valve is at neutral, if any
shock is applied to the cylinder, and an abnor-
mal pressure is generated, the oil is relieved
from this valve. In this way, it functions as a
safety valve to prevent damage to the cylinder
or hydraulic piping. On the other hand, if nega-
tive pressure is generated at cylinder end, it
functions as a suction valve to prevent a vacuum
from forming.
Operation
Acting as relief valve
• Port A is connected to the cylinder circuit and
port B is connected to the drain circuit. Oil
passes through the hole in poppet (1) and acts
on the different areas of diameters d1 and d2,
so check valve poppet (3) and relief valve pop-
pet (2) are firmly seated in position.
10-115
STRUCTURE AND FUNCTION STEERING VALVE
10-116
STRUCTURE AND FUNCTION STEERING VALVE
1. Adjustment screw
2. Spring
3. Plug
4. Pilot poppet
5. Valve seat
Function
• The steering relief valve is inside the steering
valve, and sets the maximum circuit pressure
of the steering circuit when the steering valve is
actuated. When the steering valve is being ac-
tuated, if the steering circuit goes above the set
pressure of this valve, oil is relieved from this
valve. When the oil is relieved, the flow control
spool of the demand valve is actuated, and the
oil is drained to the steering circuit.
10-117
STRUCTURE AND FUNCTION STEERING VALVE
• When the pressure in the circuit rises and • When flow control spool (6) moves, the oil from
reaches the pressure set by adjustment screw the steering pump is drained, and the oil from
(1) and spring (2), pilot poppet (4) opens and the the switch pump id released to the main control
oil is drained. valve, so the pressure in the steering circuit is
• When this happens, the balance between the prevented from going above the set value.
pressure in pressure-receiving chamber (I) and
pressure-receiving chamber (II) is lost, so de-
mand spool (6) moves to the left in the direction
of the arrow.
10-118
STRUCTURE AND FUNCTION STEERING VALVE
• The oil from the steering pump enters port A and • When the pressure at pressure-receiving cham-
the oil from the switch pump enters port B. ber (I) reaches a certain level (set by spring (5)),
• When steering spool (2) is at neutral, pressure- notch (f) opens and the oil from the steering
receiving chamber (II) is connected to the drain pump flows to the drain circuit. At the same
circuit through orifice (b), and notch (c) is closed. time, notch (g) closes, and all the oil from the
• Notch (c) is closed, so the pressure of the oil at switch pump all flows to the main control valve.
port A and port B rises. This pressure passes
through orifice (a), goes to pressure-receiving
chamber (I), and moves demand spool (1) to the
left in the direction of the arrow.
10-119
STRUCTURE AND FUNCTION STEERING VALVE
• When steering spool (2) is pushed (operated), • The merged oil passes through notches (c) and
pressure-receiving chamber (II) and the drain cir- (d), pushes up load check valve (4), and flows to
cuit are shut off, and at the same time, notch (c) the cylinder. The return oil from the cylinder
opens. passes through notch (e) and enters the drain
• Because of this, the pressure in pressure-receiv- circuit.
ing chamber (II) rises, and demand spool (1) • In this condition, the pressure before passing
moves to the right in the direction of the arrow through notch (c) is sent to pressure-receiving
until notch (h) closes. chamber (I) and the pressure after passing
• The passage from port B to the main control through notch (c) is sent to pressure- receiving
valve is shut off, the oil from the switch pump chamber (II).
pushes up merge check valve (3), and the oil is Demand spool (1) acts to keep the differential
merged with the oil at port A from the steering pressure on both sides of notch (c) at a con-
pump. stant value. Therefore, an oil flow which matches
the opening of notch (c) is discharged from the
cylinder port. These pressure differences (con-
trol pressures) are set by spring (5).
10-120
STRUCTURE AND FUNCTION STEERING VALVE
• No support oil is needed from the switch pump, • The oil from the steering pump passes through
so the steering pump pressure rises until notch notches (c) and (d), pushes up load check valve
(g) closes and the merge passage at port B is (4), and flows to the cylinder. The return oil from
shut off. the cylinder passes through notch (e) and flows
• The pressure difference on both sides of notch to the drain circuit.
(c) is controlled only by notch (f), and the ex- • Notch (g) is closed, so the oil from the switch
cess oil from the steering pump is drained from pump is sent from port B to the main control
notch (f) to the drain circuit. (At this point, notch valve.
(g) is fully closed.)
10-121
STRUCTURE AND FUNCTION STEERING VALVE
Neutral
• The steering valve is not being operated, so • When the pressure at ports A and B rises, flow
steering spool (1) does not move. control spool (4) moves to the left in the direc-
• The oil from the steering pump enters port A. tion of the arrow, and the oil from the steering
The oil from the switch pump enters port B. pump passes through port C of the spool and is
drained.
The oil from the switch pump passes through
port D, and all flows to the main control valve.
10-122
STRUCTURE AND FUNCTION STEERING VALVE
Turning right
• When the steering wheel is turned to the right, The oil from the left and right cylinders passes
the pressure oil from the Orbit-roll valve acts on through load check valve (3) of the steering spool,
steering spool (1), and steering spool moves to and is drained.
the left in the direction of the arrow. The oil from the switch pump enters port B,
The oil from the steering pump enters port A, pushes flow control spool (2) to push open check
passes through demand spool (2) to steering valve (5), and is merged with the oil from the
spool (1). It then pushes open load check valve steering pump.
(4) of the spool, and flows to the bottom end of
the left cylinder and the rod end of the right
cylinder to turn the machine to the right.
10-123
STRUCTURE AND FUNCTION STEERING VALVE
Turning left
• When the steering wheel is turned to the left, The oil from the left and right cylinders passes
the pressure oil from the Orbit-roll valve acts on through load check valve (4) of the steering spool,
steering spool (1), and steering spool moves to and is drained.
the right in the direction of the arrow. The oil from the switch pump enters port B,
The oil from the steering pump enters port A, pushes flow control spool (2) to push open check
flows through flow control spool (2) to steering valve (5), and is merged with the oil from the
spool (1). It then pushes open load check valve steering pump.
(3) of the spool, and flows to the rod end of the
left cylinder and the rod end of the right cylinder
to turn the machine to the left.
10-124
STRUCTURE AND FUNCTION EMERGENCY STEERING
EMERGENCY STEERING
Up to SN WA380H20836
Outline:
• The following two pages provide a summary of the
emergency steering installed in the WA-3H ma-
chines. These show the location of components and
flow of hydraulic oil for the WA470-3H during vari-
ous operating conditions; the summary applies ac-
cordingly for all other WA-3H machines.
Operating modes
1. Switch ignition on
• The red control lamp on the main monitor
flashes.
2. Motor started
• The red control lamp on the main monitor
goes out.
10-125
1
STRUCTURE AND FUNCTION EMERGENCY STEERING
10-126
1
STRUCTURE AND FUNCTION EMERGENCY STEERING
Function
• 8 pistons (17) are located in the pump housing
(16) in star formation. The stroke movement is
achieved with the cam shaft (14) which runs on
roller bearings. The heads of the pistons (17)
run on a slide ring (12) which itself is mounted
on a slide bearing (13) mounted on the cam.
The pistons (17) are kept in constant contact
with the slide ring (12) by springs (18). The
springs (18) are located in the hollow-drilled
pistons (17) and rest against the sealing screws.
The pump sucks in via the cam space of the
pump housing. The pistons, which have several
inlet holes around their circumference, immerse
downwards into the cam space so that oil can
flow into the inside of the piston through the inlet
holes. The inlet holes are closed again during
the upward movement by the cylinder wall after
a specific stroke distance. The oil pumped by
the further upward movement of the pistons is
fed through axial holes from the cylinder spaces
into a ring space which is sealed by a common
plate valve (10). The plate valve is held in place
by a waveform spring washer. The oil is dis-
charged via the plate valve (10) in the ring
collecting area in the cover which is connected
to the discharge connection hole. The plate valve
(10) carries out a waveform motion during this
action corresponding to the consecutive piston
strokes. A fairly even delivery of approx. 25 l/
min. sets in during acceleration at rotational 1 Circlip
speeds representing a travel speed of approx. 2 Deep-groove ball bearing
19 km/h. This characteristic results from the 3 Spacer ring
constantly decreasing time for the oil to flow 4 Double-lipped waveform sealing ring
from the cam space into the piston interior. The 5 O-ring
pump’s delivery characteristics are the same for 6 Pump cover, drive side
forward and reverse drive. 7 O-ring
8 Needle bearing
9 Waveform spring washer
10 Plate valve
11 Thrust ring
12 Slide ring
13 Slide bearing between cam shaft 14
and slide ring 12
14 Cam shaft
15 O-ring
16 Pump housing
17 Piston
18 Spring
19 Sealing ring
20 Sealing screw
21 Pump cover
10-127
STRUCTURE AND FUNCTION EMERGENCY STEERING
10-128
1
STRUCTURE AND FUNCTION EMERGENCY STEERING
EMERGENCY STEERING
SN WA380H20837 and up
Outline:
• The following two pages provide a summary of the
emergency steering installed in the WA-3H ma-
chines. These show the location of components and
flow of hydraulic oil for the WA320-3H during vari-
ous operating conditions; the summary applies ac-
cordingly for all other WA-3H machines.
2. Engine started
• The red control lamp on the main monitor
is off.
The green control lamp on the main monitor is
still off.
10-129
2
STRUCTURE AND FUNCTION EMERGENCY STEERING
1 2 3 4 5 6
7 8 9
10-130
1
STRUCTURE AND FUNCTION EMERGENCY STEERING
Function
• The gear pump employed is a self-priming pres-
sure/volume type. It produces an rpm dependent oil
volume flow. The housing (1) contains two axial free
floating bearing plates (2) that support the drive
shaft (4) and the layshaft (5).
The housing is fitted with a mounting plate (6) and
endcover (7).
The drive shaft gear and layshaft gear are meshed
together. Rotation of the shafts cause a displace-
ment of the pressure fluid form the suction side (S)
to the pressure outlet (P). The two bearing plates
are axially loaded with working pressure. This is
restricted through the use of an asymmetric pres-
sure area applied to a special sealring combination
(8). The pressure area is connected to the pres-
sure chamber of the gear housing through a chan-
nel (10). Because of this construction the bearing
surface of the bearing plates is pressed onto the
bearing surfaces of the drivegear and laygear. Lu-
brication of the support bearings is achieved with
the pressure fluid. On the suction side and the
pressure side the bearing plates have groves to
improve filling and displacement characteristics.
10-131
1
STRUCTURE AND FUNCTION EMERGENCY STEERING
1
2 2
3 3
10-132
1
STRUCTURE AND FUNCTION EMERGENCY STEERING
S109
Ground
Description Description
H111 Lamp steering oil pressure B305 Sender emergency steering pump pressure (7 bar)
H306 Lamp emergency steering pump B307 Sender air pressure (3 bar)
S109 Plug for taster test emergency steering pump K159 Time relay (6 sec.) for test emergency steering pump
V118 Diode K161 Relay emergency steering pump
XFS Connector fuses K414 Rpm sensor emergency steering pump
XL Connector platform P426 Main Monitor
XR Connector rear frame M160 Emergency steering pump
10-133
1
STRUCTURE AND FUNCTION EMERGENCY STEERING
1 1A
3
CF
H PSP
1. Pump and motor (emergency steering pump)
1A. Pressure relief valve (120 ±7 bar)
2. Pressure switch (7 bar)
3. Pressure switch (3 bar)
10-134
1
STRUCTURE AND FUNCTION BRAKE PIPING
BRAKE PIPING
10-151
STRUCTURE AND FUNCTION BRAKE CONTROL CIRCUITS
10-152
STRUCTURE AND FUNCTION BRAKE VALVE
10-153
STRUCTURE AND FUNCTION BRAKE VALVE
Outline
• There are two brake valves installed in parallel In addition, the left brake pedal operates the
under the front of the operator’s cab, and these transmission cut-off switch to actuate the trans-
are actuated by depressing the pedal. mission solenoid valve electrically and set the
• When the right pedal is depressed, oil is sent to transmission to neutral.
the brake cylinder to apply the brakes.
• When the left pedal is depressed, oil is sent to
the right pedal to apply the brakes in the same
way as when the right pedal is depressed.
10-154
STRUCTURE AND FUNCTION BRAKE VALVE
Operation
Brake applied (right brake valve)
Upper portion
• When brake pedal (1) is depressed, the operat-
ing force is transmitted to spool (3) through rod
(2) and spring (4). When spool (3) goes down,
drain port a is closed, and the oil from the pump
and accumulator flows from port A to port C
and actuates the rear brake cylinders.
Lower portion
• When brake pedal (1) is depressed, the operat-
ing force is transmitted to spool (3) through rod
(2) and spring (4). When spool (3) goes down,
spool (5) is also pushed down by plunger (6).
When this happens, drain port b is closed, and
the oil from the pump and accumulator flows
from port B to port D and actuates the front
brake cylinders.
10-155
STRUCTURE AND FUNCTION BRAKE VALVE
Lower portion
• When spool (3) in the upper portion moves up
and the circuit between port A and port C is
shut off, oil also fills the front brake cylinder at
the same time, so the pressure in the circuit
between port B and port D rises. The oil enter-
ing port J from orifice f of spool (5) pushes up
spool (5) by the same amount that spool (3)
moves, and shuts off port B and port D. Drain
port b is closed, so the oil entering the brake
cylinder is held, and the brake is applied.
• The pressure in the space in the upper portion
is balanced with the operating force of the pedal,
and the pressure in the space in the lower por-
tion is balanced with the pressure in the space
in the upper portion. When spools (3) and (5)
move to the end of their stroke, the circuits
between ports A and C and between ports B
and D are fully opened, so the pressure in the
space in the upper and lower portions and the
pressure in the left and right brake cylinders is
the same as the pressure from the pump.
Therefore, up to the point where the piston
moves to the end of its stroke, the effect of the
brake can be adjusted by the amount that the
pedal is depressed.
10-156
STRUCTURE AND FUNCTION BRAKE VALVE
Lower portion
• When the pedal is released, spool (3) in the
upper portion moves up. At the same time, the
back pressure from the brake cylinder and the
force of the spool return spring move spool (3)
up. Drain port b is opened and the oil from the
brake cylinder flows to the hydraulic tank return
circuit to release the front brake.
10-157
STRUCTURE AND FUNCTION ACCUMULATOR CHARGE VALVE
10-158
STRUCTURE AND FUNCTION ACCUMULATOR CHARGE VALVE
1. Valve body
2. Safety relief valve (R3)
3. Relief valve (R1)
4. PPC relief valve (R2)
5. Relief valve (H1)
10-159
STRUCTURE AND FUNCTION ACCUMULATOR CHARGE VALVE
Operation
1. When no oil is being supplied to accumulator
(cut-out condition)
1) Cut-in condition
• When the pressure at port B is lower than the
set pressure of the relief valve (R1), piston (8)
is pushed back down by spring (5). Valve seat
(7) and poppet (6) are brought into tight con-
tact, and port C and port T are shut off.
• The spring chamber at the right end of spool
(15) is also shut off from port T, so the pres-
sure rises, and the pressure at port P also rises
in the same way.
• When the pressure at port P goes above the
pressure at port B (accumulator pressure), the
supply of oil to the accumulator starts immedi-
ately. In this case, it is decided by the size
(area) of orifice (17) and the pressure differ-
ence (equivalent to the load on spring (14))
generated on both sides of the orifice. A fixed
amount is supplied regardless of the engine
speed, and the remaining oil flows to port A.
10-160
STRUCTURE AND FUNCTION ACCUMULATOR CHARGE VALVE
10-161
STRUCTURE AND FUNCTION ACCUMULATOR (FOR BRAKE)
1. Valve
2. Top cover
3. Cylinder
4. Piston
Function Specifications
• The accumulator is installed between the charge Gas used: Nitrogen gas
valve and the brake valve. It is charged with Charge amount: 3000 cc
nitrogen gas between cylinder (3) and free pis- Charging pressure
ton (4), and uses the compressibility of the gas For service brakes: 3.4 ± 0.15 MPa
to absorb the pulse of the hydraulic pump or to (35 ± 1.5 bar) (at 50°C)
maintain the braking force and to make it possi- For parking brakes: 15 bar (at 50°)
ble to operate the machine if the engine should
stop.
10-162
STRUCTURE AND FUNCTION ACCUMULATOR (FOR BRAKE)
1. Top cover
2. Piston
3. Cylinder
4. End cover
5. Plug
Function Specifications
• The accumulator is installed between the brake Gas used: Nitrogen gas
valve and brake piston. Nitrogen gas is injected Charge amount: 45 cc
between cylinder (1) and free piston (2), and its Charging pressure: 0.3 ± 0.05 MPa
compression is used to act as a damper when (3 ± 0.5 bar) (at 50°C)
the brake pressure between brake valve and
brake piston is rising.
10-163
STRUCTURE AND FUNCTION BRAKE CIRCUIT DIAGRAM
10-164
STRUCTURE AND FUNCTION BRAKE VALVE
Function:
Operation:
Brakes released:
A Spring assembly
C1, C2 Spool valve
R1, R2 Springs
10-165
STRUCTURE AND FUNCTION BRAKE VALVE
Partial braking:
• When the brake valve is operated hydraulic pres- • When the braking process is ended a con-
sure, proportional to the actual foot force, is applied nection is again established between brake
to the brakes. The spring assembly (A) beneath the cylinder 2.1 / 2.2 and the drain 5.1 / 5.2,
base plate (E) is designed so that braking pressure pressure ports 1.1 and 1.2 are closed.
changes according to the foot plate (B) angle. In
the lower braking range the vehicle can be braked • The arrangement of pistons in the valve en-
proportionally. sures that even if one braking circuit fails the
other remains fully operational. This is
• If the vehicle is braked more, piston (C1) is moved achieved by means of the mechanical actua-
down with the increased spring pressure (A). The tion of both pistons and requires slightly more
piston (C1) applies spring pressure (R1) to the pedal pressure.
lower piston (C2). The pistons cut off the outlet
ports 5.1 and 5.2. Further movement opens the Limiting braking pressure:
ports 1.1 and 1.2 allowing oil pressure to pass to
the wheel brake cylinders. The applied foot force • The movement restriction screw (D) on the
now determines the braking force. The pistons (C1) base plate (E) below the pedal (B) is used to
and (C2) are held in a stable position between the limit the brake pedal movement. This in turn
applied foot force and the spring pressure plus the limits the applied braking pressure.
applied brake hydraulic pressure.When this point is
reached ports 1.1 / 1.2 and 5.1 / 5.2 are closed Failure of a circuit:
and the applied pressure at 2.1 and 2.2 is held.
• In the event of the lower brake circuit failing,
Full braking: the upper circuit will remain operational. Pis-
ton (C1) is operated mechanically by spring
• When the brake pedal (B) is fully actuated piston (A). In the event of the upper circuit failing,
(C1) moves into mechanical contact with piston piston (C1) and spring (A) will mechanically
(C2). Ports 5.1 and 5.2 close. Ports 1.1 and 1.2
open and full brake pressure is allowed to flow to
the brakes.
10-166
STRUCTURE AND FUNCTION BRAKE VALVE
10-167
STRUCTURE AND FUNCTION BRAKE SYSTEM
10-168
STRUCTURE AND FUNCTION BRAKE VALVE
Function:
Operation:
Brakes released:
10-169
STRUCTURE AND FUNCTION BRAKE VALVE
• When the brake valve is operated hydraulic pres- • When the brake pedal is fully actuated, a
sure, proportional to the actual foot force, is applied final position is reached and ports 1.1 and
to the brakes. The spring assembly beneath the 1.2 are connected to port 2.1 / 2.2 at the
base plate is designed so that braking pressure brakes while drain ports 5.1 / 5.2 are closed.
changes according to the foot plate angle. In the • When the braking process is ended a con-
lower braking range the vehicle can be braked nection is again established between brake
proportionally. cylinder 2.1 / 2.2 and the drain 5.1 / 5.2,
pressure ports 1.1 and 1.2 are closed.
• If the vehicle is braked more, the upper piston is • The arrangement of pistons in the valve en-
moved down with the increased spring pressure. sures that even if one braking circuit fails the
The upper piston applies spring pressure to the other remains fully operational. This is
lower piston. The pistons cut off the outlet ports 5.1 achieved by means of the mechanical actua-
and 5.2. Further movement opens the ports 1.1 and tion of both pistons and requires slightly more
1.2 allowing oil pressure to pass to the wheel brake pedal pressure.
cylinders. The applied foot force now determines
the braking force. The pistons are held in a stable
position between the applied foot force and the Failure of a circuit:
spring pressure plus the applied brake hydraulic
pressure. When this point is reached ports 1.1 / • In the event of the lower brake circuit failing,
1.2 and 5.1 / 5.2 are closed and the applied pres- the upper circuit will remain operational. The
sure at 2.1 and 2.2 is held. piston is operated mechanically by the springs.
In the event of the upper circuit failing, the
lower circuit will remain operational. The lower
piston and is operated mechanically by the
springs and the piston.
• If the left brake valve is operated, a pressure
establishes at port 2.1 and passes to port 3
of the right brake valve. This pressure oper-
ates a piston in the right brake pedal that
operates the brake slide. Oil flows from ports
1.1 / 1.2 to the cylinder ports 2.1 / 2.2
(brake).
10-170
STRUCTURE AND FUNCTION BRAKE VALVE
10-171
STRUCTURE AND FUNCTION BRAKE SYSTEM
Ready position:
Charging process:
• When the accumulator pressure drops to a preset between port 1 and port 5 is reestablished.
value, spring pressure C will force the control valve The pump oil flow returns to the tank. Check
B to move to the charge detent position E2. Oil valve D ensures that accumulator pressure
flows via orifice F to the spring chamber of valve A. is maintained. The safety valve J check max.
This causes valve A to float. A minimum oil flow pressure of 100 bar. The pressure switch 28
goes to the return port 5 and back to the tank, the operates at 52 bar.
maximum oil flow goes to ports 21 / 23 via check
valve D. Pressure in the accumulators rises to
approx. 150 bar. The control valve B returns to the
discharge detent position E1 and the connection
10-172
STRUCTURE AND FUNCTION BRAKE SYSTEM
Function:
Operation:
10-173
STRUCTURE AND FUNCTION BRAKE SYSTEM
Function
• The accumulator is installed between the hy-
draulic pump and the PPC valve. Even if the
engine stops when the boom is raised, it is
possible to lower the boom and bucket under
their own weight by using the pressure of the
nitrogen gas compressed inside the accumula-
tor to send the pilot oil pressure to the main
control valve to actuate it.
Operation
• After the engine stops , if the PPC valve is at
"Hold", chamber A inside the bladder is com-
pressed 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 (30
bar). When this happens, the bladder is ex-
panded by the pressure of the nitrogen gas in
chamber A, and the oil inside chamber B is
used as the pilot pressure to actuate the main
control valve.
10-174
STRUCTURE AND FUNCTION BRAKE SYSTEM
Ports:
T M22 x 1,5
P, VA, HA, PPC, Orbitrol M16 x 1,5
Me1, Me2 M14 x 1,5
Me3 G 1/4
max. flow 62 l/min
max. pressure 110 bar
Outline
• The brake accumulator unit consists of the pressure
regulating valve, a hydraulic block, accumulators for
service brake and PPC circuit (emergency boom
lowering); a check valve for PPC pressure and a
hydraulic oil filter.
1. Decompression spindel
2. Decal
3. Strainer
J. Pressure regulating valve
10-175
STRUCTURE AND FUNCTION BRAKE
BRAKE
Outline
• The brakes have a wet-type multi-disc struc- • Linings are provided on both sides of disc
ture, and consist of piston (2), inner ring (3), (4). The disc is incorporated between inner
disc (4), outer ring (5) and spring (8). ring (3) and outer ring (5), and is coupled by
• The brake cylinder consists of differential hous- the sun gear shaft's spline.
ing (1) and bearing carrier (10), and incorpo-
rates piston (2).
Inner ring (3) and outer ring (5) are coupled by
the brake housing (9) spline.
10-176
STRUCTURE AND FUNCTION BRAKE
Operation
When the brakes are activated
• When the brake pedal is pressed, the oil which
has passed from the hydraulic oil tank via the
pump through the accumulator charge valve acts
on the piston in the brake cylinder and piston
(2) slides.
• Therefore, disc (4), which is between inner ring
(3) and outer ring (5), stops rotating and the
machine is braked.
10-177
STRUCTURE AND FUNCTION PARKING BRAKE CONTROL
Outline
• The parking brake is a wet type multiple-disc brake • When the parking brake is applied, the neu-
built into the transmission. It is installed to the out- tralizer relay is switched on and the transmis-
put shaft bearing, and uses the pushing force of a sion control unit keeps the transmission in
spring to apply the brake mechaniclly and hydraulic neutral, but the last selected gear is still shown
power to release the brake. on the monitor display.
• When the parking brake lever (1) installed in the • Emergency release of the parking brake is
operator's compartment is switched ON, the parking possible. It can used when moving the ma-
brake valve shuts off the oil pressure to the parking chine if the machine has stopped because of
brake and the parking is applied. When the parking trouble in the engine or transmission unit. If
brake lever is switched OFF, the oil pressure flows the engine is OFF and the parking brake
to the parking brake cylinder and the parking brake accumulators are empty, the parking brake is
is released. locked by spring force.
10-178
STRUCTURE AND FUNCTION PARKING BRAKE
PARKING BRAKE
10-179
STRUCTURE AND FUNCTION PARKING BRAKE SOLENOID VALVE
Operation
1. Parking brake applied
• When the parking brake lever is put in the ON
position, the drain circuit is open. The oil from
the park brake cylinder then flows to the drain
circuit. Therefore, the parking brake is applied
by the force of the spring in the parking brake
cylinder.
1 Transmission
2 Pump
3 Pressure control valve 27 bar
4 Park brake cylinder
5 Pressure switch
6 Park brake valve
7 Accumulator
8 Check valve
10-180
STRUCTURE AND FUNCTION HYDRAULIC PIPING
HYDRAULIC PIPING
1. Bucket cylinder
2. Steering valve
3. Hydraulic tank
4. PPC valve
5. Hydraulic pump
6. Oil cooler
7. Accumulator
8. Accumulator
charge valve
9. Cut-off valve
10. Boom cylinder
11. Main control valve
Outline
• The hydraulic system consists of the work equip- • Control of the maximum pressure in the hydrau-
ment circuit and the steering circuit. The work lic circuit is carried out by the relief valve inside
equipment circuit controls the actuation of the the main control valve. A safety valve (with suc-
bucket and attachments. tion) is installed in the bucket cylinder circuit to
• The oil in hydraulic tank (3) is sent to main protect the circuit.
control valve (11) by hydraulic pump (5). If the • Accumulator (7) is installed in the PPC pilot
spools for the bucket and boom in the main circuit, and makes it possible to lower the boom
control valve are at the HOLD position, the oil to the ground even when the engine has stopped.
flows to the drain circuit of the main control • Hydraulic tank (3) is a pressurized sealed type
valve, is filtered by the filter inside the hydraulic and has a breather equipped with a relief valve.
tank (3), and then returns to the tank. This makes it possible to pressurize the inside
• When the work equipment control levers are of the tank and also to prevent any negative
operated, the PPC valve bucket spool or boom pressure, thereby preventing any cavitation of
spool is actuated, and the spools of the main the pump.
control valve are actuated by hydraulic pressure
to send the oil from the main control valve to
boom cylinder (10) or bucket cylinder (1) to
operate the boom or bucket.
10-201
STRUCTURE AND FUNCTION WORK EQUIPMENT HYDRAULIC SYSTEM DIAGRAM
10-202
STRUCTURE AND FUNCTION WORK EQUIPMENT HYDRAULIC SYSTEM DIAGRAM
1. Hydraulic tank
2. Oil filter
3. Breather
4. Hydraulic pump
5. Steering pump
6. Switch pump
7. PPC, brake pump
8. Filter
9. Accumulator charge valve
10. Accumulator
11. PPC valve
12. Steering valve (Orbit-roll)
13. Safety valve
14. Steering demand valve
14A. Demand spool
14B. Steering spool
14C. Relief valve
14D. Safety and Suction valve
15. Steering cylinder
16. Cut-off valve
17. Main control valve
17A. Main relief valve
17B. Bucket spool
17C. Safety and suction valve
17D. Boom spool
17E. Suction valve
18. Boom cylinder
19. Bucket cylinder
20. Oil cooler
21. Safety valve
22. Float valve
23. Emergency steering pump
24. Divider valve
10-203
STRUCTURE AND FUNCTION WORK EQUIPMENT HYDRAULIC SYSTEM DIAGRAM
Serial Number:
WA380H20384 to
WA380H20500
10-204
STRUCTURE AND FUNCTION WORK EQUIPMENT HYDRAULIC SYSTEM DIAGRAM
1. Hydraulic tank
2. Oil filter
3. Breather
4. Hydraulic pump
5. Steering pump
6. Switch pump
7. PPC, brake pump
8. Safety valve
9. Brake circuit
10. Steering cylinder
11. Att. cylinder
12. Steering valve (Orbit-roll)
13. Safety valve
14. Steering demand valve
14A. Demand spool
14B. Steering spool
14C. Relief valve
14D. Safety and Suction valve
15. Accumulator charge valve
15A. Safety relief valve
15B. PPC relief valve
16. Accumulator
17A. PPC valve
17B. PPC valve att. spool
18. Boom cylinder
19. Bucket cylinder
20. Main control valve
20A. Main relief valve
20B. Bucket spool
20C. Safety and suction valve
20D. Boom spool
20E. Suction valve
20F. Att. spool (option)
20G. Cut-off valve
21. Filter
22. Emergency steering pump
23. Flow valve
24. Divider valve
25. Float valve
26. Oil cooler
10-205
STRUCTURE AND FUNCTION WORK EQUIPMENT HYDRAULIC DIAGRAM
10-206
STRUCTURE AND FUNCTION WORK EQUIPMENT HYDRAULIC DIAGRAM
1. Hydraulic tank
2. Oil filter
3. Breather
4. Hydraulic pump
5. Steering pump
6. Switch pump
7. PPC, brake pump
8. Safety valve
9. Brake circuit
10. Steering cylinder
11. Att. cylinder
12. Steering valve (Orbit-roll)
13. Steering stop valve
14. Steering demand valve
14A. Demand spool
14B. Steering spool
14C. Relief valve
14D. Safety and Suction valve
15. Accumulator charge valve
15A. Safety relief valve
15B. PPC relief valve
16A. Accumulator brake
16B. Accumulator PPC
17A. PPC valve
17B. PPC valve att. spool
18. Boom cylinder
19. Bucket cylinder
20. Main control valve
20A. Main relief valve
20B. Bucket spool
20C. Safety and suction valve
20D. Boom spool
20E. Suction valve
20F. Att. spool (option)
20G. Cut-off valve
21. Filter
22. Emergency steering pump
23. Flow valve
24. Divider valve
25. Float valve
26. Oil cooler
10-207
STRUCTURE AND FUNCTION WORK EQUIPMENT HYDRAULIC DIAGRAM
19
11
18
ALS(Option)
20E
20C
20G
20A
20D
20B
20F
10
20
14
14D
17B
14B
14C
14A
13
9
17A
12
15
16A
16B
2
15B
15A
24
21
1
22A
4 5 6 7
22
23
10-208
STRUCTURE AND FUNCTION WORK EQUIPMENT HYDRAULIC DIAGRAM
1. Hydraulic tank
2. Oil filter
3. Breather
4. Hydraulic pump
5. Steering pump
6. Switch pump
7. PPC, brake pump
8. Oil cooler
9. Brake circuit
10. Steering cylinder
11. Att. cylinder (option)
12. Steering valve (Orbit-roll)
13. Steering stop valve
14. Steering demand valve
14A. Demand spool
14B. Steering spool
14C. Relief valve
14D. Safety and Suction valve
15. Accumulator charge valve
15A. Safety relief valve
15B. PPC relief valve
16A. Accumulator brake
16B. Accumulator PPC
17A. PPC valve
17B. PPC valve att. spool
18. Boom cylinder
19. Bucket cylinder
20. Main control valve
20A. Main relief valve
20B. Bucket spool
20C. Safety and suction valve (option)
20D. Boom spool
20E. Suction valve
20F. Att. spool (option)
20G. Cut-off valve
21. Filter
22. Emergency steering pump
22A. Pressure relief valve (120 ±7 bar)
23. Pressure switch (7 bar)
24. Pressure switch (3 bar)
10-209
STRUCTURE AND FUNCTION WORK EQUIPMENT HYDRAULIC DIAGRAM
11
19
18
ALS (Option)
20E
20C
20G
20A
20H
20 I
20D
20B
20F
10
14
9
14D
17B
14B
14C
14A
13
17A
12
15
16A
16B
2
15B
15A
21
24
1
22A
4 5 6 7
23
22
10-210
STRUCTURE AND FUNCTION WORK EQUIPMENT HYDRAULIC DIAGRAM
1. Hydraulic tank
2. Oil filter
3. Breather
4. Hydraulic pump
5. Steering pump
6. Switch pump
7. PPC / Brake pump
8. Oil cooler
9. Brake circuit
10. Steering cylinder
11. Attachment cylinder (option)
12. Steering valve (Orbit-roll)
13. Steering stop valve
14. Steering demand valve
14A. Demand spool
14B. Steering spool
14C. Relief valve
14D. Safety and suction valve
15. Accumulator charge valve
15A. Safety relief valve
15B. Pressure relief valve
16A. Accumulator for brake
16B. Accumulator for PPC
17A. PPC valve
17B. PPC valve attachment spool
18. Boom cylinder
19. Bucket cylinder
20. Main control valve
20A. Main relief valve
20B. Bucket spool
20C. Safety and suction valve (option)
20D. Boom spool
20E. Suction valve
20F. Attachment spool (option)
20G. Cut-off valve
20H. Staudruckventil (10 bar)
20 I. 2-Stufen-Abschaltventil
21. Filter
22. Emergency steering pump
22A. Pressure relief valve (120 ±7 bar)
23. Pressure switch (7 bar)
24. Pressure switch (3 bar)
10-211
STRUCTURE AND FUNCTION WORK EQUIPMENT LEVER LINKAGE
10-212
STRUCTURE AND FUNCTION HYDRAULIC TANK
HYDRAULIC TANK
1. Breather
2. Filter bypass valve
3. Oil filler
4. Oil filter
5. Sight gauge
6. Hydraulic tank
Outline
• The oil sent to the cylinders from the hydraulic tank circuit. If the oil filter is clogged, the filter
via the pump and through the work equipment con- bypass valve is activated, preventing the oil
trol valve merges with the oil of the various parts in from returning directly to the tank and caus-
the return circuit. Some of this oil is cooled by the ing damage to the oil filter. In addition, the
oil cooler, flows into the tank, is filtered by oil filter filter bypass valve is also activated when a
(4), and returns to hydraulic tank (6). vacuum is generated in the circuit.
• Oil filter (4) is of a type which filters all the oil in the
10-213
STRUCTURE AND FUNCTION HYDRAULIC TANK
BREATHER
10-214
STRUCTURE AND FUNCTION PPC VALVE
PPC VALVE
Up to Serial Number: WA380H20383
10-215
STRUCTURE AND FUNCTION PPC VALVE
1. Bolt
2. Piston
3. Plate
4. Collar
5. Retainer
6. Centering spring
7. Metering spring
8. Valve
9. Body
10-216
STRUCTURE AND FUNCTION PPC VALVE
PPC VALVE
Serial Number: WA380H20384 and up
10-217
STRUCTURE AND FUNCTION PPC VALVE
• Oil, from the brake/servo pump flows to the servo • All functions with detent holding magnets,
control valve connection P. The PPC-pressure re- (lift, tilt in and float) have detent balls (19)
lief valve, fitted into the brake unit, controls the as shown in the section drawing.
amount of PPC pressure.
Oil pressure is now available at all four servo oper-
ating pistons (16) to operate the main control
pistons through the connections 1 to 4.
7
1. Lower
2. Tilt in
3. Lift
4. Tip out 8
5. Kick down switch
17
6. Joystick
9
7. Rubber cover
8. Universal joint 18
9. Rod with magnet 10
holding plate
10. Detent magnet for 19 11
connections 1 to 3
11. Rod pressure point 12
12. Pressure rod
13. Spring plate 13
14. Return spring
14
15. Control spring
16. Control piston 15
17. Rod
18. Rod guide
16
19. Detent ball 320_m c03
P. Servo oil pressure from the brake/servo pump
T. Oil return channel to the hydraulic tank
10-218
STRUCTURE AND FUNCTION PPC VALVE
1. Switch Forward-Neutral-Reverse
2
2. Switch Kickdown-Hold
Z
Z-Z
10-219
STRUCTURE AND FUNCTION PPC VALVE
Function
• The oil from the pump enters port P. The circuit
is closed by spool (8), so the oil is drained from
relief valve (1).
At the same time, the oil at port PA1 of the main
control valve is drained from port f of spool (8).
In addition, the oil at port PB1 is drained from
port f of spool (8).
10-220
STRUCTURE AND FUNCTION PPC VALVE
Operation
1. Control lever at “hold” (Fig. 1)
Ports PA1, P4, PB1 and P1 are connected to
drain chamber D through fine control hole (f) in
valve (8).
10-221
STRUCTURE AND FUNCTION PPC VALVE
3. Control lever moved back from slightly operated Schematic sketch only!
position to hold (Fine control) (Fig. 3):
When plate (10) starts to be pushed back, pis-
ton (2) is pushed up by a force corresponding
to the force of centering spring (6) and the pres-
sure at port P4.
At the same time, fine control hole (f) of valve
(8) is connected to drain chamber D, so the oil
at port P4 escapes.
If the pressure at port P4 drops too far, valve (8)
is pushed down by spring (7). Fine control hole
(f) is shut off from drain chamber D, and at
almost the same time it is connected to pump
pressure chamber PP. The pump pressure is
supplied until the pressure at port PA1 returns
to a pressure equivalent to the position of the
lever.
When the spool of the control valve returns, the
oil in drain chamber D flows in from fine control
hole (f’) of the valve which has not moved. The
extra oil then flows through port P1 to chamber
PB1.
10-222
STRUCTURE AND FUNCTION PPC RELIEF VALVE
Function
• The PPC relief valve is between the PPC, brake
pump and the PPC valve. When the PPC pump
is not being actuated, or when any abnormal
pressure is generated, the oil sent from the
pump is relieved from this valve to prevent any
damage to the pump or circuit.
Operation
• The relief valve is installed to the charge valve.
Port A is connected to the pump circuit and port
C is connected to the drain circuit.
The oil passes through the orifice in main valve
(1) and fills port B.
In addition, pilot poppet (4) is seated in valve
seat (3).
• When the pressure at port A and port B reaches
the set pressure, pilot poppet (4) opens and the
oil pressure at port B escapes from port D to
port C to lower the pressure at port B.
• When the pressure at port B goes down, a
difference in pressure is generated at ports A
and B by the orifice of main valve (1). Main
valve (1) is opened by the pressure at port A
and the oil at port A is drained to port C to
relieve the circuit.
10-223
STRUCTURE AND FUNCTION ACCUMULATOR (FOR PPC VALVE)
Specifications
Type of gas: Nitrogen gas
Gas amount: 500 cc
Max. actuation pressure: 3.4 MPa (35 bar)
Min. actuation pressure: 1.2 MPa (12 bar)
Function
• The accumulator is installed between the hy-
draulic pump and the PPC valve. Even if the
engine stops when the boom is raised, it is
possible to lower the boom and bucket under
their own weight by using the pressure of the
nitrogen gas compressed inside the accumula-
tor to send the pilot oil pressure to the main
control valve to actuate it.
Operation
• After the engine stops, if the PPC valve is at
hold, chamber A inside the bladder is com-
pressed 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 (30
bar). When this happens, the bladder is ex-
panded by the pressure of the nitrogen gas in
chamber A, and the oil inside chamber B is
used as the pilot pressure to actuate the main
control valve.
10-224
STRUCTURE AND FUNCTION MAIN CONTROL VALVE
10-225
STRUCTURE AND FUNCTION MAIN CONTROL VALVE
10-226
STRUCTURE AND FUNCTION MAIN CONTROL VALVE
A. From switch pump (via steering valve) I. From work equipment pump
B. To attachment cylinder J. From attachment PPC valve
C. To bucket cylinder rod side K. From PPC valve port P1
D. To boom cylinder rod side L. From PPC valve port P3
E. Drain port (to tank) M. From attachment PPC valve
F. To boom cylinder bottom side N. From PPC valve port P4
G. To bucket cylinder bottom side O. From PPC valve port P2
H. To attachment cylinder
10-227
STRUCTURE AND FUNCTION MAIN CONTROL VALVE
10-228
STRUCTURE AND FUNCTION MAIN CONTROL VALVE
RELIEF VALVE
Up to Serial Number: WA380H20383
1. Main valve
2. Valve seat
3. Pilot poppet
4. Spring
5. Adjustment screw
Function
The relief valve is installed to the inlet portion of
the main control valve. If the oil goes above the
set pressure, the relief valve drains the oil to
the tank to set the maximum pressure for the
work equipment circuit, and to protect the cir-
cuit.
Operation
• Port A is connected to the pump circuit and port
C is connected to the drain circuit. The oil passes
through the orifice in main valve (1), and fills port
B. Pilot poppet (3) is seated in valve seat (2).
• If the pressure inside ports A and B reaches the
set pressure of pilot poppet spring (4), pilot pop-
pet (3) opens and the oil pressure at port B es-
capes from port D to port C, so the pressure at
port B drops.
• When the pressure at port B drops, a difference
in pressure between ports A and B is created by
the orifice of main valve (1). The main valve is
pushed open and the oil at port A passes through
port C, and the abnormal pressure is released to
the drain circuit.
• The set pressure can be changed by adjusting
the tension of pilot poppet spring (4). To change
the set pressure, remove the cap nut, loosen the
locknut, then turn adjustment screw (5) to adjust
the set pressure as follows.
TIGHTEN to INCREASE pressure
LOOSEN to DECREASE pressure
10-229
STRUCTURE AND FUNCTION MAIN CONTROL VALVE
Function
• The safety valve is in the bucket cylinder circuit
inside the main control valve. If any abnormal
pressure is generated by any shock to the cylin-
der when the main control valve is at the neu-
tral position, this valve relieves the abnormal
pressure to prevent damage to the cylinder.
Operation
Operation as safety valve
• Port A is connected to the cylinder circuit and
port B is connected to the drain circuit. The oil
pressure at port A is sent to port D from the
hole in pilot piston (3). It is also sent to port C
by the orifice formed from main valve (2) and
pilot piston (3).
Pilot piston (3) is secured to the safety valve,
and the size of the cross-sectional surface
(cross-sectional area) has the following rela-
tionship: d2 > d1 > d3 > d4.
• If abnormal pressure is created at port A, suc-
tion valve (1) is not actuated because of rela-
tionship d2 > d1 >, but relationship between port
A and port C is d3 > d4, so main valve (2)
receives oil pressure equivalent to the differ-
ence between the areas of d3 and d4. If the
oil pressure reaches the force (set pressure) of
main valve spring (4), main valve (2) is actu-
ated, and the oil from port A flows to port B.
10-230
STRUCTURE AND FUNCTION MAIN CONTROL VALVE
SUCTION VALVE
1. Main poppet
Up to Serial Number: WA380H20383 2. Sleeve
3. Spring
Function
• This valve acts to prevent any negative pres-
sure from forming in the circuit.
Operation
• If any negative pressure is generated at port A
(boom cylinder rod end) (when a pressure lower
than tank circuit port B is generated), main pop-
pet (1) is opened because of the difference in
area between d1 and d2, and oil flows from port
B at the tank end to port A at the cylinder port
end.
10-231
STRUCTURE AND FUNCTION MAIN CONTROL VALVE
10-232
STRUCTURE AND FUNCTION MAIN CONTROL VALVE
1. Boom spool
2. Bucket spool
3. Main relief valve
4. Safety valve (with suction)
5. Check valve
10-233
STRUCTURE AND FUNCTION MAIN CONTROL VALVE
Operation:
• The safety valve (with suction) is mounted in the
main hydraulic-control-valve between port (A), con-
nected with the cylinder and port (B) connected to
the oil return line. If the control-spool is in the
neutral position and shook action on the cylinder
causes the pressure to rise above the normal work-
ing pressure, the valve (5) will open and protect the
cylinder and pipes.
1. Adjusting screw
2. Pilot valve housing, torque 85 Nm
3. Valve housing, torque 95 Nm
4. Pilot valve
5. Shock valve
6. Pilot spool
7. Lock nut, torque 30 Nm
8. Pilot valve spring
9. Shock and anticavitation valve spring
10. O-ring
11. Seal ring
12. Seal ring
13. Seal ring
14. Anticavitation valve
A. Connection to the cylinder
B. Connection to the oil return piping
10-234
STRUCTURE AND FUNCTION MAIN CONTROL VALVE
ANTICAVITATION VALVE
Operation:
SAFETY VALVE
(PILOT REDUCING VALVE)
Serial Number: WA380H20384 and up
1. Lock nut
2. Adjusting screw
3. Threaded hole
4. Spring
5. Pilot reducing valve
6. Valve seat
7. Spring
8. Valve piston
10-235
STRUCTURE AND FUNCTION MAIN CONTROL VALVE
K
I
J H
C
A
B
3 1 4
10-236
STRUCTURE AND FUNCTION MAIN CONTROL VALVE
K
I
J H
C
A
B
3 1 4
10-237
STRUCTURE AND FUNCTION MAIN CONTROL VALVE
Function
• The cut-off valve is mounted between the switch
pump and work equipment valve. It switches the
oil flow from the switch pump between the work-
ing equipment valve and the drain, according to
operating conditions, and controls the speed of
the work equipment.
More Less
– than than
160 bar 160 bar
Standard
Specification – 0 x
Machine
Operation
1. When the work equipment valve is held
The oil at the switch pump (the oil from the
steering valve) presses up check valve (1),
merges with the oil from the work equipment
pump and flows to the work equipment valve.
10-238
STRUCTURE AND FUNCTION MAIN CONTROL VALVE
10-239
STRUCTURE AND FUNCTION MAIN CONTROL VALVE
Operation
• The oil from the switch pump which has passed port B passes around the spool and returns to
through the cut-off valve and the work equip- the tank from the drain circuit.
ment pump's oil enter port A and the maximum • The oil from the PPC pump enters PPC valve
pressure is regulated by relief valve (1). port L, but since the boom and bucket levers
• Since the bucket spool (2) is at the neutral po- are at the neutral position, the oil returns to the
sition, the bypass circuit is open, and the oil at tank from the PPC relief valve.
port A passes around the spool and flows to
port B. The boom (3) spool is also at the neutral
position, so the bypass circuit is open, the oil at
10-240
STRUCTURE AND FUNCTION MAIN CONTROL VALVE
Operation
• When boom lever (4) is pulled, oil flows from boom spool (3) bypass circuit. The bypass cir-
PPC valve port L to port N and port S. The oil at cuit is closed by boom spool (3), so the oil
port T passes through port M and flows to the pushes open check valve (5). The oil from check
drain circuit. The oil pressure at port S presses valve (5) flows to port D and to the cylinder
boom spool (3) and sets it to the RAISE posi- bottom side.
tion. • The oil on the cylinder rod side enters drain port
• The oil from the pump passes through the F from port E and returns to the tank, causing
bucket spool (2) bypass circuit and flows to the the boom to raise.
10-241
STRUCTURE AND FUNCTION MAIN CONTROL VALVE
Operation
• When boom lever (4) is pushed, oil flows from cuit is closed by boom spool (3), so the oil
PPC valve port L to port M and port T, and the pushes open check valve (5). The oil from
oil at port S flows to the drain circuit. The oil check valve (5) flows to port E and to the
pressure at port T pushes boom spool (3) and cylinder rod side.
sets it to the LOWER position. • The oil on the cylinder bottom side enters
• The oil from the pump passes through the drain port F from port D and returns to the
bucket spool (2) bypass circuit and flows to the tank, causing the boom to lower.
boom spool (3) bypass circuit. The bypass cir-
10-242
STRUCTURE AND FUNCTION MAIN CONTROL VALVE
Operation
• When boom lever (4) is pressed in further from pushed open. In addition, boom cylinder raise
the LOWER position (to the FLOAT position), circuit D and lower circuit E are both connected
boom spool (3) moves further from the LOWER to the drain circuit, so the boom lowers under
position and is set to the FLOAT position. its own weight.
• The oil from the pump passes through the • When the bucket is touching the ground, it can
bucket spool (2) bypass circuit and flows to the move up and down in accordance with the
boom spool (3) bypass circuit. Boom spool (3) ground surface contour.
causes the oil in the bypass circuit to flow to the
drain circuit, so the check valve (5) cannot be
10-243
STRUCTURE AND FUNCTION MAIN CONTROL VALVE
Operation
• When bucket lever (6) is pulled, the oil pres- • The oil from port A passes from check valve (7)
sure at PPC valve port L is released from port through port G and to the bottom side of the
P to port R, and the oil at port V flows to the bucket cylinder.
drain circuit. The oil pressure at port R sets • The oil on the bucket cylinder's rod side flows
bucket spool (2) to the TILT position. from port H to drain port F and returns to the
• Since the bypass circuit is closed by bucket tank, causing the bucket to tilt.
spool (2), the oil at port A pushes open check
valve (7).
10-244
STRUCTURE AND FUNCTION MAIN CONTROL VALVE
Operation
• When bucket lever (6) is pushed, the oil pres- the bucket cylinder.
sure at PPC valve port L is released from port • The oil on the bucket cylinder's bottom side
Q to port V, and the oil at port R flows to the flows from port G to drain port F and returns to
drain circuit. The oil pressure at port V sets the tank, causing the bucket to dump.
bucket spool (2) to the DUMP position.
• Since the bypass circuit is closed by bucket
spool (2), the oil at port A pushes open check
valve (7). The oil from port A passes from check
valve (7) through port H and to the rod side of
10-245
AUFBAU UND FUNKTION HYDRAULIC SAFETY SYSTEM
1. Description:
2. Operation:
10-246
AUFBAU UND FUNKTION HYDRAULIC SAFETY SYSTEM
10-247
AUFBAU UND FUNKTION HYDRAULIC SAFETY SYSTEM
1. Housing
2. Valve piston
3. Spring
Function:
• If a leak occurs between the safety valve and one
of the working cylinders in one of the pipes or the
main hydraulic valve, the safety valve directs the
main oil flow back to the hydraulic tank.
If the oil level in the hydraulic tank drops to a
minimum, so that the float valve opens, the safety
valve directs the oil flow from the main working
circuit back to the hydraulic tank.
Float valve
10-248
STRUCTURE AND FUNCTION WORK EQUIPMENT LINKAGE
1. Bellcrank 4. Boom
2. Bucket cylinder 5. Bucket link
3. Boom cylinder 6. Bucket
10-261
STRUCTURE AND FUNCTION WORK EQUIPMENT LINKAGE
10-262
STRUCTURE AND FUNCTION BUCKET
BUCKET
1. Bucket (3.1m3)
2. Bolt-on cutting edge
3. Plate
10-263
STRUCTURE AND FUNCTION BUCKET POSITIONER AND BOOM KICK-OUT
1. Proximity switch
2. Plate
3. Bucket cylinder rod
4. Lever
5. Proximity switch
10-264
STRUCTURE AND FUNCTION BUCKET POSITIONER AND BOOM KICK-OUT
BUCKET POSITIONER
• The bucket positioner is an electrically actuated
system which is used to set the bucket to the
desired angle when the bucket is moved from
the DUMP position to the TILT position. When
the bucket reaches the desired position, the
bucket lever is returned from the TILT position
to the HOLD position, and the bucket is auto-
matically set to the suitable digging angle.
• Lever (4) is secured to bucket cylinder rod (3)
by bolts. In addition, proximity switch (5) fixed
to the cylinder by bolts.
• When the bucket is moved from the DUMP
position to the TILT position, the bucket cylinder
rod moves to the left, and at the same time,
lever (4) also moves to the left. Proximity switch
(5) separates from lever (4) at the desired posi-
tion, and the bucket lever is returned to neutral.
BOOM KICK-OUT
• The boom kick-out is an electrically actuated
system. It acts to move the boom lever to the
HOLD position and stop the boom at the de-
sired position before the boom reaches the maxi-
mum height.
• Plate (2) is fixed to the boom. In addition, prox-
imity switch (1) is fixed to the frame.
When the boom is moved from the LOWER
position to the RAISE position, the boom rises,
and when it reaches the desired position, the
proximity switch and lever come together and
the system is actuated to return the boom lever
to the HOLD position.
10-265
STRUCTURE AND FUNCTION BUCKET POSITIONER AND BOOM KICK-OUT
Boom RAISE
• When the boom is lower than the set position
for the kick-out, the detector (steel plate) is not
above the detection surface of the proximity
switch, so the proximity switch load circuit is
shut off.
The relay switch is turned OFF and the current
for the solenoid is shut off.
10-266
STRUCTURE AND FUNCTION BUCKET POSITIONER AND BOOM KICK-OUT
Proximity switch
Lights up Goes out
actuation display
10-267
STRUCTURE AND FUNCTION BUCKET POSITIONER AND BOOM KICK-OUT
10-268
STRUCTURE AND FUNCTION BUCKET POSITIONER AND BOOM KICK-OUT
Proximity switch
Lights up Goes out
actuation display
10-269
STRUCTURE AND FUNCTION CAB
10-270
STRUCTURE AND FUNCTION WIRING DIAGRAMS
10-273
STRUCTURE AND FUNCTION WIRING DIAGRAMS
10-275
STRUCTURE AND FUNCTION WIRING DIAGRAMS
10-277
STRUCTURE AND FUNCTION WIRING DIAGRAMS
10-279
Wiring Diagrams
From SN WA380H20501
up to SN WA380H20836
10-281/1
STRUCTURE AND FUNCTION WIRING DIAGRAMS
380EL1.tbl
10-281/2
STRUCTURE AND FUNCTION WIRING DIAGRAMS
10-281/3
STRUCTURE AND FUNCTION WIRING DIAGRAMS
10-281/4
STRUCTURE AND FUNCTION WIRING DIAGRAMS
380EL2.tbl
10-281/5
STRUCTURE AND FUNCTION WIRING DIAGRAMS
380EL3.tbl
10-281/6
STRUCTURE AND FUNCTION WIRING DIAGRAMS
10-281/7
STRUCTURE AND FUNCTION WIRING DIAGRAMS
10-281/8
STRUCTURE AND FUNCTION WIRING DIAGRAMS
380EL4.tbl
10-281/9
STRUCTURE AND FUNCTION WIRING DIAGRAMS
Connectors
XL Connector platform X TL Connector transmission
XC Connector cab XR Connector raer frame
XF Connector front frame X FS Connector fuses
X GR Connector back off alarm X RA Connector radio
XM Connector engine X LGRE Connector centr. grasing
X LOP Connector options
Fuses
F... Fuse
380EL5.tbl
Wiring colour
Abbreviation Colour Abbreviation Colour Abbreviation Colour Abbreviation Colour
W ws white G gn green Gr gr gray Ch an anthrazit
B sw black L bl blue P rs pink O or orange
R rt red Br br brown Sb hbl light blue V vi violett
Y ge yellow Lg hgn light green Dg dgn dark green
270EL6.tbl
10-281/10
STRUCTURE AND FUNCTION WIRING DIAGRAMS
10-281/11
STRUCTURE AND FUNCTION WIRING DIAGRAMS
10-281/12
Wiring Diagrams
From SN WA380H20837
up to SN WA380H20986
10-282/1
STRUCTURE AND FUNCTION WIRING DIAGRAMS
380EL1a.tbl
10-282/2
STRUCTURE AND FUNCTION WIRING DIAGRAMS
10-282/3
STRUCTURE AND FUNCTION WIRING DIAGRAMS
10-282/4
STRUCTURE AND FUNCTION WIRING DIAGRAMS
380EL2.tbl
10-282/5
STRUCTURE AND FUNCTION WIRING DIAGRAMS
380EL3a.tbl
10-282/6
STRUCTURE AND FUNCTION WIRING DIAGRAMS
10-282/7
STRUCTURE AND FUNCTION WIRING DIAGRAMS
10-282/8
STRUCTURE AND FUNCTION WIRING DIAGRAMS
380EL4a.tbl
10-282/9
STRUCTURE AND FUNCTION WIRING DIAGRAMS
Connectors
XL Connector platform X TL Connector transmission
XC Connector cab XR Connector raer frame
XF Connector front frame X FS Connector fuses
X GR Connector back off alarm X RA Connector radio
XM Connector engine X LGRE Connector centr. grasing
X LOP Connector options
Fuses
F... Fuse
380EL5.tbl
Wiring colour
Abbreviation Colour Abbreviation Colour Abbreviation Colour Abbreviation Colour
W ws white G gn green Gr gr gray Ch an anthrazit
B sw black L bl blue P rs pink O or orange
R rt red Br br brown Sb hbl light blue V vi violett
Y ge yellow Lg hgn light green Dg dgn dark green
270EL6.tbl
10-282/10
STRUCTURE AND FUNCTION WIRING DIAGRAMS
10-282/11
STRUCTURE AND FUNCTION WIRING DIAGRAMS
10-282/12
Wiring Diagrams
SN WA380H20987 and up
10-283/1
STRUCTURE AND FUNCTION WIRING DIAGRAMS
380EL1b.tbl
10-283/2
STRUCTURE AND FUNCTION WIRING DIAGRAMS
10-283/3
STRUCTURE AND FUNCTION WIRING DIAGRAMS
10-283/4
STRUCTURE AND FUNCTION WIRING DIAGRAMS
380EL2b.tbl
10-283/5
STRUCTURE AND FUNCTION WIRING DIAGRAMS
380EL3b.tbl
10-283/6
STRUCTURE AND FUNCTION WIRING DIAGRAMS
10-283/7
STRUCTURE AND FUNCTION WIRING DIAGRAMS
10-283/8
STRUCTURE AND FUNCTION WIRING DIAGRAMS
380EL4b.tbl
10-283/9
STRUCTURE AND FUNCTION WIRING DIAGRAMS
380EL5b.tbl
Wiring colour
Abbreviation Colour Abbreviation Colour Abbreviation Colour Abbreviation Colour
W ws white G gn green Gr gr gray Ch an anthrazit
B sw black L bl blue P rs pink O or orange
R rt red Br br brown Sb hbl light blue V vi violett
Y ge yellow Lg hgn light green Dg dgn dark green
270EL6.tbl
10-283/10
STRUCTURE AND FUNCTION WIRING DIAGRAMS
10-283/11
STRUCTURE AND FUNCTION WIRING DIAGRAMS
10-283/12
STRUCTURE AND FUNCTION MACHINE MONITOR SYSTEM
Sensors:
1. Fuel level
2. Engine water level
3. Torque converter oil temperature
4. Engine water temperature
5. Engine oil level
6. Brake oil pressure
7. Engine oil pressure
8. Air cleaner clogging
Outline
• The machine monitor system uses the sensors • The displays can be broadly divided into the
and other devices installed to various parts of following: Cautions displayed on the monitors
the machine to observe the condition of the ma- (abnormalities in the machine where an alarm is
chine. It processes this information swiftly and given) and normal conditions which are always
displays it on the monitor panel to inform the displayed on the instrument panel (pilot lamps
operator of the condition of the machine. and readings for the gauges, speedometer, and
• The machine monitor system consists of the service meter).
main monitor, maintenance monitor, sensors, • There are also various switches built into the
switches, relays, alarm buzzer, and power monitor panel which function to operate the ma-
source. chine.
10-291
STRUCTURE AND FUNCTION MAIN MONITOR
MAIN MONITOR
4H 4D 4E 4A 4C 4B 1 2
3A 4I
5A WORK MODE
5D
H S Ec
5E
MANUAL 5F
5C 5G
4J 4G
SDW0b228
1. CHECK lamp 5. Switches
2. CAUTION lamp 5A.**Work mode selection switch
3. Caution item 5C. ALS (if equipped)
3A. Emergency steering actuated 5D. Working lamp (front) switch
4. Pilot item 5E. Working lamp (rear) switch
4A. Turn signal (left) 5F. Transmission cut-off switch
4B. Turn signal (right) 5G.* Auto shift transmission pilot switch
4C. Hi beam
4D. Shift indicator ** Pos. 5A (added), Serial number: WA380H20987 and up
4E. Speedometer * Pos. 5G (added), Serial number: WA380H20951 and up
4F. Hold position
4G. Parking brake
4H. Emergency steering normal
4I. Preheating
4J. Failure action code
Outline
• The main motor has a display function for the • A liquid crystal display and LEDs are used for
speedometer and other gauges and a switching the display. The switches are embossed sheet
function to control the electric components and switches.
controllers.
• There is one CPU (Central Processing Unit) in-
stalled internally, and this processes the signals
from the sensors and outputs the display.
10-292
STRUCTURE AND FUNCTION MAIN MONITOR
Display
Symbol Display item Display range Display method
category
Emergency steering
When actuated Display flashes
actuated
Turn signal
When operated Display lights up
(left, right)
Display lights up
Buzzer sounds when parking
Parking brake When operated
brake is applied and shift lever
is not at N
Lights up
Lighting up time changes
according to engine water
Preheating When preheating temperature when starting
switch is turned ON (for details,
see PREHEATING OUTPUT
FUNCTION)
Shift
Shift indicator 1–4N Digital display
indicator
10-293
STRUCTURE AND FUNCTION MAIN MONITOR
**3-stage S (standard) load and carry (S) lights up Standard mode actuated,
operating mode road driving (H, Ec) off High and economy mode
stopped
10-294
STRUCTURE AND FUNCTION MAIN MONITOR
Method of switching to With engine stopped and starting All switch displays (LEDs) go out, and
trouble data display switch turned ON, press 2nd switch failure code is displayed on speedometer
mode from top on left side of main display and time elapsed since failure is
monitor (switch below emergency displayed on failure action code display.
steering display) and working lamp (1) Failure code is a two-digit display
(front) switch simultaneously given in numbers or letters.
for at least 5 seconds. The display for the failure now
occurring flashes and the display for
past failures lights up.
If there is no failure, CC is displayed
(000 is displayed for time elapsed
since failure)
(2) The time elapsed since failure is
displayed as a three-digit number
to show how long ago the failure
occurred (the oldest failure time is
displayed. Any time greater than
999H is displayed as 999H).
(3) A maximum of 9 items are stored
in memory for the failure code.
Method of sending Press working lamp (front) switch Failure code and time elapsed since
failure code failure change to next item.
Clearing failure code Press working lamp (rear) switch Failure code and time elapsed since
for at least 2 seconds failure being displayed are cleared.
Failure code for problem now occurring
(flashing display) cannot be cleared.
Resetting from travel Press 2nd switch from top on left Changes to normal display
data display mode side of main monitor (switch below
emergency steering display) and
working lamp (front) switch
simultaneously for at least
5 seconds, or start the engine.
10-295
STRUCTURE AND FUNCTION MAINTENANCE MONITOR
MAINTENANCE MONITOR
Outline
• The maintenance monitor has a display function for • The monitor module has a built-in CPU (Cen-
the caution items and gauges, and switch functions tral Processing Unit). It processes the signal
to control the work equipment controller (if equipped). from the sensors, and carries out the display
• The maintenance monitor consists of the monitor and output.
module, switch module, service meter, case, and • A liquid crystal display and LEDs are used for
other mechanisms. the display portions. The switches are em-
bossed sheet switches.
10-296
STRUCTURE AND FUNCTION MAINTENANCE MONITOR
Display
Symbol Display item Display range Display method
category
Engine water level Below low level Displays when engine is stopped and
starting switch is ON
Check Display when normal: OFF
Engine oil level Below low level Display when abnormal: Flashes
CHECK lamp flashes
Engine water level Below low level Displays when engine is running
Display when normal: OFF
Display when abnormal: Flashes
Engine oil pressure Below specified CAUTION lamp flashes
pressure Buzzer sounds
––––––––––––––––––––
Torque converter oil Above 120°C Buzzer
- sounds if above 130°C
Caution temperature
10-297
STRUCTURE AND FUNCTION TRANSMISSION AUTO-SHIFT CONTROL SYSTEM
A: Analog signal
D: Digital signal
P: Pulse signal
N: Network signal
CONTROL FUNCTION
Auto shift
Hold function
Kick-down function
Safety function
Troubleshooting
Model selection function (Engine)
Outline
• The auto-shift control system receives the posi-
tion signals from the directional lever and range
lever, the engine speed signal, travel speed sig-
nal, and signals from other switches. The trans-
mission controller drives the speed solenoid valve
and automatically carries out shift control to
select the optimum speed range for the trans-
mission.
10-298
STRUCTURE AND FUNCTION TRANSMISSION AUTO-SHIFT CONTROL SYSTEM
10-299
STRUCTURE AND FUNCTION TRANSMISSION AUTO-SHIFT CONTROL SYSTEM
10-300
STRUCTURE AND FUNCTION TRANSMISSION AUTO-SHIFT CONTROL SYSTEM
10-301
STRUCTURE AND FUNCTION TRANSMISSION AUTO-SHIFT CONTROL SYSTEM
3. Neutral safety
When the directional lever is at any position
other than N, the transmission is set in neutral
and the machine does not start even if the
starting switch is turned ON. This condition is
canceled if the directional lever is returned to
the N position. (To prevent unexpected move-
ment of the machine when the engine is started)
5. Manual shift
If there should be any disconnection in the MODEL SELECTION FUNCTION
travel speed sensor or any other failure, and the
input of the travel speed stops, the lever opera- Model selection
tion becomes manual.
• The model is selected using the CN ENG
Example: plug. This informs the transmission controller
Directional lever F, speed lever 4 à F4 of the type of engine. A dummy plug is lo-
Directional lever R, speed lever 2 à R2 cated on this connection on the Komatsu
engine. This ensures that the correct data
records for switching control are activated in
the transmission controller.
10-302
STRUCTURE AND FUNCTION TRANSMISSION AUTO-SHIFT CONTROL SYSTEM
TRANSMISSION CONTROLLER
CONNECTOR SIGNALS
10-303
STRUCTURE AND FUNCTION TRANSMISSION CONTROLLER
TRANSMISSION CONTROLLER
COMBINED T/M AND ALS-CONTROLLER
CN1 Connector
CN2 Connector
CN3 Connector
CONNECTOR SIGNALS
10-304
STRUCTURE AND FUNCTION E.C.S.S.
E.C.S.S.
(ELECTRONIC CONTROLLED SUSPENSION SYSTEM)
2. Structure of system
• The E.C.S.S. consists of the following electronic
devices.
1) E.C.S.S controller (M type controller)
2) Input devices: E.C.S.S switch (system
switch), pressure switch (boom cylinder bot-
tom pressure), travel speed sensor, model
selection wiring harness, speed range se- Serial communication
lection wiring harness Main-
3) Output devices: solenoid valves (relief valve, monitor + 24V
→
Speed range
selection
Serial communication
→ to main monitor
Model selection
wiring harness
10-321
STRUCTURE AND FUNCTION E.C.S.S.
3. Content of control
• In response to the input on the left side of the
table below, the controller carries out the output
on the right side to control the system.
œ: ON
x: OFF
Input Output
E.C.S.S switch Speed range [Note 2] Travel Solenoid Solenoid Solenoid
Pressure
(system ON-OFF) speed (1) (2) (high (3) (low
switch
[Note 1] H-L Speed [Note 3] (relief) pressure) pressure)
1 OFF – – – – x x x
OFF OFF
OFF OFF
4 ON OFF – – x x x
Min. 5 km/h
5 – –
[Note 4]
– x x x
Note 1: The E.C.S.S system is switched ON-OFF Note 3: Input pulse frequency when travel speed
by operating the E.C.S.S switch on the is 1 km/h
main monitor. Model Pulse frequency (Hz)
When the system is ON, the E.C.S.S LED
WA320-3 54.41
display on the main monitor lights up.
The ON-OFF condition of the system is WA380-3 47.70
retained even after the engine stops or WA420-3 40.96
the starting switch is turned OFF. The next WA470-3 44.46
time that the starting switch is turned ON,
the system is set to the same condition as Note 4: If the travel speed exceeds 5 km/h when
before it was turned OFF. the output is OFF, the output is turned
(Main monitor function) ON.
Starting switch OFF à Machine stops à When the output is ON, the output stays ON
Starting switch ON until the travel speed reaches 3 km/h, and
When system is ON à System ON
[
When system is OFF à System OFF
] when the travel speed goes below 3 km/h,
the output is turned OFF.
Note 2: Relationship between speed range signal
and shift position
Speed range
Shift position
H-L Speed
1st OFF ON
2nd OFF OFF
3rd ON OFF
4th ON ON
ON: +24V, OPEN
OFF: 0V, CLOSED
10-322
STRUCTURE AND FUNCTION E.C.S.S.
4. Self-diagnostic function
• This system always observes the condition of
the system, and displays the condition of the
system (LED code, see table below) in the con-
troller self-diagnostic display portion.
• If there is any abnormality in the controller itself
or in the input or output devices, the controller
carries out troubleshooting of the abnormality. It
turns all the output OFF and displays the error
code (failure code) in the self- diagnostic dis-
play portion and the main monitor.
LED codes
LED Condition
Content
display of system
01 Selects model as WA320-3
02 Selects model as WA380-3
03 Selects model as WA420-3
Normal
04 Selects model as WA470-3
Pressure switch ON
55
(displays only when ON)
Error in solenoid (relief)
d0
system
Error in solenoid
d1
(high pressure) system
Error Error in solenoid
d2 Abnormal
code (low pressure) system
Abnormality in travel speed
d3
sensor system
Abnormality in model
d4 selection (non-available
combination is selected)
1) Displays on controller
• Error code displays [E] à [dx] (where x is a
numeral from 0 to 4 in the table above)
repeatedly in turn.
• If more than one abnormality occurs at the
same time, all the appropriate error codes
are displayed in turn.
• When the starting switch is turned OFF
(controller power OFF, the error codes are
reset and not written to memory.
• When checking the LED display, read the
code with the connector facing down.
2) Displays on main monitor
• For details, see MAIN MONITOR TROU-
BLE DATA DISPLAY.
10-323
STRUCTURE AND FUNCTION E.C.S.S.
5. Controller
1. Controller
2. Self-diagnostic display
Input/output signals
CN1 CN2 CN3
Input/ Input/ Input/
No. Name of signal No. Name of signal No. Name of signal
output output output
1 Serial signal – 1 Model selection Input 1 – –
2 – – 2 Model selection Input 2 – –
3 – – 3 Model selection Input 3 – –
4 – – 4 Model selection (Parity) Input 4 Travel speed sensor (+) Input
5 – – 5 – – 5 – –
6 – – 6 – – 6 – –
7 – – 7 – 7 – –
8 Power source input (+24V) – 8 Pressure switch Input 8 – –
9 GND – 9 – – 9 – –
10 – – 10 – – 10 – –
11 Solenoid (low pressure) Output 11 – – 11 – –
12 Serial signal – 12 – – 12 Travel speed sensor (–) Input
13 – – 13 Travel speed H-L Input 13 – –
14 – – 14 Travel speed SPEED Input 14 – –
15 – – 15 SAS SW Input 15 – –
16 – – 16 – – 16 – –
Solenoid power source 17 – –
17 –
input (+24V) 18 – –
18 Power source input (+24V) – 19 – –
19 GND – 20 – –
20 Solenoid (high pressure) Output
21 Solenoid (relief) Output
10-324
STRUCTURE AND FUNCTION E.C.S.S.
10-325
STRUCTURE AND FUNCTION E.C.S.S.
10-326
STRUCTURE AND FUNCTION E.C.S.S.
E.C.S.S.-ELECTRIC-CIRCUIT DIAGRAM
10-327
STRUCTURE AND FUNCTION E.C.S.S.
ALS-CONTROL UNIT
Serial Number: WA380H20384 and up
10-328
STRUCTURE AND FUNCTION E.C.S.S.
10-329
10-330
STRUCTURE AND FUNCTION SENSORS
SENSORS
Function
• The sensors are a contact type sensor with one
end grounded to the chassis. The signal from
the sensor is input directly to the monitor panel,
and when the contacts are closed, the panel
judges the signal to be normal.
However, the engine oil pressure uses a relay
to reverse the sensor signal.
Radiator water
level Contact ON OFF
Engine water
temperature Resistance – –
Torque converter
oil temperature Resistance – –
Electro-
Engine speed magnetic – –
Engine oil
pressure Contact OFF ON
1. Connector
2. Bracket
3. Float
4. Switch Function
• This sensor is installed to the side face of the
oil pan. When the oil goes below the specified
level, the float goes down and the switch is
turned OFF. This makes the maintenance moni-
tor flash to warn of the abnormality. The check
lamp also lights up at the same time to warn of
the abnormality.
10-341
STRUCTURE AND FUNCTION SENSORS
1. Float Function
2. Sensor • This sensor is installed to the top of the radia-
3. Connector tor. If the coolant goes below the specified level,
the float goes down and the switch is turned
OFF. The caution lamp and alarm buzzer are
also actuated at the same time to warn of the
abnormality.
1. Connector Function
2. Plug • These sensors are installed to the engine cylin-
3. Thermistor der block and transmission case. The change
in the temperature changes the resistance of
the thermistor, and a signal is sent to the main-
tenance monitor to display the temperature. If
the display on the maintenance monitor reaches
the specified position, the lamp flashes and the
buzzer sounds to warn of the abnormality.
10-342
STRUCTURE AND FUNCTION SENSORS
1. Connector Function
2. Float • The fuel level sensor is installed to the side
3. Arm face of the fuel tank. The float moves up and
4. Body down as the level of the fuel changes. As the
5. Spring float moves up and down, the arm actuates a
6. Contact variable resistance, and this sends a signal to
7. Spacer the maintenance monitor to display the fuel level.
When the display on the maintenance monitor
reaches the specified level, the warning lamp
flashes.
10-343
STRUCTURE AND FUNCTION SENSORS
1. Magnet Function
2. Terminal • The engine speed sensor is installed to the ring
3. Case gear portion of the flywheel housing. A pulse
4. Boot voltage is generated by the rotation of the gear
5. Connector teeth, and a signal is sent to the controller and
monitor panel.
1. Plug Function
2. Contact ring • This sensor is installed to the engine block and
3. Contact the diaphragm detects the oil pressure. If the
4. Diaphragm pressure goes below the specified pressure, the
5. Spring switch is turned ON, and a relay is actuated to
6. Terminal turn the output OFF. This makes the mainte-
nance monitor flash to warn of the abnormality.
The caution lamp and alarm buzzer are also
actuated at the same time to warn of the abnor-
mality.
10-344
STRUCTURE AND FUNCTION SENSORS
1. Case 5. Tube
2. Seal film 6. Connector
3. Disc 7. Cover
4. Vinyl tape 8. Spring
Outline Specifications
• When the left brake pedal is operated, the switch WA380-3
detects the oil pressure in the brake circuit, Min. 18 V
Voltage
shuts off the electric power to the solenoid valve value Max. 32 V
circuit for the directional clutch, and shifts the Min. 5 mA
Current
transmission to neutral. value Max. 0.1 A
10-345
STRUCTURE AND FUNCTION ENGINE STARTING CIRCUIT
Function
• A neutral safety circuit which inhibits engine start- status is set.
ing when the directional lever is at any position • The current also flows in the following circuit:
other than N (neutral) is used to assure safety. Starting switch terminal BR à battery relay
coil à ground connection.
Operation • This closes the battery relay switch.
• When the starting switch is set to the START When the directional lever is set to the N
position, voltage flows in the following circuit: (neutral) position, the directional lever switch's
Starting switch terminal BR à stopping motor neutral contact is closed. At this time, current
relay terminals 1 and 2 à ground connection. flows to neutral relay terminals 1 and 2 and
This excites the relay coil. the coil is excited.
• The current from the battery flows in the follow- • This causes current to flow in the following
ing circuit: Engine stopping motor terminals A circuit 1: Starting switch terminal C à neu-
and B à relay terminals 5 to 3 à motor. This tral relay terminals 5 to 3 à starter terminal
turns the motor. (The cable stretches.) C.
• When the motor turns, terminal D also turns. • The following circuit is formed: à battery re-
When the non-continuous section of terminal D lay à`starter terminal B. The engine then
reaches terminal B, the circuit from terminal A starts. When the directional lever is at a po-
to terminal B opens and the current from the sition other than N (neutral), circuit 1 is not
battery to the motor is interrupted. The motor formed, so the engine does not start.
tends to keep turning due to inertia, but when
the non-continuous section of terminal D comes
in contact with terminal B, both motor poles are
grounded, so the motor stops turning.
• In this status, the stopping motor cable is fully
extended, the fuel injection pump's stopping le-
ver is at the FULL position, and the operating
10-346
STRUCTURE AND FUNCTION ENGINE STOP CIRCUIT
Function
• The system is equipped with an electrical fuel • When the motor rotates, terminal D also rotates
cut device (engine stop motor) which makes it at the same time. When the non-continuous
possible to start or stop the engine by turning portion of terminal D reaches terminal C, the
the starting switch ON or OFF. This improves circuit from terminal A to C opens, and the
the ease of operation. current from the battery to the motor is shut off.
The motor attempts to continue rotating under
Operation inertia, but when the continuous portion of ter-
• When the starting switch is turned OFF, start- minal D contacts terminal C, both poles of the
ing switch terminals B, BR and C are opened. motor are connected to the ground, and the
• The current in the stop motor relay is shut off motor stops rotating.
by the starting switch, so the coil is not excited. • In this condition, the stop motor cable is com-
Therefore, terminals 3 and 6 are closed. pletely pulled in, and the fuel injection pump
• The current from the battery flows from engine lever is set to the STOP position to stop the
stop motor terminals A – C à relay terminals 6 engine.
– 3 à motor to rotate the motor. (The cable is
pulled in)
10-347
STRUCTURE AND FUNCTION PREHEATING CIRCUIT
Outline Operation
• The quick glow system (QGS) is provided to • When the starting switch is set to the ON (ACC)
improve engine starting performance in cold re- position, a signal flows from starting switch ter-
gions. The QGS acts to reduce preheating time, minal BR to the controller in the main monitor,
and also sets the preheating time automatically and the preheat output is connected to the
according to the water temperature when the ground. The preheat relay coil is excited, the
starting switch is operated. preheat relay is activated, and this activates the
• When the starting switch is turned from OFF to glow relay.
ON (ACC), the preheat pilot lamp on the main A current flows in the following circuit: Battery
monitor panel lights up and the engine is à battery relay à glow relay à glow plug. This
preheated with the glow plug. The preheating sets the preheating mode.
time is set by the QGS controller in the main • When the signal indicated that preheating is
monitor, which detects the water temperature completed is sent from the controller, the preheat
using the QGS water temperature sensor in the relay turns OFF, the glow relay also turns OFF,
engine. and preheating is completed.
• When the pilot lamp is lighted, the engine is
being preheated. Set the starting switch to the
ON position. If the starting switch is turned to
the START position, preheating is canceled.
10-348
STRUCTURE AND FUNCTION PREHEATING CIRCUIT
10-349
STRUCTURE AND FUNCTION START / STOP / PREHEATING CIRCUIT
Ground
10-350
STRUCTURE AND FUNCTION START / STOP / PREHEATING CIRCUIT
Description Description
Sect. Sect.
6 S 43 Starting switch 6 G 10 Generator
10 S 58 Battery main switch 10 G 57 Battery
12 S 261 Switch gear selection 8 M9 Starting motor
3 P 426 Main monitor 4 H 76 Lamp pre-heating
3 R 12 Flame plug 3 Y 320 Solenoid engine stop
V Diode 4 B 14 Temp. sender pre-heating
V 118 Diode 5 x 6 K 208 Relay neutral position
7 K 106 Relay battery 2 K 282 Relay pre-heating
9 K158 Relay starting motor 2 K 283 Relay pre-heating
1 K 167 Time relay for Y 320
Connectors
XL Connector platform XT Connector transmission
XC Connector cab XR Connector rear frame
XF Connector front frame X FS Connector fuses
XM Connector engine
Fuses
F... Fuse
motor.tbl
• Voltage flows in the following circuit: Starting motor • Voltage flows in the following circuit: Starting
terminal 30, alternator terminal B+, battery relay (K motor terminal 30, alternator terminal B+,
106) terminal 30 and starting switch terminal 30. battery relay (K 106) terminal 30 and starting
When the starting switch is turned (terminal 15), switch terminal 30.
relay K106 is activated. Engine stop solenoid Y 320 When the starting switch is turned (terminal
moves for 0,5 sec with high current in B-A position, 15), relay K106 is activated. Engine stop
then moves in hold-position A-C. Current flows in solenoid Y 320 moves for 0,5 sec with high
the preheating control circuit. current in B-A position, then moves in hold-
• When the starting switch is turned further (terminal position A-C. Current flows in the preheating
50a), relay neutral position (K 208) is activated, and control circuit.
current flows via terminal 30-87 if the gear lever is in • Temperature switch B 14 is closed, ground is
neutral position. Current flows to the starting motor connected to the main monitor and terminal
relay K 158 and the starting motor starts turning. 85 of the preheating relay K 282. Relay K282
and relay K 283 are activated. Current flows
to the preheating system. The lamp on the
Engine stop main monitor is activated via pin 15 of con-
nector XL 06. Preheating time depends on
• If the starting switch is moved in the stop position, the temperature and is controlled by the main
current is interrupted on terminal 15, relay K 106 monitor.
opens and the engine stop solenoid Y 320 moves in
stop position.
10-351
STRUCTURE AND FUNCTION PREHEATING CIRCUIT
RIBBON HEATER
SN WA380H20501 and up
Pre-heating
time
T1: Time pilot light is ON
T2: Time glow plug is working
Pilot light
Temperature (°C)
Function
Controller
reset
10-352
STRUCTURE AND FUNCTION ELECTRIC TRANSMISSION CONTROL
ELECTRIC TRANSMISSION
CONTROL
10-361
STRUCTURE AND FUNCTION ELECTRIC TRANSMISSION CONTROL
COMBINATION SWITCH
Outline
• The directional lever has three positions and the body by three screws. When each lever is op-
speed lever switch has four positions. As an erated to the desired position, the switch, which
individual part, the switch does not have a detent is interconnected by a shaft, acts to allow elec-
mechanism; the detent mechanism is in the com- tric current to flow to that circuit only.
bination switch. Each switch is positioned by two
pins, and is secured to the
10-362
STRUCTURE AND FUNCTION ELECTRIC TRANSMISSION CONTROL
Operation
• Directional lever (1) and shaft (2) of the speed
lever of the combination switch form one unit
with magnet (3), and magnet (3) also moves
together with lever (1).
• Control switch (5) with built-in hole IC (4) is
installed at the bottom of magnet (3), and hole
IC (4) is positioned on the board to match each
position.
• When directional lever (1) is operated to the F
position, magnet (3) is immediately above hole
IC (4) for the F position of the control switch.
The magnetism from magnet (3) passes
through the gap and case (6), and magnetism
is applied to hole IC (4).
• When this happens, hole IC (4) is inside a mag-
netism detection circuit, so it detects the mag-
netism of magnet (3) and sends the F position
signal to the electric current amplification cir-
cuit. In the electric current amplification circuit,
a signal is output to actuate the transmission.
10-363
STRUCTURE AND FUNCTION KICK-DOWN, HOLD SWITCH
1. Kick-down switch
2. Spring
3. Wiring harness
4. Spring
5. Hold switch
10-364
STRUCTURE AND FUNCTION KICK-DOWN ELECTRIC CIRCUIT DIAGRAM
2
2
2
2
10-365
STRUCTURE AND FUNCTION KICK-DOWN ELECTRIC CIRCUIT DIAGRAM
Normal operation
(directional lever at F, speed lever at 2)
10-366
STRUCTURE AND FUNCTION KICK-DOWN ELECTRIC CIRCUIT DIAGRAM
10-367
STRUCTURE AND FUNCTION KICK-DOWN ELECTRIC CIRCUIT DIAGRAM
10-368
STRUCTURE AND FUNCTION KICK-DOWN ELECTRIC CIRCUIT DIAGRAM
10-369
STRUCTURE AND FUNCTION TRANSMISSION CUT-OFF FUNCTION
Outline
• If the transmission cut-off selector switch on the
main monitor is turned ON (pilot lamp lights
up), the transmission cut-off switch installed to
the left brake pedal is actuated. When the left
brake pedal is operated, the brakes are ap-
plied, and the transmission is shifted to neutral
at the same time. If the transmission cut-off
selector switch is set to the OFF position (pilot
lamp goes out), the transmission is not shifted
to neutral even when the brake is operated, so
the left brake functions only as a brake in the
same way as the right brake.
• When the output flow of transmission controller
terminal 16 to the ground is interrupted, it is
judged that the transmission has been cut off.
Operation
1. When transmission cut-off selector switch is
turned ON
• When the main monitor's transmission cut-off
selector switch is turned ON, the transmission
cut-off selector switch is opened, the output from
transmission controller terminal 16 passes only
through the transmission cut-off switch to the
ground, and voltage is applied to transmission
solenoid F (FORWARD) or R (REVERSE).
• When the left brake pedal is pressed, the trans-
mission cut-off switch is opened and the output
flow of transmission controller terminal 16 to
the ground is interrupted. At the same time, the
voltage of transmission controller terminals 20
(R) and 21 (F) is interrupted, the transmission
is set to neutral (N), and the brakes work nor-
mally.
10-370
STRUCTURE AND FUNCTION ELECTRIC PARKING BRAKE CONTROL
Outline
• When the starting switch is turned ON and the • At the same time the parking brake warning
parking brake is applied, current flows from the light, in the main monitor, is connected to
main battery relay through the neutralizer relay, chassis through the parking brake switch and
contacts 1. to 2. and over the parking brake switch is switched ON.
to chassis.
10-371
10-372
STRUCTURE AND FUNCTION AIR-CONDITIONER
AIR-CONDITIONER
Contents
Page
General
Introduction ............................................................................................................................................. 10-453
Summary ................................................................................................................................................ 10-453
Physical principle .................................................................................................................................... 10-453
Properties - R134a ................................................................................................................................. 10-453
Physical datas R134a and R12 .............................................................................................................. 10-454
New components in R134a circuit .......................................................................................................... 10-454
Function
Refrigeration circuit ................................................................................................................................. 10-456
Condenser .............................................................................................................................................. 10-458
Vaporiser ................................................................................................................................................ 10-459
Filter with dryer ....................................................................................................................................... 10-460
Description
Design of the air conditioning .................................................................................................................. 10-462
Installation: WA 270-3, WA320-3 H20561 and up ................................................................................... 10-462
Installation: WA 320-3 up to H20560, WA 380-3, WA 420-3, WA 470-3 ................................................. 10-463
Security
Handling coolants ................................................................................................................................... 10-466
First aid ................................................................................................................................................... 10-467
Operation
Operating controls .................................................................................................................................. 10-470
Operation: WA 270-3, WA320-3 H20561 and up .................................................................................... 10-471
Operation: WA 320-3 up to H20560, WA 380-3, WA 420-3, WA 470-3 .................................................. 10-472
Settings ................................................................................................................................................... 10-474
Maintenance
Maintenance timetable ............................................................................................................................ 10-475
Maintenance instructions ........................................................................................................................ 10-476
Regular maintenance.............................................................................................................................. 10-476
Instructions for filling ............................................................................................................................... 10-477
Evacuation .............................................................................................................................................. 10-478
Vacuum test ........................................................................................................................................... 10-478
Siphoning off coolant .............................................................................................................................. 10-478
Filling ...................................................................................................................................................... 10-478
Filling quantities (R134a) ........................................................................................................................ 10-478
Checking the coolant level ...................................................................................................................... 10-479
Checking the compressor oil level .......................................................................................................... 10-479
Changing compressor oil ........................................................................................................................ 10-480
Exchanging magnetic clutch ................................................................................................................... 10-480
Exchanging compressor ......................................................................................................................... 10-481
Installing O-ring couplings ...................................................................................................................... 10-482
Installing conical nipple connections ....................................................................................................... 10-482
10-451
STRUCTURE AND FUNCTION AIR-CONDITIONER
Page
Electrical system
Plug assignment: Controller for WA 320-3 up to H20560, WA 380-3, WA 420-3, WA 470-3 .................. 10-484
Circuit diagram: Controoler for WA 320-3 up to H20560, WA 380-3, WA 420-3, WA 470-3 ................... 10-485
Circuit diagram air conditioner unit: WA 320-3 up to H20560, WA 380-3, WA 420-3, WA 470-3 ........... 10-486
Plug assignment: circuit diagram air conditioner unit for WA 270-3, WA320-3 H20561 and up .............. 10-488
Circuit diagram air conditioner unit: WA 270-3, WA320-3 H20561 and up ............................................. 10-489
Technical details
Heater ..................................................................................................................................................... 10-490
Air conditioner ......................................................................................................................................... 10-490
Circulating air filter .................................................................................................................................. 10-490
Fresh air filter ......................................................................................................................................... 10-490
Condenser .............................................................................................................................................. 10-490
Compressor ............................................................................................................................................ 10-491
Filter dryer .............................................................................................................................................. 10-491
Filling quantities ...................................................................................................................................... 10-491
Pressure and safety switch ..................................................................................................................... 10-491
Magnetic clutch....................................................................................................................................... 10-491
Fault diagnosis
Preconditions .......................................................................................................................................... 10-494
Fan ......................................................................................................................................................... 10-495
Operating mode selector switch ............................................................................................................. 10-496
Circulating air mode ................................................................................................................................ 10-497
Temperature settings .............................................................................................................................. 10-498
Air conditioning mode ............................................................................................................................. 10-499
Troubleshooting
Checks prior to troubleshooting .............................................................................................................. 10-501
Troubleshooting ...................................................................................................................................... 10-502
10-452
STRUCTURE AND FUNCTION AIR-CONDITIONER
IN GENERAL
Introduction
The air conditioning systems of our wheel loaders are now filled with the environmentally
friendly coolant R134a (tetrafluorethane) following the withdrawal of official approval of the
coolant R12 (dichlorfluormethane) on January 1, 1995.
General
Physical principal
• Physically, heat moves from a warm element towards a cold element. When this
occurs, the fast moving molecules in the warm element transfer a part of their energy
to the slow moving molecules in the cold element. This causes the fluid used in the air
conditioner to change form. Individual atoms, which make up the molecules, change
their position. When this happens the fluid changes from gas to liquid.
e.g.: This reaction can be seen with water. Water is normally liquid between 0°C and
100°C. If the water is heated, it becomes steam. The water changes from a liquid form
into a gas form. If the water is cooled it becomes ice. The water changes from a liquid
form into a solid form.
Characteristics - R134a
10-453
STRUCTURE AND FUNCTION AIR-CONDITIONER
10-454
STRUCTURE AND FUNCTION AIR-CONDITIONER
FUNCTION
10-455
STRUCTURE AND FUNCTION AIR-CONDITIONER
• Gaseous coolant under low pressure is sucked from the vaporiser (8) by the compres-
sor (2). This places the gaseous coolant under high pressure (approx. 20 - 30 bar) and
forwards it to the condenser (3).
The gaseous coolant transcends into a liquid state in the condenser (3) because of the
applied pressure and removal of heat. Fans blow outside air through the condenser to
cool the warming coolant. The heat removed from the air fed into the operator's cab is
passed on to the outside air. The coolant is still under high pressure at this point.
The coolant passes through the filter dryer (4) and the pressure switch (5) at the
entrance to the vaporiser (8) in this state. The coolant is filtered and dried in the filter
dryer (4). It is also a compensation tank at the same time.
The throttle effect of the expansion valve (7) reduces the pressure and the temperature
of the coolant. It makes sure that only as much coolant flows into the vaporiser (8) as
can actually be vaporised. The liquid coolant then reverts to its gaseous state in the
vaporiser.
Outside air is fed through the vaporiser (8) by the fresh air fan. While passing through
the vaporiser (8) , the warmth it contains is extracted from the outside air before it flows
through the air vents into the operator's cab.
10-456
STRUCTURE AND FUNCTION AIR-CONDITIONER
10-457
STRUCTURE AND FUNCTION AIR-CONDITIONER
The condenser
With a cooling system, warmth at a place where it is not required is transported to another
place where the warmth absorbed by the vaporiser is fed on to the condenser. In the
condenser, the gaseous coolant is cooled and liquefied. The warmth removed during
liquefying is dissipated into the air by the condenser.
The pressure (condensation pressure) is approximately constant in all three zones. The
coolant leaves the condenser in a liquid state and, consequently, can be used again in the
coolant circuit.
10-458
STRUCTURE AND FUNCTION AIR-CONDITIONER
The vaporiser
Liquid coolant is sprayed into the vaporiser and converted to a gaseous state. During this
process, the coolant boils in the vaporiser. The temperature of the coolant can fall well
below the freezing point during boiling. The coolant adopts a very similar behaviour to
boiling water in the vaporiser. The warmth which the coolant requires to evaporate is
withdrawn from its environment. At the end of the vaporising process, the coolant emerges
as steam. The actual vaporiser has been lengthened in order to allow any liquid bubbles
which may possibly have been carried along as a result of the turbulence time to
evaporate as well. This extension is called the after-vaporiser.
Vaporised
overheated
coolant
Injector nozzle
Liquid
coolant
While inundated vaporisers are generally bound to upright installation and coolant flow
and require special measures for ensuring oil return and avoiding cavitation, dry expansion
vaporisers where overheated steam is fundamentally present at the outlet can be installed
in virtually any position without any special measures having to be taken.
10-459
STRUCTURE AND FUNCTION AIR-CONDITIONER
Inspection
glass
The filter/dryer to expansion
valve
Design
The filter dryer contains a cleaning sieve, a drying agent for removing the moisture from
the coolant, an inspection glass for checking the level of coolant and a pressure switch
(high and low pressure) which switches the compressor off when the pressure on the high
pressure side of the system is too low or too high.
Because the drying agent in the filter dryer is very hygroscopic it immediately absorbs
moisture on coming into contact with the air and loses its demoisturising property. The
drying agent cannot absorb more than approx. 6-12 g moisture. For this reason, the inlet
and outlet have to be sealed tight with plugs whenever the filter dryer is removed.
When installing the air conditioning unit in
the vehicle, install all other parts and
pipelines first before removing the plugs
and mounting the filter dryer. Attention must
be paid that the inlet and outlet are not
confused. If the inlet and the outlet have the
same form, the connection marked "IN" or
with an arrow pointing in the direction of the Outlet
housing has to be connected to the
condenser side. If connected the other way Inlet
round, gaseous coolant flows into the
expansion valve which results in a
considerable drop in the coolant
performance of the system.
10-460
STRUCTURE AND FUNCTION AIR-CONDITIONER
DESCRIPTION
10-461
STRUCTURE AND FUNCTION AIR-CONDITIONER
1 Compressor
2 Suck pipe
3 Pressure pipe
4 Filling valves
5 Condenser 1
6 Connection hose condenser of 1+2
7 Condenser 2
8 Filter-drier with inspection glass
9 Air intake
10 Vaporizer
11 Thermistor
12 Heat exchanger radiator
13 Fan
14 Air filter outside air
15 Air filter inside air
16 Expansion valve
17 Switch for high and low pressure
18 Air outlet
Installation: WA 270-3 /
WA 320-3 SN H20561 and up
1 2
1. Controller
2. Fan
3. Thermistor
3
4. Vaporizer
7
5. Pressure switch
4
5 6. Filter dryer
6
7. Condenser
10-462
STRUCTURE AND FUNCTION AIR-CONDITIONER
1. Vent
2. Vent (Window)
4. Dry receiver
5. Compressor
1. Vent
2. Vent (Window)
3. Vent
4. Dry reciever
6. Compressor
10-463
STRUCTURE AND FUNCTION AIR-CONDITIONER
10-464
STRUCTURE AND FUNCTION AIR-CONDITIONER
SAFETY
10-465
STRUCTURE AND FUNCTION AIR-CONDITIONER
Handling coolants
When coolant circuits are opened, the contents may escape in liquid or vapour form. The
higher the pressure in the circuit, the more violently this will happen.
Exhaust system
Opening windows and doors may not be sufficient, that means an exhaust system must be
installed at the point of exit if possible or close to the floor. This is particularly important
when working with open liquid coolants such as R 11 and R 113.
Do not smoke
Coolants can decompose in the heat of a cigarette. The substances thus produced are
toxic and should not be breathed in.
Do not let coolants escape during filling or repair work, but transfer to recycling
containers
If coolants are allowed to escape in closed rooms, higher concentrations can arise which
poses a risk to life due to narcotic effects or lack of oxygen.
Always transfer coolants from plants in need of repair into recycling containers for
temporary storage and, after the repair work, refill into the plant or return to the dealer.
10-466
STRUCTURE AND FUNCTION AIR-CONDITIONER
If high concentrations of coolant are present in the air, use respiratory equipment
which is independent of the ambient atmosphere!
Filter masks with breathing filter A (solvents) can only remove coolant vapours to a small
extent. They may only be used if the concentration does not exceed 0.5 % vol. (see
respiratory equipment specifications). If the concentration is too high, there is a risk of
suffocation particularly in pits and shafts, since coolant vapours are heavier than air. In
case of doubt, always use respiratory equipment which is independent of the ambient
atmosphere.
Before carrying out welding and soldering work on cooling systems, remove
coolant from the relevant section of the plant and eliminate residue by blowing
through with air or nitrogen!
Decomposition products generated from the coolant are not only toxic but also have a
strongly corrosive effect, so that pipelines and parts of the plant may be attacked.
First aid
1. In the event of contact with the eyes or mucous membranes, rinse out immediately
with plenty of running water and consult an eye specialist.
2. In the event of contact with the skin, remove wet clothing immediately and rinse
affected area of skin with plenty of water.
3. If coolant vapours are breathed in in higher concentrations, get the affected person
into the fresh air immediately. Summon a doctor. Administer oxygen in the event
of breathing problems. If the affected person can no longer breathe or cannot
breathe properly, bend head to back of the neck and resuscitate.
10-467
STRUCTURE AND FUNCTION AIR-CONDITIONER
10-468
STRUCTURE AND FUNCTION AIR-CONDITIONER
OPERATION
10-469
STRUCTURE AND FUNCTION AIR-CONDITIONER
CONTROLLER
WA 270-3 /
WA 320-3 SN H20561 and up
WA 320-3 up to SN H20560 /
WA 380-3 / WA 420-3 / WA 470-3
Operating mode selector switch
for setting air direction or defrosting
Air recycling mode switch
Temperature
control Air conditioning system
step-free switch
Fan switch ON/OFF
and various stages Control panel for
temperatures
- If the machine has not been operated for longer than 1 week
- If the battery voltage is extremely low
• It is possible to generate overpressure in the cab by running fan at high level and
switching to fresh air setting to prevent penetration by dust.
10-470
STRUCTURE AND FUNCTION AIR-CONDITIONER
HINT
Cab windows, doors and ventilation openings must be closed when operating the air-
conditioning, otherwise there is an excessive influx of heat which presents an effective
cooling of the cab. If the machine has been standing in the sun for a longer period of time,
we recommend airing the cab completely when starting up the engine by switching on the
air-conditioning and leaving the doors and windows open initially. This process can be
speeded up by increasing revving up engine.
Operation: WA 270-3 /
WA 320-3 SN H20561 and up
Switch on air-conditioner
4 Push the switch (6) lock (5) down, hold in position and
press switch. The air-conditioning is now switched on
and the control lamp in the switch lights up.
10-471
STRUCTURE AND FUNCTION AIR-CONDITIONER
Temperature level
indicator lamp
1. FAN SWITCH
Via these switches, the air flow can be set to four
various levels.
This switch also acts as the main switch for the air
conditioner.
When the switch is pressed, the indicator lamp above
the respective switch lights up to indicate the air flow.
10-472
STRUCTURE AND FUNCTION AIR-CONDITIONER
The settings for each mode are retained in memory even when be starting switch is turned
OFF. However, in the following cases, the settings must be made again:
• When the machine has been out of use for more than
7 days
If the air conditioner is used together with the FRESH position, the inside of the cab will be
pressurized and this will prevent the entry of dust. The higher the position of the fan switch, the
more effective the pressurizing.
10-473
STRUCTURE AND FUNCTION AIR-CONDITIONER
SETTINGS
Switch 1 2 3 4 5
3 4
1 5 Temperature 2
control lamp
Set the temperature control switch to the maximum temperature in order to improve the
performance of the system during defrosting and demoisturizing.
Set the operating mode switch to LEGROOM at the same time.
The air flow can be directed to HEADROOM or switched off when the ventilating mode is
switched on.
Do not switch to ventilating mode HEADROOM if the ventilation slots are closed.
10-474
STRUCTURE AND FUNCTION AIR-CONDITIONER
MAINTENANCE
MAINTENANCE TIMETABLE
Replace filter dryer, suck off coolant, dispose in an environmentally safe manner
and fill the system with new coolant
10-475
STRUCTURE AND FUNCTION AIR-CONDITIONER
MAINTENANCE INSTRUCTIONS
Always disconnect the battery if parts of the air conditioning system are to be removed.
Always seal cable glands immediately with cap plugs when disconnecting cables.
Apply a few drops of low temperature oil to the contact surface of the O-ring or cone nut
before connecting a hose or line.
Always use two spanners when tightening a connection in order to prevent it from twisting.
A disposal unit must be connected when draining the cooling section of the system.
REGULAR MAINTENANCE
The air conditioning system must be switched on at least once a month for a brief time
(approx. 10 min) so that the compressor is lubricated.
The following maintenance work must be carried out at the beginning, middle and end of a
cooling period:
- Check V-belt tension and compressor fastening.
Have an inspection of the air conditioning system carried out at least once a year by your
workshop.
10-476
STRUCTURE AND FUNCTION AIR-CONDITIONER
• Filling the air conditioning system should only be carried out by a specialist for air
conditioning systems.
For this reason, only a few instructions are provided here for filling the air condition-
ing systems installed in WA-3 models.
Mixing with other coolants or oils can result in the destruction of the air
conditioning system.
• The valves on the testing manometer should be closed (manometer valves turned
clockwise) when fastening the snap-fit connectors to the system. The central valve
connection for selecting vacuum pump or filling canister connection is therefore
closed.
10-477
STRUCTURE AND FUNCTION AIR-CONDITIONER
EVACUATION
- Connect ball valves
- Set vacuum meter to 100 mbar
- Evacuate, min. 45 minutes
VACUUM TEST
- Check the vacuum meter after 10 minutes for pressure increase
+ A pressure increase is not permitted.
No pressure rise
- Fill system
FILLING
- Set prescribed Quantity on fill unit or weigh
- Commence filling
- Start engine
- Check on inspection glass of filter dryer
+ The filling is OK when the coolant flows
without bubbles.
- WA 270-3 1000 g
- WA 320-3 1500 g
- WA 380-3 1500 g
- WA 420-3 1500 g
- WA 470-3 1500 g
10-478
STRUCTURE AND FUNCTION AIR-CONDITIONER
Temperature of high High pressure pipie is hot. High pressure pipe is Amost no difference in
and low Low pressure pipe is cold. warm. Low pressure pipe temperature between high
pressures pipes Clear difference in is cold. Little difference in and low pressure pipes.
temperature temperature
Sight glass Almost transparent. All Bubbles are always visible. Opaque substance is
bubbles disappear if the Sometimes becomes visible in the fluid.
engine speed is increased transparent, or white
or reduced. bubbles appear.
Pipe connections Properly connected Some parts contaminated Some parts heavily stained
with oil. with oil.
General condition of Coolant level correct, no There may be a leak Almost all coolant has
cooler abnormalities. somewhere. leaked out.
Ready for use. Call service repair shop for Contact service repair
inspection. shop immediately.
10-479
STRUCTURE AND FUNCTION AIR-CONDITIONER
4. Screw in drain plug with new washer and tighten. MA = 13-15 Nm.
5. Fill up with new compressor oil to same amount as measured quantity of drained oil.
- Remove compressor
- Remove old clutch from compressor
- Install compressor
- Switch on air conditioning system
- Switch air conditioning on for 10 seconds and off for 10 seconds at least 10 times,
check function of new clutch while doing so.
10-480
STRUCTURE AND FUNCTION AIR-CONDITIONER
EXCHANGE OF COMPRESSOR
The compressor has to be installed within the range shown in the figure.
If installed outside this range, the compressor will be adversely affected.
This compressor is equipped with a pressure feed lubrication system which cannot
function properly if the compressor is installed outside this range.
- The new compressor is filled with 150cm³ PAG oil and nitrogen gas (N2).
1. Loosen the discharge side connector's cab, release the nitrogen gas (N2) from
the compressor gently, close the connectors immediately.
3. Replace the compressor under compliance of the ranges shown in the figure above.
Adjust the clearance using the specified shims.
10-481
STRUCTURE AND FUNCTION AIR-CONDITIONER
Service operations
Always use a
back-up wrench
and tighten fittings
to the specified
torque. The torque
wrench should be
used on the fitting
which is being
tightened.
10-482
STRUCTURE AND FUNCTION AIR-CONDITIONER
ELECTRICAL SYSTEM
10-483
STRUCTURE AND FUNCTION AIR-CONDITIONER
Function
Head room Foot area
Shutter position Head room & Foot area & Front screen
foot area front screen
Shutter left à ---------- 20 32 34 End position
Shutter left à End position 31 20 32 ----------
Shutter right ß ---------- 33 13 30 End position
Shutter right ß End position 22 33 13 ----------
10-484
STRUCTURE AND FUNCTION AIR-CONDITIONER
10-485
STRUCTURE AND FUNCTION AIR-CONDITIONER
10-486
STRUCTURE AND FUNCTION AIR-CONDITIONER
10-487
STRUCTURE AND FUNCTION AIR-CONDITIONER
Section Name
40 K 292 Relay
43 S 293.1 Thermostat
10-488
STRUCTURE AND FUNCTION AIR-CONDITIONER
30
15
10-489
STRUCTURE AND FUNCTION AIR-CONDITIONER
Technical data
Heating
Type Water / Air
Nominal voltage 24 Volt
Air flow rate max. 600 m³/h
Heat output Q 100 6.5 kW
Fan stages 4
Power consumption max. 10 amperes
Condenser
Type Coolant / Air
Number 2
Nominal voltage 24 Volt
Air flow rate max. 1260 m³/h
Heat output 6 kW
Fan stages 1
Power consumption max. 4.7 amperes
Coolant R134a
10-490
STRUCTURE AND FUNCTION AIR-CONDITIONER
Technical data
Compressor
Type Seltec TM - 15H
Nominal voltage 24 Volt
Max. speed 6000 rpm
Delivery rate 147 cm³
Rotational direction Clockwise or anti-clockwise
Coolant R134a
Type of oil ZXL100PG (PAG oil)
Filling quantity 150 cm³
Weight 7 kg
Power consumption max. 3.75 amperes
Filter drier
Content 0.7 litres
Filtration Up to particle size > 6 micrometer
Water absorption of drying element (plug) 16 g
Coolant R134a
Weight 1 kg
Filling quantities
WA270-3 1000 g
WA320-3 1500 g
WA380-3 1500 g
WA420-3 1500 g
WA470-3 1500 g
Magnetic clutch
Switching capacity 3.5 amps 13 VDC
10-491
STRUCTURE AND FUNCTION AIR-CONDITIONER
10-492
STRUCTURE AND FUNCTION AIR-CONDITIONER
FAULT DIAGNOSIS
10-493
STRUCTURE AND FUNCTION AIR-CONDITIONER
PRECONDITIONS
3 4 13
II
I
b) Fuses OK
10-494
STRUCTURE AND FUNCTION AIR-CONDITIONER
FAN
OFF LO O OO HI
- Beep tone
- Control lamp on yes
- Air flow rate corresponds with O. K.
level setting
no
no
no
10-495
STRUCTURE AND FUNCTION AIR-CONDITIONER
- Beep tone
- Control lamp on yes
- Air flow on right channel O. K.
no
no
no
10-496
STRUCTURE AND FUNCTION AIR-CONDITIONER
- Beep tone
- Control lamp on
- Air suction through air recycling yes
filter, possibly visual check of shutter O. K.
position (remove filter)
no
no
no
Control yes
actuator faulty? exchange
yes
Cable set faulty? exchange
10-497
STRUCTURE AND FUNCTION AIR-CONDITIONER
TEMPERATURE SETTING
- Beep tone
- The more control lamps yes
are on, the warmer the air O. K.
- Check water valve function
no
Mech. fault?
Visual check of actuator, rods, yes exchange,
water valve, feed, return repair
no
no
yes exchange,
Cable set faulty?
repair
10-498
STRUCTURE AND FUNCTION AIR-CONDITIONER
A/C
- Beep tone
- Control lamp on
- Fan min. stage 1 yes
- Noticeable cooling of air O. K.
no
no
no
Compressor yes
exchange
faulty?
Check clutch,
apply 24 V to compressor
connection
10-499
STRUCTURE AND FUNCTION AIR-CONDITIONER
10-500
STRUCTURE AND FUNCTION AIR-CONDITIONER
Troubleshooting
- Check condenser
- Compressor clutch OK
- Air temperature OK
10-501
STRUCTURE AND FUNCTION AIR-CONDITIONER
Low pressure too low - Faulty expansion valve - Replace expansion valve
High pressure normal - Dirty or blocked vaporiser - Clean or replace vaporiser
Low pressure too low - Expansion valve faulty - Replace expansion valve
High pressure too low - Not enough coolant - Refill air conditioning system
- Insufficient cooling effect - Evacuate system, replace
only for short time; water in dryer
system, expansion valve iced - Replace dryer and expansion
up as a result valve
- Dryer or expansion valve - Check the ON and OFF
partially blocked times of the compressor
- Vaporiser iced up - Adjust or replace the
- Thermoswitch not working thermoswitch
Compressor switches on and off at - Loose contact in the - Check electrical system (air
speed electrical system conditioner switch,
- Coolant pressure too high thermostat)
- Check air conditioning
system pressure and refill if
necessary
Compressor constantly running as - Thermostat not working - Check whether sensor lead
well has been pushed into the
vaporiser correctly
- Check whether the sensor
lead is okay
- Adjust or replace thermostat
Compressor does not switch on - Not enough coolant in system - Check air conditioning
- Air conditioning system system pressure and refill if
power supply interrupted necessary
- Check electrical system
Condenser fan not working - Fault in the electrical system - Check electrical system
- Fan faulty - Repair fan or replace
10-502
STRUCTURE AND FUNCTION AIR-CONDITIONER
Cooling output too low - Vaporiser iced up - Check whether sensor lead
has been pushed into the
vaporiser correctly
- Check whether the sensor
lead is okay
- Adjust or replace thermostat
Cooling output drops after a while - Compressor not switching off - Check whether compressor
- Thermostat not working switches on and off
- Check whether sensor lead
has been pushed into the
vaporiser correctly
- Check whether the sensor
lead is okay
- Adjust or replace thermostat
Air conditioning system not - Power supply interrupted - Check electrical system
working - Not enough coolant in the - Check filling level
system - Check magnetic clutch,
- Magnetic clutch faulty replace if necessary
White smoke emerging from the - Vaporiser iced up - Check whether compressor
air vents - Thermostat set too cold switches on and off
- Check whether sensor lead
has been pushed into the
vaporiser correctly
- Check whether the sensor
lead is okay
- Adjust or replace thermostat
Windows fogged up - Circulating air flaps not - Check whether the circulating
working or not working air system is working properly
properly - Check that the condensation
- Condensation unable to drain drain hose is not blocked and
away is correctly laid
Bad smell coming from air - Condensation not draining - Check that the condensation
conditioning system away drain hose is not blocked and
is correctly laid
10-503
STRUCTURE AND FUNCTION AIR-CONDITIONER
10-504
20 TESTING AND ADJUSTING
Standard value table for engine ......................... 20-2 Measuring accelerator pedal .................... 20-137
Standard value table for chassis .......................20-4 Basic adjustment of accelerator pedal ... 20-138-1
Test certificate ...................................................20-8 Measuring operating force, travel of
Standard value table for electrical system ....... 20-12 speed lever .............................................. 20-139
Tools for testing, adjusting and Measuring stall speed............................... 20-140
troubleshooting .............................................. 20-101 Measuring torque converter, transmission,
Up to SN WA380H20500: parking brake oil pressure ....................... 20-142
Adjusting valve clearance .............................. 20-103 Method of operating emergency
Measuring compression pressure ................. 20-107 manual spool ............................................ 20-144
Measuring blow-by pressure ......................... 20-109 Measuring clearance ............................... 20-146
Testing and adjusting fuel injection timing ...... 20-111 between tire and wheel ............................. 20-146
Measuring intake air pressure ....................... 20-113 Measuring steering oil pressure ............... 20-149
Measuring engine oil pressure ...................... 20-114 Measuring operating force, travel of
Measuring engine speed ............................... 20-115 brake pedal .............................................. 20-151
Measuring stall speed.................................... 20-116 Measuring brake performance ................. 20-152
Testing the fan belt tension ............................ 20-118 Testing brake oil pressure ........................ 20-153
Measuring turbocharger clearance ............... 20-119 Testing for brake disk wear ...................... 20-154
Turbocharger wastegate actuator Bleeding air from brake system................ 20-155
- visual inspection ......................................... 20-120 Measuring parking brake performance .... 20-156
Turbocharger wastegate actuator- Manual release method for parking
functional checking ....................................... 20-122 brake ....................................................... 20-157
SN WA380H20501 and up: Testing wear of parking brake disk ........... 20-158
Adjusting valve clearance .............................. 20-123 Measuring work equipment control lever .. 20-159
Measuring compression pressure ................. 20-124 Measuring work equipment
Measuring blow-by pressure ......................... 20-125 hydraulic pressure ................................... 20-161
Testing and adjusting fuel injection timing ...... 20-126 Measuring PPC-valve pressure ................ 20-163
Measuring exhaust color ............................... 20-129 Measuring work equipment ...................... 20-167
Measuring intake air pressure Testing and adjusting bucket positioner .... 20-169
(boost pressure) ........................................... 20-130 Testing and adjusting boom kick-out ......... 20-170
Measuring exhaust gas pressure ................... 20-131 Adjusting main monitor ............................. 20-172
Measuring engine oil pressure ...................... 20-132 Gas side test and topping up gas
Measuring engine speed ............................... 20-133 pressure .................................................. 20-173
Testing and adjusting fan belt tension ............ 20-134 Hydraulic accumulator ............................. 20-175
Method for adjusting engine stop cable ......... 20-135
« 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.
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.
When carrying out work together with other workers, always use signals and do not let unauthorized people near the
machine.
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.
Be careful not to get caught in the fan, fan belt, or other rotating parts.
20-1
TESTING AND ADJUSTING STANDARD VALUE TABLE FOR ENGINE
At rated output
Blowby pressure
(SAE 30 oil) mmH2O Max. 80 160
(Water temperature:
Operating range)
(Water temperature:
Operating range)
°
Fuel injection timing Before top dead center (degree) 22 22 ± 1
20-2
TESTING AND ADJUSTING STANDARD VALUE TABLE FOR ENGINE
At rated output
Blowby pressure
(SAE 30 oil) mmH2O Max. 164 226
(Water temperature:
Operating range)
(Water temperature:
Operating range)
°
Fuel injection timing Before top dead center (degree) 16
20-3
TESTING AND ADJUSTING STANDARD VALUE TABLE FOR CHASSIS
Cate- Permissible
gory Item Measurement conditions Unit Standard value value
Torque converter stall • Engine water temperature 2,290 ± 50 2,290 ± 100
gauge: Green range
Engine
Hydraulic stall • Torque converter oil rpm 2,300 ± 100 2,300 ± 200
temperature: 60 – 80°C
Full stall • Hydraulic oil 1830 ± 200 1830 ± 300
temperature: 45 – 55°C
α1 48 —
Operating angle deg.
α2 31 ± 3 —
Stopper height L1 mm 51 ± 5 —
+4.9 +0.5
Directional lever
N – FORWARD 40 ± 10 40 ± 20
Travel mm
N – REVERSE 40 ± 10 40 ± 20
1st ↔ 2nd 40 ± 10 40 ± 20
20-4
TESTING AND ADJUSTING STANDARD VALUE TABLE FOR CHASSIS
B mm Max. 4.5 —
Clearance of wheel C 2 – 12 —
lock ring
• Engine stopped
Play • Machine facing straight mm 30 – 70 30 – 100
to front
Steering wheel
Play 5 ± 0.5 —
α1 deg. 45 —
Operating angle
α2
Brakes
15 ± 1 —
20-5
TESTING AND ADJUSTING STANDARD VALUE TABLE FOR ENGINE
37.3
LOWER à HOLD —
(3.8)
N Max. 34.3 52
LOWER à FLOAT
Work equipment control lever
HOLD à RAISE 67 ± 15 67 ± 30
HOLD à FLOAT mm 67 ± 15 67 ± 30
HOLD à DUMP 60 ± 15 60 ± 30
Bucket
HOLD à TILT 60 ± 15 60 ± 30
• Hydraulic oil
Main control
Relief pressure on High mode (from 2.94 (30 ) 2.94- 0.19 (30 - 2 )
0 0
SN WA380H20987 and up)
Boom lifting time 5.5 ± 0.3 1) Max. 8.7
Work equipment speed
Work equipment
20-6
TESTING AND ADJUSTING STANDARD VALUE TABLE FOR ENGINE
3–5 —
switch
Accumulator 20 14
ALS
• Hydraulic oil
bar
Working pressure temperature: 45 – 55°C 98 +5 103
20-7
TESTING AND ADJUSTING TEST CERTIFICATE
up to SN WA380H20500
All pressures and timings to be measured with the machine at working temp. Sep. 97
20-8
TESTING AND ADJUSTING TEST CERTIFICATE
From SN WA380H20501
up to SN WA380H20986
All pressures and timings to be measured with the machine at working temp. Jan. 98
20-9
TESTING AND ADJUSTING TEST CERTIFICATE
SN WA380H20987 and up
Operating temp ° C
8 Engine (in operating temperature)
9 Torque converter 60 - 80
10 Hydraulic oil 45 - 55
20-10
Blank for technical reason
20-11
TESTING AND ADJUSTING STANDARD VALUE TABLE FOR ELECTRICAL SYSTEM
Short connector
below, the sensor is defective. switch ON.
Normal temperature
(25°C) Approx. 38 - 48 kΩ
Engine water CN E06
temperature sensor 100°C Approx. 3.6 - 3.9 kΩ
20-12
TESTING AND ADJUSTING STANDARD VALUE TABLE FOR ELECTRICAL PARTS
chassis ground
Connec to
Terminal wiring Monitor goes off
harness disconnected
Low pressure switch CN B13 If the condition is as shown in the table Turn starting
below, the sensor is normal. switch OFF.
Check continuity
Disconnect
connector.
Oil pressure above Continuity
60 bar
Oil pressure below No continuity
40 bar
20-13
TESTING AND ADJUSTING STANDARD VALUE TABLE FOR ELECTRICAL SYSTEM
resistance
Measure
Engine water CNE 05 Normal temp. Approx. 2 kΩ 2) Disconnect
temperature sensor (male) (25°C) Between CNE05 CNE05.
Main monitor
20-14
TESTING AND ADJUSTING STANDARD VALUE TABLE FOR ELECTRICAL SYSTEM
resistance
Measure
Relief solenoid 2) Disconnect
for cylinder rod CNAF4 Between 20 - 40 Ω CNAF4.
E.C.S.S. controller (if equipped)
(male) –
resistance
Measure
High pressure 2) Disconnect
solenoid CNAF5 Between 20 - 40 Ω CNAF5.
(male) –
pressure 2) Disconnect
solenoid CNAF6 Between 20 - 40 Ω CNAF6.
(male) –
20-15
TESTING AND ADJUSTING STANDARD VALUE TABLE FOR ELECTRICAL SYSTEM
Short connector
below, the sensor is defective. switch ON.
Short connector
connected Monitor goes off
Chassis ground
connected Monitor goes off
+1
Fuel level sensor XR7 Full Approx. 10 – 3Ω
Empty Approx. 85 – 95 KΩ
20-16
TESTING AND ADJUSTING STANDARD VALUE TABLE FOR ELECTRICAL SYSTEM
chassis ground
below, the sensor is defective. switch ON.
Connect to
Terminal wiring Monitor goes off
harness disconnected
Connected to
chassis ground Monitor lights up
Engine oil pressure
sensor XB19 If the condition is as shown in the table Start engine.
Check continuity
20-17
TESTING AND ADJUSTING STANDARD VALUE TABLE FOR ELECTRICAL SYSTEM
Measure
voltage
Alternator alternator (half throttle or above) à 27.5 – 29.5 V
terminal R If the battery is old, or after starting in cold
and chassis areas, the voltage may not rise for some time.
2) Disconnect
Engine water XB14
ance Normal tem- Approx. 2 kΩ CNE05.
temperature sensor perature (25°C) Between CNE05
(male) – GND
Pre-heating 5°C Approx. 4 kΩ
resistance
2) Disconnect
F solenoid XT01 connector.
Between (1) – (2) 46 – 58 kΩ
2) Disconnect
R solenoid XT02 connector.
Between (1) – (2) 46 – 58 kΩ
2) Disconnect
H-L solenoid XT03 connector.
Between (1) – (2) 46 – 58 kΩ
2) Disconnect
Speed solenoid XT04 connector.
Between (1) – (2) 46 – 58 kΩ
2) Disconnect
Modulation valve XT12
solenoid Between (1) – (2) 12 – 15 Ω connector.
20-18
TESTING AND ADJUSTING STANDARD VALUE TABLE FOR ELECTRICAL SYSTEM
resistance
Measure
below, it is normal. switch OFF.
Relief solenoid for XF4 2) Disconnect
ALS controller (if equipped)
resistance
Measure If the condition is as shown in the table 1) Turn starting
below, it is normal. switch OFF.
Low pressure XF6 2) Disconnect
solenoid
Between (1) – (2) 20 Ω CNAF6.
resistance
20-19
TESTING AND ADJUSTING STANDARD VALUE TABLE FOR ELECTRICAL SYSTEM
Short connector
below, the sensor is defective. switch ON.
Short connector
connected Monitor goes off
Chassis ground
connected Monitor goes off
+1
Fuel level sensor XR7 Full Approx. 10 – 3Ω
Empty Approx. 85 – 95 KΩ
20-20
TESTING AND ADJUSTING STANDARD VALUE TABLE FOR ELECTRICAL SYSTEM
chassis ground
below, the sensor is defective. switch ON.
Connect to
Terminal wiring Monitor goes off
harness disconnected
Connected to
chassis ground Monitor lights up
Engine oil pressure
sensor XB19 If the condition is as shown in the table Start engine.
Check continuity
20-21
TESTING AND ADJUSTING STANDARD VALUE TABLE FOR ELECTRICAL SYSTEM
Measure
voltage
Alternator alternator (half throttle or above) à 27.5 – 29.5 V
terminal R If the battery is old, or after starting in cold
and chassis areas, the voltage may not rise for some time.
2) Disconnect
Engine water XB14
ance Normal tem- Approx. 2 kΩ XB14.
temperature sensor perature (25°C) Between XB14
(male) – GND
Pre-heating 5°C Approx. 4 kΩ
resistance
2) Disconnect
F solenoid XT01 connector.
Between (1) – (2) 46 – 58 kΩ
2) Disconnect
R solenoid XT02 connector.
Between (1) – (2) 46 – 58 kΩ
2) Disconnect
H-L solenoid XT03 connector.
Between (1) – (2) 46 – 58 kΩ
2) Disconnect
Speed solenoid XT04 connector.
Between (1) – (2) 46 – 58 kΩ
20-22
TESTING AND ADJUSTING STANDARD VALUE TABLE FOR ELECTRICAL SYSTEM
resistance
Measure
below, it is normal. switch OFF.
Relief solenoid for XF4 2) Disconnect
ALS controller (if equipped)
resistance
Measure If the condition is as shown in the table 1) Turn starting
below, it is normal. switch OFF.
Low pressure XF6 2) Disconnect
solenoid
Between (1) – (2) 20 Ω XF6.
resistance
20-23
Blank for technical reason
20-24
TESTING AND ADJUSTING TOOLS FOR TESTING, ADJUSTING, AND TROUBLESHOOTING
Pressure gauge
799–101–5002 Analog hydraulic tester 2.45, 5.88, 39.2, 58.8 MPa
(25, 60, 400, 600 bar)
Oil pressure C Pressure gauge
790–261–1203 Digital hydraulic tester 49.0 MPa (500 bar)
1 799–201–1511 Tool
2 799–201–1541 Gauge
Blowby pressure E Kit Part No.
3 799–201–1571 Tube 799–201–1504
4 799–201–1450 Adapter
Commercially Feeler gauge
Valve clearance F available —
Discoloration 0 – 70 % (with
1 799–201–9000 standard color)
Handy smoke checker (Discoloration % x 1/10 =.. Bosch
Exhaust color G index)
Commercially —
2 available Smoke meter
Commercially
Pushing angle M available Angle gauge —
Commercially
Pushing force N available Push gauge —
Commercially
Stroke O available Scale —
Commercially
Speed R available Stop watch —
20-101
20-102
TESTING AND ADJUSTING ADJUSTING VALVE CLEARANCE
Tool:
1/2 Inch Drive, 3377381 Barring Gear
20-103
TESTING AND ADJUSTING ADJUSTING VALVE CLEARANCE
When the engine timing pin engages the hole in the Camshaft-
camshaft gear, Cylinder Number 1 is at TDC on the gear
compression stroke.
Timing pin
Feeler Gauge
Tool:
14 mm, Flatbiade Screwdriver
Torque Value: 24 Nm
20-104
TESTING AND ADJUSTING ADJUSTING VALVE CLEARANCE
Torque Value: 24 Nm
Install the rubber seal into the groove in the valve cover.
Start the installation at the overlap area shown in the
illustration. Do not stretch the rubber seal.
Torque Value: 24 Nm
20-105
TESTING AND ADJUSTING ADJUSTING VALVE CLEARANCE
A = 24 Nm
B = 43 Nm
Install the air crossover tube and any other parts previ-
ously removed to gain access to the valve cover.
20-106
TESTING AND ADJUSTING MEASURING COMPRESSION PRESSURE
MEASURING COMPRESSION
PRESSURE
SN WA380H20501 and up
20-107
TESTING AND ADJUSTING MEASURING COMPRESSION PRESSURE
Service Tip: Remove the drive belt from the water pump.
Run the engine for 1 to 2 minutes and check for coolant
being blown from the radiator.
20-108
TESTING AND ADJUSTING MEASURING BLOW-BY PRESSURE
MEASURING BLOW-BY
PRESSURE
SN WA380H20501 and up
Manometer
Test specifications:
Coolant temperature: 100°C
New engine (L/min) Used engine (L/min)
Blowby: 6CT8.3 113 226
6CTA8.3 113 226
All engines built after ESN 21087046 164 226
The blowby checking tool, Cummins P/N 3822566, has a special 7.67mm orifice that must be used to
obtain an accurate reading.
20-109
TESTING AND ADJUSTING MEASURING BLOW-BY PRESSURE
1 50
2 84
3 103
4 119
5 133
6 145
7 155
8 164
9 172
10 180
11 187
12 193
13 200
14 206
15 211
16 217
17 222
18 226
19 229
20 235
21 239
22 242
23 246
24 248
20-110
TESTING AND ADJUSTING TESTING AND ADJUSTING FUEL INJECTION TIMING
The fuel injection pump also has a timing pin (1), lo-
cated in the governor housing, to position the fuel injec-
tion pump shaft to correspond with TDC for cylinder
number 1. After the fuel injection pump is installed, the
timing pin is to be reversed and stored in the housing
(2).
20-111
TESTING AND ADJUSTING TESTING AND ADJUSTING FUEL INJECTION TIMING
If the timing tooth is not aligned with the timing pin hole,
rotate the pump shaft until the timing tooth aligns.
Install and secure the timing pin with the access plug.
20-112
TESTING AND ADJUSTING MEASURING INTAKE AIR PRESSURE (BOOST PRESSURE)
20-113
TESTING AND ADJUSTING MEASURING ENGINE OIL PRESSURE
Check the oil gauge and sending unit to make sure they
are operating correctly by verifying the pressure with a
manual gage.
20-114
TESTING AND ADJUSTING MEASURING ENGINE SPEED
SN WA380H20501 and up
« Measurement conditions
20-115
TESTING AND ADJUSTING MEASURING STALL SPEED
20-116
TESTING AND ADJUSTING MEASURING STALL SPEED
20-117
TESTING AND ADJUSTING TESTING THE FAN BELT TENSION
Torque Value: 43 Nm
20-118
TESTING AND ADJUSTING TURBOCHARGER
MEASURING TURBOCHARGER
CLEARANCE
SN WA380H20501 and up
Clearance (A) mm
* min 0,10
max 0,16
** min 0,03
max 0,08
* Turbocharger up to SN 840637
** Turbocharger SN 840638 and up
Clearance (B) mm
min 0,21
max 0,46
20-119
TESTING AND ADJUSTING WASTEGATE
TURBOCHARGER WASTEGATE
ACTUATOR - VISUAL INSPECTION
SN WA380H20501 and up
20-120
TESTING AND ADJUSTING WASTEGATE
20-121
TESTING AND ADJUSTING WASTEGATE
TURBOCHARGER WASTEGATE
ACTUATOR
- FUNCTIONAL CHECKING
SN WA380H20501 and up
20-122
ADJUSTING VALVE CLEARANCE ADJUSTING VALVE CLEARANCE
« Valve arrangement
Cylinder no. 1 2 3 4 5 6
Intake valve l l ¡ l ¡ ¡
Exhaust valve l ¡ l ¡ l ¡
20-123
ADJUSTING VALVE CLEARANCE MEASURING COMPRESSION PRESSURE
MEASURING COMPRESSION
PRESSURE
Up to SN WA380H20500
20-124
TESTING AND ADJUSTING MEASURING BLOW-BY PRESSURE
MEASURING BLOW-BY
PRESSURE
Up to SN WA380H20500
20-125
TESTING AND ADJUSTING TESTING AND ADJUSTING FUEL INJECTION TIMING
20-126
TESTING AND ADJUSTING TESTING AND ADJUSTING FUEL INJECTION TIMING
20-127
TESTING AND ADJUSTING TESTING AND ADJUSTING FUEL INJECTION TIMING
20-128
TESTING AND ADJUSTING MEASURING EXHAUST COLOR
20-129
TESTING AND ADJUSTING MEASURING INTAKE AIR PRESSURE (BOOST PRESSURE)
Note:
Run the engine at a mid-range speed or above, and
use the self-seal portion of the gauge to bleed the
oil from inside the hose.
• Insert the gauge about half way, and repeatedly
open the self-seal portion to bleed the oil.
20-130
TESTING AND ADJUSTING MEASURING EXHAUST GAS TEMPERATURE
Measurement procedure
1. Measuring at torque converter stall
« If the exhaust gas temperature is measured
only at torque converter stall, and this is contin-
ued until the sensor core heats up and a stable
value is obtained, the torque converter will over-
heat.
1) Use the full stall (torque converter stall + hy-
draulic relief) to raise the exhaust gas tempera-
ture .
2) From the above condition, cancel the hydraulic
relief, and carry out only torque converter stall.
(The temperature will start to go down. If it
does not go down and continues to go up, make
the temperature setting at 1) higher.)
3) When the temperature starts to go down, record
the stable temperature.
2. When measuring maximum value for exhaust gas
temperature
Carry out actual work and measure the maximum
value when operating.
« Use the PEAK mode function (the maximum
value can be recorded) of the temperature
gauge.
20-131
TESTING AND ADJUSTING MEASURING ENGINE OIL PRESSURE
1. Remove plug.
2. Install coupler (1) on the oil pressure release
port.
3. Attach hose (2) to coupler (1) and install tool C
(gauge: 0.98 MPa (10 bar)).
4. Start the engine and measure the oil pressure.
20-132
TESTING AND ADJUSTING MEASURING ENGINE SPEED
20-133
TESTING AND ADJUSTING TESTING AND ADJUSTING FAN BELT TENSION
20-134
TESTING AND ADJUSTING METHOD FOR ADJUSTING ENGINE STOP MOTOR CABLE
20-135
TESTING AND ADJUSTING METHOD FOR ADJUSTING ENGINE STOP MOTOR CABLE
20-136
TESTING AND ADJUSTING MEASURING ACCELERATOR PEDAL
MEASURING ACCELERATOR
PEDAL
« Measurement conditions
• Engine water temperature: Within green range on
engine water temperature gauge
1. Measuring
1) Set push-pull scale K at a position 150 mm
from pedal fulcrum a.
« Put the center of push-pull scale K in con-
tact with a point 150 mm from the pedal
fulcrum.
2. Testing
1) Stop the engine.
2) Disconnect cable (1) at the bottom of the accel-
erator pedal and check that there is no heavi-
ness in the accelerator pedal linkage.
3) Connect cable (1) at the bottom of the pedal,
detach cable (2) at the injection pump connec-
tion, and check that there is no heaviness in the
cable.
Cable joint nut:
13.7 ± 0.98Nm(1.4 ± 0.1kgm)
20-137
TESTING AND ADJUSTING MEASURING ACCELERATOR PEDAL
1. Measuring
1) Stop the engine.
2. Adjusting
1) Remove the cover at the bottom of the cab, and
open the inspection cover of the engine hood.
20-138
TESTING AND ADJUSTING BASIC ADJUSTMENT OF ACCELERATOR PEDAL
BASIC ADJUSTMENT
OF ACCELERATOR PEDAL SN WA380H20987 and up
« Measurement conditions
(5)
• Engine water temperature: Within green range
on engine water temperature gauge
• Hydraulic oil temperature: 45 – 55°C
• Torque converter oil temperature: 60 – 80°C ‘A’
NOTE:
With full speed (accelerator pedal on stop), the
lever on the injection pump must not be connected
to the stop.
20-139
20-138-1
Blank for technical reason
20-138-2
20-140
TESTING AND ADJUSTING MEASURING OPERATING FORCE, TRAVEL OF SPEED LEVER
MEASURING OPERATING
FORCE, TRAVEL OF SPEED
LEVER
« Measurement conditions
• Engine stopped
• Torque converter oil temperature: 60 – 80°C
Block the tires securely.
20-139
TESTING AND ADJUSTING MEASURING STALL SPEED
« Check that low idling and high idling are the stand-
ard values.
« Before measuring each stall speed, install multi-
tachometer A to speed pickup port (1) on the en-
gine block.
« Check that the engine speed is the standard value.
If it is not within the standard range, check for loose
linkage or play.
20-140
TESTING AND ADJUSTING MEASURING STALL SPEED
20-141
MEASURING TORQUE CONVERTER, TRANSMISSION,
TESTING AND ADJUSTING PARKING BRAKE OIL PRESSURE
Preparatory work
20-142
MEASURING TORQUE CONVERTER, TRANSMISSION,
TESTING AND ADJUSTING PARKING BRAKE OIL PRESSURE
Measuring procedure
1. Priority pressure
1) Measuring port (P1, PT1/8)
2) Start the engine and measure the pressure at
low and high idle.
3. Pilot pressure
1) Measuring port (P3, PT1/8)
2) Start the engine and measure the pressure.
4. Clutch pressure
1) Measuring port (P4, PT1/8)
2) Start the engine, set the forward/reverse lever
to neutral, and measure the pressure when the
gear shift lever is operated.
20-143
TESTING AND ADJUSTING METHOD OF OPERATING EMERGENCY MANUAL SPOOL
METHOD OF OPERATING
EMERGENCY MANUAL SPOOL
Outline
20-144
TESTING AND ADJUSTING METHOD OF OPERATING EMERGENCY MANUAL SPOOL
20-145
TESTING AND ADJUSTING MEASURING CLEARANCE BETWEEN TIRE AND WHEEL
MEASURING CLEARANCE
BETWEEN TIRE AND WHEEL
« Measurement conditions
• Tire inflation pressure: Specified pressure
Method of measuring
1. Fitting of wheel lock ring
Using feeler gauge, measure dimensions A and B
at four places around the circumference.
20-146
TESTING AND ADJUSTING TESTING AND ADJUSTING STEERING WHEEL
« Measurement conditions
Measurement method
20-147
TESTING AND ADJUSTING TESTING AND ADJUSTING STEERING WHEEL
« Measurement conditions
Measurement method
20-148
TESTING AND ADJUSTING MEASURING STEERING OIL PRESSURE
20-149
TESTING AND ADJUSTING MEASURING STEERING OIL PRESSURE
Adjusting
20-150
TESTING AND ADJUSTING MEASURING OPERATING FORCE, TRAVEL OF BRAKE PEDAL
MEASURING OPERATING
FORCE, TRAVEL OF BRAKE
PEDAL
« Measurement conditions
Travel of pedal
1. Fit push gauge N to your foot.
« Set the push gauge at a position 150 mm from
the pedal fulcrum.
Pedal play
20-151
TESTING AND ADJUSTING MEASURING BRAKE PERFORMANCE
MEASURING BRAKE
PERFORMANCE
« Measurement conditions
• Road surface: Flat, horizontal, dry paved surface
• Travel speed: 20 km/h when brakes are applied
• Delay in applying brakes: 0.1 sec
• Tire inflation pressure: Specified pressure
Measurement method
1. Start the engine and move the machine.
20-152
TESTING AND ADJUSTING TESTING BRAKE OIL PRESSURE
Measuring procedure
1. Stop the engine.
2. Disconnect brake tube (1) on the side to be meas-
ured.
3. Disconnect union (2), install joint and attach
hydraulic test kit C
.
« Use the O-ring installed on the union. (O- ring:
07002-02034)
« Connect the hydraulic test kit quick coupler.
4. Loosen bleeder screw (3) and bleed the air.
« Bleed the air by activating pump .
5. Tighten bleeder screw (3), activate pump , in-
crease the pressure to 4.9 MPa (50 bar), then
tighten stop valve .
6. Let sit for five minutes with pressure applied and
check the pressure decrease.
* Do not move the hose while the pressure is
being measured, as this will cause pressure
fluctuations.
* After testing, activate pump and lower the
pressure of hydraulic test kit C before removing
the test kit.
* When testing is completed, install the brake
tube and bleed the air from the brake circuit.
20-153
TESTING AND ADJUSTING TESTING FOR BRAKE DISC WEAR
« Measurement conditions
• Engine water temperature: Within engine water tem-
perature gauge green range
Apply the parking brake and chocks the tires.
Measuring
1. Loosen drain plug (1) and drain the axle oil.
Axle oil: 32 l
Axle oil: 32 l
20-154
TESTING AND ADJUSTING BLEEDING AIR FROM BRAKE SYSTEM
20-155
TESTING AND ADJUSTING MEASURING PARKING BRAKE PERFORMANCE
Measurement method
20-156
TESTING AND ADJUSTING MANUAL RELEASE METHOD FOR PARKING BRAKE
20-157
TESTING AND ADJUSTING TESTING WEAR OF PARKING BRAKE DISC
20-158
TESTING AND ADJUSTING MEASURING WORK EQUIPMENT CONTROL LEVER
Measurement method
1. Operating force of work equipment control lever
Install push-pull scale K to the work equipment con-
trol lever and measure the operating force.
« Install the push-pull scale to the center of the
knob.
« Operate the control lever at the same speed as
for normal operations, and measure the mini-
mum value for the force needed to operate the
knob.
20-159
TESTING AND ADJUSTING MEASURING WORK EQUIPMENT CONTROL LEVER
Adjusting
1. Remove cover (1).
3. Boom lever
Operate the boom lever and adjust the length of rod
(2) so that roller (4) is dimension b at the notch at
both ends of cam (3).
Dimension b: 0 – 1 mm
4. Bucket lever
Operate the lift lever and adjust the length of rod (2)
so that roller (7) is dimension C at the notch at both
ends of cam (8).
Dimension C: 0 – 1 mm
20-160
TESTING AND ADJUSTING MEASURING WORK EQUIPMENT HYDRAULIC PRESSURE
3. Start the engine, raise the boom about 400 mm, tilt
back the bucket using the control lever, and meas-
ure the pressure when the relief valve is activated.
20-161
TESTING AND ADJUSTING MEASURING WORK EQUIPMENT HYDRAULIC PRESSURE
20-162
TESTING AND ADJUSTING MEASURING PPC VALVE PRESSURE
MEASURING PPC-VALVE
PRESSURE
Up to Serial number: WA380H20470
« Measurement conditions
• Engine water temperature : Within engine water
temperature gauge green range
• Hydraulic oil temperature : 45 to 55°C
• Engine speed : High idle
Apply the parking brake and blocks the tires.
Measuring
1. Raise boom (1), set boom prop (2), set the bucket
to an angle of approximately 45° (not to the maxi-
mum dump position) and remove front cover (3).
Set the prop securely.
2. Stop the engine, loosen the oil supply cap, release
the pressure inside the hydraulic oil tank, then stroke
the bucket control lever between the tilt and neutral
positions at least 40 times to completely release the
accumulator pressure.
« Be sure to stop the engine before operating the
lever.
« After the accumulator pressure is completely
released, set the bucket lever to the dump posi-
tion and check that the bucket does not dump.
3. Remove the work equipment dump cylinder circuit
pressure measurement plug (4).
4. Install hydraulic test kit C to the measuring port.
• Connect the hose after installing the hydraulic
test kit 90° elbow to the measuring port.
• Check that there is no oil leakage from any
joints.
• Use a hose which is long enough to reach the
operator's seat.
5. Start the engine, raise the boom about 400 mm, tilt
back the bucket using the control lever, and meas-
ure the pressure when the relief valve is activated.
• Be careful not to apply any sudden pressure to
the pressure gauge.
When removing the hydraulic pressure gauge, re-
lease the pressure inside the circuit in the same Serial Number: WA380H20384 and up
way as when it was installed.
• Connect test kit at the T-connector in the
hydraulic piping to the acc. charge valve.
20-163
TESTING AND ADJUSTING MEASURING PPC VALVE PRESSURE
Adjusting
20-164
TESTING AND ADJUSTING MEASURING PPC VALVE PRESSURE
1. Decompression spindel
2. Decal
3. Strainer
J. Pressure regulating valve
« Measurement conditions
• Engine water temperature : Within engine water
temperature gauge green range
• Hydraulic oil temperature : 45 to 55°C
• Engine speed : High idle
Measuring
1. Install the safety bar (4) to the frame.
2. Stop the engine, loosen the oil supply cap to release
the pressure inside the hydraulic oil tank and oper-
ate the bucket lever at least 40 times to release
accumulator pressure completly.
« Be sure to stop the engine before operating the
lever.
« After the accumulator pressure is completely
released, set the bucket lever to the dump posi-
tion and check that the bucket does not dump.
3. Remove plug at measuring port (Me3).
4. Install hydraulic test kit to the measuring port (Me3).
« Check that there is no oil leakage from any
joints.
« Use a hose which is long enough to reach the
operator's seat.
20-165
TESTING AND ADJUSTING MEASURING PPC VALVE PRESSURE
Adjusting
20-166
TESTING AND ADJUSTING MEASURING WORK EQUIPMENT
MEASURING WORK
EQUIPMENT
« Measurement conditions
• Engine water temperature: Within green range on
engine water temperature gauge
• Hydraulic oil temperature: 45 – 55°C
• Engine speed: High idling
• Work mode selector switch on High mode
(from SN WA380H20987 and up)
• Steering position: Neutral
• No load
Measurement method
1. Boom RAISE time
Set the bucket at the lowest position from the ground
with the bucket tilted back fully, then raise it and
measure the time taken for the bucket to reach the
maximum boom height.
20-167
TESTING AND ADJUSTING MEASURING WORK EQUIPMENT
« Measurement conditions
• Engine water temperature: Within green range on
engine water temperature gauge
• Hydraulic oil temperature: 45 – 55°C
• Stop the engine, leave for 5 minutes, then measure
for 15 minutes.
• Boom: Horizontal
• Bucket: Horizontal
• No load
Measurement method
1. Set the boom and bucket in a horizontal position,
then stop the engine.
20-168
TESTING AND ADJUSTING TESTING AND ADJUSTING BUCKET POSITIONER
Testing
1. Stop the engine and check that the clearance be-
tween switch (1) and angle (2) is the standard value.
Adjusting
1. Lower the bucket to the ground, operate the bucket
to the desired digging angle, then return the lever to
HOLD and stop the engine.
20-169
TESTING AND ADJUSTING TESTING AND ADJUSTING BOOM KICK-OUT
Testing
1. Stop the engine, and check that the clearance be-
tween switch (1) and plate (2) is the standard value.
Adjusting
1. Raise the boom to the desired position and mark it
at the position where the center of the switch is at
the lower end of the plate.
Be sure to apply the safety lock to the control lever.
20-170
TESTING AND ADJUSTING TESTING AND ADJUSTING BOOM KICK-OUT
Proximity switch
actuation Lights up Goes out
pilot lamp
When detector is positioned at detection When detector has moved away from
Detector position
surface of proximity switch detection surface of proximity switch
Bucket
positioner
Boom kick-out
20-171
TESTING AND ADJUSTING ADJUSTING MAIN MONITOR (SPEEDOMETER MODULE)
Adjustment procedure
• Turn off the power, then remove the main monitor
and adjust the switches at the back of the speedom-
eter.
1. Setting machine model
1) Remove the rubber caps from dipswitches (1),
(2), (3), and (4) at the back of the speedometer.
2) When the rubber cap is removed, a rotary switch
can be seen inside. Using a flat-headed screw-
driver, turn this switch to adjust it to the settings
in the table below.
Tire size
Switch 20,5 x 25 (695) 23,5 x 25 (760)
1 1 (4)* 2 (4)*
2 B (5)** 5 (2)**
3 0 0
* SN WA380H20501 and up
** SN WA380H20987 and up
20-172
TESTING AND ADJUSTING WORK EQUIPMENT HYDRAULIC SYSTEM
Note:
f) If the pressure, read at ambient temp., is more g) Remove the filling unit (9) from the accumu-
than 17 bar, close the gas fill screw (11) using lator. Tighten the gas filling screw (11) using
the handle (17) and the key (16). Open the an allen key to 20 +5 Nm.. Fit the protection
release screw (12) and release the gas pres- cap back on the gas connector (10) M28 x
sure in the fill unit. 1.5mm.
20-173
TESTING AND ADJUSTING WORK EQUIPMENT HYDRAULIC SYSTEM
h) As in a) to c)
j) Slowly open the gas bottle valve (22) and allow the
gas to flow at the desired pressure (adjusting valve
(24)). Pressure gauge (25) shows the filling pres-
sure, pressure gauge (26) the gas bottle pressure.
The pressure reducing valve out-let (23) is open.
l) As in f) and g).
20-174
TESTING AND ADJUSTING WORK EQUIPMENT HYDRAULIC SYSTEM
HYDRAULIC ACCUMULATOR
Service:
Note:
• With a gas pressure check, from the hydraulic
side, with two or more accumulators, it is not pos-
sible to check the condition of individual accumula-
tors. If one accumulator losses all its gas pressure
it will not show up in this check as long as the other
accumulators have gas pressure. Because of this it
is only recommended to carry out this type of test
with individual accumulators that have been removed
from the system. The position nos., in brackets
refer to the fig. on the next page.
Press.
20-175
TESTING AND ADJUSTING WORK EQUIPMENT HYDRAULIC SYSTEM
MEMO:
20-176
TROUBLESHOOTING
20-201
TROUBLESHOOTING POINTS TO REMEMBER WHEN TROUBLESHOOTING
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.
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.
Be extremely careful not to touch any hot parts or to get caught in any rotating parts.
When disconnecting wiring, always disconnect the negative (–) terminal of the battery first.
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 4) Check the stroke of the control valve spool.
disassemble the components. 5) Other maintenance items can be checked ex-
If components are disassembled immediately any ternally, so check any item that is considered to
failure occurs: be necessary.
• Parts that have no connection with the failure or 4. Confirming failure
other unnecessary parts will be disassembled. • Confirm the extent of the failure yourself, and
• It will become impossible to find the cause of judge whether to handle it as a real failure or as
the failure. a problem with the method of operation, etc.
It will also cause a waste of manhours, parts, or oil « When operating the machine to reenact the
or grease, and at the same time, will also lose the troubleshooting symptoms, do not carry out
confidence of the user or operator. any investigation or measurement that may
For this reason, when carrying out troubleshooting, make the problem worse.
it is necessary to carry out thorough prior investiga- 5. Troubleshooting
tion and to carry out troubleshooting in accordance • Use the results of the investigation and inspec-
with the fixed procedure. tion in Items 2 – 4 to narrow down the causes
2. Points to ask user or operator of failure, then use the troubleshooting flow-
1) Have any other problems occurred apart from chart to locate the position of the failure exactly.
the problem that has been reported? « The basic procedure for troubleshooting is
2) Was there anything strange about the machine as follows.
before the failure occurred? 1) Start from the simple points.
3) Did the failure occur suddenly, or were there 2) Start from the most likely points.
problems with the machine condition before this? 3) Investigate other related parts or infor-
4) Under what conditions did the failure occur? mation.
5) Had any repairs been carried out before the 6. Measures to remove root cause of failure
failure? • Even if the failure is repaired, if the root cause
When were these repairs carried out? of the failure is not repaired, the same failure
6) Has the same kind of failure occurred before? will occur again.
3. Check before troubleshooting To prevent this, always investigate why the prob-
1) Check the oil level lem occurred. Then, remove the root cause.
2) Check for any external leakage of oil from the
piping or hydraulic equipment.
3) Check the travel of the control levers.
20-202
TROUBLESHOOTING SEQUENCE OF EVENTS IN TROUBLESHOOTING
Step 1
Examination, confirmation of symptoms
Step 2 TEW00183
Determining probable location of cause
Step
1) Look at the troubleshooting section of the shop
manual to find locations of possible causes. Repair at jobsite
Hurray !
It's repaired
TEW00184
Step 3 TEW00185
Preparation of troubleshooting tools
Machine Step 6
volume Re-enacting failure
TEW00188
Step 4 Step 5
Go to jobsite Ask operator questions to confirm details of fail-
ure.
TEW00190
20-203
TROUBLESHOOTING PRECAUTIONS WHEN CARRYING OUT MAINTENANCE
TEW00192
20-204
TROUBLESHOOTING PRECAUTIONS WHEN CARRYING OUT MAINTENANCE
TEW00196
20-205
TROUBLESHOOTING PRECAUTIONS WHEN CARRYING OUT MAINTENANCE
Disconnecting connectors
(1) Hold the connectors when disconnecting. Press lightly
When disconnecting the connectors, hold when removing
the connectors and not the wires. Lock stopper
For connectors held by a screw, loosen the
screw fully, then hold the male and female
connectors in each hand and pull apart. For
connectors which have a lock stopper, press
TEW00197
down the stopper with your thumb and pull
the connectors apart.
Connecting connectors
(1) Check the connector visually.
a. Check that there is no oil, dirt, or water
stuck to the connector pins (mating por-
tion).
b. Check that there is no deformation, de-
TEW00198
fective contact, corrosion, or damage
to the connector pins.
c. 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.
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,
replace the connector.
20-206
TROUBLESHOOTING PRECAUTIONS WHEN CARRYING OUT MAINTENANCE
TEW00199
TEW00202
20-207
TROUBLESHOOTING PRECAUTIONS WHEN CARRYING OUT MAINTENANCE
TEW00203
TEW00205
TEW00206
20-208
TROUBLESHOOTING PRECAUTIONS WHEN CARRYING OUT MAINTENANCE
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.
TEW00209
20-209
TROUBLESHOOTING PRECAUTIONS WHEN CARRYING OUT MAINTENANCE
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 Flushing 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.
TEW00210
7) 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 3µ) particles that the filter
built into the hydraulic equipment cannot re-
move, so it is an extremely effective device.
TEW00211
20-210
TROUBLESHOOTING HANDLING CONNECTORS
HANDLING CONNECTORS
1. When removing the connectors from the clips, pull
the connector in a parallel direction to the clip.
« If the connector is twisted to the left and right or
up and down, the housing may break.
TBW00484
Stopper
TBW00485
TBW00486
TBW00487
20-211
TROUBLESHOOTING CHECKS BEFORE TROUBLESHOOTING
20-212
TROUBLESHOOTING METHOD OF USING TROUBLESHOOTING CHARTS
20-213
TROUBLESHOOTING METHOD OF USING TROUBLESHOOTING CHARTS
Cause Remedy
(4)
« Before carrying out troubleshooting, check that all the related connectors are properly inserted.
« Always connect any disconnected connectors before going on the next step.
20-214
20-215
TROUBLESHOOTING METHOD OF USING TROUBLESHOOTING CHARTS
[Questions]
Sections + in the chart on the right corresponds
to the items where answers can be obtained from
the user. The items in are items that can be
obtained from the user, depending on the user’s
Causes
level.
[Check items]
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 in-
formation 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 prob-
ability, starting with the causes that have been
marked as having the highest probability from infor-
mation gained from [Questions] and [Check items].
Questions
Check items
shooting
Trouble-
20-216
TROUBLESHOOTING METHOD OF USING TROUBLESHOOTING CHARTS
n)
ctio
tions] Section, ask the user, and mark the Cause
inje
column with ∆ to use as reference for locating
the cause of the failure. However, do not use
ve
e
le
enc
ozz
ssi
this when making calculations to narrow down
xce
rfer
nt
nn
the causes.
er
e
p (e
2. Use the ∆ in the Cause column as reference for
inte
em
ing
ind
c t i o
pum
r el
tim
cyl
[Degree of use (Operated for long period)] in
inje
er,
e
the [Questions] section as reference. As a rule,
arg
ng,
tion
n
tion
ed
lea
do not use it when calculating the points for
och
n ri
jec
eiz
c
ir c
inje
locating the cause, but it can be included if
turb
isto
n
d, s
da
er i
necessary to determine the order for trouble-
tive
rn p
gge
gge
zed
rop
shooting.
fec
Wo
Clo
Sei
Clo
Inp
De
>>1 Confirm recent repair history
20-217
TROUBLESHOOTING METHOD OF USING TROUBLESHOOTING CHARTS
)
tion
• Excessive injection of fuel
ead
d)
jec
ize
dh
e in
r se
eat
r an
siv
nge
es
rge
nce
ces
le
alv
, plu
cha
ozz
ere
(ex
e, v
rbo
ack
nt
nn
terf
mp
me
ing
ce
alv
nde
p (r
r
ctio
t
le
r, in
ran
u
ele
en
tim
of v
f
um
cyli
np
f
mu
inje
twe
lea
rge
ner
tion
np
ctio
act
,
ged
g
ec
e
cha
ed
lea
ctio
n rin
b
jec
t
inje
con
alv
air
eiz
log
Legend
ir c
rbo
inje
er in
isto
er v
d, s
f
: Possible causes (judging from Questions and check items)
d, c
tive
eo
da
tive
d tu
tive
: Most probable causes (judging from Questions and Check items)
rn p
rop
gge
rop
kag
gge
she
fec
fec
ize
ffec
: Possible causes due to length of use (used for a long period)
Imp
Imp
Lea
Wo
Cru
Clo
De
Clo
De
Se
: Items to confirm the cause.
De
Confirm recent repair history
Degree of use Operated for long period
Suddenly became black
Color of exhaust gas Gradually became black
Questions
Replace
Replace
Replace
Replace
Replace
Adjust
Adjust
Adjust
Repair
Clean
Remedy
20-218
TROUBLESHOOTING METHOD OF USING TROUBLESHOOTING CHARTS
Five causes
Step 1
Clarify the relaitionship between the three
symptoms in the [Questions] and [Check items]
section and the five Cause items in the vertical
column.
Three symptoms
Step 2
Step 3
The calculation in Step 2 show that the closest
relationship is with [Clogged air cleaner element].
Follow this column down to the troubleshooting area
and carry out the troubleshooting item marked l.
The Remedy is given as [Clean], so carry out
cleaning, and the exhaust gas color should return to
normal.
20-219
TROUBLESHOOTING METHOD OF USING TROUBLESHOOTING CHARTS
« It is not necessary to follow the trouble- 3 Steering can only be operated to one side.
shooting checks in order; follow an or- 4 Steering wheel is heavy and cannot be turned.
der which is easiest to carry out trou-
bleshooting.
2) Find the appropriate cause from the cause
column. If the symptom appears, the ! marks
on that line indicate the possible causes. [Example 2]
(For item No. 2 in the table on the right, the
possible causes are c or e.)
If there is only one o:
ses
20-220
TROUBLESHOOTING METHOD OF USING TROUBLESHOOTING CHARTS
es
s
Operate the machine and check the items in
Cau
the same way as in 1), and if the symptom
a b c d e
appears, mark that item. (In the chart on the
right, the symptom appears again for item 5). Remedy
C A
4) Find the appropriate cause from the cause col- Problem
umn. In the same way as in Step 2), if the 1
symptom appears, the ¡ marks on that line 2
indicate the possible causes. (For item No.5 in
3
the table on the right, the possible causes are b
or e.) 4
5
5) Narrow down the possible causes. Applicable troubleshooting item located in Step 3).
There is one common cause among the causes Applicable troubleshooting item located in Step 1).
located in Steps 2) and 4). (One cause marked
¡ appears on the line for both items.) This
cause is common to both the symptoms in trou- Ignore these causes
ses
bleshooting Steps 1) and 3).
Cau
« The causes which are not common to both
troubleshooting items (items which are not a b c d e Common causes
marked ¡ for both symptoms) are unlikely Remedy
causes, so ignore them. C A
Problem
(In the example given on the right, the 1
causes for Troubleshooting Item 2 are c or
2
e, and the causes for Troubleshooting Item
5 are b or e, so cause e is common to 3
both.) 4
6) Repeat the operations in Steps 3), 4) and 5) 5
until one cause (one common cause) remains.
« If the causes cannot be narrowed down to
one cause, narrow the causes down as far
ses
as possible.
Cau
7) Remedy a b c d e
If the causes are narrowed down to one com- Remedy Action to take
mon cause, take the aciton given in the remedy C A
Problem
column. 1
The symbols given in the remedy column indi-
2
cate the following:
X: Replace, ∆: Repair, A; Adjust, C: Clean 3
20-221
TROUBLESHOOTING CONNECTOR TYPES AND MOUNTING LOCATIONS
20-222
TROUBLESHOOTING CONNECTOR PIN ARRANGEMENT DIAGRAM
CNA18
CNR08
CNF01
CNF02
CNR07
CNE08
CNF06
CNE09
CNE03
CNF05 CNER1
CNER2
CNT05
CNT04
CNT03
CNT02 CNT01
CNT12
CNT07
CNT06
CNFR1
CNT08
CNFR2
CNF04
CNT11 TBW00712
CNF03 CNT10
20-223
TROUBLESHOOTING CONNECTOR PIN ARRANGEMENT DIAGRAM
(2/3)
Con- Con- No. Con- Con- No.
nector nector of Mounting location nector nector of Mounting location
No. Type Pins No. Type Pins
CNA5 M type 2 Thermistor
MIC
SWP CNL29 type 21 Transmission controller
CNA6 14 Air mix servo motor
type
CNA7 M type 6 Blower motor
AMP040
CNA8 S type 16 Air conditioner CNL30 20 Transmission controller
connector
CNA9 — 4 Ventilator relay (MAIN)
CNA10 — 4 Ventilator relay (Hi) AMP040
CNL31 16 Transmission controller
connector
CNA11 — 4 Ventilator relay (M2)
CNA12 — 4 Condenser relay (Hi) CNL48 — 5 Bucket relay
CNA13 — 4 Ventilator relay (M1) CNL49 — 5 Boom relay
CNA14 — 4 Condenser relay CNL52 — 5 Warning relay
CNA15 — 4 Air condit. compress. relay CNL53 — 5 Brake light relay
CNCL1 S type 12 Floor wiring harness CNL55 — 5 Horn relay
CNCL2 S type 16 Air conditioner CNL56 — 5 Pre-heating relay
CNCL3 S type 8 Air conditioner CNL57 — 5 Neutral relay
CNFS1 L type 2 Fuse box CNL60 — 6 Front working lamp relay
CNFS2 S type 12 Fuse box CNL61 — 6 Rear working lamp relay
CNFS3 M type 6 Fuse box CNL62 — 5 Engine stop relay
CNFS4 L type 2 Fuse box CNL63 — 1 Horn switch
CNFS5 M type 6 Fuse box CNL64 — 5 Engine oil pressure relay
CNFS6 M type 6 Fuse box CNL67 — 5 Reverse lights
CNL09 — 4 Starting switch CNL80 — 5 Air clogging relay
SWP Transmission combination CNL200 — 6 Parking brake neutral
CNL02 6
type switch TDR1 — 6 Transmission control
CNL03 SWP 6 Transmission combination TDR2 — 6 Transmission control.
type switch
20-224
TROUBLESHOOTING CONNECTOR PIN ARRANGEMENT DIAGRAM
20-225
TROUBLESHOOTING CONNECTOR PIN ARRANGEMENT DIAGRAM
Note: The Connector indication CN has changed into X for the actual wiring harness.
CNL52
K163.1
CNTDR2
K163.2
CNTDR1
CNL200
CNL49
K67.1
CNL48
K67.2 CNL60
CNL57 CNL56
CNL67
CNL55
TD1-TD4
CNL53 CNL61
CNL44 Z CNL80
Forward CNL64 TD5-TD8
(Fahrtrichtung)
CNFS1
CNFS2
CNL18 CNL22 Z CNFS3
CNL19 CNFS4
CNL21 CNFS5
CNFS6
CNL31
CNL30 CNA8
CNL29
CNA14
CNL03 CNA9
CNL09
CNA11
CNL02
CNL06 CNA10
CNL07
CNA13
CNL08
CNA12
CNL05
CNA15
CNL63
CNA5
CNCL1 CNA7
CNCL2 CNA6
CNCL3
CNL04
Relais_A
20-226
TROUBLESHOOTING CONNECTOR PIN ARRANGEMENT DIAGRAM
Note: The Connector indication CN has changed into X for the actual wiring harness.
CNL03 CNA9
CNL09
CNA11
CNL02
CNL06 CNA10
CNL07
CNA13
CNL08
CNA12
CNL05
CNA15
CNL63
CNA5
CNCL1 CNA7
CNCL2 CNCL3 CNA6
CNL04
Relais_m2
20-227
TROUBLESHOOTING CONNECTOR PIN ARRANGEMENT DIAGRAM
(3/3)
Con- Con- No.
nector nector of Mounting location
No. Type Pins
CNE04 X type 3 RPM sensor
CNE15 — 1 Alternator B
CNE16 — 1 Alternator R
CNE17 — 1 Alternator E
20-228
TROUBLESHOOTING CONNECTOR PIN ARRANGEMENT DIAGRAM
CNE08
CNE09
CNE11
CNE19
CNE20
CNE06
CNE04
CNE05
CNE15 CNER1
CNE16
CNE17
CNER2
CNE13
To battery
, terminal
CNE12
CNE10
TBW00724
20-229
TROUBLESHOOTING CONNECTOR PIN ARRANGEMENT DIAGRAM
Reserve 7 (K218)
Selection
work mode K443
20-230
TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
TEW00219 TEW00220
1
1
2
2
TEW00221 TEW00222
1 3 3 1
2 2
TEW00223 TEW00224
1 3
3 1
2 4 4 2
TEW00225 TEW00226
20-231
TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
4 8 8 4
1 5 5 1
TEW00227 TEW00228
6 12
12 6
12
1 7 7 1
TEW00229 TEW00230
8 16 16 8
16
1 9 9 1
TEW00231 TEW00232
10 20 20 10
20
1 11 11 1
TEW00233 TEW00234
20-232
TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
1 4 4 1
3 6 6 3
TEW00235 TEW00236
1 5 5 1
4 8 8 4
TEW00237 TEW00238
1 4 8 11 11 8 4 1
14
3 7 10 14 14 10 7 3
TEW00239 TEW00240
20-233
TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
1 1
2 2
TEW00241 TEW00242
2 3 3 2
1 1
TEW00243 TEW00244
3 2 3 1
1
4 2
TEW00244 TEW00246
1 4 4 1
3 6 6 3
TEW00247 TEW00248
20-234
TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
1 5 5 1
4 8 8 4
TEW00249 TEW00250
1 6 6 1
10
5 10 10 5
TEW00251 TEW00252
12 5 6 1
12
6 1 TEW00253 12 5 TEW00254
16 7 8 1
16
8 1 TEW00255 16 7 TEW00256
20-235
TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
1 1
6
2 2
TEW00257 TEW00258
1 11
11 1
12 21
21 21 12
TEW00259 TEW00260
1 1
2
2
2
TEW00261 TEW00262
20-236
TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
TEW00263 TEW00264
TEW00263 TEW00265
20-237
20-238
TROUBLESHOOTING OF ENGINE SYSTEM
(S MODE)
20-251
20-252
TROUBLESHOOTING S-1
ck)
Ambient 100% 90% 80% 75% 70%
er
ain
20°C 1.28 1.26 1.24 1.23 1.22
ine p str
g
eat
m
fue , plun
0°C 1.29 1.27 1.25 1.24 1.23
ole
es
y
tter
r
er h
pu
alv
–10°C 1.30 1.28 1.26 1.25 1.24
ck
l
inje ion no ed ba
el t ng, a p (ra
r el lve, v
mg
tra
t
• The specific gravity should exceed the value for the charging rate
e
e, c jection iming
tac ylinde
ir in
d p primi
ps
bre
zzl
m
of 70% in the above table.
at
u
tive gula ug
um
air
p
• In cold weather the specific gravity must exceed the value for the
tor
t
alte tor
,
c
pl
n
ane
ank
rna
ng,
ctio
charging rate of 75% in the above table.
ow
gi
e
ct
fee
or d
log
n ri
gge e con
l
ue
g
Legend
re
in
air
isto
d fu
tive
df
De ctive
: Possible causes (judging from Questions and check items)
tive
tive
Lea ctive
v
tiv
d
e
kag
: Most probable causes (judging from Questions and Check items)
rn p
gge
t
fec
gg
fec
fec
fec
fec
fe
fe
: Possible causes due to length of use (used for a long period)
fe
Clo
Wo
Clo
De
De
De
De
De
De
De
clo
: Items to confirm the cause
Confirm recent repair history
Degree of use Operated for long period
Gradually became worse
Ease of starting Starts when warm
Questions
be clogged
Heater mount does not become warm
Voltage is 26 - 30V betweem alternator terminal B and Yes
terminal E with engine at low idling No
Either specific gravity of electrolyte or voltage of battery is low
Speed of some cylinders does not change when operating
on reduced cylinders
When check is made using delivery method, injection timing
is found to be incorrect
When control rack is pushed, it is found to be heavy or does
not return (when blind plug at rear of pump is removed, it
can be seen that plunger control sleeve does not move)
When fuel cap is inspected directly, it is found to be clogged
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Adjust
Repair
Repair
Clean
Clean
Clean
Clean
Remedy
20-253
TROUBLESHOOTING S-2
ire
rw
General causes why engine does not turn
oto
• Internal parts of engine seized
itch
n
pm
it
ctio
« If internal parts of the engine are seized,
ircu
sw
o
nne
ry
t
es
carry out troubleshooting for “Engine
fety
gc
atte
gin
l co
stops during operations”.
rtin
r sa
tor
db
f en
ch
ina
mo
• Failure in power train
sta
yo
rate
wit
oto
nt o
erm
e la
• Defective electrical system
top
ela
of
gs
erio
gm
ry r
me
ry t
s
ty r
ing
rtin
ne
r
et
rtin
ust
a tte
gea
atte
Legend
afe
wir
or d
ngi
sta
sta
adj
: Possible causes (judging from Questions and check items)
b
s
ring
e
tive
tive
tiv e
tive
tive
tive
tive
tive
tive
: Most probable causes (judging from Questions and Check items)
ken
fec
fec
fec
fec
fec
fec
: Possible causes due to length of use (used for a long period)
fec
fec
fec
Bro
De
De
De
De
: Items to confirm the cause.
De
De
De
De
De
Confirm recent repair history
Questions
move out
Check items
and terminal E
to be chipped
disconnected
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Adjust
Remedy
–
20-254
TROUBLESHOOTING S-2
General causes why engine turns but no exhaust gas comes out
• Supply of fuel impossible
• Supply of fuel is extremely small Causes
• Improper selection of fuel (particularly in winter)
)
zed
Standards for use of fuel
sei
Ambient temprature
ger
Type of fuel
ey
–22 –4 14 32 50 68 86 104 122°F
ole
ft, k
n
–30 –20 –10 0 10 20 30 40 50°C
plu
rh
n
sha
isto
ck,
the
ASTM D975 No.2
r
a
g
rive
pp
r
rea
r
pin
ain
oto
(
ine
Diesel fuel
mp
pum
pd
l pi
b
pm
r
stra
ASTM D975 No.1
, st
u
air
um
fue
np
sto
eed
ter
d
ank
np
um
ctio
use
ing
l fil
ine
rn f
Legend
ctio
el t
dp
eak
inje
fue
eng
uel
rok
: Possible causes (judging from Questions and check items)
el
e
inje
d fu
f fu
d fe
d, l
er f
tive
d, b
: Most probable causes (judging from Questions and Check items)
ed
tive
gge
ken
ko
gge
rop
gge
gg
: Possible causes due to length of use (used for a long period)
fec
fec
ize
Lac
Imp
Clo
Bro
Clo
: Items to confirm the cause.
Clo
Clo
De
De
Se
Confirm recent repair history
operation manual
2) No fuel comes out even when fuel filter air bleed plug is
loosened
not return
Troubleshooting
When fuel filter, strainer are inspected directly, they are found
to be clogged
be clogged
disconnected
Replace
Replace
Replace
Replace
Replace
Repair
Repair
Clean
Clean
Remedy
Add
20-255
TROUBLESHOOTING S-2
Causes
(3) Exhaust gas comes out but engine does not start
.)
etc
(Fuel is being injected)
k)
ver
tuc
r , le
ay
rs
General causes why exhaust gas comes out but engine does
spr
cke
ge
m
not start
lun
e
, ro
ste
ve
hol
k, p
lve
i
• Lack of rotating force due to defective electrical system
l sy
ect
her
(va
tery
rac
f
r
fue
• Insufficient supply of fuel
, de
r
ine
nt
de
eat
m
ner
bat
me
e
• Insufficient intake of air
ir in
a
mp
zle
ylin
yst
r
str
ir b
trai
ele
ed
es
noz
pu
• Improper selection of fuel
g, a
c
ps
a
ter,
riat
valv
ner
lug
g,
tion
d
ank
gin
tion
pum
use
rin
eto
l fil
wp
lea
ken
Legend
log
el t
jec
inje
or d
fue
ton
uel
ir c
glo
ed
: Possible causes (judging from Questions and check items)
ro
e, c
d fu
d in
,b
d fe
er f
da
pis
tive
ed
: Most probable causes (judging from Questions and Check items)
tive
tive
tive
kag
gge
gge
gge
rop
gge
gg
fec
rn
: Possible causes due to length of use (used for a long period)
fec
fec
fec
Lea
Wo
Clo
Imp
Clo
Clo
Clo
Clo
De
: Items to confirm the cause.
De
De
De
Confirm recent repair history
Degree of use Operated for long period
Suddenly failed to start
When engine is cranked, abnormal noise is heard from
around head
Questions
nut is loosened
2) Little fuel comes out even when fuel filter air bleed plug
is loosened
There is leakage from fuel piping
When exhaust manifold is touched immediately after
starting engine, temperature of some cylinder is low
When fuel filter is drained, no fuel comes out
found to be clogged
When feed pump strainer is inspected directly, it is found to
be clogged
When air element is inspected directly, it is found to be clogged
Heater mount does not become warm
Either specific gravity of electrolyte or voltage of battery is low
When feed pump is operated, there is no response, or pump
is heavy
Speed of some cylinders does not change when operating
on reduced cylinders
When fuel cap is inspected directly, it is found to be clogged
Replace
Replace
Replace
Replace
Repair
Repair
Clean
Clean
Clean
Clean
Clean
Remedy
–
20-256
TROUBLESHOOTING S-3
y
• Improper fuel used
pra
t
es
sea
e
ctiv
hol
nce
ve
efe
val
her
ere
ger
r
g
ne
e, d
nt
ipin
ve,
eat
terf
lun
ner
r
rai
me
nde
ce
val
el p
zzl
r
pp
r, in
trai
ir b
, st
ele
ran
i
o
c yl
um
t of
ps
g fu
a
rge
ter
n
ner
lea
ank
tion
ng,
np
pum
tac
l fil
cha
kin
lea
ec
Legend
n ri
ctio
el t
jec
con
fue
a
alv
ir c
rbo
: Possible causes (judging from Questions and check items)
ed
e
d fu
d in
isto
inje
d, l
er v
d fe
da
: Most probable causes (judging from Questions and Check items)
tive
d tu
ed
rn p
gge
gge
gge
gge
zed
gge
rop
gg
: Possible causes due to length of use (used for a long period)
fec
ize
Clo
Imp
: Items to confirm the cause.
Clo
Clo
Wo
Clo
Clo
Sei
Clo
De
Se
Confirm recent repair history
Degree of use Operated for long period
Replacement of filters has not been carried out according to
operation manual
Questions
Replace
Adjust
Repair
Repair
Clean
Clean
Clean
Clean
Remedy
20-257
TROUBLESHOOTING S-4
ck)
tc)
output, carry out troubleshooting for over-
stu
er e
heating.
ger
lev
• Failure in power train
lun
rod
er,
ole
« If the engine stops because of a failure
k, p
ring
ey
ock
pum ther h
ing
n
ft, k
t
in the power train, carry out troubleshoot-
isto
in
bea
rac
e, r
ect
me
tra
g
ne
sha
pp
ing for the chassis.
pin
p(
rea
v
onn
ner
aft
rai
qui
er
( va
pum
l pi
trai
trai
ir b
ive
ksh
ow
nc
, st
ry e
fue
tem
ps
sp
isto
ear
ran
pd
ter
ed
a
tion
ank
i
pum
uxil
ing
sys
ssi
d fe
dg
dc
l fil
um
dp
Legend
c
el t
pa
eak
nje
cha
ize
ize
fue
ize
el p
ize
ve
ed
: Possible causes (judging from Questions and check items)
el
pum
d fu
i
, se
, se
, se
val
, se
d fe
d, l
f fu
: Most probable causes (judging from Questions and Check items)
tive
u
e in
ed
f
gge
gge
ken
ken
ken
ken
ken
ken
gge
ko
ken
: Possible causes due to length of use (used for a long period)
gg
fec
ilur
Clo
Lac
: Items to confirm the cause.
Bro
Clo
Bro
Bro
Bro
Bro
Clo
Bro
Bro
Clo
De
Fa
Confirm recent repair history
Degree of use Operated for long period
Abnormal noise was heard
and engine stopped suddenly
Condition when engine Engine overheated and stopped
stopped Engine stopped slowly
Questions
Replace
Replace
Repair
Clean
Clean
Clean
Remedy
–
Add
20-258
TROUBLESHOOTING S-5
p
um
zle
nism
dp
noz
fee
(engine throttle controller type)
nd
and
pa
e
pum
ck
hol
nk
l ra
l ta
or
er
r
ern
rno
fee
fue
ntro
ath
r
ine
gov
ove
en
en
ner
bre
f co
tra
we
we
of g
trai
f
nt o
bet
bet
no
r, s
air
low
ps
on
me
uit
atio
uit
e
ank
pum
t
rati
irc
o
circ
l fil
ust
o
Legend
per
el t
in c
is t
ope
fue
ir in
adj
ed
el
: Possible causes (judging from Questions and check items)
d fu
o
, air
ed
d fe
f fu
d, a
tive
ed
tive
tive
: Most probable causes (judging from Questions and Check items)
spe
gge
eed
ko
gge
ge
gee
fec
: Possible causes due to length of use (used for a long period)
fec
fec
g
Low
Clo
Lac
Clo
Clo
: Items to confirm the cause.
Clo
Clo
De
De
De
Confirm recent repair history
raised
Ocuurs on slopes
operation manual
improperly adjusted
Troubleshooting
be clogged
found to be clogged
Adjust
Adjust
Adjust
Adjust
Repair
Repair
Clean
Clean
Clean
Remedy
Add
20-259
TROUBLESHOOTING S-6
ent
• Improper condition of fuel injection
stm
y
pra
• Improper fuel used
dju
eat
es
(if non-specified fuel is used, output drops)
ole
ea
es
ctiv
e
er h
ctiv
alv
• Lack of output due to overheating
enc
efe
ger
er
« If there is overheating and insufficient
e, v
efe
ath
g
rfer
ent
e, d
ain
pin
ner
lun
er
e, d
alv
bre
inte
output, carry out troubleshooting for over-
em
ce
ind
l pi
r
zzl
trai
pp
, st
of v
ran
kag
r el
air
heating.
fue
cyl
o
er,
ps
um
ter
l ea
ane
arg
ank
act
r lin
pum
tion
ng,
np
ing
l fil
ec
Legend
och
ont
cle
n ri
el t
ctio
eak
e
jec
fue
al v
ed
lev
: Possible causes (judging from Questions and check items)
c
turb
ir
d fu
isto
d in
inje
d fe
d, l
er v
da
tive
: Most probable causes (judging from Questions and Check items)
ed
uel
rn p
gge
gge
gge
gge
zed
gge
zed
rop
gg
: Possible causes due to length of use (used for a long period)
fec
nt f
Clo
Imp
Wo
Clo
Clo
Clo
: Items to confirm the cause.
Clo
Sei
Clo
Sei
De
Be
Confirm recent repair history
Degree of use Operated for long period
Suddenly
Power was lost
Gradually
Questions
Replace
Replace
Adjust
Adjust
Repair
Repair
Clean
Clean
Clean
Clean
Remedy
20-260
TROUBLESHOOTING S-7
e d)
)
• Excessive injection of fuel
tion
eiz
ead
jec
er s
dh
e in
t
ung
r an
sea
siv
rge
, pl
nce
ve
ce s
le
cha
ack
val
ozz
ere
(ex
rbo
p (r
nt
ve,
nn
terf
ce
er
me
g
mp
u
min
val
um
r
lind
ctio
ran
t
ffle
r, in
ele
en
u
np
np
t of
n ti
lea
mu
y
inje
twe
rge
c
ner
ctio
ctio
ng,
ctio
ec
tac
ged
r be
cha
ed
lea
Legend
n ri
alv
con
inje
inje
nje
eiz
log
f ai
ir c
rbo
: Possible causes (judging from Questions and check items)
er v
isto
d, s
er i
d, c
eo
da
tive
: Most probable causes (judging from Questions and Check items)
tive
tive
d tu
rn p
rop
rop
gge
kag
gge
she
: Possible causes due to length of use (used for a long period)
fec
fec
fec
ize
Imp
Imp
Lea
: Items to confirm the cause.
Cru
Wo
Clo
Clo
De
De
De
Se
Confirm recent repair history
Degree of use Operated for long period
Suddenly became black
Questions
on reduced cylinders
When check is made using delivery method, injection timing
is found to be incorrect
Injection pump test shows that injection amount is incorrect
When valve clearance is checked directly it is found to be
outside standard value
When muffler is removed, exhaust gas color returns to normal
When control rack is pushed, it is found to be heavy, or does
not return
Replace
Replace
Replace
Replace
Replace
Replace
Adjust
Adjust
Adjust
Repair
Clean
Remedy
20-261
TROUBLESHOOTING S-8
ger
har
boc
c.
, et
Tur
eal
ead
ce
ler
urfa
tem
ns
ose
er h
r
oo
line
oke
sys
al s
er h
il c
lind
er
lug
), b
r, o
, se
ke
ath
lind
, cy
end
in p
ide
nta
d
ing
bre
filte
eal
r en
pan
, cy
, gu
mi
dra
pip
ine
ar s
r or
e
oil
ring
o
ring
low
tern
urb
ler
oil
oil
oil
r
n re
the
Legend
in f
m
coo
at b
om
om
at t
ton
om
e (s
fro
: Possible causes (judging from Questions and check items)
rea
ton
e
ed
rok
e fr
e fr
pis
e fr
oil
eal
: Most probable causes (judging from Questions and Check items)
db
eal
alv
uck
pis
ge
b
kag
kag
kag
ken
ken
rn s
rn v
rn s
: Possible causes due to length of use (used for a long period)
gge
aka
st s
rn,
rn
Bro
Bro
Wo
Wo
Wo
Wo
Clo
Du
Le
Replace
Repalce
Repalce
Repair
Repair
Repair
Repair
Repair
Repair
Repair
Clean
Remedy
20-262
TROUBLESHOOTING S-9
end
ine
urb
er t
e
ube
pip
arg
er t
ain
er
och
ath
ind
r dr
e
ve
uid
turb
bre
cyl
age
ck
val
eg
er
r
bla
ng,
er,
filte
l at
chr
Legend
fety
ool
alv
ath
s is
n ri
sea
rbo
: Possible causes (judging from Questions and check items)
e, v
il c
oil
a
re
s
t ga
isto
d tu
: Most probable causes (judging from Questions and Check items)
do
db
alv
tive
tive
ed
rn p
aus
gge
: Possible causes due to length of use (used for a long period)
gge
gge
rn v
gg
fec
fec
: Items to confirm the cause.
Exh
Clo
Wo
Clo
Clo
Clo
Wo
De
De
Confirm recent repair history
Questions
Abnormally excessive
Carry out troubleshooting for "Exhaust is black"
Oil filter caution lamp stays on even when oil pressure rises
broken
Replace
Replace
Replace
Repalce
Repalce
Clean
Clean
Clean
Remedy
20-263
TROUBLESHOOTING S-10
r
filte
)
tion
)
ton
e
uel
jec
kag
(pis
e in
g, f
r lin
mp
pin
ssiv
r
ove
eve
r
u
nge
y
l pi
dp
xce
pra
min
dc
el l
plu
fue
fee
p (e
le s
hea
f fu
n ti
mp
om
ide
ozz
nt o
um
ctio
de
u
s
e fr
np
np
nsi
l in
me
inje
n
ctio
kag
ctio
ctio
el i
sea
ust
Legend
l
fue
f fu
inje
inje
inje
adj
lea
: Possible causes (judging from Questions and check items)
oil
eo
er
: Most probable causes (judging from Questions and Check items)
tive
tive
tive
tive
tive
nal
rop
kag
: Possible causes due to length of use (used for a long period)
fec
fec
fec
ter
fec
fec
Imp
Lea
: Items to confirm the cause.
De
De
De
Ex
De
same model
Condition of fuel consumption
Gradually increased
Suddenly increased
Black
Exhaust gas color
White
cylinders
incorrect
Replace
Adjust
Adjust
Adjust
Repair
Repair
Repair
Remedy
20-264
TROUBLESHOOTING S-11
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
ing
pitt
by
ed
ain
ck
aus
r
line
blo
g
r
er t
-rin
sc
er
of
pow
ole
e, O
ind
ket
on
g, h
cyl
gas
usi
cor
for
-rin
s in
r
ad
ler
ler
rot
Legend
, he
rO
coo
coo
ack
p
: Possible causes (judging from Questions and check items)
nt
line
d
: Most probable causes (judging from Questions and Check items)
hea
l cr
oil
oil
icie
ken
: Possible causes due to length of use (used for a long period)
ken
rna
ken
ken
uff
: Items to confirm the cause.
Inte
Bro
Bro
Bro
Ins
Bro
Suddenly increased
Oil level
Gradually increased
found
Troubleshooting
Replace
Replace
Replace
Remedy
20-265
TROUBLESHOOTING S-12
SAE 10W
Diesel fuel
pan
SAE 10W-30
oil
ing
ide
pan
pip
or
SAE 15W-40
ins
ens
g
oil
lic
zin
an
or
e
ipe
rau
re s
alv
ens
ide
bra
il p
e
il p
hyd
alv
v
ins
l
ssu
el s
rna
in o
ipe
tor
no
oil
p
ef v
r
hed
ner
filte
pum
jou
pre
ula
p
lev
Legend
oke
in
oil
on
reli
trai
reg
rus
ing
oil
oil
el
oil
i
oil
r
nt
t
d, b
suc
, fu
ds
ear
g, c
: Most probable causes (judging from Questions and Check items)
tive
tive
tive
cie
tive
ed
tive
gge
gge
rn b
ter
ken
kin
gg
fec
uff
fec
fec
fec
fec
Wa
: Items to confirm the cause.
Lea
Clo
Clo
Clo
Bro
Ins
Wo
De
De
De
De
De
Replace
Replace
Adjust
Adjust
Repair
Repair
Clean
Clean
Clean
Clean
Remedy
Add
20-266
TROUBLESHOOTING S-13
er)
• Entry of oil from other component
al
e)
mb
typ
es
ent
er
cha
ing
cov
ctiv
ipm
ge
ion
pitt
e
flan
t
ead
bus
equ
f
, de
by
com
eh
p(
ade
y
ole
m
xilia
pre
sid
ve
er h
sm
u
rfac
g
g in
ing
np
lee
r au
-rin
k
ath
loc
ole
lud
ipin
ctio
er s
eat
e, O
al s
po
(inc
er b
g, h
bre
at s
r se
inje
old
pum
ket
cor
rom
-rin
mp
ind
le h
gas
t
a
s
ide
r pu
d re
cyl
rO
ler
rmo
el f
l of
Legend
ead
ozz
coo
ins
line
ide
age
f fu
ea
ate
the
: Possible causes (judging from Questions and check items)
d, h
n
es
ins
eo
dw
tive
oil
dam
ged
: Most probable causes (judging from Questions and Check items)
tive
tive
hea
ctiv
kag
ken
cks
gge
: Possible causes due to length of use (used for a long period)
fec
ma
fec
fec
ken
rn,
efe
Cra
Lea
Bro
De
Wo
De
Da
De
Bro
D
Confirm recent repair history
Questions
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Repair
Repair
Repair
Remedy
20-267
TROUBLESHOOTING S-14
Causes
S-14 Water temperature becomes too high
(overheating)
ing
pitt
re
General causes why water temperature becomes too high
n)
atu
by
ope
• Lack of cooling water (deformation, damage of fan)
per
ley
ade
e
aug
not
• Drop in heat dissipation efficiency
tem
pul
sm
fan
re g
• Defective cooling circulation system
oes
fan
oil
ole
ter
er
tor
atu
ool
• Rise in oil temperature of power train
t
e
ter
t (d
wa
e
g, h
dia
orn
alv
k
per
gas
il c
« Carry out troubleshooting for chassis.
ver
e
sta
d ra
g, w
re v
cor
-rin
ing
tem
no
con
ead
rmo
p
rO
ool
she
ssu
um
tor
pin
Legend
oke
ter
d, h
ue
dia
line
er p
the
nt c
pre
u
: Possible causes (judging from Questions and check items)
slip
wa
r
r
torq
d, b
d, c
d ra
hea
wat
: Most probable causes (judging from Questions and Check items)
tive
ged
cie
tive
tive
elt
gge
gge
gge
e in
: Possible causes due to length of use (used for a long period)
ken
uffi
ken
fec
nb
ma
fec
fec
: Items to confirm the cause.
Clo
Clo
Clo
Ris
Bro
Ins
Bro
De
Da
De
Fa
De
Confirm recent repair history
Suddenly overheated
Condition of overheating
Questions
Rises quickly
Water temperature gauge Does not go down from red
range
water temperature
Carry out troubleshooting for chassis
tank is slight
Troubleshooting
Replace
Repalce
Replace
Replace
Replace
Replace
Repair
Repair
Repair
Remedy
–
Add
20-268
TROUBLESHOOTING S-15
Causes
S-15 Abnormal noise is made
.)
)
n)
ion
etc
d)
sitio
ize
d
jec
er,
hea
f po
« Judge if the noise is an internal noise or an
r se
lev
e in
ut o
and
external noise.
nge
e
t
bel
er
siv
c
ran
do
ock
General causes why abnormal noise is made
r
plu
rge
ces
an
ce
oar
le
lea
r
• Abnormality due to defective parts
e, r
n
of f
a
ozz
ck,
line
x
ere
och
ec
gb
e
ash
• Abnormal combustion noise
(ra
alv
p(
nn
ce
alv
idin
terf
er
turb
l
n
v
pum
p
k
• Air sucked in from intake system
lind
ctio
of v
(
ere
div
r, in
bac
um
g
tem
en
hin
, cy
er (
inje
terf
np
ent
twe
rge
tion
rain
bus
sys
uffl
ring
ctio
, in
m
cha
r be
ed
jec
ar t
Legend
t
ed
em
jus
fan
eiz
ve
inje
rbo
f ai
ton
eiz
: Possible causes (judging from Questions and check items)
e
d
val
sid
i
d, s
er g
er a
ed
eo
tive
g, s
: Most probable causes (judging from Questions and Check items)
d tu
tive
pis
t in
ken
form
gge
rop
kag
rop
: Possible causes due to length of use (used for a long period)
sin
fec
fec
ize
rn
fec
Imp
Bro
Imp
Lea
Wo
Clo
: Items to confirm the cause.
Mis
De
De
De
Se
De
Confirm recent repair history
Gradually occurred
Condition of abnormal noise
Suddenly occurred
on reduced cylinders
When control rack is pushed, it is found to be heavy or does not return
Replace
Replace
Replace
Replace
Replace
Replace
Adjust
Adjust
Repair
Repair
Repair
Remedy
20-269
TROUBLESHOOTING S-16
n)
k
ctio
tuc
rain
inje
n
c) s
r)
hio
e
er t
mp
cus
, et
ive
pow
(da
ess
ver
ken
ring
and
r le
aft
exc
bro
bea
t sh
h
cke
e
p(
ts,
las
gin
g
ain
tpu
bol
hin
um
, ro
ack
e n
,m
bus
u
ing
np
lve
een
nb
o
rod
unt
e
am
ctio
(va
ilot
trai
w
sid
mo
ing
bet
Legend
r, c
rt p
t in
inje
tem
ear
ect
: Possible causes (judging from Questions and check items)
ine
nce
ent
o
par
er g
upp
onn
sys
tive
eng
: Most probable causes (judging from Questions and Check items)
nm
ala
ken
rn s
rop
rn c
alig
fec
se
lve
: Items to confirm the cause.
Imp
Bro
Loo
Mis
Wo
Wo
Wo
De
Va
Confirm recent repair history
Suddenly increased
Condition of vibration
Gradually increased
Replace
Replace
Replace
Replace
Replace
Adjust
Repair
Repair
Remedy
20-270
TROUBLESHOOTING OF
MAIN MONITOR SYSTEM
(M MODE)
20-351
M-13 Abnormality in parking brake dragging warning
(a) When parking brake is applied, buzzer sounds (intermittently) even when
directional lever is at N, and caution lamp flashes ............................................................. 20-377
(b) When parking brake is applied, buzzer does not sound and caution lamp
does not light up even when directional lever is at position other than N .......................... 20-377
M-14 When parking brake dragging warning is given, buzzer and caution lamp
are actuated continuously, or they are not actuated
(a) Actuated continuously .......................................................................................................... 20-378
(b) Not actuated ......................................................................................................................... 20-378
M-15 Abnormality in buzzer
(a) Buzzer does not sound when starting switch is turned ON (during self-check) ................. 20-379
(b) Buzzer always sounds ......................................................................................................... 20-379
M-17 Abnormality in failure display mode
(a) Does not enter failure display mode ................................................................................... 20-381
(b) Time for time elapsed since failure on failure display mode does not advance ................ 20-281
M-20 Buzzer does not sound because of transmission controller ...................................................... 20-382
M-21 Abnormality in emergency steering normal display
(a) Emergency steering normal display does not light up ........................................................ 20-383
(b) Emergency steering normal display stays lighted up .......................................................... 20-383
M-22 Abnormality in emergency steering actuation display
(a) Emergency steering actuation display does not light up ..................................................... 20-384
(b) Emergency steering actuation display stays lighted up ...................................................... 20-384
M-23 Abnormality in auto greasing system (KOMATSU auto greasing system only)
(a) Forced greasing cannot be carried out ............................................................................... 20-385
(b) Monitor display flashes rapidly ............................................................................................ 20-385
(c) When no more grease remains, monitor display flashes rapidly ........................................ 20-385
(d) Monitor display flashes slowly .............................................................................................. 20-386
(e) Monitor display goes out ...................................................................................................... 20-386
M-24 Abnormality in ECSS system
(a) Display does not change when switch is pressed .............................................................. 20-387
(b) Monitor display lights up but ECSS function does not work ............................................... 20-387
M-26B Failure code is not sent to main monitor (abnormality in network) ........................................... 20-388
20-352
TROUBLESHOOTING TROUBLE DATA DISPLAY
20-353
TROUBLESHOOTING TROUBLE DATA DISPLAY
Action code: "Epp+ CALL" means that Epp and CALL are displayed alternatly
20-354
TROUBLESHOOTING TROUBLE DATA DISPLAY
20-355
TROUBLESHOOTING TROUBLE DATA DISPLAY
WA320-3H Automatic
Actuate emergency
Shift lever system Neutral (F,R OFF)
manual spool.
E03 +
Yes Possible to travel
CALL
Directional system Neutral (F,R OFF) under own power.
Call for service
Stop machine imme-
CALL Neutral (F,R OFF), possible
Short circuit Yes diately, starting switch
that controller is burnt out
OFF, call service
20-356
TROUBLESHOOTING M-1
Cause Remedy
Power source
Battery relay
CNL05
2 9 2 1
CNE02
3
CNLR5
3
CNL06
16
CNL07 CNLR11
12
20-357
TROUBLESHOOTING M-2
Cause Remedy
1 YES
Defective main monitor Replace
Is voltage between
CNL05 (4) and
chassis ground Defective contact, or
normal? disconnection in wiring After inspection,
NO harness between CNL05 repair or replace
1) 20 - 30 V
(female) (4) and CNL57 (3)
2) Turn starting
switch START.
Neutral relay
Start signal,
neutral signal
Starting motor
CNL57
1 2 3 5 6 CNL04
CNL05
3 N Speed lever
Starting
4
CNLR5
8
Neutral
2
CNR10
Rear frame GND
CNL09
3
Starting switch
20-358
TROUBLESHOOTING M-3
Cause Remedy
2 YES
Defective main monitor Replace
Is resistance
YES between CNL07
(female) (1) and Defective contact, or
1 (2) normal ? disconnection in wiring
After inspection,
Is resistance harness between CNL07
1) 500Ω - 1 kΩ NO repair or replace
between CNT06 (female) (1), (2) - CNTL2
(male) (1) and (2) 2) Turn starting (1), (2) - CNT06 (1), (2)
normal? switch OFF.
3) Disconnect
1) 500Ω - 1 kΩ CNL07.
2) Turn starting Defective speed sensor Replace
NO
switch OFF.
3) Disconnect
CNL06.
Speedometer
1 1 1
2 2 2
20-359
TROUBLESHOOTING M-4
Cause Remedy
1 YES
Defective main monitor Replace
Is voltage between
CNL08 (7) and
chassis ground Defective contact, or
normal? disconnection in wiring After inspection,
NO harness between CNL08 repair or replace
1) 20 - 30 V
(female) (7) and CNL04 (2)
2) Turn starting
switch ON.
3) Directional
lever: F
(b) Stays at N even when directional lever is at R
1 YES
Defective main monitor Replace
Is voltage between
CNL08 (8) and
chassis ground Defective contact, or
normal? disconnection in wiring After inspection,
NO harness between CNL08 repair or replace
1) 20 - 30 V (female) (8) and CNL04 (4)
2) Turn starting
switch ON.
3) Directional
lever: R
1 YES
Defective main monitor Replace
Is voltage between
CNL08 (8) and
chassis ground Contact of power source with
normal? wiring harness between
After inspection,
CNL08 (female) (8) and
1) 0 - 5 V NO repair or replace
CNL04 (4), or defective
control lever
2) Turn starting
switch ON.
3) Directional
lever: N
20-360
TROUBLESHOOTING M-4
1 YES
Defective main monitor Replace
Is voltage between
CNL08 (7) and
chassis ground Contact of power source
normal? with wiring harness between
After inspection,
CNL08 (female) (7) and
1) 0 - 5 V NO repair or replace
CNL04 (2), or defective
control lever
2) Turn starting
switch ON.
3) Directional
lever: N
3) Speed lever: 1
2) 50 - 70 Ω
20-361
TROUBLESHOOTING M-4
Cause Remedy
(f) Does not display 3rd, 4th
(WA320-3H with manual gear shift)
1 YES
Defective main monitor Replace
Is voltage between
CNL05 (13) and
chassis ground Defective contact, or
normal? disconnection in wiring After inspection,
1) 20 - 30 V NO harness between CNL05 repair or replace
2) Turn starting (female) (13) and CNL04 (7)
switch ON.
3) Speed lever: 3
1 YES
Defective main monitor Replace
Is resistance between
CNL05 (female) (13)
and chassis ground Defective contact, or
normal? disconnection in wiring After inspection,
harness between CNL05 repair or replace
1) Disconnect NO (female) (13) and CNL29
CNL05. (10)
2) 50 - 70Ω
1 YES
Defective main monitor Replace
Is voltage between
CNL05 (12) and
chassis ground Contact of power source
normal? with wiring harness between
After inspection,
CNL05 (female) (12) and
1) 0 - 5 V NO repair or replace
CNL04 (5), or defective
2) Turn starting control lever
switch ON.
3) Speed lever: 2
H L 1
L L 2
L H 3
H H 4
20-362
TROUBLESHOOTING M-4
Cause Remedy
(h) Does not display 1st, 2nd
(WA320-3H with manual gear shift)
1 YES
Defective main monitor Replace
Is voltage between
CNL05 (13) and Contact of power source
chassis ground with wiring harness between
normal? CNL05 (female) (13) and After inspection,
CNL04 (7), or defective repair or replace
1) 0 - 5 V NO
transmission lever
2) Turn starting
switch ON.
3) Speed lever: 2
Transmission lever
WA320-3H with manual gear shift CNL04
Transmission range
2 F
CNL05 4 R
12 5 1ST
13 7 3RD
7 5 1
8 6 2
CNL05 4 R
12 1ST
13 3RD
7 5 1
8 6 2
20-363
TROUBLESHOOTING M-5
Cause Remedy
2 YES
Defective main monitor Replace
Is there continuity
YES between CNL06
(female) Defective contact, or
1 chassis ground? disconnection in wiring After inspection,
Is voltage between 1) Turn starting NO harness between CNL06 repair or replace
CNL06 (12) and switch OFF. (female) (13) and CNL02 (3)
chassis ground 2) Disconnect
normal? CNL06.
3) Dimmer switch:
1) 20 - 30 V Defective contact, or
H beam
2)Turn starting disconnection in wiring After inspection,
switch ON. NO harness between CNL06 repair or replace
(female) (12) and CNFS2
(2)
Hi beam
CNL06 CNFS2
12 2
13 1
CNL02
2 Lamp switch
Dimmer switch
10 4 2
R.H. head lamp
8 2 3
20-364
TROUBLESHOOTING M-6
Cause Remedy
2) Turn starting
switch ON.
Turn signal
B
15 3
CNL12
B
Hazard switch
E
Turn signal unit
20-365
TROUBLESHOOTING M-8
2 YES
Defective monitor panel Replace
Is resistance between
YES CNL05 (female) (7)
and chassis ground Wiring harness between
1
normal? CNL05 (female) (7) - CNLR4
After inspection,
Is resistance (2) - CNER1 (8) - CNE05
between CNE05 1) Disconnect NO repair or replace
(female) short circuiting with
(male) and chassis CNL05.
chassis ground
ground normal? 2) Turn starting
switch OFF.
1) Disconnect 3) Min. 4kΩ Defective engine water
CNE05. temperature sensor Replace
NO
2) Turn starting
switch OFF.
3) Min. 4kΩ
20-366
TROUBLESHOOTING M-8
2 YES
Defective main monitor Replace
Is resistance between
YES CNL05 (female) (7)
and chassis ground Defective contact, or
1
normal? disconnection in wiring
Is resistance
After inspection,
harness between CNL05
between CNE05 1) Max. 8 kΩ NO repair or replace
(female) (7) - CNLR4 (2) -
(male) and chassis 2) Turn starting CNER1 (8) - CNE05 (female)
ground normal? switch OFF.
3) Disconnect
1) Max. 8 kΩ CNE05. Defective engine water
temperature sensor Replace
NO
2) Turn starting
switch OFF.
3) Disconnect
CNE05.
1
3 YES
Does preheating Defective preheating relay Replace
stop? Is voltage between
YES CNL06 (4) and
2 chassis ground Wiring harness between
1) Turn starting normal? CNL06 (female) (4) and After inspection,
switch ON.
Does preheating 1) 20 - 30 V NO CNL56 (2) short circuiting repair or replace
NO stop? 2) Turn starting with chassis ground
2) Disconnect
CNL06. switch ON. Contact of power source
1) Turn starting with wiring harness between After inspection,
switch ON. NO CNL56 (3) - CNLR4 (7), repair or replace
CNL05 (19)
2) Remove
preheating
relay.
20-367
TROUBLESHOOTING M-8
Cause Remedy
(d) Preheating time becomes shorter, or there is variation
3 YES
Defective main monitor Replace
Is voltage between
YES CNL05 (3) and
2 chassis ground Defective contact of wiring
normal? harness between CNL05 (3) After inspection,
Is resistance between
1) Max. 0.1 V NO - CNLR5 (3) - CNR11 - repair or replace
YES CNL05 (female) (7)
and chassis ground 2) Turn starting chassis ground
1 normal? switch ON. Defective contact of wiring
Is resistance harness between CNL05
1) Are temperature After inspection,
between CNE05 (female) (7) - CNLR4 (2) -
and resistance repair or replace
(male) and chassis value as shown
NO CNER1 (8) - CNE05, or
ground normal? in table below? leak from chassis ground
2) Turn starting
1) Are temperature switch OFF. Defective engine water
and resistance temperature sensor Replace
value as shown NO
in table below?
2) Turn starting
switch OFF.
Temperature(°C) 10 8 6 4 2 0 2 4
Resistance value(kΩ) 7.7 7.1 6.5 6.0 5.5 5.1 4.7 4.3
19 7 4 1 + 24 V
CNE08
2
CNL06 CNER2
CNE09
4
CNL56 Glow plug
5
1 2 3 5 6
Preheating relay
Starting switch
CNL09
2 BR
Engine water
temperature sensor
20-368
TROUBLESHOOTING M-9
Cause Remedy
1 YES
Defective main monitor Replace
Is voltage between
CNL05 (16) and
chassis ground Defective contact, or
normal? disconnection in wiring After inspection,
NO harness between CNL05 repair or replace
1) 20 - 30 V
(female) (16) and CNFS2
(5)
2) Turn starting
switch ON.
Side
CNL05 CNFS2
16 5
Lighting switch
CNL02
5
20-369
TROUBLESHOOTING M-10
Cause Remedy
(a) Neither monitor display nor front working lamp light up
Defective contact, or
YES disconnection in wiring After inspection,
harness between CNL60 (1) repair or replace
- CNL05 (17), CNCL1 (7)
(b) Working lamp lights up but monitor display does not light up
1 YES
Defective main monitor Replace
Is voltage between
CNL05 (17) and
chassis ground Defective contact, or
normal? disconnection in wiring After inspection,
NO harness between CNL05 repair or replace
1) 20 - 30 V
(female) (17) and CNL60 (1)
2) Turn starting
switch ON.
20-370
TROUBLESHOOTING M-11
Cause Remedy
(a) Neither monitor display nor rear working lamp light up
Defective contact, or
disconnection in wiring
YES After inspection,
harness between CNL61 (1)
- CNL05 (18), CNLR1 (12) repair or replace
(b) Working lamp lights up but monitor display does not light up
1 YES
Defective main monitor Replace
Is voltage between
CNL05 (18) and
chassis ground Defective contact, or
normal? disconnection in wiring
harness between CNL05 After inspection,
1) 20 - 30 V NO (female) (18) and CNL61 repair or replace
2) Turn starting (1)
switch ON.
(c) Monitor lights up but working lamp does not light up Defective contact, or
disconnection in wiring
harness between CNL61 (1) After inspection,
- CNLR1 (12) - rear repair or replace
working lamp, or blown
working lamp bulb
20-371
TROUBLESHOOTING M-11
Working lamp F
CNL05 5 6 1 2 3 4 CNCL1
to front working lamp
17 7
CNL06 CNFS5
1 1 + 24 V
Working lamp R
CNL05 5 6 1 2 3 4 CNLR1
To rear working lamp
18 12
CNL06 CNFS5
2 2 + 24 V
20-372
TROUBLESHOOTING M-12A
20-373
TROUBLESHOOTING M-12A
(c) Monitor display lights up but cut-off function is not actuated Cause Remedy
YES
Defective cut-off relay Replace
2
Is voltage between
YES CNL65 (2) and
chassis ground 3 YES
normal? Defective main monitor Replace
1
1) 20 - 30 V Does cut-off
Does cut-off
NO function work? Wiring harness between
function work? 2) Turn starting CNL06 (female) (3) and After inspection,
switch ON. 1) Turn starting NO CNL65 (2) short circuiting repair or replace
switch ON. with chassis ground
1) Turn starting 2) Disconnect Contact of wiring harness
switch ON. CNL06. between CNL65 (3) and (5), After inspection,
NO or defective cut-off switch repair or replace
2) Remove cut - off
relay.
Transmission cut-off
CNFS2
CNL06 +24V
CNL08
Parking
brake
switch CNTL1
F solenoid
R solenoid
20-374
TROUBLESHOOTING M-12B
« Before carrying out troubleshooting, check that all the related connectors are properly inserted.
« Always connect any disconnected connectors before going on the next step.
(a) When monitor switch is pressed, cut-off function is not Cause Remedy
switched and display is not given
20-375
TROUBLESHOOTING M-12B
Cause Remedy
(e) Monitor display lights up but cut-off function does not work
CNL30
16
Cut-off signal
3 1
20-376
TROUBLESHOOTING M-13
YES
Defective main monitor Replace
1
Is voltage between
CNL05 (8) and Contact of power source with
chassis ground 2 YES wiring harness between After inspection,
normal? CNL05 (female) (8) and repair or replace
Is resistance
between CNL05 CNL04 (female) (3)
1) 0 - 5 V
2) Turn starting NO (male) (8) and (3)
switch ON. normal?
Defective main monitor Replace
1) 3 kΩ - 4 kΩ NO
2) Turn starting
switch OFF.
3) Disconnect Neutral relay
CNL05.
Start signal,
neutral signal
Starting motor
CNL57
1 2 3 5 6 CNL04
CNL05
3 N Speed lever
Starting
4
CNLR5
8
Neutral
2
CNR10
Rear frame GND
CNL09
3
Starting switch
20-377
TROUBLESHOOTING M-14
Cause Remedy
CNL07 CNL19
6 5
20-378
TROUBLESHOOTING M-15
Cause Remedy
(a) Buzzer does not sound when starting switch is turned
ON (during self-check)
Defective contact, or
disconnection in wiring After inspection,
YES
harness between CNL06 repair or replace
1 (female) (8) and CNL43
(male)
Does buzzer
sound? 2 YES
Defective buzzer Replace
Is voltage between
1) Turn starting CNL42 (female) and
switch ON. NO chassis ground Defective contact, or
2) Contact CNL43 normal? disconnection in wiring After inspection,
(female) to 1) 20 - 30 V NO harness between CNL42 repair or replace
chassis ground. 2) Turn starting (female) and CNFS2 (9)
switch ON.
YES
Defective main monitor. Replace
1
CNL19 CNL42
CNFS2 9
Buzzer output 4 Buzzer
+ 24 V
20-379
20-380
TROUBLESHOOTING M-17
Cause Remedy
1 YES
Defective main monitor Replace
Is voltage between
CNL05 (5) and Contact of power source
chassis ground with wiring harness between
normal? CNL05 (female) (5) - After inspection,
1) 0 - 5 V NO CNLR4 (6) - CNER1 (9) - repair or replace
2) Turn starting alternator terminal R, or
switch ON. defective alternator
1 YES
Defective main monitor Replace
Is voltage between
CNL05 (5) and Defective contact, or
chassis ground disconnection in wiring
normal? harness between CNL05
After inspection,
(female) (5) - CNLR4 (6) -
1) 20 - 30 V NO repair or replace
CNER1 (9) - alternator
2) Start engine. terminal R, or defective
alternator
Charge
Alternator
CNL05 CNLR4 CNER1
5 6 9 R
CNE16
20-381
TROUBLESHOOTING M-19, M-20
« Before carrying out troubleshooting, check that all the related connectors are properly inserted.
« Always connect any disconnected connectors before going on the next step.
Cause Remedy
Go to
2 YES Defective transmission Troubleshooting
Is resistance between controller for transmission
YES CNL31 (female) (15) controller
1 and chassis ground Defective contact, or
normal? disconnection in wiring
harness between CNL08 After inspection,
Does buzzer 1) 1kΩ - 2kΩ NO repair or replace
(female) (6) and CNL31
sound? 2) Turn starting (female) (15)
switch ON.
1) 0 - 3 V
2) Turn starting Defective main monitor Replace
switch ON. NO
CNL34
CNL08 CNL31
6 15
3.3 K
20-382
TROUBLESHOOTING M-21
Cause Remedy
3 YES
Defective main monitor Replace
Is voltage between
YES CNL05 (10) and
chassis ground Defective contact, or
2 normal? disconnection in wiring After inspection,
Is there continuity harness between CNL05 repair or replace
1) 0 - 2 V NO (female) (10) - CNTL1 (2) -
YES between CNT10
(female) (2) and 2) Turn starting CNT10 (female) (1)
1 chassis ground? switch ON.
Defective contact, or
Is there continuity 1) Disconnect disconnection in wiring
between CNT10 After inspection,
CNT10. harness between CNT10
(male) (1) and NO repair or replace
(female) (2) - CNTL1 (8) -
(2)? chassis ground
1) Disconnect
Defective emergency
CNT10. Replace
NO steering normal sensor
2) Turn starting
switch ON.
8 2
20-383
TROUBLESHOOTING M-22
Cause Remedy
(a) Emergency steering actuation display does not light up
3 YES
Defective main monitor Replace
Is voltage between
YES CNL05 (11) and
chassis ground Wiring harness between
2 normal? CNL05 (female) (11) -
After inspection,
Is there continuity CNTL1 (1) - CNT11 (female)
1) 0 - 2 V NO repair or replace
YES between CNT11 (1) short circuiting with
2) Turn starting chassis ground
(female) (2) and
switch ON.
1 chassis ground?
Defective contact, or
Is there continuity 1) Disconnect disconnection in wiring
between CNT11 After inspection,
CNT11. harness between CNT11
(male) (1) and NO repair or replace
(female) (2) - CNTL1 (8) -
(2)? chassis ground
1) Disconnect
Defective emergency
CNT11. Replace
NO steering actuation sensor
2) Turn starting
switch ON.
8 2
20-384
TROUBLESHOOTING M-23
Cause Remedy
YES
Defective main monitor Replace
1
Is voltage
between CNL08 Defective contact, or
(5) and chassis 2 YES disconnection in wiring After inspection,
ground normal ? harness between CNL08 repair or replace
Is voltage
between CNGRE (female) (5) and CNGRE (3)
1) 0 - 30 V
2) Turn starting NO (3) and chassis Go to
switch ON ground normal ? operation maintenance
NO manual for handling –
1) 0 - 30 V
2) Turn starting auto-greasing system
switch ON
YES
Defective main monitor Replace
1
Is voltage
between CNL07 Defective contact, or
(11) and chassis disconnection in wiring
2 YES After inspection,
ground normal ? harness between CNL07
Is voltage repair or replace
(female) (11) and CNGRE
1) 20 - 30 V between CNGRE (2)
2) Turn starting NO (2) and chassis
Go to
switch ON ground normal ?
operation maintenance
1) 20 - 30 V NO manual for handling –
2) Turn starting auto-greasing system
switch ON
20-385
TROUBLESHOOTING M-23
Cause Remedy
H H OFF
L H ON
Auto-greasing
CNL06 CNGRE
CNL07
A 11
CNL08
P
20-386
TROUBLESHOOTING M-24
Cause Remedy
(a) Display does not change when switch is pressed
ECSS
CNL06 CNDP2
7 1
20-387
TROUBLESHOOTING M-26B
Cause Remedy
Table
CNL29
CNL08 CNDP2
ECSS
20-388
TROUBLESHOOTING OF MAINTENANCE
MONITOR SYSTEM
(K MODE)
K- 1 When starting switch is turned ON, all lamps on maintenance monitor do not
light up for 3 seconds, maintenance monitor does not work ..................................................... 20-402
(a) All lamps on maintenance monitor do not light up for 3 seconds ....................................... 20-402
(b) Some lamps do not light up ................................................................................................. 20-403
K- 2 When starting switch is turned ON, all lamps on maintenance monitor light up
but do not go out ........................................................................................................................ 20-403
K- 3 When engine is started immediately after starting switch is turned ON
(within 3 seconds), all lamps on maintenance monitor do not go out ....................................... 20-404
K- 4 When starting switch is turned ON (engine stopped), CHECK items flash ............................... 20-405
(a) Engine oil level display flashes ............................................................................................ 20-405
(b) Engine water level display flashes ....................................................................................... 20-406
K- 5 When starting switch is turned ON (engine started), CAUTION items flash ............................. 20-407
(a) Engine oil pressure display flashes ..................................................................................... 20-407
(b) Battery charge level display flashes .................................................................................... 20-408
(c) Brake oil pressure display flashes ....................................................................................... 20-409
(d) Air cleaner display flashes ................................................................................................... 20-410
K- 6 CAUTION items are flashing but alarm buzzer does not sound ............................................... 20-411
K- 7 There is no abnormality in monitor display but alarm buzzer sounds ....................................... 20-412
K- 8 CAUTION items are flashing but warning lamp (CHECK lamp, CAUTION lamp)
does not light up ........................................................................................................................ 20-413
(a) CHECK lamp ....................................................................................................................... 20-413
(b) CAUTION lamp .................................................................................................................... 20-413
K- 9 There is no abnormality in maintenance monitor display but
warning lamp (CHECK lamp, CAUTION lamp) lights up ........................................................... 20-414
(a) CHECK lamp ....................................................................................................................... 20-414
(b) CAUTION lamp .................................................................................................................... 20-414
K-10 Night lighting does not light up when lamp switch is turned ON
(only lighting of maintenance monitor does not light up) ........................................................... 20-415
K-11 Night lighting lights up even when lamp switch is OFF, night lighting stays
lighted up .................................................................................................................................... 20-416
K-12 Service meter does not work ..................................................................................................... 20-417
K-13 Service meter is running even when engine is stopped ............................................................ 20-417
K-14 Abnormality in gauge items ........................................................................................................ 20-418
(a) Abnormality in fuel gauge .................................................................................................... 20-418
(b) Abnormality in engine water temperature gauge ................................................................. 20-419
(c) Abnormality in torque converter oil temperature gauge ...................................................... 20-420
20-401
TROUBLESHOOTING K-1
« Before carrying out troubleshooting, check that all the related connectors are properly inserted.
Defective contact, or
disconnection in wiring Repair wiring
YES harness between CNL18 harness,
1 3 (female) (1), (2) - CNFS2 replace or
Is voltage Is voltage between (9) - fuse box - CNFS1 replace fuse
between CNL18 YES CNFS1 (female) (2) (male) (2), or blow fuse
(1),(2) - (3) and chassis
Defective contact, or
normal? ground normal?
disconnection in wiring Repair wiring
2 1) 20 - 30 V harness between CNFS1 harness,
1) 20 - 30 V
Is there continuity 2) Disconnect (female) (2) - CNLR6 (1) - replace or
2) Turn starting NO
between CNL18 CNFS1. slow blow fuse - battery replace fuse
switch ON.
(female) (3) and 3) Turn starting relay, or blow fuse
NO
chassis ground? switch ON.
Defective contact, or
1) Turn starting disconnection in wiring Repair wiring
switch ON. harness between CNL18 harness or
2) Disconnect NO (3) - CNLR4 (12) - chassis replace
CNL18. ground
Battery relay
CNL18 Fuse box Slow blow fuse
3
CNLR4 Battery terminal
12
20-402
TROUBLESHOOTING K-1, K-2
Cause Remedy
Defective maintenance
monitor module Relace
Cause Remedy
Go to troubleshooting of –
main monitor
20-403
TROUBLESHOOTING K-3
« Before carrying out troubleshooting, check that all the related connectors are properly inserted.
« Always connect any disconnected connectors before going on the next step.
Cause Remedy
1
YES
When starting Defective maintenace Replace
engine, is voltage monitor module
between CNL19
(female (1) and Defective contact, or
chassis ground disconnection in wiring Repair wiring
normal? harness between CNL19 harness or
NO replace
1) 20 - 30 V (female) (1) and neutral
2) Disconnect relay
CNL19.
3) Start engine.
4) Measure when
starting motor is
turning.
CNL09
CNL19 3
1
C
Starting switch
6 5 3 2 1
CNL04
CNL57 3 N Speed lever
Neutral relay
20-404
TROUBLESHOOTING K-4
13 4 3 1
20-405
TROUBLESHOOTING K-4
8 2 1
20-406
TROUBLESHOOTING K-5
Cause Remedy
(a) Engine oil pressure display flashes
1
Does display go 3 YES Defective maintenance
monitor module Replace
out when ring Is there continuity
terminal is YES between CNL18
Defective contact, or
removed? (female) (10) and
disconnection in wiring Repair wiring
chassis ground?
1) Start engine. 2 harness between CNL18 harness,
Is voltage between
1) Disconnect NO (female) (10) - engine oil replace, or
ring terminal and CNL18. pressure relay - chassis replace relay
2) Turn starting ground, or defective relay
NO chassis ground switch OFF.
removed?
Contact off ground with
1) 20 - 30 V
wiring harness between Repair wiring
2) Remove ring
terminal. ring terminal - CNER1 (2) harness,
3) Start engine. NO - CNLR4 (3) - engine oil replace, or
pressure relay, or replace relay
defective relay
6 5 3 2 1
20-407
TROUBLESHOOTING K-5
Cause Remedy
(b) Battery charge level display flashes
R Alternator
CNR04
2 CNR12
1 1
Battery relay
20-408
TROUBLESHOOTING K-5
Cause Remedy
(c) Brake oil pressure display flashes
1) Turn starting
2
switch OFF. Defective contact, or
Is there continuity 2) Disconnect
YES between CNB08 disconnection in wiring Repair wiring
CNB13. harness between CNB13 harness or
(male) (1) and
(2)?
NO (female) (2) and CNB08 replace
(female) (1), or between
1
1) Start engine. CNB08 (female) (2) -
Is there continuity 2) Disconnect CNBR1 (1) - chassis ground
between CNB13 CNB08.
(male) (1) and Defective brake
(2)? accumulator charge oil Replace
NO
pressure switch (CNB08
1) Start engine. end)
2) Disconnect
CNB13. Defective brake Replace
accumulator charge oil
NO
pressure switch (CNB13
end)
CN41
11 8 6 1
4 2
20-409
TROUBLESHOOTING K-5
Cause Remedy
(d) Air cleaner display flashes
1 YES
Defective maintenance Replace
3
monitor
Does display go Is there continuity
YES between CNL18
out? Defective contact, or
(female) (15) and disconnection in wiring
chassis ground? harness between CNL18 Repair wiring
1) Start engine. 1) Turn starting (female) (15) and CNL80 harness,
2
2) Disconnect switch OFF. NO (female) (3), or between replace, or
CNE19. Is voltage between 2) Disconnect CNL80 (female) (6) - CNLR5 replace relay
CNE19 (female) (1) CNL18. (2) - chassis ground, or
NO and chassis ground defective dust indicator
normal? relay
1) Turn starting
switch ON. Short circuit, or contact of
Repair wiring
2) Disconnect wiring harness between
harness,
CNE19. CNE19 (female) (1) - CNER1
replace, or
3) 20 - 30 V NO (5) - CNLR4 (5) - CNL80
replace relay
(female) (2) with chassis
ground, or defective dust
indicator relay
+24V
CNL18 CNLR4 CNER1 CNE19 Dust indicator
15 5 5 1
CNER2 CNE20
5 1
6 5 3 2 1
CNLR5
2
20-410
TROUBLESHOOTING K-6
K-6 CAUTION items are flashing but alarm buzzer does not sound
« The buzzer does not sound for CHARGE or ENGINE OIL LEVEL.
« Before carrying out troubleshooting, check that all the related connectors are properly inserted.
« Always connect any disconnected connectors before going on the next step.
Cause Remedy
+24V
CNFS2 CNL42 Alarm buzzer
9 1
Maintenace monitor
CNL19 CNL43
4 1
Main monitor
CNL06
8
20-411
TROUBLESHOOTING K-7
Cause Remedy
+24V
CNFS2 CNL42 Alarm buzzer
9 1
Maintenace monitor
CNL19 CNL43
4 1
Main monitor
CNL06
8
20-412
TROUBLESHOOTING K-8
K-8 CAUTION items are flashing but warning lamp (CHECK lamp,
CAUTION lamp) does not light up
« Before carrying out troubleshooting, check that there are no blown lamp bulbs.
« Before carrying out troubleshooting, check that all the related connectors are properly inserted.
« Always connect any disconnected connectors before going on the next step.
Cause Remedy
3 9
20-413
TROUBLESHOOTING K-9
Cause Remedy
(a) CHECK lamp
Contact of chassis ground Repair wiring
1 YES with wiring harness harness or
between CNL19 (female) replace
Is there conitnuity
between CNL 19 (2) and CNL06 (female)
(female) (2) and (10)
chassis ground?
Defective maintenance Replace
NO monitor module
1) Turn starting
switch OFF.
2) Disconnect
CNL19.
3 9
20-414
TROUBLESHOOTING K-10
K-10 Night lighting does not light up when lamp switch is turned ON
(only lighting of maintenance monitor does not light up)
« Before carrying out troubleshooting, check that there are no blown lamp bulbs.
« Before carrying out troubleshooting, check that all the related connectors are properly inserted.
« Always connect any disconnected connectors before going on the next step.
Cause Remedy
Fuse box
Lighting +24V
CNL21 CNFS2 10A
1 5 CNL02 Lamp switch
2 2 4 1
5
CNLR5
20-415
TROUBLESHOOTING K-11
K-11 Night lighting lights up even when lamp switch is OFF, night
lighting stays lighted up
« Before carrying out troubleshooting, check that all the related connectors are properly inserted.
« Always connect any disconnected connectors before going on the next step.
Cause Remedy
Switch Continuity
ON Continuity
OFF NO continuity
Fuse box
Lighting +24V
CNL21 CNFS2 10A
1 5 CNL02 Lamp switch
2 2 4 1
5
CNLR5
20-416
TROUBLESHOOTING K-12, K-13
Cause Remedy
1 Defective contact, or
YES disconnection in wiring Repair wiring
Is voltage harness or
between CNL22 3 harness between CNL22
(female) (2) - CNLR4 (6) - replace
(female) (2) and Is there continuity
(1) normal? YES between CNL22 CNER1 (9) - alternator
(female) (1) and terminal R
1) 20 - 30 V 2 chassis ground? Defective contact, or
2) Start engine. Is voltage between disconnection in wiring Repair wiring
1) Turn starting
3) Disconnect alternator terminal harness between CNL22 harness or
switch ON. NO
CNL22. NO R and chassis (female) (1) - CNLR5 (2) - replace
ground normal? 2) Disconnect
chassis ground
CNL22.
1) 20 - 30 V Defective alternator Replace
2) Start engine. NO
Cause Remedy
1 YES
Defective service meter Replace
Is voltage
between CNL22
(female) (2) and Defective alternator, or Replace
(1) normal? contact of wiring harness alternator, or
NO between CNL22 (female) repair, replace
1) 0 -4 V (2) - CNLR4 (6) - CNER1 wiring harness
2) Turn starting (9) alternator terminal R
switch ON. with +24V
3) Disconnect
CNL22.
1
CNLR5
service meter
2 R Alternator
20-417
TROUBLESHOOTING K-14
YES
Defective fuel sensor Replace
1
3 YES Defective maintenance
Does fuel gauge monitor module Replace
Is there continuity
show FULL? YES between CNL18
(female) (6) and Defective contact, or
1) Disconnect
2 chassis ground? disconnection in wiring Repair wiring
CNR07. Is there continuity harness between CNR07 harness or
2) Connect short between CNR07 1) Turn starting NO (female) (1) - CNLR4 (10) - replace
connector to switch OFF. CNL18 (female) (6)
(female) (2) and
CNR07 (female). NO 2) Connect short
3) Turn starting chassis ground? connector to
switch ON. CNR07 (female).
1) Turn starting 3) Disconnect
switch OFF. CNL18.
2) Disconnect Defective contact, or
CNR07. Repair wiring
disconnection in wiring
harness or
NO harness between CNR07
replace
(female) (2) and chassis
ground
(2) Display always shows FULL and does not move
YES
Defective fuel sensor Replace
1
Do all display Contact of chassis ground
areas on fuel with wiring harness Repair wiring
gauge go out? 2 YES between CNR07 (female) harness or
Is there continuity (1) - CNLR4 (10) - CNL18 replace
1) Disconnect between CNR07 (female) (6)
CNR07. (female) (1) and
2) Turn starting
NO
chassis ground?
switch ON. Defective maintenance
Replace
1) Turn starting NO monitor module
switch OFF.
2) Disconnect
CNR07.
Fuel sensor
20-418
TROUBLESHOOTING K-14
1
Do all display 3 YES Defective maintenance
areas on engine Replace
Is there continuity monitor module
water temperature YES between CNL18
gauge go out? (female) (4) and Defective contact, or
2 chassis ground? Repair wiring
disconnection in wiring
1) Disconnect Is there continuity harness between CNE06 harness or
CNE06. 1) Trun starting NO replace
between CNE06 (female) (1) - CNER1 (6) -
2) Connect short switch OFF.
connector to NO (female) (2) and CNLR4 (1) - CNL18
CNE06 (female). chassis ground? 2) Connect short
(female) (4)
3) Turn starting connector to
switch ON. 1) Trun starting CNE06 (female).
switch OFF. 3) Disconnect Defective contact, or
2) Disconnect CNL18. disconnection in wiring Repair wiring
CNE06. harness between CNE06 harness or
NO (female) (2) - CNER1 (7) - replace
chassis ground
4 1 6 1
7 2
20-419
TROUBLESHOOTING K-14
1
Do all display areas 3 YES Defective maintenance
on torque converter Replace
Is there continuity monitor module
oil temperature YES between CNL18
gauge go out? (female) (5) and Defective contact, or
2 chassis ground? disconnection in wiring Repair wiring
1) Disconnect
CNT07. Is there continuity harness between CNT07 harness or
2) Connect short 1) Turn starting NO (female) (1) - CNTL2 (4) - replace
between CNT07
connector to switch OFF. CNL18 (female) (5)
CNT07 (female). NO (female) (2) and 2) Connect short
3) Turn starting chassis ground? connector to
switch ON. CNT07 (female).
1) Turn starting 3) Disconnect
switch OFF. CNL18.
2) Disconnect Defective contact, or
CNT07. disconnection in wiring Repair wiring
harness between CNT07 harness or
NO (female) (2) - CNTL2 (5) - replace
CNLR4 (12) - chassis
ground
12 5 2
CNLR4
20-420
TROUBLESHOOTING OF ELECTRICAL SYSTEM
(E MODE)
20-451
TROUBLESHOOTING E-1
YES
YES
3
5
Is voltage between
YES starting motor Is voltage between
YES both battery relay
terminal (E) and
chassis 20 - 30 V? terminals and
chassis 20 - 30 V?
1) Turn starting
1) Turn starting
switch ON 4 NO
switch ON
Is actuating sound
2) Check voltage
heard from battery
NO relay ? between chassis
and both YES
terminals
2 1) Turn starting connected by
Is there continuity switch thick cable 6
YES between starting ON OFF Is voltage 20 - 30V
motor terminal (E) between both
and chassis? connection terminals of
NO CNR12 and CNR13 of
B battery relay?
1) Turn starting
switch OFF 1) Turn starting
1 switch ON
NO
Is voltage between
CNE13 (female)
(1) and chassis
20 - 30 V ?
1) Disconnect
CNE13
NO
2) Directional
lever: Neutral
Go to A on next page
3) Turn starting NO
switch to
START
20-452
TROUBLESHOOTING E-1
Cause Remedy
Defective contact, or
disconnection in cable After inspection,
between battery relay and repair or replace
starting motor
Defective contact, or
disconnection in wiring
harness between starting
switch terminal BR-CNL09
YES (2) - CNLR4 (9) - CNR03 After inspection,
7 (diode) - CNR12 (female) repair or replace
Is voltage between or defective contact, or
starting switch disconnection in wiring
terminal BR and harness between CNR13
chassis 20 - 30 V ? and chassis ground
Defective contact, or
After inspection,
disconnection in starting
repair or replace
motor ground cable
20-453
TROUBLESHOOTING E-1
YES
YES
3
Is voltage between
YES CNL57 (female)
(5) and chassis 5 YES
1
20 - 30 V? YES Is voltage between
Does starting 4 starting switch
motor turn when 1) Disconnect terminal C and
A Is voltage between
CNL57 chassis 20 - 30 V?
relay is replaced? starting switch
NO terminal B and 1) Turn starting NO
1) Replace neutral 2) Turn starting chassis 20 - 30 V? switch to
relay (CNL57) switch to START START
with stop lamp 1) Turn starting
relay (CNL53) switch OFF
NO
2) Directional lever:
Neutral
3) Turn starting 2
switch to START Is voltage between
CNL57 (female) 8 YES
NO (1) and (2) Is voltage between
20 - 30 V ?
YES CNL04 (3) and
chassis 20 ? 30 V?
1) Disconnect
CNL57
NO
1) Connect T-
2) Directional lever: 7 adapter to
Neutral
Is voltage between CNL04
YES CNL04 (female) 2) Directional lever:
3) Turn starting
(1) and chassis Neutral
switch to START
20 - 30 V? 3) Turn starting
switch ON
1) Disconnect
CNL04 9 YES
6
2) Turn starting Is actuating sound
Is there continuity heard from battery
between CNL57 switch ON NO relay?
Go to B on
NO (female) (2) and
chassis? previous
1) Turn starting NO page
1) Turn starting switch ON OFF
switch OFF
2) Disconnect
CNL57
NO
20-454
TROUBLESHOOTING E-1
Cause Remedy
Defective contact, or
disconnection in wiring
harness between CNL57 After inspection,
(female) (3) - CNLR4 (8) - repair or replace
CNR01, 02 (diode) - CNER1
(10) - CNE13 (female) (1)
Defective contact, or
disconnection in wiring
harness between starting After inspection,
switch terminal C - CNL09 repair or replace
(3) - CNL57 (female) (5)
Defective contact, or
disconnection in wiring
harness between starting
switch terminal B - CNL09 After inspection,
(1) - CNFS3 (4) - fuse - repair or replace
CNFS3 (6) - CNLR5 (1) -
CNR17 - slow blow fuse
30A - battery relay
Defective contact, or
disconnection in wiring
harness between CNL04 After inspection,
(female) (3) and CNL57 repair or replace
(female) (1)
Defective contact, or
disconnection in wiring
harness between battery
YES After inspection,
relay - slow blow fuse 80A -
repair or replace
CNR15 - CNLR6 (1) -
10
CNFS1 (2) - fuse - CNFS2
Is voltage between (8) - CML04 (female) (1)
both battery relay
terminals and • If answer is NO for both
chassis 20 - 30 V? terminals: Defective contact
or disconnection in wiring
1) Turn starting harness between battery After inspection,
switch ON and battery relay repair or replace
2) Check valtage NO
• If answer is NO for one
between chassis terminal: Defective battery
and both relay
terminals
connected by Defective contact, or
thick cable. disconnection in wiring
After inspection,
harness between CNL57
repair or replace
(female) and chassis ground
ground
20-455
TROUBLESHOOTING E-1
YES
YES
3 YES
1
YES Is voltage between
CNE03 (7) and
Does engine stop
chassis 20 - 30 V ?
motor work ?
1) Connect T-
1) Turn starting adapter to 4
CNE03 YES
switch ON
OFF and check Does engine stop
2) Turn starting
visually. switch ON motor work when
NO relay is replaced ? 6
Is there continuity
1) Replace engine YES between CNL62
2 stop relay (female) (2) and
(CNL62) with
Is voltage between Stop lamp relay chassis?
CNE03 (female) (CNL53) 5 1) Turn starting
NO (4) and chassis 2) Turn starting Is voltage between switch OFF
20 - 30 V ? switch ON CNL62 (female)
OFF and check 2) Disconnect
1) Turn starting visually NO (1) and chassis CNL62 NO
switch OFF 20 - 30V ?
2) Disconnect 1) Disconnect
CNE03 CNL62
2) Turn starting
switch ON NO
NO
20-456
TROUBLESHOOTING E-1
Cause Remedy
YES
Defective engine stop motor Replace
7
Is there continuity
between CNE03 Defective contact, or
(female) (5) and disconnection in wiring
(7) ? harness between CNE03
(female) (5) - CNER2 (3) -
1) Disconnect CNLR3 (5) - CNL62 (female) After inspection,
CNE03 NO (5), or between CNE03 repair or replace
(female) (7) - CNER2 (4) -
2) Turn starting CNLR3 (6) - CNL62 (female)
switch ON (3)
Defective contact, or
disconnection in wiring
harness between CNL62 After inspection,
(female) (2) and chassis repair or replace
ground
Defective contact, or
disconnection in wiring
harness between CNL62 After inspection,
(female) (1) and CNL09 repair or replace
(female) (2)
20-457
TROUBLESHOOTING E-2, E3
« When connecting or disconnecting the T-adapter (or socket adapter) or short connector to carry out
checks, always turn the starting switch OFF before starting.
« When connecting the T-adapter (or socket adapter), connect to the connector specified as CN¡∆( ).
« After checking, connect the disconnected connectors and disconnect the T-adapter immediately to return
to the original condition before going on to the next check.
Cause Remedy
Defective adjustment
YES
between engine stop motor Adjust
and stop lever
1
YES
Does engine stop Defective engine stop motor Replace
motor work?
Defective contact, or
2 disconnection in wiring
1) Turn starting harness between CNE03
Is voltage between
switch ON (female) (3) - CNER2 (2) -
CNE03 (7) and (8)
OFF and check CNLR3 (4) - CNL62
visually NO 20 - 30 V ? YES After inspection,
(female), or between
CNL62 (female) (3) - repair or replace
1) Connect 3 CNLR3 (6) - CNER2 (4) -
T-adapter to CNE03 (female) (7)
CNE03 (engine Is voltage between
or defective relay
stop motor CNE03 (3) and (8)
(CNL62)
connector) NO 20 - 30 V ?
pin) 4 YES Defective engine stop motor Replace
1) Connect Is voltage between
2) Turn starting T-adapter to
switch OFF CNE03 (4) and (8) Defective contact, or
CNE03
NO 20 - 30 V ? disconnection in wiring
harness between CNE03
2) Turn starting After inspection,
(female) (4) - CNER2 (2) -
switch OFF 1) Connect NO CNLR3 (3) - CNFS2 repair or replace
T-adapter to
(female) 11, or blown fuse
CNE03
20-458
TROUBLESHOOTING E-8
Cause Remedy
If condition is as shown in
Table 2 - 1 (transmission is
always in 2nd) Problem in common circuit
Go to E-8(a)
for transmission
If condition is as shown in
Table 1 or Table 2 - 2
Problem in H-L circuit Go to E-8(b)
If condition is as shown in
2 Table 1 or Table 2 - 3
Problem in speed circuit Go to E-8(c)
Travels in both Check voltage If condition is as shown in Table
FORWARD and between CNT03 (1) 2 - 4 or Table 2 - 5 or Table 2 -
REVERSE. (female) and chassis 6 (does not enter 4th)
and between CNT04 Problem in 4th circuit Go to E-8(d)
(1) (female) and
chassis. If condition is as shown in
Table 2 - 7
1) Disconnect Contact in H - L circuit Go to E-8(e)
CNT03 and
CNT04 If condition is as shown in
2) Turn parking Table 2 - 8
switch ON Contact in speed circuit Go to E-8(f)
3) Turn parking If condition is as shown in
1 switch ON Table 2 - 9 (transmission is
OFF always in 4th)
Does machine 4) Operate speed Contact in 4th circuit Go to E-8(g)
?
travel forward and lever with
directional lever If condition is as shown in
in reverse? at FORWARD, Table 3 or Table 4 - 1
NEUTRAL, and (REVERSE is normal) Problem in FORWARD
REVERSE to circuit Go to E-8(h)
1) Start engine
check condition If condition is as shown in
2) Turn parking Table 3 or Table 4 - 2
switch ON Travels in only (FORWARD is normal) Problem in REVERSE
OFF circuit Go to E-8(i)
FORWARD or
REVERSE, or 3 If condition is as shown in
3) Operate directional does not travel Table 4 - 3 (does not travel in Problem in common circuit
lever FORWARD Check voltage either direction)
REVERSE in either between CNT01 (1) for FORWARD and Go to E-8(j)
direction. (female) and chassis REVERSE
If condition is as shown in
and between CNT02 Table 4 - 4 (REVERSE is
(1) (female) and normal) Contact in FORWARD
chassis. circuit Go to E-8(k)
If condition is as shown in
1) Disconnect Table 4 - 5 (FORWARD is
CNT01 and normal) Contact in REVERSE circuit
CNT02 Go to E-8(l)
2) Turn parking If condition is as shown in
switch ON Table 4 - 6 (does not travel in
3) Turn parking either direction) Problem in common circuit
switch ON for FORWARD and Go to E-8(m)
OFF REVERSE
4) Operate directional lever with speed lever
in all positions (1st to 4th) to check condition
Go to applicable item.
20-459
TROUBLESHOOTING E-8
1 ¡ l 1 ¡ ¡ 1 ¡ l 1 ¡ ¡
2 ¡ ¡ 2 ¡ ¡ 2 ¡ ¡ 2 ¡ ¡
3 l ¡ 3 ¡ ¡ 3 ¡ ¡ 3 l ¡
4 l l 4 ¡ ¡ 4 ¡ l 4 l ¡
Table 1 (normal) Table 2-1 (abnormal) Table 2-2 (abnormal) Table 2-3 (abnormal)
1 ¡ l 1 ¡ l 1 ¡ l
2 ¡ ¡ 2 ¡ ¡ 2 ¡ ¡
3 l ¡ 3 l ¡ 3 l ¡
4 ¡ ¡ 4 l ¡ 4 ¡ l
Table 2-4 (abnormal) Table 2-5 (abnormal) Table 2-6 (abnormal)
1 l l 1 ¡ l 1 l l
2 l ¡ 2 ¡ l 2 l l
3 l ¡ 3 l l 3 l l
4 l l 4 l l 4 l l
Table 2-7 (abnormal) Table 2-8 (abnormal) Table 2-9 (abnormal)
(F) (R)
Between Between Between Between Between Between Between Between
CNT01 CNT02 CNT01 CNT02 CNT01 CNT02 CNT01 CNT02
Direc- (female) (1) (female) (1) Direc- (female) (1) (female) (1) Direc- (female) (1) (female) (1) Direc- (female) (1) (female) (1)
tional chassis chassis tional chassis chassis tional chassis chassis tional chassis chassis
lever ground ground lever ground ground lever ground ground lever ground ground
20-460
TROUBLESHOOTING E-8
Cause Remedy
l: 20 30 V
¡: 0 0.5 V
Transmission
Between Between Between Between
range CN04(5) chassis CN04(6) chassis CN04(7) chassis CN04(8) chassis
1 l ¡ ¡ ¡
2 ¡ l ¡ ¡
3 ¡ ¡ l ¡
4 ¡ ¡ ¡ l
Cause Remedy
YES
Defective H - L solenoid Replace
2
Is voltage between
YES CNT03 (female) Defective contact, or
disconnection in wiring
(1) and chassis 3 YES After inspection,
harness between CNL04
20 - 30 V ? repair or replace
Is voltage between (female) (7) - CNTL1 (5) -
1 1) Disconnect CNL04 (7) and CNT03 (female) (1)
CNT03 NO chassis 20 - 30V?
Is there continuity
between CNT03 2) Turn starting Defective speed lever switch Replace
(female) (2) and switch OFF 1) Connect NO
T-adapter to
chassis ? CNL04
2) Turn starting
1) Disconnect switch ON
CNT03 3) Speed lever: 3rd Defective contact, or
2) Turn starting disconnection in wiring
harness between CNT03 After inspection,
switch OFF
NO (female) (2) and chassis repair
ground
20-461
TROUBLESHOOTING E-8
YES
Defective speed solenoid Replace
2
Is voltage between
YES CNT04 (female) Defective contact, or
(1) and chassis 3 YES disconnection in wiring
After inspection,
20 - 30 V ? harness between CNL04
repair or replace
1 Is voltage between (female) (5) - CNTL1 (6) -
Is there continuity 1) Disconnect CNL04 (5) and CNT04 (female) (1)
CNT04 NO chassis 20 - 30 V?
between CNT04
(female) (2) 2) Turn starting Defective speed lever switch Replace
chassis ? switch ON 1) Connect NO
T-adapter to CNL04
1) Disconnect 3) Speed lever: 1st 2) Turn starting switch ON Defective contact, or
CNT04 3) Speed lever: 1st disconnection in wiring
After inspection,
harness between CNT04
2) Turn starting NO repair or replace
switch OFF (female) (2) and chassis
ground
Defective contact, or
disconnection in wiring
harness between CNL04
1 YES
After inspection,
(female) (8) - CN37 -
repair or replace
Is voltage between CNTL1 (male) (6) or CNL04
CNL04 (8) and (female) (8) - CN38 -
chassis ground 20 CNTL1 (male) (5)
- 30V?
1) Connect Defective speed lever switch Replace
NO
T-adapter
to CNL04
2) Turn starting
switch ON
3) Speed lever: 4th
20-462
20-463
TROUBLESHOOTING E-8
YES
1
Is voltage between
CNT03 (female) YES
(1) and chassis
20 - 30 V ?
1) Disconnect
CNT03
2) Disconnect 2
CNTL1
Is there continuity
3) Turn starting between CNTL1 YES
switch ON NO (female) (5) and
(3)(4)(6)?
1) Turn starting
switch OFF
2) Disconnect 3
CNT03 Is voltage between
CNTL1 (male) (5) YES
3) Disconnect
CNTL1 NO and chassis 20 -
30 V ?
1) Disconnect
CNTL1
2) Disconnect
4
CNL04 Is there continuity
between CNTL1
3) Turn starting
switch ON NO (male) (5) and
(3)(4)(6)?
2) Disconnect 5
CNTL1 Is there continuity
3) Disconnect between CNL04
CNL04 NO (female) (7) and
(1)(2)(3)(4)(6)?
1) Turn starting
switch OFF
NO
2) Disconnect
CNTL1
3) Disconnect
CNL04
4) Disconnect
CNL66
20-464
TROUBLESHOOTING E-8
Defective transmission
control switch Replace
20-465
TROUBLESHOOTING E-8
YES
1
Is voltage between
CNT04 (female) YES
(1) and chassis
20 - 30 V ?
1) Disconnect
CNT04
2) Disconnect 2
CNTL1
Is there continuity
3) Turn starting between CNTL1 YES
switch ON NO (female) (6) and
(3)(4)(5)?
1) Turn starting
switch OFF
2) Disconnect 3
CNT04 Is voltage between
CNTL1 (male) (6) YES
3) Disconnect
CNTL1 NO and chassis 20 -
30 V ?
1) Disconnect
CNTL1
2) Disconnect
4
CNL68 Is there continuity
between CNTL1
3) Disconnect
CNL04 NO (male) (6) and
(3)(4)(5)?
4) Turn starting
switch ON 1) Turn starting YES
switch OFF
2) Disconnect 5
CNTL1 Is there continuity
3) Disconnect between CNL04
CNL68 NO (female) (5) and
(1)(2)(3)(4)(6)?
4) Disconnect
CNL04
1) Turn starting
switch OFF
NO
2) Disconnect
CNTL1
3) Disconnect
CNL68
4) Disconnect
CNL04
5) Disconnect
CNL66
20-466
TROUBLESHOOTING E-8
Defective transmission
After inspection,
control switch, or abnormal
repair or replace
contact of CNL68 (3) (4)
(male)
20-467
TROUBLESHOOTING E-8
2) Turn starting
switch ON
20-468
20-469
TROUBLESHOOTING E-8
2 YES
Is there continuity
YES between CNT01
(female) (2) and
chassis ?
1) Disconnect NO
CNT01
2) Turn starting
1 switch OFF YES
Is voltage between
CNT01 (female)
(1) and chassis
20 - 30V? 7 YES
1) Disconnect Is voltage between
CNT01 YES CNL66 (female) (5)
and chassis 20 -
2) Turn starting 3
switch ON 6 30V?
Is problem Is there continuity 1) Disconnect NO
3) Turn parking
switch ON removed when YES between CNL66 CNL66
OFF NO relay is replaced ? (female) (6) 2) Turn starting
switch ON
chassis? 3) Directional lever:
4) Dirctional 5
lever: 1) Replace FORWARD
FORWARD Is there continuity 1) Disconnect
FORWARD CNL66
solenoid relay YES between CNL66
(CNL66) with NO
REVERSE (female) (2) and 2) Turn starting
solenoid relay chassis? switch OFF
(CNL67) 4
1) Disconnect
2) Start engine Is voltage between CNL66
CNL66 (female)
3) Turn parking 2) Turn starting NO
switch ON NO (1) and chassis switch OFF
OFF 20 - 30V?
4) Dirctional 1) Disconnect
lever: FORWARD CNL66
2) Turn starting
switch ON NO
3) Turn parking
switch ON
OFF
20-470
TROUBLESHOOTING E-8
Cause Remedy
Defective contact, or
disconnection in wiring After inspection,
harness between CNT01 repair or replace
(female) (2) and chassis
Defective FORWARD
solenoid Replace
Defective contact, or
disconnection in wiring
After inspection,
harness between CNL04
repair or replace
(female) (2) and CNL66
(female) (5)
Defective contact, or
disconnection in wiring After inspection,
harness between CNL66 repair or replace
(female) (6) and chassis
Defective contact, or
disconnection in wiring
After inspection,
harness between CNL66
repair or replace
(female) (2) - CNTL1 (3) -
CNT01 (female) (1)
Defective contact, or
disconnection in wiring
After inspection,
harness between CNL66
repair or replace
(female) (1) and CNL67
(female) (1)
20-471
TROUBLESHOOTING E-8
2 YES
Is there continuity
YES between CNT02
(female) (2) and
chassis ?
1) Disconnect NO
CNT02
2) Turn starting
1 switch OFF YES
Is voltage between
CNT02 (female)
(1) and chassis
20 - 30V? 7 YES
1) Disconnect Is voltage between
CNT02 YES CNL67 (female) (5)
and chassis 20 -
2) Turn starting 3
switch ON 6 30V?
Is problem Is there continuity 1) Disconnect NO
3) Turn parking
switch ON removed when YES between CNL67 CNL67
OFF NO relay is replaced ? (female) (6) 2) Turn starting
switch ON
chassis? 3) Directional lever:
4) Dirctional 5
lever: 1) Replace REVERSE
REVERSE Is there continuity 1) Disconnect
REVERSE CNL67
solenoid relay YES between CNL67
(CNL67) with NO
FORWARD (female) (2) and 2) Turn starting
solenoid relay chassis? switch OFF
(CNL66) 4
1) Disconnect
2) Start engine Is voltage between CNL67
CNL67 (female)
3) Turn parking 2) Turn starting NO
switch ON NO (1) and chassis switch OFF
OFF 20 - 30V?
4) Dirctional 1) Disconnect
lever: REVERSE CNL67
2) Turn starting
switch ON NO
3) Turn parking
switch ON
OFF
20-472
TROUBLESHOOTING E-8
Cause Remedy
Defective contact, or
disconnection in wiring After inspection,
harness between CNT02 repair or replace
(female) (2) and chassis
Defective REVERSE
solenoid Replace
Defective contact, or
disconnection in wiring
After inspection,
harness between CNL04
repair or replace
(female) (4) and CNL67
(female) (5)
Defective contact, or
disconnection in wiring After inspection,
harness between CNL67 repair or replace
(female) (6) and chassis
Defective contact, or
disconnection in wiring
After inspection,
harness between CNL67
repair or replace
(female) (2) - CNTL1 (4) -
CNT02 (female) (1)
Defective contact, or
disconnection in wiring
After inspection,
harness between CNL66
repair or replace
(female) (1) and CNL67
(female) (1)
20-473
TROUBLESHOOTING E-8
YES
2
Is voltage between
YES CNL04 (2), (4) -
chassis as shown in 3 YES
table? Is voltage between
CNL04 (female)
1) Connect
T-adapter to NO (1) and chassis
CNL04 20 - 30 V ?
2) Turn starting 1) Disconnect NO
1 switch ON CNL04
1) Disconnect
CNL58
2) Turn starting NO
switch ON
3) Turn parking
brake switch
ON OFF
l: 20 30 V
¡: 0 0.5 V
Divectional
Between Between
lever CN04(2) chassis CN04(4) chassis
F l ¡
N ¡ ¡
R ¡ l
20-474
TROUBLESHOOTING E-8
Cause Remedy
Defective contact, or
disconnection in wiring
harness between CNFS2 After inspection,
(female) (8) and CNL04 repair or replace
(female) (1)
Defective contact, or
disconnection in wiring
harness between CNL65
After inspection,
(female) (3) and CNL12
repair or replace
(female) (1), or between
CNL12 (female) (12) and
CNL65 (female) (5)
Defective contact, or
disconnection in wiring
harness between CNL58
(female) (5) and CNL12 After inspection,
(female) (1), or between repair or replace
CNL12 (female) (2) -
CNL66 (female) (1), CNL67
(female) (1)
Defective contact, or
disconnection in wiring
harness between CNL58 After inspection,
(female) (3) - CNFS2 (8) - repair or replace
fuse - CNFS1 (male) (2)
Defective contact, or
disconnection in wiring After inspection,
harness between CNL58 repair or replace
(female) (2) and chassis
Defective contact, or
disconnection in wiring
harness between CNL58 After inspection,
(female) (1) and CNL01 repair or replace
(female) (2)
20-475
TROUBLESHOOTING E-8
YES
1 YES
Is problem
removed when
relay is replaced?
1) Replace
FORWARD relay 2
(CNL66) with F
working lamp Is voltage between
relay (CNL60) CNT01 (female) YES
NO (1) and chassis
2) Start engine 20 - 30 V ?
3) Turn parking 1) Disconnect
brake switch ON CNT01
OFF
2) Disconnect 3
4) Directional lever: CNTL1
FORWARD Is there continuity
3) Turn starting between CNTL1 YES
switch ON
NO (female) (3) and
(4)(5)(6)?
1) Turn starting
switch OFF
2) Disconnect 4
CNT01
Is voltage between YES
3) Disconnect CNTL1 (male) (3)
CNTL1
NO and chassis
20 - 30 V?
1) Disconnect
CNTL1
2) Disconnect
CNL66 5
Is there continuity
3) Turn starting
switch ON between CNTL1
NO (male) (3) and
(4)(5)(6)?
2) Disconnect
CNTL1 6
3) Disconnect Is there continuity
CNL66 between CNL04
NO (female) (2) and (1)
(3)(4)(5)(6)(7)(8)?
1) Turn starting
switch OFF
2) Disconnect NO
CNL66
3) Disconnect
CNL04
20-476
TROUBLESHOOTING E-8
Defective transmission
Replace
control switch
20-477
TROUBLESHOOTING E-8
YES
1 YES
Is problem
removed when
relay is replaced?
1) Replace
REVERSE relay 2
(CNL67) with F
working lamp Is voltage between
relay (CNL60) CNT02 (female) YES
NO (1) and chassis
2) Start engine 20 - 30 V ?
3) Turn parking 1) Disconnect
brake switch ON CNT02
OFF
2) Disconnect 3
4) Directional lever: CNTL1
REVERSE Is there continuity
3) Turn starting between CNTL1 YES
switch ON
NO (female) (4) and
(3)(5)(6)?
1) Turn starting
switch OFF
2) Disconnect 4
CNT02
Is voltage between YES
3) Disconnect CNTL1 (male) (4)
CNTL1
NO and chassis
20 - 30 V?
1) Disconnect
CNTL1
2) Disconnect
CNL67 5
Is there continuity
3) Turn starting
switch ON between CNTL1
NO (male) (4) and
(3)(5)(6)?
2) Disconnect
CNTL1 6
3) Disconnect Is there continuity
CNL67 between CNL04
NO (female) (4) and (1)
(2)(3)(5)(6)(7)(8)?
1) Turn starting
switch OFF
2) Disconnect NO
CNL67
3) Disconnect
CNL04
20-478
TROUBLESHOOTING E-8
Defective transmission
Replace
control switch
20-479
TROUBLESHOOTING E-9
Cause Remedy
20-480
20-481
TROUBLESHOOTING E-9
YES
YES
2
Is problem
YES
removed when
relay is replaced?
1) Replace kick-
down realy
(CNL68) with
REVERSE
solenoid relay
(CNL67) 3 YES
2) Start engine
Is problem
removed when
NO relay is replaced? 6
Is there continuity
1) Replace YES between CNL15
FORWARD (female) 1)
1 soleniod realy CNL66 (female) (4)?
(CNL66) with
Is there continuity REVERSE 5
solenoid relay 1) Disconnect
between CNL15 CNL15 and
(CNL67) Is there continuity
(male) (1) and CNL66
YES between CNL68
(male) (2) ? 2) Start engine
(female) (5) 2) Turn starting
switch OFF NO
1) Disconnect CNL15 (female) (2)?
CNL15
4 1) Disconnect
2) Press kick-down CNL68 and
switch Is there continuity CNL15
3) Turn starting between CNL68
switch OFF 2) Turn starting
NO (female) (6) and switch OFF
NO
chassis ground?
1) Disconnect
CNL68
2) Turn starting
switch OFF NO
NO
20-482
TROUBLESHOOTING E-9
Cause Remedy
Defective FORWARD
solenoid relay Replace
Defective contact, or
YES disconnection in wiring
After inspection,
8 harness between CNL68
repair or replace
(female) (4) and CNL04
Is voltage between
YES CNL68 (female) (female) (5)
(3) and chassis Defective contact, or
20 - 30V ? disconnection in wiring
7 After inspection,
1) Disconnect harness between CNL68
NO repair or replace
Is voltage between CNL68 (female) (3) and CNFS2
CNL66 (female) (female) (3)
2) Turn starting
(3) and chassis switch ON
20 - 30V ? Defective contact, or
disconnection in wiring
1) Disconnect 9 YES After inspection,
harness between CNL66
CNL66 Is voltage between repair or replace
(female) (3) and CNL04
2) Speed lever: CNL04 (6) and (female) (6)
2nd NO chassis 20 - 30V?
3) Turn starting Defective speed lever switch Replace
switch ON 1) Connect NO
T-adapter to CNL04
2) Speed lever: 2nd Defective contact, or
3) Turn starting switch ON disconnection in wiring
harness between CNL15 After inspection,
(female) (1) and CNL66 repair or replace
(female) (4)
Defective contact, or
disconnection in wiring
harness between CNL68 After inspection,
(female) (5) and CNL15 repair or replace
(female) (2)
Defective contact, or
disconnection in wiring
After inspection,
harness between CNL68
repair or replace
(female) (6) and chassis
ground
20-483
TROUBLESHOOTING E-10, E-11
Cause Remedy
1 YES
Defective kick-down relay Replace
Is problem Defective contact, or
removed when disconnection in wiring
relay is replaced? harness between CNL66
After inspection,
(female) (4) - CNL68
1) Replace kick- NO repair or replace
(female) (1) or CNL68
down relay
(CNL68) with (female) (2) - CNL68
REVERSE (female) (5)
solenoid relay
(CNL67)
2) Start engine
Cause Remedy
2) Start engine
20-484
20-485
TROUBLESHOOTING E-11
YES
1
Is there continuity YES
between CNL04
(female) (1) and
CNL04 (female) (6)?
2
1) Turn starting
switch OFF Is there continuity
between CNL04
YES
2) Disconnect
CNL04 NO (female) (2) and
CNL04 (female) (6)?
3) Disconnect 3
CNL66 1) Turn starting
switch OFF Is voltage between
CNL66 (female) YES
2) Disconnect
CNL04 NO (3) and chassis
20 - 30 V ?
3) Disconnect
CNL66 1) Disconnect 4
CNL66 Is voltage between
2) Disconnect CNL66 (female)
CNL04 NO (4) and chassis YES
20 - 30 V?
3) Turn starting
switch ON 1) Disconnect 5
CNL66
Is voltage between
2) Disconnect CNL68 (female) YES
CNL68 NO (2) and chassis
3) Disconnect
20 - 30 V?
6
CNL15
1) Disconnect
CNL68 Is there continuity
4) Turn starting between CNL04
switch ON
2) Disconnect NO (female) (1) and
CNL15 CNL04 (female) (5)?
3) Turn starting
switch ON 1) Turn starting
switch OFF
2) Disconnect NO
CNL04
3) Disconnect
CNFT1
20-486
TROUBLESHOOTING E-11
20-487
TROUBLESHOOTING E-12
Cause Remedy
YES
Defective kick-down switch Replace
1
Is there continuity
between CNL15 YES
(male) (1) and Defective kick-down relay Replace
CNL15 (male) (2) ? 2
1) Disconnect Is there continuity
CNL15 between CNL68 YES Contact of wiring harness
After inspection,
NO (male) (1) - (2) 3
between CNL15 (female) (1)
repair or replace
2) Turn starting and (3) - (4) ? (2)
switch OFF
Is there continuity
1) Disconnect between CNL15
3) Do not press
4 YES Contact of wiring harness
kick-down relay
kick-down (CNL68) NO (female) (1) and After inspection,
switch CNL15 (female) (2) ?
between CNL68 (female) (1)
Is there continuity
repair or replace
2) Turn starting (2)
switch OFF 1) Disconnect between CNL68
CNL15 NO (female) (1) and
CNL68 (female) (2) ? Contact of wiring harness
After inspection,
2) Turn starting between CNL68 (female) (3)
switch OFF NO (4) repair or replace
1) Disconnect
CNL68
3) Directional
lever: N 2) Turn starting
switch OFF
3) Directional
lever: N
20-488
TROUBLESHOOTING OF TRANSMISSION
CONTROLLER SYSTEM
(A MODE)
20-501
TROUBLESHOOTING OUTLINE
OUTLINE
1. Function
The control mechanism of the transmission con-
troller consists of the controller, sensors, input
switch, solenoid output, and buzzer output. The
controller receives the input signal, processes it,
and carries out the auto-shift control by control-
ling the solenoid to a transmission range that
matches the travel speed.
Abnormality in directional
A-8 20 A-18 Network signal system
lever signal system
Abnormality in speed Abnormality in controller
A-9 21 A-19
lever signal system power source voltage
Abnormality in travel speed Abnormality in model
A10 22 A-20
sensor signal system selection wiring harness
20-502
TROUBLESHOOTING OUTLINE
4. Table of troubleshooting modes and causes
Cause of failure Related equipment
20-503
TROUBLESHOOTING A-1
Cause Remedy
2 YES
Defective controller Replace
Is insulation
YES between CNL29 Wiring harness between Repair wiring
3 YES CNL29 (female) (3), (14), harness, or
(female) (3) and
chassis normal ? CNTL2 (7), (8) - CNT12 replace
s insulation (19), (2) short circuiting
between CNT12 with chassis ground.
1) Disconnect
(male) (1) and
1 CNL29. NO chassis normal ?
2) Min. 1MΩ Defective modulation Replace
Is resistance 1) Disconnect NO solenoid valve
between CNL29 CNT12.
(female) (3) and (14) 4 YES 2) Min. 1MΩ Defective contact, Repair wiring
disconnection, or short harness, or
normal? Is resistance circuit in wiring harness replace
between CNT12 between CNL29 (female)
1) Disconnect (male) (1) and (2) (13), (14) - CNTL2 (7), (8)
NO
CNL29. normal? - CNT12 (1), (2)
2) 12 - 15 Ω
NO Defective modulation Replace
1) Disconnect
solenoid valve
CNT12.
2) 12 - 15 Ω
20-504
TROUBLESHOOTING A-2
« Before carrying out troubleshooting, check that all the related connectors are properly inserted.
« Always connect any disconnected connectors before going on the next step.
« When disconnecting connectors to connect the T-adapter (or socket adapter), always turn the starting
switch OFF.
Cause Remedy
3 YES
Defective controller Replace
Is voltage between
2 YES CNT12 (male) (1) and
chassis normal?
Is voltage between Short circuit of solenoid Replace
YES
CNL29 (female) (14) power source
1) Disconnect NO
and chassis normal?
CNT12.
2) Max. 1V
1) Disconnect
3) Turn starting switch ON. Wiring harness between Repair wiring
CNL29 and
1 CNL29 (female) (14) - harness or
CNT12. CNTL2 (8) - CNT12 (2) - replace
Is voltage between NO
2) Max. 1V solenoid short circuiting
CNL29 (female) (3) and 3) Turn starting with power source
chassis normal? switch ON.
20-505
TROUBLESHOOTING A-3, A-4
· Defective contact, or
disconnection in wiring
1 harness between CNL29
(female) (21) - CNTL1 (3)
Is resistance
- CNT01 (female) (1) or
between CNL29
short circuit with ground Repair wiring
(female) (21) and 2 YES
· Disconnection in wiring harness or
(19) normal? Is resistance harness between CNT01 replace
1) Disconnect between CNT01 (female) (2) and chassis
NO (male) (1) and (2)
CNL29 and
normal?
CNT1R Defective F solenoid Replace
(if equipped). 1) Disconnect NO
2) 46 - 58 Ω CNT01.
2) 46 - 58 Ω
· Defective contact, or
disconnection in wiring
1 harness between CNL29
Is resistance between (female) (20) - CNTL1 (4)
CNL29 (female) (20) - CNT02 (female) (1) or
Repair wiring
and (19) normal? 2 YES short circuit with ground
harness or
· Disconnection in wiring
Is resistance between replace
harness between CNT02
CNT02 (male) (1) and (female) (2) and chassis
1) Disconnect
NO (2) normal?
CNL29
(If equipped). Defective R solenoid Replace
2) 46 - 58 Ω 1) Disconnect CNT02. NO
2) 46 - 58 Ω
CNL 29
GND 19
R - solenoid CNTL 1 CNT02 R - solenoid
20
F - solenoid
21
CNT01 F - solenoid
CNTIR
F - solenoid
20-506
TROUBLESHOOTING A-5
CNL29
GND
CNTL1 CNT03 H-L solenoid
H-L solenoid
Speed solenoid 11
CNTIR
Speed solenoid
H-Lsolenoid
CNL05
12 Transmission range 1
13 Transmission range 2
20-507
TROUBLESHOOTING A-6
Cause Remedy
YES
Defective controller Replace
Wiring harness between Repair wiring
3 YES CNL29 (female) (11) - harness or
CNTL1 (female) (6), replace
Is resistance between CNL05 (female) (12) short
YES CNTL1 (female) (6) circuiting with chassis
ground, or disconnection,
and chassis normal ?
defective contact
1 Repair wiring
· Wiring harness harness or
Is resistance between NO between CNTL1 (female)
1) Disconnect replace
CNL29 (female) (11) (6) and CNT04 (female)
and (19) normal? 2 CNTL1.
(1) short circuiting with
2) 46 - 58 Ω chassis ground, or
Is resistance between
disconnection, defective
CNT04 (male) (1) and contact
1) Disconnect
CNL29, CNT1R NO (2) normal? · Disconnection in wiring
(if equiped) harness between CNT04
and CNL05. (female) (2) and chassis
1) Disconnect
2) 46 - 58 Ω
CNT04. Defective speed solenoid Replace
NO
2) 46 - 58 Ω
CNL29
GND
CNTL1 CNT03 H-L solenoid
H-L solenoid
Speed solenoid 11
CNTIR
Speed solenoid
H-Lsolenoid
CNL05
12 Transmission range 1
13 Transmission range 2
20-508
20-509
TROUBLESHOOTING A-8
14
Speed lever 3 CNL05
Neutral
20-510
TROUBLESHOOTING A-9
4
Is voltage
YES
between CNL30 Wiring harness between
(3) and (9) CNL30 (female) (3) -
Repair wiring
3 normal? CNL04 (8) - directional
harness or
speed lever switch short
Is voltage NO replace
YES between CNL30 circuiting with chassis
1) Speed lever
ground, or disconnection,
(14) and 4th: 20 - 30 V
defective contact
(9)normal? Other than 4th:
2
0V Wiring harness between
Is voltage 1) Speed lever 2) Turn starting
YES between CNL30 CNL30 (female) (14) - Repair wiring
3rd: 20 - 30 V swtich ON. CNL04 (7) - directional
(2) and (9) harness or
Other than 3rd: speed lever switch short replace
normal? 0V NO circuiting with chassis
2) Turn starting ground, or disconnection,
1) Speed lever
swtich ON. defective contact
2nd: 20 - 30 V
1
Other than 2nd:
Is voltage 0V
between CNL30 Wiring harness between
2) Turn starting CNL30 (female) (2) -
(13) and (9) swtich ON. Repair wiring
CNL04 (6) - directional harness or
normal?
speed lever switch short replace
1) Speed lever NO circuiting with chassis
1st: 20 - 30 V ground, or disconnection,
Other than 1st: defective contact
0V
2) Turn starting Wiring harness between
swtich ON. CNL30 (female) (13) -
CNL04 (5) - directional Repair wiring
speed lever switch short harness or
NO circuiting with chassis replace
Fuse 24 V ground, or disconnection,
defective contact
CNFS2
Directional
CNL04 lever switch
CNL30
Directional lever F
Speed lever 2 Main monitor
Speed lever 4
CNL08
Signal ground Transmission
Directional lever N 11 signal F input
Transmission
Directional lever R 12
signal R input
Speed lever 1 13
14
Speed lever 3 CNL05
Neutral
20-511
TROUBLESHOOTING A-10
Cause Remedy
YES
Defective controller Replace
Main monitor
CNL07
Speedometer (+)
Speedometer (-)
Tachometer (+)
20-512
TROUBLESHOOTING A-11
Cause Remedy
2 YES
Defective controller Replace
Is continuity between
YES CNL31 (female) (5)
and (12) normal?
Defective contact, or Repair wiring
1 disconnection in wiring harness or
1) Disconnect CNL31, NO harness between CNL31 replace
Is insulation between
CNLGL and CNL07. (female) (5) and CNLGL
CNL31 (female) (5),
2) Short circuiting CNLGL (female) (14), (15). (female) (14)
(12) and chassis
normal?
Main monitor
CNL07
Speedometer (+)
Speedometer (-)
Tachometer (+)
20-513
TROUBLESHOOTING A-12, A-13
1
Is continuity between Wiring harness between Repair wiring
CNL30 (female) (18) CNL30 (female) (18) and harness or
and chassis normal? 2 YES CNL15 (female) (3) short replace
circuiting with chassis
Is continuity between
ground, or disconnection,
CNL15 (male) (3) and
1) Disconnect defective contact.
NO (4) normal?
CNL30.
2) Hold switch Defective hold switch Replace
ON: Max. 1 Ω NO
OFF: Min. 1 ΜΩ
1
Is continuity between Wiring harness between
CNL30 (female) (17) CNL30 (female) (17) and
and chassis normal? 2 YES CNL15 (female) (1) short Repair wiring
circuiting with chassis harness or
Is continuity between replace
ground, or disconnection,
CNL15 (male) (1) and
1) Disconnect defective contact
NO (2) normal?
CNL30.
2) Kick-down- switch Defective kick-down Replace
1) Disconnet NO switch
ON: Max. 1 Ω
CNL15.
OFF: Min. 1 ΜΩ
2) Kick-down switch
ON: Max. 1 Ω
OFF: Min. 1 ΜΩ
CNL30 CNL15
17
Kick-down switch
Hold switch 18
20-514
TROUBLESHOOTING A-14
« Check that the fuses of CNFS2 (10), CNFS5 (6) are not blown.
« Before carrying out troubleshooting, check that all the related connectors are properly inserted.
« Always connect any disconnected connectors before going on the next step.
« When disconnecting connectors to connect the T-adapter (or socket adapter), always turn the starting
switch OFF.
Cause Remedy
2 YES Go to troubleshooting of
Is voltage between engine throttle controller
YES CNLGL2 (female) (2) Wiring harness between Repair wiring
and chassis normal? CNRES (female) (2) and harness or
CNLGL2 (female) (2) replace
short circuiting with
1) Disconnect CNLGL2 NO chassis ground, or
1 2) Starting switch ON: Max. 1 V disconnection, defective
3) Kick-down switch ON: 20 - 30 V contact.
Is voltage between
CNL31 (6) and
chassis normal? 3 YES
Defective controller Replace
Is voltage between
1) Insert T-adapter CNL31 (female) (6)
NO Wiring harness between Repair wiring
and chassis normal?
2) Hold switch CNL31 (female) (6) and harness or
ON: Max. 1 Ω CNFS5 (female) (6) replace
3) Kick-down 1) Disconnect CNL31 NO short circuiting with
2) 20 - 30 V chassis ground, or
switch ON: disconnection, defective
10 - 15 V contact.
+ 25 V
CNFS5
CNRES
CNL31
Kick-down signal output
CNLGL2
Switch pump cut-off
Kick-down signal
To engine throttle controller
floor wiring harness
20-515
TROUBLESHOOTING A-15
« Before carrying out troubleshooting, check that all the related connectors are properly inserted.
« Always connect any disconnected connectors before going on the next step.
« When disconnecting connectors to connect the T-adapter (or socket adapter), always turn the starting
switch OFF.
Cause Remedy
YES
Defective controller Replace
CNL30
CNL12
Transmission cut-off switch 16
Transmission
cut-off switch
Main monitor
CNL06
3
Transmission cut-off
output
20-516
20-517
TROUBLESHOOTING A-17
Cause Remedy
3 YES
Defective controller Replace
Is resistance between
YES CNL31 (female) (15)
and chassis normal ?
2 Short circuit between Repair wiring
CNL34 (female) and harness or
Is continuity between NO resistor, or replace
YES 1) Disconnect
CNL31 (female) (15) disconnection, defective
and chassis normal? CNL31 and CNL08.
contact
2) 4 - 7 ΚΩ
1 Defective contact, or Repair wiring
Is insulation CNL31 1) Disconnect disconnection in wiring harness or
(female) (15) and CNL31, CNL08 and NO harness between CNL31 replace
CNL34. (female) (15) and CNL08
chassis normal?
2) Short circuit CNL08 (female) (6)
(female) (6) - chassis
1) Disconnect 3) Max. 1 Ω
CNL31, CNL08 and
Wiring harness between Repair wiring
CNL34.
CNL31 (female) (15) - harness or
2) Min. 1 ΜΩ NO CNL08 (female) (6) - replace
CNL34 (male) (7) short
circuiting with chassis
ground
+ 24 V
Main monitor
CNL42
CNL06
Caution buzzer
Buzzer output
CNL43
CNL31 CNL08
Buzzer signal output 15 Buzzer ON input
CNL34
Resistor
20-518
TROUBLESHOOTING A-18
Cause Remedy
4 YES
Defective controller Replace
Is continuity
YES between CNL30
(female) (9), and
chassis Wiring harness between Repair wiring
3
normal ? harness or
CNL30 (female) (9) and
Is insulation 1) Disconnect replace
NO CNL08 (female) (2), (4)
YES between CNL30 CNL30 and
(female) (9) and short circuiting with
CNL08.
chassis 2) Short circuit chassis ground
2 normal ? CNL08 (female)
(2), (4) with chassis
Is continuity 1) Disconnect ground.
YES between CNL29 CNL30 and 3) Max. 1 Ω
Wiring harness between Repair wiring
(female) (1), (12) CNL08.
and chassis CNL30 (female) (9) and harness or
normal ? 2) Min. 1 ΜΩ CNL08 (female) (2), (4) replace
NO short circuiting with
1) Disconnect
chassis ground
CNL29 and
1 CNL08.
Defective contact, or Repair wiring
Is insulation 2) Short circuit harness or
between CNL29
NO disconnection in wiring
CNL08 (female) replace
(female) (1), (12) harness between CNL29
(1), (12) -
and chassis (female) (1), (12) and
chassis.
normal ? CNL08 (female) (1), (3)
3) Max. 1 Ω
1) Disconnect Wiring harness between Repair wiring
CNL29 and CNL29 (female) (1), (12) harness or
CNL08. NO and CNL08 (female) (1), replace
2) Min. 1 ΜΩ (3) short circuiting with
chassis ground
Main monitor
CNL29 CNL08
Netzwork (+) Netzwork (+)
Signal GND
20-519
TROUBLESHOOTING A-19
Cause Remedy
YES
Defective controller Replace
1
Short circuit with chassis Repair wiring
Is voltage between ground between CNL29 harness or
CNL29 (female) (8), (female) (8), (17), (18) replace
(17), 2 YES and CNFS5 (female) (6),
(18) -(9),(19) normal? or disconnection,
Is continuity between
CNL29 defective contact
1) Insert T-adapter (female) (9),(19)and
NO
2) 20 - 30 V chassis normal?
Defective contact, or Repair wiring
NO disconnection in wiring harness or
1) Disconnect
CNL29. harness between CNL29 replace
2) Max. 1 Ω (female) (9), (19) - CNCL1
(female) (9), (12) - chassis
ground
+24 V
CNFS5
CNL29
Power source 24V
GND
Solenoid power source 17
12
20-520
TROUBLESHOOTING OF HYDRAULIC AND
MECHANICAL SYSTEM (CHASSIS RELATED)
(T MODE)
POWER TRAIN
T- 1 Machine does not start ............................................................................................................... 20-552
T- 2 Travel speed is slow, thrusting power is weak, lacks power on slopes .................................... 20-554
T- 3 Excessive shock when starting machine or shifting gear .......................................................... 20-556
T- 4 Excessive time lag when starting machine or shifting gear ....................................................... 20-557
T- 5 Torque converter oil temperature is high ................................................................................... 20-558
STEERING SYSTEM
T- 6 Steering wheel does not turn ..................................................................................................... 20-559
T- 7 Steering is heavy ....................................................................................................................... 20-560
T- 8 Steering wheel shakes or there is excessive shock .................................................................. 20-561
T- 9 Machine deviates to one side when traveling ............................................................................ 20-561
T-10 Turning radius is different between left and right ...................................................................... 20-561
BRAKE SYSTEM
T-11 Brakes do not work or braking effect is poor ............................................................................ 20-562
T-12 Brakes are not released or brakes drag .................................................................................... 20-563
WORK EQUIPMENT
T-14 Boom does not rise .................................................................................................................... 20-565
T-15 Boom movement is slow or boom lacks lifting power ............................................................... 20-566
T-16 When boom is raised, it moves slowly at a certain height ........................................................ 20-567
T-17 Bucket cannot be pushed with boom cylinder (bucket floats) ................................................... 20-567
T-18 Excessive hydraulic drift of boom .............................................................................................. 20-567
T-19 Boom shakes during operation .................................................................................................. 20-568
T-20 Boom drops momentarily when control lever is operated from HOLD to RAISE ...................... 20-568
T-21 Bucket does not tilt back ............................................................................................................ 20-569
T-22 Bucket movement is slow or tilt back lacks power .................................................................... 20-570
T-23 Bucket movement becomes slow during tilt-back operation ...................................................... 20-571
T-24 Bucket cannot be pushed with bucket cylinder.......................................................................... 20-571
T-25 Excessive hydraulic drift of bucket ............................................................................................. 20-571
T-26 Bucket shakes during loading operation .................................................................................... 20-572
T-27 Bucket dumps momentarily when control lever is operated from HOLD to TILT ...................... 20-572
T-28 Boom, bucket control levers are heavy or do not move smoothl .............................................. 20-573
20-551
TROUBLESHOOTING T-1
POWER TRAIN
T-1 Machine does not start
Ask the operator the following questions.
Did the problem suddenly start?
Yes = Internal part seized or broken
.)
Was there any abnormal noise when this
etc
happened?
eal,
e
r, s
Yes = Component broken.
alv
tato
ol v
Checks before troubleshooting
tc.)
p, s
ntr
Does the machine monitor function prop-
g, e
f co
um
erly?
in
eo
e, p
uf f
valv
Is the transmission oil level correct?
bin
, sc
lv e
Is the type of oil correct?
tur
tor
ght
f va
la
,
cau
ing
Is the transmission filter or strainer clogged?
egu
es
reli
nd
O)
e
ear
alv
er
dirt
Does the electrical circuit of the transmis-
ne
s
PT
ter
Cau
sur
e
io
e(
ver
(
tive
valv
trol
sion control work properly?
uct
er
res
lv
con
con
t
fec
ps
l va
ver
e
Is the transmission oil deteriorated? Does
oid
p
alv
e
um
ue
ch
n
cin
p (d
tro
len
issio
ol v
the oil smell of burning?
t
gp
f clu
con
r
f so
que
um
f to
ntr
p
sm
rgin
Is there any damage or leakage of oil that
um
gp
no
no
no
f co
ion
tor
an
a
gp
rgin
io
can be seen externally?
ratio
io
e tr
t ch
rat
eo
ide
rat
rat
rgin
cha
id
ope
in a
rific
Is the drive shaft broken?
ins
ope
ope
ope
ins
cha
do
e fo
ked
ge
kge
tive
Is the wheel brake or parking brake locked?
tive
tive
tive
ive
aka
gge
driv
suc
aka
fec
ect
fec
fec
fec
Bre
Clo
Bre
Def
De
De
De
De
No
Air
Charging Torque
pump converter Transmision control valve
a b c d e f g h i j
Remedy C
No. Problems
1 Does not start in any transmision range
20-552
k
Exc
l
ess
iv e le
aka
De ge
fec of o
m
tive il fr
o per om
Me atio tran
cha n in sm
n
iss
Transmission
nis
che side ion
rS tra clu
Bre ch nsm tch
aka ade iss sha
ge n im ion ft s
ins c eal
o
ide Ge lutc por
t
valve
r ieb h ( tion
tran
sm e (La se ize (wo
Bre is sin g er, d,w rn,
aka ( o bro
ge b Z
TROUBLESHOOTING
p
b
valve
ula
tor s ing e ) rok
valv ) en)
De
fec e (a
20-553
T-1
TROUBLESHOOTING T-2
tc.)
when traveling on level ground and on
g, e
slopes, and check if there is actually an
arin
abnormality or whether it is just the feeling
.)
ve
etc
, be
tc.)
of the operator.
val
,
e
ing
r ol
tato
ol,
pr
ont
spo
Checks before troubleshooting
p, s
sna
of c
,
Is the transmission oil level correct?
ve
pum
hes
ng,
val
lve
Is the type of oil correct?
ratc
shi
r va
e
rol
rbin
, bu
Is the transmission filter or strainer clogged?
e, s
ont
lato
, tu
her
ring
Is there any oil leaking from the joints of the
of c
egu
g
e (w
piping or valves?
arin
eal
ve
er
end
ve
ses
val
r (s
Is there any dragging of the wheel brake or
(be
sur
val
val
tion
on
res
parking brake?
ter
Cau
trol
ert
lief
suc
lati
ver
hp
onv
n
Is the tire inflation pressure and tread pat-
r re
odu
pum
nc
con
lutc
ec
rte
tern normal?
of m
sio
of c
rqu
nve
que
ing
p
Is the method of operation correct?
mis
um
e to
arg
tion
ion
tor
c
gp
ans
t ch
sid
rat
que
ide
a
rgin
e tr
r
ope
in a
ope
e in
ins
tor
cha
sid
kag
ked
ge
tive
tive
tive
t in
tive
aka
suc
lea
fec
fec
fec
fec
fec
Bre
De
De
De
De
Oil
De
Air
Remedy
No. Problems
1 Abnormality in all transmission ranges
20-554
C
i
valve
Clo
Control
g ged
j
orif
ice
of c
Lea ont
k
kag rol
eo val
f oi ve
Lea
l
l fro
kag ms
eo eal
f oi ring
C
Bre l fro
m
aka mt of t
ge ran
Torque converter,
ins ran sm
sm
TROUBLESHOOTING
iss
transmission circuit
Clo ide i ssi ion
n
gge tran
sm o nc clu
d tr
ans issio l utc tch
Clo mis n hp pag
s isto
o
sha
gge
d to
ion
bre n sea ft
rqu a the l
Exc
ess
ec
onv r
ive erte
p
lea
valve
kag r co
eo ole
Bre f oil
r ci
rcu
aka from it
Accumulator
ge
q
ins par
ide kin
acc gb
Lea um rak
es
r
kag ula eal
eo tor
v
Others
(wo
f oi alv rn,
De l fro e (ab bro
fec m nor ken
t in sea ma )
eng l of l we
ine
rela
sha
ft in a r of
ted wo spo
par rk e ol p
t q ui orti
pm on)
ent
and
ste
erin
gc
ircu
it p
um
p
20-555
T-2
TROUBLESHOOTING T-3
ing
cessive in the following cases.
spr
When it is clear that the shock has become
urn
greater than before.
ret
ve
When the machine is compared with an-
er
ack
val
ind
other machine of the same class and the
hp
tor
cyl
shock is found to be greater.
lutc
ula
ack
reg
of c
p
ch
re
Checks before troubleshooting
age
t
ssu
l u
of c
Is the engine idling speed too high?
eak
pre
Is there play in any of the drive shafts?
nce
, br
tch
ing
lve
fere
clu
ses
r va
ettl
um
ion
to s
lato
Cau
circ
iss
mu
nsm
ue
nd
nd
ccu
rou
ra
isto
of a
of t
ton
le a
pis
of p
o
ion
on
in h
tor
rati
rat
urn
dra
ula
ope
ope
ret
um
il
do
tive
tive
tive
acc
gge
fec
fec
fec
ck
Clo
Stu
De
De
De
Accumulator
Control valve Transmission valve
a b f g h
Remedy C
No. Problems
1 Shock is excessive in every transmission range
20-556
TROUBLESHOOTING T-4
ool
ing force? Was there any lack of power
r sp
when traveling up slopes?
cto
Yes = Go to T-2 Travel speed is slow, thrust-
ele
ing power is weak, lacks power on
al s
slopes
tion
ing
ring
rec
ol)
ve
spo
al r
f di
Checks before troubleshooting
val
l
sea
t se
it o
o rn
and
Is the transmission oil level correct?
ore
aft
haf
,w
ircu
, sh
Is the type of oil correct?
rb
ing
ing
k, s
in c
l, o
s
ack
spr
Is there any oil leaking from the joints of the
hou
pac
dra
poo
hp
en
piping or valves?
ion
v
rok
e in
n, s
lutc
lutc
val
ses
iss
e (b
isto
alv
nc
nc
on
sm
valv
Cau
kv
lati
o
sio
of p
tran
i
iss
hec
odu
tor
i
sm
sm
ar
t of
ula
of c
of m
we
ran
ran
oin
um
e to
mt
mt
on
mj
ion
acc
i
l fro
l fro
l du
rat
l fro
rat
ide
e
ope
ope
f oi
f oi
f oi
rific
f oi
ins
eo
eo
eo
eo
do
tive
tive
ge
kag
kag
kag
kag
gge
aka
fec
fec
Lea
Lea
Lea
Lea
Clo
Bre
De
De
Transmission Accumulator
control valve Transmission valve
a c e f g h i j
Remedy C
No. Problems
1 Time lag is excessive in every transmission range
20-557
TROUBLESHOOTING T-5
tc.)
p
um
g, e
verter stall and go down when there is no
it p
arin
ircu
load?
it
ircu
tc.)
, be
gc
Yes = Selection of transmission range
r, e
dc
erin
ring
Does oil temperature rise only when carry-
gge
ato
ste
nap
ing out scooping work?
, st
clo
and
g, s
Yes = Improvement in method of operation
ine
or
uit
shin
urb
ler
lve
circ
coo
p, t
, bu
r va
Checks before troubleshooting
ent
um
ter
ing
lato
Are the radiator water level and fan belt
ipm
end
g, p
ver
al r
equ
tension correct?
reg
con
arin
tion
(se
Is the transmission oil level correct?
ork
ve
ure
suc
(be
ter
es
que
val
in w
s
Is the type of oil correct?
ver
res
s
nd
rter
tor
lief
Cau
con
pa
t
Is the transmission filter or strainer clogged?
hp
haf
nve
om
r re
r
n
pum
t
the
lutc
par
s
ue
sio
r fr
o
e
l of
c
rea
orq
ert
is
nc
f ai
ted
ing
ue
Checking for abnormalities
sm
sea
p
nb
t
um
sio
con
torq
o
arg
rela
e
tran
Measure the torque converter oil tempera-
id
sio
ng
from
gp
mis
t ch
ins
ue
ide
mis
edi
ine
rgin
ide
ture. Is it actually high?
s
q
in a
f oil
tran
f oil
ins
ble
eng
ans
tor
ins
cha
eo
ked
ge
d tr
tive
tive
tive
ge
t in
ive
kag
kag
aka
aka
gge
suc
fec
fec
ect
fec
fec
Lea
Lea
Bre
Bre
Def
Clo
De
De
De
De
Air
a b c d e f g h i j k
Remedy C
No. Problems
When oil temperature is low, abnormal noise comes from charging
1
pump
20-558
TROUBLESHOOTING T-6
STEERING SYSTEM
T-6 Steering wheel does not turn
Ask the operator the following questions.
Did the problem suddenly start?
Yes = Steering equipment damaged or
,
TO
broken
p, P
ve
Was there previously any symptom, such
um
al
gv
as heavy steering?
cp
erin
auli
Yes = Wear of internal parts of steer-
ste
ydr
ing equipment, defective seal
of h
ide
ns
l)
or p kage
se a
Checks before troubleshooting
ct i
ump
fe
a
ton
Is the hydraulic oil level correct?
Bre
De
pis
Is the type of oil correct?
en
es
Is there any part broken in the steering gear
rok
s
box or steering linkage?
Cau
(b
box
der
Has the safety bar been removed from the
ear
ylin
frame?
gg
p
gc
pum
Is the steering linkage properly adjusted?
erin
ve
erin
ste
val
ch
ste
swit
ide
ief
ide
ins
rel
ol
e
nd
valv
spo
s
ga
ge
t in
ng
and
aka
erin
eri
fety
fec
Dem
Ste
Bre
Ste
De
Hydraulic Sa
pump Valves Others
a b c d e f
Remedy
No. Problems
1 Steering wheel does not turn either to left or to right
There is a close connection between the steering circuit and the work equipment circuit, so if any
abnormality is felt in the steering, check the operation of the work equipment also.
20-559
TROUBLESHOOTING T-7
e
alv
Checks before troubleshooting
gv
p
um
Is the hydraulic oil level correct?
ve
erin
lic p
val
Is the type of oil correct?
ste
rau
ss
al)
Is there any abnormality in the steering gear
ide
ypa
hyd
e
ns
box mount, column, or linkage?
ins
b
tive
isto
ve
Is the stopper for the steering valve control
)
fec
nut
fec
mp
i
ect
e
lever properly adjusted?
De
orm
D
fro
f
, de
Is there any leakage of oil from the hydrau-
,w
ge
ide
ring
lic hoses, valves, or cylinders?
aka
eaa
ses
Is there any scuffing of the center hinge pin
l le
urn
i
x (b
r (o
ret
bearing or steering cylinder pin or bushing? Cau
nde
oil
r bo
Is the tire inflation pressure correct?
ulic
i
gea
cyl
p
a
pum
ring
ydr
Checking for abnormalities
ring
lve
at h
e
ch
er
tee
Measure the operating force of the steering
f va
ste
swit
ool
es
lter
wheel and the time taken to turn the steer-
elie
ide
il c
ol
e
nd
sid
d fi
alv
spo
do
gr
t in
t in
ty v
gge
erin
gge
and
erin
fec
fe
Dem
Clo
Ste
Clo
Ste
De
De
Sa
mality.
Tank -
pump Valves Others
a b c d e f g i
Remedy A C C
No. Problems
1 Steering is heavy when turned in both direction (left and right)
20-560
TROUBLESHOOTING T-8, T-9, T-10
olt)
Is the type of oil correct?
t, b
Is there any abnormality in the steering gear
, nu
box mount, column, or linkage?
l
sea
Is there any play in the center hinge pin
n
al v
isto
bearing or steering cylinder pin or bushing?
gv
r, p
Is there any variation in the tire inflation
erin
nde
ste
pressure?
cyli
tive
Is the steering wheel play correct?
of
fec
ce
De
l
poo
Checking for abnormalities
fa
sur
or s
Operate at a safe place and check how the
ide
ect
ses
steering wheel shakes and under what con-
(ins
sel
ditions.
Cau
ve
er
In cases where the steering wheel is
val
nd
cyli
heavy but does not shake, go to
ing
eer
g
T-7 Steering is heavy.
erin
f st
ste
no
itio
e
sid
e
pos
valv
t in
ong
fec
ftey
De
Wr
Sa
Valves Cylinder
a b d
Remedy A
No. Problems
1 Chassis shakes when traveling on rough road surface
20-561
TROUBLESHOOTING T-11
BRAKE SYSTEM
T-11 Brakes do not work or braking effect is poor
Ask the operator the following questions.
Did the problem suddenly start?
Yes = Brake equipment broken
xle
Did the problem gradually appear?
ea
sid
Yes = Deterioration of seal, wear of lin-
g in
ing, disc
nin
re
e li
ssu
Checks before troubleshooting
rak
pre
of b
e
Is the hydraulic oil level correct?
axl
gas
Is the brake pedal play correct?
ear
xle
ide
ent
ea
te w
ins
Is there any leakage of oil from the brake
fing
fici
sid
ng
ple
tube or connector?
suf
cuf
n in
lini
om
ses
, in
Is there any deformation of the tube?
), s
ke
e
isto
to c
e
eal
axl
alv
Cau
a
Is the tire inflation pressure and tread pat-
rge
e
f br
ep
axl
ns
ev
due
ide
cha
tern normal?
o
rak
sto
arg
ide
ins
ity
tion
lve
(for
of b
r pi
s
f ch
l
tion
rma
l in
por
a
lato
ev
Checks before abnormalities
no
mp
sea
ion
it
por
bno
ircu
tal
rak
mu
ratio
t pu
rat
Measure the braking force and compare with
me
ton
ke
er a
eb
ccu
ec
ope
pilo
ope
bra
the Standard Value Table to check if the
pis
ith
h
sid
rak
a
r ot
ct w
tive
tive
tive
tive
tive
tive
brakking effect is poor.
t in
in b
ar o
fec
nta
fec
fec
fec
fec
fec
fec
We
Air
De
De
De
De
De
Co
De
De
a b c d e f g h i j
Remedy
No. Problems
1 Resistance is low when brake pedal is depressed
2 Break pedal is heavy when it is depressed
3 Abnormal operating force is needed to obtain specified braking force
4 Abnormal noise is heard from axle brake when brake is applied
5 Machine cannot travel (lacks rimpull)
Jack up 4 wheels and set axles on stand. In F1, when brakes are
6
applied, only certain wheels rotate quickly
Air can be seen flowing out when air is bled from brake circuit.
7
Returns after air is bled.
8 Abnormal oil leakage is found when checking leakage of oil inside axle.
9 Many metal particles are found in axle oil
20-562
TROUBLESHOOTING T-12
e
axl
e
sid
ck)
xle
es
n in
stu
ea
s
isto
Cau
ton
sid
ep
(pis
g in
rak
ve
n
lini
of b
val
ke
ke
ion
ra
bra
rat
in b
ope
ide
lity
s
tive
ma
t in
nor
fec
fec
De
De
Ab
a b c
Remedy
No. Problems
1 Brake remains applied even when brake pedal is released
When brake pedal is released and oil is bled from air bleeder ,
2
circuit pressure goes down and brake is released
20-563
20-564
TROUBLESHOOTING T-14
WORK EQUIPMENT
T-14 Boom does not rise
Ask the operator the following questions.
Did the problem suddenly start?
Yes = Equipment seized, damaged Was
there any abnormal noise when
this happened? (from where?)
Was there previously any symptom, such
as the speed becoming slow?
Yes = Wear of internal parts, deterio-
ration in spring
il
in o
Checks before troubleshooting
air
ve
Is the hydraulic oil level correct?
ssi
e
p
alv
Is the travel of the boom control lever and
ol)
um
xce
es
spo
ef v
p
spool properly adjusted?
ol
re
ch
s
lve
spo
l
om
reli
sea
Cau
po
swit
f va
(bo
nd
any
pum
ton
ool
and
e
ma
ody
r pis
reli
f sp
of m
f de
t of
eb
um
nde
f
n o
o
mp
por
no
ion
valv
lic p
ion
cyli
r pu
atio
p
ratio
rat
pum
ion
rat
rau
ide
oom
e fo
per
ope
uct
ope
ope
hyd
ins
PC
driv
db
ds
eP
tive
tive
ge
tive
ive
tiv
age
PTO
gge
ectiv
aka
fec
ect
fec
fec
fec
Dam
Clo
Bre
Def
De
Def
De
De
De
No
a b c d e f g h i j
Remedy C
No. Problems
1 Bucket cannot be operated and boom cannot be raised
Chassis can be raised with boom but boom cannot be raised, or
2
bucket can be operated but boom cannot be raised
20-565
TROUBLESHOOTING T-15
ent
Is there any seizure of the work equipment
stm
linkage? (Is there any abnormal noise?)
nt
me
dju
ust
ea
Checking for abnormalities
il
adj
ctiv
in o
There is a strong connection between lifting
ive
efe
ol)
air
power and speed, so this problem first ap-
ect
s po
rd
ve
eo
def
pears as a lack of lifting speed. Measure
ssi
om
p
alv
xce
pum
or
the boom lifting speed when the bucket is
(bo
es
ef v
ve
re
ve
ody
loaded and use the Stand-
ch
val
Cau
ol
reli
po
val
swit
eal
eb
spo
ard Value Table to judge if there is any
off
pum
ns
lief
ain
l
valv
poo
nd
ut-
and
abnormality.
isto
f re
fm
pa
of c
of s
t of
ide
dem
p
um
no
der
por
ins
ion
on
on
lic p
o
n
ylin
i
i
ratio
rat
rat
ear
rati
rat
ion
rau
mc
ope
ope
ope
or w
ope
uct
ope
hyd
boo
ds
tive
tive
tive
tive
ge
tive
ive
age
gge
aka
fec
fec
fec
ect
fec
fec
Dam
Clo
Bre
Def
De
De
De
De
De
a b c d e f g h i
Remedy C A
No. Problems
Bucket tilting power and speed are abnormal and boom lifting
1
speed is slow
Bucket tilting power and speed are normal but boom lifting speed
2
is slow
20-566
TROUBLESHOOTING T-16, T-17, T-18, T-19
« However, if this problem appears frequently, the suction valve at the boom cylinder rod end is
defective.
20-567
TROUBLESHOOTING T-20
20-568
TROUBLESHOOTING T-21
il
in o
Checks before troubleshooting
air
Is the travel of the bucket control lever and
ve
ssi
spool properly adjusted?
e
p
ool)
alv
pum
xce
ses
ef v
t sp
ol
re
ch
spo
Cau
reli
po
cke
swit
l
sea
nd
pum
(bu
ain
and
ton
ma
of m
ody
r pis
f de
t of
p
um
eb
mp
alv
por
nde
no
ion
lic p
alv
r pu
ef v
ratio
cyli
rat
pum
ion
ev
rau
l
poo
e fo
ope
reli
uct
ket
ope
sid
hyd
PC
driv
buc
ds
e in
tive
eP
tive
tive
tive
ive
PTO
gge
ectiv
akg
ge
fec
ect
fec
fec
fec
Dam
Clo
Bre
Def
De
Def
De
De
De
No
a b c d e f g h i j
Remedy C
No. Problems
1 Boom cannot be operated and bucket cannot be tilted back
Chassis can be raised with bucket but bucket cannot be tilted
2
back, or boom can be operated but bucket cannot be tilted back
20-569
TROUBLESHOOTING T-22
nd
Is there any seizure of the work equipment
me
linkage? (Is there any abnormal noise?)
otto
er b
Checking for abnormalities
lind
ent
t cy
Check if there is lack of tilt-back power dur-
stm
cke
nt
ing actual operations.
me
dju
t bu
Measure the operating speed of the bucket
ust
ea
e) a
adj
and use the Standard Value Table to check
il
ctiv
in o
valv
ive
if there is any abnormality
efe
air
ect
tion
rd
ve
def
suc
eo
ssi
ol)
p
alv
or
spo
xce
um
h
es
(wit
ve
ef v
ve
ool
hp
re
l
cke
sea
s
val
lve
val
p
c
Cau
reli
po
swit
ds
(bu
a
off
ton
lief
ty v
pum
ain
l
poo
nd
ma
ut-
r pis
ody
f re
afe
of m
pa
of c
f de
of s
t of
eb
of s
no
nde
um
no
por
valv
ion
ion
on
atio
lic p
cyli
n
ratio
ratio
rat
rati
rat
tion
ide
rau
per
ket
ope
ope
ope
ope
ope
uc
ins
hyd
buc
o
ds
tive
tive
tive
tive
ge
tive
tive
ive
ge
gge
aka
fec
fec
fec
ect
fec
ma
fec
fec
Clo
Bre
Def
De
De
De
De
De
De
Da
Tank - Steering Main control Cut-off
PPC valve Cylinder
pump valve valve valve
a b c d e f g h i j
Remedy C A
No. Problems
Boom lifting power and speed are abnormal and bucket tilt-back
1
power or speed are abnormal
Boom lifting power and speed are abnormal but bucket tilt-back
2
power or speed are abnormal
rises
4 Abnormal noise comes from hydraulic pump
20-570
TROUBLESHOOTING T-23, T-24, T-25
Cause
Swelling or internal damage to bucket cylinder tube
For other abnormalities when the bucket is operated, go to "T- 22 Bucket movement is slow or tilt back
lacks power."
Cause
Defective seating of safety valve (with suction valve) at bucket cylinder rod end of main control valve
Oil leakage from bucket cylinder piston seal
Cause
Oil leakage inside bucket cylinder
Defective seating of safety valve (with suction valve) at bottom end
Defective oil tightness of bucket spool
20-571
TROUBLESHOOTING T-26, T-27
Cause
Defective bucket cylinder piston seal
Defective operation of safety valve (with suction valve) at bucket cylinder rod end. If any other
problem occurs at the same time, carry out troubleshooting according to the nature of the problem.
Cause
Defective seating of check valve for bucket spool in main control valve
20-572
TROUBLESHOOTING T-28
s
bolt
ing
Checking for abnormalities
ol
unt
spo
Check the values in the Standard Value Table
mo
, lin
to check if the operating force of the lever is
and
lve
ver
ol
actually excessive.
f va
ody
s po
ol
l le
l
poo
spo
go
eb
tro
nd
s
lve
in
alv
ya
nd
con
ol
ten
a
a
spo
ol v
bod
ol v
dy
tigh
of
r
o
and
ol
ont
r
lve
eb
ion
ont
ven
spo
ses
in c
valv
c
or t
ody
v
une
ain
C
ve
a
gp
Cau
PP
eb
fm
PC
fm
val
ol
e
atin
l
P
spo
valv
o
f
poo
o
so
yd
rol
en
ss
ess
rot
es
ont
bod
e
dne
lve
trol
dne
etw
ndn
alv
of
in c
con
n
l
Cv
lve
oun
b
poo
rou
rou
v
ss
ce
ma
f va
trol
PP
ain
r
es
fne
-of-
ran
-of-
-of-
con
no
t in
of m
alv
t in
clea
stif
cut
cut
cut
Cv
atio
ugh
ugh
ain
tive
tive
re,
tive
ing
ive
t PP
form
nt m
t ca
t ca
izu
ect
fec
tch
fec
fec
Ben
Def
Se
Dir
Dir
Ca
De
De
De
De
Be
Lever PPC valve Main control valve
a b c d e f g h i j k
Remedy C
No. Problems
1 Lever are heavy when there is a load and oil pressure is high
2 Levers become heavy as oil temperature changes
20-573
20-574
TROUBLESHOOTING OF ECSS (ELECTRONICALLY
CONTROLLED SUSPENSION SYSTEM)
(D MODE)
20-601
TROUBLESHOOTING JUDGEMENT TABLE FOR CONTROLLER ELECTRICAL SYSTEM
Failure mode d0 d1 d2 d3 d4
ECSS does not
work or does not D-1 (a) D-1 (b) D-1 (c) D-1 (d) D-1 (e) D-1 (f)
work properly
ECSS cannot be
canceled D-2
Output is turned
ON but travel
speed does not D-3
become 5 km/h
(deviates)
Output is turned
ON when
transmission is in D-4
1st
Output is turned
ON when
transmission is in D-5
4th
LED code display
is not given D-6
ECSS is abnromal
but main monitor
does not give D-7
abnormality
display
20-602
TROUBLESHOOTING D-1
Cause Remedy
2 5
1
Displaying [d3]. Go to Item (d) -
Is there an
abnormality
display
7
Go to Item (f) -
NO
20-603
TROUBLESHOOTING D-1
YES Replace
Defective controller
1
Is resistance between
CNAL1 (female) (21) YES
and chassis ground Defective solenoid Replace
normal? 2
Is there continuity
1) Disconnect Disconnection in wiring
between CNAL1
CNAL 1. YES harness between CNAL1 After inspection,
NO (female) (21) and 3
chassis ground? (female) (21) - CNSAS (4) repair or replace
2) DC resistance: Is there continuity - CNAF4 (female) (1)
20 - 40 Ω 1) Disconnect between CNAF4
CNAL1. NO (female (2) and
chassis ground Disconnection is wiring
2) Disconnect harness between CNAF4 After inspection,
CNAF4. 1) Disconnect NO (female) (2) - CNTL1 (8) - repair or replace
CNAF4. CNCL1 (12) - chassis
3) Connect short ground
connector to
CNAF4 (female).
(b) Error code [d1] is displayed
YES
Defective speed sensor Replace
1
Is resistance between
CNAL1 (female) (20) YES
and chassis ground Defective controller Replace
normal? 2
Is there continuity
1) Disconnect between CNAL1
CNAL 1. (female) (20) and Disconnection in wiring
NO YES harness between CNAL1 After inspection,
chassis ground? 3
2) DC resistance: Is there continuity (female (20) - CNSAS (5) repair or replace
20 - 40 Ω 1) Disconnect between CNAF4 - CNAF5 (female) (1)
CNAL1. NO (female (2) and
chassis ground Disconnection is wiring
2) Disconnect harness between CNAF5 After inspection,
CNAF5. 1) Disconnect NO (female) (2) - CNTL1 (8) - repair or replace
CNAF5. CNCL1 (12) - chassis
3) Connect short ground
connector to
CNAF5 (female).
20-604
TROUBLESHOOTING D-1
YES Replace
Defective controller
1
Is resistance between
CNAL1 (female) (11) YES
and chassis ground Defective solenoid Replace
normal? 2
Is there continuity
1) Disconnect Disconnection in wiring
between CNAL1
CNAL 1. YES harness between CNAL1 After inspection,
NO (female) (11) and 3
chassis ground? (female) (11) - CNSAS (6) repair or replace
2) DC resistance: Is there continuity - CNAF6 (female) (1)
20 - 40 Ω 1) Disconnect between CNAF6
CNAL1. NO (female (2) and
chassis ground Disconnection is wiring
2) Disconnect harness between CNAF6 After inspection,
CNAF6. 1) Disconnect NO (female) (2) - CNTL1 (8) - repair or replace
CNAF6. CNCL1 (12) - chassis
3) Connect short ground
connector to
CNAF6 (female).
Does error
display go off?
YES
Defective controller Replace
2
Is there continuity
1) Connect short between CNAL3
connector to NO (female) (4) and
CNT06 (female). (12)?
Disconnection in wiring After inspection,
2) Turn starting 1) Disconnect harness between CNAL3 repair or replace
switch OFF CNAL3. NO (4) - CNSAS (9) or CNAL3 (if any other
ON. (12) - CNSAS (10) controller is
3) Connect short abnormal, check
connector to all wiring
CNT06 (female). harness for the
speed sensor
system)
20-605
TROUBLESHOOTING D-1
2 YES
Defective controller Replace
Is continuity of
YES wiring harness
Disconnection in wiring
normal? harness between CNAL2
1 After inspection,
(female) and CNAL4
NO repair or replace
1) Disconnect (male), or contact with
Is connection of
CNAL2. chassis ground
wiring harness
normal ? 2) Is continuity between CNAL2
(female) (1) - (4) and chassis Defective contact, or
1) Disconnect ground as shown in the table? disconnection in wiring
CNAL4. harness between CNAL4 After inspection,
2) Is continuity NO (female) and chassis repair or replace
between CNAL4 (female) ground, or contact with
(1), (2), (3), (5) - chassis ground as chassis ground
shown in the table?
Table
Connector CNAL4(female) CNAL2(female)
20-606
TROUBLESHOOTING D-1
1
3 YES Defective controller Replace
Does controller Is voltage
LED display 55? YES between CNAL 2 Defective contact, or
(8) and chassis disconnection in wiring
ground normal? harness between CNAL2
2 After inspection,
1) Turn starting (female) (8) - CNSAS (7) -
switch ON. Is there continuity 1) 0 - 3 V NO CNAF 7 (female) (1), or repair or replace
2) Load bucket. between CNAF7 2) Turn starting between CNAF7 (female)
NO (male) (1) and switch ON. (2) - CNSAS (8) - CNAL4
(2)? 3) Load bucket. (4) - chassis ground
20-607
TROUBLESHOOTING D-1
CNAL1 CNSAS
11 5 1
20 6 1 2
21 4 1 2
CNAF6
2
CNAF5
CNAF4
8 12
CNTL1 CNCL1
12 10 2 2
Speed (-)
b b b b b
2 2
c c c c c
3 3
d d d d d
4 1
20-608
TROUBLESHOOTING D-1
12 3
3 2
CNAL2 4
Netzwork (-)
9 1
CNL06
15
ECSS operation switch 7
8 7 1
8 2
CNAL4
20-609
TROUBLESHOOTING D-2
Cause Remedy
YES
Defective controller Replace
1
Is voltage
between CNAL2 Contact chassis ground
(15) and chassis with wiring harness
2 YES After inspection,
ground normal? between CNAL2 (female)
Is there continuity (15) - CNDP2 (1) - CNL06 repair or replace
1) 20 - 30 V between CNAL2 (female) (7)
2) Turn starting NO (female) (15) and
switch ON. chassis ground?
Defective main monitor Go to
3) Turn main NO troubleshooting
1) Diconnect
monitor ECSS of main monitor
CNAL2.
switch OFF.
2) Disconnect
CNL06.
12 3
3 2
CNAL2 4
Network (-)
9 1
CNL06
15
ECSS operation switch 7
20-610
TROUBLESHOOTING D-3, D-4
Cause Remedy
Go to Troubleshooting –
1) Check LED NO D-1 (e)
display code.
2) See
STRUCTURE
AND FUNCTION
for details of the
codes.
1 YES
Defective controller Replace
Is resistance between
CNAL2 (female) (14)
and chassis ground Defective contact, or
normal? disconnection in wiring After inspection,
harness between CNAL2 repair or replace
1) Disconnect NO
(female) (14) - CNSAS (3)
CNAL2. - speed solenoid
2) 50 - 70 Ω
To solenoid
WA-3H automatic transmission
CNAL2 CNSAS CNTL1 CNL29
Hi/Lo
HYPER 13 2 5 10
specification Transmission
machine controller
14 3 6 11
Speed
To solenoid
20-611
TROUBLESHOOTING D-5
Cause Remedy
1 YES
Defective controller Replace
Is resistance between
CNAL2 (female) (13)
and chassis ground Defective contact, or
normal? disconnection in wiring After inspection,
harness between CNAL2 repair or replace
1) Disconnect NO
(female) (13) - CNSAS (3)
CNAL2. - Hi/Lo solenoid
2) 50 - 70 Ω
14 3 6 5
14 3 6 11
20-612
TROUBLESHOOTING D-6, D-7
YES
Defective controller Replace
1 Defective contact, or
disconnection in wiring
3 YES After inspection,
Ist die Spannungs- harness between CNAL1
Is voltage between repair or replace
versorgung normal ? (female) (8), (18) - CNDP1
YES CNDP1 (male) (1)
(female) (1)
2 and chassis
1) 20 - 30 V ground normal?
Is there coninuity Anormality in fuse box Repair
2) Measure voltage between CNAL1 NO
1) 20 - 30 V
between CNAL1
NO (female) (9), (19) - 1) Disconnect Defective contact, or
(8), (18) - (9), (19). chassis ground? disconnection in wiring
CNDP1.
harness between CNAL1 After inspection,
1) Disconnect (female) (9), (19) - CNSAS repair or replace
CNAL1.
NO
(1) - CNTL1 (8) - CNCL1
(12) - chassis ground
CNAL1 CNDP1
+ 24V
8 1 Fuse box
17
18
D-7 ECSS is abnormal but main monitor does not give abnormality
display
Cause Remedy
Check that the ECSS controller is displaying an error code.
Go to troubleshooting of –
main monitor
20-613
20-614
30 DISASSEMBLY AND ASSEMBLY
30-1
Installation ............................................. 30-193 Removal ................................................. 30-247
RIGHT BRAKE VALVE (TANDEM) Installation ............................................. 30-248
Disassembly .......................................... 30-194 MAINTENANCE MONITOR
Assembly ............................................... 30-195 Removal and Installation ........................ 30-249
LEFT BRAKE VALVE (SINGLE) AIR CONDITIONER UNIT
Disassembly .......................................... 30-196 Removal ................................................. 30-250
Assembly ............................................... 30-197 Installation ............................................. 30-255
PARKING BRAKE DISC AIR CONDITIONER CONDENSER
Removal ................................................. 30-198 Removal ................................................. 30-256
Installation ............................................. 30-200 Installation ............................................. 30-257
HYDRAULIC TANK DRY RECEIVER
Removal ................................................. 30-201 Removal and Installation ........................ 30-258
Installation ............................................. 30-203 AIR CONDITIONER CONDENSER
HYDRAULIC FILTER COMPRESSOR
Removal and Installation ........................ 30-204 Removal and Installation ........................ 30-259
HYDRAULIC, STEERING, SWITCH,
PPC PUMP
Removal ................................................. 30-205
Installation ............................................. 30-208
MAIN CONTROL VALVE
Removal ................................................. 30-209
Installation ............................................. 30-211
Disassembly .......................................... 30-212
Assembly ............................................... 30-214
PPC VALVE
Removal ................................................. 30-217
Installation ............................................. 30-219
Disassembly .......................................... 30-220
Assembly ............................................... 30-221
BUCKET CYLINDER
Removal ................................................. 30-222
Installation ............................................. 30-224
BOOM CYLINDER
Removal ................................................. 30-225
Installation ............................................. 30-226
HYDRAULIC CYLINDER
Disassembly .......................................... 30-227
Assembly ............................................... 30-230
WORK EQUIPMENT
Removal ................................................. 30-233
Installation ............................................. 30-236
COUNTERWEIGHT
Removal and Installation ........................ 30-238
FUEL TANK
Removal ................................................. 30-239
Installation ............................................. 30-241
CAB, FLOOR FRAME
Removal ................................................. 30-242
Installation ............................................. 30-244
CAB
Removal ................................................. 30-245
Installation ............................................. 30-246
MAIN MONITOR
30-2
DISASSEMBLY AND ASSEMBLY METHOD OF USING MANUAL
(1) When removing or installing a unit assembly, the order of work and techniques used are given for the
removal operation; the order of work for the installation operation is not given.
(2) Any special techniques applying only to the installation procedure are marked ❈ 1 , and the same
mark is placed after the relevant step in the removal procedure to indicate which step in the installation
procedure it applies to.
(Example)
REMOVAL OF O O O ASSEMBLY ................ Title of operation
................................................................. Precautions related to safety when carrying out the
operation
1. XXXX (1) ............................................ Step in operation
« .......................................................... Technique or important point to remember when re-
moving XXXX (1).
2. ∆ ∆ ∆ (2): ............................................ ❈ 1 Indicates that a technique is listed for use
during installation
3. oooo assembly (3)
.................................................... See Lubricant and Coolant Table
INSTALLATION OF O O O ASSEMBLY ........ Title of operation
• Carry out installation in the reverse
order to removal.
❈ 1 ................................................ Technique used during installation
« ................................................ Technique or important point to remember when install-
ing ∆ ∆ ∆ (2).
• Adding water, oil ................................ Step in operation
« ................................................ Point to remember when adding water or oil
................................................ Quantity of filling oil and water
2. General precautions when carrying out installation or removal (disassembly or assembly) of units are given
together as PRECAUTION WHEN CARRYING OUT OPERATION, so be sure to follow these precautions
when carrying out the operation.
(1) For details of the description, part number, and quantity of any tools (A1, etc.) that appear in the
operation procedure, see the SPECIAL TOOLS LIST given in this manual.
30-3
DISASSEMBLY AND ASSEMBLY PRECAUTIONS WHEN CARRYING OUT OPERATION
3) If the part is not under hydraulic pressure, the following corks can be used.
Nominal Dimensions
Part number
number D d L
06 07049-00608 6 5 8
08 07049-00811 8 6.5 11
10 07049-01012 10 8.5 12 Taper 1/8
øD
ød
12 07049-01215 12 10 15
14 07049-01418 14 11.5 18
16 07049-01620 16 13.5 20
18 07049-01822 18 15 22
20 07049-02025 20 17 25 L
22 07049-02228 22 18.5 28
24 07049-02430 24 20 30 DEW00401
27 07049-02734 27 22.5 34
30-4
DISASSEMBLY AND ASSEMBLY PRECAUTIONS WHEN CARRYING OUT OPERATION
• Tighten all bolts and nuts (sleeve nuts) to the specified (KES) torque.
• Install the hoses without twisting or interference.
• Replace all gaskets, O-rings, cotter pins, and lock plates with new parts.
• Bend the cotter pin or lock plate securely.
• When coating with adhesive, clean the part and remove all oil and grease, then coat the threaded portion
with 2 – 3 drops of adhesive.
• When coating with gasket sealant, clean the surface and remove all oil and grease, check that there is no
dirt or damage, then coat uniformly with gasket sealant.
• Clean all parts, and correct any damage, dents, burrs, or rust.
• Coat rotating parts and sliding parts with engine oil.
• When press fitting parts, coat the surface with antifriction compound (LM-P).
• After fitting snap rings, check that the snap ring is fitted securely in the ring groove.
• When connecting wiring connectors, clean the connector to remove all oil, dirt, or water, then connect
securely.
• When using eyebolts, check that there is no deformation or deterioration, screw them fully, and align the
direction of the hook.
• When tightening split flanges, tighten uniformly in turn to prevent excessive tightening on one side.
« When operating the hydraulic cylinders for the first time after reassembling cylinders, pumps and other
hydraulic equipment removed for repair, 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.
3) Next, operate the steering, bucket, and boom cylinders 3 - 4 times to the end of their strokes, then stop
the engine and loosen air bleed plug (1) to bleed the air from the hydraulic tank. After bleeding the air,
tighten plug (1).
4 Following this, raise the engine speed, repeat the procedure in Step 3)
to bleed the air. Repeat this operation until no more air comes out from
the plug hole.
Plug : 11.3 ± 1.5 Nm (1.15 ± 0.15 kgm) 1
5) After doing this, run the engine at normal speed.
« When using the machine for the first time after repair or
long storage, follow the same procedure.
• If the coolant has been drained, tighten the drain valve, and add water to the specified level. Run the engine
to circulate the water through the system. Then check the water level again.
• If the hydraulic equipment has been removed and installed again, add engine oil to the specified level.
Run the engine to circulate the oil through the system. Then check the oil level again.
• If the piping or hydraulic equipment, such as hydraulic cylinders, pumps, or motors, have been removed
for repair, always bleed the air from the system after reassembling the parts.
« For details, see TESTING AND ADJUSTING, Bleeding air.
• Add the specified amount of grease (molybdenum disulphide grease) to the work equipment related parts.
30-5
DISASSEMBLY AND ASSEMBLY SPECIAL TOOL LIST
Disassembly, assembly of 3 793-415-1220 Lifting tool 1 For 1st, 2nd, 3rd 4th clutch
A
transmission assembly 793-415-1150 Plate 1
Removal, installation of
4 01010-51075 Bolt 4
parking brake disc
01580-11008 Nut 4
1 793-310-1300 Stand 1
5 790-301-1720 • Joint 1
Bolt 2 790-101-2900
2 790-101-2920
Removal of axle shaft
Disassembly, assembly of
D 3 790-101-2930 Nut 2 bearing
axle housing assembly
4 793-422-1140 Seal support 2 Holder for oil seal when
press fitting oil seal
4-1 01016-30840 • Adjustment bolt 6
30-6
DISASSEMBLY AND ASSEMBLY SPECIAL TOOL LIST
2 792-103-0400 Grip 1
3 790-101-1002 Pump 1
4 790-101-2102 Puller 1
Installation of center 5 790-101-2300 Push-puller 1 Press fitting of bearing
E
hinge pin
6 793-520-2370 Push tool 1
8 793-520-2540 Guide 1
9 793-520-2360 Bar 2
790-502-1003
or Cylinder repair stand 1
F 790-502-2000
790-101-1102 Pump 1
G Steering Removal, installation
790-330-1100 Wrench ass'y 1 Cylinder of round head
H Commercially Socket Steering Removal, installation
available (width across flats: 46) 1 Cylinder of nylon nut
790-101-5021 Grip 1 Press fitting of coil bushing
01010-50816 Bolt 1 Kit Part No.: 790-201-1702
I Bucket
790-201-1841 Push tool 1 cylinder
Steering
790-201-1751 Push tool 1 Cylinder
1 790-720-1000 Expander 1 Installation of piston ring
Disassembly, assembly of
hydraulic cylinder 796-720-1680 Ring 1 Boom
07281-01589 Clamp 1 cylinder
30-7
30-8
DISASSEMBLY AND ASSEMBLY STARTING MOTOR
REMOVAL OF STARTING
MOTOR ASSEMBLY
2
Disconnect the cable from the negative (–) terminal
of the battery.
INSTALLATION OF STARTING
MOTOR ASSEMBLY
❈1
« When installing the starting motor assembly,
install ground connection (5) securely.
30-9
DISASSEMBLY AND ASSEMBLY ALTERNATOR
REMOVAL OF ALTERNATOR
ASSEMBLY
3
Disconnect the cable from the negative (–) terminal 4
of the battery. 1
INSTALLATION OF
ALTERNATOR ASSEMBLY
❈1 Mounting bolt
Adjust the belt tension. For details, see TESTING and nut
AND ADJUSTING, Testing and adjusting fan belt
tension.
❈2 DEW01349
30-10
DISASSEMBLY AND ASSEMBLY ENGINE OIL COOLER
DBW00010
30-11
DISASSEMBLY AND ASSEMBLY FUEL INJECTION PUMP
DBW00006
14
DBW00008
30-12
DISASSEMBLY AND ASSEMBLY FUEL INJECTION PUMP
INSTALLATION OF FUEL
INJECTION PUMP ASSEMBLY
❈1
Joint bolt : 29.4 ± 4.9 Nm (3.0 ± 0.5 kgm)
❈2
Joint bolt : 29.4 ± 4.9 Nm (3.0 ± 0.5 kgm)
❈3
Fuel injection pipe sleeve nut :
22.6 ± 2.9 Nm (2.3 ± 0.3 kgm)
❈4
Mounting bolt of fuel injection pump as-
sembly : 66.7 ± 7.8 Nm (6.8 ± 0.8 kgm)
30-13
DISASSEMBLY AND ASSEMBLY WATER PUMP
DBW00011
5
4 DBW00012
6
DBW00013
INSTALLATION OF WATER
PUMP ASSEMBLY
13
• Carry out installation in the reverse order to re- 12
moval.
❈1
Adjust the belt tension. For details, see TESTING
AND ADJUSTING, Testing and adjusting fan belt
tension.
• Refilling with water
Add water through the water filler to the specified
level. Run the engine to circulate the water through
the system. Then check the water level again.
DBW00014
30-16
DISASSEMBLY AND ASSEMBLY TURBOCHARGER
REMOVAL OF
TURBOCHARGER ASSEMBLY
1
1. Lift off engine hood assembly.
DBW00015
2 3
3. Remove muffler assembly (2), then remove lubrica-
tion inlet tube (3).
DBW00016
4
DBW00017
INSTALLATION OF
TURBOCHARGER ASSEMBLY
30-17
DISASSEMBLY AND ASSEMBLY NOZZLE HOLDER
REMOVAL OF NOZZLE
HOLDER ASSEMBLY
1 2
1. Lift off engine hood assembly.
DEW01373
DEW01374
INSTALLATION OF NOZZLE
HOLDER ASSEMBLY
❈1
Fuel injection pipe sleeve nut :
22.6 ± 2.9 Nm (2.3 ± 0.3 kgm)
Lead mounting nut :
1.5 ± 0.5 Nm (0.15 ± 0.05 kgm)
❈2
Holder mounting bolt :
44.1 ± 4.9 Nm (4.5 ± 0.5 kgm)
30-18
DISASSEMBLY AND ASSEMBLY THERMOSTAT
REMOVAL OF THERMOSTAT
ASSEMBLY
1
1. Open engine hood side cover.
2
2. Drain engine coolant.
INSTALLATION OF
THERMOSTAT ASSEMBLY
30-19
DISASSEMBLY AND ASSEMBLY CYLINDER HEAD
REMOVAL OF CYLINDER
HEAD ASSEMBLY
9
10 11 8
30-20
DISASSEMBLY AND ASSEMBLY CYLINDER HEAD
DBW00024
q
w DBW00025
19 18
17
DBW00027
30-21
DISASSEMBLY AND ASSEMBLY CYLINDER HEAD
21
DBW00028
23
DBW00029
25 DBW00030
27 28 29 27
DBW00031
30-22
DISASSEMBLY AND ASSEMBLY CYLINDER HEAD
DBW00032
DBW00033
❈6 29 28
24. Remove holder (29).
25. Remove spill hoses (30) and nozzles (31).
« Spill hoses: 25; nozzles: 6
DBW00034
29
30 31
DBW00036 DBW00035
30-23
DISASSEMBLY AND ASSEMBLY CYLINDER HEAD
DBW00037
DBW00038
34
DBW00039
35
DBW00040
30-24
DISASSEMBLY AND ASSEMBLY CYLINDER HEAD
INSTALLATION OF CYLINDER
HEAD ASSEMBLY
• Carry out installation in the reverse order to re-
moval.
❈1
Hose clamp : 8.8 ± 0.5 Nm (0.9 ± 0.05
kgm)
« Insert the hose until it contacts the turbocharger
flange.
❈2
« Tighten the bolts in the order – shown in
the diagram on the right.
The length of the bolts marked ✰ is 60 mm; the DEW01398
❈3
Mounting bolt of after-cooler assembly:
24.5 ± 9.8 Nm (2.5 ± 1.0 kgm)
(Only the bolts marked ✰ in the diagram DEW01399
on the right.)
❈4 Fuel injection pipe
Sleeve nut : 22.6 ± 2.9 Nm (2.3 ± 0.3 kgm)
❈5
Lead mounting nut :
1.5 ± 0.5 Nm (0.15 ± 0.05 kgm)
❈6
Mounting bolt of nozzle holder :
44.1 ± 4.9 Nm (4.5 ± 0.5 kgm)
❈7
Mounting bolt of cylinder head cover :
8.8 ± 1.0 Nm (0.9 ± 0.1 kgm)
30-25
DISASSEMBLY AND ASSEMBLY CYLINDER HEAD
❈8
« Tighten the mounting bolts and nuts in turn,
starting from the center and working to the out-
side.
« Check that the ball of the adjustment screw is
fitted securely in the socket of the push rod.
« Adjust the valve clearance. For details, see TEST-
ING AND ADJUSTING, Adjusting valve clear-
ance.
Rocker arm mounting bolt, nut :
24.5 ± 4.9 Nm (2.5 ± 0.5 kgm)
Locknut : 44.1 ± 4.9 Nm (4.5 ± 0.5 kgm)
❈9
« If any rust of more than 5 mm square is found
on the shaft or the thread of the bolt, replace the
Order tightening head bolts
head bolt with a new bolt.
« Be careful to check that there is no dirt or dust
on the mounting surface of the cylinder head or Intake side
inside the cylinder. 22 14 3 5 11 19
Torque
Step Tightening torque (Nm (kgm))
1st step 98 ± 9.8 (10 ± 1.0)
DEW01401
30-26
DISASSEMBLY AND ASSEMBLY RADIATOR
REMOVAL OF RADIATOR
ASSEMBLY
1. Cover
1) Remove mounting bolts, then remove inspection
cover (1). DBW01864
DBW01865
2. Draining water ❈1
Loosen drain valve (4) and drain coolant.
« If the colant contains antifreeze, dispose of it
correctly.
Coolant : 53 l
4 DLW01866
30-27
DISASSEMBLY AND ASSEMBLY RADIATOR
3. Grill
1) Loosen mounting bolts of grill (5), then fit grill to 7 8
engine hood (6) temporarily, and remove light
wiring from clip portion of engine hood (6).
2) Disconnect wiring connector (7), and remove 5
grill (5).
« Open left and right side panels (8) to make
it possible to fit the lifting tool. 6
DLW01867
4. Engine hood
1) Remove radiator left and right plates (9) and
bottom cover (10).
9
2) Pass nylon rope through left and right hinge
portions of side panel (8), then connect to lifting
chain and lift at 4 points.
« Be careful that the lifting tool does not come
off.
« Fit the lifting tool with the exhaust pipe still
installed.
10
3) Remove the front, rear, left, and right mounting DLW01868
Hood assembly : 6 8
200 kg (without rear fender)
Hood assembly :
260 kg (with rear fender)
« Thread size when using eyebolts for re-
moval : 12 mm
DLW01869
5. Wiring
13
1) Disconnect wiring connector (12) for radiator
water level sensor.
2) Disconnect hose (13) between radiator and sub-
tank at radiator end.
« To prevent the water from leaking out of the
sub-tank, bend the tip of the hose and fix it 12
with a band.
« Remove the sub-tank hose and wirings (14) 14
from the radiator clip.
DLW01870
30-28
DISASSEMBLY AND ASSEMBLY RADIATOR
DLW01871
7. Radiator hoses ❈3
1) Disconnect radiator upper hose (17) at engine
end.
2) Disconnect radiator lower hose (18) at radiator 18
end.
19
« Loosen the hose clamp of the connection
portion at the radiator end.
17
DLW01872 DLW01873
8. Hydraulic piping ❈4
Disconnect oil cooler hoses (19), (20), (21), and
(22) at connection portion of tube at bottom of 21
radiator.
« Mask the openings to prevent water or dust from
entering.
22
20
DLW01874
9. Radiator ❈5
Remove mounting bolts of radiator (23) and lift off. 23
Radiator : 165 kg
« Be careful not to damage the radiator fins when
removing.
DLW01875
30-29
DISASSEMBLY AND ASSEMBLY RADIATOR
INSTALLATION OF RADIATOR
ASSEMBLY
• Carry out installation in the reverse order to re-
moval.
❈1
« Run the engine to circulate the water through
the system. Then check the water level again.
❈2
« Temporarily install the radiator stays.
Mounting bolt :
110.3 ± 12.3 Nm (11.25 ± 1.25 kgm)
« Install the fan guard so that the clearance be-
tween the fan and fan guard is uniform.
❈3
Hose clamp : 5.9 ± 0.5 Nm (0.6 ± 0.05
kgm)
❈4
« Fit the O-ring securely into the groove and be
careful that it does not get caught when assem-
bling.
« Install the hoses without twisting or interference.
Joint nut : 196 ± 49 Nm (20.0 ± 5.0 kgm)
(width across flats: 41 mm)
❈5
« Be careful not to damage the radiator fins.
« Install the radiator from the counterweight slowly.
« Install so that the clearance from the fan is
uniform.
Radiator mounting bolt :
176 ± 19.6 Nm (18.0 ± 2.0 kgm)
« Tighten the mounting bolts of the radiator stay
fully.
Transmission : 35 l
2) Tighten plug at top of hydraulic tank filter and
plug of pump piping, then add hydraulic oil
through oil filler to specified level.
30-30
DISASSEMBLY AND ASSEMBLY ENGINE
REMOVAL OF ENGINE
ASSEMBLY
3. Heater hoses
1) Leave left heater hose (6) installed to radiator
lower tube (4). 7
30-31
DISASSEMBLY AND ASSEMBLY ENGINE
4. Electric wiring ❈3
Disconnect the following electric wiring. 11
« When disconnecting the wiring, fit tags to distin-
guish them.
1) Disconnect slow blow fuse wiring (10) from slow
blow fuse (11).
10
Starting motor
10
DBW01879
15
16 DBW01883
13
14
DBW01881
5. Fuel hoses ❈4
Disconnect fuel hoses (17), (18), and (19) from fuel
tank end.
« When disconnecting the hoses, fit tags to distin-
19
guish them.
17
« Disconnect the hose clamps and bands.
« Disconnect the connectors of the fuel tank level
sensor wiring. 18
DBW01882
30-32
DISASSEMBLY AND ASSEMBLY ENGINE
20
DBW01884
DBW01886
9. Drive shaft ❈7
Remove rear drive shaft (27). 27
« Make match marks to show the mounting posi-
tion.
DBW01887
30-33
DISASSEMBLY AND ASSEMBLY ENGINE
q DBW00075
30
DBW01888
32 DBW01889
DBW01890
30-34
DISASSEMBLY AND ASSEMBLY ENGINE
DBW01891 DBW01892
DBW01893
7 DBW01896
30-35
DISASSEMBLY AND ASSEMBLY ENGINE
INSTALLATION OF ENGINE
ASSEMBLY
• Carry out installation in the reverse order to re-
moval.
❈1
« Install air conditioner compressor.
For details, see INSTALLATION OF AIR CON-
DITIONER COMPRESSOR.
❈2
« Install radiator assembly.
For details, see INSTALLATION OF RADIATOR
ASSEMBLY.
❈3
« Connect the electric wiring connectors securely.
❈4
« Match the distinguishing tags and connect the
hoses.
❈5
« See TESTING AND ADJUSTING for details of
adjusting the cable length.
❈7
« When connecting the drive shaft, clean the mat-
ing surface of the spider and the coupling,
mesh the pilot securely, and install.
Mounting bolt :
110.3 ± 12.3 Nm (11.25 ± 1.25 kgm)
❈8
« Check that there is an O-ring at the torque
converter mating surface.
« When connecting the engine to the torque con- Bracket
verter, adjust the height so that the torque con-
verter pilot can enter smoothly. Never use force
to connect them. Washer
Outside circumference of O-ring : Cushion
Soapy water Engine
« Be careful of the direction of assembly of the Cushion
rubber cushion.
Washer
« Fit the rubber cushion securely into the groove
of the bracket. DBW01897
333.5mm
667.0mm
DBW01898
30-36
DISASSEMBLY AND ASSEMBLY TORQUE CONVERTER CHARGING PUMP
REMOVAL OF TORQUE
CONVERTER CHARGING
PUMP ASSEMBLY 3
DLW01899
3. Hydraulic piping
Disconnect the following hydraulic piping. (WA350-
3S)
• Tube (6) between transmission strainer and
charging pump
• Hose (7) between charging pump and torque
converter oil filter
• Hose (8) between charging pump and top of
transmission
« Disconnect the tubes and hoses from the
6
pump end.
DLW01900
DLW01901
30-41
DISASSEMBLY AND ASSEMBLY TORQUE CONVERTER CHARGING PUMP
CONVERTER CHARGING
PUMP ASSEMBLY
• Carry out installation in the reverse order to re-
moval.
❈1
« Check that there is an O-ring at the mating
surface with the housing.
« Fit the O-ring securely in the groove and be
careful not to get it caught when assembling.
30-42
DISASSEMBLY AND ASSEMBLY TORQUE CONVERTER, TRANSMISSION
REMOVAL OF TORQUE
CONVERTER, TRANSMISSION
ASSEMBLY
Stop the machine on level ground and install the
safety bar on the frame. Lower the bucket to the
ground and stop the engine. Then apply the parking
brake and put blocks under the wheels to prevent
the machine from moving.
3
DBW01905
DBW01907
5 4 DBW01906
30-43
DISASSEMBLY AND ASSEMBLY TORQUE CONVERTER, TRANSMISSION
DBW01908
10
8 DBW01909
12
11 DBW01910
DBW01911
30-44
DISASSEMBLY AND ASSEMBLY TORQUE CONVERTER, TRANSMISSION
16
DBW01912
19
18
DBW01913
20
DBW01914
DBW01915
30-45
DISASSEMBLY AND ASSEMBLY TORQUE CONVERTER, TRANSMISSION
20
21 22
DBW01916
DBW01918
30-46
DISASSEMBLY AND ASSEMBLY TORQUE CONVERTER, TRANSMISSION
INSTALLATION OF TORQUE
CONVERTER, TRANSMISSION
ASSEMBLY
❈1
Air conditioner hose sleeve nut :
22.1 ± 2.5 Nm (2.25 ± 0.25 kgm)
❈2
« When connecting the 3 hoses at the bottom of
the hydraulic and steering pump, check the
hose and spacer mount O-rings for damage and
deterioration before installing.
❈3 ❈4
Drive shaft mounting bolt :
110.3 ± 12.3 Nm (11.25 ± 1.25 kgm)
❈5
• Position torque converter and transmission assem-
bly as follows.
1) Replace the O-ring at the mating surface of the
engine and transmission with a new part, fit
securely in the groove, then align the tooth
groove of the ring gear and connect to the
engine.
2) Assemble cushion (27) and spacer (26).
« Assemble the cushion so that the cham-
fered surface is on the spacer side.
« When assembling the cushion, do not use 25 26
oil or soapy water under any circumstances.
3) Tighten mounting bolt (25) temporarily.
4) Adjust clearance of clearance adjustment bolt
(28). (4 places)
« Standard value for clearance a of clearance
adjustment bolt : 1 – 2 mm
Clearance adjustment nut :
549 ± 59 Nm (56.0 ± 6.0 kgm)
❈6
Mounting bolt (25) : 24 28 27
DBW01917
549 ± 59 Nm (56.0 ± 6.0 kgm)
DBW01919
30-47
DISASSEMBLY AND ASSEMBLY TORQUE CONVERTER
DISASSEMBLY OF TORQUE
CONVERTER ASSEMBLY
DEW00529
DEW00530 DEW00531
DEW00532
18
DEW00533 DEW00534
30-48
DISASSEMBLY AND ASSEMBLY TORQUE CONVERTER
2. Stator
1) Remove snap ring (9).
2) Remove stator (10).
3. Stator shaft
Using forcing screws 1, push from stator shaft (11) 11
end and disconnect from pump assembly (12).
12
DEW00536
4. Gear
Remove gear (13) from pump (14). 13
14
DEW00537
5. Bearing
Remove bearing (15) from gear (13). 13
15
DEW00538
30-49
DISASSEMBLY AND ASSEMBLY TORQUE CONVERTER
ASSEMBLY OF TORQUE
CONVERTER ASSEMBLY
13
1. Bearing
Install bearing (15) to gear (13).
15
DEW00539
2. Gear
Install gear (13) to pump (14). 13
Mounting bolt:
66.2 ± 7.4 Nm (6.75 ± 0.75 kgm)
14
DEW00537
3. Stator shaft
1) Install seal ring (16) to stator shaft (11).
Seal ring: Grease (G2-LI)
« Make the protrusion of the seal ring uniform. 11
16
DEW00540
12
11
DEW00541
30-50
DISASSEMBLY AND ASSEMBLY TORQUE CONVERTER
4. Stator
1) Install stator (10). 10 9
2) Install snap ring (9).
DEW00535
DEW00543
18
DEW00533
DEW00545
30-51
DISASSEMBLY AND ASSEMBLY TORQUE CONVERTER
DEW00531 DEW00530
DEW00529
30-52
DISASSEMBLY AND ASSEMBLY TRANSMISSION
DISASSEMBLY OF
TRANSMISSION ASSEMBLY
• Remove the left and right mount brackets from the
transmission assembly first.
1. Oil filler, rear coupling 1
Remove oil filler (1) and rear coupling (2).
« Lower the transmission assembly and install it
to the assembly stand.
DLW00170 DLW00171
2. Hydraulic piping
1) Remove tube hose (3) between strainer and
charging pump.
3
2) Remove tube hose (4) between torque converter 4
filter and transmission valve from transmission
valve.
« Remove the tube clamps.
DBW00173
4. Charging pump
1) Remove hoses and flanges (8) and (9) from
charging pump (10) and housing.
2) Remove charging pump (10).
« For the WA380-3, the charging pump pip-
ing and transmission valve portion are dif-
ferent.
10
9
8
DBW00174
30-53
DISASSEMBLY AND ASSEMBLY TRANSMISSION
5. Hydraulic piping 11
1) Remove PTO lubrication tube (11).
« Be careful not to crush the tube during the
operation. 9
« After removing the tube, fit a cover to pro-
tect the thread.
2) Remove clamp of hose (9).
DBW00175
6. Oil filter 11
1) Remove mounting bracket of oil filter (12), then
remove together with bracket, filter, and hose.
12 DBW00176
7. Rear housing
1) Remove torque converter pilot cap (13). A1 13
2) Install tool A1 to rear housing (14) and sling.
« Install tool A1 securely so that it does not
come off.
A1
14
DBW00177
DBW00178
30-54
DISASSEMBLY AND ASSEMBLY TRANSMISSION
8. Torque converter
14
Lift off torque converter (16) from rear housing (14).
« Before removing, use a felt pen to make match
marks on the mating surface of the housing
and torque converter.
16 DBW00179
DBW00180
14 19 18
18
21 20
DBW00181
23
22 DLW00183
21
17
20
30-55
DISASSEMBLY AND ASSEMBLY TRANSMISSION
23
22
DLW00184
24 DBW00185
25 DBW00186
DBW00187
30-56
DISASSEMBLY AND ASSEMBLY TRANSMISSION
25
DBW00188
27
32 DBW00189
13. Bearing 32
1) Remove FORWARD, REVERSE outer bearing 31
(28), 1st, 3rd outer bearing (29), and 2nd, 4th
outer bearing (30) from housing.
30
32
33 DBW00191
30-57
DISASSEMBLY AND ASSEMBLY TRANSMISSION
34,35
DBW00192
39
2) Remove mounting bolts, then remove lock plate
(38) and manual cancel bolt (39).
40
6) Tighten tool A4 with coupling mounting bolts.
« Bolt length of tool A4: 64 mm 42 DBW00194
43
44 45 DBW00195
30-58
DISASSEMBLY AND ASSEMBLY TRANSMISSION
50 DLW00196
47 48 47 48
DLW00200
43 43 - 1
9) Set guide bolts (43-1) to parking brake housing
(43), then remove mounting bolts, and lift off.
« Loosen the mounting bolts uniformly a little
at a time.
« Guide bolt : (12 mm, pitch 1.75 mm, length:
130 mm)
« Install the lifting tool. (12 mm, pitch: 1.75
mm)
Parking brake housing : 21 kg
DBW00197
51
52 DBW00198
11. Remove piston (53) and snap ring (54) from park-
ing brake housing (43). 53 43
54
DLW00199
30-59
DISASSEMBLY AND ASSEMBLY TRANSMISSION
55
53 56
DLW00201
57,58 DBW00202
59 60
DBW00203
61
62
DLW00205
30-60
DISASSEMBLY AND ASSEMBLY TRANSMISSION
DLW00206
Cover
DBW00207
DBW00208
65
DBW00209
30-61
DISASSEMBLY AND ASSEMBLY TRANSMISSION
67
DLW00210
63 66
DLW00211
72
19. Covers
1) Remove covers (70) and (71).
« Remove both the O-rings.
70 DBW00212
30-62
DISASSEMBLY AND ASSEMBLY TRANSMISSION
ASSEMBLY OF TRANSMISSION
ASSEMBLY
72
1. Covers
Assemble O-rings and assemble covers (70) and
(71) to front housing.
« Be careful not to the O-rings fall out.
« Install O-ring (72) to the mating surface of the 71
parking brake housing.
Outside circumference of O-ring :
Grease (G2-LI)
70 DBW00212
67
DLW00213
DLW00206
30-63
DISASSEMBLY AND ASSEMBLY TRANSMISSION
64
DBW00208
DLW00214
15
DLW00215
30-64
DISASSEMBLY AND ASSEMBLY TRANSMISSION
DLW00205
30-65
DISASSEMBLY AND ASSEMBLY TRANSMISSION
57,58 DBW00202
55
53 56
DLW00201
54
DLW00199
52 DBW00198
30-66
DISASSEMBLY AND ASSEMBLY TRANSMISSION
DBW00197
58
57
DLW00220
30-67
DISASSEMBLY AND ASSEMBLY TRANSMISSION
43
11) Install snap ring (44), and remove tool A4.
« Check that the snap ring is fitted securely in
the groove.
« Check that the shaft turns, then remove
manual cancel bolt (39).
44 45 DBW00195
12) Press fit oil seal (42) and dust seal (41) to
cover (40).
Press-fitting dimension a : 28.5 ± 1 mm
Press-fitting dimension b : 17.5 ± 1 mm 41
Lip of oil seal : Grease (G2-LI)
Coat lip of
oil seal with G2-LI
13) Install gasket (40-1) to parking brake housing
(43), align with dowel pin, then install cover (40). 42 ba
« Knock the cover in uniformly with a plastic 41
hammer.
« Be careful not to let the oil seal contact the
shaft.
Mounting bolt : 42 40 DLW00221
110.3 ± 12.3 Nm (11.25 ± 1.25 kgm)
39
38 40 - 1 DBW00193
30-68
DISASSEMBLY AND ASSEMBLY TRANSMISSION
DLW00223
b a 34 35
DLW00224
6. Idler gear
1) Press fit bearings (33) to idler gear (32). 32
2) Press fit idler gear (32) to shaft, and install
snap ring (31).
« If the shaft has been removed, cool the
shaft to –70°C, then press fit it to dimen-
sion g.
« Shaft dimension g : 46.5 ± 0.5 mm
32 g
33 DBW00191
32 31
30
DLW00225
7. Bearing
1) Assemble FORWARD, REVERSE outer bear-
ing (28), 1st, 3rd outer bearing (29), and 2nd, 28
4th outer bearing (30) to housing. 29 DBW00190
30-69
DISASSEMBLY AND ASSEMBLY TRANSMISSION
DBW00226
25
DBW00227
26
DBW00228
73
74
DLW00229
30-70
DISASSEMBLY AND ASSEMBLY TRANSMISSION
25 DLW00230
24 DBW00185
22
23
DLW00321
22 DLW00232
30-71
DISASSEMBLY AND ASSEMBLY TRANSMISSION
21 20
22 DLW00233
DBW00180
16-1
DLW00235
30-72
DISASSEMBLY AND ASSEMBLY TRANSMISSION
DBW00178
´2
DBW00236
A1
14
DBW00177
12 DBW00176
30-73
DISASSEMBLY AND ASSEMBLY TRANSMISSION
´85
´115
DBW00237
30-74
DISASSEMBLY AND ASSEMBLY TRANSMISSION
DLW00170
30-75
DISASSEMBLY AND ASSEMBLY TRANSMISSION
DLW00239
30-76
DISASSEMBLY AND ASSEMBLY TRANSMISSION CLUTCH PACK
DISASSEMBLY OF TRANSMISSION
CLUTCH PACK ASSEMBLY
Disassembly of FORWARD, REVERSE clutch pack
The clutch pack is oily, so be careful not to let it slip
when setting the clutch pack on the stand. Be care-
ful also not to get your fingers caught between the
1
stand and the clutch pack.
« Set on tool B1 with the FORWARD clutch side at
the top.
1. Bearing
Using puller, remove bearing (1).
DBW00242
8 6 5 3
DBW00243
3. End plate B5
B3
1) Install tools B3 and B5, then tighten tool B4,
and remove ring (9). B4
« After removing the ring, remove tool B3.
DBW00244
10
DBW00245
30-79
DISASSEMBLY AND ASSEMBLY TRANSMISSION CLUTCH PACK
4. Clutch plate
Remove plate (11), disc (12), and spring (13) from 13 12 11
housing.
B1
DBW00246
5. Piston
Blow air in FORWARD oil hole of shaft and remove 14
piston (14).
« If the piston is at an angle and cannot be re-
moved, push the piston in and try to remove it
again.
« Do not use force to remove it. The inside cir-
cumference of the cylinder will be damaged.
DBW00247
7. Snap ring
« Set on tool B1 with the REVERSE clutch side at
the top. 15
16
Remove snap ring (15). 18
19
8. Bearing, REVERSE gear 20
Using puller, remove spacer (16), gear (17), inner 21
17
bearing (18), spacer (19), thrust washer (20), nee-
dle bearing (21), thrust washer (22), thrust bearing
(23), and washer (24). 22
Use the same procedure as in Steps 3 – 5 for the 23
FORWARD gear to continue disassembly.
24 DBW00248
30-80
DISASSEMBLY AND ASSEMBLY TRANSMISSION CLUTCH PACK
DLW01921
25
DLW00249
30-81
DISASSEMBLY AND ASSEMBLY TRANSMISSION CLUTCH PACK
35
32
2. 1st gear
1) Remove snap ring (33), then remove thrust DBW00250 DBW00251
washer (34).
2) Remove 1st gear (35), and needle bearings (36)
and (37).
37 36
35 34
DBW00252
3. End plate
1) Install tool B3 and B5, then tighten tool B4, and
remove ring (38).
B4
« After removing the ring, remove tool B3. B5
B3
38
B1
DBW00253
39
DBW00254
30-82
DISASSEMBLY AND ASSEMBLY TRANSMISSION CLUTCH PACK
4. Clutch plate
42
1) Remove plate (40), disc (41), and spring (42) 41 43
from housing.
2) Remove thrust washer (43).
40
DBW00255 DBW00256
5. Piston
Blow air in REVERSE oil hole of shaft, and remove
piston (44). 44
« If the piston is at an angle and cannot be re-
moved, push the piston in and try to remove it
again.
« Do not use force to remove it. The inside cir-
cumference of the cylinder will be damaged.
DBW00257
6. Bearing
Set on tool B1 with the 3rd clutch side at the top.
Using puller, remove bearing (45).
45
B1
DBW00258
7. 3rd gear
Remove spacer (46), thrust washer (47), needle
bearing (48), and 3rd gear (49). 48
« Use the same procedure as in Steps 3 – 5 for 46
the 1st gear to continue disassembly.
49 47
DLW00259
30-83
DISASSEMBLY AND ASSEMBLY TRANSMISSION CLUTCH PACK
DBW00260
2. 4th gear
1) Remove thrust washer (52), 4th gear (53), nee-
dle bearing (54), and thrust washer (55).
2) Remove snap ring (56), spacer (57), and nee-
dle bearing (58) from 4th gear (53).
55 53 54 52
DBW00261
3. End plate
1) Install tools B3 and B5, then tighten tool B4, 56 57 58 53
and remove ring (59).
« After removing the ring, remove tool B3.
60 B4
59
B5
B3
DBW00263 DBW00262
30-84
DISASSEMBLY AND ASSEMBLY TRANSMISSION CLUTCH PACK
4. Clutch plate 63
Remove plate (61), disc (62), and spring (63) from
62
housing. 61
B1
DBW00264
5. Piston
Blow air in 4th oil hole of shaft, and remove piston
64
(64).
« If the piston is at an angle and cannot be re-
moved, push the piston in and try to remove it
again.
« Do not use force to remove it. The inside cir-
cumference of the cylinder will be damaged.
DBW00265
6. Idler gear
« Set on tool B1 with the 2nd clutch side at the
top.
65
1) Remove snap ring (65).
68 66
2) Using puller, remove spacer (66), inner bearing
(67), and idler gear (68). 67
« When fitting the puller, put the plate in contact
with the center first. 69
70
DLW02267
7. 2nd gear
Remove thrust washer (69), needle bearing (70),
2nd gear (71), and thrust washer (72).
« Use the same procedure as in Steps 3 – 5 for
the 2nd gear to continue disassembly.
72 71 70 69
DBW00266
30-85
DISASSEMBLY AND ASSEMBLY TRANSMISSION CLUTCH PACK
ASSEMBLY OF
TRANSMISSION CLUTCH
PACK ASSEMBLY
Assembly of FORWARD, REVERSE clutch pack 25
The clutch pack is oily, so be careful not to let it slip
when setting the clutch pack on the stand. Be care-
ful also not to get your fingers caught between the
stand and the clutch pack.
• Set on the assembly stand with the REVERSE clutch
26
side at the top.
1.Housing 28
Assemble snap ring (28) to one side of housing
27
(27). DLW00267
2. Shaft, housing
1) Put housing (27) and snap ring (27) on tool B1.
2) Assemble shaft and housing to housing (27),
and install snap ring (26).
73
3. Piston seal Piston seal
Assemble piston seal (73-1) to piston (73). 73-1
before using tool B6
« When assembling a new piston seal, use tool
B6 to make the seal fit well (time: approx. 2 – 3 73
minutes), then assemble the seal.
« If the seal is assembled to the cylinder without
making it fit first, the seal will be damaged.
Inside surface of tool B6 : 73-1 B6
Transmission oil (F¥R)
DLW00268
4. REVERSE piston
Install REVERSE piston (73).
« Be careful not to damage the piston seal.
« Check that the spring pin does not extend from 73
the circumference of the shaft.
Sliding surface of piston seal :
Spring side
Transmission oil
24-4
B1
Cylinder side
30-90
DISASSEMBLY AND ASSEMBLY TRANSMISSION CLUTCH PACK
6. Clutch plate 74
Insert tool B2 into housing, then assemble plate 75
(74), disc (75), and spring (76) in turn. 76
« Soak disc (75) in clean transmission oil for at
least 2 minutes before assembling. B2
« Be careful to assemble so that disc (75) and
spring (76) are not resting on each other.
« Be careful that the plate or spring are not caught
in the clutch housing ring groove when assem-
bling.
DBW00270
7. End plate
1) Install tools B3 and B5, then tighten tool B4 to B3
B4
push in end plate (77). B5
2) Assemble ring (78), and remove tool B3.
« Check that the disc rotates smoothly by
hand.
78
77
DBW00271
8. Thrust washer
Assemble washer (24), thrust bearing (23), thrust
washer (22).
9. REVERSE gear 21
Align spline groove on inside of plate with a screw- 17
driver to assemble gear (17).
« If the gear spline does not match, turn lightly 22
when assembling. Never use force to push it in.
23
10. Needle bearing 24
Assemble needle bearing (21) and thrust washer DLW02268
(20).
« Check that the end face of the thrust washer is
below the surface of the stepped portion of the
shaft. 15
16
11. Bearing 18
19
1) Assemble spacer (19), then press fit inner bear- 20
ing (18) and spacer (16).
« Press fit completely so that there is no clear-
ance.
Thrust washer : Transmission oil
2) Assemble snap ring (15).
DLW02269
30-91
DISASSEMBLY AND ASSEMBLY TRANSMISSION CLUTCH PACK
DLW02270
14-4
Cylinder side
DLW01924
DLW02297
30-92
DISASSEMBLY AND ASSEMBLY TRANSMISSION CLUTCH PACK
11
DBW00273
10
DBW00274
30-93
DISASSEMBLY AND ASSEMBLY TRANSMISSION CLUTCH PACK
19. Spacer
Assemble thrust washer (3), then assemble spacer 3
(2). 2
« Check that the end face of the thrust race of
the thrust washer is below the surface of the
stepped portion of the shaft.
Thrust washer : Transmission oil
DBW00277
20. Bearing
Press fit bearing (1).
« Press fit completely so that the spacer is in tight 1
contact with bearing (1) at the stepped portion
of the shaft.
DBW00278
DLW02271
DBW00279
30-94
DISASSEMBLY AND ASSEMBLY TRANSMISSION CLUTCH PACK
1. Piston seal
Assemble piston seal (79-1) to piston (79). 79
« When assembling a new piston seal, use tool
B7 to make the seal fit well (time: approx. 2 – 3 79-1 Piston seal before
using tool B7
minutes), then assemble the seal.
« If the seal is assembled to the cylinder without 79
making it fit first, the seal will be damaged.
Inside surface of tool B7 :
Transmission oil
79-1
B7
DLW00280
2. 3rd piston
Install 3rd piston (79).
« Be careful not to damage the piston seal.
79
« Check that the spring pin does not extend from
the circumference of the shaft.
Sliding surface of piston seal :
Transmission oil
B1
DBW00281
3. Clutch plate
Assemble plate (80), disc (81), and spring (82) in
82 81 80
turn to housing.
« Soak disc (81) in clean transmission oil for at
least 2 minutes before assembling.
« Be careful to assemble so that disc (81) and
spring (82) are not resting on each other.
« Be careful that plate (80) or spring (82) are not
caught in the clutch housing ring groove when
assembling.
DBW00282
30-95
DISASSEMBLY AND ASSEMBLY TRANSMISSION CLUTCH PACK
4. End plate
1) Install tools B3 and B5, then tighten tool B4 to B3 B4
push in end plate (83).
2) Assemble ring (84), and remove tool B3.
« Check that ring (84) is fitted securely in the
groove. 84
« Check that the disc rotates smoothly by
hand.
83
B5
DBW00283
DBW00284 DBW00285
6. Bearing
Assemble thrust washer (47) and spacer (46), then
press fit bearing (45).
« Check that the end face of the thrust washer is 45
below the surface of the stepped portion of the
shaft.
46
« Press fit completely so that the spacer is in tight
contact with bearing (45) at the stepped portion
of the shaft. 47
DBW00286
« After press fitting bearing, check that clearance
"d" between thrust washer (47) and spacer (46)
is within standard value.
« d = 0.1 - 0.9 mm
d
46
DLW02272
30-96
DISASSEMBLY AND ASSEMBLY TRANSMISSION CLUTCH PACK
7. 1st piston
1) Turn over clutch pack. 44
When turning over the clutch pack, be care-
ful not to get your fingers caught between
the stand and clutch pack.
2) In the same way as with 3rd piston, make sure
that piston seal fits well before assembling it to
piston (44).
3) Assemble piston (44) in the same way as 3rd
piston.
Sliding surface of piston seal :
Transmission oil DBW00287
8. Clutch plate
42 41
Assemble plate (40), disc (41), and spring (42) in
turn to housing.
« Assemble in the same way as for the 3rd clutch
plate.
40
DLW00288
9. End plate
1) Install tools B3 and B5, then tighten tool B4 to
push in end plate (39). B3 B4
B5
2) Assemble ring (38), and remove tools B3 and
B4.
« Assemble in the same way as for the 3rd 39
end plate.
38
DBW00289
DBW00290 DBW00291
30-97
DISASSEMBLY AND ASSEMBLY TRANSMISSION CLUTCH PACK
DBW00292
DBW00251 DBW00250
DBW00293
DBW00294
30-98
DISASSEMBLY AND ASSEMBLY TRANSMISSION CLUTCH PACK
1. Piston seal
Assemble piston seal (86-1) to piston (86). 86
« When assembling a new piston seal, use tool Piston seal before
B7 to make the seal fit well (time: approx. 2 – 3 using tool B7
86-1
minutes), then assemble the seal.
« If the seal is assembled to the cylinder without
making it fit first, the seal will be damaged. 86
Inside surface of tool B7 :
Transmission oil
86-1
B7
DLW01926
2. 2nd piston
Install 2nd piston (86).
« Be careful not to damage the piston seal.
86
« Check that the spring pin does not extend from
the circumference of the shaft.
Shaft housing
B1
DBW00296
3. Clutch plate
Assemble plate (87), disc (88), and spring (89) in 89
88
turn to housing.
« Soak disc (88) in clean transmission oil for at
least 2 minutes before assembling.
« Be careful to assemble so that disc (88) and
spring (89) are not resting on each other.
« Be careful that the plate or spring are not caught
in the clutch housing ring groove when assem-
bling.
87
DBW00297
30-99
DISASSEMBLY AND ASSEMBLY TRANSMISSION CLUTCH PACK
4. End plate
B3 B4
1) Install tools B3 and B5, then tighten tool B4 to
push in end plate (90).
2) Assemble ring (91), and remove tool B3.
B5
« Check that the disc rotates smoothly by
hand. 91
90
DBW00298
5. Thrust washer
Assemble thrust washer (72). 71 70
6. 2nd gear 72
Assemble 2nd gear (71), then assemble needle bear-
ing (70).
« If the gear spline does not match, turn lightly
when assembling. Never use force to push it in.
7. Idler gear
Assemble thrust washer (69) and idler gear (68).
« Check that the end face of the thrust washer is
below the surface of the stepped portion of the
shaft.
Thrust washer : Transmission oil DBW00299 DBW00300
8. Bearing
1) Press fit inner bearing (67) and spacer (66).
2) Assemble snap ring (65). 65
« Fit the snap ring securely in the shaft groove.
68 66
« After press fitting the bearing, check that
clearance "e" between the thrust washer 67
and the idler gear is within the standard
value. 69
« e = 0.34 – 1.66 mm
70
DLW02267
65
66
67
e
68
DLW02273 DBW00301
30-100
DISASSEMBLY AND ASSEMBLY TRANSMISSION CLUTCH PACK
9. 4th piston
1) Turn over clutch pack.
When turning over the clutch pack, be care-
ful not to get your fingers caught between 64
the stand and clutch pack.
2) In the same way as with 1st piston, make sure
that piston seal fits well before assembling it to
piston (64).
3) Assemble piston (64) in the same way as 2nd
piston.
Sliding surface of piston seal :
Transmission oil DBW00302
DBW00303
B5
B4
DBW00304
55
DBW00305
30-101
DISASSEMBLY AND ASSEMBLY TRANSMISSION CLUTCH PACK
DLW02260
13. Bearing
Assemble idler gear (50), then press fit bearing (51). 52
« Press fit completely so that the idler gear is in 54
tight contact with bearing (51) at the stepped
portion of the shaft.
« After press fitting the bearing, check that clear- 53
ance "f" between the thrust washer and the
idler gear is within the standard value.
« f = 0.17 – 1.43 mm
DBW00306
51 50
f
DLW02274
DBW00307
DBW00308
30-102
DISASSEMBLY AND ASSEMBLY TRANSMISSION CONTROL VALVE
REMOVAL OF TRANSMISSION
CONTROL VALVE ASSEMBLY
3
Stop the machine on level ground and install the
safety bar on the frame. Lower the bucket to the
ground and stop the engine. Then apply the parking
brake and put blocks under the wheels to prevent 1
the machine from moving.
2 DBW00084
6 5
DBW00309
8 9 8
DBW00312 DBW00311
30-103
DISASSEMBLY AND ASSEMBLY TRANSMISSION CONTROL VALVE
5. Electric wiring
1) Disconnect clamp of transmission wiring (10)
from transmission valve. 10
2) Disconnect transmission wiring (11), (12), (13),
(14), and (15) from transmission valve. 11 (T05)
❈3
« Fit tags to distinguish the wiring. 12 (T04)
13 (T03)
14 (T01)
DBW00313
17
DBW00314
Transmission valve : 46 kg
« The valve mounting bolts for the WA350-3S
and WA350-3H are different, so record the
mounting position of the mounting bolts.
20 DBW00316
30-104
DISASSEMBLY AND ASSEMBLY TRANSMISSION CONTROL VALVE
INSTALLATION OF
TRANSMISSION CONTROL WA350-3S
VALVE ASSEMBLY
´80 ´90
• Carry out installation in the reverse order to re-
moval.
20
❈4
❈3
´140
Connect the wiring connector securely.
❈5
« Use a new part for the gasket.
« Wash and remove all oil and grease from the
mounting bolts and bolt holes.
20
Mounting bolt: Thread tightener (LT-2)
Mounting bolt :
34.3 ± 4.9 Nm (3.5 ± 0.5 kgm) ´115 DBW00317
❈6
20
´=115 ´=40
DLW01928
30-105
DISASSEMBLY AND ASSEMBLY TRANSMISSION CONTROL VALVE
DISASSEMBLY OF
TRANSMISSION CONTROL
VALVE ASSEMBLY
35
57 a
49 56
48 b
55
36
37
38
46
58
47
56
55 40
34 39
45
63 59 50 38
33
39 1
40 59
38
41
43 42
44
54
a 53
b 62
61 - 1
52
10
51 20 11 - 1
Lower valve 12 - 1
21
1 3 22
15
16
17
2 18
19
31 - 1
13 - 1
13 - 3 13 - 2
13 - 4
14 -1
14 - 3
8
14 - 2 9
32
7
5
6
24 - 1
23 - 1 4
DBW01930
30-112
DISASSEMBLY AND ASSEMBLY TRANSMISSION CONTROL VALVE
30-113
DISASSEMBLY AND ASSEMBLY TRANSMISSION CONTROL VALVE
ASSEMBLY OF TRANSMISSION
CONTROL VALVE ASSEMBLY
35
57 a
49 56
48 b
55
36
37
38
46
58
47
56
55 40
34 39
45
63 59 50 38
33
39 1
40 59
38
41
43 42
44
54
a 53
b 62
61 - 1
52
10
51 20 11 - 1
Lower valve 12 - 1
21
1 3 22
15
16
17
2 18
19
31 - 1
13 - 1
13 - 3 13 - 2
13 - 4
14 -1
14 - 3
8
14 - 2 9
32
7
5
6
24 - 1
23 - 1 4
DBW01930
30-114
DISASSEMBLY AND ASSEMBLY TRANSMISSION CONTROL VALVE
Guide bolts
48
DBW00320
Mounting bolt :
30.9 ± 3.4 Nm (3.15 ± 0.35 kgm)
« Install guide bolts.
« Replace the gasket with a new part.
6) Install return spring (47) (L=46) and brake
valve (46).
7) Install priority valve (45).
8) Install sleeve (44) and F return spring (43)
(L=42), set gasket (42) in position, then in-
stall cover (41).
Mounting bolt :
30.9 ± 3.4 Nm (3.15 ± 0.35 kgm)
« Install guide bolts.
« Replace the gasket with a new part.
9) Assemble O-rings (40) and (39) to solenoid
valve (38), then install solenoid valve (38).
30-115
DISASSEMBLY AND ASSEMBLY TRANSMISSION CONTROL VALVE
6-7mm 2-1
2-3mm 2-1
DLW00319
30-116
DISASSEMBLY AND ASSEMBLY TRANSMISSION ACCUMULATOR VALVE
DISASSEMBLY OF
TRANSMISSION
ACCUMULATOR VALVE
ASSEMBLY
1. Remove accumulator valve (4) from transmission
assembly (3).
2. Remove O-rings (1) and (2) from accumulator valve
3
(4). 2
3. Using pads, set accumulator valve body (9) in vice. 1 9
4
DBW00322
6 8
DBW00323
« Reference
• WA350-3S
Spring Stopper Spacer
8 Guide bolt 7
l = 135.8 l = 10
10 DBW00324
FWD l = 184.8
12 12
• WA350-3H
Spring Stopper Spacer 13 14
FWD l = 184.8 l = 135.8 l = 10
15 13
1ST l = 157.5 l = 110 l = 30
10
2ND l = 157.5 l = 110 l = 30
16 1ST FWD 2ND 16
17 DLW00325
30-117
DISASSEMBLY AND ASSEMBLY TRANSMISSION ACCUMULATOR VALVE
DBW00326
6 — 7mm 2 — 3mm
DAW00327
ASSEMBLY OF TRANSMISSION
ACCUMULATOR VALVE
ASSEMBLY 9
30-118
DISASSEMBLY AND ASSEMBLY DRIVE SHAFT
DISASSEMBLY OF DRIVE
SHAFT ASSEMBLY
a
1. Front drive shaft
1
1) Remove coupling and tube (1).
« Make match marks a to prevent the cou-
pling from being installed in the opposite
direction.
« Cover (2) is caulked at 2 places with a
punch, so do not remove it unless neces-
sary.
• If cover (2) was removed and the oil seal
was replaced. DEW00809
i) Remove cover (2).
« When removing cover (2), be care-
ful not to damage cover (2) or tube
(3). Caulking 5 4
« When removing the caulking, use a
screwdriver to raise the caulked
portion.
ii) Remove washer (4), oil seal (5) and
washer (6).
6
3 2
DBW01931
DBW01932
DLW01933
30-121
DISASSEMBLY AND ASSEMBLY DRIVE SHAFT
DBW01934
13
12
DBW01935
DBW01936
DBW01937
30-122
DISASSEMBLY AND ASSEMBLY DRIVE SHAFT
14
15
14
15 DBW01938
14 14
17 14
16 17
14
DBW01940
Transmission
14 17 DBW01939
30-123
DISASSEMBLY AND ASSEMBLY DRIVE SHAFT
DBW01935
6
3 2
DBW01931
DBW01942
30-124
DISASSEMBLY AND ASSEMBLY DRIVE SHAFT
19
8
DBW01943
DEW00819
DBW01936
DBW01937
30-125
DISASSEMBLY AND ASSEMBLY FRONT AXLE
2. Tire, wheel
Put sling around tire (1), then remove mounting
bolts and lift off. ❈2
1
DLW01945
3. Drive shaft ❈3
Disconnect front drive shaft (2).
4. Axle
1) Disconnect brake tube (3). ❈4
When removing the front frame inspection cover
and disconnecting the brake tube to carry out
the operation, set support under the lift arm.
2
DLW01946
q DBW01948 DLW01947
30-126
DISASSEMBLY AND ASSEMBLY REAR AXLE
1. Fuel tank
Remove fuel tank (1).
For details, see REMOVAL OF FUEL TANK AS-
SEMBLY. DLW01951
2. Jacking up chassis
1) Set blocks between left and right rear axles
and rear frame.
« Set the blocks so that the angle of the tire
angle on the opposite side does not change
when the tire assembly is removed.
DLW01952
w
DLW01953
e
DLW01954
30-129
DISASSEMBLY AND ASSEMBLY REAR AXLE
3. Tire, wheel
Put sling around tire (3), then remove mounting
bolts and lift off. ❈1
DLW01955
4. Drive shaft
Remove rear drive shaft (4). ❈2 4
« Make match marks to show the mounting posi-
tion.
DLW01956
DLW01957 DLW01958
DLW01959
30-130
DISASSEMBLY AND ASSEMBLY REAR AXLE
6. Axle
1) Secure rear pivot (8) to axle with chain or r
wire.
« Fix the pivot securely so that it does not
move.
« When removing the axle assembly, fit a
cover to the coupling to prevent damage to
the dust seal and bushing at the front pivot.
8
DLW01960
9 DLW01961
DLW01962 DLW01963
DBW01964
30-131
DISASSEMBLY AND ASSEMBLY REAR AXLE
7. Rear pivot
1) Remove trunnion cap (14). ❈5 15 14
« Sling the rear pivot.
16
2) Remove mounting bolts, them remove thrust
plate (15) and thrust washer (16). ❈6
18
17 8
8 8 16
DBW01967 DBW01968
18
DLW01970
19
20
21
5) Remove retainer (19) from rear pivot, then re-
move packing (20) from retainer. ❈7
8. Front pivot
1) Remove retainer from front pivot (22), then re-
move packing (23) from retainer. ❈9
25
22
DBW01969
30-132
DISASSEMBLY AND ASSEMBLY REAR AXLE
❈1
Mounting bolt :
927 ± 103 Nm (94.5 ± 10.5 kgm)
(Width across flats: 36 mm)
❈2
« Align the match marks, and take care to as-
semble the coupling facing in the correct direc-
tion.
« Align the pilot portion securely and take care to
assemble with the yoke facing in the correct
direction.
Mounting bolt :
110.3 ± 12.3 Nm (11.25 ± 1.25 kgm)
❈3
« Be careful not to tighten the tube nut too far.
Tube nut :
80.9 ± 12.3 Nm (8.25 ± 1.25 kgm)
❈4
« Use the bolt as a guide to set to the mounting
position.
« When tightening the mounting bolts, do not
tighten in one step. Divide the torque and tighten
in three steps.
« After installing the axle assembly, remove the
chain or wire.
Mounting bolt :
1,324 ± 147 Nm (135.0 ± 15.0 kgm)
(Width across flats : 41 mm)
❈5
Mounting bolt :
108 ± 14.7 Nm (11.0 ± 1.5 kgm)
❈6
« Wash and remove all oil and grease from the
Front of front pivot Rear of front pivot
mounting bolts and bolt hole.
Rear pivot Bushing
« Coat the mounting bolts with thread tightener.
Mounting bolt : Thread tightener (LT-2)
Retainer
❈ 7 ❈ 9 ❈10
« Check the assembly direction of the packing
Dust Grease Grease Dust
and dust seal. seal seal side
side side
Packing, dust seal : Grease (G2-LI) side
DBW01971 DBW01972
30-133
DISASSEMBLY AND ASSEMBLY REAR AXLE
❈8 ❈10
Bushing : Grease (G2-LI)
• Greasing
Grease each pivot well.
« Wipe off any grease that is squeezed out.
30-134
DISASSEMBLY AND ASSEMBLY DIFFERENTIAL
DISASSEMBLY OF
DIFFERENTIAL ASSEMBLY
1. Draining oil
Remove drain plug (1), and drain oil.
Axle oil : 37 l
1 DBW01973
2. Axle assembly 3 3
1) Set axle assembly (2) on pallet. 2
DBW01974
4
3. Differential cover
Remove bleeder screws (4), then remove differen-
tial cover (5).
4. Axle housing
1) Sling axle housing assembly (6), and remove
housing mounting bolts.
« Make match marks on the housings to pre-
vent mistakes between the left and right
axle housings. 5
« Set blocks to prevent the assembly from DBW01975
tilting when the housing assembly on one
side is removed.
.
2) Lift off axle housing assembly (6).
6
DBW01976
30-135
DISASSEMBLY AND ASSEMBLY DIFFERENTIAL
5. Cage
1) Screw in forcing screws, and using guide bolts
(7) (16 mm, P=2, L=50mm), remove cage as- 8
sembly (8).
« Check the number of shims and use as
reference when assembling.
« Loosen the mounting bolts of the coupling, 7
9
and fit temporarily.
Cage assembly : 46 kg
2) Remove O-ring (9) from cage.
DBW01977
6. Brake piston
10
Install bleeder screw, blow in compressed air from
portion a, raise housing and piston (10), and re-
move.
« If the D-ring is damaged, blow in air suddenly to
make a gap between the housing and piston, a
then use a screwdriver to lever it out and re-
move it.
« When removing the piston, be careful not to
damage the housing and piston surface.
Air gun
DBW01978
13
DBW01980
30-136
DISASSEMBLY AND ASSEMBLY DIFFERENTIAL
11
DBW01981
17
15
DBW01982
18
DBW01983
19
DBW01984
30-137
DISASSEMBLY AND ASSEMBLY DIFFERENTIAL
23
DBW01985
Bevel gear : 24 kg
Flange half : 25 kg
25 14
27 DBW01987
31 28 29
30
30
28
32
DLW00379 DBW01988
30-138
DISASSEMBLY AND ASSEMBLY DIFFERENTIAL
Press
34
33
33
DBW01989
Press stand 36 33
DLW00383
35
DBW01990
11. Cage
Remove bearing cups (38) and (39) from cage (37). 37
38 39
DBW01991
30-139
DISASSEMBLY AND ASSEMBLY DIFFERENTIAL
ASSEMBLY OF DIFFERENTIAL
ASSEMBLY
1. Cage 37
Press fit bearing cups (39) and (38) to cage (37).
« After press fitting the cup, check that there is 38
no clearance at portion a.
« Coat the cup press-fitting portion with oil.
Cup press-fitting portion : Oil (axle oil) a
39
DLW00384
2. Pinion gear
1) Press fit bearing cone (36) to pinion gear (33),
and assemble spacer (35).
36
« Check that there is no clearance at the
mating surface of each part. 35
2) Assemble pinion gear (33) to cage (37), and
press fit bearing cone (34). 33
« Use a press to apply pressure at the speci-
fied load to the bearing, and rotate the case
to settle the bearing.
« Press load : 145 KN (14.8 ton)
Bearing : Oil (axle oil) DBW01992
« Reference
• Starting turning force : Max. 62 N (6.3
kg)
• End play : 0 – 0.187 mm
« When the case has been rotated at the A
specified load, check that it can be rotated 37
smoothly by hand.
« If the rotation is heavy, replace the bearing
and spacer, then check again.
3) Coat seal press-fitting portion of cage (37) with
gasket sealant, then press fit oil seal (32).
« Press fit so that the oil seal is level with the
surface of portion b.
Oil press-fitting portion : DBW01993
PCD
275mm
DBW01994
DLW00388
30-140
DISASSEMBLY AND ASSEMBLY DIFFERENTIAL
3. Coupling
Install coupling (30), O-ring (31), and holder (29) to 31 29
30
pinion gear (33), and tighten mounting bolts.
« Tighten the mounting bolts temporarily, and
tighten fully after assembling.
« When inserting the coupling, be extremely care-
ful not to damage the seal 33
Mounting bolt : Thread tightener (LT-2)
(When tightening fully)
Mounting bolt :
549 ± 59 Nm (56.0 ± 6.0 kgm)
DLW00389
14 27
14 DBW01995
c c
DLW00393 25
26 q q
25
d DLW00394
w
2) Set bevel gear (40) on block with gear side 40 DBW01996
at bottom, then install guide bolts (Thread
dia. = 14mm, Pitch = 2mm, Length =
55mm).
« Check that there is no clearance at mating 25
e
portion e of flange half (25) and bevel gear
(40).
« Wash and remove all oil and grease from
the threaded hole of the bevel gear.
« Tighten the mounting bolts on diametrically
opposite sides.
Mounting bolt :
Thread tightener (LT-2)
Mounting bolt : e e
176.5 ± 19.6 Nm (18.0 ± 2.0 kgm) 40 DBW01997
30-141
DISASSEMBLY AND ASSEMBLY DIFFERENTIAL
41
41
DBW01998
DLW00398
19
Thrust washer sliding surface :
Oil (axle oil) 21
18
18
15
DLW00373
DLW00399
30-142
DISASSEMBLY AND ASSEMBLY DIFFERENTIAL
DBW02001
t
Dimension b
(unit: mm)
B C1
Dimension a
A L
(unit: mm) C
« Always use the bevel pinion gear and bevel
gear in pairs with the same number. D
DBW02004
30-143
DISASSEMBLY AND ASSEMBLY DIFFERENTIAL
6. Bearing carrier
Press fit bearing cones (42) and (43) to bearing 42
carrier assemblies (12) and (12-1). 43
Bearing cup press-fitting portion :
Oil (axle oil)
« After press fitting the bear-
ing, check that there is no 42,43
clearance at portion f.
f 12
DBW02009 f
7. Adjusting shim of bearing carrier 12-1
DBW02005
1) Raise differential carrier assembly (11), then
set to mounting position on differential housing.
30-144
DISASSEMBLY AND ASSEMBLY DIFFERENTIAL
8. Cage
8
1) Fit O-ring (9) in groove of cage assembly (8).
O-ring : Oil (axle oil)
« Coat thinly with oil.
9
DBW02010
DBW02011 DBW02012
9. Adjusting backlash
1) Measure backlash of bevel gear with dial gauge.
« Backlash standard value: 0.30 – 0.46 mm
« Measure the backlash at three places
around the circumference of the bevel
gear, and check that the variation be-
tween each measurement is less than
0.1 mm.
DBW02013
DBW02014
30-145
DISASSEMBLY AND ASSEMBLY DIFFERENTIAL
« When adjusting the bevel gear, do not change the preload of the bearing. Adjust by moving shims between the left
and right. Always keep the same total thickness of shims.
30-146
DISASSEMBLY AND ASSEMBLY DIFFERENTIAL
DBW02017
C4 C3 C3
C2
C4
Pad
10
Adjustment
washer
C2
Differential housing
DBW02019
DBW02018
30-147
DISASSEMBLY AND ASSEMBLY DIFFERENTIAL
DBW02021
14. Coupling
Tighten mounting bolts of coupling (30) fully.
Mounting bolt : Thread tightener (LT-2) 13
Mounting bolt :
549 ± 59 Nm (56.0 ± 6.0 kgm)
30-148
DISASSEMBLY AND ASSEMBLY DIFFERENTIAL
DLW01588
DBW02023
30-149
DISASSEMBLY AND ASSEMBLY AXLE HOUSING
DISASSEMBLY OF AXLE
HOUSING ASSEMBLY
1. Draining oil
Remove drain plug (1) and drain oil.
Axle oil : 37 l
1 DBW01973
DBW02024
2. Differential cover 3
Using forcing screws, remove differential cover (3).
« Do not remove the differential cover unless nec-
essary.
« When removing the differential cover, be care-
ful not to damage the bleeder screw.
« When moving the differential assembly, remove
the 4 cover mounting bolts, and use eyebolts to
lift at 4 points and move.
3. Axle housing
1) Sling axle housing assembly (4), and remove
housing mounting bolts.
« Make match marks on the housings to pre-
vent mistakes between the left and right
axle housings.
« Set blocks to prevent the assembly from
tilting when the housing assembly on one
side is removed.
4
DLW02026
30-150
DISASSEMBLY AND ASSEMBLY AXLE HOUSING
4
DBW02027
4. Brake disc, plate
1) Remove lock bolts (7) of plate (6) and brake
disc (5).
7
7 6
5 6
DBW02028
DLW01598
10
DBW02030
DBW02031
30-151
DISASSEMBLY AND ASSEMBLY AXLE HOUSING
6. Brake housing
Remove mounting bolts (11), then remove brake
housing (12).
« Remove the O-ring.
11
O-ring
12
Detail P DBW02032
DLW01604
t 13
Brake housing : 25 kg
« Lifting tool
t 14
40mm
235mm
DBW02035
DLW01602
8. Ring gear q
Use puller and pull up uniformly to remove ring
gear (15) from axle housing (16).
w
« Assemble spacer to the end face of the puller
bolt to adjust the height. 15
« When pulling up with the puller, be extremely
careful that the teeth of the puller do not come 16
off the ring gear.
30-152
DISASSEMBLY AND ASSEMBLY AXLE HOUSING
9. Axle shaft
1) Stand housing and shaft assembly, then raise
housing (16).
2) Put a copper hammer in contact with end face
of axle shaft (17), then knock in shaft and ro-
tate housing (16) to remove shaft.
Copper hammer
16
DBW02036
16
Pad
(copper
hammer)
17
DLW01609 17
16
Axle shaft assembly : 90 kg
Axle housing : 85 kg
DBW02037
DBW02038
DBW02039
30-153
DISASSEMBLY AND ASSEMBLY AXLE HOUSING
d
D1
D3 D3
DLW01611
19
DBW02041
30-154
DISASSEMBLY AND ASSEMBLY AXLE HOUSING
16
22
DBW02043
16
24
DLW01614
DLW02300
DBW02299
30-155
DISASSEMBLY AND ASSEMBLY AXLE HOUSING
26
27
DBW02045
Planetary carrier : 30 kg
28
28
29 29
30
DBW02046
DLW01619
30-156
DISASSEMBLY AND ASSEMBLY AXLE HOUSING
DBW02047
16
DBW02051
23
Bearing cup press-fitting portion :
Oil (axle oil)
DBW02048
2. Axle shaft
1) Press fit axle shaft (17) and oil seal sleeve (19).
« Be careful not to deform the parts when
hitting with a hammer. c
« Coat the sleeve contact surface portion b of b
the oil seal thinly with axle oil.
Sleeve contact surface of shaft :
Oil (axle oil)
« After press fitting the oil seal sleeve, check
that surface c is level with the surrounding
surface.
DBW02049
DBW02301 DBW02050
30-157
DISASSEMBLY AND ASSEMBLY AXLE HOUSING
3. Housing, shaft
1) Stand shaft (17) upright and install tool D4.
« Adjust the height of the seal support with 17
the adjustment bolts, put the top surface of
tool D4 in light contact with seal (22), then
D4
set so that the clearance is uniform. D4
« Set tool D4 securely so that it does not
come off.
2) Assemble oil seal (22) to oil seal sleeve (19).
« When assembling the oil seal, be extremely
careful not to damage the lip surface. 22 19
Lip of oil seal : Grease (G2-LI) DBW02052
D4 22 19
17
Flange surface
DBW02053
16
DBW02055
30-158
DISASSEMBLY AND ASSEMBLY AXLE HOUSING
30
DBW02056
D4 17
DBW02059
30-159
DISASSEMBLY AND ASSEMBLY AXLE HOUSING
17
18
DLW01629
20 — 30mm
DLW01630
30-160
DISASSEMBLY AND ASSEMBLY AXLE HOUSING
DLW01631
5. Planetary carrier
1) Assemble spacer (32) inside planetary carrier
(25). 25
« Assemble the spacer from the brake hous-
ing side.
2) Assemble bearing cone (29) to gear (28), lift up
spacer (32), and set gear (28) in position.
32
29
32
28
DBW02060
28
29
29 DLW01636
32
3) Align shaft (27) and spring pin hole (33), and
press fit shaft.
Shaft : Oil (axle oil)
Make surface level
27 28
28 DBW02070
26
27
27
DLW01637
30-161
DISASSEMBLY AND ASSEMBLY AXLE HOUSING
29
27 28
DBW02072
6. Ring gear
Press fit ring gear (15) to axle housing (16), then 15
insert pin (34).
DBW02073
DBW02074
Mounting bolt :
Thread tightener (LT-2)
Mounting bolt : 14
927 ± 98 Nm (94.5 ± 10.0 kgm)
« Clean the end face of the shaft and the
planetary carrier spline before assembling.
When assembling the planetary carrier, be
extremely careful not to get your fingers
caught in the gear.
13
DBW02075
30-162
DISASSEMBLY AND ASSEMBLY AXLE HOUSING
8. Brake housing
1) Assemble O-ring (35) in groove of axle housing 35
(4).
« Coat the O-ring thinly with grease.
O-ring : Grease (G2-LI)
4
DBW02077
12
i
12 DBW02032
30-163
DISASSEMBLY AND ASSEMBLY AXLE HOUSING
10
DBW02080
DBW02082 9
8
DBW02030
DBW02029
30-164
DISASSEMBLY AND ASSEMBLY AXLE HOUSING
DBW02028
DBW02084
4
37 DLW01654
30-165
DISASSEMBLY AND ASSEMBLY AXLE HOUSING
DBW02025
Oil level
1 DBW01973
HIGH
LOW
38
DBW01656
30-166
DISASSEMBLY AND ASSEMBLY CENTER HINGE PIN
2
2. Remove cab and floor frame assembly.
For details, see REMOVAL OF CAB AND FLOOR
FRAME ASSEMBLY. ❈1
1 DBW01904
DBW02085
DBW02086
30-167
DISASSEMBLY AND ASSEMBLY CENTER HINGE PIN
DBW02087
8
DBW02088
12
DBW02090
30-168
DISASSEMBLY AND ASSEMBLY CENTER HINGE PIN
13
DBW02091 DLW02092
16
15
DBW02093
16
DLW02096
9) Jack up front differential, and pull out front frame Front frame
towards front.
« Be careful not to get the spacer at the bot- Rear frame
tom of the upper hinge caught in the rear
frame. After disconnecting, remove the
spacer.
« Be extremely careful to maintain the bal-
ance during the operation. A
A
A A
DBW02095
30-169
DISASSEMBLY AND ASSEMBLY CENTER HINGE PIN
20
DBW02095
19
DLW02101 22
23
21
24 23 DBW02099
DAW02102
3) Remove bearing (25).
25
DLW02100
30-170
DISASSEMBLY AND ASSEMBLY CENTER HINGE PIN
INSTALLATION OF CENTER
HINGE PIN
• Carry out installation in the reverse order to re-
moval.
❈1
Install cab and floor assembly.
For details, see INSTALLATION OF CAB, FLOOR
FRAME ASSEMBLY.
❈2
« Be careful not to forget to assemble the shim.
« Adjust the shims so that the clearance between
the cylinder and frame is 0 – 0.5 mm.
❈3
Connect the frame as follows.
1) Jack up front differential, then move front frame
towards rear frame end, and align pin holes.
« Be careful that the spacer at the bottom of
the upper hinge does not interfere with the
rear frame.
« Align the pin holes securely.
When aligning the position of the pin hole,
always use a bar. Never insert your fingers
in the pin hole. 16
2) Assemble spacer (16) to upper hinge.
DBW02103
« Assemble spacer (16) from the top so that
the large chamfered side is on the bearing
side.
« Be careful not to damage the dust seal lip. 14
Outside circumference of hinge : 16
Grease (G2-LI) 15
Inside circumference of spacer :
Grease (G2-LI)
3) Assemble upper hinge pin (14) from bottom.
4) Tighten retainer (15) to upper hinge pin with 3
mounting bolts (27), then select shims so that
clearance b between hinge and retainer is be-
low 0.2 mm, and assemble.
Pin mounting bolt :
DLW02104
19.6 ± 2 Nm (2.0 ± 0.2 kgm)
(When adjusting shims)
« Temporarily tighten mounting bolts (28),
leaving a clearance of approx. 5 mm from
the surface of retainer (15).
27
28
DBW02105
30-171
DISASSEMBLY AND ASSEMBLY CENTER HINGE PIN
13
DBW02107
❈4
1. Lower hinge bearing
17 18
1) Assemble snap ring (19) to front frame lower
hinge, then use tools E1 and E2 to press fit
bearing (20), and secure with snap ring (18).
« Press fit so that the bearing is level with the 20
surface of snap ring (19).
19
17 DLW02303
DLW02108
30-172
DISASSEMBLY AND ASSEMBLY CENTER HINGE PIN
❈5
2. Upper hinge bearing
1) Assemble tools E3, E4, E5, E7, E8, and E9 to
top of front frame upper hinge, set bearing (25) E9
in tool E6, then set to press-fitting portion from
above and press fit.
« When press fitting, use tool E8 as a guide.
« Be careful that the bearing is not at an an- E6
gle.
« Fill the inside of bearing (25) with an ample
amount of grease. E8
« When assembling the bearing, do not for- E7
DBW02109
get to assemble spacer (26).
« The clearance of bearing (25) is adjusted,
so do not change the combination with
spacer (26). E5
When replacing, always replace the parts
as a set. E4 22
2) Press fit dust seal (22) to retainer (21). E9
« Replace the dust seal with a new part, and
E6
press fit so that the lip surface is facing the
To E3
outside. E8
Lip of seal : Grease (G2-LI) 25 26 21
3) Tighten retainer (21) with 3 mounting bolts, and 25 Front
select shims so that maximum clearance a be- frame
tween retainer and hinge is below 0.1 mm, then E7 Block
DBW02110 DBW02111
assemble.
Clearance a
DLW02114
30-173
DISASSEMBLY AND ASSEMBLY STEERING GEAR
❈1
3. Column cover
1) Remove steering post cover (4).
2) Remove plug and pull up boot (5).
4 5
DBW02117 DLW02118
4. Steering gear ❈2
1) Remove lock bolt (6).
« Remove the lock bolt at column joint (6–1)
end.
« Make match marks on the joint and the
steering gear shaft.
6-1 6
DLW02119
30-174
30-175
DISASSEMBLY AND ASSEMBLY STEERING GEAR
INSTALLATION OF ORBIT-ROLL
ASSEMBLY
• Carry out installation in the reverse order to re-
moval.
Lock bolt :
55.9 ± 6.9 Nm (5.7 ± 0.7 kgm)
30-176
DISASSEMBLY AND ASSEMBLY STEERING VALVE
DISASSEMBLY OF STEERING
ASSEMBLY
« Use a wire brush to remove all the dirt and dust
stuck to the joint around the outside circumference
of the unit.
DISASSEMBLY OF ROTOR
30-177
DISASSEMBLY AND ASSEMBLY STEERING VALVE
8
7
9
DLW01703
10
10. Raise tip of snap ring (11) with screwdriver, and
DLW01704
DLW01705
13
12. Remove X-ring seal (13) from bushing (12).
13. Remove dust seal (14) from bushing (12) with screw-
driver. 12
« Be careful not to damage the bushing.
14
DLW01706
30-177-1
DISASSEMBLY AND ASSEMBLY STEERING VALVE
DLW01707
15. Pull out spool and sleeve assembly (17) from hous-
ing (10) in the direction of the arrow.
« To prevent the spool and sleeve assembly from 10
catching in the housing, rotate the spool and
sleeve assembly slowly to the left and right when
pulling out from the housing.
17
16. Pull out pin (18) from spool and sleeve assembly
(17). 18
DLW01708
20
18. Turn spool (20) slowly and pull out from rear of
sleeve (19) (in the direction of the arrow).
19 20
DLW01709
25
22. Remove O-rings (25) and (26) from check sheet
(24).
28
23 24 27
23. Tap housing, and remove ball (27) and retainer (28). 26
DLW01710
30-177-2
DISASSEMBLY AND ASSEMBLY STEERING VALVE
ASSEMBLY OF STEERING
VALVE
« Check all parts for damage or burrs.
« Wash all metal parts in clean solvent and blow dry
with air.
« Do not use a file or polish any part with rough
sandpaper.
« Coat the O-rings with clean grease. (No need to put
grease on new X-ring seals)
« Coat the O-ring for the rotor set with a small amount
of grease.
30-178
DISASSEMBLY AND ASSEMBLY STEERING VALVE
19
DLW01713
17
18
DLW01714
16 15
10. Fit 2 bearing races (15) and thrust needle (16) in 15
case (10).
22
10
DLW01716
30-179
DISASSEMBLY AND ASSEMBLY STEERING VALVE
12 14
13. Insert bushing (12) in spool, and rotate to install.
• Tap with a plastic hammer to assemble to the
specified position. 10
• It must be in contact horizontally with the bear-
ing race.
DLW01717
14. Fit snap ring (11) in housing.
Screw-
14 driver
11
12
13
22
DLW01718
ASSEMBLY OF ROTOR
DLW01719
8
17. Put on spacer plate (8), and align positions of bolt
hole and tap hole of housing.
DLW01720
30-180
DISASSEMBLY AND ASSEMBLY STEERING VALVE
18
DLW01721
5
DLW01722
DLW01724
30-180-1
DISASSEMBLY AND ASSEMBLY STEERING VALVE
DLW01725
30-180-2
DISASSEMBLY AND ASSEMBLY STEERING VALVE
REMOVAL OF STEERING
VALVE ASSEMBLY
1. Covers
Remove covers (3) under cab.
2. Steering pipes
Remove the orbit-roll servo pipes (4).
.
30-181
DISASSEMBLY AND ASSEMBLY STEERING VALVE
3. Hydraulic piping ❈2
Disconnect following hydraulic piping from steering
valve.
• Tube (8) between switch pump and steering
valve
• Tube (9) between steering pump and steering
valve
• Tube (10) between steering valve and main con-
trol valve
• Tubes (11) and (12) between steering valve
and steering cylinder
• Tube (13) between steering valve and hydraulic
tank
4. Steering valve ❈2
Sling steering valve (6), and remove mounting bolts
(14), then lift off steering valve.
Steering valve : 24 kg
« Carry out the removal operation with two work-
ers.
The steering valve is oily, so be careful not to
let it slip.
30-182
DISASSEMBLY AND ASSEMBLY STEERING VALVE
INSTALLATION OF STEERING
VALVE ASSEMBLY
30-183
DISASSEMBLY AND ASSEMBLY STEERING VALVE
DISASSEMBLY OF STEERING
VALVE ASSEMBLY
1. Relief valves 33
1) Remove overload relief valve (33) from valve
housing (1).
2) Remove main relief valve (33) from plug (4) in
same way.
« Remove the O-ring at the mount, but do not
disassemble the relief valve any further. 4
1 32
DEW01028 DEW01029
2. Flow control
1) Remove plug (4).
2) Remove spring (9).
9
4
DEW01030 DEW01031
DEW01032
30-184
DISASSEMBLY AND ASSEMBLY STEERING VALVE
30-185
30-186
DISASSEMBLY AND ASSEMBLY STEERING VALVE
ASSEMBLY OF STEERING
VALVE ASSEMBLY
1. Spool assembly
1) Install poppet (10) and spring (11) to head end
of steering spool (3).
30-187
DISASSEMBLY AND ASSEMBLY STEERING VALVE
3. Flow control
1) Fit O-ring to plug (5) and install to valve hous-
ing.
Plug: 142 ± 2.5 Nm (14.05 ± 0.25
kgm)
4. Relief valve
1) Install overload relif valve (33)
Valve: 73.6 ± 4.9 Nm (7.5 ± 0.5kgm)
30-188
30-189
DISASSEMBLY AND ASSEMBLY STEERING CYLINDER
REMOVAL OF STEERING
CYLINDER ASSEMBLY
Stop the machine on level ground and install the
safety bar on the frame. Lower the bucket to the
ground and stop the engine. Then apply the parking
brake and put blocks under the wheels to prevent
the machine from moving.
1. Hydraulic piping
Disconnect steering cylinder rod and bottom hoses
(1) and (2) at cylinder end.
« After removing the hoses, fit plugs to prevent
the entry of dirt or dust.
2
DEW01081
2. Steering cylinder ❈1
1) Remove rod bolt, then remove pin (3).
3
DEW00965
Steering cylinder: 25 kg
DEW01083
30-190
DISASSEMBLY AND ASSEMBLY STEERING CYLINDER
INSTALLATION OF STEERING
CYLINDER ASSEMBLY
❈1 a
30-191
DISASSEMBLY AND ASSEMBLY BRAKE VALVE
1. Covers 6
Remove covers (1) under cab.
30-192
DISASSEMBLY AND ASSEMBLY BRAKE VALVE
5. Pedal
Pull out cotter pin (16) of pin (15) of brake pedal 18 19
(14), then pull out pin, and remove pedal.
« Carry out the same procedure for both the left
and right brake pedals.
6. Brake valve ❈5 14
1) Remove brake valve mounting bolts (17), and
disconnect mount flange (18) and body (19),
then pull out cap (20). 15
2) Remove mount flange mounting bolts (21), then
remove mount flange from floor portion. 20 17
16
DEW01088 DEW01089
INSTALLATION OF BRAKE
VALVE ASSEMBLY
• Carry out installation in the reverse order to re-
moval.
❈1 ❈2 ❈3 ❈4
« Replace the O-ring with a new part.
❈5
Mounting bolt :
66.2 ± 7.4 Nm (6.75 ± 0.75 kgm)
Mounting bolt :
66.2 ± 7.4 Nm (6.75 ± 0.75 kgm)
« After completion of assembly, bleed the air.
For details, see TESTING AND ADJUSTING,
Bleeding air from brake system.
30-193
DISASSEMBLY AND ASSEMBLY RIGHT BRAKE VALVE
DISASSEMBLY OF RIGHT
BRAKE VALVE ASSEMBLY
(TANDEM) 1 104 4-11ø
52
2
25.75
1. Bracket assembly
1) Remove seat (1), pedal stopper (2), and boot 3
104
(3) from brake valve. 5
51.5
52
2) Remove mounting bolts (5) of bracket assem- 4
bly (4), then remove bracket assembly. 51ø
3) Remove oil seal (6) from upper portion of brake 25.75
51.5
10
valve. 6
6 6
2. Valve DEW01090 Jig q DEW01091
1) Install valve to jig 1 with bolts (5), and secure jig
in vice.
« Make match marks before disassembling
the valve. Match marks 7
2) Remove valve mounting bolts (10), then remove
S cylinder assembly (7). 8
3) Remove plug (13) of S cylinder assembly, then
remove spring (14) and O-ring.
4) Remove spring (11) and O-ring (12), then re- Jig
move P cylinder assembly (8).
« Remove spring (15) inside the plunger of 9
the P cylinder assembly. Vice
5) Remove holder (16), springs (17), (18), and (19)
and O-ring (20) from T flange assembly (9). DEW01092
« The cylinders, plungers, and spools inside
the T flange assembly and the S and P
cylinders form sets, so be careful not to mix
14 13
the parts for any set.
« Fit seals to prevent dirt or dust from enter-
ing, and be careful not to damage the cylin- 7
13
ders or flange assembly. 10
10 11
7 12
8
8 15
DEW01093 DDW01094
16
17 20
17
18
9
20 19
DEW01095 DDW01096
30-194
DISASSEMBLY AND ASSEMBLY RIGHT BRAKE VALVE
bly (9).
« When setting in position, align the match
marks. 13
14
4) Install spring (11) and spring (15) inside plunger
of P cylinder assembly to P cylinder assembly 7
(8). 13
5) Install O-ring (12) to P cylinder assembly (8). 10
« Use a new part for the O-ring. 10 11
O-ring: Lithium grease 7 12
6) Set S cylinder assembly (7) to P cylinder as- 8
sembly (8), and tighten with mounting bolts (10).
8 15
« When setting the S cylinder assembly in
position, align the match marks.
Mounting bolt: DEW01093 DDW01094
2. Bracket assembly
Remove valve from jig .
1) Set T flange assembly facing up, and install oil
seal (6).
« Use a new part for the oil seal.
Lip of oil seal: Lithium grease
2) Install bracket assembly (4), and tighten with
mounting bolts (5).
Mounting bolt:
58.8 – 73.6 Nm (6.0 – 7.5 kgm)
3) Install seat (1), pedal stopper (2), and boot (3)
to valve.
30-195
DISASSEMBLY AND ASSEMBLY LEFT BRAKE VALVE
25.75
1) Remove seat (1), pedal stopper (2), and boot
(3) from brake valve. 3
104
5
51.5
52
2) Remove mounting bolts (5) of bracket assem- 4
bly (4), then remove bracket assembly. 51ø
25.75
51.5
10
3) Remove oil seal (6) from upper portion of brake 6
valve.
6 6
DEW01090 Jig q DEW01091
2. Valve
1) Install valve to jig with bolts (5), and secure 7
jig in vice. Match mark
« Make match marks before disassembling
the valve. 8
Jig
Vice
DEW01103
DEW01104 DDW01105
30-196
DISASSEMBLY AND ASSEMBLY LEFT BRAKE VALVE
DEW01104 DDW01105
30-197
DISASSEMBLY AND ASSEMBLY PARKING BRAKE DISC
Transmission oil : 40 l 1
DBW01729
2. Drive shaft
Remove protector (2-1) of drive shaft, and discon-
nect center drive shaft (2) at transmission end.
❈1
« After disconnecting the drive shaft, move it to
the right end.
2-1
2
DBW02132
5
4 DBW01731
8
DBW01732
30-198
DISASSEMBLY AND ASSEMBLY PARKING BRAKE DISC
11
DBW01733
12
A4
DBW01734
A4
DBW01735
15
14
13
DBW01736
30-199
DISASSEMBLY AND ASSEMBLY PARKING BRAKE DISC
INSTALLATION OF PARKING
BRAKE DISC
❈1
« Be careful to connect the coupling facing in the
correct direction.
Mounting bolt :
110.3 ± 12.3 Nm (11.25 ± 1.25 kgm)
❈2
« Be careful to assemble the coupling facing in
the correct direction.
« Fit the O-ring securely in the groove.
Mounting bolt :
549 ± 59 Nm (56.0 ± 6.0 kgm)
❈3
« Be careful not to damage or get dirt on the oil
seal lip surface.
Mounting bolt :
110.3 ± 12.3 Nm (11.25 ± 1.25 kgm)
Lip of oil seal : Grease (G2-LI)
❈4
« Assemble the ring securely in the ring groove of
the housing.
Transmission oil : 40 l
30-200
DISASSEMBLY AND ASSEMBLY HYDRAULIC TANK
REMOVAL OF HYDRAULIC
TANK ASSEMBLY
1. Cover
Remove covers (1) on right side of floor.
1
DBW02133
2. Ladder
Sling ladder (2), then remove mounting bolts, and
lift off.
« Use the lifting tool to lift at two places.
DBW02134
3. Hydraulic piping ❈1
1) Loosen plugs (3) at top of hydraulic tank filter
and plugs (4) of pump piping to prevent oil in-
side tank from flowing out.
3
DLW02135
30-201
DISASSEMBLY AND ASSEMBLY HYDRAULIC TANK
4. Hydraulic tank
1) Sling hydraulic tank (12), and remove front, rear,
and bottom mounting bolts (13).
12
13
DBW02137
Hydraulic tank :
365 kg (including oil 190 l)
12
DBW02138
30-202
DISASSEMBLY AND ASSEMBLY HYDRAULIC TANK
INSTALLATION OF HYDRAULIC
TANK ASSEMBLY
DBW02139
30-203
DISASSEMBLY AND ASSEMBLY HYDRAULIC FILTER
REMOVAL OF HYDRAULIC
FILTER ASSEMBLY
1
Loosen the oil filler cap slowly to release the pres-
sure inside the hydraulic tank.
1. Cover
Remove mounting bolts, then remove covers (1)
and (1-1). ❈1
The tension of the spring is applied to cover (1-
1), so be careful when removing.
« Be careful not to damage the O-ring at the mat-
ing surface of cover (1-1) and the tank.
DBW02140
2. Filter
Remove spring (2) and bypass valve (3), then re-
move filter (4). 1-1
DBW02141
INSTALLATION OF HYDRAULIC
FILTER ASSEMBLY
2
• Carry out installation in the reverse order to re-
moval.
❈1
« Replace the O-ring with a new part.
« Fit the O-ring securely in the groove and be
careful not to get it caught when assembling.
DBW02142
3 4
DBW02143
30-204
DISASSEMBLY AND ASSEMBLY HYDRAULIC, STEERING, SWITCH, PPC PUMP
REMOVAL OF HYDRAULIC,
STEERING, SWITCH, PPC
PUMP ASSEMBLY
Stop the machine on level ground and install the
safety bar on the frame. Lower the bucket to the
ground and stop the engine. Then apply the parking
brake and put blocks under the wheels to prevent
the machine from moving.
1. Cover
Remove covers (1) on right side of floor.
1
DBW02133
2. Ladder
Sling ladder (2), then remove mounting bolts, and
lift off.
« Use the lifting tool to lift at two places.
DBW02134
3
DLW02135
30-205
DISASSEMBLY AND ASSEMBLY HYDRAULIC, STEERING, SWITCH, PPC PUMP
4. Floor support ❈2
1) Remove inspection covers (5) and (6) on right 5
side.
6
DBW02144 DBW02145
Support : 19 kg
q
DBW02146
5. Hydraulic piping
1) Remove clamps of air conditioner hose (8) and
hydraulic hose (9), then move to rear.
9
8
DBW02147
10 12 13
11
DBW02148
30-206
DISASSEMBLY AND ASSEMBLY HYDRAULIC, STEERING, SWITCH, PPC PUMP
16
q
DBW02149
6. Hydraulic pump
Remove mounting bolts, and take care to maintain
balance when lifting off hydraulic pump (10).
❈4
« The working space is confined, so be extremely
careful when carrying out this operation.
« Carry out the removal operation with two work-
ers.
Hydraulic pump : 46 kg
10
q
DBW02150
30-207
DISASSEMBLY AND ASSEMBLY HYDRAULIC, STEERING, SWITCH, PPC PUMP
INSTALLATION OF HYDRAULIC,
STEERING, SWITCH, PPC
PUMP ASSEMBLY
• Carry out installation in the reverse order to re-
moval.
❈1
« Wash and remove all oil and grease from the
plug thread and piping thread.
Thread of plug : Gasket sealant (LG-4)
❈2
« Tighten the floor support mounting bolts fully
after installing the floor.
Mounting bolt :
277 ± 31.9 Nm (28.25 ± 3.25 kgm)
❈3
« Fit the O-ring securely in the groove and be
careful not to get it caught when assembling.
« Install the hoses without twisting or interference.
❈4
« Fit the O-ring securely in the groove and be
careful not to get it caught when assembling.
30-208
DISASSEMBLY AND ASSEMBLY MAIN CONTROL VALVE
q
DBW02151
3 4
DBW02152
1. PPC hoses ❈1
Disconnect following hoses from main control valve.
• Hose (5) for bucket spool between PPC valve
(P4) and main control valve (J)
• Hose (6) for boom spool between PPC valve
(P2) and main control valve (K)
• Hose (7) for bucket spool between PPC valve
(P1) and main control valve (H)
• Hose (8) for boom spool between PPC valve
(P3) and main control valve (I)
« After disconnecting the hoses, move them to-
wards the rear of the machine.
« After disconnecting the hoses, mark them with 5 6 DBW02153
2. Hydraulic hoses ❈2
Disconnect following hydraulic piping. 9
« After removing each hose and tube, move them
to the side.
• Hose (9) between steering valve and main con- 8 7
trol valve
DBW02154
30-209
DISASSEMBLY AND ASSEMBLY MAIN CONTROL VALVE
10
DBW02155
DBW02156
16
DBW02157
30-210
DISASSEMBLY AND ASSEMBLY MAIN CONTROL VALVE
INSTALLATION OF MAIN
CONTROL VALVE ASSEMBLY
• Carry out installation in the reverse order to re-
moval.
❈1
« Check the tags on the hoses, then connect the
hoses.
« Install the hoses without twisting or interference.
❈2
« Fit the O-ring securely in the groove and be
careful not to get it caught when assembling.
« Install the hoses without twisting or interference.
❈3
« Tighten the mounting bolts on diametrically op-
posite sides, and be careful not to deform the
valve when tightening.
« Be careful of the angle of the tube when tight-
ening the clamp.
« Be careful that the tube does not interfere with
any other part.
30-211
DISASSEMBLY AND ASSEMBLY MAIN CONTROL VALVE
DISASSEMBLY OF MAIN
CONTROL VALVE ASSEMBLY
14
15
16
27 17
18 13
44
28
29
25
30
31
26
a
2
32
1
b
41
45 25
42
24 40
39
38
43 37
36
35
34
33
a
19
12
11
10
9 b
8
7
6
5
4
23
22
21
3 20
DDW01547
30-212
DISASSEMBLY AND ASSEMBLY MAIN CONTROL VALVE
30-213
DISASSEMBLY AND ASSEMBLY MAIN CONTROL VALVE
14
15
16
27 17
18 13
44
28
29
25
30
31
26
a
2
32
1
b
41
45 25
42
24 40
39
38
43 37
36
35
34
33
a
19
12
11
10
9 b
8
7
6
5
4
23
22
21
3 20
DDW01547
30-214
DISASSEMBLY AND ASSEMBLY MAIN CONTROL VALVE
30-215
DISASSEMBLY AND ASSEMBLY MAIN CONTROL VALVE
DEW01551
30-216
DISASSEMBLY AND ASSEMBLY PPC VALVE
1. Cover
1) Remove floor inspection cover (4).
2
3 DBW02158
2. Hydraulic piping 7
6
Disconnect following hydraulic piping from PPC
valve.
• Hose (6) between PPC valve and PPC valve
• Hose (7) between PPC valve and hydraulic tank
• Hoses P2 (8) and P3 (9) for boom spool
• Hoses P4 (10) and P1 (11) for bucket spool
9
8
Front of
machine
11 10
DBW02160
30-217
DISASSEMBLY AND ASSEMBLY PPC VALVE
3. Linkage ❈1
1) Remove console box side face cover (11).
11
DBW02161
12
13
DBW02164
14
DBW02162
4. PPC valve
Remove mounting bolts, then remove PPC valve
(14) from under floor.
« The working space is confined, so be extremely
careful when carrying out this operation.
14
DBW02163
30-218
DISASSEMBLY AND ASSEMBLY PPC VALVE
30-219
DISASSEMBLY AND ASSEMBLY PPC VALVE
8 8
9 9
10 10
6 11 6
11
12 12
13
13
DEW01222
30-220
DISASSEMBLY AND ASSEMBLY PPC VALVE
P3 Boom LOWER 2
14
P4 Bucket DUMP 3
5
« The position of each port is stamped on the
valve body. 9
10
2. Assemble shim (11), spring (10), and retainer (9) to
valve (12), and install collar (8). 13
12 12
13
13
DEW01222
30-221
DISASSEMBLY AND ASSEMBLY BUCKET CYLINDER
REMOVAL OF BUCKET
CYLINDER ASSEMBLY
Stop the machine on level ground and install the
safety bar on the frame. Lower the bucket to the
ground and stop the engine. Then apply the park- 1
ing brake and put blocks under the wheels to pre-
vent the machine from moving.
1. Bucket positioner ❈1
1) Disconnect connector (1).
2) Remove wiring clamp (1-1) for bucket positioner.
1-1
DBW02166
2. Rod pin ❈2
Sling cylinder, and remove lock bolt, then remove 2
pin (2).
« Be careful of the center of gravity when sling-
ing, and lift at two places.
« Check the number and thickness of the shims,
and keep in a safe place.
DBW02167
3. Hydraulic piping ❈3
1) Disconnect hose (3) at rod end from cylinder.
3
DBW02168
30-222
DISASSEMBLY AND ASSEMBLY BUCKET CYLINDER
4
5
DBW02169
4. Bucket cylinder ❈4
1) Remove lock bolt, then remove bottom pin (6). 6 7
« If there are shims, check the number and
thickness of the shims, and keep in a safe
place.
2) Lift off bucket cylinder (7).
« Be careful not to damage the cylinder rod
portion.
DBW02170
30-223
DISASSEMBLY AND ASSEMBLY BUCKET CYLINDER
INSTALLATION OF BUCKET
CYLINDER
• Carry out installation in the reverse order to re-
moval.
❈1
« Adjust the bucket positioner.
For details, see TESTING AND ADJUSTING.
❈2
« Clearance a : Max. 1.5 mm
DBW02171
❈3
« Fit the O-ring securely in the groove.
« Install the hoses without twisting or interference.
❈4
b b
« Clearance b : Max. 1.5 mm
DBW02172
30-224
DISASSEMBLY AND ASSEMBLY BOOM CYLINDER
1. Rod pin ❈1
1) Sling boom cylinder (1), and remove lock bolt,
then remove pin (2).
6
« If there are shims, check the number and
thickness of the shims, and keep in a safe
place. 4
2) Start engine, and operate control lever to re- 5
tract cylinder rod of cylinder which has been
removed.
3
2. Hydraulic piping ❈2
1) Disconnect tube (3) and hose (4) at rod end DBW02174
from disconnection.
2) Disconnect tube (5) and hose (6) at bottom end
from connection.
DBW02175
3. Boom cylinder ❈3
1) Remove lock bolt, then remove bottom pin (7).
« If there are shims, check the number and
thickness of the shims, and keep in a safe 1
place.
2) Remove boom cylinder (1).
« Be careful of the center of gravity, and re-
move slowly.
« Be careful not to damage the cylinder rod
portion.
30-225
DISASSEMBLY AND ASSEMBLY BOOM CYLINDER
INSTALLATION OF BOOM
CYLINDER ASSEMBLY
a a
• Carry out installation in the reverse order to re-
moval.
When aligning the position of the pin hole, use a
bar. Never insert your fingers in the pin hole.
❈1
« Clearance (a) : Max. 1.5 mm
DBW02177
❈2
« Fit the O-ring securely in the groove.
« Install the hoses without twisting or interference.
❈3
« Clearance (e) : Max. 2.0 mm
« Remove the support.
« Coat each pin with grease.
e
DBW02178
30-226
DISASSEMBLY AND ASSEMBLY HYDRAULIC CYLINDER
DISASSEMBLY OF HYDRAULIC
CYLINDER ASSEMBLY
(STEERING, BOOM, BUCKET CYLINDER AS- Steering cylinder
SEMBLY) G 2 1
DBW01794
DEW01246
Bucket cylinder 27
DBW01795
DEW01248
30-227
DISASSEMBLY AND ASSEMBLY BOOM CYLINDER
3. Cylinder head
• Steering cylinder assembly H 9 3 2
1) Set cylinder head and piston rod assembly (3)
to tool F.
2) Using tool H, remove nut (8).
« Width across flats of nut: 46 mm F
3) Remove piston (9), then remove cylinder head 8
(2).
DBW01796
11 F
DBW01797
DEW01251
16
15
DEW01252
30-228
DISASSEMBLY AND ASSEMBLY BOOM CYLINDER
21 19
DEW01253
26
24
DEW01254
30-229
DISASSEMBLY AND ASSEMBLY HYDRAULIC CYLINDER
ASSEMBLY OF HYDRAULIC
CYLINDER ASSEMBLY
(STEERING, BOOM, BUCKET CYLINDER AS-
SEMBLY)
I
22
24
26 DBW01799
DEW01257
I
4) Install O-ring and backup ring (26).
« Do not try to force the backup ring into
position. Warm it in warm water (50 – 60°C)
before fitting it.
20
• Steering assembly
1) Using tool I, press fit bushing (20) to cylinder
head (2).
2
DBW01800
18
19
DBW01801
30-230
DISASSEMBLY AND ASSEMBLY HYDRAULIC CYLINDER
21
DEW01260
DBW01802 DBW01803
15
DEW01252 DEW01251
30-231
DISASSEMBLY AND ASSEMBLY HYDRAULIC CYLINDER
5. Cylinder head
• Boom, bucket cylinder 7 2 6
1) Set cylinder (7) to tool F.
2) Raise cylinder head and piston rod assembly
(6) and assemble to cylinder (7). F
3) Install cylinder head (2) to cylinder (7).
Mounting bolt:
Cylinder Nm(kgm)
Boom cylinder 1,324 ± 147 (135 ± 15)
Bucket cylinder 343 ± 34 (35 ± 3.5)
Steering cylinder
G 2 1
DBW01794
30-232
DISASSEMBLY AND ASSEMBLY WORK EQUIPMENT
REMOVAL OF WORK
EQUIPMENT ASSEMBLY
Stop the machine on level ground and install the
Wire
safety bar on the frame. Lower the bucket to the
ground and stop the engine. Then apply the park-
ing brake and put blocks under the wheels to pre-
vent the machine from moving.
1. Bucket link
1) Remove bucket link mounting pin (1). ❈1
« Secure the bucket link to the bellcrank with
wire. 1 2
DBW02179 DBW02180
3) Bucket
Move machine towards rear, then disconnect
bucket (2-1).
2-1
DBW02181
q
DBW02182 DBW02183
w DBW02184
30-233
DISASSEMBLY AND ASSEMBLY WORK EQUIPMENT
DBW02185
10
11
12
DBW02186 DBW02187
Bellcrank : 310 kg
14
15
15
15
16
14
DLW02190 14
DBW02188 DBW02189
30-234
DISASSEMBLY AND ASSEMBLY WORK EQUIPMENT
17
DBW02191
18
17
18 P
P
DBW02192
19 12
DBW02193
12
19
20
DLW02194
30-235
DISASSEMBLY AND ASSEMBLY WORK EQUIPMENT
INSTALLATION OF WORK
EQUIPMENT ASSEMBLY
• Carry out installation in the reverse order to re-
moval.
When aligning the position of the pin hole, use a
bar. Never insert your fingers in the pin hole.
❈1
« Operate the control levers, align the mounting
pin holes for the bucket and bucket link, install
cord ring (21), insert shims so that clearances a
21
and b on the left and right are uniform, then
assemble the mounting pin and lock with the
bolt. DBW02195
a a b b
DBW02196 DBW02197
❈3
« After assembling the mounting pin, remove block
. c c
« Clearance c : Max. 1.5 mm
DBW02306
❈4
« Clearance d : Max. 2.0 mm
DBW02264
30-236
DISASSEMBLY AND ASSEMBLY WORK EQUIPMENT
❈5
« After installing the boom, install boom kickout
switch.
« Clearance e : Max. 1.5 mm
« After assembling the pin, set the support to the
tip of the boom.
e e
DBW02198
❈6
« Press fit bushing (16) to each of bucket link,
bellcrank, and boom with press, then assemble
dust seal (15).
Bushing : Grease (G2-LI)
16
16 15
DBW02199
DLW02201
« Greasing
Coat each pin with grease.
DBW02200
30-237
DISASSEMBLY AND ASSEMBLY COUNTERWEIGHT
REMOVAL OF
COUNTERWEIGHT
1
Stop the machine on level ground and install the 2
safety bar on the frame. Lower the bucket to the
ground and stop the engine. Then apply the parking
brake and put blocks under the wheels to prevent
the machine from moving.
DBW02202
1. Grill
1) Sling grill (1), and remove from engine hood 1
(2), then make a clearance.
2) Disconnect wiring connector (3), then lift off grill
(1).
2. Counterweight ❈1
Sling counterweight (5), then remove mounting bolts
and lift off. 3
« Be careful to maintain the balance when lifting
off.
DBW02203
Counterweight: 1,170 kg
INSTALLATION OF 4
COUNTERWEIGHT
• Carry out installation in the reverse order to re-
moval.
❈1
DBW02204
Mounting bolt :
927 ± 103 Nm (94.5 ± 10.5 kgm)
(Width across flats: 36 mm)
DBW02205
30-238
DISASSEMBLY AND ASSEMBLY FUEL TANK
1. Grill
1) Loosen mounting bolts of grill (1), then fit grill to 2
engine hood (2) temporarily, and remove light
wiring from engine hood (3-1) clip portion. DBW02206
3-1
DBW02207
2. Draining fuel
Loosen drain valve (4) and drain fuel.
DBW02208
3. Drain valve
Remove engine oil drain valve (5) from fuel tank.
« Remove the drain valve, then tie with wire and
move to the side.
DBW02209
30-239
DISASSEMBLY AND ASSEMBLY FUEL TANK
DBW02210
5. Fuel tank ❈1
1) Sling fuel tank (10), then remove mounting bolts
and lift off. DBW02211
« Use two nylon ropes of a length of approx.
5 m to sling the tank.
« Set a pallet under the tank, then slowly lower
the fuel tank on to the pallet, taking care to
maintain the balance.
11
11
10
DBW02214 DBW02213
30-240
DISASSEMBLY AND ASSEMBLY FUEL TANK
❈2
« Pull the breather tube under the chassis before
connecting.
DBW02215
DBW02216
30-241
DISASSEMBLY AND ASSEMBLY CAB, FLOOR FRAME
Ladder : 60 kg
1
DBW02217
DBW02218
5
DBW02219
11 9
DBW02220
30-242
DISASSEMBLY AND ASSEMBLY CAB, FLOOR FRAME
14
13 DBW02221
16
DBW02222
17
DBW02223
30-243
DISASSEMBLY AND ASSEMBLY CAB, FLOOR FRAME
10. Sling cab and floor frame assembly (22), then re-
move mount bolts, and lift off cab and floor frame 22
assembly (22). ❈3
DBW02226
❈3
23 DBW02227
30-244
DISASSEMBLY AND ASSEMBLY CAB
1. Cover
1) Remove covers (1), (2), and (3) from under
floor. 1
2
3
DBW01832
6 DBW01833
2. Electric wiring
1) Disconnect cab wiring connectors (7). ❈1
« Fit tags to distinguish the connectors.
(Connectors CL1, CL2, CL3)
8
3. Hoses
1) Disconnect 2 window washer hoses (8).
« Make marks to distinguish the hoses.
« Drain the washer fluid. 7
DBW01834
4. Cab
1) Remove steering post and cab mounting bolts
(9).
« Pull the steering post to tip it down.
9
DBW01835
30-245
DISASSEMBLY AND ASSEMBLY CAB
10
11
DBW01836 DBW01837
Cab : 295 kg
13
DBW01838 DBW01839
14
DBW01840
INSTALLATION OF CAB
ASSEMBLY
• Carry out installation in the reverse order to re-
moval.
❈1
« Connect the wiring connectors securely.
30-246
DISASSEMBLY AND ASSEMBLY MAIN MONITOR
7
DLW01841
DEW01306
10
DEW01307
30-247
DISASSEMBLY AND ASSEMBLY MAIN MONITOR
12
DEW01308
16
DEW01309
INSTALLATION OF MAIN
MONITOR ASSEMBLY 15 14 13
11
❈1
« Fit the connector lock securely.
16
DEW01310
30-248
DISASSEMBLY AND ASSEMBLY MAINTENANCE MONITOR
REMOVAL OF MAINTENANCE
MONITOR ASSEMBLY
Stop the machine on level ground and install the
safety bar on the frame. Lower the bucket to the
ground and stop the engine. Then apply the parking
brake and put blocks under the wheels to prevent
the machine from moving.
1
Disconnect the cable from the negative – terminal
of the battery.
1. Cover
2
1) Remove cover (1) from cab. DBW01842
DBW01843
2. Maintenance monitor
1) Remove mounting bolts, then remove mainte-
nance monitor (6).
« Move the maintenance monitor to the side.
6
DBW01844
INSTALLATION OF 7
MAINTENANCE MONITOR
ASSEMBLY
• Carry out installation in the reverse order to re-
moval.
❈1
6
« Connect the connectors securely.
DBW01845
30-249
DISASSEMBLY AND ASSEMBLY AIR CONDITIONER UNIT
REMOVAL OF AIR
CONDITIONER UNIT ASSEMBLY
Stop the machine on level ground and install the
safety bar on the frame. Lower the bucket to the
ground and stop the engine. Then apply the parking 1
brake and put blocks under the wheels to prevent
the machine from moving.
DEW01316
5
DEW01318 DEW01317
30-250
DISASSEMBLY AND ASSEMBLY AIR CONDITIONER UNIT
6 DEW01319
DEW01320
DEW01321
16 17 DEW01322
30-251
DISASSEMBLY AND ASSEMBLY AIR CONDITIONER UNIT
19
DEW01323
21
22
20
DEW01324 DEW01325
23
DEW01326
25
23
26 DEW01327
30-252
DISASSEMBLY AND ASSEMBLY AIR CONDITIONER UNIT
DBW01848
DEW01329
DEW01330 DEW01331
33
23
DEW01332
30-253
DISASSEMBLY AND ASSEMBLY AIR CONDITIONER UNIT
34
16
DEW01333
18. Disconnect heater hoses (35) and (36) from air con-
ditioner unit, then remove air conditioner unit (23).
❈2
36
23
35 DEW01334
37
DEW01335
DEW01336
30-254
DISASSEMBLY AND ASSEMBLY AIR CONDITIONER UNIT
INSTALLATION OF AIR
CONDITIONER UNIT ASSEMBLY
• Carry out installation in the reverse order to re-
moval.
❈1
Tube mounting bolt:
9.8 ± 2 Nm (1.0 ± 0.2 kgm)
« Coat the O-ring with compressor oil ND-OIL8.
❈2
« Pass the air conditioner drain hose through the
floor support grommet.
30-255
DISASSEMBLY AND ASSEMBLY AIR CONDITIONER CONDENSER
REMOVAL OF AIR
CONDITIONER CONDENSER
ASSEMBLY
Stop the machine on level ground and install the
safety bar on the frame. Lower the bucket to the
ground and stop the engine. Then apply the parking
brake and put blocks under the wheels to prevent
the machine from moving.
DBW02232
9
8
DBW02235
6 10 DBW02236 DBW02234
30-256
DISASSEMBLY AND ASSEMBLY AIR CONDITIONER CONDENSER
INSTALLATION OF AIR
CONDITIONER CONDENSER
ASSEMBLY
• Carry out installation in the reverse order to re-
moval.
❈1 ❈2
« Do not remove the covers from the hoses until
immediately before installing.
« To prevent the hoses from twisting, use two 13
12
wrenches to hold the hoses securely in position 15
when tightening. 14 DBW02238
Hose joint, thread : Compressor oil
« The tightening torques for the air conditioner
piping are as follows.
a Compressor
Thread size Tightening torque
Nm (kgm) d d b b b
Air conditioner a e
a M16 x 1.5 11.8 – 14.7 (1.2 – 1.5) unit
30-257
DISASSEMBLY AND ASSEMBLY DRY RECEIVER
INSTALLATION OF DRY
RECEIVER ASSEMBLY
• Carry out installation in the reverse order to re- 3
4
moval. DBW02240
❈1
Hose mounting bolt :
5.4 ± 1.5 Nm (0.55 ± 0.15 kgm)
« To prevent dirt, dust, or water from entering, do
not remove the covers from the air conditioner
hoses until immediately before installing.
Hose joint : Compressor oil
❈2
U-bolt : 18.6 ± 7.8 Nm (1.9 ± 0.8 kgm)
« Be careful not to tighten the U-bolts too far.
30-258
DISASSEMBLY AND ASSEMBLY AIR CONDITIONER CONDENSER COMPRESSOR
REMOVAL OF AIR
CONDITIONER CONDENSER
COMPRESSOR ASSEMBLY
Open the hood and apply the lock.
INSTALLATION OF AIR
CONDITIONER CONDENSER 5 DBW02241
COMPRESSOR ASSEMBLY
• Carry out installation in the reverse order to re-
V-belt adjustment procedure
moval.
❈1 Adjust belt
with adjustment
Hose mounting bolt : 10kg bolt
7.8 – 11.8 Nm (0.8 – 1.2 kgm)
❈2
« Adjust the V-belt as follows.
10 — 15mm
« V-belt deflection at approx. 98 N (10 kg): (deflection)
10 – 15 mm
30-259
30-260
40 MAINTENANCE STANDARD
40-1
MAINTENANCE STANDARD ENGINE MOUNT, TRANSMISSION MOUNT
Unit: mm
40-2
MAINTENANCE STANDARD TORQUE CONVERTER CHARGING PUMP
Unit: mm
4 Rotating torque of
spline shaft 5.9 – 13.7Nm (0.6 – 1.4kgm)
Standard Delivery
Rotating Delivery delivery amount limit
Model speed pressure amount
Discharge amount 2.9MPa
— Oil: EO10-CD SAL(2)45 3,000rpm 2
(30kg/cm ) 126 l/min 115 l/min —
Oil temperature: 45 – 55°C
2.9MPa
SAL(2)20 3,000rpm 59 l/min 53 l/min
(30kg/cm2)
40-3
MAINTENANCE STANDARD TORQUE CONVERTER
TORQUE CONVERTER
Unit: mm
– 0.01
Width 3 – 0.03 2.7
3 Wear of stator
shaft seal ring
Thickness 4.3 ± 0.1 3.9 Replace
40-4
MAINTENANCE STANDARD TRANSMISSION
TRANSMISSION
40-5
MAINTENANCE STANDARD TRANSMISSION
40-6
MAINTENANCE STANDARD TRANSMISSION
40-7
MAINTENANCE STANDARD TRANSMISSION
Unit: mm
40-8
MAINTENANCE STANDARD TRANSMISSION
Unit: mm
0
Thickness of seal ring 2.29 –0.1 2.1
40-9
MAINTENANCE STANDARD TRANSMISSION
Unit: mm
Clearance at forward/reverse
10 clutch shaft spacer press- +0.025 0 –0.009 –
50.5 +0.009 –0.030 –0.055 —
fitted section (F)
Clearance at forward/reverse
11 clutch shaft bearing end +0.034 –0.020 –0.041 – Replace
50 +0.021 –0.040 –0.074 —
spacer press-fitted section
Standard size Repair limit
Forward/reverse clutch Free length Installed length Installed load Free length Installed load
12 piston return spring
100 45 612±25N 96 551N
(62.4±2.6kg) (56.2kg)
Standard size Tolerance Repair limit
Thickness of forward/reverse
13 clutch thrust washer 3.0 ±0.1 2.7
40-10
MAINTENANCE STANDARD TRANSMISSION
Unit: mm
40-11
MAINTENANCE STANDARD TRANSMISSION
Unit: mm
40-12
MAINTENANCE STANDARD TRASMISSION CONTROL VALVE
UPPER VALVE
40-13
MAINTENANCE STANDARD TRASMISSION CONTROL VALVE
Unit: mm
266.7±13.7N 240N
10 Pilot valve spring 59.8 37 (27.2±1.4kg) 57.4 (24.5kg)
411.9±20.6N 370.7N
12 Main relief valve spring 170.5 132 (42±2.1kg) 163.7 (37.8kg)
40-14
MAINTENANCE STANDARD TRASMISSION CONTROL VALVE
LOWER VALVE
40-15
MAINTENANCE STANDARD TRASMISSION CONTROL VALVE
Unit: mm
841.4±42.2N 757N
8 Priority valve spring 150 111 (85.8±4.3kg) 144 (77.2kg)
81.4±3.9N 73.5N
9 Parking brake valve spring 46 37 (8.3±0.4kg) 44.2 (7.5kg)
40-16
MAINTENANCE STANDARD FLOW CONTROL VALVE
Unit: mm
40-17
MAINTENANCE STANDARD ACCUMULATOR VALVE
Unit: mm
spring 158N
4 157.7 145 (16.1kg) 151.4 —
40-18
MAINTENANCE STANDARD DRIVE SHAFT
DRIVE SHAFT
40-19
MAINTENANCE STANDARD DIFFERENTIAL
DIFFERENTIAL (1/2)
Unit: mm
40-20
MAINTENANCE STANDARD DIFFERENTIAL
DIFFERENTIAL (2/2)
40-21
MAINTENANCE STANDARD DIFFERENTIAL
Unit: mm
0 –0.048 –0.088 –
Clearance at Outer lace 140 –0.018 –0.088 –0.030 —
pinion shaft
3 coupling side
bearing +0.039 0 –0.054 –
Inner lace 65 +0.020 –0.015 –0.020 — Replace
4
Clearance between pinion –0.06 +0.10 0.11 –
gear and spider 34.93 –0.11 +0.05 0.21 0.3
5
Differential housing piston –0.125 +0.089 0.125 –
mount (housing piston) 326.5 –0.214 0 0.303 —
6
Bearing carrier piston mount –0.110 +0.081 0.110 –
(piston carrier) 304 –0.191 0 0.272 —
7
Standard size Tolerance Repair limit
Thickness of side gear
8 washer 4 ±0.05 3.8
40-22
MAINTENANCE STANDARD FINAL DRIVE
FINAL DRIVE
40-23
MAINTENANCE STANDARD FINAL DRIVE
Unit: mm
0 –0.045 –0.085 –
Clearance at axle Outer lace 160 –0.025 –0.085 –0.020 —
housing bearing
3 press-fitted
section +0.035 0 –0.055 –
Inner lace 105 +0.013 –0.020 –0.013 —
Replace
0 –0.045 –0.085 –
Clearance at axle Outer lace 180 –0.025 –0.085 –0.020 —
housing bearing
4 press-fitted
section Inner lace +0.045 0 –0.065 –
120 +0.023 –0.020 –0.023 —
+0.072
Axle shaft seal Housing 215 — 0 — —
5 press-fitted
section 0
Shaft 180 — — —
–0.063
40-24
MAINTENANCE STANDARD AXLE MOUNT
AXLE MOUNT
Unit: mm
40-25
MAINTENANCE STANDARD CENTER HINGE PIN
40-26
MAINTENANCE STANDARD CENTER HINGE PIN
Unit: mm
Clearance between
6 frame and 130 0 –0.048 –0.088 – —
bearing –0.025 –0.088 –0.023
40-27
MAINTENANCE STANDARD STEERRING COLUMN
STEERING COLUMN
Unit: mm
40-28
MAINTENANCE STANDARD STEERING VALVE
STEERING VALVE
Unit: mm
182N 145N
4 Relief valve spring 24.0 22.19 (18.6kg) — (14.8kg)
2.3N 1.8N
5 Check valve return spring 21.6 17.0 (0.23kg) — (0.18kg)
40-29
MAINTENANCE STANDARD STEERING CYLINDER MOUNT
Unit: mm
Clearance between
mounting pin and bushing 0 +0.150 0.050 –
2 at connection of steering 50 –0.025 +0.050 0.175 —
cylinder bottom and frame Replace
40-30
MAINTENANCE STANDARD BRAKE
BRAKE
Unit: mm
40-31
MAINTENANCE STANDARD BRAKE VALVE
BRAKE VALVE
BRAKE VALVE (LEFT)
Unit: mm
459N
2 Control spring 46.3 34.3 (46.8kg) 45.3 —
16.7N
4 Return spring 31.5 19.5 (1.7kg) 28 — Replace
40-32
MAINTENANCE STANDARD BRAKE VALVE
40-33
MAINTENANCE STANDARD BRAKE VALVE
Unit: mm
459N
2 Control spring 46.3 34.3 (46.8kg) 45.3 —
69.6N
4 Spring 17 15 (7.1kg) 16.2 — Replace
40-34
MAINTENANCE STANDARD PARKING BRAKE
PARKING BRAKE
Unit: mm
1,049±52.9N 394N
3 Parking brake spring 76.5 53.7 (107±5.4kg) 68.9 (40.2kg)
Standard size Tolerance Repair limit
Depth of
lining +0.175
5 Brake disc 0.45 0 0.375
groove
Lining
thickness 0.7 ±0.075 —
40-35
MAINTENANCE STANDARD HYDRAULIC PUMP
Unit: mm
40-36
MAINTENANCE STANDARD MAIN CONTROL VALVE
40-37
MAINTENANCE STANDARD MAIN CONTROL VALVE
Unit: mm
259N 208N
7 Relief valve poppet spring 49.3 41.9 (26.4kg) 47.8 (21.2kg)
44.1N
8 Check valve spring 32.6 24.5 (4.5kg) — —
6.9N
9 Suction valve spring 27.9 19 (0.7kg) — —
40-38
MAINTENANCE STANDARD MAIN CONTROL VALVE
3-SPOOL VALVE
40-39
MAINTENANCE STANDARD MAIN CONTROL VALVE
Unit: mm
259N 208N
7 Relief valve poppet spring 49.3 41.9 (26.4kg) 47.8 (21.2kg)
44.1N
8 Check valve spring 32.6 24.5 (4.5kg) — —
6.9N
9 Suction valve spring 27.9 19 (0.7kg) — —
40-40
MAINTENANCE STANDARD PPC VALVE
PPC VALVE
Unit: mm
40-41
MAINTENANCE STANDARD HYDRAULIC CYLINDER
HYDRAULIC CYLINDER
Unit: mm
40-42
MAINTENANCE STANDARD WORK EQUIPMENT LINKAGE
40-43
MAINTENANCE STANDARD WORK EQUIPMENT LINKAGE
Unit: mm
and frame
13 Connection of bellcrank and 90+0.8 93.5 +3 2.7 – 6.5
0 0
40-44
MAINTENANCE STANDARD BUCKET
BUCKET
Unit: mm
1
Bucket tooth wear 50 18.5 Replace
Reverse or
3 Cutting edge wear 93 — replace
40-45
MAINTENANCE STANDARD BUCKET POSITIONER AND BOOM KICK-OUT
Unit: mm
Clearance at bucket
1 positioner switch 3–5
Adjust
Clearance at boom
2 kickout switch 3–5
40-46
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22
A
A
B B
Condenser blower
Blower stage 1
Blower stage 4
Blower stage 3
Blower stage 2
C C
Clutch
Box 2 Pos.4
FU M2
20 A
D Box2 Pos.3 FU M1 D
L/R
L/R
B/Y
20 A
L/R
L/R
L/R
L/R
L/R
L/R
RL C RL BM RL EC
RL BM RL BH RL BM2 RL BM1 RL C RL EC
E E
Box 1
Pos.13
R/G
W/L
G/R
20 A
G/B
G
24V VE MAX0,1A
SW K FU B MB
F OFF Nightdesign F
CM B Vaporiser
gr
C ADC
D SP M motor
Kl.30
blower
Kl.15
M M R B1 EC
G/R
> 24 bar open
G G
G/Y
G/Y
G/B
Y/B
Lg
Clutch
D1 D3
4 3 2 1 4 3 2 1
GA Motor Motor
D+
E 27 28 10 11 4 5 35 3 2 22 33 13 30 7 6 31 20 32 34 16 8
H Condenser R B2 H
motors
BR/R
wt/G
L/R
Br/W
R/W
R/Y
Y/R
Y/R
W/L
CM B
G/W
G/W
Y/W
Y/W
Y/G
Y/G
W/B
W/B
Y/B
Br
L
G
Y
CM
D2
0,4-9V R B3
I I
0V
GND
L/W
or
L/B
Y
24V
R
+ E
E +
TH F 3 5 RL BM1 RL BM2 RL BH
4 1
B C D F B C D F
M AM
K M VR M VL M RF K
841019 841016
(Greenball)
2 A E G A E G 2 5
- - - -
Br
W/B
W/B
W/B
L L
B
M M
Sensor Valve(Water) Ventilation flap right Ventilation flap left Fresh/ circulating air
N N
Controller
P
* Up to SN WA320H20560 Air-conditioner P
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22
10-485
Fuse
Fuse
Fuse
Ground
Battery 24V
Generator D+
Ground air-conditioner
Compressor air-conditioner
Blower air-conditioner
10-486
To platform wiring harness
(Heater opt.)
Switch air-conditioner
L.H. blower
Servomotor
Fresh/circulating air
Ventilation flap L.H. + -
Ventilation flap L.H. + -
Valve (water)
Valve (water)
Ventilation flap R.H. + -
Ventilation flap R.H. + -
Memory
Fresh/circulating air
Blower stage 4
Sidelight
Ventilation flap R.H. potentiom. pos. 2
not used
Sensor digital GND
Sensor
Power supply
Option
Controller air-conditioner
Compressor clutch
Blower stage 1
Blower stage 3
Digital (-) only used in controller
Alternator
Ventilation flap L.H. potentiom. pos. 1
Ventilation flap R.H. potentiom. pos. 3
Ventilation flap L.H. potentiom. pos. 2
Ventilation flap L.H. potentiom. pos. 4
Ventilation flap R.H. potentiom. pos. 1
Blower stage 2
Supply (-)
Supply (-)
Servomotor
R.H. blower
fresh air
Thermistor
Servomotor
Circulating /
& resistor
Vaporiser blower
Air-conditioner
Wiring diagram
Wiring harness relays air-conditioner
* Up to SN WA320H20560
Relay
Relay
Relay
Relay
Relay
Relay
blower
blower
blower
blower
(Stage 2)
(Stage 3)
(Stage 4)
(Stage 1)
condenser
compressor
WA420-3 WA470-3
* WA320-3 WA380-3
Ground
From SN WA380H20501
up to SN WA380H20836
Page 1 / 5
10-281/3
1
Ground
From SN WA380H20501
up to SN WA380H20836
Page 2 / 5
10-281/4
1
Ground
From SN WA380H20501
up to SN WA380H20836
Page 3 / 5
10-281/7
1
Ground
From SN WA380H20501
up to SN WA380H20836
Page 4 / 5
10-281/8
1
Ground
From SN WA380H20501
up to SN WA380H20836
Page 5 / 5
10-281/11
1
10-281/12
1
Ground
From SN WA380H20837
up to SN WA380H20986
Page 1 / 5
10-282/3
2
Ground
From SN WA380H20837
up to SN WA380H20986
Page 2 / 5
10-282/4
2
Ground
From SN WA380H20837
up to SN WA380H20986
Page 3 / 5
10-282/7
2
Ground
From SN WA380H20837
up to SN WA380H20986
Page 4 / 5
10-282/8
2
Ground
From SN WA380H20837
up to SN WA380H20986
Page 5 / 5
10-282/11
2
10-282/12
2
Ground
SN WA380H20987 and up
Page 1 / 5
10-283/3
1
Ground
SN WA380H20987 and up
Page 2 / 5
10-283/4
1
Ground
SN WA380H20987 and up
Page 3 / 5
10-283/7
1
Ground
SN WA380H20987 and up
Page 4 / 5
10-283/8
1
Ground
SN WA380H20987 and up
Page 5 / 5
10-283/11
1
10-283/12
1