Vebm480104 Wa470-3 PDF
Vebm480104 Wa470-3 PDF
Vebm480104 Wa470-3 PDF
VEBM480104
WA470-3
Wheel Loader
Serial Number
WA470H20051 and up
© 2000
All Rights Reserved
Printed in Europe 03/2000
CONTENTS
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 WA470H20668:
Dimensions and weights ................................. 01- 3
Specifications ................................................. 01- 4
Weight table ................................................... 01- 6
List of lubricant and water ............................. 01- 7
From SN WA470H20669
up to SN WA470H20941:
Dimensions and weights ................................. 01- 8
Specifications ................................................. 01- 9
Weight table ...................................................01-11
List of lubricant and water ............................. 01-12
SN WA470H20942 and up:
Specifications ................................................. 01-13
Weight table ...................................................01-14
List of lubricant and water ............................. 01-15
Outlines of service .......................................... 01-16
General view of controls and gauges ............01-21
Torque list .................................................... 01-23
01-1
Blank for technical reason
01-2
GENERAL DIMENSIONS, WEIGHTS AND OPERATING DATA
Buckets
01-3
GENERAL SPECIFICATIONS
SPECIFICATIONS
H20001 - H20668
Serial No.
Weight
01-4
GENERAL SPECIFICATIONS
H20001 - H20668
Serial No.
Model S6D125
4-cycle, water-cooled, in-line,
Type 6-cylinder, direct injection, with turbocharger
No. of cylinders – bore x stroke (mm) 6 – 125 mm x 150 mm
– –
Alternator 24 V 50 A
Battery 12 V 143 Ah x 2
Transmission
hydraulically actuated, modulation type
Tire 26.5-25-16PR
01-5
GENERAL WEIGHT TABLE
WEIGHT TABLE
This weight table is a guide for use when transporting or handling components.
Unit: kg
Engine 1120
Radiator 168
Steering valve 24
PPC valve 3
Bucket link 89
Bellcrank 415
01-6
GENERAL LIST OF LUBRICANT AND WATER
CCMC D4
Transmission Engine oil EO EO 10 or, if not available, - SAE 10W 60
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, 240
API CD
steering, brakes (155 **)
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 68
prevention prevention
SP-C
CFPP class B up to 0°C
CFPP class D up to -10°C
Fuel tank Diesel fuel ³) DIN-EN 590 400
CFPP class E up to -15°C
CFPP class F up to -20°C
U:\DTP\BA470gb\FÜLL-BI.TBL 02.97
01-7
GENERAL DIMENSIONS, WEIGHTS AND OPERATING DATA
Buckets
01-8
GENERAL SPECIFICATIONS
SPECIFICATIONS
Machine model WA470-3
Alternator 24 V 50 A
Battery 12 V 143 Ah x 2
Transmission
hydraulically actuated, modulation type
Tire 26.5-25
01-9
GENERAL SPECIFICATIONS
PPC/brake pump 62
Hydraulic system
Control valve
01-10
GENERAL WEIGHT TABLE
WEIGHT TABLE
This weight table is a guide for use when transporting or handling components.
Unit: kg
Engine 981
Radiator 168
Steering valve 24
PPC valve 3
Bucket link 89
Bellcrank 415
01-11
GENERAL LIST OF LUBRICANT AND WATER
CCMC D4
60
Transmission Engine oil EO EO 10 or, if not available, - SAE 10W
(60 **)
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, 240
API CD
steering, brakes (155 **)
HEES
or hydraulic oil ISO VG 46
BIO-E-HYD 0530 (to VDMA fluid -35° to 50° C
BIO-E-HYD
technology)
U:\DTP\BA470gb\470gb_mc\füllmc.TBL 07.97
01-12
GENERAL SPECIFICATIONS
H20942 and up
Serial No.
– –
Alternator 24 V 50 A
Battery 12 V 143 Ah x 2
Transmission
hydraulically actuated, modulation type
Tire 26.5-25-16PR
01-13
GENERAL WEIGHT TABLE
WEIGHT TABLE
This weight table is a guide for use when transporting or handling components.
Unit: kg
Engine 1250
Radiator 168
Steering valve 24
PPC valve 3
Bucket link 89
Bellcrank 415
01-14
GENERAL LIST OF LUBRICANT AND WATER
CCMC D4
Transmission Engine oil EO EO 10 or, if not available, - SAE 10W 60
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, 240
API CD
steering, brakes (155 **)
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 68
prevention prevention
SP-C
CFPP class B up to 0°C
CFPP class D up to -10°C
Fuel tank Diesel fuel ³) DIN-EN 590 400
CFPP class E up to -15°C
CFPP class F up to -20°C
U:\DTP\BA470gb\FÜLL-BI.TBL 02.97
01-15
GENERAL LUBRICANT AND WATER
Note 1
Axle oils (AXO)
These axles must be filled with the following recommended oil brands:
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 Manual.
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.
01-17
GENERAL OUTLINES OF SERVICE
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.
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.
01-18
GENERAL OUTLINES OF SERVICE
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).
FILTERS
• Filters are extremely important safety parts. They prevent impurities in the fuel and air circuits from entering
important equipment and causing problems.
Replace all filters periodically. For details, see the Operation and Maintenance Manual.
However, when working under severe conditions, it is necessary to consider replacing the filters at shorter
intervals according to the oil and fuel (sulfur content) being used.
• Never try to clean the filters (cartridge type) and use them again. Always replace with new filters.
• When replacing oil filters, check if any metal particles are stuck to the old filter. If any metal particles are
found, please contact your Komatsu distributor.
• Do not open packs of spare filters until just before they are to be used.
01-19
GENERAL OUTLINES OF SERVICE
• 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.
01-20
GENERAL GENERAL VIEW OF CONTROLS AND GAUGES
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
01-21
GENERAL GENERAL VIEW OF CONTROLS AND GAUGES
1. Main monitor
2. Horn switch
3. Hazard lamp switch
01-22
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.
01-23
Blank for technical reason
01-24
10 STRUCTURE AND FUNCTION
10-1
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 (7) and rear drive shaft (5),
shaft of transmission (1). and is then transmitted to front axle (8) and rear
• The transmission has six hydraulically actuated axle (4) to drive the wheels.
clutches, and these provide four speed ranges
for both FORWARD and REVERSE. The trans-
mission speed ranges are selected manually.
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 SYSTEM DIAGRAM
10-7
STRUCTURE AND FUNCTION TRANSMISSION HYDRAULIC CIRCUIT DIAGRAM
1. Transmission case 12. Torque converter outlet valve 24. Range selector valve
2. Strainer 13. Oil cooler 25. Accumulator
3. Torque converter charging 14. Transmission lubrication 26. Parking brake valve
pump 15. Emergency manual spool 27. Parking brake
4. Flow valve 16. Solenoid valve (FORWARD) 28. 4th clutch
5. Oil filter 17. Directional selector valve 29. 3rd clutch
6. Pilot reducing valve 18. Solenoid valve (REVERSE) 30. 2nd clutch
7. Pilot oil filter 19. REVERSE clutch 31. 1st clutch
8. Priority valve 20. FORWARD clutch 32. Accumulator
9. Electronic modulation valve 21. Solenoid valve (H-L selection)
10. Main relief valve 22. H-L selector valve
11. Torque converter 23. Solenoid valve (range selec-
tion)
10-8
STRUCTURE AND FUNCTION TORQUE CONVERTER
TORQUE CONVERTER
1. Breather Specifications
2. Housing Model: TCA38-4Z
3. Steering, witch tandem pump mount Type: 3 element, 1 stage, 1 phase
4. Hydraulic, PPC tandem pump mount Stall torque ratio: 3.15
10-9
STRUCTURE AND FUNCTION TORQUE CONVERTER
10-10
STRUCTURE AND FUNCTION TORQUE CONVERTER
Flow of oil
• The oil supplied from the torque converter charging
pump enters inlet port A, passes through the oil
passage of stator shaft (13), and flows to pump (8).
The oil is given centrifugal force by pump (8), en-
ters turbine (7), and transmits the energy of the oil
to the turbine. Turbine (7) is fixed to transmission
input shaft (10), so the motive force is transmitted to
the transmission input shaft.
The oil from turbine (7) is sent to stator (9), and
enters the pump again. However, part of the oil is
sent from the stator through outlet port B to the
cooler.
10-11
STRUCTURE AND FUNCTION TORQUE CONVERTER OIL FILTER
Specifications
Filter mesh size: 10 microns
Filtering area: 8900 cm2
Relief pressure: 0.3 MPa (3.25 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.
10-12
STRUCTURE AND FUNCTION TRANSMISSION
TRANSMISSION
10-21
STRUCTURE AND FUNCTION TRANSMISSION
14. PTO gear (No. of teeth: 65) 28. 3rd gear (No. of teeth: 49)
15. PTO gear (No. of teeth: 76) 29. 3rd gear (No. of teeth: 43)
16. PTO gear (No. of teeth: 74) 30. 3rd clutch
17. 1st clutch (No. of teeth: 26) 31. 4th clutch
18. FORWARD clutch 32. REVERSE, 2nd shaft
19. Input gear (No. of teeth: 30) 33. 2nd gear (No. of teeth: 26)
20. Torque converter 34. 2nd clutch
21. PTO drive gear (No. of teeth: 74) 35. 2nd gear (No. of teeth: 50)
22. FORWARD gear (No. of teeth: 48) 36. REVERSE clutch
23. REVERSE gear (No. of teeth: 46) 37. FORWARD, 1st shaft
24. 3rd, 4th shaft 38. 1st gear (No. of teeth: 26)
25. 4th gear (No. of teeth: 53) 39. 3rd gear (No. of teeth: 37)
26. Output shaft 40. Countershaft
27. Output gear (No. of teeth: 41) 41. 4th gear (No. of teeth: 27)
10-22
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 forward or reverse clutches and the four speed
converter passes through the transmission input clutches to shift to F1 – 4 or R1 – 4, and
shaft and enters the transmission. transmits the motive force from the input shaft to
the output shaft.
CLUTCH
FORWARD, 1ST CLUTCH
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 (5) to actuate the
piston.
• When piston (5) 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.
10-25
STRUCTURE AND FUNCTION TRANSMISSION
FORWARD 1ST
Operation
• In the case of FORWARD 1st, FORWARD clutch • The 1st clutch is engaged, so the motive force
(18) and 1st clutch (17) are engaged. The mo- transmitted to the FORWARD 1st cylinder passes
tive force transmitted from the torque converter through 1st clutch (17) and is transmitted from
to input shaft (2) is transmitted to gear (19), 1st gear (38) to 2nd clutch gears (35, 33). It
which is installed to the input shaft. then passes through 3rd clutch gear (28) and
• Each clutch disc of FORWARD clutch (18) and output gear (27) and is transmitted to output
1st clutch (17) is engaged by the oil pressure shaft (26).
applied to the piston.
• The motive force from the torque converter
passes from input shaft (2) through gear (19)
and is transmitted to FORWARD gear (22). When
FORWARD clutch (18) is engaged, the motive
force is transmitted to the FORWARD 1st cylin-
der.
10-26
STRUCTURE AND FUNCTION TRANSMISSION
FORWARD 2ND
Operation
• In the case of FORWARD 2nd, FORWARD • The motive force is transmitted to REVERSE
clutch (18) and 2nd clutch (34) are engaged. 2nd cylinder gear (43) and REVERSE 2nd shaft
The motive force transmitted from the torque (32), which are meshed with the FORWARD 1st
converter to input shaft (2) is transmitted to gear cylinder gear. 2nd clutch (34) is engaged, so
(19), which is installed to the input shaft. the motive force transmitted to the REVERSE
• The clutch discs of FORWARD clutch (18) and 2nd shaft passes through the 2nd clutch and
2nd clutch (34) are engaged by the oil pressure goes from 2nd gear (33) through 3rd gear (28)
applied to the piston. and output gear (27), and is transmitted to out-
• The motive force from the torque converter put shaft (26).
passes from input shaft (2) through gear (19)
and is transmitted to FORWARD gear (22). FOR-
WARD clutch (18) is engaged, so the motive
force is transmitted to FORWARD 1st cylinder
gear (42).
10-27
STRUCTURE AND FUNCTION TRANSMISSION
FORWARD 3RD
Operation
• In the case of FORWARD 3rd, FORWARD clutch • The motive force is transmitted through RE-
(18) and 3rd clutch (30) are engaged. The mo- VERSE 2nd cylinder gear (43) and REVERSE
tive force transmitted from the torque converter 2nd shaft (32), which is meshed with the FOR-
to input shaft (2) is transmitted to gear (19), WARD 1st cylinder gear, and is transmitted to
which is installed to the input shaft. 3rd, 4th cylinder gear (44) and 3rd, 4th shaft
• The clutch discs of FORWARD clutch (18) and (24). 3rd clutch (30) is engaged, so the motive
3rd clutch (30) are engaged by the oil pressure force passes through the 3rd clutch and goes
applied to the piston. from 3rd gear (28) through output gear (27),
• The motive force from the torque converter and is transmitted to output shaft (26).
passes from input shaft (2) through gear (19)
and is transmitted to FORWARD gear (22).
FORWARD clutch (18) is engaged, so the mo-
tive force is transmitted to FORWARD 1st cylin-
der gear (42).
10-28
STRUCTURE AND FUNCTION TRANSMISSION
FORWARD 4TH
Operation
• In the case of FORWARD 4th, FORWARD clutch • The motive force is transmitted through RE-
(18) and 4th clutch (31) are engaged. The mo- VERSE 2nd cylinder gear (43), which is meshed
tive force transmitted from the torque converter with the FORWARD 1st cylinder gear, and is
to input shaft (2) is transmitted to gear (19), transmitted to 3rd, 4th cylinder gear (44) and
which is installed to the input shaft. 3rd, 4th shaft (24). 4th clutch (31) is engaged,
• The clutch discs of FORWARD clutch (18) and so the motive force transmitted to the 3rd, 4th
4th clutch (31) are engaged by the oil pressure shaft passes through the 4th clutch and goes
applied to the piston. from 4th gear (25) through 4th counter gear
• The motive force from the torque converter (41), countershaft (40), and 3rd counter gear
passes from input shaft (2) through gear (19) (39), is transmitted to 3rd gears (29) and (28),
and is transmitted to FORWARD gear (22). FOR- and then passes through output gear (27), and
WARD clutch (18) is engaged, so the motive is transmitted to output shaft (26).
force is transmitted to FORWARD 1st cylinder
gear (42).
10-29
STRUCTURE AND FUNCTION TRANSMISSION
REVERSE 1ST
Operation
• In the case of REVERSE 1st, REVERSE clutch • The motive force is transmitted to FORWARD
(36) and 1st clutch (17) are engaged. The mo- 1st cylinder gear (42) and FORWARD 1st shaft
tive force transmitted from the torque converter (37), which are meshed with REVERSE 2nd
to input shaft (2) is transmitted to gear (19), cylinder gear (43). 1st clutch (17) is engaged,
which is installed to the input shaft. so the motive force transmitted to the FOR-
• With reverse clutch (36) and 1st clutch (17), WARD 1st shaft passes through 1st clutch (17)
each clutch disc is engaged by the oil pressure and is transmitted from 1st gear (38) to 2nd
applied to the piston. gears (35, 33), passes through 3rd gear (28)
• The motive force from the torque converter and output gear (27) and is transmitted to output
passes from input shaft (2) through gear (19) shaft (26).
and is transmitted to REVERSE gear (25). When
REVERSE clutch (36) is engaged, the motive
force is transmitted to the REVERSE 2nd cylin-
der.
10-30
STRUCTURE AND FUNCTION TRANSMISSION CONTROL
Outline
• The oil from the pump passes through the flow • The T/M-controller senses the travel speed and
valve and torque converter oil filter, enters the the engine speed when the machine is traveling.
transmission, and is divided into the pilot circuit The T/M-controller actuates the proportional so-
and clutch actuation circuit. The priority valve lenoid valve according to the command current
adjusts the delivery pressure of the pump and from the transmission controller to control the oil
ensures the pilot pressure and oil pressure used flow and oil pressure. This allows the clutch to
to release the parking brake. engage smoothly and reduces the shock when
• The pressure of the oil flowing to the clutch shifting gear.
circuit 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
In addition, the oil relieved by the main relief actuates 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
1. Solenoid valve [] for FORWARD selector 3. Solenoid valve [] for H-L selector
2. Solenoid valve [] for REVERSE selector 4. Solenoid valve [] for range selector
Solenoid valve
F • 1 ¡ ¡
Structure
F • 2 ¡
• The transmission solenoid valve is installed to
the lower valve of the transmission valve. When F • 3 ¡ ¡
the speed lever is operated, the movement is F • 4 ¡ ¡ ¡
converted to electricity, and this opens or closes
N
each solenoid valve to move the spool inside the
transmission valve. R•1 ¡ ¡
R•2 ¡
R•3 ¡ ¡
R•4 ¡ ¡ ¡
10-44
STRUCTURE AND FUNCTION TRANSMISSION CONTROL
Function
• When the speed lever in the operator’s com-
partment is operated, the four solenoid valves
installed to the transmission control valve are
switched ON or OFF to actuate the directional
selector spool, H-L selector spool and range
selector spool`.
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.
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 prior-
ity valve, then through ports A and B of until the
main relief valve (1) specified pressure is
reached, and flows to the clutch valve.
10-46
STRUCTURE AND FUNCTION TRANSMISSION CONTROL
Function
• The torque converter outlet port valve is installed
Operation
• The oil at port a passes through the orifice in
spool (1) and flows to port c.
• When the pressure at port a rises, the pressure
at port c also rises. This overcomes the tension
10-47
STRUCTURE AND FUNCTION TRANSMISSION CONTROL
PRIORITY VALVE
Function
• The priority valve regulates the delivery pres-
sure of the pump, and ensures the pilot pres-
sure and oil pressure for releasing the parking
brake.
In addition, if the pressure in the circuit goes
above the specified pressure, it acts as a relief
valve to protect the hydraulic circuit.
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
10-49
STRUCTURE AND FUNCTION TRANSMISSION CONTROL
10-50
STRUCTURE AND FUNCTION TRANSMISSION CONTROL
10-51
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.
10-52
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.
10-53
STRUCTURE AND FUNCTION TRANSMISSION CONTROL
10-54
STRUCTURE AND FUNCTION TRANSMISSION CONTROL
Function
• If there should be a failure in the electrical
system and the directional solenoid valve cannot
be actuated, it is possible to actuate the FOR-
WARD or REVERSE clutch manually.
Operation
1. When emergency manual spool is at neutral
• The oil from upper valve (pilot reducing valve)
passes around emergency manual spool (1) and
is blocked by solenoid valves (2) and (3).
• During normal operations, the emergency manual
spool is at the neutral position.
10-55
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.
10-56
STRUCTURE AND FUNCTION TRANSMISSION CONTROL
10-57
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
10-58
STRUCTURE AND FUNCTION TRANSMISSION CONTROL
A. Inlet port
B. Outlet port
10-59
STRUCTURE AND FUNCTION TRANSMISSION CONTROL
ACCUMULATOR VALVE
10-60
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.
10-61
STRUCTURE AND FUNCTION TRANSMISSION CONTROL
FLOW VALVE
Operation
• The oil from the pump flows to the transmission
clutch circuit but when it becomes greater than
the specified flow, the flow valve acts to send oil
to the transmission lubrication circuit.
• When the oil from the pump becomes greater
then the specified flow, valve spool (2) moves
and part of the oil from the oil pump flows to the
transmission lubrication circuit.
10-62
STRUCTURE AND FUNCTION TRANSMISSION CONTROL
CHECK VALVE
Outline
1. Directional spool
2. check valve
10-63
STRUCTURE AND FUNCTION TRANSMISSION CONTROL
MODULATION VALVE
1. Body
2. Coil ass’y
3. Case
4. Adjustment screw
5. Plunger
6. Shaft
1. Nut 6. Pin
2. Core ass’y 7. Spring
3. Coil ass’y 8. Valve seat
4. Plunger 9. Body
5. Spring 10. Connector
10-64
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
FRONT DIFFERENTIAL
1. Shaft Specifications
2. Bevel gear Type: Spiral bevel gear, splash lubrica-
3. Bevel pinion tion
4. Side gear Reduction ratio: 4.10
5. Pinion Differential type: Torque proportioning, splash lu-
brication
10-84
STRUCTURE AND FUNCTION DIFFERENTIAL
REAR DIFFERENTIAL
1. Shaft Specifications
2. Bevel gear Type: Spiral bevel gear, splash lubrica-
3. Bevel pinion tion
4. Side gear Reduction ratio: 4.10
5. Pinion Differential type: Torque proportioning, splash lu-
brication
10-85
STRUCTURE AND FUNCTION DIFFERENTIAL
DIFFERENTIAL
FRONT DIFFERENTIAL WITH LSD
1. Shaft Specifications
2. Bevel gear Type: Spiral bevel gear, splash lubrica-
3. Bevel pinion tion
4. Side gear Differential type: Limited slip differential, splash lu-
5. Pinion brication
10-86
STRUCTURE AND FUNCTION DIFFERENTIAL
DIFFERENTIAL
REAR DIFFERENTIAL WITH LSD
1. Shaft Specifications
2. Bevel gear Type: Spiral bevel gear, splash lubrica-
3. Bevel pinion tion
4. Side gear Differential type: Limited slip differential, splash lu-
5. Pinion brication
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 mufti-disc brakes, in fact it will
become increasingly more difficult with increasing
torque.
10-88
STRUCTURE AND FUNCTION DIFFERENTIAL
Outline
• The motive force from the drive shaft passes
through bevel pinion (1) and is transmitted to
bevel gear (5). The bevel gear changes the
direction of the motive force by 90°, and at the
same time reduces the speed. It then transmits
the motive force through differential (4) to sun
gear shaft (2).
When turning
• When turning, the rotating speed of the left and
right wheels is different, so pinion gear (4) and
side gear (3) inside the differential assembly
rotate in accordance with the difference between
the rotating speed of the left and right wheels.
The motive force of carrier (6) is then transmit-
ted to sun gear shafts (2).
10-89
STRUCTURE AND FUNCTION FINAL DRIVE
10-90
STRUCTURE AND FUNCTION FINAL DRIVE
FINAL DRIVE
1. Axle shaft
2. Ring gear (No. of teeth: 67)
3. Planet gear (No. of teeth: 24)
4. Planetary carrier
5. Sun gear (No. of teeth: 17)
6. Wheel
Outline
• The final drive uses a planetary gear mecha-
nism to obtain a large drive force, and transmits
the drive force to the tires.
Operation
• The motive force transmitted to sun gear (5)
from the differential through axle shaft (1) is
transmitted to planet gear (3). The planet gear
rotates inside ring gear (2), which is fixed, and
transmits the motive force to wheel (6), which is
installed to the planetary carrier.
10-91
STRUCTURE AND FUNCTION AXLE MOUNT, CENTER HINGE PIN
10-92
STRUCTURE AND FUNCTION STEERING PIPING
STEERING PIPING
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 between roll passes oil to the steering demand valve.
the front and rear machine frame. The steering ac- The amount of oil is proportional to the turn-
tion is achieved through pipes, hoses and the steer- ing of the steering wheel. The steering de-
ing cylinders. mand valve is moved to the left or right de-
pending on the turned direction of the steer-
ing wheel.
10-112
STRUCTURE AND FUNCTION HYDRAULIC CIRCUIT FOR STEERING
10-113
STRUCTURE AND FUNCTION ORBIT-ROLL-VALVE
ORBIT-ROLL VALVE
10-114
STRUCTURE AND FUNCTION STEERING DEMAND VALVE
10-115
STRUCTURE AND FUNCTION STEERING DEMAND 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.
10-116
STRUCTURE AND FUNCTION STEERING DEMAND VALVE
10-117
STRUCTURE AND FUNCTION STEERING DEMAND 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.
10-118
STRUCTURE AND FUNCTION STEERING DEMAND VALVE
• The oil from the steering pump enters port A • When the pressure at pressure-receiving cham-
and the oil from the switch pump enters port B. ber (I) reaches a certain level (set by spring
• When steering spool (2) is at neutral, pressure- (5)), notch (f) opens and the oil from the steer-
receiving chamber (II) is connected to the drain ing 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 DEMAND VALVE
• When steering spool (2) is pushed (operated), • The merged oil passes through notches (c) and
pressure-receiving chamber (II) and the drain (d), pushes up load check valve (4), and flows
circuit are shut off, and at the same time, notch to the cylinder. The return oil from the cylinder
(c) opens. passes through notch (e) and enters the drain
• Because of this, the pressure in pressure-re- circuit.
ceiving chamber (II) rises, and demand spool • In this condition, the pressure before passing
(1) moves to the right in the direction of the through notch (c) is sent to pressure-receiving
arrow 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 DEMAND 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 switch pump id released to the main control
the 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.
10-121
STRUCTURE AND FUNCTION STEERING DEMAND VALVE
é ê
• 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
shut off. from the cylinder passes through notch (e) and
• The pressure difference on both sides of notch flows 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.)
10-122
STRUCTURE AND FUNCTION STEERING VALVE
FLOW AMP
10-123
STRUCTURE AND FUNCTION STEERING VALVE
• When oil flows to port PiA, the pressure inside the • Port PiB is connected to the drain circuit
cap at end A rises and moves steering spool (1) in through the orbit-roll valve, so the oil flowing
the direction of the arrow. to end B is drained.
• The oil entering from port PiA passes through the • the pressure generated at port PiA is propor-
hole in spring seat (3), through flow amp notch (9) tional to the amount of oil flowing in, so
in steering spool (1), and then flows to the opposite steering spool (1) moves to a position where
end (B end). Piston (6) is also pushed up and oil the opening of the flow amp notch balances
fills damper chamber C. the pressure generated with the force of return
spring (4).
10-124
STRUCTURE AND FUNCTION STEERING VALVE
• When the steering wheel (orbit-roll valve) is stopped, • In this way, the return speed of steering spool
ports PiA and PiB are both connected to the drain (1) is made slower.
circuit through the orbit-roll valve. For this reason,
steering spool (1) is returned to the neutral position
by return spring (4).
• In damper chamber C, at first, piston (6) and spring
seat (3) are closed (in item 2), when the damper
camber becomes full, piston (6) and spring seat (3)
are almost closed because of piston return spring
(8); the oil damper chamber C passes through
throttle a and returns to port PiA.
10-125
STRUCTURE AND FUNCTION STEERING DEMAND VALVE
Neutral
• The steering wheel 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.
10-126
STRUCTURE AND FUNCTION STEERING DEMAND 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
steering spool (1), and steering spool moves to spool, 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.
10-127
STRUCTURE AND FUNCTION STEERING DEMAND 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
steering spool (1), and steering spool moves to spool, 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.
10-128
STRUCTURE AND FUNCTION EMERGENCY STEERING
EMERGENCY STEERING
Up to SN WA470H21064
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.
10-129
STRUCTURE AND FUNCTION EMERGENCY STEERING
10-130
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
10-131
STRUCTURE AND FUNCTION EMERGENCY STEERING
10-132
STRUCTURE AND FUNCTION EMERGENCY STEERING
EMERGENCY STEERING
SN WA470H21065 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.
10-133
STRUCTURE AND FUNCTION EMERGENCY STEERING
1 2 3 4 5 6
7 8 9
10-134
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.
10-135
STRUCTURE AND FUNCTION EMERGENCY STEERING
1
2 2
3 3
10-136
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
10-137
STRUCTURE AND FUNCTION EMERGENCY STEERING
1 1A
3
CF
H PSP
10-138
STRUCTURE AND FUNCTION BRAKE PIPING
BRAKE PIPING
10-151
STRUCTURE AND FUNCTION BRAKE CIRCUIT DIAGRAM
10-152
STRUCTURE AND FUNCTION BRAKE VALVE
10-153
STRUCTURE AND FUNCTION BRAKE VALVE
Outline
• There are two brake valves installed in parallel mission solenoid valve electrically and set the
under the front of the operator’s cab, and these transmission to neutral.
are actuated by depressing the pedal.
• When the right pedal is depressed, oil is sent to
the brake cylinder to apply the brakes.
• When the left pedal is depressed, oil is sent to
the right pedal to apply the brakes in the same
way as when the right pedal is depressed.
In addition, the left brake pedal operates the
transmission cut-off switch to actuate the trans-
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 CHARGE VALVE
CHARGE VALVE
10-158
STRUCTURE AND FUNCTION CHARGE VALVE
1. Valve body
2. Main relief valve (R3)
3. Relief valve (R1)
4. PPC relief valve (R2)
5. Relief valve (H1)
10-159
STRUCTURE AND FUNCTION 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 CHARGE VALVE
10-161
STRUCTURE AND FUNCTION ACCUMULATOR (FOR BRAKE)
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 brake: 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- Charging pressure
ble to operate the machine if the engine should for parking brake: (15 bar) (at 50°C)
stop.
10-162
STRUCTURE AND FUNCTION SLACK ADJUSTER
SLACK ADJUSTER
1. Bleeder
2. Cylinder
3. Check valve
4. Piston
5. Spring
A. Inlet port
B. Outlet port
Function Specifications
• The slack adjuster is installed in the brake oil Piston actuation pressure:
line from the brake valve to the brake piston. It 0.01 +0.01 +0.1
0 MPa (0.1 0 bar)
acts to provide a fixed time lag when the brake Check valve cracking pressure:
is applied. 0.93 ± 0.05 MPa (9.5 ± 0.5 bar)
Check valve closing pressure:
0.6 ± 0.05 MPa (6.0 ± 0.5 bar)
10-163
STRUCTURE AND FUNCTION SLACK ADJUSTER
Operation
1. When brake pedal is depressed
• Before the brake is depressed, piston (4) is
returned by the distance of stoke S (full stroke).
When the brake pedal is depressed, the oil dis-
charged from the brake valve flows from port P
of the slack adjuster and is divided to left and
right cylinders (2), where it moves piston (4) by
stroke S to the left and right.
10-164
STRUCTURE AND FUNCTION SLACK ADJUSTER
10-165
STRUCTURE AND FUNCTION BRAKE CIRCUIT DIAGRAM
10-166
STRUCTURE AND FUNCTION BRAKE VALVE
Function:
Operation:
Brakes released:
A Spring assembly
C1, C2 Spool valve
R1, R2 Springs
10-167
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 ap- nection is again established between brake
plied to the brakes. The spring assembly (A) be- cylinder 2.1 / 2.2 and the drain 5.1 / 5.2,
neath the base plate (E) is designed so that brak- pressure ports 1.1 and 1.2 are closed.
ing pressure changes according to the foot plate
(B) angle. In the lower braking range the vehicle • The arrangement of pistons in the valve
can be braked proportionally. ensures 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 ac-
down with the increased spring pressure (A). The tuation of both pistons and requires slightly
piston (C1) applies spring pressure (R1) to the more 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 base plate (E) below the pedal (B) is used
(C1) and (C2) are held in a stable position be- to limit the brake pedal movement. This in
tween the applied foot force and the spring pres- turn limits the applied braking pressure.
sure plus the applied brake hydraulic
pressure.When this point is reached ports 1.1 / Failure of a circuit:
1.2 and 5.1 / 5.2 are closed and the applied pres-
sure at 2.1 and 2.2 is held. • In the event of the lower brake circuit fail-
ing, the upper circuit will remain operational.
Full braking: Piston (C1) is operated mechanically by
spring (A). In the event of the upper circuit
• When the brake pedal (B) is fully actuated piston failing, piston (C1) and spring (A) will me-
(C1) moves into mechanical contact with piston chanically
(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.
10-168
STRUCTURE AND FUNCTION BRAKE VALVE
10-169
STRUCTURE AND FUNCTION BRAKE CIRCUIT DIAGRAM
10-170
STRUCTURE AND FUNCTION BRAKE VALVE
Function:
Operation:
Brakes released:
10-171
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 ap- final position is reached and ports 1.1 and
plied to the brakes. The spring assembly beneath 1.2 are connected to port 2.1 / 2.2 at the
the base plate is designed so that braking pres- brakes while drain ports 5.1 / 5.2 are closed.
sure changes according to the foot plate angle. In • When the braking process is ended a con-
the 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
moved down with the increased spring pressure. ensures that even if one braking circuit fails
The upper piston applies spring pressure to the the other remains fully operational. This is
lower piston. The pistons cut off the outlet ports achieved by means of the mechanical ac-
5.1 and 5.2. Further movement opens the ports tuation of both pistons and requires slightly
1.1 and 1.2 allowing oil pressure to pass to the more pedal pressure.
wheel brake cylinders. The applied foot force now
determines the braking force. The pistons are held
in a stable position between the applied foot force Failure of a circuit:
and the spring pressure plus the applied brake
hydraulic pressure. When this point is reached • In the event of the lower brake circuit fail-
ports 1.1 / 1.2 and 5.1 / 5.2 are closed and the ing, the upper circuit will remain operational.
applied pressure at 2.1 and 2.2 is held. The piston is operated mechanically by the
springs. In the event of the upper circuit
failing, the lower circuit will remain opera-
tional. The lower piston and is operated
mechanically by the springs and the piston.
• If the left brake valve is operated, a pres-
sure establishes at port 2.1 and passes to
port 3 of the right brake valve. This pres-
sure operates 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).
10-172
STRUCTURE AND FUNCTION BRAKE VALVE
10-173
STRUCTURE AND FUNCTION BRAKE SYSTEM
Ready position:
Charging process:
• When the accumulator pressure drops to a preset the connection between port 1 and port 5 is
value, spring pressure C will force the control reestablished. The pump oil flow returns to
valve B to move to the charge detent position E2. the tank. Check valve D ensures that ac-
Oil flows via orifice F to the spring chamber of cumulator pressure is maintained. The
valve A. This causes valve A to float. A minimum safety valve J check max. pressure of 100
oil flow goes to the return port 5 and back to the bar. The pressure switch 28 operates at 52
tank, the maximum oil flow goes to ports 21 / 23 bar.
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
10-174
STRUCTURE AND FUNCTION BRAKE SYSTEM
Function:
Operation:
10-175
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.
10-176
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 pres-
sure regulating valve, a hydraulic block, accumu-
lators for service brake and PPC circuit (emer-
gency boom lowering); a check valve for PPC
pressure and a hydraulic oil filter.
1. Decompression spindel
2. Decal
3. Strainer
J. Pressure regulating valve
10-177
STRUCTURE AND FUNCTION BRAKE SYSTEM
2
8
10
Front
axle
1 10
Rear
axle
5
3
6
1. Housing
2. PPC pressure filter
3. Pressure limiting valve
(PPC pressure)
4. PPC pressure accumulator
5. Check valve
6. Checkpoint PPC pressure
7. Brake pressure accumulator
8. Decompression spindel
9. By-pass valve
10. Checkpoint brake pressure
10-178
STRUCTURE AND FUNCTION BRAKE
BRAKE
1. Guide pin
2. Return spring
3. Cylinder
4. Brake piston
5. Outer gear (No. of teeth: 138)
6. Inner gear (No. of teeth: 105)
7. Plate
8. Disc
10-179
STRUCTURE AND FUNCTION BRAKE
Function
• Service brakes are wet-type multiple-disc brakes
and are installed to all four wheels.
Operation
• When the brake pedal is depressed, the pres-
sure oil from the brake valve moves brake pis-
ton (4) to the right in the direction of the arrow.
This brings disc (8) and plate (7) into contact,
and friction is generated between the disc and
plate. The wheel is rotating together with the
disc, so the machine speed is reduced and the
machine is stopped by this friction.
10-180
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 trans-
put shaft bearing, and uses the pushing force of a mission control unit keeps the transmission
spring to apply the brake mechaniclly and hydraulic in neutral, but the last selected gear is still
power to release the brake. shown 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 park- possible. It can used when moving the ma-
ing brake valve shuts off the oil pressure to the chine if the machine has stopped because of
parking brake and the parking is applied. When the trouble in the engine or transmission unit. If
parking brake lever is switched OFF, the oil pres- the engine is OFF and the parking brake
sure flows to the parking brake cylinder and the accumulators are empty, the parking brake
parking brake is released. is locked by spring force.
10-181
STRUCTURE AND FUNCTION PARKING BRAKE
PARKING BRAKE
10-182
STRUCTURE AND FUNCTION PARKING BRAKE 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
10-183
10-184
STRUCTURE AND FUNCTION HYDRAULIC PIPING
HYDRAULIC PIPING
Outline • Control of the maximum pressure in the hy-
• The hydraulic system consists of the work equip- draulic circuit is carried out by the relief valve
ment circuit and the steering circuit. The work inside the main control valve. A safety valve
equipment circuit controls the actuation of the (with suction) is installed in the bucket cylin-
bucket and attachments. der circuit to protect the circuit.
• The oil in hydraulic tank (4) is sent to main • Accumulator (10) is installed in the PPC pilot
control valve (1) by hydraulic pump (12). If the circuit, and makes it possible to lower the
spools for the bucket and boom in the main boom to the ground even when the engine
control valve are at the HOLD position, the oil has stopped.
flows to the drain circuit of the main control • Hydraulic tank (4) is a pressurized sealed
valve, is filtered by the filter inside the hydraulic type and has a breather equipped with a re-
tank, and then returns to the tank. lief valve. This makes it possible to pressu-
• When the work equipment control levers are rize the inside of the tank and also to prevent
operated, the PPC valve bucket spool or boom any negative pressure, thereby preventing any
spool is actuated, and the spools of the main cavitation of the pump.
control valve are actuated by hydraulic pres-
sure to send the oil from the main control valve
to boom cylinder (15) or bucket cylinder (2) to
operate the boom or bucket.
10-201
STRUCTURE AND FUNCTION WORK EQUIPMENT HYDRAULIC SYSTEM DIAGRAM
10-202
10-203
STRUCTURE AND FUNCTION WORK EQUIPMENT HYDRAULIC CIRCUIT DIAGRAM
10-204
STRUCTURE AND FUNCTION WORK EQUIPMENT HYDRAULIC CIRCUIT DIAGRAM
1. Hydraulic tank
2. Oil filter
3. Breather
4. T.C. pump
5. Hydraulic pump
6. PPC, brake pump
7. Steering pump
8. Switch pump
9. Filter
10. Accumulator charge valve
11. Accumulator
12. PPC valve
13. Orbit-roll
14. Steering stop valve
15. Steering valve
16. Flow control spool
17. Relief valve
18. Steering spool
19. Safety valve with suction
20. Cut-off valve
21. Steering cylinder
22. Relief valve
23. Bucket spool
24. Safety valve with suction
25. Float selector valve
26. Unload valve
27. Boom spool
28. Suction valve
29. Slow return valve
30. Boom cylinder
31. Bucket cylinder
32. Cooler
35. Security valve
36. Emerg. steering pump
37. Emerg. steering valve
10-205
STRUCTURE AND FUNCTION WORK EQUIPMENT HYDRAULIC CIRCUIT DIAGRAM
28
37
29
25
26
24
22
21
210
27
23
36
20
19
18
12
17
16
15
34
35
31
14
12
13
11A
10
1
31
3
11B
9
32
8
4
5
30
10-206
STRUCTURE AND FUNCTION WORK EQUIPMENT HYDRAULIC CIRCUIT DIAGRAM
10-207
STRUCTURE AND FUNCTION WORK EQUIPMENT HYDRAULIC DIAGRAM
28
37
29
25
26
24
22
21
23
27
36
20
26A
20A
19
18
12
17
15
16
35
34
14
12
13
11A
10
1
3
11B
31
9
32A
8
LO S/W
32
S/T Pi
33
T/C
5
30
10-208
STRUCTURE AND FUNCTION WORK EQUIPMENT HYDRAULIC CIRCUIT DIAGRAM
10-209
STRUCTURE AND FUNCTION WORK EQUIPMENT LEVER LINKAGE
10-210
STRUCTURE AND FUNCTION HYDRAULIC TANK
HYDRAULIC TANK
10-211
10-110-1
STRUCTURE AND FUNCTION HYDRAULIC TANK
BREATHER
1. Body
2. Filter element
3. Poppet
4. Sleeve
• Preventing negative pressure inside tank • Preventing rise in pressure inside tank
The tank is a pressurized sealed type, so if the If the pressure in the circuit rises above the set
oil level inside the hydraulic tank goes down, pressure during operations because of the
there will be negative pressure in the tank. If change in the oil level in the hydraulic cylinders
this happens, a poppet is opened by the differ- or the rise in the temperature, the sleeve is
ence between the pressure inside the tank and actuated to release the pressure inside the hy-
the atmospheric pressure, and air is let in to draulic tank.
prevent negative pressure from forming inside
the tank.
10-110-2
10-212
STRUCTURE AND FUNCTION PPC VALVE
PPC VALVE
10-211
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
Function
• The PPC valve is installed at the bottom of the
work equipment control lever and is connected
by a linkage to the control lever.
• The oil from the PPC pump is supplied to the
end of each spool of the main control valve in
accordance with the movement of the control
lever, and this actuates the spool. For this rea-
son, the operating force of the control lever is
small and this helps to reduce operator fatigue.
10-212
STRUCTURE AND FUNCTION PPC VALVE
PPC VALVE
10-213
STRUCTURE AND FUNCTION PPC VALVE
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
10-214
STRUCTURE AND FUNCTION PPC VALVE
1. Switch Forward-Neutral-Reverse
2
2. Switch Kickdown-Hold
Z
Z-Z
10-215
STRUCTURE AND FUNCTION PPC VALVE
10-216
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).
10-217
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.
10-218
STRUCTURE AND FUNCTION PPC RELIEF VALVE
1. Main valve
2. Spring
3. Valve seat
4. Pilot poppet
5. Spring
6. Screw
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.
10-219
STRUCTURE AND FUNCTION ACCUMULATOR (FOR PPC VALVE)
1. Gas plug
2. Shell
3. Poppet
4. Holder
5. Bladder
6. Oil port
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 kg/
cm2). 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.
10-220
STRUCTURE AND FUNCTION CUT-OFF VALVE
CUT-OFF VALVE
Up to SN WA470H632
10-221
STRUCTURE AND FUNCTION CUT-OFF VALVE
CUT-OFF VALVE
SN WA470H633 and up
1. Port G
2. Port F
3. Port K
4. Port H
5. Cut-off pressure relief valve
G H
Ø 0 ,8
Ø 1,2
F. Pump pressure
K. Checkpoint
G. To main control valve
H. Drain
K F
10-222
STRUCTURE AND FUNCTION MAIN CONTROL VALVE
2-SPOOL
10-223
STRUCTURE AND FUNCTION MAIN CONTROL VALVE
10-224
STRUCTURE AND FUNCTION MAIN CONTROL VALVE
Up to SN WA470H632
3-spool
(if equipped)
MA1: From PPC valve A1: To bucket cylinder bottom end P: Pump port
MA2: From PPC valve A2: To boom cylinder bottom end T: Drain port
MA3: From PPC valve A3: To attachment cylinder (to hydraulic tank)
MB1: From PPC valve B1: To bucket cylinder head end D1: Drain port
MB2: From PPC valve B2: To boom cylinder head end D2: Drain port
MB3: From PPC valve B3: To attachment cylinder
10-225
STRUCTURE AND FUNCTION MAIN CONTROL VALVE
10-226
STRUCTURE AND FUNCTION MAIN CONTROL VALVE
2-SPOOL
T
A2 B2
PA2 PB2
PA1 PB1
A1 B1
10-227
STRUCTURE AND FUNCTION MAIN CONTROL VALVE
7 7
6 4
9 9
1 5
10-228
STRUCTURE AND FUNCTION MAIN CONTROL VALVE
SN WA470H633 and up
3-spool
(if equipped) T
A2 B2
PA3 PB3
A1
PA2 PB2
PB1
PA1 A3
B1
B3
PA1: From PPC valve A1: To bucket cylinder bottom end P: Pump port
PA2: From PPC valve A2: To boom cylinder bottom end T: Drain port
PA3: From PPC valve A3: To attachment cylinder (to hydraulic tank)
PB1: From PPC valve B1: To bucket cylinder head end
PB2: From PPC valve B2: To boom cylinder head end
PB3: From PPC valve B3: To attachment cylinder
10-229
STRUCTURE AND FUNCTION MAIN CONTROL VALVE
7 7
6
8 8
3
10-230
STRUCTURE AND FUNCTION MAIN CONTROL VALVE
RELIEF VALVE
1. Main valve
2. Valve seat
3. Pilot poppet
4. Spring
5. Adjustment screw
6. Lock nut
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
escapes 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
10-231
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 (4). It is also sent to port C
by the orifice formed from main valve (2) and
pilot piston (4).
Pilot piston (4) 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 (3), main valve (2) is actu-
ated, and the oil from port A flows to port B.
10-232
STRUCTURE AND FUNCTION MAIN CONTROL VALVE
SUCTION VALVE
1. Main poppet
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.
10-233
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
working equipment valve and the drain, accord-
ing to operating conditions, and controls the
speed of the work equipment.
• The cut-off valve is activated by oil pressure for
standard models, by electronic governor con-
troller on Hyper models.
Standard
specification – • 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.
10-234
2) When the work equipment pump pres-
sure is higher than the cut-off pressure
When the cut-off pressure is reached, the
pressure of the oil in chamber a opens cut-
off valve (2), and the oil in unload valve (3)
chamber b passes through cut-off valve (2)
chamber c and is drained. The oil in unload
valve (3) chamber d passes through ori-
fices e and f, and into chamber b causing
the oil pressure in chamber d decrease,
and unload valve (3) to open. Thus, the oil
from the switch pump is drained.
10-235
STRUCTURE AND FUNCTION MAIN CONTROL VALVE
Function
• The float selector valve and unload valve are inside
the main control valve. When the boom lever is
operated to the FLOAT position, the float selector
valve detects this, and it is actuated to actuate the
unload valve and set the boom to the FLOAT posi-
tion.
Operation
• If the boom lever is pushed further from the LOWER
position, it is set to the FLOAT position and the
PPC valve is set to the same condition as for the
LOWER position.
The pressure at port A becomes high pressure and
the pressure at port B becomes low pressure.
• The oil from the working pump fills chamber F and
chamber E.
10-236
STRUCTURE AND FUNCTION MAIN CONTROL VALVE
10-237
STRUCTURE AND FUNCTION MAIN CONTROL VALVE
10-238
STRUCTURE AND FUNCTION MAIN CONTROL VALVE
10-239
STRUCTURE AND FUNCTION MAIN CONTROL VALVE
Operation
• When boom lever (3) is pushed to the FLOAT posi- and connects to the drain circuit. When port
tion, the PPC valve spool moves beyond the LOWER C1 is connected to the drain circuit, unload
position to the FLOAT position. The pressure oil at valve (8) moves up and the oil from the pump
port L flows to port M, and at the same time, it also flows to the drain circuit.
flows to port T and port W. In addition, the pressu- • Therefore, the oil at the cylinder rod end
rized oil at port S flows to port N. passes from port K through unload valve (8)
• The pressurized oil at port T pushes boom spool (2) and flows to the drain circuit. The oil at the
to the LOWER position. cylinder bottom flows from port I to port C,
• If a difference in pressure greater than the specified and then flows to the drain circuit. There-
pressure is generated at port W and port X, valve fore, the boom is set to the FLOAT condition.
(7) moves to the right, opens port C1 and port C,
10-240
STRUCTURE AND FUNCTION MAIN CONTROL VALVE
Operation The oil from check valve (9) flows from port
• When bucket lever (4) is pushed, the pressure oil at F to port G, and then flows to the cylinder
port L of the PPC valve flows from port 0 to port V. rod end.
In addition, the oil at port R flows to the drain circuit. • At the same time, the oil at the cylinder bot-
The pressure oil at port V moves bucket spool (1) tom flows from port D to drain port C, and
to the DUMP position. returns to the tank, so the bucket is dumped.
• The bypass circuit is closed by bucket spool (1), so
the oil from port A pushes open check valve (9).
10-241
STRUCTURE AND FUNCTION MAIN CONTROL VALVE
Operation
• When bucket lever (4) is pulled, the pressure oil at • The bypass circuit is closed by bucket spool
port L of the PPC valve flows from port P to port R. (1), so the oil from port A pushes open check
In addition, the oil at port V flows to the drain circuit. valve (9). The oil from check valve (9) flows
The pressure oil at port R moves bucket spool (1) from port D to port E, and then flows to the
to the TILT position. cylinder bottom.
• At the same time, the oil at the cylinder rod
end flows from port G to drain port C, and
returns to the tank, so the bucket is tilted.
10-242
AUFBAU UND FUNKTION HYDRAULIC SAFETY SYSTEM
2. Operation:
10-243
AUFBAU UND FUNKTION HYDRAULIC SAFETY SYSTEM
10-244
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
10-245
Blank for technical reason
10-246
STRUCTURE AND FUNCTION WORK EQUIPMENT LINKAGE
10-251
STRUCTURE AND FUNCTION WORK EQUIPMENT LINKAGE
10-252
STRUCTURE AND FUNCTION BUCKET
BUCKET
1. Bucket
2. Bolt-on cutting edge
3. Bucket tooth
10-253
STRUCTURE AND FUNCTION BUCKET POSITIONER AND BOOM KICK-OUT
1. Proximity switch
2. Proximity switch
3. Bucket cylinder rod
4. Lever
5. Plate
10-254
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 (1) fixed
to the cylinder by bolts.
• When the bucket is moved from the DUMP
position to the TILT position, the bucket cylin-
der rod moves to the left, and at the same time,
lever (4) also moves to the left. Proximity switch
(1) 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 (5) is fixed to the boom. In addition, prox-
imity switch (2) 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.
10-255
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.
10-256
STRUCTURE AND FUNCTION BUCKET POSITIONER AND BOOM KICK-OUT
Proximity switch
Lights up Goes out
actuation display
10-257
STRUCTURE AND FUNCTION BUCKET POSITIONER AND BOOM KICK-OUT
10-258
STRUCTURE AND FUNCTION BUCKET POSITIONER AND BOOM KICK-OUT
Proximity switch
Lights up Goes out
actuation display
10-259
10-260
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 (abnormalities in the machine where an alarm
machine. It processes this information swiftly is given) and normal conditions which are al-
and displays it on the monitor panel to inform ways displayed on the instrument panel (pilot
the operator of the condition of the machine. lamps and readings for the gauges, speedom-
• The machine monitor system consists of the eter, and 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.
10-281
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: WA470H21164 and up
4E. Speedometer * Pos. 5G (added), Serial number: WA470H21104 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 switch- the display. The switches are embossed sheet
ing function to control the electric components switches.
and controllers.
• There is one CPU (Central Processing Unit)
installed internally, and this processes the sig-
nals from the sensors and outputs the display.
10-282
STRUCTURE AND FUNCTION MAIN MONITOR
Display
Symbol Display item Display range Display method
category
Emergency steering
When actuated Display flashes
actuated (if equipped)
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
10-283
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
10-284
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.
10-285
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
other mechanisms. for the display portions. The switches are
embossed sheet switches.
10-286
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
10-287
STRUCTURE AND FUNCTION MAIN MONITOR
10-288
STRUCTURE AND FUNCTION TRANSMISSION AUTO-SHIFT CONTROL SYSTEM
D: Digital signal
P: Pulse signal
N: Network signal
CONTROL FUNCTION
Auto shift
Hold function
Kick-down function
Safety function
Troubleshooting
Model (engine) selection function
Outline
The auto-shift control system receives the position
signals from the directional lever and range lever,
the engine speed signal, travel speed signal, and
signals from other switches. The transmission con-
troller drives the speed solenoid valve and auto-
matically carries out shift control to select the opti-
mum speed range for the transmission.
10-289
STRUCTURE AND FUNCTION TRANSMISSION AUTO-SHIFT CONTROL SYSTEM
10-290
STRUCTURE AND FUNCTION TRANSMISSION AUTO-SHIFT CONTROL SYSTEM
10-291
STRUCTURE AND FUNCTION TRANSMISSION AUTO-SHIFT CONTROL SYSTEM
3.Engine speed (less than 1450 rpm 4→2 Less than 8,7 2
→ more than 1450 rpm) 3→2 Less than 7,6 2
10-292
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 start-
ing 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)
2016
downhill, the transmission is shifted down im-
mediately to make use of the braking force of
the engine.
MODEL SELECTION FUNCTION
5. Manual shift
If there should be any disconnection in the travel Model selection
speed sensor or any other failure, and the input
of the travel speed stops, the lever operation • The model is selected using the CN ENG
becomes manual. plug. This informs the transmission controller
of the type of engine. A dummy plug is lo-
Example: cated on this connection on the Komatsu
Directional lever F, speed lever 4 à F4 engine. This ensures that the correct data
Directional lever R, speed lever 2 à R2 records for switching control are activated in
the transmission controller.
10-293
STRUCTURE AND FUNCTION TRANSMISSION CONTROLLER
TRANSMISSION CONTROLLER
1. Connector
CONNECTOR SIGNALS
10-294
STRUCTURE AND FUNCTION TRANSMISSION CONTROLLER
TRANSMISSION CONTROLLER
COMBINED T/M AND ALS-CONTROLLER
CN1 Connector
CN2 Connector
CN3 Connector
CONNECTOR SIGNALS
10-295
Blank for technical reason
10-296
STRUCTURE AND FUNCTION E.C.S.S.
devices.
Solenoid
1) E.C.S.S controller (M type controller) Travel speed sensor (relief)
2) Input devices: E.C.S.S switch (system +
Solenoid
switch), pressure switch (boom cylinder bot-
tom pressure), travel speed sensor, model - E.C.S.S.
(High pressure accumulator)
Pressure switch
selection wiring harness, speed range se- Solenoid
controller
lection wiring harness (Low pressure
accumulator)
3) Output devices: solenoid valves (relief valve,
high pressure accumulator, low pressure ac- Speed range
selection
cumulator)
Serial communication
→ to main monitor
Model selection
wiring harness
10-311
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.
¡: ON
Note 1: The E.C.S.S system is switched ON-OFF
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
ON ON
ON ON
4 OFF ON – – x x x
Min. 5 km/h
5 – –
[Note 4]
– x x x
by operating the E.C.S.S switch on the Note 3: Input pulse frequency when travel speed
main monitor. is 1 km/h
When the system is ON, the E.C.S.S LED Model Pulse frequency (Hz)
display on the main monitor lights up.
WA320-3 54.41
The ON-OFF condition of the system is
retained even after the engine stops or WA380-3 47.70
the starting switch is turned OFF. The next WA420-3 40.96
time that the starting switch is turned ON, WA470-3 44.46
the system is set to the same condition as
before it was turned OFF. Note 4: If the travel speed exceeds 5 km/h when
(Main monitor function) the output is OFF, the output is turned
Starting switch OFF à Machine stops à ON.
Starting switch ON When the output is ON, the output stays ON
When system is ON à System ON
[
When system is OFF à System OFF
] until the travel speed reaches 3 km/h, and
when the travel speed goes below 3 km/h,
Note 2: Relationship between speed range signal the output is turned OFF.
and shift position
Speed range
Shift position
H-L Speed
1st OFF ON
2nd OFF OFF
3rd ON OFF
4th ON ON
ON: +24V, OFF: OPEN
10-312
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
1) Displays on controller
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)
10-313
STRUCTURE AND FUNCTION E.C.S.S.
5. Controller
1. ECSS-Controller
2. Self-diagnostic display
CN1 Connector
CN2 Connector
CN3 Connector
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
10-314
STRUCTURE AND FUNCTION E.C.S.S.
E.C.S.S.-SYSTEM
Up to SN WA470H20525
10-315
STRUCTURE AND FUNCTION E.C.S.S.
E.C.S.S.-SYSTEM (E.C.S.S.-PLUS)
SN WA470H20526 to WA470H20567
10-316
STRUCTURE AND FUNCTION E.C.S.S.
E.C.S.S.-ELECTRIC-CIRCUIT DIAGRAM
10-317
STRUCTURE AND FUNCTION ALS
ALS-CONTROL UNIT
Serial Number: WA470H20568 and up
10-318
STRUCTURE AND FUNCTION ALS
10-319
10-320
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.
Electro-
Speed sensor magnetic
Radiator water
level Contact ON OFF
Engine oil
pressure Contact OFF ON
Engine water
temperature Resistance
Torque converter
oil temperature Resistance
SPEEDOMETER SENSOR
Function
• The speedometer sensor is installed to the trans-
mission output gear. A pulse voltage is gener-
ated by the rotation of the gear teeth, and the
signal is sent to the machine monitor to display
the travel speed.
1. Connector
2. Magnet
3. Case
10-331
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.
10-332
STRUCTURE AND FUNCTION SENSORS
10-333
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. Bracket • This sensor is installed to the side face of the
3. Float oil pan. When the oil goes below the specified
4. Switch 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.
10-334
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 sub monitor to display the fuel level. When
the display on the maintenance monitor reaches
the specified level, the warning lamp flashes.
10-335
STRUCTURE AND FUNCTION SENSORS
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 sub monitor reaches the speci-
fied position, the lamp flashes and the buzzer
sounds to warn of the abnormality.
10-336
STRUCTURE AND FUNCTION ENGINE STARTING CIRCUIT
10-337
STRUCTURE AND FUNCTION ENGINE STOP CIRCUIT
10-338
STRUCTURE AND FUNCTION PREHEATING CIRCUIT
Outline Operation
• To improve the ease of starting in cold areas, an • When the starting switch is turned to the ON
automatic preheating system is installed. This sys- (ACC) position, a circuit is formed from start-
tem helps to reduce the preheating time and also ing switch terminal BR à controller inside
automatically sets the preheating time to match the main motor à preheating output ground.
engine water temperature when the starting switch The preheating relay coil is excited, so the
is operated. preheating relay is actuated to actuate the
• When the starting switch is turned to the ON (ACC) heater relay.
position, the preheating pilot lamp on the main moni- • Current flow from the battery à battery relay
tor lights up and preheating is carried out on the à heater relay à electrical intake air heater
intake air for the electric intake air heater. to carry out preheating. When the preheating
The engine water temperature is detected by the completion signal is sent from the controller,
water temperature sensor, and the preheating time the preheating relay and heater relay are
is set by the controller built into the main monitor. turned OFF and the preheating is completed.
• While the pilot lamp is lighted up, preheating is
being carried out, so the starting switch must be
kept at the ON position. If the starting switch is
turned to the START position while the pilot lamp is
ON, the preheating is canceled.
10-339
STRUCTURE AND FUNCTION ENGINE STARTING, STOP, PREHEATING CIRCUIT
Ground
10-340
STRUCTURE AND FUNCTION ENGINE STARTING, 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 mo- • Voltage flows in the following circuit: Start-
tor terminal 30, alternator terminal B+, battery re- ing motor terminal 30, alternator terminal
lay (K 106) terminal 30 and starting switch terminal B+, battery relay (K 106) terminal 30 and
30. starting switch terminal 30.
When the starting switch is turned (terminal 15), When the starting switch is turned (terminal
relay K106 is activated. Engine stop solenoid Y 15), relay K106 is activated. Engine stop
320 is activated, current flows in the preheating solenoid Y 320 is activated, current flows in
control circuit. the preheating control circuit.
• When the starting switch is turned further (terminal • Temperature switch B 14 is closed, ground
50a), relay neutral position (K 208) is activated, is connected to the main monitor and termi-
and current flows via terminal 30-87 if the gear nal 85 of the preheating relay K 282. Relay
lever is in neutral position. Current flows to the K282 and relay K 283 are activated. Current
starting motor relay K 158 and the starting motor flows to the preheating system. The lamp on
starts turning. the main monitor is activated via pin 15 of
connector XL 06. Preheating time depends
on the temperature and is controlled by the
Engine stop main monitor.
10-341
STRUCTURE AND FUNCTION ENGINE STARTING, STOP, PREHEATING CIRCUIT
Ground
Maav_aa
10-342
STRUCTURE AND FUNCTION ENGINE STARTING, STOP, PREHEATING CIRCUIT
Description Description
Sect. Sect.
6 S 43 Starting switch 5 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 2 K 320 Engine stop motor relay
1 M 320 Engine stop motor 4 B 14 Temp. sender pre-heating
8 V 118.2 Diode 5 K 208 Relay neutral position
6 K 106 Relay battery 2 K 282 Relay pre-heating
8 K158 Relay starting motor 3 K 283 Relay pre-heating
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_a.tbl
• Voltage flows in the following circuit: Starting mo- • Voltage flows in the following circuit: Start-
tor terminal 30, alternator terminal B+, battery re- ing motor terminal 30, alternator terminal
lay (K 106) terminal 30 and starting switch terminal B+, battery relay (K 106) terminal 30 and
30. starting switch terminal 30.
When the starting switch is turned (terminal 15), When the starting switch is turned (terminal
relay (K106) is activated. Engine stop motor 15), relay (K106) is activated. Engine stop
(M 320) is activated by the engine stop motor relay solenoid (Y 320) is activated, current flows
(K 320) (wire is being pulled out). in the preheating control circuit.
The preheating control circuit is activated. • Temperature switch (B 14) is closed, ground
• When the starting switch is turned further (terminal is connected to the main monitor and termi-
50a), relay neutral position (K 208) is activated, nal 85 of the preheating relay (K 282). Relay
and current flows via terminal 30-87 if the gear (K 282) and relay (K 283) are activated.
lever is in neutral position. Current flows to the Current flows to the preheating system. The
starting motor relay (K 158) and the starting motor lamp on the main monitor is activated via
starts turning. pin 15 of connector XL 06. Preheating time
depends on the temperature and is control-
led by the main monitor.
Engine stop
10-343
STRUCTURE AND FUNCTION PREHEATING CIRCUIT
RIBBON HEATER
Pre-heating
time
T1: Time pilot light is ON
T2: Time glow plug is working
Pilot light
Temperature (°C)
Function
Controller
reset
10-344
STRUCTURE AND FUNCTION ELECTRIC TRANSMISSION CONTROL
Function
1 Selection of F, R, and N positions Using directional lever
2 Selection of speed range Using speed lever
When traveling in F2, it is possible to shift down to 1st using this switch
3 Kick-down switch without using the speed lever. If directional lever is operated to R or N,
speed range automatically returned to 2nd.
4 Transmission cut-off function Transmission is shifted to neutral when left brake is operated
It is possible to select whether to actuate or not actuate the
transmission cut-off function. In this way, it is possible to obtain the
5 Transmission cut-off selector function same or greater ease of operation as on conventional loaders with the
left brake when carrying out scooping work or when loading or unloading
the machine from a trailer.
To prevent seizure of the parking brake when traveling with the parking
6 Neutralizer brake applied, the transmission is shifted to neutral when the parking
brake is applied.
If the directional lever is not at the N position, the engine will not start
7 Neutral safety function when the starting switch is turned. This prevents the machine from
starting suddenly. (For details, see STARTING CIRCUIT.)
8 Warning function When traveling in reverse, the backup lamp lights up and the backup
horn sounds to warn people in the area.
10-361
STRUCTURE AND FUNCTION ELECTRIC TRANSMISSION CONTROL
COMBINATION SWITCH
Outline
• The directional lever has three positions and the When each lever is operated to the desired
speed lever switch has four positions. As an position, the switch, which is interconnected by
individual part, the switch does not have a detent a shaft, acts to allow electric current to flow to
mechanism; the detent mechanism is in the com- that circuit only.
bination switch. Each switch is positioned by two
pins, and is secured to the body by three screws.
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
magnetism detection circuit, so it detects the
magnetism of magnet (3) and sends the F
position signal to the electric current amplifica-
tion circuit. In the electric current amplification
circuit, a signal is output to actuate the trans-
mission.
10-363
STRUCTURE AND FUNCTION KICK-DOWN, HOLD SWITCH
KICK-DOWN, HOLD-SWITCH
1. Kick-down switch
2. Spring
3. Wiring harness
4. Spring
5. Hold switch
10-364
STRUCTURE AND FUNCTION TRANSMISSION ELECTRIC CIRCUIT DIAGRAM
2
2
2
2
10-365
STRUCTURE AND FUNCTION TRANSMISSION ELECTRIC CIRCUIT DIAGRAM
Normal operation
(directional lever at F, speed lever at 2)
Solenoid F1 F2 F3 F4 N R1 R2 R3 R4
FORWARD (1) ¡ l ¡ ¡
REVERSE (2) ¡ ¡ ¡ ¡
H-L select (3) ¡ ¡ ¡ ¡
Speed select (4) ¡ ¡ ¡ ¡
10-366
STRUCTURE AND FUNCTION TRANSMISSION ELECTRIC CIRCUIT DIAGRAM
Solenoid F1 F2 F3 F4 N R1 R2 R3 R4
FORWARD (1) l ¡ ¡ ¡
REVERSE (2) ¡ ¡ ¡ ¡
H-L select (3) ¡ ¡ ¡ ¡
Speed select (4) l ¡ ¡ ¡
10-367
STRUCTURE AND FUNCTION TRANSMISSION ELECTRIC CIRCUIT DIAGRAM
Solenoid F1 F2 F3 F4 N R1 R2 R3 R4
FORWARD (1) ¡ ¡ ¡ ¡
REVERSE (2) ¡ l ¡ ¡
H-L select (3) ¡ ¡ ¡ ¡
Speed select (4) ¡ ¡ ¡ ¡
10-368
STRUCTURE AND FUNCTION TRANSMISSION ELECTRIC CIRCUIT DIAGRAM
Solenoid F1 F2 F3 F4 N R1 R2 R3 R4
FORWARD (1) ¡ ¡ l ¡
REVERSE (2) ¡ ¡ ¡ ¡
H-L select (3) l ¡ ¡ ¡
Speed select (4) ¡ ¡ ¡ ¡
10-369
STRUCTURE AND FUNCTION TRANSMISSION CUT-OFF SWITCH
1. Case 5. Tube
2. Seal film 6. Connector
3. Disc 7. Cover
4. Vinyl tape (Red) 8. Spring
Outline Specifications
• When the left brake pedal is operated, the switch
detects the oil pressure in the brake circuit, WA470-3
shuts off the electric power to the solenoid valve
circuit for the directional clutch, and shifts the Voltage Min. 18 V
transmission to neutral. value Max. 30 V
Current Min. 5 mA
value Max. 0.1 A
10-370
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 applied, and
the transmission is shifted to neutral at the same
time. If the transmission cut-off selector switch
is set to the OFF position (pilot lamp goes out),
the transmission is not shifted to neutral even
when the brake is operated, so the left brake
functions only as a brake in the same way as
the right brake.
Operation
1. Transmission cut-off selector switch ON
• If the transmission cut-off selector switch is turned
ON, the current from the transmission cut-off
switch (main monitor) is shut off, and current
flows only from the transmission cut-off switch
to terminal 16 of the transmission cut-off circuit
in the transmission controller. Voltage is applied
to transmission control valve solenoids F and R.
• When the left brake pedal is depressed, the
contacts of the transmission cut-off switch are
opened, so the voltage to solenoids R and F is
shut off. As a result, the brakes are applied as
normal, and the transmission is also shifted to
neutral at the same time.
10-371
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
contacts 1. to 2. and over the parking brake and is switched ON.
switch to chassis.
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 ............................................................................................................................. 10-462
Installation: WA 320-3, 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 .............................................................................................................................. 10-471
Operation: WA 320-3, 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, WA 380-3, WA 420-3, WA 470-3 ......................................... 10-484
Circuit diagram: Controoler for WA 320-3, WA 380-3, WA 420-3, WA 470-3 .......................................... 10-485
Circuit diagram air conditioner unit: WA 320-3, WA 380-3, WA 420-3, WA 470-3 ................................... 10-486
Plug assignment: circuit diagram air conditioner unit for WA 270-3 ........................................................ 10-488
Circuit diagram air conditioner unit: WA 270-3 ........................................................................................ 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
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
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
Switch on air-conditioner
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
• When the fan switch is turned OFF (the setting is not kept in memory with only the air condi-
tioner switch active)
If the air conditioner is used together with the FRESH position, the inside of the cab will be pressu-
rized 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
condi- tioning 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
CONTROLLER
Plug assignment
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
Masse
Signal
31
WA 270-3
31
39 40 41 42 43 44
Wiring Diagram
Air Conditioner
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
STRUCTURE AND FUNCTION WIRING DIAGRAMS
10-601
STRUCTURE AND FUNCTION WIRING DIAGRAMS
10-603
STRUCTURE AND FUNCTION WIRING DIAGRAMS
10-605
STRUCTURE AND FUNCTION WIRING DIAGRAMS
10-607
Wiring Diagrams
SN WA470H20669 and up
10-609
STRUCTURE AND FUNCTION WIRING DIAGRAMS
470EL1.tbl
10-610
STRUCTURE AND FUNCTION WIRING DIAGRAMS
10-611
STRUCTURE AND FUNCTION WIRING DIAGRAMS
10-612
STRUCTURE AND FUNCTION WIRING DIAGRAMS
470EL2.tbl
10-613
STRUCTURE AND FUNCTION WIRING DIAGRAMS
470EL3.tbl
10-614
STRUCTURE AND FUNCTION WIRING DIAGRAMS
10-615
STRUCTURE AND FUNCTION WIRING DIAGRAMS
10-616
STRUCTURE AND FUNCTION WIRING DIAGRAMS
470EL4.tbl
10-617
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
470EL5.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
10-618
STRUCTURE AND FUNCTION WIRING DIAGRAMS
10-619
STRUCTURE AND FUNCTION WIRING DIAGRAMS
10-620
Wiring Diagrams
From SN WA470H20942
Up to SN WA470H21064
10-621
STRUCTURE AND FUNCTION WIRING DIAGRAMS
470EL1a.tbl
10-622
STRUCTURE AND FUNCTION WIRING DIAGRAMS
10-623
STRUCTURE AND FUNCTION WIRING DIAGRAMS
10-624
Wiring Diagrams
SN WA470H21164 and up
Notice:
The electrical emergency steering pump has already been installed from Serial number
WA470H21065 and up. Alterations in connection with the wiring diagram are marked with (*)
in the legend.
The same is valid for the use of the auto transmission pilot switch from Serial number
WA470H21104 and up. Alterations in the wiring diagram are marked with (**) in the legend.
10-625
STRUCTURE AND FUNCTION WIRING DIAGRAMS
470EL1b.tbl
** SN WA470H21104 and up
10-626
STRUCTURE AND FUNCTION WIRING DIAGRAMS
10-627
STRUCTURE AND FUNCTION WIRING DIAGRAMS
10-628
STRUCTURE AND FUNCTION WIRING DIAGRAMS
420EL2b.tbl
10-629
STRUCTURE AND FUNCTION WIRING DIAGRAMS
470EL3b.tbl
* SN WA470H21065 and up
10-630
STRUCTURE AND FUNCTION WIRING DIAGRAMS
10-631
STRUCTURE AND FUNCTION WIRING DIAGRAMS
10-632
STRUCTURE AND FUNCTION WIRING DIAGRAMS
470EL4b.tbl
10-633
STRUCTURE AND FUNCTION WIRING DIAGRAMS
470EL5b.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
10-634
STRUCTURE AND FUNCTION WIRING DIAGRAMS
10-635
STRUCTURE AND FUNCTION WIRING DIAGRAMS
10-636
20 TESTING AND ADJUSTING
Standard value table for engine ............................ 20-2 Testing and adjusting fan belt tension ............... 20-131
Standard value table for chassis .......................... 20-5 Measuring accelerator pedal ............................ 20-132
Test certificate ...................................................... 20-8 Basic adjustment of accelerator pedal ........... 20-133-1
Standard value tables for electrical parts ............ 20-13 Measuring operating force,
Tools for testing, adjusting travel of speed lever ......................................... 20-134
and troubleshooting .......................................... 20-101 Measuring stall speed....................................... 20-135
From SN WA470H20669 Measuring torque converter, transmission,
up to SN WA470H20941: MTA11 (STC) parking brake oil pressure ............................... 20-137
Measuring engine speed .................................. 20-103 Method of operating emergency manual spool . 20-139
Measuring intake air pressure .......................... 20-104 Measuring clearance between tire and wheel ... 20-141
Testing and adjusting valves and injectors......... 20-105 Measuring steering oil pressure ....................... 20-144
Measuring blow-by pressure ............................ 20-112 Measuring brake performance ......................... 20-147
Measuring engine oil pressure ......................... 20-113 Testing brake oil pressure ................................ 20-148
Testing and adjusting fan belt tension ............... 20-114 Measuring brake disc wear .............................. 20-149
Measuring stall speed....................................... 20-116 Bleeding air from brake system........................ 20-150
Up to SN WA470H20668: S6D125-1 Measuring parking brake performance ............ 20-151
SN WA470H20942 and up: SA6D125E-2 Method for manual release of parking brake .... 20-152
Measuring engine speed .................................. 20-119 Testing wear of parking brake disc ................... 20-153
Measuring intake air pressure Measuring work equipment control lever .......... 20-154
(boost pressure) .............................................. 20-120 Measuring work equipment
Adjusting valve clearance ................................. 20-121 hydraulic pressure ........................................... 20-156
Measuring exhaust colour ................................ 20-122 Measuring PPC valve pressure ........................ 20-160
Measuring exhaust gas temperature ................. 20-123 Measuring work equipment .............................. 20-162
Measuring blow-by pressure ............................ 20-124 Testing and adjusting bucket positioner ............ 20-164
Measuring compression pressure .................... 20-125 Testing and adjusting boom kick-out ................. 20-165
Measuring engine oil pressure ......................... 20-126 Adjusting main monitor (speedometer module) . 20-167
Testing and adjusting fuel injection timing ......... 20-127 Checking for abnormality in fuel level sensor ... 20-168
Method for adjusting engine motor stop cable .. 20-129
« 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) 24 ± 1 24 ± 1
20-2
TESTING AND ADJUSTING STANDARD VALUE TABLE FOR ENGINE
20-3
TESTING AND ADJUSTING STANDARD VALUE TABLE FOR ENGINE
At rated output
Blowby pressure
(SAE30 or SAE15W-40 oil) mmH2O Max. 100 200
(Water temperature:
Min. 70°C)
(Water temperature:
Operating range)
°
Fuel injection timing Before top dead center (degree) 15.25 – 16.75 –
20-4
TESTING AND ADJUSTING STANDARD VALUE TABLE FOR CHASSIS
a1 48 —
Operating angle deg.
a2 30 —
N – FORWARD 35 ± 10 35 ± 20
Travel mm
N – REVERSE 35 ± 10 35 ± 20
temperature: 60 – 80°C
3rd – 4th 5.9 +5
–3 (0.6 +0.5
–0.3) Max. 16.7 (Max.1.7)
1st – 2nd 35 ± 10 35 ± 20
3rd – 4th 35 ± 10 35 ± 20
Engine water temperature
Torque converter stall gauge: Green range 2,180 - 2,280 –
Engine
B mm Max. 4.0 —
Clearance of wheel C 2 – 10 —
lock ring
20-5
TESTING AND ADJUSTING STANDARD VALUE TABLE FOR CHASSIS
Cate- Permissible
gory Item Measurement conditions Unit Standard value value
Engine stopped, machine
Play facing straight to front mm 30 – 70 30 – 100
Steering wheel
a1 45 —
Operating angle
a2 deg. 15+1 —
–0
Brakes
Play a3 5 ± 0.5 —
HOLD • RAISE
(Max. 2.4) (Max. 3.6)
Max. 15.7 Max. 23.5
RAISE • HOLD (Max. 1.6) (Max. 2.4)
Operating force
HOLD • LOWER Engine speed: Low idling Max. 24.5 Max. 37.3
Boom Hydraulic oil N (Max. 2.5) (Max. 3.8)
temperature: 45 – 55°C (kg)
LOWER • HOLD — —
20-6
TESTING AND ADJUSTING STANDARD VALUE TABLE FOR ENGINE
HOLD à RAISE 67 ± 15 67 ± 30
Engine speed: Low idling
Boom HOLD à LOWER Hydraulic oil 53 ± 15 53 ± 30
temperature: 45 – 55°C
Travel
HOLD à FLOAT 67 ± 15 67 ± 30
mm
HOLD à DUMP 60 ± 15 60 ± 30
Bucket
HOLD à TILT 60 ± 15 60 ± 30
PPC Maincontrolvalve
Clearance of bucket
Proximity
switch
Accumulator 20 14
ALS
• Hydraulic oil
bar
Working pressure temperature: 45 – 55°C 98 +5 103
+0,39 +0,4
1)* Serial No WA470H20618 and up: Standard: 2,94 0 (30 0 )
Permiss.: 2,94 +0,39 (30 +4 )
- 0,19 -2
20-7
TESTING AND ADJUSTING TEST CERTIFICATE
Up to SN WA470H20668
All pressures and timings to be measured with the machine at working temp. July 96
20-8
TESTING AND ADJUSTING TEST CERTIFICATE
All pressures and timings to be measured with the machine at working temp. January 98
20-9
TESTING AND ADJUSTING TEST CERTIFICATE
From SN WA470H20942
up to SN WA470H21163
All pressures and timings to be measured with the machine at working temp. March 1999
20-10
!
TESTING AND ADJUSTING TEST CERTIFICATE
SN WA470H21164 and up
Operating temp ° C
8 Engine (in operating temperature)
9 Torque converter 60 - 80
10 Hydraulic oil 45 - 55
20-11
Blank for technical reason
20-12
TESTING AND ADJUSTING STANDARD VALUE TABLE FOR ELECTRICAL PARTS
Short connector
below, the sensor is defective. switch ON.
Short connector Monitor goes off
connected
CN R06
disconnected Monitor lights up
Radiator water level CN R06
sensor If the condition is as shown in the table Turn starting
Check continuity
+1
Fuel level sensor CN R07 Full Approx. 10 – 3Ω
Empty Approx. 85 – 95 KΩ
20-13
TESTING AND ADJUSTING STANDARD VALUE TABLE FOR ELECTRICAL PARTS
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 CNE 11 If the condition is as shown in the table Start engine.
Check continuity
20-14
TESTING AND ADJUSTING STANDARD VALUE TABLE FOR ELECTRICAL PARTS
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 CNE 05
ance Normal tem- Approx. 2 kΩ CNE05.
temperature sensor (male) perature (25°C) Between CNE05
(male) – GND
Pre-heating 5°C Approx. 4 kΩ
resistance
2) Disconnect
F solenoid CNT01 connector.
(male) Between (1) – (2) 46 – 58 kΩ
2) Disconnect
R solenoid CNT02 connector.
(male) Between (1) – (2) 46 – 58 kΩ
2) Disconnect
H-L solenoid CNT03 connector.
(male) Between (1) – (2) 46 – 58 kΩ
2) Disconnect
Speed solenoid CNT04 connector.
(male) Between (1) – (2) 46 – 58 kΩ
2) Disconnect
Modulation valve CNT12
solenoid (male) Between (1) – (2) 12 – 15 Ω connector.
20-15
TESTING AND ADJUSTING STANDARD VALUE TABLE FOR ELECTRICAL PARTS
resistance
Measure
below, it is normal. switch OFF.
Relief solenoid for CNAF4 2) Disconnect
(male)
cylinder rod Between (1) – (2) 20 – 40 Ω CNAF4.
resistance
Measure
below, it is normal. switch OFF.
High pressure CNAF5 2) Disconnect
solenoid (male)
E.C.S.S. controller (if equipped)
2) Disconnect
Pressure switch CNAF7 Oil pressure above CNAF7.
(male) Continuity
5.4 MPa (55 kg/cm2) Between
Oil pressure below (1) – (2)
4.4 MPa (45 kg/cm2) No continuity
resistance
20-16
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
20-17
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
20-18
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.
20-19
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
20-20
TESTING AND ADJUSTING TOOLS FOR TESTING, ADJUSTING, AND TROUBLESHOOTING
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
J Commercially Scale ––
Stroke, hydraulic drift available
Commercially
Work equipment speed K available Stop watch ––
Troubleshooting of wiring
harnesses and sensors L 799-601-7400 T-adapter ––
Measuring voltage and Commercially
resistance values M available Tester ––
Commercially
Clearance O available Feeler gauge
20-101
20-102
TESTING AND ADJUSTING MEASURING ENGINE SPEED
20-103
TESTING AND ADJUSTING MEASURING INTAKE AIR PRESSURE (BOOST PRESSURE)
Note:
Intake manifold pressure (turbocharger boost) must
be corrected for variations due to intake air tem-
perature. Use the 'Boost Pressure Correction Fac-
tor' explained in Engine Testing - General Informa-
tion'.
20-104
TESTING AND ADJUSTING TESTING AND ADJUSING VALVES AND INJECTORS
1. Adjust the valves and the injectors at each 1,500 Intake valve 0,35
hour maintenance interval. If the valves and injectors Exhaust valve 0,68
have been adjusted during troubleshooting or before
the 1,500 hour scheduled maintenance interval, ad-
justment is not required at this time.
20-105
TESTING AND ADJUSTING TESTING AND ADJUSING VALVES AND INJECTORS
20-106
TESTING AND ADJUSTING TESTING AND ADJUSING VALVES AND INJECTORS
11. Rotate the tool around the tappet until the tool’s
locating pin is inserted into one of the four holes in
the top of the tappet.
20-107
TESTING AND ADJUSTING TESTING AND ADJUSING VALVES AND INJECTORS
Locknut: 61 Nm
(without torque wrench adapter)
Locknut: 47 Nm
(with torque wrench adapter (1))
20-108
TESTING AND ADJUSTING TESTING AND ADJUSING VALVES AND INJECTORS
mm
Intake valve 0,36
Exhaust valve 0,69
20-109
TESTING AND ADJUSTING TESTING AND ADJUSING VALVES AND INJECTORS
Locknut: 61 Nm
(without torque wrench adapter)
Locknut: 47 Nm
(with torque wrench adapter (1))
20-110
TESTING AND ADJUSTING TESTING AND ADJUSING VALVES AND INJECTORS
20-111
TESTING AND ADJUSTING MEASURING BLOW-BY PRESSURE
MEASURING BLOW-BY
PRESSURE
From SN WA470H20669
up to SN WA470H20941
20-112
TESTING AND ADJUSTING MEASURING ENGINE OIL PRESSURE
20-113
TESTING AND ADJUSTING TESTING AND ADJUSTING FAN BELT TENSION
New Used
Fan belt tension (N) 1330 530 to 1070
2. Adjustment
20-114
TESTING AND ADJUSTING TESTING AND ADJUSTING FAN BELT TENSION
New Used
Drive belt tension (N) 670 270 to 530
NOTE:
A belt is considered used if it has been in operation
for 10 minutes or longer.
2. Adjustment
1) Loosen the adjusting screw locknut (1).
20-115
TESTING AND ADJUSTING MEASURING STALL SPEED
« Measurement conditions
« Check that low idling and high idling are the stand-
ard values.
Person A:
1. Attach a reflective marker to the fan pulley.
Person B:
2. Start the engine and run at low idling.
20-116
TESTING AND ADJUSTING MEASURING STALL SPEED
Person B:
6. Check engine speed at high idling, using the digital
optical tachometer.
Person A:
1. Start the engine and run at high idling.
Person B:
3. Check engine speed at high idling, using the digital
optical tachometer.
20-117
TESTING AND ADJUSTING MEASURING STALL SPEED
20-118
TESTING AND ADJUSTING MEASURING ENGINE SPEED
20-119
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.
20-120
ADJUSTING VALVE CLEARANCE ADJSTING VALVE CLEARANCE
« Valve arrangement
Cylinder no. 1 2 3 4 5 6
Intake valve l l ¡ l ¡ ¡
Exhaust valve l ¡ l ¡ l ¡
20-121
TESTING AND ADJUSTING MEASURING EXHAUST COLOR
20-122
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 continued
until the sensor core heats up and a stable value
is obtained, the torque converter will overheat.
1) Use the full stall (torque converter stall + hydrau-
lic relief) to raise the exhaust gas temperature .
2) From the above condition, cancel the hydraulic
relief, and carry out only torque converter stall.
(The temperature will start to go down. If it does
not go down and continues to go up, make the
temperature setting at 1) higher.)
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.
20-123
TESTING AND ADJUSTING MEASURING BLOW-BY PRESSURE
20-124
ADJUSTING VALVE CLEARANCE MEASURING COMPRESSION PRESSURE
MEASURING COMPRESSION
PRESSURE
Up to SN WA470H20668
SN WA470H20942 and up
When measuring the compression pressure, be careful
not to touch the exhaust manifold or muffler, or to
get your clothes caught in the fan, fan belt or other
rotating parts.
20-125
TESTING AND ADJUSTING MEASURING ENGINE OIL PRESSURE
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 METHOD FOR ADJUSTING ENGINE STOP MOTOR CABLE
20-129
TESTING AND ADJUSTING METHOD FOR ADJUSTING ENGINE STOP MOTOR CABLE
4. Tighten all nuts and bolts. « Problems caused by improper adjustment of en-
gine stop motor cable
5. Turn the engine starting switch repeatedly to the
• When engine stop motor • Engine does not
ON and OFF positions, and check that the en-
cable is pulled and clear- stop
gine stop motor and cable work smoothly, then
ance between stop lever
carry out the following checks again.
and STOP stopper is too
large
1) Check visually that there is slack in the en-
• When cable is free and • Engine does not
gine stop motor cable when the engine is
clearance between stop give full output be-
running, and that the stop lever of the fuel
lever and RUN stopper is cause of drop in
injection pump has returned fully to the RUN
too large amount of fuel in-
position.
jected
2) Check that the clearance between the stop
lever (4) and stopper at the STOP end is 1 –
2 mm when the engine is stopped.
20-130
TESTING AND ADJUSTING TESTING AND ADJUSTING FAN BELT TENSION
2. Adjusting belt
1) Loosen alternator mount bolt (1) and adjust plate
mounting bolt (2).
2) Loosen the locknut, then tighten adjustment nut (3)
to adjust the tension of the belt.
3) After adjusting the belt tension to the standard value,
tighten the locknut, then tighten adjust plate mount-
ing bolt (2) and alternator mount bolt (1).
20-131
TESTING AND ADJUSTING MEASURING ACCELERATOR PEDAL
MEASURING ACCELERATOR
PEDAL
« Measurement conditions
• Engine water temperature: Within green range on
engine water temperature gauge
Measuring
1. Set push-pull scale I2 at a position 150 mm from
pedal fulcrum a.
« Put the center of push-pull scale I2 in contact
with a point 150 mm from the pedal fulcrum.
20-132
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.
20-133
TESTING AND ADJUSTING BASIC ADJUSTMENT OF ACCELERATOR PEDAL
BASIC ADJUSTMENT
OF ACCELERATOR PEDAL SN WA470H21164 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.
20-134
20-133-1
Blank for technical reason
20-135
20-133-2
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
20-134
TESTING AND ADJUSTING MEASURING STALL SPEED
« Measurement conditions
« 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 engine
block.
« Check that the engine speed is the standard value.
If it is not within the standard range, check for loose
linkage or play.
20-135
TESTING AND ADJUSTING MEASURING STALL SPEED
20-136
MEASURING TORQUE CONVERTER, TRANSMISSION,
TESTING AND ADJUSTING PARKING BRAKE OIL PRESSURE
Preparatory work
Measurement method
1. Priority pressure
1) Measurement port (P1, PT 1/8)
2) Start the engine, run at low idling, and measure
the pressure at the rated speed.
20-137
MEASURING TORQUE CONVERTER, TRANSMISSION,
TESTING AND ADJUSTING PARKING BRAKE OIL PRESSURE
Measurement method
1. Priority pressure
1) Measurement port (P1, PT 1/8)
2) Start the engine,run at low idling,and meas-
ure the pressure at the rated speed.
3. Pilot pressure
1) Measurement port (P3, PT 1/8)
2) Start the engine and measure the pressure.
4. Clutch pressure
1) Measurement part (P4, PT 1/8)
2) Start the engine.
3) Release the parking brake.
4) Place the directional lever at neutral, and meas-
ure the pressure when the speed lever is op-
erated.
20-138
TESTING AND ADJUSTING METHOD OF OPERATING EMERGENCY MANUAL SPOOL
METHOD OF OPERATING
EMERGENCY MANUAL SPOOL
Outline
20-139
TESTING AND ADJUSTING METHOD OF OPERATING EMERGENCY MANUAL SPOOL
20-140
TESTING AND ADJUSTING MEASURING CLEARANCE BETWEEN TIRE AND WHEEL
Method of measuring
1. Fitting of wheel lock ring
Using feeler gauge O, measure dimensions a and b
at four places around the circumference.
20-141
TESTING AND ADJUSTING TESTING AND ADJUSTING STEERING WHEEL
« Measurement conditions
Measurement method
20-142
TESTING AND ADJUSTING TESTING AND ADJUSTING STEERING WHEEL
« Measurement conditions
Measurement method
20-143
TESTING AND ADJUSTING MEASURING STEERING OIL PRESSURE
20-144
TESTING AND ADJUSTING MEASURING STEERING OIL PRESSURE
Adjusting
20-145
TESTING AND ADJUSTING MEASURING OPERATING FORCE, TRAVEL OF BRAKE PEDAL
MEASURING OPERATING
FORCE, TRAVEL OF SPEED
LEVER
« Measurement conditions
Travel of pedal
Pedal play
20-146
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.
20-147
TESTING AND ADJUSTING TESTING BRAKE OIL PRESSURE
Testing
1. Remove bleeder screw (1) and nipple (3), then
install tool Q2, nipple (3), and tool Q1 in order in the
mount of bleeder screw (1).
20-148
TESTING AND ADJUSTING MEASURING BRAKE DISC WEAR
Measurement method
1. Remove plug (1).
20-149
TESTING AND ADJUSTING BLEEDING AIR FROM BRAKE SYSTEM
20-150
TESTING AND ADJUSTING MEASURING PARKING BRAKE PERFORMANCE
Measurement method
20-151
TESTING AND ADJUSTING METHOD FOR MANUAL RELEASE OF PARKING BRAKE
1. Loosen bolt (1), then remove lock plate (2) from bolt
(3) (3 places).
20-152
TESTING AND ADJUSTING TESTING WEAR OF PARKING BRAKE DISC
20-153
TESTING AND ADJUSTING MEASURING WORK EQUIPMENT CONTROL LEVER
Measurement method
1. Operating force of work equipment control lever
Install push-pull scale I2 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.
20-154
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 (4) is dimension C at the notch at both
ends of cam (3).
Dimension C: 0 – 1 mm
20-155
TESTING AND ADJUSTING MEASURING WORK EQUIPMENT HYDRAULIC PRESSURE
« Measurement conditions
• Engine water temperature: Within green range on
engine water temperature gauge
• Hydraulic oil temperature: 45 – 55°C
• Engine speed: High idling
20-156
TESTING AND ADJUSTING MEASURING WORK EQUIPMENT HYDRAULIC PRESSURE
Adjusting
20-157
TESTING AND ADJUSTING MEASURING WORK EQUIPMENT HYDRAULIC PRESSURE
Measurement method
20-158
TESTING AND ADJUSTING MEASURING WORK EQUIPMENT HYDRAULIC PRESSURE
Adjusting
20-159
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 tem-
perature gauge green range
• Hydraulic oil temperature: 45 to 55°C
• Engine speed: High idle
• Work mode selector switch on High mode
(from SN WA470H21164 and up)
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 re-
leased, set the bucket lever to the dump position 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.
20-160
TESTING AND ADJUSTING MEASURING PPC VALVE PRESSURE
Adjusting
20-161
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 WA470H21164 and up)
• Steering position: Neutral
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.
20-162
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.
20-163
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.
20-164
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 height, return the
boom lever to the HOLD position, then stop the
engine.
20-165
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
Detectorposition
surface of proximity switch detection surface of proximity switch
Bucket
positioner
Boom kick-out
20-166
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 23,5 x 25 26,5 x 25
1 4 4
2 C (2)** 7
3 0 0
** SN WA470H21164 and up
20-167
TESTING AND ADJUSTING CHECKING FOR ABNORMALITY IN FUEL LEVEL SENSOR
Measurement method
• Connect one end of the probe of terminal (1), con-
tact the other probe with terminal (2), and measure
the resistance.
20-168
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.
20-169
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).
20-170
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.
20-171
TESTING AND ADJUSTING WORK EQUIPMENT HYDRAULIC SYSTEM
MEMO:
20-172
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 exter-
If components are disassembled immediately any fail- nally, so check any item that is considered to be
ure occurs: 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 judge
• It will become impossible to find the cause of the whether to handle it as a real failure or as a prob-
failure. lem with the method of operation, etc.
It will also cause a waste of manhours, parts, or oil or « When operating the machine to reenact the
grease, and at the same time, will also lose the confi- troubleshooting symptoms, do not carry out
dence of the user or operator. any investigation or measurement that may
For this reason, when carrying out troubleshooting, it make the problem worse.
is necessary to carry out thorough prior investigation 5. Troubleshooting
and to carry out troubleshooting in accordance with • Use the results of the investigation and inspec-
the fixed procedure. tion in Items 2 – 4 to narrow down the causes of
2. Points to ask user or operator failure, then use the troubleshooting flowchart to
1) Have any other problems occurred apart from the locate the position of the failure exactly.
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 prob- 2) Start from the most likely points.
lems 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 fail- 6. Measures to remove root cause of failure
ure? • Even if the failure is repaired, if the root cause of
When were these repairs carried out? the failure is not repaired, the same failure will
6) Has the same kind of failure occurred before? 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
connector, warm the inside of the wir-
ing 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 enter-
ing. If the opening is left open or is blocked with
a rag, there is danger of dirt entering or of the
surrounding area being made dirty by leaking
oil so never do this.
Do not simply drain oil out on to the ground,
collect it and ask the customer to dispose of it,
or take it back with you for disposal.
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
secondary flushing is carried out with the speci-
fied 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
N O
or the NO line to go to the next . (Note: The number written at the top right corner of
the is an index number; it does not indicate the order to follow.)
• Following the YES or NO lines according to the results of the check or measurement will lead finally
to the Cause column. Check the cause and take the action given in the Remedy column on the
right. (See Example (3))
• Below the [ ] there are the methods for inspection or measurement, and the judgement values.
If the judgement values below the are correct or the answer to the question inside the is
YES, follow the YES line; if the judgement value is not correct, or the answer to the question is NO,
follow the NO line.
• Below the is given the preparatory work needed for inspection and measurement, and the
judgement values. If this preparatory work is neglected, or the method of operation or handling is
mistaken, there is danger that it may cause mistaken judgement, or the equipment may be
damaged. Therefore, before starting inspection or measurement, always read the instructions
carefully, and start the work in order from Item 1).
4) General precautions
When carrying out troubleshooting for the failure mode (problem), precautions that apply to all items
are given at the top of the page and marked with «. (See Example (4))
The precautions marked « are not given in the , but must always be followed when carrying out
the check inside the .
5) Troubleshooting tools
When carrying out the troubleshooting, prepare the necessary troubleshooting tools. For details, see
TOOLS FOR TESTING, ADJUSTING, AND TROUBLESHOOTING.
6) Installation position, pin number
A diagram or chart is given for the connector type, installation position, and connector pin number
connection. When carrying out troubleshooting, see this chart for details of the connector pin number
and location for inspection and measurement of the wiring connector number appearing in the
troubleshooting flow chart for each failure mode (problem).
20-213
TROUBLESHOOTING METHOD OF USING TROUBLESHOOTING CHARTS
(3)
2016
(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
2016
20-215
TROUBLESHOOTING METHOD OF USING TROUBLESHOOTING CHARTS
[Questions]
Sections + in the chart on the right corre-
sponds 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
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 information
gained from [Questions] and [Check items].
20-216
TROUBLESHOOTING METHOD OF USING TROUBLESHOOTING CHARTS
20-217
TROUBLESHOOTING METHOD OF USING TROUBLESHOOTING CHARTS
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
20-220
TROUBLESHOOTING METHOD OF USING TROUBLESHOOTING CHARTS
7) Remedy
If the causes are narrowed down to one com-
mon cause, take the aciton given in the remedy
column.
The symbols given in the remedy column indi-
cate the following:
X: Replace, ∆: Repair, A; Adjust, C: Clean
20-221
TROUBLESHOOTING CONNECTOR TYPES AND MOUNTING LOCATIONS
20-222
TROUBLESHOOTING CONNECTOR TYPES AND MOUNTING LOCATIONS
20-223
TROUBLESHOOTING CONNECTOR TYPES AND MOUNTING LOCATIONS
20-224
TROUBLESHOOTING CONNECTOR TYPES AND MOUNTING LOCATIONS
C N L6 7
C N L52 C N L 52
CNL60 K 163.1 TDR2 K 163 .1 TD R 2
C N L2 0 0 C N L 61 TDR1 TDR1
C N L200 C N L200
C N L 55 K1 63 .2 K163.2
C N L4 9 C N L49
TDR 1 C N L 56 C N L67.1 C N L48 K 67.1 C N L48
C N L6 4 C N L67.2 C N L53 K67.2 C N L53
CNFS1
CNFS2
C NL22 CNFS3
C NL18 Z CNFS4
C NL19
C NL21 CNFS5
CNFS6
C N L3 1
C N L3 0 CNA8
CNL29
C N A 14
CNL03 CNA9
CNL09
C N A 11
CNL02
CNL06 CNA10
CNL07
CNA13
CNL08
CNA12
CNL05
CN A15
CNL63
CNA5
CN CL1 CNA7
CNCL2 CNA6
CNCL3 re l_ m c
C NL04
20-225
TROUBLESHOOTING CONNECTOR TYPES AND MOUNTING LOCATIONS
20-226
TROUBLESHOOTING CONNECTOR TYPES AND MOUNTING LOCATIONS
SN WA470H21164 and up
K101
K67 KTDR2
K161.1 KTDR1
K200
K414 K139
K209
(K218) K432
K443
K208 K282
K385
K8 K159
V118.1 K433
K165
Z V118.3
K337 K262
Forward K19 V118.2
(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 CNCL3 CNA6 Rel_m2
CNL04
20-227
TROUBLESHOOTING CONNECTOR TYPES AND MOUNTING LOCATIONS
(3/3)
Con- Con-
nector nector Mounting location
No . Type
CNE04 X type RPM sensor
CNE15 — Alternator B
CNE16 — Alternator R
CNE17 — Alternator E
20-228
TROUBLESHOOTING CONNECTOR TYPES AND MOUNTING LOCATIONS
20-229
TROUBLESHOOTING MOUNTING LOCATION OF DIODES
Add-
Diode - No. See page:
ress:
CNTD 1 20-230 Q6
CNTD 2 20-230 Q6
CNTD 3 20-230 Q6
CNTD 4 20-230 Q6
CNR 01 20-229 B3
CNR 02 20-229 B3
CNR 03 20-229 B3
CNR 04 20-229 B3
CNB 05 20-228 G6
CNB 06 20-228 G6
CNF 23 20-228 H7
F 12 20-228 E3
CNT 15 20-228 G4
CNT 16 20-228 G4
CNT 17 20-228 G4
CN 203 20-230 R3
20-230
TROUBLESHOOTING MOUNTING LOCATION OF DIODES
20-231
TROUBLESHOOTING MOUNTING LOCATION OF DIODES
20-232
TROUBLESHOOTING MOUNTING LOCATION OF DIODES
20-233
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
20-234
TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
1 5 8 4
4 8 5 1
TEW00237 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
20-235
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
20-236
TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
1 1
2 2
TEW00241 TEW00242
2 3 3 2
1 1
TEW00243 TEW00244
1 3
3 1
2 4 4 2
TEW00245 TEW00246
1 4 4 1
3 6 6 3
TEW00247 TEW00248
20-237
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
20-238
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
20-239
TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
TEW00263 TEW00264
TEW00263 TEW00265
20-240
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
STEERING, SWITCH PUMP COUNTERWEIGHT
Removal .................................................. 30-184 Installation .......................................... 30-256
Installation .............................................. 30-187 FUEL TANK
STEERING CYLINDER Removal .............................................. 30-253
Removal .................................................. 30-188 Installation .......................................... 30-254
Installation .............................................. 30-189 CAB
BRAKE VALVE Removal .............................................. 30-255
Removal .................................................. 30-190 Installation .......................................... 30-256
Installation .............................................. 30-191 MAIN MONITOR
RIGHT BRAKE VALVE (TANDEM) Removal .............................................. 30-257
Disassembly ........................................... 30-192 Installation .......................................... 30-258
Assembly ............................................... 30-193 MAINTENANCE MONITOR
LEFT BRAKE VALVE (SINGLE) Removal and Installation ..................... 30-259
Disassembly ........................................... 30-194 AIR CONDITIONER UNIT
Assembly ............................................... 30-195 Removal .............................................. 30-260
SLACK ADJUSTER Installation .......................................... 30-265
Removal .................................................. 30-196 AIR CONDITIONER CONDENSER
Installation .............................................. 30-197 Removal .............................................. 30-266
Disassembly ........................................... 30-198 Installation .......................................... 30-267
Assembly ............................................... 30-199 DRY RECEIVER
BRAKE Removal and Installation ..................... 30-268
Disassembly ........................................... 30-200 AIR CONDITIONER COMPRESSOR
Assembly ............................................... 30-206 Removal .............................................. 30-269
PARKING BRAKE DISC Installation .......................................... 30-270
042103
Removal .................................................. 30-214 TIRES
Installation .............................................. 30-216 Procedure for changing tires ............... 30-271
HYDRAULIC TANK
Removal .................................................. 30-217
Installation .............................................. 30-219
WORK EQUIPMENT, PPC PUMP
Removal .................................................. 30-220
Installation .............................................. 30-223
PPC VALVE
Removal .................................................. 30-224
Installation .............................................. 30-225
Disassembly ........................................... 30-227
Assembly ............................................... 30-228
MAIN CONTROL VALVE
Removal .................................................. 30-229
Installation .............................................. 30-231
Disassembly ........................................... 30-232
Assembly ............................................... 30-234
BUCKET CYLINDER
Removal .................................................. 30-237
Installation .............................................. 30-238
BOOM CYLINDER
Removal .................................................. 30-239
Installation .............................................. 30-240
HYDRAULIC CYLINDER
Disassembly ........................................... 30-241
Assembly ............................................... 30-244
WORK EQUIPMENT
Removal .................................................. 30-247
Installation .............................................. 30-250
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 ¡¡¡ 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 remov-
ing XXXX (1).
2. ∆ ∆ ∆ (2): ............................................... 1 Indicates that a technique is listed for use during
installation
3. pppp assembly (3)
.................................................... See Lubricant and Coolant Table
INSTALLATION OF ¡¡¡ ASSEMBLY .......... Title of operation
l Carry out installation in the reverse
order to removal.
1 ................................................ Technique used during installation
042103
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
042103
Nominal Plug (nut end) Sleeve nut (elbow end)
number Use the two items below as a set
02 07376-50210 07221-20210 (Nut), 07222-00210 (Plug)
03 07376-50315 07221-20315 (Nut), 07222-00312 (Plug)
04 07376-50422 07221-20422 (Nut), 07222-00414 (Plug)
05 07376-50522 07221-20522 (Nut), 07222-00515 (Plug)
06 07376-50628 07221-20628 (Nut), 07222-00616 (Plug)
10 07376-51034 07221-21034 (Nut), 07222-01018 (Plug)
12 07376-51234 07221-21234 (Nut), 07222-01219 (Plug)
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
12 07049-01215 12 10 15 Taper 1/8
øD
ød
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
l Tighten all bolts and nuts (sleeve nuts) to the specified (KES) torque.
l Install the hoses without twisting or interference.
l Replace all gaskets, O-rings, cotter pins, and lock plates with new parts.
l Bend the cotter pin or lock plate securely.
l When coating with adhesive, clean the part and remove all oil and grease, then coat the threaded portion
with 2 – 3 drops of adhesive.
l 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.
l Clean all parts, and correct any damage, dents, burrs, or rust.
l Coat rotating parts and sliding parts with engine oil.
l When press fitting parts, coat the surface with antifriction compound (LM-P).
l After fitting snap rings, check that the snap ring is fitted securely in the ring groove.
l When connecting wiring connectors, clean the connector to remove all oil, dirt, or water, then connect
securely.
l When using eyebolts, check that there is no deformation or deterioration, screw them fully, and align the
direction of the hook.
l 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.
042103
3. Next, operate the hydraulic cylinder 3 – 4 times to the end of its stroke.
4. 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.
l 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.
l 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.
l 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.
l Add the specified amount of grease (molybdenum disulphide grease) to the work equipment related parts.
30-5
DISASSEMBLY AND ASSEMBLY SPECIAL TOOL LIST
For
1 793-615-1310 Lifting tool (A) 1 FORWARD/
1st clutch
Installation,
For removal of
REVERSE/ clutch pack
2 793-615-1320 Lifting tool (B) 2 2nd, 3rd/
Disassembly, assembly of 4th clutch
transmission assembly,
transmission clutch pack A 3 793-615-1330 Pin 3
assembly For
FORWARD, Jig for
4 793-615-1220 Holder 1 REVERSE settling
piston piston seal
For 1st – ring
5 793-615-1210 Holder 1 4th piston
E 790-425-1620 Fixture 3
Disassembly, assembly of F 790-425-1630 Fixture 3
final drive assembly
G 793-520-2320 Fixture 2
042103
H 790-101-1002 Pump 1
I 790-101-2102 Puller 1
J 790-101-2300 Push-puller 1
Installation of center
hinge pin 1 793-520-2370 Push tool 1
2 793-520-2350 Push tool 1
K
3 793-520-2540 Guide 1
4 793-520-2360 Bar 2
793-463-1110 Stopper 2
30-6
DISASSEMBLY AND ASSEMBLY SPECIAL TOOL LIST
790-502-1003
or Cylinder repair stand 1
N 790-502-2000
790-101-1102 Pump 1
Removal,
Steering installation
O 790-330-1100 Wrench ass’y 1 cylinder of round
head
Removal,
Socket Steering installation
P 799-302-1270 (width across flats: 50) 1 cylinder of nylon
nut
Press fitting of
790-101-5021 Grip 1 coil bushing
Kit Part No.:
01010-50816 Bolt 1 790-201-1702
Boom
Q 790-201-1841 Push tool 1 cylinder
Bucket
790-201-1851 Push tool 1 cylinder
Disassembly, assembly of
hydraulic cylinder Steering
790-201-1751 Push tool 1 cylinder
Installation of
042103
Insertion of
790-101-5021 Grip 1 dust seal
Kit Part No.:
01010-50816 Bolt 1 790-201-1500
Bucket
S 790-201-1660 Plate 1 cylinder
Steering
790-201-1560 Plate 1 cylinder
Boom
790-201-1650 Plate 1 cylinder
1 793-520-2680 Installer 1
2 790-425-1640 Eye bolt 2
Disassembly, assembly of
T 3 793-570-1010 Push plate 1
brake assembly
4 790-425-1620 Fixture 3
5 790-425-1630 Fixture 3
30-7
30-8
042103
DISASSEMBLY AND ASSEMBLY STARTING MOTOR
REMOVAL OF STARTING
MOTOR ASSEMBLY
Disconnect the cable from the negative (-) terminal of
the battery.
INSTALLATION OF STARTING
MOTOR ASSEMBLY
• Carry out installation in the reverse order to removal.
1
« When installing the starting motor assembly, install
ground connection (4) securely.
042103
30-9
DISASSEMBLY AND ASSEMBLY ALTERNATOR
REMOVAL OF ALTERNATOR
ASSEMBLY
Disconnect the cable from the negative (-) terminal of
the battery.
042103
INSTALLATION OF
ALTERNATOR ASSEMBLY
• Carry out installation in the reverse order to removal.
1
« Adjust the belt tension. For details, see TESTING
AND ADJUSTING, Testing and adjusting fan belt ten-
sion.
30-10
DISASSEMBLY AND ASSEMBLY ENGINE OIL COOLER
1
Core mounting nut:
042103
30-11
DISASSEMBLY AND ASSEMBLY FUEL INJECTION PUMP
042103
6. Remove 2 lock bolts (12) of cross coupling and lami-
nate coupling. 2
« Before removing the bolts, mark the mounting
position of the laminate coupling and cross
coupling.
30-12
DISASSEMBLY AND ASSEMBLY FUEL INJECTION PUMP
INSTALLATION OF FUEL
INJECTION PUMP ASSEMBLY
1
Injection tube sleeve nut:
23.5 ± 1 Nm (2.4 ± 0.1 kgm)
2
Laminate coupling mounting bolt:
61.8 ± 3 Nm (6.3 ± 0.3 kgm)
3
« Install the injection pump. For details, see TEST-
ING AND ADJUSTING, Testing and adjusting fuel
injection timing.
30-13
30-14
042103
042103
30-15
DISASSEMBLY AND ASSEMBLY WATER PUMP
042103
INSTALLATION OF WATER
PUMP ASSEMBLY
• Carry out installation in the reverse order to removal.
« Adjustthebeittension.Fordetails,seeTESTING
AND ADJUSTING, Testing and adjusting fan belt
tension.
Mounting bolt:
66.7 ± 7.9 Nm (6.8 ± 0.8 kgm)
30-16
DISASSEMBLY AND ASSEMBLY TURBOCHARGER
REMOVAL OF
TURBOCHARGER ASSEMBLY
1. Lift off engine hood.
INSTALLATION OF
TURBOCHARGER ASSEMBLY
• Carry out installation in the reverse order to
removal.
042103
30-17
DISASSEMBLY AND ASSEMBLY NOZZELE HOLDER
REMOVAL OF NOZZLE
HOLDER ASSEMBLY
1. Disconnect fuel injection pipe (1) and spill
tube (2). 1
INSTALLATION OF NOZZLE
HOLDER ASSEMBLY
• Carry out installation in the reverse order to removal.
1
Spill pipe mounting joint bolt:
042103
24.5 ± 5 Nm (2.5 ± 0.5 kgm)
2
« Tighten the nozzle holder mounting bolts in turn
uniformly.
Nozzle holder assembly mounting bolt.
21.6 ± 3 Nm (2.2 ± 0.3 kgm)
30-18
DISASSEMBLY AND ASSEMBLY THERMOSTAT
REMOVAL OF THERMOSTAT
ASSEMBLY
1. Open engine hood left side cover and lock in posi-
tion.
INSTALLATION OF
THERMOSTAT ASSEMBLY
• Carry out installation in the reverse order to removal.
30-19
DISASSEMBLY AND ASSEMBLY CYLINDER HEAD
042103
4. Disconnect dust indicator wiring (5) and heater relay
wiring (6).
« Disconnect wiring clamps (6-1) and (6-2).
30-20
DISASSEMBLY AND ASSEMBLY CYLINDER HEAD
30-21
DISASSEMBLY AND ASSEMBLY CYLINDER HEAD
042103
16. Remove head cover (25). 4
30-22
DISASSEMBLY AND ASSEMBLY CYLINDER HEAD
30-23
DISASSEMBLY AND ASSEMBLY CYLINDER HEAD
INSTALLATION OF CYLINDER
HEAD ASSEMBLY
• Carry out installation in the reverse order to removal.
1
Air cleaner intake connector clamp:
8.3 ± 0.5 Nm (0.85 ± 0.05 kgm)
2
Fuel injection pipe sleeve nut:
29.4 ± 5 Nm (3.0 ± 0.5 kgm)
Spill pipe mounting bolt:
24.5 ± 5 Nm (2.5 ± 0.5 kgm)
3
« Screw in the exhaust manifold mounting bolts 2
- 3 threads by hand, tighten mounting bolts - ,
then tighten the other mounting bolts.
Exhaust manifold mounting bolt:
66.7 ± 7.9 Nm (6.8 ± 0.8 kgm)
4
Head cover mounting bolt:
9.8 ± 1 Nm (1.0 ± 0.1 kgm)
5
« Tighten the nozzle holder mounting bolts in turn uni-
formly.
042103
Nozzle holder mounting bolt:
21.6 ± 3 Nm (2.2 ± 0.3 kgm)
6
« 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
TESTING AND ADJUSTING, Adjusting valve
clearance.
Rocker arm assembly mounting bolt:
66.2 ± 7.4 Nm (6.75 ± 0.75 kgm)
Locknut:
66.2 ± 7.4 Nm (6.75 ± 0.75 kgm)
7
Rocker arm housing mounting bolt:
66.2 ± 7.4 Nm (6.75 ± 0.75 kgm)
« Adjust the crosshead as follows.
i) Loosen the locknut and turn the adjustment
screw back.
ii) Press the top of the crosshead lightly and screw
in the adjustment screw.
iii) When the adjustment screw contacts the valve
stem, screw it in a further 20°.
iv) Tighten the locknut to hold it in position.
Locknut:
66.2 ± 7.4 Nm (6.75 ± 0.75 kgm)
30-24
DISASSEMBLY AND ASSEMBLY CYLINDER HEAD
30-25
DISASSEMBLY AND ASSEMBLY RADIATOR
REMOVAL OF RADIATOR
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.
042103
1. Drain Loosen drain valve (3) and drain coolant.
« If the coolant contains antifreeze, dispose of it
correctly.
2. Radiator guard
1) Remove 4 mounting bolts of radiator guard, and dis-
connect wiring connector (4) of working lamp and
radiator water level sensor (4-1) at radiator end.
2) Lift off radiator guard (5).
30-26
DISASSEMBLY AND ASSEMBLY RADIATOR
3. Hood
1) Disconnect connector (6) of electric wiring at
inside of rear left of hood.
2) Remove left and right radiator baffles (7).
3) Sling hood (8), then remove front and rear, left
and right mounting bolts (9) and 3 top front mount-
ing bolts (10), and lift off hood.
Hood assembly:
230 kg (without rear fender)
305 kg (with rear fender)
042103
4. Hoses
6. Fan
Remove mounting bolts (19) of engine fan, then re-
move fan.
7. Radiator
Sling radiator assembly (20), then remove mounting
bolts (21), and lift off radiator.
30-27
DISASSEMBLY AND ASSEMBLY RADIATOR
INSTALLATION OF RADIATOR
ASSEMBLY
• Carry out installation in the reverse order to removal.
Cooiant: 40 l (radiator)
3 l (sub-tank)
042103
30-28
DISASSEMBLY AND ASSEMBLY ENGINE
REMOVAL OF ENGINE
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. Radiator
Remove radiator.
For details, see REMOVAL OF RADIATOR.
30-29
DISASSEMBLY AND ASSEMBLY ENGINE
2. Electric wiring
1) Disconnect CNER1 connector (4) and CNER2
connector (5) of engine wiring harness (3).
2) Disconnect slow blow fuse 120A connector
(6) and 80A connector (7).
3) Disconnect cable (8) between starting motor and
battery relay.
4) Disconnect starting motor ground cable.
3. Fuelhose
1) Disconnect hose (9) between fuel tank and feed
pump at feed pump end.
2) Disconnect fuel return hose (10) at injection pump
end.
3) Disconnect spill hose (11) at fuel tank end.
« After disconnecting the hoses, fit plugs to
prevent the entry of dirt or dust.
042103
4. Air conditioner, heater hoses
1) Disconnect air conditioner hoses (12) and
(13) from compressor. 1
2) Disconnect heater hoses (14) and (15) from en-
gine.
« After disconnecting the hoses, fit plugs to
prevent the entry of dirt or dust.
30-30
DISASSEMBLY AND ASSEMBLY ENGINE
6. Bulkhead
1) Remove cover (28) at bottom front of bulkhead
(27).
30-31
DISASSEMBLY AND ASSEMBLY ENGINE
Bulkhead: 135 kg
(including accumulator charge valve)
3) Raise bulkhead (27) straight up for approx. 400 mm.
« The bulkhead comes near the cab when
it is lifted, so be careful not to hit anything.
042103
8. Transmission support stand
Remove rear drive shaft (33), and set support stand
under transmission (34). 6
30-32
DISASSEMBLY AND ASSEMBLY ENGINE
9. Engine assembly
1) Remove engine oil drain valve (35) and radiator cool-
ant drain valve (36) from fuel tank.
30-33
INSTALLATION OF ENGINE
ASSEMBLY
• Carry out installation in the reverse order to removal.
1
Compressor hose:
7.9 ± 1.8 Nm (0.8 ± 1.2 kgm)
2 3
Accelerator cable mounting bolt:
53.9 ± 5 Nm (5.5 ± 0.5 kgm)
3
Condenser hose:
19.6 ± 24.5 Nm (2.0 ± 2.5 kgm)
4
Receiver hose:
3.9 ± 6.9 Nm (0.4 ± 0.7 kgm)
6
« Clean the connection and mating surface of the
drive shaft before installing.
7
« Be careful of the direction of installation of the
042103
cushions and spacers at the engine mount when
assembling.
Mount bolt:
926.7 ± 103 Nm (94.5 ± 10.5 kgm)
8
« When connecting the engine to the torque con-
verter, adjust the height so that the torque con-
verter shaft and ring gear go in smoothly.
Never try to use force when connecting.
« Use new parts for the torque converter and fly-
wheel housing O-rings.
O-ring at mating surface of torque con-
verter and engine flywheel:
Soapy water
30-34
• Bleeding air
1) Bleed air from brake line.
For details of the procedure for bleeding the air,
see TESTING AND ADJUSTING.
2) Bleed air from steering line.
For details of the procedure for bleeding the air,
see TESTING AND ADJUSTING.
30-35
DISASSEMBLY AND ASSEMBLY TORQUE CONVERTER CHARGING PUMP
REMOVAL OF TORQUE
CONVERTER CHARGING
PUMP
1. Drive shaft
Remove guard of center drive shaft, and disconnect
drive shaft (1) at transmission end. 1
« Move the drive shaft towards the side of the
frame.
Center drive shaft: 36 kg
2. Piping
1) Remove suction tube (2) of charging pump from
pump. 2 1
2) Disconnect hose (3) between pump and flow
valve at pump end. 3
5
INSTALLATION OF TORQUE 2
3
CONVERTER CHARGING
PUMP 4
1 Drive shaft:
112.8 ± 9.8 Nm (11.5 ± 1.0 kgm)
DEW01437
2 3
« Replace the O-ring with a new part.
4
« Replace the O-ring with a new part.
Pump mounting bolt:
279.5 ± 29.4 Nm (28.5 ± 3.0 kgm)
30-42
DISASSEMBLY AND ASSEMBLY TORQUE CONVERTER, TRANSMISSION
REMOVAL OF TORQUE
CONVERTER, TRANSMISSION
ASSEMBLY
1. Cover
Remove cover (3) at bottom of cab.
2. Ladders
Remove left and right ladders (3-1). 3-1
Ladder rail (right): 64.5 kg
Ladder rail (left): 59.5 kg
DEW01440
30-43
DISASSEMBLY AND ASSEMBLY TORQUE CONVERTER, TRANSMISSION
3. Electric wiring
10 11 9
Disconnect the following electric wiring.
1) Disconnect transmission wiring TL1 (4) and TL2
(5).
8
2) Disconnect floor wiring harnesses LR5 (6), LR6
(7), LR3 (8), LR4 (9), LR1 (10), and LR2 (11).
« After disconnecting the connectors, mark with 6
a tag to distinguish when installing.
4
5 7 DEW00497
10 11
8 9
6 7
042103
4 5 DEW00500
4. PPC piping
1) Disconnect hose (12) of PPC valve port “P2”,
hose (13) of port “P4”, hose (14) of port “P3”,
and hose (15) of port “P1” at valve end.
2) Disconnect hose (16) between PPC accumula-
tor and PPC valve at valve end.
3) Disconnect hose (17) of PPC valve drain port at
valve end.
« After disconnecting the hoses, mark with a
tag to distinguish when installing.
« After disconnecting the hoses, fit plugs to
prevent the entry of dirt or dust.
30-44
DISASSEMBLY AND ASSEMBLY TORQUE CONVERTER, TRANSMISSION
5. Brake piping
1) Disconnect hoses (18) and (19) between right
brake valve and accumulator at pedal end.
« Remove 2 brake hose clamps under floor
board.
2) Disconnect hose (20) between left brake valve
and accumulator at pedal end.
3) Disconnect right brake valve drain hose (21)
and left brake valve drain hose (22) at rear
frame portion.
4) Disconnect hose (23) between front brake and 18 19 28
right brake valve at center hinge pin. DEW01425
21 22
042103
DEW00504
7. Accelerator cable 3
Disconnect accelerator cable (28) under pedal.
26 27 25 24
« Remove the cable clamp at the floor board. DEW00505
8. Steering pipes 4
Remove the orbit-roll servo pipes (4).
30-45
DISASSEMBLY AND ASSEMBLY TORQUE CONVERTER, TRANSMISSION
10. Bulkhead
1) Disconnect piping inside bulkhead. 34
i) Disconnect hose (39) between air conditioner
compressor and condenser at condenser
end. 6
« After disconnecting the hose, fit plugs in
the hose and condenser connector to
prevent the entry of dirt or dust.
ii) Disconnect hose (34) between PPC accu-
mulator and PPC valve inside bulkhead. 33
iii) Disconnect hose (36) of radiator sub-tank
(35) and hose (38) of window washer tank DEW00509 DEW00510
(37) at tank end.
« Remove the hose from the hose clamp.
« After disconnecting the hoses, fit plugs
to prevent the entry of dirt or dust.
39
36
2) Bulkhead
i) Remove cover (40) at bottom front of bulk- 38
DEW00511
head (39-1). 35 37
ii) Remove mounting bolts (42) at top of hood
(41) and bulkhead (39-1).
« Be careful not to lose the washers and
rubber of the mounting portion.
iii) Install eyebolts at the top 4 corners of bulk- 41
head (39-1), then sling and remove the bot-
tom mounting bolts. 42
40
Bulkhead: 135 kg 39-1
(including accumulator and charge
pump)
39-1
DEW00513 DEW00512
30-46
DISASSEMBLY AND ASSEMBLY TORQUE CONVERTER, TRANSMISSION
30-47
DISASSEMBLY AND ASSEMBLY TORQUE CONVERTER, TRANSMISSION
042103
Center drive shaft: 36 kg
30-48
DISASSEMBLY AND ASSEMBLY TORQUE CONVERTER, TRANSMISSION
30-49
DISASSEMBLY AND ASSEMBLY TORQUE CONVERTER, TRANSMISSION
INSTALLATION OF TORQUE
CONVERTER, TRANSMISSION
ASSEMBLY
3 Cable locknut:
53.9 ± 5 Nm (5.5 ± 0.5 kgm)
042103
6 Air conditioner condenser hose:
New refrigerant compressor oil (ND-OILB)
Air conditioner condenser hose:
19.6 – 24.5 Nm (2.0 – 2.5 kgm)
7 8
« Replace the O-rings with new parts.
« Install the clamps before connecting the hoses
and tubes.
9 10
Mounting bolt:
112.8 ± 9.8 Nm (11.5 ± 1.0 kgm)
« Check that the match mark is aligned.
11
« Remove block at the bottom of the flywheel
housing.
12
« Replace the O-rings with new parts.
Mounting bolt:
68.6 ± 5 Nm (7.0 ± 0.5 kgm)
30-50
DISASSEMBLY AND ASSEMBLY TORQUE CONVERTER, TRANSMISSION
13
• Bleeding air
1) Bleed air from brake line.
For details of the procedure for bleeding the air,
see TESTING AND ADJUSTING.
042103
30-51
DISASSEMBLY AND ASSEMBLY TORQUE CONVERTER
DISASSEMBLY OF TORQUE
CONVERTER ASSEMBLY
DEW00529
042103
DEW00530 DEW00531
DEW00532
18
DEW00533 DEW00534
30-52
DISASSEMBLY AND ASSEMBLY TORQUE CONVERTER
2. Stator
1) Remove snap ring (9). 10 9
2) Remove stator (10).
DEW00535
3. Stator shaft
Using forcing screws , push from stator shaft (11) 11
end and disconnect from pump assembly (12).
12
042103
DEW00536
4. Gear
Remove gear (13) from pump (14). 13
14
DEW00537
5. Bearing
Remove bearing (15) from gear (13). 13
15
DEW00538
30-53
DISASSEMBLY AND ASSEMBLY TORQUE CONVERTER
ASSEMBLY OF TORQUE
CONVERTER ASSEMBLY
1. Bearing
Install bearing (15) to gear (13).
2. Gear
Install gear (13) to pump (14). 13
Mounting bolt:
66.2 ± 7.4 Nm (6.75 ± 0.75 kgm)
042103
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
30-54
DISASSEMBLY AND ASSEMBLY TORQUE CONVERTER
4. Stator
1) Install stator (10). 10 9
2) Install snap ring (9).
DEW00535
DEW00543
18
DEW00533
DEW00545
30-55
DISASSEMBLY AND ASSEMBLY TORQUE CONVERTER
DEW00531 DEW00530
042103
DEW00529
30-56
DISASSEMBLY AND ASSEMBLY TRANSMISSION
DISASSEMBLY OF
TRANSMISSION ASSEMBLY
11 4
1. Coupling
5
1) Pull out lower rear coupling (1). 13
2) Remove lower front coupling (2) and mounting
bolt (3), then remove coupling.
12
3) Remove sensors.
2. Accumulator valve
Remove mounting bolts (5) of accumulator valve (4), 10
then remove accumulator valve and gasket. 9
« After removing, cover with tape to prevent the 14 15 6 8 7 1 DEW00549
sembly. 3
« After removing, cover with tape to prevent DEW00550
4. Flow valve
Remove mounting bolts (11) of flow valve (10), then
remove flow valve and O-ring.
« Remove the hose from the pump and the hose
from the oil filter.
« After removing, cover with tape to prevent the
entry of dirt or dust.
6. Filler tube
Remove mounting bolts (15) of filler tube (14), then
remove filler tube.
30-57
DISASSEMBLY AND ASSEMBLY TRANSMISSION
8. Transmission assembly
M12, P=1.75 70 112
Install transmission assembly to stand. Depth 21
(949)
(939)
in the diagram on the right.
10
Flywheel
mating
120 surface
250 130 728 M16, P=2.0
042103
Depth 31
500 DEW00553
DEW00554
[TORQUE CONVERTER]
1. Torque converter Lifting tool
i) Remove 6 bolts installing torque converter case 24
(22) and torque converter.
ii) Fit lifting tool to gear portion of drive case (24) 23
of torque converter assembly (23) and lift off
from torque converter case (22). 22
DEW00555
30-58
DISASSEMBLY AND ASSEMBLY TRANSMISSION
2. PTO gear
1) PTO idler assembly PTO gear PTO idler
i) Remove lock bolts (26) of idler shaft (25),
then remove idler shaft, O-ring (27), and
gear assembly (28).
PTO gear
DEW00556
28 25
042103
26 27 DDW00557
31 30 29 34
DDW00558
2) PTO gear
i) Remove snap ring (35), then lower ring (35), 37 42 38 43 35 36
and remove split spacer (37).
ii) Pull out shaft (38) and remove gear (39).
iii) Remove snap rings (40) and (42), then re-
move bearings (41) and (43).
« Remove the PTO gear on the opposite
side in the same way.
41 40 39 DDW00559
30-59
DISASSEMBLY AND ASSEMBLY TRANSMISSION
[TRANSMISSION]
Counter gear
1st, FORWARD clutch DEW00560
042103
1) Install puller to countershaft (2) and bearing (3)
1st, FORWARD cluth 2nd, REVERSE clutch
and remove bearing, then remove gear (4) from DEW00561 DEW00562
shaft.
2) Remove snap ring (5), then remove gear (6).
3) Remove shaft (2), then remove bearing (7) with
puller. 3 Puller
« When setting the puller in position, use a
4
block at the end face of the clutch shaft
when carrying out the operation. 5 2
BRAKE ASSEMBLY.
6. Output shaft
1) Remove mounting bolts (9) of gear cover (8), 10
then remove cover.
8
Transmission
case
DEW00565
30-60
DISASSEMBLY AND ASSEMBLY TRANSMISSION
11 DEW00567
7. Transmission case
1) Remove O-rings (17-1) and (18) from transmis-
sion case.
2) Remove bearing (19) and snap ring (20) of
19 W
driven gear from case.
20
17-1 19
W
18 W-W
DEW00568
18
17-1
DEW00569
30-61
DISASSEMBLY AND ASSEMBLY TRANSMISSION
ASSEMBLY OF TRANSMISSION
ASSEMBLY
1. Transmission case
1) Press fit bearing (19) of driven gear to trans-
19 W
mission case, and install snap ring (20).
2) Install O-rings (17-1) and (18) to transmission 20
case. 17-1 19
W
18 W-W
DEW00568
18
042103
17-1
DEW00569
2. Output shaft
1) Press fit bearing outer race (15) to transmission 8 13
case.
2) Press fit bearing inner (14) at output shaft rear
coupling end. 9
« Press fit securely so that there is no clear- 11
14
ance at the end face of the bearing.
3) Install snap ring (12) to output shaft (10), then 15 12
install output gear (11), and press fit inner bear-
ing (13). 16 10
« Press fit securely so that there is no clear-
ance at the end face of the bearing. 17 DDW00566
Mounting bolt:
Thread tightener (LT-2) 8
Mounting bolt: Transmission
case
112.8 ± 9.8 Nm (11.5 ± 1.0 kgm)
DEW00565
30-62
DISASSEMBLY AND ASSEMBLY TRANSMISSION
3. Parking brake
a
Assemble parking brake.
For details, see ASSEMBLY OF PARKING BRAKE 16 b
ASSEMBLY.
Q
4. Rear coupling oil seal
Install oil seal (16) and dust seal (17) to transmis-
sion case so that they are at position given below.
« a: 50 ± 0.2 mm Grease
portion Q
« b: 35 ± 0.2 mm
Oil seal, lip of dust seal: Grease (G2-LI) 17
DEW00574
5. Counter gear
1) Install snap ring (5) and gear (6) to shaft (2), 3
and press fit bearing (7). 4
2) Install snap ring and gear (4) to opposite end of
shaft (2), and press fit bearing (3). 5 2
« Press fit securely so that there is no clear-
ance at the end face of the bearing. 7
6
042103
DEW00563
8. Seal rings
Install seal rings (1) to shafts of 1st, FORWARD Input shaft 2nd, REVERSE clutch
clutch, 2nd, REVERSE clutch, and 3rd, 4th clutch. 3rd, 4th clutch
Counter gear
1st, FORWARD clutch DEW00560
30-63
DISASSEMBLY AND ASSEMBLY TRANSMISSION
Portion P DEW00579
042103
tion.
iii) Set split spacer (37) in position, then install 41 40 39 DDW00559
26 27 DDW00557
30-64
DISASSEMBLY AND ASSEMBLY TRANSMISSION
3) Torque converter
i) Fit lifting tool to gear portion of drive case
(24) of torque converter assembly (23), and
set to torque converter case (22).
ii) Tighten bolts (22-1) installing torque con-
verter case (22) and torque converter.
Torque converter mounting bolt:
112.8 ± 9.8 Nm (11.5 ± 1.0 kgm) 22-1
DDW00583
Outside
042103
´1
DEW00555
´1 ´2 B
Inside H
´2
B= 2–5 mm
H= 2–5 mm
Transmission Portion Q
case
DEW00554 DEW00587
30-65
DISASSEMBLY AND ASSEMBLY TRANSMISSION
042103
13. Filler tube 11 4
Fit filler tube (14) with mounting bolt (15) temporar-
ily, and move towards inside of transmission. 5
« After mounting the transmission on the machine, 13
install the filler tube at the specified position.
12
14. Transmission oil filter
1) Install bracket (13) and oil filter to transmission.
Oil filter mounting bolt:
10
68.6 ± 4.9 Nm (7.0 ± 0.5 kgm)
Filter bracket mounting bolt: 9
112.8 ± 9.8 Nm (11.5 ± 1.0 kgm) 14 15 6 8 7 1 DEW00549
30-66
DISASSEMBLY AND ASSEMBLY TRANSMISSION
9
18. Couplings 14 15 6 8 7 1 DEW00549
1) Front coupling
Install front coupling (2) to output shaft, and
tighten O-ring and washer with coupling mount-
ing bolt (3).
Mounting bolt:
926.7 ± 98.1 Nm (94.5 ± 10.0 kgm)
2) Rear coupling
Install rear coupling (1) to rear end of output
shaft.
30-67
DISASSEMBLY AND ASSEMBLY TRANSMISSION CLUTCH PACK
DISASSEMBLY OF
TRANSMISSION CLUTCH PACK
ASSEMBLY A1, A2 ø140
FORWARD, ø115.3 +0.2
0
1st
FORWARD, 1ST CLUTCH ASSEMBLY
2C
1. Assembly of FORWARD clutch pack assembly
50+0.5
2C
0
6
« Lift the clutch pack assembly with lifting tools A1
110
and A2, and install to lifting stand . ø90
5
6 – 9t
FORWARD, 1st clutch assembly: 100
76.5 kg 200°
DEW00593 DEW00594
1) Seal rings
Puller
Remove 3 seal rings (1) installed to shaft.
2) Bearing, thrust washer
i) Install puller to end face of shaft, and re- 1
move bearing (2).
« When setting the puller in position, in-
stall a block to the end face of the 2
clutch shaft before carrying out the op-
eration. 4
ii) Remove thrust washer (3) and spacer (4) 2 3
042103
from shaft.
DEW00595 DEW00596
7
7-1
DEW00597 DDW00598
4) End plate
Push end plate (8) with tool in diagram below,
remove snap ring (9), then remove end plate (8)
from clutch case (10). 9
8
11
ø170
ø85
9
12
ø101.6
13
10
10
9 – 12 290 9 – 12 DEW00600 DDW00601
Tool
DEW00599
30-68
DISASSEMBLY AND ASSEMBLY TRANSMISSION CLUTCH PACK
5) Clutch plates
Remove separator plates (12), disc plates (11), 12 11
and wave springs (13) from inside clutch (10).
« Be careful not to let the separator plates or
disc plates catch in the clutch case ring
groove.
13
DEW00602
6) FORWARD piston
Remove FORWARD piston (14) from inside clutch
case, then remove piston seals (15) and (16)
14 15 14
from piston.
16
042103
DEW00603 DEW00604
5c
8
100
200°
DEW00605 DEW00606
DEW00607 DEW00608
30-69
DISASSEMBLY AND ASSEMBLY TRANSMISSION CLUTCH PACK
22
22-1
DEW00609 DDW00610
3) End plate
Push end plate (8) at 1st clutch end with tool ,
remove snap ring (9), then remove end plate
from clutch case (10). 9
8
11 9
12
10 13
042103
DEW00611 DDW00612
4) Clutch plates
Remove separator plates (12), disc plates (11),
and wave springs (13) from inside clutch case
(10).
« Be careful not to let the separator plates or 11
disc plates catch in the clutch case ring
groove.
12
13
DEW00613
5) 1st piston
Remove 1st piston (23) from inside clutch case,
then remove piston seals (24) and (25) from 23
23
piston.
« The shape of the 1st piston is different from
the shape of the FORWARD piston on the
opposite side.
25 24
DEW00614 DEW00615
30-70
DISASSEMBLY AND ASSEMBLY TRANSMISSION CLUTCH PACK
DEW00616
1) Seal rings
Puller
Remove 3 seal rings (1) installed to shaft.
2) Bearing, thrust washer
i) Install puller to end face of shaft, and re- 1
move bearing (2).
« When setting the puller in position, in-
stall a block to the end face of the 2
clutch shaft before carrying out the op-
eration. 4
ii) Remove thrust washer (3) and spacer (4) 2 3
042103
from shaft.
DEW00595 DEW00596
7
DDW00620
DEW00619 7-1
4) End plate
Push end plate (8) with tool , remove snap
ring (9), then remove end plate from clutch case
(10). 9
8
11
9
12
10 13
10
DEW00600 DDW00621
30-71
DISASSEMBLY AND ASSEMBLY TRANSMISSION CLUTCH PACK
5) Clutch plates
Remove separator plates (12), disc plates (11),
and wave springs (13) from inside clutch case.
« Be careful not to let the separator plates or 11
disc plates catch in the clutch case ring
groove.
12
13
DEW00623
6) REVERSE piston
Remove REVERSE piston (14) from inside clutch
case, then remove piston seals (15) and (16) 14
15 14
from piston.
16
042103
DEW00624 DEW00604
DEW00626
DEW00627 DEW00628
30-72
DISASSEMBLY AND ASSEMBLY TRANSMISSION CLUTCH PACK
22
22-1
DEW00629 DDW00630
3) End plate
Push end plate (8) at 2nd clutch end with tool
9
, remove snap ring (9), then remove end plate
from clutch case (10).
11 8
9
12
13
042103
10 10
DEW00631
DDW00632
4) Clutch plates
Remove separator plates (12), disc plates (11),
and wave springs (13) from inside clutch case
(10).
« Be careful not to let the separator plates or 11
disc plates catch in the clutch case ring
groove.
12
13
DEW00633
5) 2nd piston
Remove 2nd piston (23) from inside clutch case,
23
then remove piston seals (24) and (25) from
23
piston.
« The shape of the 2nd piston is different
from the shape of the REVERSE piston on
the opposite side.
25 24
DEW00634 DEW00615
30-73
DISASSEMBLY AND ASSEMBLY TRANSMISSION CLUTCH PACK
DEW00636
1) Seal rings
Puller
Remove 3 seal rings (1) installed to shaft.
042103
ii) Remove thrust washer (3) and spacer (4) 2
from shaft. DEW00637 DEW00596
7
7-1 DDW00640
DEW00639
4) End plate
Push end plate (8) with tool , remove snap
ring (9), then remove end plate from clutch case
(10). 9
8
11
9
10 12
13 10
DEW00641 DDW00642
30-74
DISASSEMBLY AND ASSEMBLY TRANSMISSION CLUTCH PACK
5) Clutch plates
Remove separator plates (12), disc plates (11),
and wave springs (13) from inside clutch case
(10). 11
« Be careful not to let the separator plates or
disc plates catch in the clutch case ring
groove. 12
13
DEW00643
6) 4th piston
Remove 4th piston (14) from inside clutch case,
then remove piston seals (15) and (16) from 14 15 14
piston.
16
042103
DEW00644 DEW00604
DEW00646
DEW00647 DEW00648
30-75
DISASSEMBLY AND ASSEMBLY TRANSMISSION CLUTCH PACK
3rd gear: 29 kg
3) End plate
Push end plate (8) at 3rd clutch end with tool ,
remove snap ring (9), then remove end plate
from clutch case (10). 9
8
11
9
10 12
13
042103
10
DEW00651 DDW00652
4) Clutch plates
Remove separator plates (12), disc plates (11),
and wave springs (13) from inside clutch case
11
(10).
« Be careful not to let the separator plates or
disc plates catch in the clutch case ring
12
groove.
13
DEW00653
5) 3rd piston
Remove 3rd piston (23) from inside clutch case, 23
then remove piston seals (24) and (25) from
piston. 23
« The shape of the 3rd piston is different from
the shape of the 4th piston on the opposite
side.
25 24
DEW00654 DEW00615
30-76
DISASSEMBLY AND ASSEMBLY TRANSMISSION CLUTCH PACK
ASSEMBLY OF TRANSMISSION
CLUTCH PACK ASSEMBLY
FORWARD/1st clutch
FORWARD, 1ST CLUTCH ASSEMBLY
When assembling the FORWARD, 1st clutch, al-
ways check dimension “A” of the FORWARD clutch
case.
« A: 90.5 mm A
DDW00656
16
042103
DEW00603 DEW00604
A4 A5
DEW00659 DEW00660
2) Clutch plates
Install separator plates (12), disc plates (11), 12 11
and wave springs (13) inside clutch case (10).
« Before assembling the clutch disc plates,
put them in a soaking bath for at least 2
minutes.
Oil: EO10-CD
(API 10W-CD Class or above)
13
DEW00602
30-77
DISASSEMBLY AND ASSEMBLY TRANSMISSION CLUTCH PACK
3) End plate
Assemble end plate (8) to clutch case (10), then
push with tool , and secure with snap ring (9).
9
4) Needle bearing, FORWARD gear
i) Assemble spacer (7-1) and thrust washer 8
(7) inside clutch case in order.
11 9
« Before assembling the spacer, warm it
up at 80°C – 120°C for 80 minutes. 12
13
10
Thrust washer (7): Oil (EO10-CD) 10
DEW00600 DDW00601
042103
7-1
DEW00597 DDW00598
30-78
DISASSEMBLY AND ASSEMBLY TRANSMISSION CLUTCH PACK
6) Seal rings
Install 3 seal rings (1) to shaft.
DEW00595
25 24
042103
DEW00614 DEW00615
A4 A5
DEW00659 DEW00660
2) Clutch plates
Install separator plates (12), disc plates (11),
and wave springs (13) inside clutch case (10).
« Before assembling clutch disc plates (1),
put them in a soaking bath for at least 2 11
minutes.
Oil: EO10-CD (API 10W-CD Class or above)
12
13
DEW00613
30-79
DISASSEMBLY AND ASSEMBLY TRANSMISSION CLUTCH PACK
3) End plate
Assemble end plate (8) to clutch case (10), then
push with tool , and secure with snap ring (9).
9
8
11 9
12
10 13
DEW00611 DDW00612
22
042103
22-1
DEW00609 DDW00610
30-80
DISASSEMBLY AND ASSEMBLY TRANSMISSION CLUTCH PACK
DDW02348
16
042103
DEW00624 DEW00604
A4 A5
DEW00659 DEW00660
2) Clutch plates
Install separator plates (12), disc plates (11),
and wave springs (13) inside clutch case (10).
« Before assembling clutch disc plates (11), 11
put them in a soaking bath for at least 2
minutes.
Oil: EO10-CD (API 10W-CD Class or above) 12
13
DEW00623
30-81
DISASSEMBLY AND ASSEMBLY TRANSMISSION CLUTCH PACK
3) End plate
Assemble end plate (8) to clutch case (10), then
push with tool , AND secure with snap ring
(9). 9
Thrust washer: Oil (EO10-CD)
8
11
9
10 12
13 10
DEW00641 DDW00642
042103
7
DEW00639
7-1 DDW00640
30-82
DISASSEMBLY AND ASSEMBLY TRANSMISSION CLUTCH PACK
6) Seal rings
Install 3 seal rings (1) to shaft.
DEW00595
25 24
042103
DEW00634 DEW00615
A4 A5
DEW00659 DEW00660
2) Clutch plates
Install separator plates (12), disc plates (11),
and wave springs (13) inside clutch case (10).
« Before assembling clutch disc plates (11),
put them in a soaking bath for at least 2 11
minutes.
Oil: EO10-CD
(API 10W-CD Class or above)
12
13
DEW00633
30-83
DISASSEMBLY AND ASSEMBLY TRANSMISSION CLUTCH PACK
3) End plate
Assemble end plate (8) to clutch case (10), then
push with tool , and secure with snap ring (9). 9
11 8
9
12
13 10
10
DEW00631 DDW00632
22
042103
22-1
DEW00629 DDW00630
30-84
DISASSEMBLY AND ASSEMBLY TRANSMISSION CLUTCH PACK
2) Clutch plates
Install separator plates (12), disc plates (11),
and wave springs (13) inside clutch case (10).
« Before assembling clutch disc plates (11),
put them in a soaking bath for at least 2
minutes.
Oil: EO10-CD
(API 10W-CD Class or above)
3) End plate
Assemble end plate (8) to clutch case (10), then
push with tool , and secure with snap ring (9).
30-85
DISASSEMBLY AND ASSEMBLY TRANSMISSION CLUTCH PACK
7
DEW00639
7-1 DDW00640
042103
ii) Press fit bearing (2) to shaft. DDW00709
2
DEW00637
30-86
DISASSEMBLY AND ASSEMBLY TRANSMISSION CLUTCH PACK
2) Clutch plates
Install separator plates (12), disc plates (11),
and wave springs (13) inside clutch case (10).
« Before assembling clutch disc plates (11),
put them in a soaking bath for at least 2 min-
utes.
Oil: EO10-CD (API 10W-CD Class or above)
3) End plate
Assemble end plate (8) to clutch case (10), then
push with tool , and secure with snap ring (9).
30-87
DISASSEMBLY AND ASSEMBLY TRANSMISSION CLUTCH PACK
042103
CD)
DEW00647
DDW00721
30-88
DISASSEMBLY AND ASSEMBLY PARKING BRAKE
DISASSEMBLY OF PARKING
BRAKE ASSEMBLY
Transmission: 40 l
2. Drive shaft
Remove guard of drive shaft, and disconnect lower 1
front drive shaft (1) at transmission end.
« Move the disconnected drive shaft to the right
end.
3. Suction tube
1) Remove mounting bolt (3) and washer (4) of
coupling (2) at front end of transmission, then
remove coupling.
042103
4. Parking brake
1) Remove lock plates (7) of manual release bolts 6
(6) and parking brake, then remove 3 release
bolts (6). 7
2) Remove parking bake case (8).
5 8
DEW00723
9 10 DEW00724
30-89
DISASSEMBLY AND ASSEMBLY PARKING BRAKE
14
15
DDW00725
042103
16
DEW00726
30-90
DISASSEMBLY AND ASSEMBLY PARKING BRAKE
ASSEMBLY OF PARKING
BRAKE ASSEMBLY
17 18
1. Parking brake Raise
1) Press fit bearing outer race to retainer (16),
and bearing inner race to output shaft (11). 11
2) Install output shaft to transmission case, then Bearing
insert shim (18) in retainer (16), and tighten
with mounting bolts (17).
« Keep the output shaft horizontal when rais-
ing it. 16
DEW00726
3) Adjusting shim
i) Assemble shim of standard value, then
tighten retainer (16) with 3 bolts. 3 places
(bolts)
« Standard shim thickness: 1.2 mm 16
Mounting bolt:
112.8 ± 9.8 Nm (11.5 ± 1.0 kgm)
14
15
DDW00725
30-91
DISASSEMBLY AND ASSEMBLY PARKING BRAKE
10 DDW00730
10° 15t
A 3-M12
300
45
0
26
30°
30°
M10,
´65
110 160
M12, ´100
All screws
27
8
M12 mm
042103
Eyebolt
mount A A-A
DEW00731
9 10 DEW00724
5 8
DEW00723
30-92
DISASSEMBLY AND ASSEMBLY PARKING BRAKE
3. Coupling
Tighten transmission front coupling (2), O-ring and 1
washer (4) with mounting bolt (3).
« Use a new part for the O-ring.
4. Drive shaft 2 3 4
1) Connect front drive shaft (1). DEW00722
« Clean the connection and mating surface of
the drive shaft before installing.
Drive shaft:
112.8 ± 9.8 Nm (11.5 ± 1.0 kgm)
2) Install drive shaft guard.
Transmission: 40 l
30-93
DISASSEMBLY AND ASSEMBLY TRANSMISSION CONTROL VALVE
REMOVAL OF TRANSMISSION
CONTROL VALVE ASSEMBLY
3 1
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 2
brake and put blocks under the wheels to prevent
the machine from moving.
DEW01456
1. Ladder
Remove left ladder (1).
Ladder (left): 66 kg
2. Covers
1) Remove left side cover (2) of rear frame. 10 11
2) Remove bottom cover (3) of cab.
3) Remove front cover (3-1) of bulkhead. 3-1
8 9
3. Electric wiring
Disconnect following electric wiring.
6 7
1) Disconnect wiring TL1 (4) and TL2 (5) for trans-
5
042103
mission. 4
2) Disconnect floor wiring harnesses LR5 (6), LR6 DEW00736 DEW00500
(7), LR3 (8), LR4 (9), LR1 (10), and LR2 (11).
3) Disconnect solenoid valve wiring (12) of trans-
mission control valve at connector.
« After disconnecting the connectors, mark 10 11 9
with tags to distinguish when installing.
8
4
5 7 DEW00497
13
12
DEW01460
30-94
DISASSEMBLY AND ASSEMBLY TRANSMISSION CONTROL VALVE
5. Hydraulic piping 14
1) Disconnect hose (14) between transmission,
15
torque converter pump and flow valve at flow
valve end. 1
2) Disconnect hose (15) between flow valve and 16
transmission oil filter at flow valve end. 2 19
3) Disconnect hose (16) between transmission oil
filter and transmission control valve at control
valve end. 3
17
4) Disconnect hose (17) between transmission con-
trol valve and cooler at control valve end.
4 20 DEW01463
Wedge
Valve
DEW01464
25 mm DEW01462
30-95
DISASSEMBLY AND ASSEMBLY TRANSMISSION CONTROL VALVE
INSTALLATION OF
TRANSMISSION CONTROL
VALVE ASSEMBLY
• Carry out installation in the reverse order to re-
moval.
1 3
Hose connection:
176.5 ± 29.4 Nm (18.0 ± 3.0 kgm)
2 4
« Use a new part for the O-ring.
5
« Use a new part for the O-ring.
Mounting bolt:
34.3 ± 4.9 Nm (3.5 ± 0.5 kgm)
6
« When installing the control valve, be careful not
042103
to hit the solenoid valve or other parts.
7
« Use a new part for the gasket.
30-96
DISASSEMBLY AND ASSEMBLY TRANSMISSION CONTROL VALVE
DISASSEMBLY OF
TRANSMISSION CONTROL
VALVE ASSEMBLY
1. Disassembly of modulation, accumulator, upper, lower
valve
1) Remove mounting bolts (3) (marked with ) of
upper valve assembly, then remove gasket (4).
« After removing, cover with tape to prevent
dirt or dust from entering the valve.
042103
30-97
DISASSEMBLY AND ASSEMBLY TRANSMISSION CONTROL VALVE
Torque converter
outlet valve
042103
DEW00750
3) Modulation valve
i) Remove modulation valve (14) from upper 14 13
valve body (13).
ii) Remove spring (15) and modulation piston
(16) from modulation valve (14).
« After removing, cover with tape to pre-
vent dirt or dust from entering the valve. P
P
15 16
DDW00751
DDW00752
21
30-98
DISASSEMBLY AND ASSEMBLY TRANSMISSION CONTROL VALVE
23
24
DDW00753
6) Pilot valve
i) Remove mounting bolts (26) from upper R
cover (25), then remove cover and gasket 26
(27). 28 25
ii) Remove pilot valve (28) and pilot spring (29)
from valve body. 27
« After removing, cover with tape to pre-
29
vent dirt or dust from entering the valve.
042103
DDW00754
4
1
3 2 3 2
DEW00746 DDW00747
30-99
DISASSEMBLY AND ASSEMBLY TRANSMISSION CONTROL VALVE
2) Upper L cover
i) Remove mounting bolts (7) of connector 7
bracket (6), then remove bracket. 6
ii) Remove remaining mounting bolts (7) of
upper L cover (8), then remove cover and 8
gasket (9).
« After removing, cover with tape to pre- 9
vent dirt or dust from entering the valve.
DDW00757
3) Pilot valve
Remove pilot valve (11) and pilot spring (12) 12 11 10
from valve body (10).
« After removing, cover with tape to prevent
dirt or dust from entering the valve.
042103
DDW00758
DDW00759
20
DDW00760
30-100
DISASSEMBLY AND ASSEMBLY TRANSMISSION CONTROL VALVE
1
1
2
3
042103
4 Lower valve
DDW00763
30-101
DISASSEMBLY AND ASSEMBLY TRANSMISSION CONTROL VALVE
2) Lower L cover
Remove mounting bolts (6) of lower L cover (5), 6
then remove cover and gasket (7).
« After removing, cover with tape to prevent 5
dirt or dust from entering the valve. 7
DDW00764
042103
DDW00765
14
13
DDW00766
18
17
DDW00767
30-102
DISASSEMBLY AND ASSEMBLY TRANSMISSION CONTROL VALVE
6) Priority valve
Remove spool (20) and stopper (21) of priority 20
valve from valve body.
« After removing, cover with tape to prevent
dirt or dust from entering the valve.
21
DDW00768
23
042103
DDW00769
8) Lower R cover
i) Remove mounting bolts (25) of lower R cover 24 29 30 31
(24), then remove cover and gasket (26). 25
ii) Remove R return spring (27) and sleeve 26
(28) of directional valve, return springs (29)
and (30) of H-L selector valve and range
27
selector valve, and spring (31) of priority
valve from valve body.
28
« After removing, cover with tape to pre-
vent dirt or dust from entering the valve.
DDW00770
30-103
DISASSEMBLY AND ASSEMBLY TRANSMISSION CONTROL VALVE
ASSEMBLY OF TRANSMISSION
CONTROL VALVE ASSEMBLY
24 29 30 31
1. Assembly of lower valve assembly 25
1) Lower R cover 26
i) Install R return spring (27) and sleeve (28)
of directional valve, return springs (29) and
(30) of H-L selector valve and range selec- 27
tor valve, and spring (31) of priority valve to
valve body. 28
« Free height of spring:
42 mm (27)
48 mm (29), (30) DDW00770
150 mm (31)
ii) Install gasket (26), and tighten lower R cover
(24) with mounting bolts (25).
« Use a new part for the O-ring.
042103
2) Parking brake valve
Install spool (22) and return spring (23) of park- 22
ing brake valve to valve body.
« Free height of spring: 46 mm (23)
DDW00769
3) Priority valve
Install spool (20) and stopper (21) of priority 20
valve in valve body.
21
DDW00768
30-104
DISASSEMBLY AND ASSEMBLY TRANSMISSION CONTROL VALVE
DEW02325
DDW00765
30-105
DISASSEMBLY AND ASSEMBLY TRANSMISSION CONTROL VALVE
« WA470-3H: 8.0 mm
WA400-3S:8.0
WA420-3H: 5.0 mm
mm
WA400-3H: 8.0 mm
DEW02326
7) Lower L cover
Install gasket (7) to valve body, and set lower L 6
cover (5) in position, then tighten with mounting
bolts (6). 5
« Use a new part for the gasket. 7
042103
DDW00764
30-106
042103
30-107
042103
30-108
DISASSEMBLY AND ASSEMBLY TRANSMISSION CONTROL VALVE
24
DDW00753
30-109
DISASSEMBLY AND ASSEMBLY TRANSMISSION CONTROL VALVE
4) Modulation valve
i) Install spring (15) and modulation piston (16) 14 13
to modulation valve (14).
ii) Install modulation valve (14) to valve body
(13).
« Free height of spring (15): 24 mm
P
Outside circumference of modu
lation valve spool, piston: P
Oil (EO10-CD) 15 16
042103
ECMV mounting bolt (7): 12 8
11.8 – 14.7 Nm (1.2 – 1.5 kgm) 11
DEW00748 DEW00749
Torque converter
outlet valve
DEW00750
6) Manual valve
i) Install plug (5) to valve body.
ii) Assemble manual valve spool (3), and install
5
O-ring (4), then secure lock plate (1) with
mounting bolt (2).
1
Outside circumference of manual
valve spool: Oil (EO10-CD)
Plug (4): 4
39.2 ± 4.9 Nm (4.0 ± 0.5 kgm) 1
3 2 3 2
Lock plate mounting bolt: DEW00746 DDW00747
30-110
DISASSEMBLY AND ASSEMBLY TRANSMISSION CONTROL VALVE
Mounting bolt:
49.0 ± 4.9 Nm (5.0 ± 0.5 kgm)
042103
30-111
DISASSEMBLY AND ASSEMBLY TRANSMISSION ACCUMULATOR VALVE
DISASSEMBLY OF
TRANSMISSION
ACCUMULATOR VALVE 2 1
2nd
1st
ASSEMBLY
FORWARD
1. Remove mounting bolts (2) of cover (1) from accu-
mulator valve assembly, then remove cover and O-
ring (3).
Accumulator valve
assembly DEW00801 DEW00802
2. Accumulator valve
FORWARD 1st 2nd
1) Remove accumulator valves (5) from FORWARD, 1 2
1st, and 2nd ports in accumulator body (4).
3
2) Remove accumulator spring (6) and stopper (7)
from FORWARD port. 5
3) Remove accumulator spring (6) and stopper (7)
4 6
from 1st port.
4) Remove accumulator spring (6) and stopper (7)
from 2nd port.
7
042403
3. Remove mounting bolts (2) of bottom cover (1) from
accumulator body (4), then remove cover and O-ring DEW00804
(3).
30-112
DISASSEMBLY AND ASSEMBLY TRANSMISSION ACCUMULATOR VALVE
ASSEMBLY OF TRANSMISSION
ACCUMULATOR VALVE
ASSEMBLY 2 1
2nd
1st
FORWARD
1. Install bottom cover (1) and O-ring (3) to accumu-
lator body (4), and tighten with mounting bolts (2).
Mounting bolt: Thread tightener (LT-2)
Mounting bolt:
34.3 ± 4.9 Nm (3.5 ± 0.5 kgm)
Accumulator valve
assembly DEW00801 DEW00802
7
042403
DEW00804
30-113
DISASSEMBLY AND ASSEMBLY TRANSMISSION ACCUMULATOR VALVE
042403
30-114
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.
DEW00809
11
DEW00810
Caulking 11 Washer
Seal
DEW00811
DDW00812
30-115
DISASSEMBLY AND ASSEMBLY DRIVE SHAFT
3. Spider, bearing
1) Remove bolts (6) of spider and bearing assem-
bly (5), and tap with plastic hammer to remove. 5 6
042403
DEW00813
3 10
DEW00814
30-116
DISASSEMBLY AND ASSEMBLY DRIVE SHAFT
DEW00813
DEW00817
9
3
DEW00818
30-117
DISASSEMBLY AND ASSEMBLY DRIVE SHAFT
DEW00819
042403
11
DEW00810
Caulking 11 Washer
Seal
DEW00811
30-118
DISASSEMBLY AND ASSEMBLY FRONT AXLE
DEW00822 DEW00823
2. Drive shaft
Disconnect front drive shaft (2) from front axle.
2
Front drive shaft: 31.2 kg
« Make match marks on the drive shaft and the
coupling.
DEW00824
30-119
DISASSEMBLY AND ASSEMBLY FRONT AXLE
3. Brake piping
1) Remove cover of plate at front of front frame,
disconnect front brake piping and tube (3) be-
tween brake valve and slack adjuster at slack 3
adjuster end.
2) Remove tubes (4) and (5) between slack ad-
juster and left and right wheel cylinders.
« After disconnecting the piping, fit plugs to
prevent the entry of dirt or dust.
5
4 DEW02327
4. Front axle
1) Sling one end of front axle housing and fit a
jack under other end. 6
2) Fit jack under differential case.
3) Remove mounting bolts (7), then use hoist and
jack to maintain balance and lift off.
3
« Be careful not to let slack adjuster on top
of axle housing hit frame.
042403
Front axle: 1388 kg
7 DEW02328
30-120
DISASSEMBLY AND ASSEMBLY FRONT AXLE
INSTALLATION OF FRONT
AXLE ASSEMBLY
1
Tire mounting nut:
470.7 ± 49.0 Nm (48.0 ± 5.0 kgm)
« Remove the block from under the front frame.
2
« Clean the connections and mating surface of
the drive shaft.
Drive shaft mounting bolt:
112.8 ± 9.8 Nm (11.5 ± 1.0 kgm)
3
Front axle mounting bolt:
1618.1 ± 166.7 Nm (165.0 ± 17.0 kgm)
• Bleed the air from the brake system and carry out
an actuation check.
« For details, see TESTING AND ADJUSTING,
Bleeding air.
042403
30-121
DISASSEMBLY AND ASSEMBLY REAR AXLE
042403
Garage jack DEW00827 DEW00828
1. Tire, wheel
Sling left and right tires and wheels (1) of rear axle,
then remove mounting nuts and lift off.
1
1
Tire, wheel: 550 kg (23.5-25 tire)
644 kg (26.5-25 tire)
DEW00829
2. Drive shaft
Disconnect rear drive shaft (2) from rear axle. 2
2
Rear drive shaft: 19 kg
DEW00830
30-122
DISASSEMBLY AND ASSEMBLY REAR AXLE
3. Brake piping
1) Disconnect rear brake piping and hose (3) be- 6
tween brake valve and slack adjuster at slack
adjuster end.
4. Grease tubes
Disconnect grease tubes (6) and (7) from rear axle
support. 4 5
042403
DEW00850
30-123
DISASSEMBLY AND ASSEMBLY REAR AXLE
6. Rear support
(Front Rear axle 13 (Rear
1) Sling rear support of rear axle and support support) support)
assembly, and remove thrust cap (9). 5
rear support. 8
7. Front support
1) Remove retainer (18) of front support, then re-
move O-ring and packing. 9
042403
30-124
DISASSEMBLY AND ASSEMBLY REAR AXLE
1
Tire mounting nut:
470.7 ± 49 Nm (48.0 ± 5.0 kgm)
« Remove the block from under the rear frame.
2
« Clean the connections and mating surface of
the drive shaft.
Drive shaft mounting bolt:
112.8 ± 9.8 Nm (11.5 ± 1.0 kgm)
3
Axle support mounting bolt:
1029.7 ± 98.7 Nm (105.0 ± 10.0 kgm)
« After installing the rear axle, install the fuel tank.
« For details, see INSTALLATION OF FUEL TANK.
4
« Secure the rear axle and the axle support (rear
042403
5
Thrust cap mounting bolt:
279.5 ± 29.4 Nm (28.5 ± 3.0 kgm)
6
Thrust washer: Grease (G2-LI)
Thrust plate mounting bolt:
279.5 ± 29.4 Nm (28.5 ± 3.0 kgm)
Thrust plate mounting bolt:
Thread tightener (LT-2)
30-125
DISASSEMBLY AND ASSEMBLY REAR AXLE
7
Rear support
« Pay attention to the direction of the packing, fit
it securely in the groove, and assemble so that Packing
Clearance b
the lip is not turned over. Chamfered side
« Check that the slit in the bushing is facing the Bushing
side.
Rear axle mount: Grease (G2-LI)
8 10
« Set so that the chamfered side of the bushing is
on the axle housing side, and assemble so that
the clearance is clearance b. DEW00832
« Clearance b: Min. 0.5 mm
« Pay attention to the direction of the packing, fit
it securely in the groove, and assemble so that
Front support
the lip is not turned over. Clearance c
Packing
« Install the bushing and packing to the front sup-
Bushing
port in the same way as for the rear support. 14
« Clearance c: Min. 0.5 mm
042403
DEW00833
9
« Use new parts for the O-rings and packing.
« Pay attention to the direction of the packing, fit
it securely in the groove, and assemble so that
the lip is not turned over.
Retainer mounting bolt: 18
Thread tightener (LT-2) O-ring
• Bleed the air from the brake system and carry out
an actuation check.
« For details, see TESTING AND ADJUSTING,
Bleeding air. Packing
• Add hydraulic oil through the oil filler of the hydrau- DEW00834
lic tank to the specified level.
30-126
DISASSEMBLY AND ASSEMBLY FRONT DIFFERENTIAL
REMOVAL OF FRONT
DIFFERENTIAL ASSEMBLY
1. Tires, wheels
Sling left and right tires and wheels (1) of front axle, 1
then remove mounting nuts, and lift off.
1
Tire, wheel: 550 kg (23.5-25 tire)
644 kg (26.5-25 tire)
042403
DEW00822 DEW00823
2. Drive shaft
1) Disconnect front drive shaft (2) from front axle.
2
30-127
DISASSEMBLY AND ASSEMBLY FRONT DIFFERENTIAL
3. Draining oil
Set plug (3-1) immediately at bottom, then remove it
4
and drain oil.
Axle oil: 60 l
4. Cover
Remove cover (3), then remove O-ring (4). 3
3-1 3
DEW00839 DEW00840
5. Axle shaft
Using forcing screws (Thread dia.=12mm,
Pitch=1.75mm), pull out axle shaft (5) approx. 200
mm together with sun gear (6).
5 6
042403
DEW00841
6. Slack adjuster
1) Remove following hydraulic piping clamps.
• Clamps for tube (7) between slack adjuster
and axle.
8
« Remove both the left and right clamps.
• Clamp for tube (8) between slack adjuster
and brake chamber.
2) Remove mounting bolts of slack adjuster bracket
(9), and insert block between slack adjuster and 7
axle.
« When removing the differential, set the
bracket at a height where there is no inter- DEW02329
9 DEW02330
ference.
7. Differential
1) Remove 2 mounting bolts of differential (10),
and install guide bolts (Thread Dia.=14mm, 10 11
Pitch=2mm, Length=50mm).
« Screw in the thread of the guide bolts fully.
« First, screw in the guide bolts, then remove
the remaining mounting bolts.
2) Fit lifting tool to differential case (11).
DEW00844
30-128
DISASSEMBLY AND ASSEMBLY FRONT DIFFERENTIAL
13
042403
DEW00847
30-129
DISASSEMBLY AND ASSEMBLY FRONT DIFFERENTIAL
INSTALLATION OF FRONT
DIFFERENTIAL ASSEMBLY
2 2
• Fit flange bearing (2-1) temporarily.
• Connect front drive shaft (2) to the differential DEW00837 DEW00838
and the center drive shaft ends.
• Tighten flange bearing (2-1) fully.
« When connecting the drive shaft, clean the
mating surface of the spider and the cou-
pling, then install.
Mounting bolt:
112.8 ± 9.8 Nm (11.5 ± 1.0 kgm)
Flange bearing mounting bolt:
549.2 ± 58.8 Nm (56.0 ± 6.0 kgm)
3
« Use a new part for the O-ring.
042403
4
• Adjust the lifting tool and the height of the jack
for the differential, and assemble the differential
along the guide bolt.
« Fit the O-ring securely in the groove, and 11
be careful that it does not get caught when
installing.
• When the clearance between axle housing (12)
and differential (10) is approx. 20 mm, remove
installation tool B and tighten the mounting bolts
uniformly.
Differential mounting bolt: B
Thread tightener (LT-2)
12
Differential mounting bolt: 10
176.5 ± 19.6 Nm (18.0 ± 2.0 kgm) C DEW00845 DEW00846
5
« Use a new part for the O-ring.
30-130
DISASSEMBLY AND ASSEMBLY FRONT DIFFERENTIAL
Axle oil: 60 l
• Add hydraulic oil through the oil filler of the
hydraulic tank to the specified level.
• Bleed the air from the brake system and carry
out an actuation check.
« For details, see TESTING AND ADJUST-
ING, Bleeding air.
042403
30-131
DISASSEMBLY AND ASSEMBLY REAR DIFFERENTIAL
REMOVAL OF REAR
DIFFERENTIAL ASSEMBLY
042403
Garage jack DEW00827 DEW00828
1. Tires, wheels
Sling left and right tires and wheels (1) of rear axle,
then remove mounting nuts, and lift off.
1
1
Tire, wheel: 550 kg (23.5-25 tire)
644 kg (26.5-25 tire)
DEW00829
2. Drive shaft
Disconnect rear drive shaft (2) from rear axle. 2
2
Rear drive shaft: 19 kg
DEW02361
30-132
DISASSEMBLY AND ASSEMBLY REAR DIFFERENTIAL
3. Brake piping
1) Disconnect hose (3) (between brake valve and 6
slack adjuster) of rear brake piping at slack
adjuster end.
2) Remove tubes (4) and (5) between slack ad-
juster and left and right wheel cylinders.
« Always remove the brake tubes before re-
moving the axle. There is danger that they
may be crushed when the axle is lifted off. 3 7
« After disconnecting the piping, fit plugs to
prevent the entry of dirt or dust.
DEW00856
4. Grease tubes
Disconnect grease tubes (6) and (7) from rear axle
support.
4 5
042403
DEW00857
30-133
DISASSEMBLY AND ASSEMBLY REAR DIFFERENTIAL
6. Draining oil
Set plug (9-1) immediately at bottom, then remove it
10
and drain oil.
Axle oil: 65 l
7. Cover
Remove cover (9), then remove O-ring (10).
5
9-1 9
DEW00859 DEW00860
8. Axle shaft
Using forcing screws (Thread dia.=12mm, 14 13
Pitch=1.75mm), pull out axle shaft (11) and sun
gear (12) approx. 200 mm. 6
11 12
9. Slack adjuster
Remove cover (13) from axle, then remove slack
adjuster (14) together with bracket.
042403
DEW00861 DEW00862
DEW00863
30-134
DISASSEMBLY AND ASSEMBLY REAR DIFFERENTIAL
INSTALLATION OF REAR
DIFFERENTIAL ASSEMBLY
1
Tire mounting nut:
470.7 ± 49 Nm (48.0 ± 5.0 kgm)
« Remove the block from under the rear frame.
2
« Clean the connections and mating surface of
the drive shaft.
Drive shaft mounting bolt:
112.8 ± 9.8 Nm (11.5 ± 1.0 kgm)
3
Axle support mounting bolt:
1029.7 ± 98.1 Nm (105.0 ± 10 kgm)
4
« When installing the rear axle to the chassis, be
extremely careful not to damage the bushing
and packing of the front support with the differ-
ential coupling.
« Secure the rear axle and the support (rear end)
with a chain, then install to the chassis.
Rear axle front support portion:
Grease (G2-LI)
5
« Use a new part for the O-ring.
6
« When inserting axle shaft (11), rotate the differ-
ential coupling lightly by hand to install.
Do not push it in by force.
30-135
DISASSEMBLY AND ASSEMBLY REAR DIFFERENTIAL
7
« Use a new part for the O-ring.
« Fit the O-ring securely in the groove, and be
careful that it does not get caught when install-
ing.
Differential mounting bolt:
Thread tightener (LT-2)
Differential mounting bolt:
176.5 ± 19.6 Nm (18.0 ± 2.0 kgm)
Axle oil: 65 l
• Add hydraulic oil through the oil filler of the
hydraulic tank to the specified level.
• Bleed the air from the brake system and carry
out an actuation check.
« For details, see TESTING AND ADJUST-
ING, Bleeding air.
042403
30-136
DISASSEMBLY AND ASSEMBLY DIFFERENTIAL
DISASSEMBLY OF
DIFFERENTIAL ASSEMBLY
1. Differential gear
2
1) Remove ring gear adjustment bolt. 1
2) Loosen adjustment ring lock bolt, and remove
lock plate (2).
« Rotate the adjustment ring, and separate the
differential gear from the pinion gear.
3) Remove bearing cap (2).
« Check the match marks on the left and right
bearing caps. Make new match marks if the
old match marks cannot be seen. DEW00864
4) Remove adjustment ring (3) and bearing cup
(4).
4
3
042403
DEW00865
DEW00866
2. Plain half
1) Remove bearing (6).
2) Remove plain half (7).
« Check the match marks. Make new match
marks if the old match marks cannot be 7
seen. 6
DEW00867
30-137
DISASSEMBLY AND ASSEMBLY DIFFERENTIAL
042403
11 10 DEW00869
4. Turning over
Turn over differential gear.
14
13
DEW00870
5. Pinion gear
1) Loosen mounting bolts of coupling (15).
« Leave the coupling temporarily fitted.
15
DEW00871
30-138
DISASSEMBLY AND ASSEMBLY DIFFERENTIAL
DEW00872
6. Pinion shaft
1) Using press, pull out pinion shaft (18).
19
042403
18
DEW00873
20 19
DEW00874
22 23 DEW00875
30-139
DISASSEMBLY AND ASSEMBLY DIFFERENTIAL
ASSEMBLY OF DIFFERENTIAL
ASSEMBLY
Block
« When replacing the pinion or ring gear, always
replace them as a set, and be careful not to mix 22
them with other sets. 18 23
Replace the flange half and plain half also as a set. 18
1. Pinion shaft
1) Press fit pilot bearing (22) to pinion shaft (18).
042403
no clearance.
19
DEW00878 18 DEW00879
2. Adjusting preload
1) Press fit bearing (24) to pinion shaft (18).
DEW00881
30-140
DISASSEMBLY AND ASSEMBLY DIFFERENTIAL
DDW00882
3. Pinion gear
1) Press fit oil seal (27) and dust seal (27A) to Make
cage (26). 27A surfaces flush Make surfaces flush
« Use new parts for the oil seal and dust seal, 10 ± 0.5 10 ± 0.5
and be careful to install facing in the correct 27A
direction.
Lip of oil seal, lip of dust seal: 27
Grease (G2-LI)
Press-fitting portion of oil seal, 26
dust seal: Thread tightener (LT-2) 27 26
042403
Front Rear
DEW00883
DDW00884
16
DDW00885
30-141
DISASSEMBLY AND ASSEMBLY DIFFERENTIAL
Depth micrometer
DEW00887
D Thickness of tool
Dimensions a and
b stamped here L 17
16
DEW00886
042403
6) Assemble pinion gear (17) and shim to differen-
tial case (16), and tighten mounting bolts. DEW00872
Mounting bolt:
Thread tightener (LT-2)
Mounting bolt:
176.5 ± 19.6 Nm (18.0 ± 2 kgm) 27 14 12
4. Ring gear
1) Knock pin (27) into flange half (14) so that it
protrudes distance a from case. a
« a = 3.5 mm
2) Press fit bearing (12) to flange half (14).
3) Install flange half (14) to ring gear (13).
Mounting bolt:
Thread tightener (LT-2) 14
Mounting bolt: DEW00889 DEW00890
279.5 ± 29.4 Nm (28.5 ± 3.0 kgm)
14 13
DEW00891
30-142
DISASSEMBLY AND ASSEMBLY DIFFERENTIAL
5. Side gear
Install washer (28), LSD inner (A), outer (B) clutch
plates, and cage halfs (C) and assemble side
gear (8).
« Insert the washer securely to the pin inside the
case.
Washer: Grease (G2-LI) (both faces)
6. Pinion gear
Assemble pinion gear (11) and thrust washer (10) to 9 7
cross shaft (9).
« Align the stopper position of the thrust washer
when assembling.
Thrust washer (gear contact surface): a
Axle oil
7. Plain half
1) Knock pin (27) into plain half (7) so that it 27
protrudes distance a from plain half.
« a = 3.5 mm 11
042403
10
DEW00893 DEW00895
DEW00896
DEW00897 DEW00898
30-143
DISASSEMBLY AND ASSEMBLY DIFFERENTIAL
8. Differential gear
1) Raise gear (5), and assemble bearing cup (4)
5
to bearing, then install to case.
4
DEW00899
042403
DEW00900
DEW00902
30-144
DISASSEMBLY AND ASSEMBLY DIFFERENTIAL
DEW00903
30-145
DISASSEMBLY AND ASSEMBLY DIFFERENTIAL
042403
close to bevel gear. gear to move away
from bevel gear. 2
2. Move bevel gear closer
to pinion gear and adjust
backlash correctly.
1
DEW00905 DEW00909
« 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
DEW00864
DDW00913
30-147
DISASSEMBLY AND ASSEMBLY FINAL DRIVE
DISASSEMBLY OF FINAL
DRIVE ASSEMBLY
042403
Garage jack DEW00827 DEW00828
1. Tire, wheel
Jack up axle, and insert support stand under axle,
then lift off tire and wheel (1). 1
« After removing the tire and wheel, set the sup-
port stand under the axle housing portion.
DEW00823
2. Draining oil 2 DEW00917
Axle oil: 55 l 4
3. Cover
Remove cover (3), then remove O-ring (4).
3
DEW00918 DEW00919
30-148
DISASSEMBLY AND ASSEMBLY FINAL DRIVE
4. Axle shaft
Using forcing screws (Thread dia.=12mm, 5
Pitch=1.75mm), pull out axle shaft (5) approx. 200
mm.
6
5. Planetary carrier
Remove 3 mounting bolts, and lift off planetary car-
rier (6).
« Make match marks to use as a guide when
assembling.
« Be careful of the center of gravity, and remove
slowly. DEW00920 DEW00921
Planetary carrier: 86 kg
6. Ring gear E F
1) Using tools E and F, secure wheel hub (8) and
brake (9) in position.
9 8
« Install tools E and F at three equally spaced
places, then use a washer to adjust the
clearance.
042403
DEW00922
Ring gear: 35 kg
11
DEW00923
14
DEW00924
30-149
DISASSEMBLY AND ASSEMBLY FINAL DRIVE
DEW00925
21
22
042403
DEW00926
20
23
DEW00927
30-150
DISASSEMBLY AND ASSEMBLY FINAL DRIVE
DEW00928
22 21
DEW00929
17
DEW00930 DEW00931
DEW00932 DEW00933
30-151
DISASSEMBLY AND ASSEMBLY FINAL DRIVE
17
13
12 DEW00934
3. Ring gear
1) Raise ring gear (11), and insert in axle housing.
« Align the spline groove and insert slowly. 11
042403
DEW00935
DEW00922
30-152
DISASSEMBLY AND ASSEMBLY FINAL DRIVE
4. Planetary carrier
Assemble O-ring to wheel hub (8), then raise plan-
etary carrier (6), and install.
« Align the mounting holes and install slowly so
that the O-ring does not come out of position. 6
042403
DEW00940
5. Axle shaft
Install axle shaft (5). 5
« If the sun gear is not aligned, rotate the wheel
hub to align the position.
DEW00920
6. Cover
Insert O-ring (4) in groove of cover, and install
3
cover (3).
Mounting bolt:
112.8 ± 9.8 Nm (11.5 ± 1.0 kgm)
4
DEW00942
30-153
DISASSEMBLY AND ASSEMBLY FINAL DRIVE
7. Tire, wheel
Install tire and wheel, then remove support.
Mounting nut:
470.7 ± 49 Nm (48.0 ± 5.0 kgm)
(Width across flats: 30 mm)
1
DEW00943
042403
DEW00944
30-154
DISASSEMBLY AND ASSEMBLY CENTER HINGE PIN
1. Covers
Remove cover (3) at bottom of cab. 1 2
3
DEW01466 DEW01439
2. Ladders
Remove left and right ladders (3-1). 3-1
DEW01440
30-155
DISASSEMBLY AND ASSEMBLY CENTER HINGE PIN
3. Electric wiring
Disconnect the following electric wiring.
1) Disconnect front frame wiring FR1 (4) and FR2
(5).
2) Disconnect transmission wiring TL1 (6) and TL2
(7).
3) Disconnect floor wiring harnesses LR5 (8), LR6
(9), LR3 (10), LR4 (11), LR1 (12), and LR2
(13).
« After disconnecting the connectors, mark
with a tag to distinguish when installing.
12 13 11
10
11
10
8 9
8
6 7
4 5 DEW00500
6
042403
9 DEW01470
7
4. PPC piping
1) Disconnect hose (14) of PPC valve “P2” port, 19 14 16 18
hose (15) of “P4” port, hose (16) of ”P3” port,
and hose (17) of “P1” hose at PPC valve end.
15
2) Disconnect hose (18) between PPC accumula-
tor and PPC valve at valve end.
3) Disconnect hose (19) of PPC valve drain port at
valve end.
« When disconnecting the hoses, fit tags to 17
distinguish them. 14
« Fit blind plugs in the hoses to prevent the
16 17 15
entry of dirt or dust. DEW01471 DEW01472
20
PPC piping
DEW01473
30-156
DISASSEMBLY AND ASSEMBLY CENTER HINGE PIN
5. Brake piping
1) Disconnect hoses (21) and (22) between R.H. 27
23
brake valve and accumulator at pedal end.
« Remove 2 clamps (24) of the brake hose
under the floor board.
2) Disconnect hose (23) between L.H. brake valve
and accumulator at pedal end.
3) Disconnect R.H. brake valve drain hose (25)
and L.H. brake valve drain hose (26) at rear
frame.
4) Disconnect hose (27) between front brake and
21 22 32
R.H. brake valve at center hinge pin. DEW01475 DEW01476
24
25 26
042403
21, 22
DEW01477 DEW01478
7. Accelerator cable 3 30
Disconnect accelerator cable (32) at bottom of pedal. 31
« Remove the cable clamp under the floor board. 29
28
DEW01479
DEW01480
8. Orbit-roll hoses 4
1) Disconnect hoses (33) from steering valve.
35
33
34
DEW01482
30-157
DISASSEMBLY AND ASSEMBLY CENTER HINGE PIN
37
36
DEW01483 DEW01484
042403
39
DEW01485
DEW01486
30-158
DISASSEMBLY AND ASSEMBLY CENTER HINGE PIN
DEW01489
DEW00970
Blocks
Roller
Blocks DEW00971
30-159
DISASSEMBLY AND ASSEMBLY CENTER HINGE PIN
50
DEW01492
042403
hand. 53
DEW01493
52 DEW01491
DEW01494
30-160
DISASSEMBLY AND ASSEMBLY CENTER HINGE PIN
30-161
DISASSEMBLY AND ASSEMBLY CENTER HINGE PIN
042403
3) Remove spacer (65) and dust seal (66) from
front frame.
30-162
DISASSEMBLY AND ASSEMBLY CENTER HINGE PIN
INSTALLATION OF CENTER
HINGE PIN
1
Air conditioner unit hose:
29.4 – 34.3 Nm (3.0 – 3.5 kgm)
Air conditioner hose: New refrigerant
compressor oil (ND-OILB)
2
Receiver hose:
11.8 – 14.7 Nm (1.2 – 1.5 kgm)
Receiver hose: New refrigerant compres-
sor oil (ND-OILB)
3
Cable locknut:
55 - 55 Nm (5.0 - 5.5 kgm)
4
« Refit orbit-roll hoses. Check the steering direc-
tion.
5
« Align securely with the notch hole of the viscous
042403
30-163
DISASSEMBLY AND ASSEMBLY CENTER HINGE PIN
10
Upper hinge pin
1) Assemble upper hinge pin (57), and assemble
spacer (58).
Outside circumference of hinge:
Grease (G2-LI)
042403
Pin mounting bolt:
205.9 ± 19.6 Nm (21.0 ± 2.0 kgm)
(When adjusting shims)
Pin mounting bolt:
205.9 ± 19.6 Nm (21.0 ± 2.0 kgm)
Retainer mounting bolt:
107.9 ± 9.8 Nm (11.0 ± 1.0 kgm)
11
Connection of frame
30-164
DISASSEMBLY AND ASSEMBLY CENTER HINGE PIN
12
Lower hinge K2
1) Using tools H, I, K1, K2, and K3, press fit
bearing (56) and spacer (63) to front frame.
56 63
« When press fitting, use tool K3 as a guide.
« Be careful not to fit the bearing at an angle.
K3
« Fill the inside of the bearing with grease.
« When assembling the bearing, be careful H K1
K4
not to forget to assemble the spacer.
« The bearing clearance is adjusted, so do I
not change the combination with the spacer. Block
When replacing, always replace as a set. DEW02332
2) Press fit dust seal (55) to retainer.
« Press fit so that the dust seal lip surface is
facing the outside.
Lip of oil seal: Grease (G2-LI)
54 55
042403
DEW02333
Feeler gauge
DEW00993
54
DDW02334
30-165
DISASSEMBLY AND ASSEMBLY CENTER HINGE PIN
DEW01505
13
Upper hinge
1) Assemble tools H, I, J, K2, K3, and K4 to top of
front frame upper hinge. Set bearing (61) in tool K4
K1, then set to press-fitting portion from above
and press fit.
« When press fitting, use tool K3 as a guide.
« Be careful not to fit the bearing at an angle. K1
« Fill the inside of the bearing with grease.
« When assembling the bearing, be careful
042403
not to forget to assemble spacer (62). K3
« The bearing clearance is adjusted, so do K2 DEW00997
J
I
K4
K1
From H
K3
61 62
61 Front frame
K2 Block
DEW01507
61
DEW01508
30-166
DISASSEMBLY AND ASSEMBLY CENTER HINGE PIN
DEW02335
57
Clearance
a
DDW02337
DEW02338
30-167
DISASSEMBLY AND ASSEMBLY CENTER HINGE PIN
• Bleeding air
1) Bleed air from brake line.
For details of the procedure for bleeding the air,
see TESTING AND ADJUSTING.
2) Bleed air from steering line.
For details of the procedure for bleeding the air,
see TESTING AND ADJUSTING.
042403
repeat vacuum method to completely evacuate.
(Attainment of vacuum: Min. 750 mmHg.)
4) Charge with 1.5 – 1.6 kg of refrigerant.
5) Do not use the can of refrigerant upside-down
or use any other mistaken method. Be careful
not to let liquid freon get into the refrigerating
system.
6) Do not operate the compressor before charging
with refrigerant.
30-168
DISASSEMBLY AND ASSEMBLY ORBIT-ROLL
REMOVAL OF ORBIT-ROLL
ASSEMBLY
1. Covers
Remove covers (1) under cab.
042103
2. ORBIT~ROLL
1) Remove cover (2) of steering column.
2) Loosen lock bolt and pull out column joint
(3) from ORBIT-ROLL. 1
3) Remove hydraulic hoses (4).
4) Remove mounting bolts (5), then remove the ORBIT-
ROLL unit (6)
30-168/1
DISASSEMBLY AND ASSEMBLY ORBIT-ROLLL
INSTALLATION OF ORBIT-ROLL
ASSEMBLY
Lock bolt:
55.9 ± 6.9 Nm (5.7 ± 0.7 kgm)
042103
30-168/2
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
30-169
DISASSEMBLY AND ASSEMBLY STEERING VALVE
8
7
9
DLW01703
042403
DLW01704
DLW01705
13. Remove dust seal (14) from bushing (12) with screw-
driver. 13
« Be careful not to damage the bushing.
12
14
DLW01706
30-170
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
042403
DLW01708
20
18. Turn spool (20) slowly and pull out from rear of sleeve
(19) (in the direction of the arrow).
19 20
DLW01709
21. Screw a threaded bar into check sheet (24), and pull
out check sheet (24).
25
22. Remove O-rings (25) and (26) from check sheet (24).
28
23. Tap housing, and remove ball (27) and retainer (28). 23 24 27
26
DLW01710
30-171
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 sand-
paper.
« 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.
042403
« Be careful to set the top and bottom of the
check sheet facing in the correct direction.
30-172
DISASSEMBLY AND ASSEMBLY STEERING VALVE
19
DLW01713
17
18
042403
DLW01714
16 15
10. Fit 2 bearing races (15) and thrust needle (16) in 15
case (10).
22
10
DLW01716
30-173
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
042403
DLW01718
ASSEMBLY OF ROTOR
DLW01719
DLW01720
30-174
DISASSEMBLY AND ASSEMBLY STEERING VALVE
18
DLW01721
4
042403
5
DLW01722
20. Make O-ring (5) end of rotor set to spacer plate end,
then align insert portion of star of rotor (4) with drive. Inset portion of star of rotor set A
1
22. Set end cap (2) on rotor set, and align bolt hole. 2
3
6
DLW01724
30-175
DISASSEMBLY AND ASSEMBLY STEERING VALVE
DLW01725
042403
30-176
DISASSEMBLY AND ASSEMBLY STEERING VALVE
1. Covers
Remove covers (3) under cab.
2. Steering pipes
Remove the orbit-roll servo pipes (4).
.
042403
30-177
DISASSEMBLY AND ASSEMBLY STEERING VALVE
3. Hydraulic piping
Disconnect following hydraulic piping from steering
valve. ❈2
• 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
Sling steering valve (6), and remove mounting bolts
(14), then lift off steering valve. ❈2
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.
042403
30-178
DISASSEMBLY AND ASSEMBLY STEERING VALVE
INSTALLATION OF STEERING
VALVE ASSEMBLY
❈1
« Check that the steering valve is at neutral.
❈2
« Replace the O-ring with a new part.
« Remove the clamp to avoid applying force when
installing the tube.
30-179
DISASSEMBLY AND ASSEMBLY STEERING VALVE
DISASSEMBLY OF STEERING
VALVE ASSEMBLY
1. Relief valves 33
1) Remove overload relief valve (33) from valve hous-
ing (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
042403
DEW01030 DEW01031
DEW01032
30-180
DISASSEMBLY AND ASSEMBLY STEERING VALVE
30-181
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).
042403
3) Merge check valve
1) Assemble poppet (34) and spring (35) to valve
housing.
2) Install O-ring, then tighten plug (25).
Plug: 63.7 ± 4.9 Nm (6.5 ± 0.5 kgm)
30-182
DISASSEMBLY AND ASSEMBLY STEERING VALVE
3. Flow control
1) Fit O-ring to plug (5) and install to valve housing.
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)
30-183
DISASSEMBLY AND ASSEMBLY STEERING, SWITCH PUMP
REMOVAL OF STEERING,
SWITCH PUMP ASSEMBLY
042403
When releasing the refrigerant from the air condi-
tioner, carry out the oil return operation, then use a
gauge manifold and release the refrigerant slowly
from the core of the compressor high-pressure and
low-pressure valves. 3-1
1. Covers
Remove covers (3) at bottom of cab.
2. Ladders
Remove left and right ladders (3-1).
30-184
DISASSEMBLY AND ASSEMBLY STEERING, SWITCH PUMP
DEW01515
18
16
4. Bulkhead
15
1) Remove cover (16) at bottom front face of bulk-
head (15).
2) Remove top mounting bolts (18) holding bulk-
head (15) and hood (17).
« Be careful not to lose the rubber and wash- 15
DEW01408 DEW01412
ers of the mounting portion.
30-185
DISASSEMBLY AND ASSEMBLY STEERING, SWITCH PUMP
Bulkhead: 135 kg
(including accumulator, charge valve) 19
400 mm
mm.
« The bulkhead comes near the cab when it is
lifted, so be careful not to hit anything.
(Opposite end) (This end)
« To prevent the bulkhead from falling after it DEW01529 DEW00470
is raised, place blocks on the left and right
at opposite ends.
5. Pump piping 4 23 22
1) Disconnect suction tube between hydraulic tank
and steering pump at pump end.
2) Disconnect tube (20) between steering pump
and steering valve at pump end.
3) Disconnect tube (21) between switch pump and
steering valve at pump end.
« After disconnecting the tubes, fit plugs to
prevent the entry of dirt or dust.
042403
6. Pump 5 20 21 DEW01517
30-186
DISASSEMBLY AND ASSEMBLY STEERING, SWITCH PUMP
INSTALLATION OF STEERING,
SWITCH PUMP ASSEMBLY
1
Accelerator cable mounting nut:
53.9 ± 4.9 Nm (5.5 ± 0.5 kgm)
2
Condenser hose:
19.6 – 24.5 Nm (2.0 – 2.5 kgm)
3
Receiver hose:
3.9 – 6.9 Nm (0.4 – 0.7 kgm)
4 5
« Use a new part for the O-ring.
• Bleeding air
1) Bleed air from brake line.
For details of the procedure for bleeding the air,
see TESTING AND ADJUSTING.
2) Bleed air from steering line.
For details of the procedure for bleeding the air,
see TESTING AND ADJUSTING.
30-187
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
042403
DEW01518
2. Steering cylinder 1
1) Remove rod bolt, then remove pin (3). 3
DEW01519
DEW01083
30-188
DISASSEMBLY AND ASSEMBLY STEERING CYLINDER
INSTALLATION OF STEERING
CYLINDER ASSEMBLY
30-189
DISASSEMBLY AND ASSEMBLY BRAKE VALVE
1. Covers 6
Remove covers (1) under cab.
042403
cumulator and brake valve, and adapters (4)
13
and (5) at valve end. 1 7 8 19 DEW01086
2) Disconnect brake valve drain hose and tube
(6) at valve end.
3) Disconnect hose (7) going to left brake valve
at valve end. 19 12 13
4) Disconnect tube (8) which goes to front
brake and tube (9) going to rear brake at
valve end. 2
11
30-190
DISASSEMBLY AND ASSEMBLY BRAKE VALVE
5. Pedals
Pull out cotter pin (26) from pin (15) of brake pedal 18 19
(14), then pull out pin, and remove pedal.
« Carry out the same operation for both the left
and right brake pedals.
6. Brake valve 14
Remove brake valve mounting bolts (17), and dis-
connect mount flange (18) and body (19), then pull
out cap (20). 15
20 17
16
DEW01088 DEW01089
INSTALLATION OF BRAKE
VALVE ASSEMBLY
• Carry out installation in the reverse order to re-
moval.
1 2 3 4
« Use a new part for the O-ring.
« After completing the assembly, bleed the air
042403
30-191
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
4
2) Remove mounting bolts (5) of bracket assem-
bly (4), then remove bracket assembly. 51ø
25.75
3) Remove oil seal (6) from upper portion of brake
51.5
10
valve. 6
6 6
2. Valve DEW01090 Jig q DEW01091
1) Install valve to jig 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 re-
move 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
042403
5) Remove holder (16), springs (17), (18), and
(19) and O-ring (20) from T flange assembly DEW01092
(9).
« The cylinders, plungers, and spools inside
the T flange assembly and the S and P
cylinders form sets, so be careful not to 13
14
mix the parts for any set.
« Fit seals to prevent dirt or dust from enter- 7
13
ing, and be careful not to damage the cylin- 10
ders or flange assembly. 10 11
7 12
8
15
8
DEW01093 DEW01094
16
17 20
17
18
9
20 19
DEW01095 DEW01096
30-192
DISASSEMBLY AND ASSEMBLY RIGHT BRAKE VALVE
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.
30-193
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
4
2) Remove mounting bolts (5) of bracket assem-
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 marks
« Make match marks before disassembling
the valve. 8
Jig
Vice
042403
DEW01103
11
3) Remove plug (10) of S cylinder assembly, then 7
remove spring (11) and O-ring (12).
9
10
DEW01104 DDW01105
30-194
DISASSEMBLY AND ASSEMBLY LEFT BRAKE VALVE
DEW01104 DDW01105
30-195
DISASSEMBLY AND ASSEMBLY SLACK ADJUSTER
REMOVAL OF SLACK
ADJUSTER ASSEMBLY
ing.
042403
DEW01521
3. Brake piping
1) Disconnect tube (2) between slack adjuster and
brake valve at adjuster end.
« For the rear, remove slack adjuster cover 2
(4) and disconnect tube (3).
5
2) Disconnect tubes (5) between slack adjuster
and left and right brake pistons at slack ad-
juster end.
4. Slack adjuster
Remove mounting bolts, then remove slack adjuster 6 5
(6). 1 DEW01522
5
3 4
DEW01523
30-196
DISASSEMBLY AND ASSEMBLY SLACK ADJUSTER
INSTALLATION OF SLACK
ADJUSTER ASSEMBLY
1
Installation of the slack adjuster
« Tighten the mounting bolts temporarily, and
tighten them fully after connecting the piping.
30-197
DISASSEMBLY AND ASSEMBLY SLACK ADJUSTER
DISASSEMBLY OF SLACK
ADJUSTER ASSEMBLY
1 2
1. Bleeder
Remove bleeder (2) from body (1).
DEW01117
2. Cylinder
Remove mounting bolts, and disconnect body (1) 4 1
and cylinder (4) together with bracket (3).
042403
3 DEW01118
3. Piston
1) Remove spring (5) and O-ring (6). 6 7
2) Push out piston (7), and remove O-ring.
« When removing the piston, push out slowly 6
5
with a 10 mm diameter rod.
« Be careful not to damage the thread with
the rod.
DEW01119 DEW01120
4. Poppet
4
1) Remove cover (8) from cylinder (4), then re-
move plug (9), spring (10), and poppet (11).
« When removing the poppet, blow in air from
the oil hole in the cylinder.
« Hold the cylinder oil port by hand and be 12
careful not to blow the air in strongly.
2) Remove O-ring (12) from poppet.
8 9 10 11 DEW01121
30-198
DISASSEMBLY AND ASSEMBLY SLACK ADJUSTER
ASSEMBLY OF SLACK
ADJUSTER ASSEMBLY
4
1. Poppet
1) Assemble O-ring (12) to poppet (11).
11 12
2) Assemble poppet (11), spring (10), plug (9),
and cover (8), then assemble to cylinder (4).
8 9 10 11
DEW01122 DEW01123
2. Piston
1) Install O-ring (13) to piston (7).
4
2) Insert piston (7) in cylinder (4).
« Check that the piston moves smoothly. 7 7
13
042403
DEW01124 DEW01125
3. Cylinder
1) Install O-ring (6) and spring (5) to cylinder.
« Installed load of spring: 4.4 kg
2) Install body (1) and cylinder (4) together with
bracket (3).
5
6
4. Bleeder DEW01126
1
4
2
3
DEW01128 DEW01127
30-199
DISASSEMBLY AND ASSEMBLY BRAKE
DISASSEMBLY OF BRAKE
ASSEMBLY
042403
644 kg (26.5-25 tire)
DEW00823 2 DEW01130
2. Draining oil
Set drain plug (2) immediately at bottom, then re-
move plug and drain oil from case.
Axle oil: 55 l
30-200
DISASSEMBLY AND ASSEMBLY BRAKE
3. Cover
Remove cover (3), then remove O-ring (4).
4
3
DEW01131 DEW00840
4. Axle shaft
Using forcing screws (Thread dia.=12mm, 5
Pitch=1.75mm), pull out axle shaft (5) approx.
200 mm.
6
5. Planetary carrier
Remove 3 mounting bolts, and lift off planetary
carrier (6).
« Make match marks and use as a guide when
assembling.
« Be careful of the center of gravity and remove
042403
Planetary carrier: 86 kg
6. Ring gear
1) Using tools T4 and T5, secure wheel hub (8) 9 T4 T5 8
and brake (9).
« Install tools T4 and T5 at three equally
spaced places, then use a washer to ad-
just the clearance.
DEW01135
Ring gear: 35 kg
11
DEW00923
30-201
DISASSEMBLY AND ASSEMBLY BRAKE
DEW01137
042403
DEW01138
8. Axle housing
Remove bearing (14), O-ring (15), trunnion (16),
14
and O-ring of trunnion mount portion from axle hous-
16
ing.
Trunnion: 54 kg
15
DEW01139
9. Piston, cylinder
1) Set wheel hub (17) at bottom, and remove tool
T4.
2) Using eyebolts, lift off cylinder assembly (18).
18
Cylinder assembly: 63 kg
17
DEW01140
30-202
DISASSEMBLY AND ASSEMBLY BRAKE
19 DEW01141
20
042403
DEW01142 DEW01143
DEW01144
25
26
DEW01145
30-203
DISASSEMBLY AND ASSEMBLY BRAKE
30
27
28
DEW01146
042403
31
DEW01147
3) Using tool T2, lift off outer gear (27) from wheel
hub (35), and remove seal ring (32) and O-ring
(33).
4) Remove oil seal (34) from outer gear (27). T2
32
33
27
34
(14 mm, P = 2)
DEW01148
35
DEW01149
30-204
DISASSEMBLY AND ASSEMBLY BRAKE
35
DEW01150
DEW01151
30-205
DISASSEMBLY AND ASSEMBLY BRAKE
ASSEMBLY OF BRAKE
ASSEMBLY
40 39
1. Wheel hub
1) Press fit bearing cups (39) and (40) to wheel
hub (35).
2) Install O-ring (38) to seal ring (37), and using
tool T1, install to wheel hub.
« Use alcohol to completely remove the white
powder from the surface of the O-ring.
« Remove all oil and grease from the O-ring
contact surface of the seal ring and re-
tainer. DEW01151
« Be careful not to twist the O-ring when in-
stalling it.
37 38
042403
DEW01153
T1
DEW01154
2. Inner gear
Install inner gear (36) to wheel hub (35).
Mounting bolt: 36
279.5 ± 29.4 Nm (28.5 ± 3.0 kgm)
35
DEW01149
30-206
DISASSEMBLY AND ASSEMBLY BRAKE
3. Outer gear
1) Press fit oil seal (34) to outer gear (27).
Protrusion or depression
« When press fitting the oil seal, be careful of of end of oil seal and
the direction of the oil seal breather hole. 27 34 end of outer gear shall
be within 0.5 mm
DEW01158
042403
T1
27
DEW01160
30-207
DISASSEMBLY AND ASSEMBLY BRAKE
DEW01161
27
042403
35
DEW01162
30
27
28
DEW01146
30-208
DISASSEMBLY AND ASSEMBLY BRAKE
4. Piston, cylinder
1) Install seals (25) and (26) to piston (24).
« Fit the seal in the groove securely. 24
Seal: Brake oil
25
26
DEW01145
41 DEW01166
21
20
DEW01142 DEW01143
19 DEW01141
30-209
DISASSEMBLY AND ASSEMBLY BRAKE
18
17
DEW01140
27 35
042403
DEW01171
5. Axle housing
1) Install O-ring to trunnion and axle housing, and
14
tighten with bolts.
16
« Use a new part for the O-ring.
Mounting bolt:
926.7 ± 103 Nm (94.5 ± 10.5 kgm)
2) Install O-ring (15) to trunnion (16), and press fit
bearing (14).
« Use a new part for the O-ring.
15
DEW01139
30-210
DISASSEMBLY AND ASSEMBLY BRAKE
12
DEW01137
7. Ring gear
1) Raise ring gear (11) and set in mounting posi-
tion, then install to axle housing. 11 10
« Align the spline groove and install slowly.
2) Tighten retainer (10) with 3 bolts temporarily,
and remove tools T4 and T5.
« Temporarily tighten the retainer without in-
serting shims.
« Rotate the wheel hub to settle the bearing
and tighten uniformly until the torque is the 11
042403
specified torque.
Retainer mounting bolt: DEW01175 DEW01176
73.6 ± 1 Nm (7.5 ± 0.1 kgm)
3) Measure clearance b between end face of hous-
ing and end face of retainer from measurement
hole of retainer (10) with depth micrometer. 11
« Measure at two places and take the aver-
age.
« Shim thickness = Clearance b + 0.3 mm.
« Select the shim thickness to give the mini- b
mum number of shims.
10
« Shim thickness: 1.0 mm, 0.5 mm, 0.2 mm,
0.05 mm
DEW01177
30-211
DISASSEMBLY AND ASSEMBLY BRAKE
8. Planetary carrier
Assemble O-ring to wheel hub (8), then raise plan-
etary carrier (6), set in mounting position, and in-
stall.
« Use a new part for the O-ring.
« Align the mounting holes and install slowly so
that the O-ring does not come out of position.
042403
6
8 DEW01179
9. Axle shaft
Install axle shaft (5). 3
« Rotate the wheel hub to align the position when 5
installing the sun gear.
10. Cover
Fit O-ring into groove of cover, and install cover (3).
Mounting bolt:
112.8 ± 9.8 Nm (11.5 ± 1.0 kgm)
4
DEW01180 DEW01181
DEW00823
30-212
DISASSEMBLY AND ASSEMBLY BRAKE
30-213
DISASSEMBLY AND ASSEMBLY PARKING BRAKE DISC
2. Drive shaft
Remove guard of drive shaft, and disconnect lower
front drive shaft (1) at transmission end. 6
1
« After disconnecting the drive shaft, move it to 7
the right.
3. Suction tube
1) Remove mounting bolt (3) and washer (4) of
coupling (2) at front of transmission, then re-
move coupling. 2
042403
2) Remove suction tube (5) at transmission end. 5 8
DEW00723
4. Parking brake
1) Remove lock plates (7) of parking brake manual
release bolts (6), then remove 3 release bolts.
2) Remove parking brake case (8).
3) Screw in 3 manual release bolts (6), and re- 6
lease parking brake.
« Distance l to screw in bolt = 28 mm
Screw in all three bolts uniformly.
´
6
6
DEW01185 DDW01186
30-214
DISASSEMBLY AND ASSEMBLY PARKING BRAKE DISC
M1, M2, M3
3 DEW01187 3 DDW01188
9 DEW01189
30-215
DISASSEMBLY AND ASSEMBLY PARKING BRAKE DISC
INSTALLATION OF PARKING
BRAKE DISC
Wave spring Plate
• Carry out installation in the reverse order to re-
moval.
10 Disc
1
Drive shaft:
112.8 ± 9.8 Nm (11.5 ± 1.0 kgm)
Tool mark
2 (1 groove)
Coupling mounting bolt:
921.8 ± 98.1 Nm (94.0 ± 10.0 kgm) DDW01192
End face of coupling:
Anti-friction compound (LM-G)
3
Insert the plates and discs in the case in order, and Coupling
assemble the wave springs between the plates.
« When assembling end plate (10), pay attention
to the tool mark (one groove) on the face.
• Tighten the drain plug of the transmission, and add
oil.
Transmission: 40 l
042403
« Run the engine to circulate the oil through the Coat with anti-friction compound DDW01193
30-216
DISASSEMBLY AND ASSEMBLY HYDRAULIC TANK
1. Draining oil
1) Remove cover (1) on top of ladder, then re-
move plugs (2) and (3) at the top of the hydrau-
lic tank filter, and prevent the oil inside the tank
from flowing out. 1
042403
2. Ladder floor
1) Sling right ladder floor (6), then remove mount-
ing bolts and lift off.
« Be careful of the center of gravity of the
ladder floor when lifting off.
Ladder floor: 63 kg
30-217
DISASSEMBLY AND ASSEMBLY HYDRAULIC TANK
3. Hydraulic piping
1) Loosen clamps of hose (7) between hydraulic
tank and hydraulic pump and disconnect at tank
end.
2) Disconnect return tube (8) between main control
valve and hydraulic tank at tank end. 2
042403
fit plugs to prevent the entry of dirt or dust.
4. Hydraulic tank
Sling hydraulic tank (14), then remove mounting bolts
and lift off.
« Raise the hydraulic tank slightly and move it to
the outside to lift it off from the machine.
30-218
DISASSEMBLY AND ASSEMBLY HYDRAULIC TANK
INSTALLATION OF HYDRAULIC
TANK ASSEMBLY
1
Hydraulic tank filter plug
Plug on top of filter:
11.8 ± 1 Nm (1.2 ± 0.1 kgm)
2 3
Installation of tubes (8) and (9)
« Use a new part for the O-ring.
• Bleeding air
For details of the bleeding air from the brake sys-
tem and the hydraulic line, see TESTING AND
042403
ADJUSTING.
30-219
DISASSEMBLY AND ASSEMBLY WORK EQUIPMENT, PPC PUMP
REMOVAL OF WORK
EQUIPMENT, 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 park-
ing brake and put blocks under the wheels to pre-
vent the machine from moving.
042403
When releasing the refrigerant from the air condi-
tioner, carry out the oil return operation, then use a
gauge manifold and release the refrigerant slowly
from the core of the compressor high-pressure and
low-pressure valves. 3-1
1. Covers
Remove covers (3) at bottom of cab.
2. Ladders
Remove left and right ladders (3-1).
DEW01440
Ladder rail (left): 59.5 kg
30-220
DISASSEMBLY AND ASSEMBLY WORK EQUIPMENT, PPC PUMP
16 17 19
DEW00463 DEW00464
4. Bulkhead
1) Remove cover (16) at bottom front face of bulk-
head (15).
17
2) Remove top mounting bolts (18) holding bulk-
head (15) and hood (17). 16 18
« Be careful not to lose the rubber and wash-
ers of the mounting portion.
15
15 DEW01077
DEW02346
30-221
DISASSEMBLY AND ASSEMBLY WORK EQUIPMENT, PPC PUMP
Bulkhead: 135 kg
(including accumulator, charge valve) 19
400 mm
mm.
« The bulkhead comes near the cab when it
is lifted, so be careful not to hit anything.
(Opposite end) (This end)
« To prevent the bulkhead from falling after it DEW01529 DEW00470
is raised, place blocks on the left and right
at opposite ends.
5. Pump piping 4 22 23
21
1) Disconnect suction tube between hydraulic tank
and hydraulic, PPC pump at pump end.
2) Disconnect tube (20) between hydraulic pump
and main control valve at pump end.
3) Disconnect tube (21) between PPC pump and
charge valve at pump end.
« After disconnecting the tubes, fit plugs to
prevent the entry of dirt or dust.
042403
20
6. Pump 5 DEW01533
Remove mounting bolts (23) of hydraulic and PPC
pump assembly (22), then remove pump assembly.
30-222
DISASSEMBLY AND ASSEMBLY WORK EQUIPMENT, PPC PUMP
INSTALLATION OF WORK
EQUIPMENT, PPC PUMP
ASSEMBLY
• Carry out installation in the reverse order to re-
moval.
1
Accelerator cable mounting nut:
53.9 ± 4.9 Nm (5.5 ± 0.5 kgm)
2
Condenser hose:
19.6 – 24.5 Nm (2.0 – 2.5 kgm)
3
Receiver hose:
3.9 – 6.9 Nm (0.4 – 0.7 kgm)
4 5
« Use a new part for the O-ring.
30-223
DISASSEMBLY AND ASSEMBLY WORK EQUIPMENT, PPC PUMP
1. Covers
Remove covers (3) at bottom of cab.
2. Ladders
042403
Remove left and right ladders (3-1).
DEW01440
4. Cover
Remove side cover (11) of console box (10).
10
11 DEW01536
30-224
DISASSEMBLY AND ASSEMBLY WORK EQUIPMENT, PPC PUMP
5. PPC valve
1) Remove joints (13) and (14) of rod installed to 14
PPC valve assembly (12).
15 13 12 DEW01220
• Bleeding air
Bleed air from PPC line.
For details of the procedure for bleeding the air,
see TESTING AND ADJUSTING.
30-225
042403
30-226
DISASSEMBLY AND ASSEMBLY PPC VALVE
8 8
9 9
10 10
6 11 6
11
12 12
13
13
DEW01222
30-227
DISASSEMBLY AND ASSEMBLY PPC VALVE
4
Port position No. of coils of spring
P1 Bucket TILT
P2 Boom RAISE 11
P3 Boom LOWER 2
P4 Bucket DUMP 14
3
« The position of each port is stamped on the
5
valve body.
9
2. Assemble shim (11), spring (10), and retainer (9) to 10
valve (12), and install collar (8).
13
3. Assemble valve assembly (6) to body (7).
042403
DEW01221
the boom LOWER spool which was marked
with a distinguishing mark, then install the
spools.
10 10
6 11 6
11
12 12
13
13
DEW01222
30-228
DISASSEMBLY AND ASSEMBLY MAIN CONTROL VALVE
1. Cover
Remove inspection cover (3) of front frame.
042403
2. Bucket cylinder
1) Disconnect connector (4) of bucket positioner
wiring.
2) Disconnect grease hose (5) at front frame end.
3) Disconnect rod hose (6) at cylinder end. 1
4) Disconnect bottom hose (7) at cylinder end.
2
« After disconnecting the hoses, fit plugs to
prevent the entry of dirt or dust.
30-229
DISASSEMBLY AND ASSEMBLY MAIN CONTROL VALVE
3. Hydraulic piping
Disconnect following hydraulic piping. 4
1) Disconnect tube (11) between hydraulic pump
and valve at main control valve end.
2) Disconnect hose (12) between cut-off valve and
main control valve at main control valve end.
3) Disconnect tubes (13) and (14) between main
control valve and dump cylinder at valve end.
4) Disconnect tubes (15) and (16) between main
control valve and lift cylinder at valve end.
042403
5) Disconnect drain tube (17) of main control valve
at valve end.
6) Disconnect tubes (18), (19), (20), (21), (22) and
(23) between PPC valve and main control valve
at main control valve end.
« After disconnecting the tubes and hoses,
mark with a tag to distinguish when install-
ing.
« After disconnecting the tubes and hoses, fit
plugs to prevent the entry of dirt or dust.
30-230
DISASSEMBLY AND ASSEMBLY MAIN CONTROL VALVE
INSTALLATION OF MAIN
CONTROL VALVE ASSEMBLY
1 2
« Install the hoses without twisting or interfer-
ence.
« Use a new part for the O-ring.
3
Bucket cylinder
1) Align the bottom pin hole, assemble shims so
that the total for clearance a between the cylin- 9
der and frame is within the standard value,
then install pin (9).
« Clearance a: 1.5 mm
2) Align the rod pin hole and assemble pin (8).
5
« When setting the valve in the mounting posi-
tion, pay attention to the balance and be care-
ful not to hit any other part inside the frame.
• Bleeding air
Bleed air from hydraulic line.
For details of the procedure for bleeding the air,
see TESTING AND ADJUSTING.
30-231
DISASSEMBLY AND ASSEMBLY MAIN CONTROL VALVE
042403
30-232
DISASSEMBLY AND ASSEMBLY MAIN CONTROL VALVE
1. Tube,hose
1) Remove tube (2) and hose (3) from valve body
(1).
2) Remove tee (4), nipple (5), and elbow (6).
2. Spool assembly
1) Remove sleeve (7), then remove spacer (8), spring
(9), and piston (10).
2) Remove case (11), spring (12), and retainer (13),
then remove spool assembly (14).
« Do not remove plug(16) from spool (15) un-
less necessary.
3) Remove sleeve (17), then remove spacer (18),
spring (19), and piston (20).
4) Remove case (21), then remove spring (22), re-
tainer (23), spring (24), and retainer (25).
30-233
DISASSEMBLY AND ASSEMBLY MAIN CONTROL VALVE
042403
30-234
DISASSEMBLY AND ASSEMBLY MAIN CONTROL VALVE
Tube, hose
1) Install elbow (6), nipple (5), and tee (4) to body (1).
Nipple: 29.4 ± 4.9 Nm (3.0 ± 0.5 kgm)
Tee: 29.4 ± 4.9 Nm (3.0 ± 0.5 kgm)
2) Install hose (3) and tube (2).
Hose sleeve nut:
91.2 ± 12.8 Nm (9.3 ± 1.3 kgm)
Tube sleeve nut:
49.0 ± 19.6 Nm (5.0 ± 2.0 kgm)
30-235
DISASSEMBLY AND ASSEMBLY MAIN CONTROL VALVE
042403
ring to case (13) and install.
DEW01548
8. Install cut-off valve (2) to valve body (1).
Mounting bolt:
107.9 ± 9.8 Nm (11.0 ± 1.0 kgm)
« Tighten the bolts in the order shown in the
diagram on the right.
DEW01551
30-236
DISASSEMBLY AND ASSEMBLY BUCKET CYLINDER
REMOVAL OF BUCKET
CYLINDER ASSEMBLY
1 DEW01552
4. Bucket cylinder
1) Sling bucket cylinder (7), then remove lock bolts, 7
and remove pin (5) and pin (6). 2
« When slinging, be careful of the center of
gravity and sling from two points.
« If there are shims installed, check the
number and thickness of the shims, and
keep in a safe place.
2) Lift off bucket cylinder (1).
4
Bucket cylinder: 192.5 kg 3
DEW01553
30-237
DISASSEMBLY AND ASSEMBLY BUCKET CYLINDER
INSTALLATION OF BUCKET
CYLINDER ASSEMBLY
1
« Use a new part for the O-ring.
« Install the hoses without twisting or interfer-
ence.
2
Bucket cylinder
1) Align the bottom pin hole, assemble shims so a a DEW01238
that the total for clearance a between the cylin-
der and frame is within the standard value,
then install pin (6).
« Clearance a: 1.5 mm
042403
specified level.
• Bleeding air
Bleed air from hydraulic line.
For details of the procedure for bleeding the air,
see TESTING AND ADJUSTING.
30-238
DISASSEMBLY AND ASSEMBLY BOOM CYLINDER
1. Rod pin
1) Sling boom cylinder (1), then remove lock bolt 1
7
of rod pin, and remove pin (2). 1
« If there are shims installed, check the
number and thickness of the shims, and 2
keep in a safe place.
2) Start engine, and use control lever to retract
cylinder rod on side that was removed.
« Retract to a point 20 mm before the end of
the stroke.
042403
DEW02339 DEW02340
1
2. Hydraulic piping
1) Disconnect cylinder rod from connecting por-
tion. 2
2) Disconnect cylinder bottom tube (5) and hose
(6) at connecting portion. 3
« After disconnecting the tubes and hoses, fit
plugs to prevent the entry of dirt or dust.
DEW01241
3. Boom cylinder
1) Remove lock bolt of cylinder bottom pin, then
remove pin (7). 4
« If there are shims installed, check the
number and thickness of the shims, and
keep in a safe place.
2) Lift off boom cylinder (1).
« Be careful of the center of gravity and lift
off slowly.
« Be careful not to damage the cylinder por-
tion.
30-239
DISASSEMBLY AND ASSEMBLY BOOM CYLINDER
INSTALLATION OF BOOM
CYLINDER ASSEMBLY
1
Start the engine, operate the control levers, and Rod pin
extend the rod. Align the pin holes and assemble
shims so that clearance a is uniform on the left and
right, then install the pin.
« Clearance a: Max. 1.5 mm
DEW01243
2 3
« Use a new part for the O-ring.
4
Bottom pin
Align the pin at the cylinder bottom, assemble shims
so that the total for clearance b between the cylin-
der and frame is within the standard value, then
install the pin.
042403
Never insert your fingers.
b b DEW01244
30-240
DISASSEMBLY AND ASSEMBLY HYDRAULIC CYLINDER
DISASSEMBLY OF HYDRAULIC
CYLINDER ASSEMBLY
(STEERING, BOOM, BUCKET CYLINDER AS- Steering cylinder
SEMBLY)
O 2 1
DEW01245
2) Pull out cylinder head and piston rod assembly Steering cylinder
(3) from cylinder (4), and lift off. 4 3
« Oil will flow out when the piston rod assem-
bly is removed from the cylinder, so place
a container under the cylinder to catch the
oil.
042403
DEW01246
Bucket cylinder 30
DEW01247
DEW01248
30-241
DISASSEMBLY AND ASSEMBLY BOOM CYLINDER
3. Cylinder head
• Steering cylinder assembly P 9 3 2
1) Set cylinder head and piston rod assembly (3)
to tool N.
2) Using tool P, remove nut (8).
« Width across flats of nut: 55 mm N
3) Remove piston (9), then remove cylinder head 8
(2).
DEW01249
042403
DEW01250
DEW01251
16
15
DEW01252
30-242
DISASSEMBLY AND ASSEMBLY BOOM CYLINDER
21 19
DEW01253
26
042403
24
DEW01254
30-243
DISASSEMBLY AND ASSEMBLY HYDRAULIC CYLINDER
ASSEMBLY OF HYDRAULIC
CYLINDER ASSEMBLY
(STEERING, BOOM, BUCKET CYLINDER AS-
SEMBLY)
Q
22 23
24
042403
DEW01256
26
DEW01257
18
19
DEW01259
30-244
DISASSEMBLY AND ASSEMBLY HYDRAULIC CYLINDER
21
DEW01260
DEW01261 DEW01262
16
15
DEW01263 DEW01264
30-245
DISASSEMBLY AND ASSEMBLY HYDRAULIC CYLINDER
5. Cylinder head
• Boom, bucket cylinder 7 2 6
1) Set cylinder (7) to tool N.
2) Raise cylinder head and piston rod assembly N
(6) and assemble to cylinder (7).
3) Install cylinder head (2) to cylinder (7).
Mounting bolt:
Cylinder Nm(kgm)
Boom cylinder 343.2 ± 34.3(35 ± 3.5)
Bucket cylinder 490.3 ± 49.0(50 ± 5)
042403
DEW01267
4) Remove cylinder assembly (1) from tool N.
O 2 1
DEW01269
30-246
DISASSEMBLY AND ASSEMBLY WORK EQUIPMENT
REMOVAL OF WORK
EQUIPMENT ASSEMBLY
1
DEW01549
DEW01550
DEW01554
30-247
DISASSEMBLY AND ASSEMBLY WORK EQUIPMENT
042403
number and thickness of the shims, and
keep in a safe place. DEW01555
Bucket link: 56 kg 11
13 12
DEW01275
11
DEW01556
30-248
DISASSEMBLY AND ASSEMBLY WORK EQUIPMENT
11
15
15
16
16 15 11 DEW01279
DEW01277
7 18
17 17
17
042403
18 18
DEW01280
DEW01278
19
19
20
DEW01266
30-249
DISASSEMBLY AND ASSEMBLY WORK EQUIPMENT
INSTALLATION OF WORK
EQUIPMENT ASSEMBLY
1
Bucket and bucket link
« Be careful that the cord ring does not get
caught.
« Clearance c at mount portion: 1.5 mm c c DEW01281
2
Bucket cylinder
« After assembling the mounting pin, remove
the block.
042403
3
Boom cylinder
« Clearance b at mount portion: Max. 1.5 mm
b b
DEW01282
4
Boom, bellcrank, bucket link
« Clearance a at mount portion: Max. 1.5 mm
a a
DEW01283
30-250
DISASSEMBLY AND ASSEMBLY WORK EQUIPMENT
5
Bellcrank, bucket link
« Secure the bucket to the bellcrank with wire.
« Be careful that the cord ring does not get
caught.
6 Bushing
Use a press to press fit the bushing to the bucket 12 12
link, bellcrank, and boom. After press fitting, as-
semble the dust seal.
Inside surface of bushing:
Grease (G2-LI) DEW01284
042403
Hydraulic cylinder
DEW01285
30-251
DISASSEMBLY AND ASSEMBLY COUNTERWEIGHT
REMOVAL OF
COUNTERWEIGHT
042403
DEW01286
INSTALLATION OF
COUNTERWEIGHT
30-252
DISASSEMBLY AND ASSEMBLY FUEL TANK
1. Radiator guard
1) Remove 4 radiator guard mounting bolts, and 2 3
disconnect connector (1) of rear working lamp
wiring and radiator water level sensor (2) at 1
radiator end.
2) Lift off radiator guard (3).
042403
DEW01288
2. Draining fuel
Loosen drain valve (4) and drain fuel.
Fuel: 400 l 9
3. Drain valves 5
Remove engine oil drain valve (5) from fuel tank.
4
DEW01558 DEW01559
6
7 DEW01560
30-253
DISASSEMBLY AND ASSEMBLY FUEL TANK
5. Fuel tank
1) Put pallet under fuel tank (11), then put blocks
so that tank does not tilt, and support tank with 12
pallet truck.
DEW01561 DEW01562
11
042403
Blocks Pallet
Pallet truck DEW01534
1
« When installing the fuel tank, keep it horizontal,
and set it in position on the machine.
« Tighten the bolts in the following order: left,
rear, right. DEW01295
Fuel tank mounting bolt:
926.7 ± 104.9 Nm (94.5 ± 10.5 kgm)
• Tighten the drain valve and add oil through oil
filler.
11
DEW01296
30-254
DISASSEMBLY AND ASSEMBLY CAB
3 4 DEW01297
5
DEW01298
3
7
DEW01299
9 DEW01300
30-255
DISASSEMBLY AND ASSEMBLY CAB
10
DEW01301
042403
DEW01302
Cab: 300 kg
13
DEW01303
INSTALLATION OF CAB
ASSEMBLY
30-256
DISASSEMBLY AND ASSEMBLY MAIN MONITOR
7 DEW01305
DEW01306
10
DEW01307
30-257
DISASSEMBLY AND ASSEMBLY MAIN MONITOR
12
DEW01308
042403
16
DEW01309
INSTALLATION OF MAIN
15 14 13
MONITOR ASSEMBLY 11
1
« Fit the connector lock securely.
16
DEW01310
30-258
DISASSEMBLY AND ASSEMBLY MAINTENANCE MONITOR
REMOVAL OF MAINTENANCE
MONITOR ASSEMBLY
DEW01311
5
042403
3
DEW01312
7 7
DEW01313
INSTALLATION OF
MAINTENANCE MONITOR
ASSEMBLY
• Carry out installation in the reverse order to re-
moval.
30-259
DISASSEMBLY AND ASSEMBLY AIR CONDITIONER UNIT
REMOVAL OF AIR
CONDITIONER UNIT ASSEMBLY
042403
1. Loosen clamp of heater hoses (1-3) and (1-4), and DEW01316
disconnect hoses.
DEW01317
5
DEW01318
30-260
DISASSEMBLY AND ASSEMBLY AIR CONDITIONER UNIT
6 DEW01319
DEW01320
DEW01321
16 17 DEW01322
30-261
DISASSEMBLY AND ASSEMBLY AIR CONDITIONER UNIT
19
DEW01323
21
22
20
042403
DEW01324 DEW01325
23
DEW01326
25
23
26 DEW01327
30-262
DISASSEMBLY AND ASSEMBLY AIR CONDITIONER UNIT
28 29
DEW01328
DEW01329
DEW01330 DEW01331
33
23
DEW01332
30-263
DISASSEMBLY AND ASSEMBLY AIR CONDITIONER UNIT
34
16
DEW01333
36
042403
23
35 DEW01334
37
DEW01335
DEW01336
30-264
DISASSEMBLY AND ASSEMBLY AIR CONDITIONER UNIT
INSTALLATION OF AIR
CONDITIONER UNIT ASSEMBLY
• Carry out installation in the reverse order to removal.
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.
30-265
DISASSEMBLY AND ASSEMBLY AIR CONDITIONER CONDENSER
REMOVAL OF AIR
CONDITIONER
CONDENSER ASSEMBLY
042403
DEW01338 3 DEW01339
DEW01340
12 DEW01341
30-266
DISASSEMBLY AND ASSEMBLY AIR CONDITIONER CONDENSER
INSTALLATION OF AIR
CONDITIONER CONDENSER
ASSEMBLY
• Carry out installation in the reverse order to re-
moval.
1
« Do not remove the plugs from the hoses or
condenser connections until immediately before
installing.
« Install the hoses without twisting.
Hose, connection:
Compressor oil for new refrigerant (ND-
OIL8)
Condenser top connection:
19.6 – 24.5 Nm (2.0 – 2.5 kgm)
Condenser bottom connection:
11.8 – 14.7 Nm (1.2 – 1.5 kgm)
30-267
DISASSEMBLY AND ASSEMBLY DRY RECEIVER
INSTALLATION OF DRY
RECEIVER ASSEMBLY 5
• Carry out installation in the reverse order to re-
moval.
1 4
042403
« Do not remove the plugs from the hoses or dry
receiver connections until immediately before DEW01343
installing.
« Install the hoses without twisting.
Hose, connection:
Compressor oil for new refrigerant (ND-
OIL8)
Receiver connection:
4 – 6.8 Nm (0.4 – 0.7 kgm)
2
Receiver mounting U-bolt:
10.8 – 26.5 Nm (1.1 – 2.7 kgm)
• Fill the air conditioner with new refrigerant.
« Precautions when filling air conditioner line with
new refrigerant
1) Keep the temperature inside the room at above
3°C.
(If the temperature is below 3°C, the system
will not work.)
2) Use R134a as the refrigerant.
3) When filling with refrigerant, always use the
repeat vacuum method to completely evacu-
ate. (Attainment of vacuum: Min. 750 mmHg.)
4) Charge with 1.5 – 1.6 kg of refrigerant.
5) Do not use the can of refrigerant upside-down
or use any other mistaken method. Be careful
not to let liquid freon get into the refrigerating
system.
6) Do not operate the compressor before charg-
ing with refrigerant.
30-268
DISASSEMBLY AND ASSEMBLY AIR CONDITIONER COMPRESSOR
REMOVAL OF AIR
CONDITIONER COMPRESSOR
ASSEMBLY 1
6 2
1. Disconnect electric wiring connector (2) of com-
pressor clutch.
dirt or dust 1
4 6
DEW01566
3. Remove compressor adjustment bolt (5) and mount-
ing bolt (6), remove V-belt, then remove air condi-
tioner compressor (7). 2
30-269
DISASSEMBLY AND ASSEMBLY AIR CONDITIONER COMPRESSOR
INSTALLATION OF AIR
CONDITIONER COMPRESSOR
ASSEMBLY
• Carry out installation in the reverse order to re-
moval.
1
« Do not remove the plugs in the hoses or con-
nections until immediately before installing.
« Install the hoses without twisting.
Hose, connection:
Compressor oil for new refrigerant (NB-
OIL8)
Connection nuts of hoses (3), (4):
7.9 – 11.8 Nm (0.8 – 1.2 kgm)
1
Adjust the V-belt.
For details, see TESTING AND ADJUSTING.
042403
3°C.
(If the temperature is below 3°C, the system
will not work.)
2) Use R134a as the refrigerant.
3) When filling with refrigerant, always use the
repeat vacuum method to completely evacu-
ate. (Attainment of vacuum: Min. 750 mmHg.)
4) Charge with 1.5 – 1.6 kg of refrigerant.
5) Do not use the can of refrigerant upside-down
or use any other mistaken method. Be careful
not to let liquid freon get into the refrigerating
system.
6) Do not operate the compressor before charg-
ing with refrigerant.
30-270
DISASSEMBLY AND ASSEMBLY TIRES
30-271
DISASSEMBLY AND ASSEMBLY TIRES
042403
When the body inclines, insert blocks D (for stopper)
between rear axle and rear frame from both sides until
there is no play and set the rear axle level.
30-272
DISASSEMBLY AND ASSEMBLY TIRES
Raise ( )
Hold ( )
Lower ( )
Dangerous à Float ( )
30-273
DISASSEMBLY AND ASSEMBLY TIRES
042403
c) Jack up axle differential bottom or both sides
of axle housing to lift the body.
30-274
DISASSEMBLY AND ASSEMBLY TIRES
2.4.
d) Set block B, C on both sides of rear frame bottom
and adjust the height with iron plate I (for adjusting).
30-275
DISASSEMBLY AND ASSEMBLY TIRES
042403
4. Installing Tire Wheel Assembly
30-276
DISASSEMBLY AND ASSEMBLY TIRES
30-277
042403
30-278
40 MAINTENANCE STANDARD
40-1
MAINTENANCE STANDARD ENGINE MOUNT, TRANSMISSION MOUNT
B
A
Kgm 123 ± 24 Nm
(12.5 ± 2.5 kgm)
A–A B–B
SDW00331
Unit: mm
40-2
MAINTENANCE STANDARD TORQUE CONVERTER
TORQUE CONVERTER
1
2
SDW00403
Unit: mm
– 0.01 Replace
Width 3 – 0.03 2.7
3 Wear of stator
shaft seal ring
Thickness 4.3 ± 0.1 3.9
40-3
MAINTENANCE STANDARD TRANSMISSION
TRANSMISSION
1 2
kgm 113 ± 10 Nm
4 3 6 5 7 8 (11.5 ± 1.0 kgm)
16
18 21
15
20
17
23
21
25
kgm 927 ± 103 Nm
(94.5 ± 10.5 kgm)
19
21
10 27 13 24 14 11 12 26 22 9
SDW00333
40-4
MAINTENANCE STANDARD TRANSMISSION
Unit: mm
40-5
MAINTENANCE STANDARD TRANSMISSION
Unit: mm
+ 0.076
Width of seal ring groove 3.2 0 3.5
21
0
Thickness of seal ring 2.29 – 0.1 2.1
40-6
40-7
MAINTENANCE STANDARD TRANSMISSION
4 11 2 2 1 1 12 3
10 5 6 7 11 12 8 9 SDW00334
40-8
MAINTENANCE STANDARD TRANSMISSION
Unit: mm
40-9
MAINTENANCE STANDARD TRANSMISSION
6 8 7 5 SDW00335
Unit: mm
Clearance (outside)
between piston and 145 –0.30 +0.13 0.3 – 0.43
cylinder –0.35 0 0.48
Clearance (inside)
between piston (2nd) and 96.73 0 +0.18 0.05 – 0.43
shaft –0.015 +0.05 0.195
2 Clearance (outside)
between piston and 176 –0.27 +0.13 0.27 – 0.43
cylinder –0.32 0 0.45
Clearance (R) at bearing
3 press-fitting portion of 75 +0.030 0 –0.045 – —
REVERSE, 2nd clutch shaft +0.011 –0.015 –0.011
Clearance (F) at bearing Replace
4 press -fitting portion of 75 +0.071 0 –0.086 – —
REVERSE, 2nd clutch shaft +0.061 –0.015 –0.061
40-10
MAINTENANCE STANDARD TRANSMISSION
3 6 1 1 7 2
4 6 7 5 SDW00336
Unit: mm
Clearance (outside)
between piston and 176 –0.27 +0.13 0.27 – 0.43
cylinder –0.32 0 0.45
Clearance (R) at bearing
2 press-fitting portion of 3rd, 75 +0.030 0 –0.045 – —
4th clutch shaft +0.011 –0.015 –0.011
Clearance (F) at bearing
3 press-fitting portion of 3rd, 35 +0.071 0 –0.086 – —
4th clutch shaft +0.061 –0.015 –0.061
Replace
4 End play of 3rd gear 0.34 – 1.56
40-11
40-12
40-13
MAINTENANCE STANDARD TRANSMISSION CONTROL VALVE
9
6
4
1
2
5
8 10 SDW00339
40-14
MAINTENANCE STANDARD TRANSMISSION CONTROL VALVE
Unit: mm
40-15
MAINTENANCE STANDARD TRANSMISSION CONTROL VALVE
40-16
MAINTENANCE STANDARD TRANSMISSION CONTROL VALVE
Unit: mm
40-17
MAINTENANCE STANDARD DRIVE SHAFT
DRIVE SHAFT
kgm 113 ± 10 Nm kgm 549 ± 58 Nm kgm 927 ± 103 Nm kgm 113 ± 10 Nm kgm 113 ± 10 Nm
(11.5 ± 1.0 kgm) (56.0 ± 6.0 kgm) (94.5 ± 10.5 kgm) (11.5 ± 1.0 kgm) (11.5 ± 1.0 kgm)
40-18
40-19
MAINTENANCE STANDARD DIFFERENTIAL
DIFFERENTIAL
15 12 9
17
16
11
13
10
2 1
A–A
5 4 3
A A
14 8 6 7 SDW00342
40-20
MAINTENANCE STANDARD DIFFERENTIAL
Unit: mm
Backlash of differential
13 gear 0.10 – 0.43 —
40-21
MAINTENANCE STANDARD FINAL DRIVE
FINAL DRIVE
2 6 5
kgm 113 ± 10 Nm
(11.5 ± 1.0 kgm)
kgm 176 ± 20 Nm
(18 ± 2.0 kgm)
Unit: mm
Replace
2 Clearance between ring 180 +0.040 0 –0.065 – —
gear hub and bearing +0.015 –0.025 0.015
40-22
MAINTENANCE STANDARD AXLE MOUNT
AXLE MOUNT
A A
kgm 279.5 ± 29 Nm
(28.5 ± 3.0 kgm)
4
3
kgm 279.5 ± 29 Nm
(28.5 ± 3.0 kgm)
2
A–A
SDW00344
Unit: mm
+0.3
2 Thickness of wear plate 5 –0.1 —
40-23
MAINTENANCE STANDARD STEERING COLUMN, GEAR BOX
STEERING COLUMN
Unit: mm
40-24
40-25
MAINTENANCE STANDARD STEERING VALVE
STEERING VALVE
Unit: mm
40-26
MAINTENANCE STANDARD
STANDARD STEERING CYLINDER MOUNT
1, 2
a
3, 4
A–A SDW00348
Unit: mm
40-27
MAINTENANCE STANDARD SLACK ADJUSTER
SLACK ADJUSTER
SEW00349
Unit: mm
40-28
MAINTENANCE STANDARD BRAKE VALVE
2
3
kgm 7.8 ± 2 Nm
(0.8 ± 0.2 kgm)
6
kgm 66.2 ± 7.3 Nm
(6.75 ± 0.75 kgm)
5
7 4
kgm 152 ± 24.5 Nm
(15.5 ± 2.5 kgm) SDW00350
Unit: mm
40-29
MAINTENANCE STANDARD BRAKE VALVE
2
3
kgm 7.8 ± 2 Nm
(0.8 ± 0.2 kgm)
7 4
40-30
MAINTENANCE STANDARD BRAKE VALVE
Unit: mm
40-31
MAINTENANCE STANDARD BRAKE
BRAKE
40-32
MAINTENANCE STANDARD BRAKE
Unit: mm
40-33
MAINTENANCE STANDARD PARKING BRAKE
PARKING BRAKE
1 2 3 SDW00353
Unit: mm
40 ±0.05 3.9
1 Thickness of plate
Depth of
2 Brake disc lining groove 0.45 +0.175 0.3
Thickness of
lining 0.7 ±0.075
40-34
MAINTENANCE STANDARD TORQUE CONVERTER, TRANSMISSION PUMP
A 4 3 3
1
A–A
kgm 277 ± 32 Nm
(28.5 ± 3 kgm)
SEW00354
Unit: mm
Rotating torque of
4 spline shaft 6.9 – 11.8 Nm (0.7 – 1.2 kgm)
40-35
MAINTENANCE STANDARD STEERING, SWITCH PUMP
4 2 3 1 3 2 3 1 3
SEW00355
Unit: mm
Rotating torque of
4 spline shaft 13.8 – 23.6 Nm (1.4 – 2.4 kgm)
40-36
MAINTENANCE STANDARD HYDRAULIC, PPC PUMP
4 2 3 1 3 2 3 1 3
Unit: mm
Rotating torque of
4 spline shaft 11.8 – 19.6 Nm (1.2 – 2.0 kgm)
40-37
MAINTENANCE STANDARD PPC VALVE
PPC VALVE
kgm 44 ± 5Nm
(4.5 ± 0.5 kgm)
SEW00357
Unit: mm
16.8 N 13.7 N
3 Metering spring 31.4 x 7.4 29.4 (1.7 kg) — (1.4 kg)
40-38
MAINTENANCE STANDARD CUT-OFF VALVE
CUT-OFF VALVE
Unit: mm
40-39
MAINTENANCE STANDARD MAIN CONTROL VALVE
40-40
MAINTENANCE STANDARD MAIN CONTROL VALVE
Unit: mm
40-41
MAINTENANCE STANDARD MAIN CONTROL VALVE
3-SPOOL VALVE
40-42
MAINTENANCE STANDARD MAIN CONTROL VALVE
Unit: mm
31.4 N 25.5 N
10 Spool return spring 62.6 52.0 (3.2 kg) — (2.6 kg)
18.8 N 14.7 N
11 Check valve spring 78.2 52.0 (1.92 kg) — (1.5 kg)
161.8 N 129.5 N
12 Float selector valve spring 53.0 40.1 (16.5 kg) — (13.2 kg)
49.0 N 39.2 N
13 Unload valve spring 82.7 47.0 (5.0 kg) — (4.0 kg)
40-43
MAINTENANCE STANDARD BOOM CYLINDER
BOOM CYLINDER
Unit: mm
40-44
MAINTENANCE STANDARD BUCKET CYLINDER
BUCKET CYLINDER
Unit: mm
40-45
MAINTENANCE STANDARD CENTER HINGE PIN
kgm 113 ± 10 Nm
(11.5 ± 1.0 kgm)
15 16
5
7
4
14
12
3 8
13
6 9
2
11 10
A–A 1 B–B
kgm 113 ± 10 Nm
(11.5 ± 1.0 kgm)
SDW00363
40-46
MAINTENANCE STANDARD CENTER HINGE PIN
Unit: mm
Tightening torque of 19.6 ± 2 Nm (2.0 ± 0.2 kgm) (when adjusting with shim)
15 upper hinge retainer
mounting bolt
112.8 ± 9.8 Nm (11.5 ± 1.0 kgm) (final value)
Tightening torque of 19.6 ± 2 Nm (2.0 ± 0.2 kgm) (when adjusting with shim)
16 upper hinge retainer
mounting bolt
205.9 ± 19.6 Nm (21 ± 2 kgm) (final value)
40-47
MAINTENANCE STANDARD WORK EQUIPMENT LINKAGE
1 2 3
J
J
E
D
F E
D H
F
BB C H
C
G
G
A A
6 5 4
2 1 1
5 4 6
16 9 15
D–D E–E F–F
7 8 3
40-48
MAINTENANCE STANDARD WORK EQUIPMENT LINKAGE
Unit: mm
Connection of boom
13 cylinder and frame 120 +0.8
0
125 +0.5
0
2.2 – 5.5
Connection of bellcrank
14 and bucket link 138 +3
–0.5
143 ± 1.5 1 – 5.5
Connection of bellcrank
15 and boom 220 ± 0.5 223 ± 0.5 2–4 Replace
Connection of bucket
16 cylinder and bellcrank 115 +0.8
0
118 ± 1.5 1.2 – 3.0
40-49
MAINTENANCE STANDARD BUCKET
BUCKET
B C
B C
A–A
B–B
kgm 902 ± 39 Nm
2 (92 ± 4 kgm)
C–C D–D
Unit: mm
40-50
MAINTENANCE STANDARD BUCKET POSITIONER AND BOOM KICK-OUT
kgm 88 ± 34 Nm
(9.0 ± 3.5 kgm)
kgm 17.2 ± 2.4 Nm
(1.75 ± 0.25 kgm)
1 A–A
SEW00366
Unit: mm
Clearance at bucket
1 positioner switch 3–5
Adjust
40-51
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
SN WA470H20669 and up
1 / 5
10-611
Ground
SN WA470H20669 and up
2 / 5
10-612
Ground
SN WA470H20669 and up
3 / 5
10-615
Ground
SN WA470H20669 and up
4 / 5
10-616
Ground
SN WA420H30297 and up
5 / 5
10-619
10-620
Ground
From SN WA470H20942
up to SN WA470H21064
1 / 1
10-623
2
10-624
2
Ground
SN WA470H21164 and up
Page 1 / 5
10-627
1
Ground
SN WA470H21164 and up
Page 2 / 5
10-628
1
Ground
SN WA470H21164 and up
Page 3 / 5
10-631
1
Ground
SN WA470H21164 and up
Page 4 / 5
10-632
1
Ground
SN WA470H21164 and up
Page 5 / 5
10-635
1
10-636
1