Shop Manual Wa500
Short Description
manual de taller...
Description
CEBM001202
SHOP MANUAL WA500-3 WHEEL LOADER MACHINE MODEL
WA500-3LE
SERIAL NUMBERS
A70001 and up
This material is proprietary to Komatsu America International Company and is not to be reproduced, used, or disclosed except in accordance with written authorization from Komatsu America International Company. It is our policy to improve our products whenever it is possible and practical to do so. We reserve the right to make changes or add improvements at any time without incurring any obligation to install such changes on products sold previously. Due to this continuous program of research and development, periodic revisions may be made to this publication. It is recommended that customers contact their distributor for information on the latest revision.
CONTENTS
01 GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-1 10 STRUCTURE AND FUNCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-1 20 TESTING, ADJUSTING, AND TROUBLESHOOTING . . . . . . . . . . . 20-1 30 DISASSEMBLY AND ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . 30-1 40 MAINTENANCE STANDARD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-1 90 OTHER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-1
00-2
PRODUCT PUBLICATIONS INFORMATION
VARIOUS PRODUCT PARTS & SERVICE PUBLICATIONS ARE AVAILABLE TO ALL KOMATSU CONSTRUCTION EQUIPMENT OWNERS, INCLUDING OPERATION & MAINTENANCE MANUALS, PARTS BOOKS AND SHOP MANUALS.
SPECIAL PUBLICATIONS SUCH AS SERVICE TOOL, AIR CONDITIONING, AND TURBOCHARGER SHOP MANUALS ARE ALSO AVAILABLE AS WELL AS SELECTED OPERATION & MAINTENANCE AND SHOP MANUALS IN FOREIGN LANGUAGES.
THE PUBLICATIONS LISTED BELOW ARE AVAILABLE FOR THIS PARTICULAR MACHINE(S).
DESCRIPTION
FORM NUMBER
PARTS BOOK - PAPER: Engine and Chassis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
BEPB002201
PARTS BOOK - MICROFICHE: Engine and Chassis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
BEPM002201
OPERATION & MAINTENANCE MANUAL: Chassis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CEAM001400 3666095
SHOP MANUAL: Chassis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Engine: Shop Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Troubleshooting & Repair Manual - Base Engine . . . . . . . . . . . . . . . . . . . . . . . Specifications Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Standard Repair Times . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Performation Degradation Troubleshooting Procedure . . . . . . . . . . . . . . . . . . . Outer Base Circle Overhead Set Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . Overhead Set Specifications Service Bulletin . . . . . . . . . . . . . . . . . . . . . . . . . . .
CEBM001202
SAFETY MANUAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
WLT70-1
3810487 3666142 3666090 3666031 3666006 3666007 3666089
PARTS AND SERVICE PUBLICATIONS CAN ONLY BE ACQUIRED BY AUTHORIZED KOMATSU DISTRIBUTORS, USING THE KOMATSU AMERICA INTERNATIONAL COMPANY PARTS INFORMATION PROCESSING SYSTEM (PIPS). IF THE PIPS SYSTEM IS NOT AVAILABLE AT THE DISTRIBUTOR LOCATION, THEN THE FOLLOWING REQUISITION FOR TECHNICAL SERVICE PUBLICATIONS AND SERVICE FORMS CAN BE USED. FORM KDC91D IS SHOWN ON THE REVERSE SIDE OF THIS PAGE.
REQUISITION FOR TECHNICAL SERVICE PUBLICATIONS AND SERVICE FORMS
COMPLETE FORM AND RETURN TO
Komatsu America International Company 440 North Fairway Drive Vernon Hills, IL 60061-8112 U.S.A. Attn: Technical Publications Fax No. (847) 970-4186 Tel No. (847) 970-5887
COMPANY NAME
PURCHASE ORDER NO.
SHIP TO ATTN.
ORDER DATE
STREET ADDRESS
TYPE or PRINT ONLY
CITY, STATE, ZIP CODE COUNTRY
PHONE NO.
FAX NO.
SHIPPING METHOD
DISTR/BRANCH CODE
IMPORTANT - TO ASSURE SHIPMENT OF THE CORRECT PUBLICATION(S), THE MODEL NUMBER AND MACHINE SERIAL NUMBER MUST BE SHOWN. PARTS BOOK QTY.
KDC91D 081696
PUBLICATION FORM NO.
P-Paper M-Microfiche
PUBLICATION DESCRIPTION
MODEL NUMBER
CURRENT PRICES WILL BE CHARGED
SERIAL NUMBER
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SAFETY
SAFETY NOTICE
SAFETY SAFETY NOTICE
IMPORTANT SAFETY NOTICE Proper service and repair is extremely important for the safe operation of your machine. The service and repair techniques recommended and described in this manual are both effective and safe methods of operation. Some of these operations require the use of tools specially designed for the purpose. To prevent injury to workers, the symbols and are used to mark safety precautions in this manual. The cautions accompanying these symbols should always be followed carefully. If any dangerous situation arises or may possibly arise, first consider safety, and take the necessary actions to deal with the situation.
GENERAL PRECAUTIONS Mistakes in operation are extremely dangerous. Read the OPERATION & MAINTENANCE MANUAL carefully BEFORE operating the machine.
7. Before adding oil or making repairs, park the machine on hard, level ground, and block the wheels or tracks to prevent the machine from moving.
1. Before carrying out any greasing or repairs, read all the precautions given on the decals which are fixed to the machine.
8. Before starting work, lower blade, ripper, bucket or any other work equipment to the ground. If this is not possible, insert the safety pin or use blocks to prevent the work equipment from falling. In addition, be sure to lock all the control levers and hang warning signs on them.
2. When carrying out any operation, always wear safety shoes and helmet. Do not wear loose work clothes, or clothes with buttons missing. Always wear safety glasses when hitting parts with a hammer. Always wear safety glasses when grinding parts with a grinder, etc. 3. If welding repairs are needed, always have a trained, experienced welder carry out the work. When carrying out welding work, always wear welding gloves, apron, glasses, cap and other clothes suited for welding work. 4. When carrying out any operation with two or more workers, always agree on the operating procedure before starting. Always inform your fellow workers before starting any step of the operation. Before starting work, hang UNDER REPAIR signs on the controls in the operator's compartment. 5. Keep all tools in good condition and learn the correct way to use them.
9. When disassembling or assembling, support the machine with blocks, jacks or stands before starting work. 10. Remove all mud and oil from the steps or other places used to get on and off the machine. Always use the handrails, ladders or steps when getting on or off the machine. Never jump on or off the machine. If it is impossible to use the handrails, ladders or steps, use a stand to provide safe footing. PRECAUTIONS DURING WORK 11. When removing the oil filler cap, drain plug or hydraulic pressure measuring plugs, loosen them slowly to prevent the oil from spurting out. Before disconnecting or removing components of the oil, water or air circuits, first remove the pressure completely from the circuit. 12. The water and oil in the circuits are hot when the engine is stopped, so be careful not to get burned. Wait for the oil and water to cool before carrying out any work on the oil or water circuits.
6. Decide a place in the repair workshop to keep tools and removed parts. Always keep the tools and parts in their correct places. Always keep the work area clean and make sure that there is no dirt or oil on the floor. Smoke only in the areas provided for smoking. Never smoke while working. PREPARATIONS FOR WORK
00-3
SAFETY 13. Before starting work, remove the leads from the battery. ALWAYS remove the lead from the negative (-) terminal first. 14. When raising heavy components, use a hoist or crane. Check that the wire rope, chains and hooks are free from damage. Always use lifting equipment which has ample capacity. Install the lifting equipment at the correct places. Use a hoist or crane and operate slowly to prevent the component from hitting any other part. Do not work with any part still raised by the hoist or crane. 15. When removing covers which are under internal pressure or under pressure from a spring, always leave two bolts in position on opposite sides. Slowly release the pressure, then slowly loosen the bolts to remove. 16. When removing components, be careful not to break or damage the wiring, Damaged wiring may cause electrical fires.
SAFETY NOTICE 19. Be sure to assemble all parts again in their original places. Replace any damaged part with new parts. When installing hoses and wires, be sure that they will not be damaged by contact with other parts when the machine is being operated. 20. When installing high pressure hoses, make sure that they are not twisted. Damaged tubes are dangerous, so be extremely careful when installing tubes for high pressure circuits. Also check that connecting parts are correctly installed. 21. When assembling or installing parts, always use the specified tightening torques. When installing protective parts such as guards, or parts which vibrate violently or rotate at high speed, be particularly careful to check that they are installed correctly. 22. When aligning two holes, never insert your fingers or hand. Be careful not to get your fingers caught in a hole.
17. When removing piping, stop the fuel or oil from spilling out. If any fuel or oil drips on to the floor, wipe it up immediately. Fuel or oil on the floor can cause you to slip, or can even start fires.
23. When measuring hydraulic pressure, check that the measuring tool is correctly assembled before taking any measurements.
18. As a general rule, do not use gasoline to wash parts. In particular, use only the minimum of gasoline when washing electrical parts.
24. Take care when removing or installing the tracks of tracktype machines. When removing the track, the track separates suddenly, so never let anyone stand at either end of the track.
00-4
FOREWORD
GENERAL
FOREWORD GENERAL This shop manual has been prepared as an aid to improve the quality of repairs by giving the serviceman an accurate understanding of the product and by showing him the correct way to perform repairs and make judgements. Make sure you understand the contents of this manual and use it to full effect at every opportunity.
This shop manual mainly contains the necessary technical information for operations performed in a service workshop. For ease of understanding, the manual is divided into the following sections. These sections are further divided into each main group of components. GENERAL This section lists the general machine dimensions, performance specifications, component weights, and fuel, coolant and lubricant specification charts. STRUCTURE AND FUNCTION This section explains the structure and function of each component. It serves not only to give an understanding of the structure, but also serves as reference material for troubleshooting. TESTING AND ADJUSTING This section explains checks to be made before and after performing repairs, as well as adjustments to be made at completion of the checks and repairs. Troubleshooting charts correlating "Problems" to "Causes" are also included in this section. DISASSEMBLY AND ASSEMBLY This section explains the order to be followed when removing, installing, disassembling or assembling each component, as well as precautions to be taken for these operations. MAINTENANCE STANDARD This section gives the judgement standards when inspecting disassembled parts.
NOTICE The specifications contained in this shop manual are subject to change at any time and without any advance notice. Contact your distributor for the latest information.
00-5
FOREWORD
HOW TO READ THE SHOP MANUAL
HOW TO READ THE SHOP MANUAL VOLUMES
REVISED EDITION MARK
Shop manuals are issued as a guide to carrying out repairs. They are divided as follows: Chassis volume: Issued for every machine model Engine volume: Issued for each engine series Electrical volume: Each issued as one to cover all models Attachment volume: Each issued as one to cover all models
When a manual is revised, an edition mark ( recorded on the bottom outside corner of the pages.
These various volumes are designed to avoid duplication of information. Therefore to deal with all repairs for any model, it is necessary that chassis, engine electrical and attachment be available. DISTRIBUTION AND UPDATING Any additions, amendments or other changes will be sent to your distributors. Get the most up-to-date information before you start any work. FILING METHOD 1. See the page number on the bottom of the page. File the pages in correct order. 2. Following examples show how to read the page number: Example 1 (Chassis volume):
REVISIONS Revised pages are shown at the LIST OF REVISED PAGES between the title page and SAFETY page. SYMBOLS So that the shop manual can be of ample practical use, important places for safety and quality are marked with the following symbols. Symbol
Item
Consecutive page number for each item Example 2 (Engine volume): Refer to the pertinent engine manual. 3. Additional pages: Additional pages are indicated by a hyphen (-) and numbered after the page number. File as in the example. Example: 10-4 10-4-1 Added pages 10-4-2 10-5
00-6
Remarks
Safety
Special safety precautions are necessary when performing the work.
Caution
Special technical precautions or other precautions for preserving standards are necessary when performing the work.
Weight
Weight of parts or systems. Caution necessary when selecting hoisting wire or when working posture is important, etc.
10 - 3 Item number (10. Structure and Function)
....) is
Tightening torque
Coat
Places that require special attention for tightening torque during assembly. Places to be coated with adhesives and lubricants etc.
Oil, water
Places where oil, water or fuel must be added, and the capacity.
Drain
Places where oil or water must be drained, and quantity to be drained.
FOREWORD
HOISTING INSTRUCTIONS
HOISTING INSTRUCTIONS HOISTING
Heavy parts (25 kg or more) must be lifted with a hoist etc. In the DISASSEMBLY AND ASSEMBLY section, every part weighing 25 kg or more is indicated clearly with the symbol
If a part cannot be smoothly removed from the machine by hoisting, the following checks should be made: 1) Check for removal of all bolts fastening the part to the relative parts. 2) Check for existence of another part causing interface with the part to be removed. WIRE ROPES 1) Use adequate ropes depending on the weight of parts to be hoisted, referring to the table below:
3)
Slinging with one rope may cause turning of the load during hoisting, untwisting of the rope, or slipping of the rope from its original winding position on the load, which can result in a dangerous accident.
4) Wire ropes (Standard "Z" or "S" twist ropes without galvanizing Rope diameter (mm) 10.0 11.2 12.5 14.0 16.0 18.0 20.0 22.4 30.0 40.0 50.0 60.0
Allowable load (tons) 1.0 1.4 1.6 2.2 2.8 3.6 4.4 5.6 10.0 18.0 28.0 40.0
Do not sling a heavy load with one rope alone, but sling with two or more ropes symmetrically wound on to the load.
Do not sling a heavy load with ropes forming a wide hanging angle from the hook. When hoisting a load with two or more ropes, the force subjected to each rope will increase with the hanging angles. The table below shows the variation of allowable load (kg) when hoisting is made with two ropes, each of which is allowed to sling up to 1000 kg vertically, at various hanging angles. When two ropes sling a load vertically, up to 2000 kg of total weight can be suspended. This weight becomes 1000 kg when two ropes make a 120 r hand, two ropes are subject to an excessive force as large as 4000 kg if they sling a 2000 kg load at a lifting angle of 150
The allowable load value is estimated to be 1/6 or 1/7 of the breaking strength of the rope used. 2)
Sling wire ropes from the middle portion of the hook. Slinging near the edge of the hook may cause the rope to slip off the hook during hoisting, and a serious accident can result. Hooks have maximum strength at the middle portion.
00-7
FOREWORD
COATING MATERIALS
COATING MATERIALS The recommended coating materials prescribed in the shop manuals are listed below. Category
Code
Part No.
Qty
Container
LT-1A
790-129-9030
150 g
Tube
Used to prevent rubber gaskets, rubber cushions and cork plugs from coming out
LT-1B
790-129-9050
20 g (x2)
Plastic container
Used in places requiring an immediately effective, strong adhesive. Used for plastics (except polyethylene, polypropylene, tetrafluoroethylene, and vinyl chloride), rubber, metal and non-metal.
LT-2
09940-00030
50 g
Plastic container
Features: Resistance to heat, chemicals Used for anti-loosening and sealant purposes for bolts and plugs.
LT-3
790-129-9060 Set of adhesive and hardening agent
Adh 1 kg Hard agt 500 kg
Can
LT-4
790-129-9040
250 g
Plastic container
Loctite 648-50
79A-129-9110
50 cc
---
LG-1
790-129-9010
200 g
Tube
Used as adhesive or sealant for gaskets and packing of power train case, etc.
Can
Features: Resistance to heat Used as sealant for flange surfaces and bolts at high temperature locations; used to prevent seizure. Used as sealant for heat resistant gasket for at high temperature locations such as engine pre-combustion chamber, exhaust pipe. Features: Resistance to water, oil Used as sealant for flange surface, thread. Also possible to use as sealant for flanges with large clearance. Used as sealant for mating surfaces of final drive case, transmission case.
Adhesive
LG-3
790-129-9070
1 kg
Main applications, features
Used as adhesive or sealant for metal, glass or plastic.
Used as sealant for machined holes. Features: Resistance to heat, chemicals Used at joint portions subject to high temperature.
LG-4
790-129-9020
200 g
Tube
LG-5
790-129-9080
1 kg
Plastic container
LG-6
09940-00011
250 g
Tube
Features: Silicon based, resistant to heat, cold. Used as sealant for flange surface, thread. Used as sealant for oil pan, final drive case, etc.
LG-7
09920-00150
150 g
Tube
Features: Silicon based, quick hardening type. Used as sealant for flywheel housing, intake manifold, oil pan, thermostat housing, etc.
Rust prevention lubricant
---
09940-00051
60 g
Can
Used as lubricant for sliding parts (to prevent squeaking).
Molybdenum disulfide lubricant
---
09940-00040
200 g
Tube
Used to prevent seizure or scuffing of the thread when press fitting or shrink fitting. Used as lubricant for linkage, bearings, etc.
G2-L1
SYG-350Ll SYG-400Ll SYG-400Ll-A SYG-160Ll SYGA-160CNLl
Various
Various
General purpose type
Calcium grease
G2-CA
SSG2-400CA SYG2-350CA SYG2-400CA-A SYG2-160CA SYGA-16CNCA
Various
Various
Used for normal temperature, light load bearing at places in contact with water or steam.
Molybdenum disulfide grease
---
SYG2-400M
400 g (10/case)
Bellows type
Gasket sealant
Lithium grease
00-8
Used as sealant for various threads, pipe joints, flanges. Used as sealant for tapered plugs, elbows, nipples of hydraulic piping.
Used for places with heavy load.
FOREWORD
STANDARD TORQUE REQUIREMENTS
STANDARD TORQUE REQUIREMENTS STANDARD TORQUE REQUIREMENTS OF BOLTS AND NUTS The following charts give the standard torques values of bolts and nuts. Exceptions are given in sections of DISASSEMBLY AND ASSEMBLY. 1 kgm = 9.806 Nm Thread diameter of bolt
Width across flat
mm
mm
kgm
Nm
6
10
1.35 ±0.15
13.2 ±1.4
8
13
3.20 ±0.3
31.4 ±2.9
10
17
6.70 ±0.7
65.7 ±6.8
12
19
11.5 ±1.0
112 ±9.8
14
22
18 ±2.0
177 ±19
16
24
28.5 ±3
279 ±29
18
27
39 ±4
383 ±39
20
30
56 ±6
549 ±58
22
32
76 ±8
745 ±78
24
36
94.5 ±10
927 ±98
27
41
135 ±15
1320 ±140
30
46
175 ±20
1720 ±190
33
50
225 ±25
2210 ±240
36
55
280 ±30
2750 ±290
39
60
335 ±35
3280 ±340
This torque table does not apply to the bolts with which nylon packing or other non-ferrous metal washers are to be used, or which require torquing to otherwise specified values.
00-9
FOREWORD
STANDARD TORQUE REQUIREMENTS
TORQUE REQUIREMENTS OF SPLIT FLANGE BOLTS Use these torques values for split flange bolts. Thread diameter of bolt
Width across flat
torque requirement values
mm
mm
kgm
Nm
10
14
6.70 ±0.7
65.7 ±6.8
12
17
11.5 ±1.0
112 ±9.8
16
22
28.5 ±3
279 ±29
TORQUE REQUIREMENTS FOR FLARED NUTS Use these torque values for flared part of nut. Thread diameter of bolt
Width across flat
mm
mm
kgm
Nm
14
19
2.5 ±0.5
24.5 ±4.9
18
24
5 ±2
49 ±19.6
22
27
8 ±2
78.5 ±19.6
24
32
14 ±3
137.3 ±29.4
30
36
18 ±3
176.5 ±29.4
33
41
20 ±5
196.1 ±49
36
46
25 ±5
245.2 ±49
42
55
30 ±5
294.2 ±49
00-10
torque requirement values
FOREWORD
ELECTRIC WIRE CODE
ELECTRIC WIRE CODE In the wiring diagrams, various colors and symbols are employed to indicate the thickness of wires. This wire code table will help you understand WIRING DIAGRAMS. Example: 05WB indicates a cable having a nominal number 05 and white coating with black stripe. CLASSIFICATION BY THICKNESS Copper wire Nominal number
Cable O.D. (mm)
Current rating (A)
0.88
2.4
12
Starting, lighting, signal etc.
0.32
2.09
3.1
20
Lighting, signal etc.
65
0.32
5.23
4.6
37
Charging and signal
15
84
0.45
13.36
7.0
59
Starting (Glow plug)
40
85
0.80
42.73
11.4
135
Starting
60
127
0.80
63.84
13.6
178
Starting
100
217
0.80
109.1
17.6
230
Starting
Number of strands
Dia. Of strand (mm)
Cross section (mm²)
0.85
11
0.32
2
26
5
Applicable circuit
CLASSIFICATION BY COLOR AND CODE Priority
Classification
1
Primary
Circuits
Charging
Ground
Starting
Lighting
Instruments
Signal
Other
Code
W
B
B
R
Y
G
L
Color
White
Black
Black
Red
Yellow
Green
Blue
Code
WR
---
BW
RW
YR
GW
LW
Color
White/Red
---
Black/White
Red/White
Yellow/Red
Green/White
Blue/White
Code
WB
---
BY
RB
YB
GR
LR
Color
White/Black
---
Black/Yellow
Red/Black
Yellow/Black
Green/Red
Blue/Red
Code
WL
---
BR
RY
YG
GY
LY
Color
White/Blue
---
Black/Red
Red/Yellow
Yellow/Green
Green/Yellow
Blue/Yellow
Code
WG
---
---
RG
YL
GB
LB
Color
White/Green
---
---
Red/Green
Yellow/Blue
Green/Black
Blue/Black
Code
---
---
---
RL
YW
GL
---
Color
---
---
---
Red/Blue
Yellow/White
Green/Blue
---
2
3
4
Auxiliary
5
6
00-11
FOREWORD
CONVERSION TABLES
CONVERSION TABLES METHOD OF USING THE CONVERSION TABLE The Conversion Table in this section is provided to enable simple conversion of figures. For details of the method of using the Conversion Table, see the example given below. EXAMPLE Method of using the Conversion Table to convert from millimeters to inches. 1. Convert 55 mm into inches. (1) Locate the number 50 in the vertical column at the left side, take this as , then draw a horizontal line from . (2) Locate the number 5 in the row across the top, take this as , then draw a perpendicular line down from . (3) Take the point where the two lines cross as . This point gives the value when converting from millimeters to inches. Therefore, 55 millimeters = 2.165 inches. 2. Convert 550 mm into inches. (1) The number 550 does not appear in the table, so divide by 10 (move the decimal one place to the left) to convert it to 55 mm. (2) Carry out the same procedure as above to convert 55 mm to 2.165 inches. (3) The original value (550 mm) was divided by 10, so multiply 2.165 inches by 10 (move the decimal one place to the right) to return to the original value. This gives 550 mm = 21.65 inches.
Millimeters to Inches 1 mm = 0.03937 in mm
0
1
2
3
4
5
6
7
8
9
0
0
0.039
0.079
0.118
0.157
0.197
0.236
0.276
0.315
0.354
10
0.394
0.433
0.472
0.512
0.551
0.591
0.630
0.669
0.709
0.748
20
0.787
0.827
0.866
0.906
0.945
0.984
1.024
1.063
1.102
1.142
30
1.181
1.220
1.260
1.299
1.339
1.378
1.417
1.457
1.496
1.536
40
1.575
1.614
1.654
1.693
1.732
1.772
1.811
1.850
1.890
1.929
50
1.969
2.008
2.047
2.087
2.126
2.165
2.244
2.283
2.323
60
2.362
2.402
2.441
2.480
2.520
2.559
2.205 2.598
2.638
2.677
2.717
2.953
2.992
3.032
3.071
3.110
3.346
3.386
3.425
3.465
3.504
3.740
3.780
3.819
3.858
3.898
70 80 90
00-12
2.756 3.150 3.543
2.795 3.189 3.583
2.835 3.228 3.622
2.874 3.268 3.661
2.913 3.307 3.701
FOREWORD
CONVERSION TABLES
Millimeters to Inches 1 mm = 0.03937 in mm
0
1
2
3
4
5
6
7
8
9
0
0
0.039
0.079
0.118
0.157
0.197
0.236
0.276
0.315
0.354
10
0.394
0.433
0.472
0.512
0.551
0.591
0.630
0.669
0.709
0.748
20
0.787
0.827
0.866
0.906
0.945
0.984
1.024
1.063
1.102
1.142
30
1.181
1.220
1.260
1.299
1.339
1.378
1.417
1.457
1.496
1.536
40
1.575
1.614
1.654
1.693
1.732
1.772
1.811
1.850
1.890
1.929
50
1.969
2.008
2.047
2.087
2.126
2.165
2.205
2.244
2.283
2.323
60
2.362
2.402
2.441
2.480
2.520
2.559
2.598
2.638
2.677
2.717
70
2.756
2.795
2.835
2.874
2.913
2.953
2.992
3.032
3.071
3.110
80
3.150
3.189
3.228
3.268
3.307
3.346
3.386
3.425
3.465
3.504
90
3.543
3.583
3.622
3.661
3.701
3.740
3.780
3.819
3.858
3.898
Kilogram to Pound 1 kg = 2.2046 lb kg
0
1
2
3
4
5
6
7
8
9
0
0
2.20
4.41
6.61
8.82
11.02
13.23
15.43
17.64
19.84
10
22.05
24.25
26.46
28.66
30.86
33.07
35.27
37.48
39.68
41.89
20
44.09
46.30
48.50
50.71
51.91
55.12
57.32
59.53
61.73
63.93
30
66.14
68.34
70.55
72.75
74.96
77.16
79.37
81.57
83.78
85.98
40
88.18
90.39
92.59
94.80
97.00
99.21
101.41
103.62
105.82
108.03
50
110.23
112.44
114.64
116.85
119.05
121.25
123.46
125.66
127.87
130.07
60
132.28
134.48
136.69
138.89
141.10
143.30
145.51
147.71
149.91
152.12
70
154.32
156.53
158.73
160.94
163.14
165.35
167.55
169.76
171.96
174.17
80
176.37
178.57
180.78
182.98
185.19
187.39
189.60
191.80
194.01
196.21
90
198.42
200.62
202.83
205.03
207.24
209.44
211.64
213.85
216.05
218.26
00-13
FOREWORD
CONVERSION TABLES
Liter to U.S. Gallon 1 0
1
2
3
4
5
6
7
8
9
0
0
0.264
0.528
0.793
1.057
1.321
1.585
1.849
2.113
2.378
10
2.642
2.906
3.170
3.434
3.698
3.963
4.227
4.491
4.755
5.019
20
5.283
5.548
5.812
6.076
6.340
6.604
6.869
7.133
7.397
7.661
30
7.925
8.189
8.454
8.718
8.982
9.246
9.510
9.774
10.039
10.303
40
10.567
10.831
11.095
11.359
11.624
11.888
12.152
12.416
12.680
12.944
50
13.209
13.473
13.737
14.001
14.265
14.529
14.795
15.058
15.322
15.586
60
15.850
16.115
16.379
16.643
16.907
17.171
17.435
17.700
17.964
18.228
70
18.492
18.756
19.020
19.285
19.549
19.813
20.077
20.341
20.605
20.870
80
21.134
21.398
21.662
21.926
22.190
22.455
22.719
22.983
23.247
23.511
90
23.775
24.040
24.304
24.568
24.832
25.096
25.361
25.625
25.889
26.153
Liter to U.K. Gallon 1 0
1
2
3
4
5
6
7
8
9
0
0
0.220
0.440
0.660
0.880
1.100
1.320
1.540
1.760
1.980
10
2.200
2.420
2.640
2.860
3.080
3.300
3.520
3.740
3.950
4.179
20
4.399
4.619
4.839
5.059
5.279
5.499
5.719
5.939
6.159
6.379
30
6.599
6.819
7.039
7.259
7.479
7.699
7.919
8.139
8.359
8.579
40
8.799
9.019
9.239
9.459
9.679
9.899
10.119
10.339
10.559
10.778
50
10.998
11.281
11.438
11.658
11.878
12.098
12.318
12.528
12.758
12.978
60
13.198
13.418
13.638
13.858
14.078
14.298
14.518
14.738
14.958
15.178
70
15.398
15.618
15.838
16.058
16.278
16.498
16.718
16.938
17.158
17.378
80
17.598
17.818
18.037
18.257
18.477
18.697
18.917
19.137
19.357
19.577
90
19.797
20.017
20.237
20.457
20.677
20.897
21.117
21.337
21.557
21.777
00-14
FOREWORD
CONVERSION TABLES
kgm to ft. lb 1 kgm = 7.233 ft. lb kgm
0
1
2
3
4
5
6
7
8
9
0
0
7.2
14.5
21.7
28.9
36.2
43.4
50.6
57.9
65.1
10
72.3
79.6
86.8
94.0
101.3
108.5
115.7
123.0
130.2
137.4
20
144.7
151.9
159.1
166.4
173.6
180.8
188.1
195.3
202.5
209.8
30
217.0
224.2
231.5
238.7
245.9
253.2
260.4
267.6
274.9
282.1
40
289.3
296.6
303.8
311.0
318.3
325.5
332.7
340.0
347.2
354.4
50
361.7
368.9
376.1
383.4
390.6
397.8
405.1
412.3
419.5
426.8
60
434.0
441.2
448.5
455.7
462.9
470.2
477.4
484.6
491.8
499.1
70
506.3
513.5
520.8
528.0
535.2
542.5
549.7
556.9
564.2
571.4
80
578.6
585.9
593.1
600.3
607.6
614.8
622.0
629.3
636.5
643.7
90
651.0
658.2
665.4
672.7
679.9
687.1
694.4
701.6
708.8
716.1
100
723.3
730.5
737.8
745.0
752.2
759.5
766.7
773.9
781.2
788.4
110
795.6
802.9
810.1
817.3
824.6
831.8
839.0
846.3
853.5
860.7
120
868.0
875.2
882.4
889.7
896.9
904.1
911.4
918.6
925.8
933.1
130
940.3
947.5
954.8
962.0
969.2
976.5
983.7
990.9
998.2
1005.4
140
1012.6
1019.9
1027.1
1034.3
1041.5
1048.8
1056.0
1063.2
1070.5
1077.7
150
1084.9
1092.2
1099.4
1106.6
1113.9
1121.1
1128.3
1135.6
1142.8
1150.0
160
1157.3
1164.5
1171.7
1179.0
1186.2
1193.4
1200.7
1207.9
1215.1
1222.4
170
1129.6
1236.8
1244.1
1251.3
1258.5
1265.8
1273.0
1280.1
1287.5
1294.7
180
1301.9
1309.2
1316.4
1323.6
1330.9
1338.1
1345.3
1352.6
1359.8
1367.0
190
1374.3
1381.5
1388.7
1396.0
1403.2
1410.4
1417.7
1424.9
1432.1
1439.4
00-15
FOREWORD
CONVERSION TABLES
kg/cm² to lb/in² 1kg/cm² = 14.2233 lb/in² kg/cm²
0
1
2
3
4
5
6
7
8
9
0
0
14.2
28.4
42.7
56.9
71.1
85.3
99.6
113.8
128.0
10
142.2
156.5
170.7
184.9
199.1
213.4
227.6
241.8
256.0
270.2
20
284.5
298.7
312.9
327.1
341.4
355.6
369.8
384.0
398.3
412.5
30
426.7
440.9
455.1
469.4
483.6
497.8
512.0
526.3
540.5
554.7
40
568.9
583.2
597.4
611.6
625.8
640.1
654.3
668.5
682.7
696.9
50
711.2
725.4
739.6
753.8
768.1
782.3
796.5
810.7
825.0
839.2
60
853.4
867.6
881.8
896.1
910.3
924.5
938.7
953.0
967.2
981.4
70
995.6
1010
1024
1038
1053
1067
1081
1095
1109
1124
80
1138
1152
1166
1181
1195
1209
1223
1237
1252
1266
90
1280
1294
1309
1323
1337
1351
1365
1380
1394
1408
100
1422
1437
1451
1465
1479
1493
1508
1522
1536
1550
110
1565
1579
1593
1607
1621
1636
1650
1664
1678
1693
120
1707
1721
1735
1749
1764
1778
1792
1806
1821
1835
130
1849
1863
1877
1892
1906
1920
1934
1949
1963
1977
140
1991
2005
2020
2034
2048
2062
2077
2091
2105
2119
150
2134
2148
2162
2176
2190
2205
2219
2233
2247
2262
160
2276
2290
2304
2318
2333
2347
2361
2375
2389
2404
170
2418
2432
2446
2460
2475
2489
2503
2518
2532
2546
180
2560
2574
2589
2603
2617
2631
2646
2660
2674
2688
190
2702
2717
2731
2745
2759
2773
2788
2802
2816
2830
200
2845
2859
2873
2887
2901
2916
2930
2944
2958
2973
210
2987
3001
3015
3030
3044
3058
3072
3086
3101
3115
220
3129
3143
3158
3172
3186
3200
3214
3229
3243
3257
230
3271
3286
3300
3314
3328
3343
3357
3371
3385
3399
240
3414
3428
3442
3456
3470
3485
3499
3513
3527
3542
00-16
FOREWORD
CONVERSION TABLES
Temperature Fahrenheit Centigrade Conversion; a simple way to convert a Fahrenheit temperature reading into a Centigrade temperature reading or vise versa is to enter the accompanying table in the center or boldface column of figures. These figures refer to the temperature in either Fahrenheit or Centigrade degrees. If it is desired to convert from Fahrenheit to Centigrade degrees, consider the center column as a table of Fahrenheit temperatures and read the corresponding Centigrade temperature in the column at the left. If it is desired to convert from Centigrade to Fahrenheit degrees, consider the center column as a table of Centigrade values, and read the corresponding Fahrenheit temperature on the right.
1
-40.4 -37.2 -34.4 -31.7 -28.9
-40 -35 -30 -25 -20
-40.0 -31.0 -22.0 -13.0 -4.0
-11.7 -11.1 -10.6 -10.0 -9.4
11 12 13 14 15
51.8 53.6 55.4 57.2 59.0
7.8 8.3 8.9 9.4 10.0
46 47 48 49 50
114.8 116.6 118.4 120.2 122.0
27.2 27.8 28.3 28.9 29.4
81 82 83 84 85
117.8 179.6 181.4 183.2 185.0
-28.3 -27.8 -27.2 -26.7 26.1
-19 -18 -17 -16 -15
-2.2 -0.4 1.4 3.2 5.0
-8.9 -8.3 -7.8 -7.2 -6.7
16 17 18 19 20
60.8 62.6 64.4 66.2 68.0
10.6 11.1 11.7 12.2 12.8
51 52 53 54 55
123.8 125.6 127.4 129.2 131.0
30.0 30.6 31.1 31.7 32.2
86 87 88 89 90
186.8 188.6 190.4 192.2 194.0
-25.6 -25.0 -24.4 -23.9 -23.3
-14 -13 -12 -11 -10
6.8 8.6 10.4 12.2 14.0
-6.1 -5.6 -5.0 -4.4 -3.9
21 22 23 24 25
69.8 71.6 73.4 75.2 77.0
13.3 13.9 14.4 15.0 15.6
56 57 58 59 60
132.8 134.6 136.4 138.2 140.0
32.8 33.3 33.9 34.4 35.0
91 92 93 94 95
195.8 197.6 199.4 201.2 203.0
-22.8 -22.2 -21.7 -21.1 -20.6
-9 -8 -7 -6 -5
15.8 17.6 19.4 21.2 23.0
-3.3 -2.8 -2.2 -1.7 -1.1
26 27 28 29 30
78.8 80.6 82.4 84.2 86.0
16.1 16.7 17.2 17.8 18.3
61 62 63 64 65
141.8 143.6 145.4 147.2 149.0
35.6 36.1 36.7 37.2 37.8
96 97 98 99 100
204.8 206.6 208.4 210.2 212.0
-20.0 -19.4 -18.9 -18.3 -17.8
-4 -3 -2 -1 0
24.8 26.6 28.4 30.2 32.0
-0.6 0 0.6 1.1 1.7
31 32 33 34 35
87.8 89.6 91.4 93.2 95.0
18.9 19.4 20.0 20.6 21.1
66 67 68 69 70
150.8 152.6 154.4 156.2 158.0
40.6 43.3 46.1 48.9 51.7
105 110 115 120 125
221.0 230.0 239.0 248.0 257.0
-17.2 -16.7 -16.1 -15.6 -15.0
1 2 3 4 5
33.8 35.6 37.4 39.2 41.0
2.2 2.8 3.3 3.9 4.4
36 37 38 39 40
96.8 98.6 100.4 102.2 104.0
21.7 22.2 22.8 23.3 23.9
71 72 73 74 75
159.8 161.6 163.4 165.2 167.0
54.4 57.2 60.0 62.7 65.6
130 135 140 145 150
266.0 275.0 284.0 293.0 302.0
-14.4 -13.9 -13.3 -12.8 -12.2
6 7 8 9 10
42.8 44.6 46.4 48.2 50.0
5.0 5.6 6.1 6.7 7.2
41 42 43 44 45
105.8 107.6 109.4 111.2 113.0
24.4 25.0 25.6 26.1 26.7
76 77 78 79 80
168.8 170.6 172.4 174.2 176.0
68.3 71.1 73.9 76.7 79.4
155 160 165 170 175
311.0 320.0 329.0 338.0 347.0
00-17
FOREWORD
00-18
MEMORANDA
01
GENERAL
DIMENSIONS
. . . . . . 01-2
.............................
SPECIFICATIONS
.........................
WEIGHT TABLE ........................... FUEL, COOLANT
AND LUBRICANTS
..............
ENGINE OIL SPECIFICATIONS TRANSMISSION,
HYDRAULIC,
.................
DIESEL FUEL SPECIFICATIONS COOLANT
SPECIFICATIONS
AND BRAKE OIL ................
AXLE OIL SPECIFICATIONS GREASE SPECIFICATIONS
.........
............. ................
.....
01-4
.....
01-7
.....
01-8
. . . . . . 01-9 . . . . 01-10 . . . . . 01-10 . . . . . 01-10 . . . . 01-10 . . . . . 01-10
01-I
GENERAL
DIMENSIONS
With General Purpose Bucket 4.3 m3 (5.6 yd3)
A
With Excavating Bucket 4.0 m3 (5.2 yd3)
With Spade Nose Rock Bucket 4.0 m3 (5.2 yd3)
26.5 x 25 Tires
29.5 x 25 Tires
26.5 x 25 Tires
29.5 x 25 Tires
26.5 x 25 Tires
29.5 x 25
Tread
2.4 m (7 ft 10 in)
2.4 m (7 ft 10 in)
2.4 m (7ft 10 in)
2.4 m (7 ft 10 in)
2.4 m (7ft 10 in)
2.4 m (7 ft IO in)
Width over tires
3.1 m (10 ft 2 in)
3.2 m (lOft6in)
3.1 m (IO ft 2 in)
3.2 m (lOft6in)
3.1 m (lOft2in)
3.2 m (lOft6in)
Wheelbase
3.5 m (11 ft8 in)
3.5 m (11 ft 8 in)
3.5 m (11 ft 8 in)
(113.5 ft 8m in)
I
iiiixz
B
Hinge pin height - maximum
4.3 m (14 ft 5 in)
4.4 m (14 ft 7 in)
4.3 m (14 ft 5 in)
4.4 m (14 ft 7 in)
4.3 m (14 ft 5 in)
4.4 m (14 ft 7 in)
C
Hinge pin height - carry position
0.54 m (1 ft 9 in)
0.59 m (1 ft 11 in)
0.54 m (1 ft 9 in)
0.59 m (1 ft 11 in)
0.54 m (1 ft 9 in)
0.59 m (1 ft 11 in)
D
Ground clearance
0.44 m (1 ft 5 in)
0.49 m (1 ft 7 in)
0.44 m (1 ft 5 in)
0.49 m (1 R 7 in)
0.44 m (1 ft 5 in)
0.49 m (1 ft 7 in)
E
Hitch height
1.13 m (3 ft 9 in)
1.18 m (3ft 11 in)
1.13m (3 ft 9 in)
1.18 m (3 ft 11 in)
1.13 m (3 ft 9 in)
1.18 m (3ft 11 in)
01-2
DIMENSIONS
GENERAL With General Purpose Bucket 4.3 m3 (5.6 yd3)
F
Overall height to top of exhaust
With Excavating Bucket 4.0 m3 (5.2 yd3)
With Spade Nose Rock Bucket 4.0 m3 (5.2 yd3)
26.5 x 25 Tires
29.5 x 25 Tires
26.5 x 25 Tires
29.5 x 25 Tires
26.5 x 25 Tires
29.5 x 25 Tires
3.63 m (11 ft 11 in)
3.68 m (12 ft 1 in)
3.63 m (11 ftll in)
3.68 m (12 ft 1 in)
3.63 m (11 ft 11 in)
3.68 m (12 ft 1 in)
3.94 m (12ft 11 in)
3.89 m (12 ft 9 in)
3.94 m (12ft 11 in)
3.89 m (12 ft 9 in)
3.94 m (12 ft 11 in)
3.27 m (loftgin)
3.32 m (lot? 11 in)
3.11 m (lOft2in)
pipe G
Overall height to top of ROPS canopy
3.89 m (12 ft 9 in)
H
Dumping clearance at maximum height & 45” dump angle
3.21 m (lOft7in)
J
3.27 m (lOftgin)
3.16 m (10 ft 4 in)
Reach @ 2.13 m (7 ft) cutting edge clearance 8 45” dump angle
2.03 m (6 ft 8 in)
1.98m (6 ft 6 in)
1.99 m (6 ft 7 in)
1.94m (6 ft 5 in)
2.08 m (6 ft 10 in)
2.03 m (6 ft 8 in)
Reach @ maximum height & 45”dump angle
1.37 m (4 ft 6 in)
1.32 m (4 ft 4 in)
1.32 m (4 ft 4 in)
1.27 m (4 ft 2 in)
1.46 m (4 ft 10 in)
1.41 m (4 ft 8 in)
Reach with lift arm horizontal & bucket level
2.81 m (9 ft 3 in)
2.76 m (9 ft 1 in)
2.73 m (8 ft 11 in)
2.68 m (8 ft 10 in)
2.95 m (9 ft 8 in)
2.90 m (9 ft 6 in)
6.07 m (19ft 11 in)
6.13 m (20 ft 2 in)
6.18 m (20 ft 4 in)
6.21 m (20 ft 5 in)
6.26 m (20 ft 7 in)
K
Operating height - fully raised
6.02 m (19ft9in)
L
Overall length
8.97 m (29 ft 5 in)
8.93 m (29 ft 4 in)
8.89 m (29 ft 2 in)
8.85 m (29 rT 1 in)
9.12 m (29 ft 11 in)
9.08 m (29 ft 10 in)
Loader clearance circle at outside corner of bucket & bucket in carry position
14.39 m (47 ft 3 in)
14.39 m (47 ft 3 in)
14.35 m (47 ft 1 in)
14.35 m (47 ft 1 in)
14.35 m (47 ft 1 in)
14.35 m (47 ft 1 in)
Digging depth at 0”
0.175 m (6.9 in)
0.125 m (4.9 in)
0.115 m (4.5 in)
0.065 m (2.6 in)
0.125 m (4.9 in)
0.075 m (3.0 in)
Digging depth at IO”
0.460 m (1 ft 6 in)
0.410 m (1 ft 4 in)
0.330 m (1 ft 1 in)
0.290 m (11.4 in)
0.385 m (1 ft 3 in)
0.330 m (1 ft 1 in)
NOTICE:
All specifications
are subject to change without notice.
01-3
GENERAL
SPECIFICATIONS
SPECIFICATIONS Machine model
WA500-3L
Serial number
E
.o,
3
f
Operating weight Distribution (front) Distribution (rear)
A70001 and up 28,430 kg (63,711 lb) 13,120 kg 15,310 kg
Bucket capacity (piled) Rated load
4.3 m3 (5.6 yd3) 75.9 kN (7,740 kg)
Travel speed: FORWARD FORWARD FORWARD FORWARD REVERSE REVERSE REVERSE REVERSE
1st 2nd 3rd 4th 1st 2nd 3rd 4th
7.1 km/h (4.4 mph) 12.6 km/h (7.8 mph) 21.2 km/h (13.2 mph) 34.8 km/h (21.6 mph) 7.9 km/h (4.9 mph) 14.1 km/h (8.8 mph) 23.5 km/h (14.6 mph) 38.1 km/h (23.7 mph)
Grade-ability
25 deg
Turning radius (bucket at carry - outside corner of bucket)
7390 mm (24 ft 3 in)
Overall length
9320 mm (30 ft 6 in)
Overall width (Chassis)
3,190mm(10ft5in)
Bucket width (with bolt on cutting edge)
3460 mm (11 ft 4 in)
Overall height (top of cab)
3860 mm (12 ft 7 in)
Overall height (bucket raised)
6115 mm (20 ft 1 in)
Wheelbase
3600mm(11ft10in)
Tread
2400 mm (7 ft 10 in)
Minimum ground clearance
450 mm (1 ft 5 in)
Height of bucket hinge pin
4500 mm (14 ft 8 in)
Dumping clearance Dumping
reach
(tip of cutting
(tip of cutting
edge)
3335 mm (10 ft 9 in) 1255mm4ftl
Bucket dump angle
45 deg
Bucket tilt angle (SAE carrying position)
48 deg
Digging depth (10” dump angle)
01-4
edge)
in)
425 mm (1.4 in)
GENERAL
SPECIFICATIONS Machine
model
WA500-3L
Serial number
A70001 and up
Model
Cummins NTA14C diesel engine 4-cycle, water cooled, direct injection, turbocharged
Type No. of cylinders - bore x stroke
6 - 140 mm (5.5”) x 152 mm (5.9”)
Piston displacement
14 Q(855 ins) (14,000 cc)
Gross power @ 2100 rpm Maximum
torque (gross) @ 1500 rpm High idle Low idle
Fuel consumption
ratio
Torque converter
908 N*m (670 Ibf ft)
220 g/kW lh (164 g/HP*h) 24V, 25 kW 24V, 70A 12V, 170Ahx2 3-element, single-stage, single-phase (TCA40-1 C)
Transmission
Planetary gear, constant-mesh multiple-disc, hydraulic actuated, modulation type
Reduction gear
Spiral bevel gear, splash lubrication
Differential
Straight bevel gear
Final drive
planetary gear, single stage, splash lubrication Drive type
Front I rear wheel drive
Front axle
Fixed frame full-floating type
Rear axle
Center pin support full-floating type
Tire
m
(315 HP)
2300 rpm 760 rpm
Starting motor Alternator Battery
9E
235kW
29.525-22pr
tubeless (L3)
Wheel rim
25.00 x 25 WTB
Inflation pressure Front tire
4.5 kg/cm2 (64.0 psi) (440 kPa)
Inflation pressure Rear tire
3.5 kg/cm* (49.8 psi) (340 kPa)
Service brakes
Front I rear wheel braking, separate front/rear wheel, wet disc, hydraulically actuated
Parking brake
Drive shaft, wet type disc brake Hydraulically released spring type
01-5
GENERAL
SPECIFICATIONS
Machine model
WA500-3L
Serial number
A70001 and
Type
Articulated
Structure
pump
135 P (Gear type: SAR(3) - 63)
Steering pump
172e (Gear type: SAR(3) - 80)
PPC pump
6OP (Gear type: SAR(1)
Set pressure for steering
Boom cylinder Bucket cylinder Steering cylinder stroke
Bucket edge type
01-6
348 P (Gear type: SAR(4) - 160)
Switch pump
Set pressure for work equipment
Linkage type
steering
Fully hydraulic power steering
Work equipment Hydraulic Pump Delivery
UD
qty. - bore x stroke qty. - bore x stroke qty. - bore x
Spool type
20.58 Mpa
Orbit-roll valve type
- 28)
(210 kg/cm*)
20.58 Mpa
210 kg/cm2)
Reciprocating
piston 2-200 x 839 (mm)
Reciprocating
piston l-225 x 613 (mm)
Reciprocating
piston 2 - 110 x 486 (mm)
Single link (Z-bar linkage) Flat edge with bolt on cutting edge
GENERAL
WEIGHT TABLE
WEIGHT TABLE This weight table is a guide for use when transporting
Machine
model
Serial No.
I I
Engine
WA500-3LE
723 lb (328 kg)
Transmission converter
with torque
Machine
A70001 and UQ 3,038 lb (1,378 kg)
Radiator
or handling components.
2,524 lb (1,145 kg)
Upper drive shaft
I
40 lb (18 kg)
Center drive shaft
I
73 lb (33 kg)
Front drive shaft
99 lb (45 kg)
Rear drive shaft
86 lb (41 kg)
Center support
93 lb (42 kg)
Front axle assembly
4,277 lb (1,940 kg)
Rear axle assembly
I 4,138 lb (1,877kg)
Axle pivot (Rear axle)
114 lb (251 kg)
Tire and wheel (each)
1,740 lb (789 kg) 591 lb (268 kg)
Tire (each)
1,149 lb (521 kg)
I
Serial No.
Hydraulic
WA500-3L A70001 and up
I 1
Hydraulic tank pump
507 lb (230 kg) 45 lb (20.3 kg)
Switch and PPC pump
42 lb (19 kg)
Steering pump
1
27 lb (12.2 kg)
PPC valve
I
8 lb (3.5 kg)
Main control valve
I
199 lb (90 kg)
Steering cylinder (each)
I
104 lb (47 kg)
Boom cylinder (each)
1
600 lb (272 kg)
Rear frame
1 4.817 lb (2,185 kg)
Bucket link
1
234 lb (106 kg)
Bellcran k
I
1,151 lb (522 kg)
Boom including
Wheel (each)
model
bushings
4,449 lb (2,018 kg) I
Bucket with bolt on cutting edge
I
Counterweight
1 4,954 lb (2,247 kg)
5,997 lb (2,720 kg)
Front differential
assembly
I
591 lb (268 kg)
Fuel tank
1
670 Ib(213 kg)
Rear differential
assembly
I
612 lb (278 kg)
Battery (each)
I
117 lb (53 kg)
I
137 lb (62 kg)
Floor, dash, console
1
472 lb (214 kg)
227 lb (103 kg)
Cab (ROPS)
I
661 lb (300 kg)
52 lb (23.5 kg)
Air conditioner
I
117 lb (53 kg)
Planetary carrier (each) Planetary
hub (each) I
Brake valve (Tandem)
I I I
Brake valve (Single)
I
Steering valve Orbit-roll valve
12 lb (5.3 kg)
Operator’s seat
unit
88 lb (40 kg)
19 lb (8.5 kg) 12 lb (5.3 kg)
01-7
GENERAL
FUEL, COOLANT AND LUBRICANTS
COOLANT, AND LUBRICANTS RESERVOIR
FLUID -22 -30
TYPE
Engine with filter
-4 -20
AMBIENT TEMPERATURE 86 32 50 68 14 30 0 10 20 -10 SAE 15W-40
I
Engine oil See NOTE 1
SAE low-30
I
Hydraulic system
I Engine oil See NOTE 2
Refill
42 e 11.1 gal
36 P 9.5 gal
70 P 18.5 gal
62 e 16.4 ga
284P 75.0 gal
1751 46.2 ga
78 P 20.6 gal each
78 e 20.6 ga each
I
I
I SAE tOW
I SAE 5W-20
Specified
1
SAE 30W
SAE 1ow
122°F 59°C
I
Synthetic SAE 5W-30
Torque converter, Transmission, Transfer case & Oil cooler
CAPACITY 104 40
1 1
Drive axles Front & rear
Axle oil
411lubrication %tings
Grease
See NOTE 4
Fill as instructed
--
=uel tank
Diesel fuel
See NOTE 5
465 e 122.8 gal
--
Cooling system
Coolant
See NOTE 6
83~ 21.9 gal
--
API: ASTM: SAE:
See NOTE 3
American Petroleum Institute American Society of Testing and Material Society of Automotive Engineers
Specified capacity: Total amount of oil including oil for components and oil in piping. Refill capacity: Amount of oil needed to refill system during normal inspection and maintenance.
01-8
GENERAL
FUEL, COOLANT AND LUBRICANTS
NOTES: 1. ENGINE OIL Normal Operation Oil performance
recommendations
are as follows:
The use of a high quality engine lubricating oil combined with appropriate oil and filter change intervals are critical factors in maintaining engine performance and durability. SAE 15W-40 multi-viscosity heavy duty engine oil meeting the American classification of CF-4 or CG-4 is recommended.
Petroleum
Institute (API) performance
NOTE: CE oil may be used in areas where CF-4 or CG-4 oil is not yet available. A sulfated ash content of 1.O mass percent is suggested for optimum valve and piston deposit and oil consumption control. The sulfated ash must not exceed 1.85 mass percent. The sulfated ash limit of 1.85 mass percent has been placed on all engine lubricating oils recommended for use in the engine. Higher ash oils can cause valve and/or piston damage and lead to excessive oil consumption. The API service symbol displays the following information. The upper half of the symbol displays the appropriate oil categories; the lower half may contain words to describe oil energy conserving features. The center section identifies the SAE oil viscosity grade. Oil viscosity
recommendations
are as follows:
The use of a multi-graded lubricating oil has been found to improve oil consumption control and improve engine cranking in cold temperatures while maintaining lubrication at high operating temperatures. While SAE 15W-40 multi-viscosity oil is recommended oil viscosity recommendations for extreme climates.
for most operating climates, refer to the previous table for
Limited use of low viscosity oils, such as SAE 1OW-30 may be used for easier starting and providing sufficient oil flow at ambient temperatures below -5°C (+23”F). However, continuous use of low viscosity oils can decrease engine life due to wear. Special “break-in” lubricating oils are not recommended during the “break-in” as specified for normal operation.
for a new or rebuilt engine. Use the same type of oil
Additional information regarding lubricating oil availability throughout the world is available in the “E.M.A. Lubricating Oils Data Book for Heavy Duty Automotive and Industrial Engines.” The data book may be ordered from the Engine Manufacturers Association, One Illinois Center, 111 East Wacker Drive, Chicago, IL U.S.A. 60601. The telephone number is (312) 644-6610. Arctic Operation If an engine is operated in ambient temperatures consistently below -23°C (-10°F) and there are no provisions to keep the engine warm when it is not in operation, use a synthetic API performance classification CE/SF engine oil with adequate low temperature properties such as SAE 5W-20 or 5W-30. The oil supplier must be responsible
for meeting the performance
service specifications.
IMPORTANT: The use of a synthetic base oil does not justify extended oil change intervals. intervals can decrease engine life due to factors such as; corrosion, deposits and wear.
Extended
oil change
01-9
GENERAL
FUEL, COOLANT AND LUBRICANTS
2. TRANSMISSION,
HYDRAULIC
Use API performance
classification
SYSTEM AND BRAKE SYSTEM
OIL
CE engine oil.
When using SAE 5W-20 engine oil in the work equipment the cold season ends.
hydraulic system in cold areas, return to SAE 1OW when
3. AXLE OIL For axle oil, use only the recommended SHELL: CALTEX: CHEVRON: TEXACO: MOBIL: j,
oil as follows:
DONAX lT or TD RPM TRACTOR HYDRAULIC FLUID TRACTOR HYDRAULIC FLUID TDH OIL MOBIL AND SUPER UNIVERSAL
It is possible to substitute engine oil SAE 30W API classification may result, durability should not be affected.
CD for axle oil. Although
increased
brake noise
4. GREASE The recommended
lubricating grease is No. 2 multi-purpose
lithium grease with 3% molybdenum
disulfide.
5. DIESEL FUEL
A
WARNING!
Do not mix gasoline or alcohol with diesel fuel. This mixture can cause an explosion.
IMPORTANT: Due to the precise tolerances of diesel injection systems, it is extremely important that the fuel be kept clean and free of dirt or water. Dirt or water in the system can cause severe damage to both the injection pump and nozzles. For normal service above -12°C (+lO”F), the use of ASTM Grade No. 2-D diesel fuel with a minimum Cetane number of 40 is recommended. The use of No. 2-D diesel fuel will result in optimum engine performance under most operating conditions. Fuels with Cetane numbers higher than 40 may be needed in high altitudes or extremely low ambient temperatures to prevent misfires and excessive smoke. At operating temperatures reduce fuel economy.
below -12°C (+lO”F), use ASTM Grade No. I-D diesel fuel. The use of lighter fuels can
Where a winterized blend of Grade No. 2-D and No. I-D fuels is available, it may be substituted for Grade No. I-D fuel. However, it is the supplier’s responsibility to provide the fuel for the anticipated ambient temperature. Use a low sulfur content fuel having a cloud point that is at least 10 degrees below the lowest expected temperature. Cloud point is the temperature at which crystals begin to form in the fuel. The viscosity
fuel
of the fuel must be kept above 1.3 cSt at 100°C (212°F) to provide adequate fuel system lubrication.
6. COOLANT General Selection and maintenance of the engine coolant is important to long engine life. The following information provides recommendations for selecting the engine coolant and maintaining the supplemental coolant additive (SCA).
01-10
GENERAL
FUEL, COOLANT AND LUBRICANTS
Heavy duty diesel engines require a balanced coolant mixture of water, antifreeze, and supplemental coolant additive. Supplemental coolant additive recommendations are included in the section entitled “Supplemental Coolant Additive”. The coolant mixture must be drained and replaced at the specified service interval shown in the “SCHEDULED MAINTENANCE GUIDE” or every two years of operation, whichever comes first. Water Use water which has a low mineral content. Water used in conjunction water must meet the following standards:
with antifreeze,
coolant filters and inhibited
Total Hardness - Not to exceed 170 parts per million (10 grains/gallon maximum) to prevent scale deposits. Water containing dissolved magnesium and calcium (the usual reason for water hardness) above the specified amount will cause scale deposits to develop in the engine. Chlorides
- Not to exceed 40 parts per million (2.5 grains/gallon
Sulfites - Not to exceed 100 parts per million (5.8 grains/gallon
maximum) maximum)
Dissolved Solids - Not to exceed 340 parts per million (20 grains/gallon scale deposits, corrosion or a combination of these.
to prevent corrosion. to prevent corrosion
maximum) to minimize sludge deposits,
If any of the above requirements cannot be met, use distilled, de-ionized, or de-mineralized water. To determine if local water supplies meet these standards, water samples can be tested by water treatment laboratories. “Softened” water that is prepared using common salt (sodium chloride) contains excessive amounts of chlorides and should not be used. NOTE: Never use water alone in the cooling system because corrosion
will occur
Antifreeze In climates where the temperature is above -37°C (-34°F) use a coolant mixture that contains 50 percent antifreeze. Antifreeze is essential in any climate. It broadens the operating temperature range by lowering the coolant freezing point and by raising its boiling point. Do not use more than 50 percent antifreeze in the mixture unless additional freeze protection is required. Never use more than 68 percent antifreeze under any condition. An antifreeze concentration greater than 68% will adversely affect freeze protection and heat transfer rates. Antifreeze concentrations between 68% and 100% actually have a higher freezing point than a 68% antifreeze concentration and should not be used due to reduced heat transfer rates. Low silicate ethylene glycol antifreeze is recommended. The antifreeze should contain no more than 0.1% anhydrous alkali metasilicate. Low silicate antifreeze is recommended to avoid the formation of silica-gel (hydro-gel). This gel formation can occur when the cooling system contains an over concentration of high silicate antifreeze and/or supplemental coolant additive. DO NOT use methanol or alcohol as an antifreeze because of its low boiling point. Antifreeze may retain its freeze protection maintain corrosion protection. Antifreeze
formulated
with methoxy
for more than one season
but coolant conditioners
propanol, or propylene glycol, is not recommended
must be added to
for this system.
NOTE: Do not mix types of antifreeze solutions. Mixed solutions make it impossible to determine the protection against freezing, Antifreeze containing sealer or anti-leak additives should NOT be used in this system. Sealer or anti-leak additives will cause plugging problems in the cooling system. , Check the solution periodically protection against freezing.
and at normal operating
temperature,
to be sure the cooling system has sufficient
01-I 1
GENERAL
FUEL, COOLANT AND LUBRICANTS
The following table shows the approximate
percentage
solution required for various temperatures.
Percentage of Antifreeze Concentration by Volume
Approximate Freezing Point
+32”F +2O”F +lO”F 0°F -10°F -20°F -30°F -40°F -50°F -60°F -70°F -80°F -90°F -92°F
of antifreeze
1 .ooo 1.025 1.040 1.053 1.062 1.070 1.074 1.080 1.083 1.088 1.092 1.095 1.097 1.098
0 15 25 33 40 45 48 53 56 59 62 65 67 68
(O°C) (-7°C) (-12°C) (-18°C) (-23°C) (-29°C) (-34°C) (-40°C) (-46°C) (-51 “C) (-57°C) (-62°C) (-68°C) (-96°C)
In tropical climates where antifreeze availability cooling system.
Specific Gravity at 60°F (16°C)
may be limited, use a corrosion
inhibitor SCA, to protect the engine
Supplemental Coolant Additives 1. All supplemental cooling system additives, including those in antifreeze solutions, become depleted through normal operation. If the coolant additive in antifreeze are allowed to become depleted, the antifreeze becomes corrosive and attacks and coats the metallic surfaces of the cooling system which reduces heat transfer. Cooling system conditioners which contain these additives must be added to maintain corrosion protection. 2. SOLUBLE OIL IS NOT RECOMMENDED internal engine damage.
for use in this engine as its use will reduce heat transfer and allow
3. There are no miracle additives that will increase heat transfer or prevent overheating. the best coolant. 4. SCA is recommended l
l
to inhibit corrosion
in the cooling system for the following
OF SUPPLEMENTAL
Keeping the engine coolant corrosion.
properly
COOLANT inhibited
water is still
reasons:
Improved compatibility with high silicate antifreezes to minimize hydro-gel formation occurs. Provides engine protection in the following areas: - Solder corrosion/bloom - Copper corrosion/erosion/stress cracking - Oil fouling - Cylinder liner cavitation corrosion -Aluminum cavitation corrosion - Seal and gasket degradation
MAINTENANCE
if over concentration
ADDITIVES
will keep the engine and radiator free of rust, scale deposits
New machines are delivered with antifreeze protection. Service at regular scheduled “SCHEDULED MAINTENANCE GUIDE” with a service DCA4 filter.
01-12
Conditioned
interval
specified
and
in the
GENERAL
FUEL, COOLANT AND LUBRICANTS
Each time the coolant is drained and replaced, the coolant must be recharged with SCA. New coolant can be correctly charged with supplemental coolant additives by using a DCA4 service filter or SCA concentrate listed in the table entitled. “DCA4 Unit Guide”. If coolant is added between drain intervals, additional SCA will be required. COOLANT
TESTING
FOR CONDITIONER
When the cooling system is maintained SCA concentration must not fall below The only accurate method for testing laboratory analysis. For this reason, MAINTENANCE GUIDE”.
CONCENTRATION
as recommended, the conditioner concentration should be satisfactory. The 1 .O unit per 3.8 P (1 US gal) or exceed 2 units per 3.8 e (1 US gal) of coolant. chemical concentrations in coolant with mixed chemical compounds is a the coolant inhibitor should be maintained as shown in the “SCHEDULED
NOTE: Inadequate concentration of the supplemental coolant additive can result in major corrosive damage to cooling system components. Over concentration can cause formation of “gel” that can cause restriction, plugging of passages and overheating. REPLENISHING
COOLANT
CONDITIONER
Install a “precharge” DCA4 filter when the coolant is changed or a significant (more than 50%) coolant loss occurs. Install a service DCA4 filter as specified in the “SCHEDULED MAINTENANCE GUIDE”. When antifreeze is added, add coolant conditioner equal to 1 .O unit per 3.8 e (1 US gal) of antifreeze. NOTE: Mixing of DCA4 and other supplemental coolant additives is not recommended because there is currently no test kit available to measure concentration levels with mixed chemical solutions. SCA UNIT MAINTENANCE
GUIDE
Use supplemental coolant additives (corrosion inhibitors) to protect the engine cooling system from corrosion. Antifreeze alone does not provide enough corrosion protection for a heavy duty diesel engine. Supplemental corrosion protection must be supplied through periodic additions of supplemental coolant additives to the coolant. To protect against corrosion, a new coolant charge must be brought up to 0.26 SCA unit per liter [one unit per U.S. gallon] of coolant (initial charge). Maintain the correct SCA concentration by changing the service coolant filter at each engine oil and filter change interval. Each time the coolant is drained and replace, the coolant must be recharged with supplemental coolant additives. Use the appropriate DCA4 spin-on filter listed in following table. The coolant mixture must be drained and replaced as defined under “General”. The amount of replacement inhibitor is determined by the length of the service interval and the cooling system capacity. Refer to the DCA4 Unit Guide for the selection of the correct filter to replenish the SCA. If coolant is added between drain intervals, additional SCA will be required. Check the coolant DCA concentration level anytime make-up coolant is added to the system. The SCA concentration must not fall below 0.13 units per liter or exceed 0.5 units per liter [0.5 units per U.S. gallon or exceed 2 units per U.S. gallon].
01-13
GENERAL
FUEL, COOLANT AND LUBRICANTS DCA4 Unit Guide Fleetguard Part No.
DCA4 Units
DCA4 Coolant Filter WF-2070 WF-2071 WF-2072 WF-2073 WF-2074 WF-2075 WF-2076 WF-2077
2 4 6 8 12 15 23 0
DCA4 Liquid DCAGOL DCA80L
4 (1 Pint) 1760 (55 US gal)
DCA4 Powder DCA95
20
DCA4 Precharge System Capacity
and Service Filters
Precharge Filter (See NOTE 1)
Service Filter (See NOTE 3)
WF-2072 WF-2073 WF-2074 WF-2075 WF-2076 (See NOTE 2)
WF-2070 WF-2071 WF-2071 WF-2071 WF-2072 WF-2073
Gallons 5-7 8-l 0 11-15 16-20 21-30 31-50 NOTE l-
After draining and replacing coolant, always precharge the cooling concentration between 1 .O and 2.0 units per 3.8 P (1 US gal). NOTE:
NOTE 2 l
l
NOTE 3 -
01-14
to maintain
the SCA
When performing service which requires draining the cooling system, discard the coolant. Reusing coolant can introduce contaminates or over concentrated chemicals, resulting in premature failure of cooling system components.
To precharge cooling systems larger than 114 r?(30 gal) do the following: Install appropriate
service filter listed in the above table based on cooling system capacity.
Example:
l
system
95 gal (360 Q)cooling system capacity -15 Units (1) WF-2075 Filter 80 Units
The answer represents the additional units required to precharge the cooling system. Four bottles of powder, part number DCA95, will provide a sufficient amount of SCA units (80) to precharge the example cooling system. Install the appropriate service filter at the next and subsequent maintenance intervals. Change the coolant filter at every engine oil and filter change interval to protect the cooling system.
GENERAL
FUEL, COOLANT AND LUBRICANTS
Maintain a nominal SCA concentration of 1 .O unit per 3.8 Q(1 US gal) of coolant in the system. Less than 0.5 unit per 3.8 P (1 US gal) indicates an under-concentrated coolant solution. More than 2.0 units per 3.8 e (1 US gal) indicates an over-concentrated coolant solution. To check the SCA concentration
level, use coolant test kit, CC-2606. Instructions SCA Unit Concentration
Number of Solution A Drops to Cause Color Change
are included with the test kit.
Guide
Coolant Condition
Action Required
0- 10 Drops
Extremely under-concentrated less than 0.4 SCA units per 3.8 P (1 US gal)
11 - 16 Drops
Marginally under-concentrated 0.45 to 0.8 SCA units per 3.8 e (1 US gal)
17 - 25 Drops
Acceptable - 0.85 to 1.3 SCA units per 3.8 e (1 US gal)
None.
26 - 35 Drops
Highly acceptable - 1.35 to 2.0 SCA units per 3.8 P (1 US gal)
None.
36 - 55 Drops
Marginally over-concentrated - 2.1 to 3.3 SCA units per 3.8 P (1 US
Review maintenance
Initially charge the system to a minimum of 1 .O SCA unit per 3.8 e (1 US gal). i Add SCA liquid units to maintain ~ 1.0 SCA unit per 3.8 e (1 US gal) minimum or change the DCA 4 coolant filter.
practice.
gal) Over 55 Drops
Extremely
over-concentrated
Drain 50% of the coolant and replace with water antifreeze mixture. Retest the system for correct SCA unit concentration.
01-15
GENERAL
01-16
MEMORANDA
10 STRUCTURE AND FUNCTION General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-2 Radiator and oil cooler . . . . . . . . . . . . . . . . . . . . 10-4 Damper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-5 Torque converter and transmission piping . . . . . 10-7 Hydraulic circuit for power train . . . . . . . . . . . . . . 10-8 Hydraulic circuit diagram for power train . . . . . . 10-9 Torque converter and PTO . . . . . . . . . . . . . . . . 10-10 Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-12 Transmission control valve . . . . . . . . . . . . . . . . 10-22 ECMV (electronic control modulation valve) . . 10-24 Main relief, torque converter relief valve . . . . . . 10-30 Lubricating relief valve . . . . . . . . . . . . . . . . . . . . 10-32 Torque converter oil filter . . . . . . . . . . . . . . . . . 10-33 Pilot filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-34 Transfer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-35 Drive shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-36 Center support . . . . . . . . . . . . . . . . . . . . . . . . . . 10-37 Axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-38 Differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-40 Final drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-44 Axle mount . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-46 Center hinge pin . . . . . . . . . . . . . . . . . . . . . . . . 10-48 Tire and wheel . . . . . . . . . . . . . . . . . . . . . . . . . . 10-49 Steering piping . . . . . . . . . . . . . . . . . . . . . . . . . . 10-50 Steering column . . . . . . . . . . . . . . . . . . . . . . . . 10-51 Steering valve . . . . . . . . . . . . . . . . . . . . . . . . . . 10-52 Orbit-roll valve . . . . . . . . . . . . . . . . . . . . . . . . . . 10-66 Stop valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-70 Diverter valve . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-71 Brake circuit diagram . . . . . . . . . . . . . . . . . . . . 10-75 Brake valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-76 Charge valve . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-82 Accumulator (for brake) . . . . . . . . . . . . . . . . . . 10-86 Slack adjuster . . . . . . . . . . . . . . . . . . . . . . . . . . 10-87 Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-90 Parking brake control . . . . . . . . . . . . . . . . . . . . 10-92 Parking brake . . . . . . . . . . . . . . . . . . . . . . . . . . 10-93 Parking brake solenoid valve . . . . . . . . . . . . . . 10-94 Parking brake emergency release solenoid valve . . . . . . . . . . . . . . . . 10-95 Hydraulic circuit system . . . . . . . . . . . . . . . . . . 10-102 Work equipment lever linkage . . . . . . . . . . . . 10-104 Hydraulic tank . . . . . . . . . . . . . . . . . . . . . . . . . 10-105
Accumulator (for PPC valve) . . . . . . . . . . . . . 10-108 PPC valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-110 PPC relief valve . . . . . . . . . . . . . . . . . . . . . . . . 10-117 Cut-off valve . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-118 Main control valve . . . . . . . . . . . . . . . . . . . . . . 10-122 Work equipment linkage . . . . . . . . . . . . . . . . . 10-138 Bucket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-140 Bucket positioner and boom kick-out . . . . . . . 10-142 Proximity switch . . . . . . . . . . . . . . . . . . . . . . . . 10-144 Cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-150 ROPS canopy . . . . . . . . . . . . . . . . . . . . . . . . . 10-151 Air conditioner . . . . . . . . . . . . . . . . . . . . . . . . . 10-152 Air conditioner piping . . . . . . . . . . . . . . . . 10-152 Basic information on air conditioners . . . . 10-153 Units related to refrigeration . . . . . . . . . . . 10-153 Principle of cooling . . . . . . . . . . . . . . . . 10-155-2 Refrigerants . . . . . . . . . . . . . . . . . . . . . 10-155-7 Safety precautions . . . . . . . . . . . . . . . . 10-155-7 Refrigerator oil (lube oil) . . . . . . . . . . . . 10-155-8 Air conditioning condenser . . . . . . . . . . . . 10-155-10 Function . . . . . . . . . . . . . . . . . . . . . . . 10-155-10 General description . . . . . . . . . . . . . . 10-155-10 Air conditioner compressor . . . . . . . . . . . . 10-155-13 Receiver with sight glass . . . . . . . . . . . . . . 10-155-14 Air conditioner unit . . . . . . . . . . . . . . . . . . . 10-155-16 Outline . . . . . . . . . . . . . . . . . . . . . . . . . 10-155-16 Electric circuit diagrams . . . . . . . . . . . . . . . . . 10-156 Machine monitor system . . . . . . . . . . . . . . . . . 10-166 Main monitor . . . . . . . . . . . . . . . . . . . . . . . . . . 10-167 Maintenance monitor . . . . . . . . . . . . . . . . . . . . 10-171 All-range electronic control automatic transmission system . . . . . . . . . . . . . . . . . 10-174 Transmission controller . . . . . . . . . . . . . . . . . . 10-186 Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-188 Engine starting circuit . . . . . . . . . . . . . . . . . . . 10-194 Engine stop circuit . . . . . . . . . . . . . . . . . . . . . . 10-196 Ether start circuit . . . . . . . . . . . . . . . . . . . . . . . 10-197 Electric transmission control . . . . . . . . . . . . . . 10-198 Combination switch . . . . . . . . . . . . . . . . . . . . . 10-199 Kick-down hold switch . . . . . . . . . . . . . . . . . . . 10-201 Kick-down electric circuit . . . . . . . . . . . . . . . . . 10-202 Electric parking brake control . . . . . . . . . . . . . 10-205
10-1
STRUCTURE AND FUNCTION
GENERAL
GENERAL
OUTLINE The power from the engine (1) is transmitted from the flywheel to damper (2) through the ring gear. The damper alleviates the torsional vibration caused by the variation of the engine torque and transmits the power to torque converter (4) through drive shaft (3). The torque converter converts the delivered torque according to the variation in the load on the oil used as the medium, and transmits the power to the input shaft of transmission (10). The engine power then is transmitted to PPC pump (7), steering pump (9), hydraulic pump (8), switch pump (6), and torque converter charging pump (5) through the pump driving gear in torque converter (4). In transmission (10), the six hydraulic clutches are operated by the forward-reverse spool and the speed change spools in the transmission valves, which are themselves activated by solenoid valves. Thus, the desired travel speed can be selected from among the 4 forward and 4 reverse gear speeds.
10-2
A multiple disc parking brake is installed to the output shaft of transmission (10). At the front end, the power from the output shaft passes through center drive shaft (12) and front drive shaft (14) and is transmitted to front differential (15), at the rear end it is transmitted to rear differential (20) by rear drive shaft (19). The power transmitted to front differential (15) and rear differential (20) is transmitted to the axle shafts. The power from the axle shafts has its speed reduced by final drives (16) and (21), and it is then transmitted to tires (18) and (23) through the planetary carrier.
STRUCTURE AND FUNCTION
1. 2. 3. 4. 5. 6. 7. 8.
Engine Damper Upper drive shaft Torque converter Torque converter charging pump Switch pump PPC pump Hydraulic pump
10-3
GENERAL
9. 10. 11. 12. 13. 14. 15. 16.
Steering pump Transmission Parking brake Center drive shaft Center support Front drive shaft Front differential Front final drive
17. 18. 19. 20. 21. 22. 23.
Front brake Front tire Rear drive shaft Rear differential Rear final drive Rear brake Rear tire
STRUCTURE AND FUNCTION
RADIATOR AND OIL COOLER
RADIATOR AND OIL COOLER
1. 2. 3. 4. 5.
Radiator Coolant level sensor Fan guard Torque converter oil cooler Hydraulic oil cooler
A. B. C. D. E. F.
Coolant inlet port Coolant outlet port Hydraulic oil outlet port Hydraulic oil inlet port Torque converter oil outlet port Torque converter oil inlet port
10-4
Specifications: Radiator Radiator core type: G7 type Total heat dissipation area: 98.44 m2 Cross-sectional area of water flow: 193.8 cm2 Torque converter oil cooler Type: PTO-OL (multiple disc type) Heat dissipation area: 1, 829 m2 Type: SF-2 (Air to Air) Heat dissipation area: 14.04 m2 Hydraulic oil cooler Type: PTO-LS (multiple disc type) Heat dissipation area: 1.147 m2
STRUCTURE AND FUNCTION
DAMPER
DAMPER
FUNCTION 1. 2. 3. 4. 5. 6. 7. 8.
Coupling Output shaft Cover Bearing Bearing Outer body Rubber cushion Inner body
10-5
The damper reduces the twisting and vibration caused by the variations in the engine torque, and acts to protect the engine and other parts from such twisting and vibration.
STRUCTURE AND FUNCTION
OPERATION
The engine power is transmitted to the flywheel and outer body (6) and rubber cushion (7) absorbs the twist and vibration of the engine. The engine power is then transmitted through the inner body (8) to output shaft (2). From here, the engine power is transmitted through the coupling to the torque converter and drive shaft.
10-6
DAMPER
STRUCTURE AND FUNCTION
TORQUE CONVERTER AND TRANSMISSION PIPING
TORQUE CONVERTER AND TRANSMISSION PIPING
1. 2. 3. 4. 5. 6. 7a.
Transmission Transmission valve Torque converter Accumulator Parking brake emergency release valve Radiator Oil cooler (water-cooled type)
7b. 8. 9. 10. 11. 12.
Oil cooler (air-cooled type) Torque converter charging pump Parking brake solenoid valve Oil filter Parking brake Torque converter oil cooler (air to air)
10-7
STRUCTURE AND FUNCTION
HYDRAULIC CIRCUIT FOR POWER TRAIN
HYDRAULIC CIRCUIT FOR POWER TRAIN
10-8
STRUCTURE AND FUNCTION
HYDRAULIC CIRCUIT DIAGRAM FOR POWER TRAIN
HYDRAULIC CIRCUIT DIAGRAM FOR POWER TRAIN
1. Transmission case 2. Strainer 12. 3. Torque converter charging pump 4. Torque converter oil filter 5. Main relief valve 14. 6. Torque converter relief valve 15. 7. Torque converter 8a. Oil cooler (water-cooled type) 8b. Oil cooler (air-cooled type) 9. Transmission lubrication 19. 10. Lubrication relief valve
11. Pilot oil filter Parking brake solenoid valve 13. Parking brake emergency release valve Accumulator Parking brake 16. FORWARD ECMV 17. REVERSE ECMV 18. 3rd ECMV 4th ECMV 20. 2nd ECMV
21. 1st ECMV 22. Flow detector valve 23. Pressure control valve 24. FORWARD clutch 25. REVERSE clutch 26. 3rd clutch 27. 4th clutch 28. 2nd clutch 29. 1st clutch
10-9
STRUCTURE AND FUNCTION
TORQUE CONVERTER AND PTO
10-10
TORQUE CONVERTER AND PTO
STRUCTURE AND FUNCTION
TORQUE CONVERTER AND PTO
Flow of motive force The torque converter is installed between the damper and transmission. The motive force from the damper passes through the drive shaft and enters drive case (7). Drive case (7), pump (10) and PTO gear (drive) (13) are fixed with bolts. They are rotated directly by the rotation of the engine. The motive force of pump (10) uses oil to rotate turbine (8). This transmits motive force to transmission input shaft (12). The motive force of drive case (7) passes through PTO gear (drive) (13) and is also used as the motive force to drive the gear pump.
Flow of oil The oil pressure is adjusted by the torque converter relief valve and then enters inlet port A, passes through the oil passage in housing (9) and flows to pump (10). In pump (10) centrifugal force is applied. The oil enters turbine (8) and the energy of the oil is transmitted to the turbine. Turbine (8) is fixed to transmission input shaft (12), so the motive force is transmitted to the transmission input shaft (12). The oil from turbine (8) is sent to stator (11) and again enters the pump. However, part of the oil passes from the stator through outlet port B and is sent to the cooler.
10-11
STRUCTURE AND FUNCTION
TRANSMISSION
TRANSMISSION
1. 2. 3. 4. 5.
Main relief, torque converter relief valve Transmission valve Transmission input shaft Transmission Transfer
10-12
6. 7. 8. 9. 10.
Parking brake Output coupling (front) Output coupling (rear) Oil filler port Strainer
STRUCTURE AND FUNCTION
A. B. C. D. E. F. G. H.
To torque converter From torque converter case Breather mount port From oil filter Transmission main oil pressure port To parking brake emergency release valve Lubricating oil pressure port From oil cooler
TRANSMISSION
I. Mounting port for parking brake actuation pilot lamp J. To torque converter charging pump K. To REVERSE clutch L. To 3rd clutch M. To 1st clutch N. To 2nd clutch O. To 4th clutch P. To FORWARD clutch
10-13
STRUCTURE AND FUNCTION
TRANSMISSION 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24. 25. 26. 27. 28. 29. 30.
10-14
Input shaft No. 1 sun gear (22 teeth) No. 1 planet gear (24 teeth) No. 1 ring gear (90 teeth) No. 1 clutch No. 1 idler gear (70 teeth) Lubrication relief valve No. 2 clutch No. 3 sun gear (15 teeth) (Output shaft) No. 3 planet gear (30 teeth) No. 3 clutch No. 3 ring gear (75 teeth) No. 4 sun gear (33 teeth) No. 4 planet gear (21 teeth) No. 4 ring gear (75 teeth) No. 4 clutch No. 5 sun gear (39 teeth) No. 5 planet gear (18 teeth) No. 5 ring gear (75 teeth) No. 5 clutch No. 6 gear (90 teeth) No. 6 clutch Output shaft No. 5 carrier No. 3, 4 carrier No. 2 planet gear (23 teeth) No. 2 sun gear (23 teeth) No. 2 carrier No. 1 carrier No. 2 ring gear (75 teeth)
STRUCTURE AND FUNCTION OUTLINE The transmission consists of a 4-FORWARD, 4REVERSE speed planetary gear transmission, transfer, and transmission control valve. In the transmission, the motive force of the input shaft is changed by the combination of No.1 or No.2 clutch with No.3,4,5, or 6 clutch to give FORWARD 1 - 4 or REVERSE 1 - 4 speed, and is transmitted to the output shaft
TRANSMISSION Speed range
Clutch combination
F1
No.2, No.6
F2
No.2, No.5
F3
No.2, No.4
F4
No.2, No.3
R1
No.1, No.6
R2
No.1, No.5
R3
No.1, No.4
R4
No.1, No.3
OPERATION OF CLUTCH Engaged The oil sent from the transmission control valve passes through the oil passage inside the transmission. When it reaches the rear piston (1), it moves the piston (1). When the piston (1) moves, disc (2) and plate (3) are pressed together. Ring gear (4) is meshed with disc (2), so the rotation is stopped.
Disengaged When the supply of oil from the transmission control valve is shut off, the pressure of the oil is acting on the rear of piston (1) is reduced. The piston is then pushed back to the right by return spring (5), and disc (2) and plate (3) are separated. Ring gear (4) then rotates freely, and no motive force is transmitted.
10-15
STRUCTURE AND FUNCTION
TRANSMISSION
FORWARD 1st
In 1st FORWARD, No. 2 clutch and No. 6 clutch are engaged. The motive force transmitted from the torque converter by input shaft (2) is transmitted to output shaft (31). No. 2 clutch is actuated by the hydraulic pressure applied to the clutch piston, and it locks ring gear (15) in position. No. 6 clutch is actuated by the hydraulic oil pressure applied to the clutch piston and holds gear (29) to carrier (32).
10-16
The motive force from the torque converter is transmitted to the input shaft (2). The rotation of the input shaft (2) is transmitted to planetary gear (14) through sun gear (13). Ring gear (15) is held in position by No. 2 clutch so the rotation of planetary gear (14) rotates carriers (33) and (34), which is on the inside ring gear (15). This carrier is connected to No. 5 carrier (32) through No. 4 ring gear (23, so when No. 6 clutch is actuated, the rotation of carrier (32) is transmitted to gear (29) and rotate output shaft (31).
STRUCTURE AND FUNCTION
TRANSMISSION
FORWARD 2nd
In 2nd FORWARD, No. 2 clutch and No. 5 clutch are engaged. The motive force transmitted from the torque converter by input shaft (2) is transmitted to output shaft (31). No. 2 clutch is actuated by the hydraulic pressure applied to the clutch piston, and it locks ring gears (15) and (27) in position. The motive force from the torque converter is transmitted to the input shaft (2). The rotation of the input shaft (2) is transmitted to planetary gear (14) through sun gear (13).
Ring gear (15) is held in position by No. 2 clutch so the rotation of planetary gear (14) rotates carriers (33) and (34), which is on the inside ring gear (15). The rotation of carrier (33) is transmitted through ring gear (23) to carrier (32). Ring gear (27) is held in position by No. 5 clutch, so the rotation of carrier (32) rotates planetary gear (26). The planetary gear rotates on the inside of ring gear (27), and rotates sun gear (25). The sun gear rotates output shaft (31).
10-17
STRUCTURE AND FUNCTION
TRANSMISSION
FORWARD 3rd
In 3rd FORWARD, No. 2 clutch and No. 4 clutch are engaged. The motive force transmitted from the torque converter by input shaft (2) is transmitted to output shaft (31). No. 2 clutch and No. 4 clutch are actuated by the hydraulic pressure applied to the clutch piston, and it locks ring gears (15) and (23) in position. The motive force from the torque converter is transmitted to the input shaft (2). The rotation of the input shaft is transmitted to planetary gear (14) through sun gear (13).
10-18
Ring gear (15) is held in position by No. 2 clutch, so the rotation of planetary gear (14) rotates carriers (33) and (34), which is on the inside ring gear (15). Ring gear (23) is held in position by No. 4 clutch, so the rotation of carrier (33) is transmitted to planetary gear (22) rotates on the inside of ring gear (23), and rotates sun gear (21). The sun gear rotates output shaft (31).
STRUCTURE AND FUNCTION
TRANSMISSION
FORWARD 4th
In 4th FORWARD, No. 2 clutch and No. 3 clutch are engaged. The motive force transmitted from the torque converter by input shaft (2) is transmitted to output shaft (31). No. 2 clutch and No. 3 clutch are actuated by the hydraulic pressure applied to the clutch piston, and it locks ring gears (15) and (19) in position. The motive force from the torque converter is transmitted to the input shaft (2). The rotation of the input shaft is transmitted to planetary gear (14) through sun gear (13).
Ring gear (15) is held in position by No. 2 clutch so the rotation of planetary gear (14) rotates carriers (33) and (34), which is on the inside ring gear (15). Ring gear (19) is held in position by No. 3 clutch, so the rotation of carrier (33) is transmitted to planetary gear (18). The planetary (18) rotates on the inside of ring gear (19), and rotates sun gear (17), which forms one unit with output shaft (31).
10-19
STRUCTURE AND FUNCTION
TRANSMISSION
REVERSE 1st
In 1st REVERSE, No. 1 clutch and No. 6 clutch are engaged. The motive force transmitted from the torque converter by input shaft (2) is transmitted to output shaft (31). No. 1 clutch is actuated by the hydraulic pressure applied to the clutch piston, and it locks carrier (35) in position. No. 6 clutch is actuated by the hydraulic pressure applied to the clutch piston and hold ring gear (29) in position. The motive force from the torque converter is transmitted to the input shaft (2). The rotation of the input shaft is transmitted to planetary gear (10) through sun gear (9).
10-20
Carrier (35) is held in position by No. 1 clutch, so the rotation of planetary gear rotates the ring gear. Ring gear (15) rotates in the opposite direction from the input shaft. Ring gear (15) rotates carrier (34), and the rotation of carrier (34) rotates ring gear (23), which then rotates carrier (32). Carrier (32) rotates No. 6 clutch (30). When No. 6 clutch is actuated, the rotation of carrier (32) is transmitted to gear (29) and rotates output shaft (31).
STRUCTURE AND FUNCTION
TRANSMISSION - MEMORANDA -
10-21
STRUCTURE AND FUNCTION
TRANSMISSION CONTROL VALVE
10-22
TRANSMISSION CONTROL VALVE
STRUCTURE AND FUNCTION 1. 2. 3. 4. 5. 6. 7. 8.
TRANSMISSION CONTROL VALVE
ECMV (for FORWARD clutch) ECMV (for REVERSE clutch) ECMV (for 3rd clutch) ECMV (for 4th clutch) ECMV (for 2nd clutch) Parking brake solenoid valve ECMV (for 1st clutch) Pilot filter
A, A’: B, B’: C, C’: D, D’: E, E’: F, F’: G’: H’:
FORWARD clutch oil pressure measurement port. REVERSE clutch oil pressure measurement port. 3rd clutch oil pressure measurement port. 4th clutch oil pressure measurement port. 2nd clutch oil pressure measurement port. 1st clutch oil pressure measurement port. To parking brake emergency release valve. To parking brake emergency release valve (Pilot pressure).
ECMV actuation table Speed range
Clutch FORWARD REVERSE 3rd 4th 2nd
Auto N
Manual
O
F1
O
F2
O
F3
O
F4
O
O
O
O
O
1st
O O
O O O
R1
O
R2
O
R3
O
R4
O
O O O O
When at manual N, the clutch of the speed range where the gear shift lever is placed, is ON.
10-23
STRUCTURE AND FUNCTION
ECMV (ELECTRONIC CONTROL MODULATION VALVE)
A. D. P. T.
To clutch Drain port From pump Clutch drain port
10-24
ECMV
STRUCTURE AND FUNCTION
1. 2. 3. 4. 5. 6. 7. 8. 9.
ECMV
Connector Connector Spring Pressure control valve spool Proportional solenoid Fill switch Pin Spring Flow detector valve spool
10-25
STRUCTURE AND FUNCTION OUTLINE OF ECMV The ECMV (Electronic Control Modulation Valve) consist of two valves: The pressure control valve and the flow detection valve. Pressure control valve The proportional solenoid receives the flow of electricity sent from the transmission controller, and the pressure control valve converts this into hydraulic pressure. Flow detection valve This valve is actuated by a trigger from the pressure control valve and has the following functions: 1) When the clutch is filled with oil, it sends a signal (fill signal) to the controller to inform the controller that the filling is completed. 2) While oil pressure is applied to the clutch, it outputs a signal (fill signal) to the controller to inform the controller of the existence of the oil pressure.
ECMV AND PROPORTIONAL SOLENOID There is one proportional solenoid installed to each ECMV. It generates propulsion as shown in the diagram on the right according to the command current from the transmission controller. The propulsion generated by the proportional solenoid acts on the pressure control valve spool and generates oil pressure as shown in the diagram on the right. In this way, the command current is controlled and the propulsion force varies to actuate the pressure control valve and control the oil flow and oil pressure. ECMV AND FILL SWITCH There is one fill switch installed to each ECMV. When the filling of the clutch is completed, the fill switch is turned on by the action of the flow detection valve. With this signal, the oil pressure starts the build-up.
10-26
ECMV
STRUCTURE AND FUNCTION
ECMV
ACTUATION OF ECMV The ECMV is controlled by the command current from the transmission controller to the proportional solenoid and the fill switch output signal. The relationship between ECMV proportional solenoid command current and the clutch input pressure and fill switch output signal is as shown in the diagram on the right. Range A: Range B: Range C: Range D: Range E:
Before shifting gear (when draining) Fill starts (during trigger) Fill completed Pressure adjustment During filling
1. Before gear shifting (during draining) - Range A in graph. When no current is flowing to proportional solenoid (5), proportional solenoid (5) is pushed back by the reaction of pressure control valve spring (3) through pressure control valve spool (4), so pressure control valve (4) drains the oil at clutch port A through drain port T. When this happens, there is no hydraulic force acting on flow detection valve spool (9), so flow detection valve spool (9) is separated from fill switch (6) by the reaction force of fill switch spring (8).
10-27
STRUCTURE AND FUNCTION 2. Start of fill (when trigger command is input to pressure control valve) - Range B in graph . When there is no oil inside the clutch, if the trigger current is applied to proportional solenoid (5) (if the maximum current is applied), the proportional solenoid moves and pressure control valve spool (4) moves to the left. As a result, the circuit between pump port P and the pressure control valve output port B opens, and oil passage through orifice “a” of flow direction valve spool (9) and starts to fill the clutch.
3. Filling completed (pressure control valve set to default pressure) 1) To reduce the transmission shock, action must be taken to prevent peak pressure from being generated at clutch port A when the filling is completed. In order to do this, the electric current in proportional solenoid (5) is lowered to the default pressure before the filling is completed and pressure control valve spool (4) is moved to the right. This allows a small amount of oil to leak from pressure control valve output port B to drain port T. In this way, the generation of peak pressure at clutch port A can be prevented when the filling is completed.
10-28
ECMV
STRUCTURE AND FUNCTION
ECMV
2) When the clutch is filled with oil, the oil stops flowing from pressure control valve output port B to clutch port A. The area receiving the pressure on the left and right sides of orifice a of flow detection valve spool (9) is different. The left side is larger, so when the oil pressure on both sides of orifice a becomes equal, fill switch spring (8) is compressed, and as a result, pin (7) contacts fill switch (6) and sends the clutch fill completion signal to the shift controller. At this point, the default pressure current is flowing to proportional solenoid (5), and the oil pressure is set to the default pressure setting by pressure control valve spool (4).
4. Adjusting pressure (Range D in graph) When electric current flows to proportional solenoid (5), the solenoid generates a force proportional to the current. The total of this propulsion force of the solenoid and the propulsion force of the oil pressure at the clutch port and the reaction force of pressure control valve spring (3) is balanced. Flow detection valve spool (9) is pushed to the right by the difference in the force of the oil pressure applied to both sides of orifice a, and it continues to send the fill signal to the shift controller.
10-29
STRUCTURE AND FUNCTION
MAIN RELIEF, T.C. RELIEF VALVE
MAIN RELIEF, TORQUE CONVERTER RELIEF VALVE
1. 2. 3. 4. 5. 6. 7. 8. 9.
Body Torque converter relief valve Valve spring Piston Piston spring Main relief valve Valve spring Piston spring Piston
A. B. C. D. E. P1
Drain port (torque converter relief) Drain port From pump Drain port To torque converter Main relief oil pressure detection port
10-30
OUTLINE 1. Main relief valve. Main relief valve (6) sets the pressure of the transmission oil. 2. Torque converter relief valve. Torque converter relief valve (2) acts to protect the torque converter from abnormally high pressure. It relieves the pressure when the pressure at the inlet port of the torque converter goes above the specified pressure. Specified pressure Main relief pressure
3.52 MPa (35.9 kg/cm2) (engine at rated speed
Torque converter inlet port pressure
0.84 MPa (8.5 kg/cm2) (cracking pressure)
STRUCTURE AND FUNCTION
MAIN RELIEF, T.C. RELIEF VALVE
OPERATION OF MAIN RELIEF VALVE The oil from the torque converter charging pump passes through the filter, enters port A of the main relief valve, and then passes through orifice a and enters port B. When the oil from the pump fills the circuit, the pressure starts to raise. When the oil pressure in the circuit rises, the oil entering port B pushes piston (4). The reaction compresses spring (7) and moves main relief valve (6) to the left to open the passage between port A and port C. When this happens, the oil from the pump is relieved from port A to port C, and flows from port C, into the torque converter. The oil pressure at port A at this point is 3.52 MPa (35.9 kg/cm2) engine at rated speed.
OPERATION OF TORQUE CONVERTER RELIEF VALVE The oil relieved from the main relief valve flows from port C into the torque converter, and at the same time, passes through orifice b and enters port D. When the oil fills the circuit to the torque converter, the oil pressure starts to raise.
When the oil pressure in the circuit to the torque converter rises, the oil entering port D pushes piston (9). The reaction compresses spring (3), and moves relief valve (2) to the right to open the passage between port C and port E. When this happens, the oil from port C is relieved to port E and flows to the transmission lubrication circuit. The oil pressure at port C at this point is 0.84 MPa (8.5 kg/cm2) cranking pressure.
10-31
STRUCTURE AND FUNCTION
LUBRICATING RELIEF VALVE
LUBRICATING RELIEF VALVE
1. Piston 2. Spring 3. REVERSE clutch housing
A. From oil cooler B. Drain C. Drain
OUTLINE The lubricating relief valve is assembled to the left face of the REVERSE clutch housing, and protects the lubricating circuit and oil cooler
Unit: MPa (kg/cm2) Specified value Pressure when normal Cracking pressure
10-32
0.15 - 0.23 (1.5 - 2.3) 0.3 (3.0)
STRUCTURE AND FUNCTION
TORQUE CONVERTER OIL FILTER
TORQUE CONVERTER OIL FILTER
OPERATION The oil from the torque converter charging pump enters the filter inlet port A and passes from the outside of element (2) to the inside. It then flows to the outlet port B.
If the element (2) is clogged with dirt, or the oil temperature is low, the pressure at the inlet port A rises. When this happens, the oil from the inlet port A opens relief valve (1) and flows directly to the outlet port B. This prevents damage to the pump or element (2).
10-33
STRUCTURE AND FUNCTION
PILOT FILTER
PILOT FILTER
OUTLINE The oil flows from the transmission case to pump to torque converter oil filter, and is then divided and flows to the torque converter and transmission control valve. There is a pilot filter installed at the inlet port of the transmission control valve, and this filters the dirt out of the oil flowing to the control valve.
10-34
Specifications Filter mesh size: 10 Filtering area: 0.063 m2 (630 cm2) Element pressure resistance: 4.9 MPa (50 kg/cm2)
STRUCTURE AND FUNCTION
TRANSFER
TRANSFER Outline The transfer is installed at the power output end of the transmission and is secured to the transmission case by bolts. Transmission path Output shaft (1) of the transmission is coupled to transfer input gear (2) by a spline. The motive force is transmitted to output gear (4) through idler gear (3) and output shaft (5).
1. 2. 3. 4. 5. 6. 7. 8.
Transmission output shaft Transfer input gear (teeth 48) Transfer idler gear (teeth 45) Output gear (teeth 43) Output shaft Front coupling Rear coupling Parking brake
Part of the power transmitted to the output shaft is transmitted to the front axle through the center drive shaft and front drive shaft. The rest of the power is transmitted to the rear axle through the rear drive shaft.
10-35
STRUCTURE AND FUNCTION
DRIVE SHAFT
DRIVE SHAFT
1. Front drive shaft 2. Center support 3. Center drive shaft Outline The motive force from the engine passes through the damper, upper drive shaft (5), torque converter, transmission and transfer. Part of this motive force passes through rear drive shaft (4) and goes to the rear axle: the rest of the motive force passes through center drive shaft (3), center support (2) and front drive shaft (1) and is sent to the front axle. In addition to transmitting the motive force, the drive shafts have the following purposes.
10-36
4. Rear drive shaft 5. Upper drive shaft
When the body is articulated, or when there is shock from the road surface during traveling, or when there is shock during operations, the axle in front and behind the engine and transmission change position. To allow the motive force to be transmitted without damage to parts of the machine when there is shock or when the components move position, the drive shafts have a universal joint and a sliding joint. This allows them to handle changes in angle and length.
STRUCTURE AND FUNCTION
CENTER SUPPORT
CENTER SUPPORT
Function
1. 2. 3. 4.
Front coupling Case Grease fitting Rear coupling
The center support is installed to the front frame between the center drive shaft and the front drive shaft. With the articulating frame, this part is constantly twisting from side to side, so there is liable to be a large amount of stress on the drive shafts. Therefore, the center support is used to transmit the power smoothly, to reduce the stress on the drive shafts, and improve the durability of the drive shafts.
10-37
STRUCTURE AND FUNCTION
AXLE FRONT
10-38
AXLE
STRUCTURE AND FUNCTION
AXLE
Rear
10-39
STRUCTURE AND FUNCTION
DIFFERENTIAL Front
1. 2. 3. 4. 5.
Slide gear (18 teeth) Bevel pinion (9 teeth) Bevel gear (37 teeth) Pinion (10 teeth) Shaft
10-40
DIFFERENTIAL
STRUCTURE AND FUNCTION
DIFFERENTIAL
Rear
1. 2. 3. 4. 5.
Bevel gear (37 teeth) Shaft Slide gear (18 teeth) Pinion (10 teeth) Bevel pinion (9 teeth)
10-41
STRUCTURE AND FUNCTION OUTLINE The motive force from the drive shaft passes through bevel pinion (1) and is transmitted to the bevel gear (5). The bevel gear changes the direction of the motive force by 90 the same time reduces the speed. It then transmits the motive force through the differential (4) to the sun gear shaft (2).
When driving straight forward
When the machine is driven straight forward, the rotating speed of the left and right wheels is the same, so the pinion gear (4) inside the differential assembly (6) is sent through the pinion gear (4) and the side gear (3) and is transmitted equally to the left and right sun gear shafts (2).
When turning When turning, the rotating speed of the left and right wheels is different, so the pinion gear (4) and side gear (3) inside the differential assembly rotate in accordance with difference between the rotating speed of the left and right wheels. The motive force of the carrier (6) is then transmitted to the sun gear shafts (2).
10-42
DIFFERENTIAL
STRUCTURE AND FUNCTION TORQUE PROPORTIONING DIFFERENTIAL FUNCTION Because of the nature of their work, 4-wheel-drive loaders have to work in places where the road surface is bad. In such places, if the tires slip, the ability to work as a loader is reduced, and also the life of the tire is reduced. The torque proportioning differential is installed to overcome this problem.
DIFFERENTIAL "b" is less than 1 : 1.38 (that is, the difference between the resistance from the road surface to the left and right tires is less than 38%), the pinion gear will not rotate freely, so drive force will be given to both side gears, and the tires will not slip. Because of this effect, the tire life can be increased by 20 - 30%, and at the same time the operating efficiency is also increased.
In structure it resembles the differential of an automobile, but the differential pinion gear (4) has an odd number of teeth. Because of the difference in the resistance from the road surface, the position of meshing of the pinion gear (4) and side gear (3A), (3B) changes, and this changes the traction of the left and right tires. OPERATION When traveling straight (equal resistance from road surface to left and right tires) If the resistance from the road surfaces to the left and right wheels is the same, the distance between the pinion gear and the meshing point "a" of the left side gear is the same as the distance between the pinion gear and meshing point "b" of right side gear (3B). Therefore the left side traction TL and the right side traction TR are balanced. When traveling on soft ground (resistance from road surface to left and right tires is different) On soft ground, if the tire on one side slips, the side gear of the tire on the side which has least resistance from the road surface tires to rotate forward. Because of this rotation, the meshing of the pinion gear and side gear changes. If left side gear (A) rotates slightly forward, the distance between the pinion gear and the meshing point "a" of the left side gear becomes longer than the distance between the pinion gear and the meshing port "b" of the right side gear. The position is balanced as follows: a x TL = b x TR The ratio between the distances to "a" and "b" can change to 1 : 1.38.
Therefore when the ratio of the distances to "a" and
10-43
STRUCTURE AND FUNCTION
FINAL DRIVE
FINAL DRIVE
1. 2. 3. 4. 5. 6.
Axle shaft Planetary gear (29 Teeth) Ring gear (78 Teeth) Planetary carrier Sun Gear (18 Teeth) Wheel
10-44
Outline To gain a large drive force, the final drive uses a planetary gear system to reduce speed and send drive force to the tires.
STRUCTURE AND FUNCTION
FINAL DRIVE
Operation The motive force transmitted from the differential through axle shaft (1) to sun gear (5) is transmitted to planetary gear (2). The planetary gear rotates around the inside of a fixed ring gear (3) and in this way transmits rotation at a reduced speed to the planetary carrier (4). This motive force is then sent to the wheels (6) which are installed to the planetary carriers (4).
10-45
STRUCTURE AND FUNCTION
AXLE MOUNT
10-46
AXLE MOUNT
STRUCTURE AND FUNCTION
1. 2. 3. 4. 5.
Front axle Rear axle Front frame Rear frame Axle mounting bolts
AXLE MOUNT
Front axle The front axle (1) receives the force directly during operations, so it is fixed directly to the front frame (3) by axle mounting bolts (5).
Rear axle The rear axle (2) has a structure which allows the center of the rear axle to float, so that all tires can be in contact with the ground when traveling over soft ground.
10-47
STRUCTURE AND FUNCTION
CENTER HINGE PIN
CENTER HINGE PIN
1. 2. 3. 4. 5. 6.
Front axle Rear axle Front frame Rear frame Upper hinge pin Lower hinge pin
10-48
OUTLINE The front frame (3) and rear frame (4) are connected through a bearing by the center hinge pin (5) and (6). The steering cylinders are connected to the left and right front and rear frames, so when the cylinders are operated, the frame bends at the middle to give the desired angle, that is the desired turning radius.
STRUCTURE AND FUNCTION
TIRE AND WHEEL
TIRE AND WHEEL The tire acts to absorb the shock from the ground surface to the machine, and at the same time they must rotate in contact with the ground to gain the power which drives the machine Various types of tires are available to suit the purpose. Therefore it is very important to select the correct tires for the type of work and bucket capacity.
1. 2. 3. 4. 5.
Specifications Tire type: 26.5 x 25, 20PR TRA code: L3 Nominal size of wheel: 22.00 x 25WTB Nominal inflation pressure: FRONT tire: 441.3 kPa (4.5 kg/cm², 63.9 psi) REAR tire: 343.2 kPa (3.5 kg/cm², 49.7 psi)
Tire Rim Air valve Lock ring Side ring
10-49
STRUCTURE AND FUNCTION
STEERING PIPING
STEERING PIPING
1. 2. 3. 4. 5. 6.
Steering cylinder (R.H.) Orbit-roll valve Stop valve (R.H.) Hydraulic tank Hydraulic pump Oil cooler
10-50
7. Switch pump and PPC pump 8. Steering pump 9. Stop valve (L.H.) 10. Steering valve 11. Steering cylinder (L.H.)
STRUCTURE AND FUNCTION
STEERING COLUMN
STEERING COLUMN
1. 2. 3. 4.
Steering wheel Steering column Joint Orbit-roll valve
10-51
STRUCTURE AND FUNCTION
STEERING VALVE
STEERING VALVE
1. 2. 3. 4. 5.
Safety valve (with suction) Check valve Steering spool Relief valve Demand spool
10-52
A: B: Pa: Pb: P1: P2: PB: T:
To steering cylinder To steering cylinder From orbit-roll valve From orbit-roll valve From steering pump From steering pump To main control valve Drain (to oil cooler)
STRUCTURE AND FUNCTION
STEERING VALVE
OPERATION OF DEMAND VALVE Steering spool at neutral
The oil from the steering pump enters port A, and the oil from the switch pump enters port B. When steering spool (2) is at neutral, pressurereceiving chamber (II) is connected to the drain circuit through orifice (b), and notch (c) is closed. Notch (c) is closed, so the pressure of the oil at 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.
When the pressure at pressure-receiving camber (I) reaches a certain value (set by spring {5}), notch (f) opens, and the oil from the steering pump flows to the drain circuit. At the same time, notch (g) closes, and the oil from the switch pump all flows to the main control valve.
10-53
STRUCTURE AND FUNCTION
STEERING VALVE
Steering spool operated Engine at low speed
When steering spool (2) is pressed (operated), pressure-receiving chamber (III) and the drain circuit are shut off, ans at the same time notch (c) opens. When this happens, the pressure in pressurereceiving chamber (III) rises, and demand spool (1) moves to the right in the direction of the arrow until notch (h) closes. The passage from port B to the main control valve is shut off, so the oil from switch pump pushes up merge check valve (3), and merges with the oil at port A from the steering pump.
10-54
The merged oil passes through notch (c) and notch (d), pushes up load check valve (4), and flows to the cylinder. The oil returning from the cylinder passes through notch (e) and enters the drain circuit. In this condition, the pressure before passing through notch (c) goes to pressure-receiving chamber (I), and the pressure after passing notch (c) goes to pressure-receiving chamber (II). Demand spool (1) moves to maintain the pressure difference on the two sides of notch (c) at a constant value. Therefore, a flow corresponding to the amount of opening notch (c) is discharged from the cylinder port. These pressure differences (control pressure are set by spring (5).
STRUCTURE AND FUNCTION
STEERING VALVE
Engine at high speed
The extra oil from the switch pump is not needed, so the steering pump pressure rises until notch (g) closes, and shuts off the merge passage at port B. The pressure difference on the two sides of notch (c) is controlled only by notch (f), so the excess oil from the steering pump is drained from notch (f) to drain the circuit (when this happens, notch (g) is completely closes.
The oil from steering passes through notch (c) and notch (d), pushes up load check valve (4), and flows to the cylinder. The oil returning from the cylinder passes through notch (e) and flows to the drain circuit. Notch (g) is closed, so the oil from the switch pump is sent from port B to the main control valve.
10-55
STRUCTURE AND FUNCTION
STEERING VALVE
FLOW AMP
1. 2. 3. 4.
Steering spool Valve housing (body) Spring seat Return spring
5. Cap 6. Capscrew 7. Orifice
A: From orbit-roll valve B: From orbit-roll valve C: Passage (inside housing)
Operation of flow amp 1. Spool at neutral (Orbit-roll valve not actuated)
When the Orbit-roll valve is not actuated, both pilot port PiA and pilot port PiB are connected through the Orbit-roll to the drain (return) circuit, so steering
10-56
spool (1) is kept at neutral by return spring (4).
STRUCTURE AND FUNCTION
STEERING VALVE
2. Spool actuated (oil flows to port PiA)
When oil flows to port PiA, the pressure inside the cap end A rises and moves steering spool (1) in the direction of the arrow. The oil entering from port PiA passes through the hole in spring seat (3), through orifice (7) in steering spool (1), and then flows to the opposite end (B end).
Port PiB is connected to the drain circuit through the Orbit-roll valve, so the oil flowing to end B is drained. The pressure generated at port PiA is proportional to the amount of oil flowing in, so steering spool (1) moves to a position where the opening of the flow amp notch balances the pressure generated with the force of return spring (4).
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STRUCTURE AND FUNCTION 3. Spool returning (steering wheel stopped, flow of oil to port PiA cut)
When steering wheel (Orbit-roll valve) is stopped, ports PiA and PiB are both connected to the drain circuit through the Orbit-roll valve. For this reason, steering spool (1) is returned to neutral position by return spring (4).
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STEERING VALVE
STRUCTURE AND FUNCTION
STEERING VALVE
OPERATION OF STEERING VALVE Neutral
The steering wheel is not being operated, so steering spool (1) does not move. The oil from the steering pump enters port A, the oil from the switch pump enters port B.
When the pressure at ports A and B rises, demand spool (4) moves to the left in the direction of the arrow. The oil from the steering pump passes through port C of the spool and is drained. The oil from the switch pump passes through port D and flows to the main control valve.
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STRUCTURE AND FUNCTION
STEERING VALVE
Turning right
When the steering wheel is turned to the right, the pressure oil from the Orbit-roll valve acts on steering spool (1), and steering spool (1) moves to the left in the direction of the arrow. The oil from the steering pump enters port A, passes through demand spool (2), and flows to steering spool (1). It pushes open load check valve (4) of the spool, and the oil flows to the bottom end of the left cylinder and the rod end of the right cylinder to turn the machine to the right.
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The oil from the left and right cylinders passes through load check valve (3) of the steering spool, and is drained. The oil from the switch pump enters port B, flows through demand spool (2), pushes open check valve (5), and merges with the oil from the steering pump.
STRUCTURE AND FUNCTION
STEERING VALVE
Turning left
When the steering wheel is turned to the left, the pressure oil from the Orbit-roll valve acts on steering spool (1), and steering spool (1) moves to the right in the direction of the arrow. The oil from the steering pump enters port A, passes through demand spool (2), and flows to steering spool (1). It pushes open load check valve (3) of the spool, and the oil flows to the bottom end of the right cylinder and the rod end of the left cylinder to turn the machine to the left.
The oil from the left and right cylinders passes through load check valve (4) of the steering spool, and is drained. The oil from the switch pump enters port B, flows through demand spool (2), pushes open check valve (5), and merges with the oil from the steering pump.
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STRUCTURE AND FUNCTION
STEERING VALVE
STEERING RELIEF VALVE 1. 2. 3. 4. 5.
Function The steering relief valve is inside the steering valve, and sets the maximum circuit pressure of the steering circuit when the steering valve is actuated. When the steering valve is being actuated, if the steering circuit goes above the set pressure of this valve, oil is relieved from this valve. When the oil is relieved, the flow control spool of the demand valve is actuated, and the oil is drained to the steering circuit.
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Adjustment screw Spring Plug Pilot popper Valve seat
STRUCTURE AND FUNCTION
STEERING VALVE
Operation of relief valve
When the pressure in the circuit rises, and it reaches the pressure set by adjustment screw (1) and spring (2), pilot poppet (4) opens, and the oil is drained. When this happens, the balance in pressure between pressure-receiving chamber (I) and pressure-receiving chamber (II) is lost, so demand spool (6) moves to the left in the direction of the arrow.
When demand spool (6) moves, the oil from the steering pump is drained, and the oil from the switch pump is released to the main control valve. This prevents the pressure in the steering circuit from going above the set value.
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STRUCTURE AND FUNCTION
STEERING VALVE
SAFETY VALVE (WITH SUCTION) 1. 2. 3. 4. 5.
Function The safety valve is installed to the steering valve. It has the following two functions: 1) When the steering valve is at neutral, if any shock is applied to the cylinder, and an abnormal pressure is generated, the oil is relieved from the valve. In this way, it functions as a safety valve to prevent damage to the cylinder or hydraulic piping. 2) If negative pressure is generated at cylinder end, it functions as a suction valve to prevent a vacuum from forming.
Operation Acting as relief valve Port A is connected to the cylinder circuit and port B is connected to the drain circuit. Oil passes through the hole in poppet (1) and acts on the different areas of diameters d1 and d2, so check valve poppet (3) and relief valve poppet (2) are firmly seated in position. When the pressure at port A reaches the set pressure of the relief valve, pilot poppet (4) opens. The oil flows around pilot poppet (4), passes through the drill hole, and flows to port B.
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Poppet Relief valve poppet Check valve poppet Pilot poppet Spring
STRUCTURE AND FUNCTION
STEERING VALVE
When pilot poppet (4) opens, the pressure at the back of poppet (1) drops, so poppet (1) moves and is seated with pilot poppet (4).
Compared with the pressure at port A, the internal pressure is low, so relief valve poppet (2) opens. When this happens, the oil flows from port A to port B, and prevents any abnormal pressure from forming.
Acting as suction valve When negative pressure is formed at port A, the difference in area of diameters d3 and d4 causes check valve poppet (3) to open. When this happens, the oil from port B flows to port A, and prevents any vacuum from forming.
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STRUCTURE AND FUNCTION
ORBIT-ROLL VALVE
ORBIT-ROLL VALVE
1. 2. 3. 4.
Needle bearing Center spring Drive shaft Valve body
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5. 6. 7. 8.
Rotor Cover Center pin Sleeve
9. Spool 10. Stator 11. Lower cover 12. Check valve
STRUCTURE AND FUNCTION
ORBIT-ROLL VALVE
Outline The steering valve is connected directly to the shaft of the steering wheel. It switches the flow of oil from the steering pump to the left and right steering cylinders to determine the direction of travel of the machine. The orbit-roll valve, broadly speaking, consists of the following components: Rotary type spool (9) and sleeve (8), which have the function of selecting the direction, and the Girotor set (a combination of rotor (5) and stator (10)), which acts as a hydraulic motor during normal steering operations, and as a hand pump (in fact, the operating force of the steering wheel is too high, so it cannot be operated) when the steering pump or engine have failed and the supply of oil has stopped.
Structure Spool (9) is directly connected to the drive shaft of the steering wheel, and is connected to sleeve (8) by center pin (7) (it does not contact the spool when steering wheel is at neutral) and centering spring (2). The top of drive shaft (3) is meshed with center pin (7), and forms one unit with sleeve (8), while the bottom of the drive shaft is meshed with the spline of rotor (5) of the Girotor.
There are four ports in valve body (4), and they are connected to the pump circuit, tank circuit, and the circuits at the head end and bottom end of the steering cylinders. The pump port and tank port are connected by the check valve inside the body. If the pump or engine fail, the oil can be sucked in directly from the tank by the check valve.
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STRUCTURE AND FUNCTION CONNECTION BETWEEN HAND PUMP AND SLEEVE
The diagrams above show the connections with the sleeve ports used to connect the suction and discharge ports of the Girotor. If the steering wheel has been turned to the right, ports a, c, e, g, I, and k are connected by the vertical grooves in the spool to the pump side. At the same time, ports b, d, f, h, j, and l are connected to the head end of the left steering cylinder in the same way. In the condition in Fig. 1, ports 1, 2, and 3 are the discharge ports of the Girotor set. They are connected to ports l, b, and d, so oil is sent to the cylinder. Ports 5, 6, and 7 are connected and the oil flows in from the pump. If the steering wheel is turned 90 n changes to the condition shown in Fig. 2. In this case ports 1, 2, and 3 are the suction ports, and are connected to ports I, k, and c. Ports 5, 6, and 7 are the discharge ports, and are connected to ports d, f, and h.
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ORBIT-ROLL VALVE
STRUCTURE AND FUNCTION
ORBIT-ROLL VALVE
In this way the ports of the Girotor acting as delivery ports are connected to ports which are connected to the end of the steering valve spool. The ports acting as suction ports are connected to the pump circuit Adjusting delivery in accordance with angle of the steering wheel: For every 1/7 turn of the steering wheel, the inner teeth of the Girotor gear advances one position so the oil flow from the pump is adjusted by this movement. In this way, the oil delivered from the pump is directly proportional to the amount the steering wheel is turned. FUNCTION OF CENTER SPRING Centering spring (2) consists of four layers of leaf springs crossed to form an X shape. The springs are assembled in spool (9) and sleeve (8) as shown in the diagram on the right. When the steering wheel is turned, the spring is compressed and a difference in rotation (angle variation) arises between the spool and the sleeve. Because of this, the ports in the spool and sleeve are connected and oil is sent to the cylinder. When the turning of the steering wheel is stopped, the Girotor also stops turning, so no more oil is sent to the cylinder and the oil pressure rises. To prevent this, when the turning of the steering wheel is stopped, the action of the centering spring only allows it to turn by an amount equal to the difference in angle of rotation (angle variation) of the sleeve and spool, so the steering wheel returns to the NEUTRAL position.
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STRUCTURE AND FUNCTION
STOP VALVE
STOP VALVE
1. 2. 3. 4. 5. 6. 7.
Boot Wiper Seal Poppet Spring Spool Spring
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A: B: DR:
From orbit-roll To steering valve To drain
STRUCTURE AND FUNCTION
DIVERTER VALVE
DIVERTER VALVE
1. 2. 3. 4.
Spool Valve body Check valve Check valve
A. B. C. D. E. F. G.
From steering pump To steering valve To hydraulic tank Sensor mounting port Ground driven steering pump port Ground driven steering pump port From hydraulic tank
FUNCTION If the engine stops or the pump seizes while the machine is traveling, it becomes impossible to steer, the rotation of the transmission is used to turn the ground driven steering pump to make steering possible
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STRUCTURE AND FUNCTION OPERATION Pump and engine are working normally.
When the steering pump and engine are working normally, the hydraulic pump, steering pump, and switch pump are rotated by the engine. Therefore, oil is sent to the steering valve, and the machine can be steered. In addition, the ground driven steering pump is rotated by the transmission, so oil from port A of the diverter valve (1) pushes open check valve (2) and enters port B. Pressure oil from steering pump is flowing to port D, so it pushes spool (3) in the direction of the arrow. As a result, the oil from port B flows to port C and is drained to the hydraulic tank.
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DIVERTER VALVE
STRUCTURE AND FUNCTION
DIVERTER VALVE
Failure in pump or engine when machine is traveling.
If there is a failure in the pump or engine when the machine is traveling, the rotation of the wheels is transmitted through the transfer to rotate the ground driven steering pump. The steering pump is not rotating, so no oil pressure is formed at port D. As a result, spool (3) is pushed in the direction of the arrow by spring (4). The oil from the ground driven steering pump passes from port A through port B and flows to the steering valve to make steering possible. The ground driven steering pump is designed so that it can rotate both directions.
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STRUCTURE AND FUNCTION
BRAKE PIPING
1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18.
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Brake valve (right) Hydraulic tank Parking brake switch Emergency release parking brake switch Rear brake (right) Charge valve Filter Accumulator Parking brake valve Slack adjuster (rear) Rear brake (left) PPC pump (also for brake) Transmission control valve Parking brake (built into transmission) Brake valve (left) Front brake (left) Slack adjuster (front) Front brake (right)
STRUCTURE AND FUNCTION
BRAKE CIRCUIT DIAGRAM
BRAKE CIRCUIT DIAGRAM
1. 2. 3. 4. 5. 6. 7. 8. 9. 10.
Hydraulic tank Brake, PPC pump Charge valve Check valve Accumulator (rear brake) Brake valve (right) Rear slack adjuster Rear brake cylinder Front slack adjuster Front brake cylinder
11. Check valve 12. Accumulator (Front brake, emergency parking brake) 13. Brake valve (left) 14. Transmission (case) 15. Torque converter charging pump 16. Transmission control valve (Parking brake valve) 17. Emergency parking brake 18. Parking brake
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STRUCTURE AND FUNCTION
BRAKE VALVE
BRAKE VALVE BRAKE VALVE (RIGHT)
1. 2. 3. 4. 5. 6. 7. 8. 9. 10.
Brake pedal (left, right brake) Rod (right brake) Pilot piston (right brake) Spool (right brake) Upper cylinder (right brake) Spool (right brake) Lower cylinder (right brake) Rod (left brake) Spool (left brake) Cylinder (left brake)
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A. B. C. D. E.
Pilot port (right brake) To rear brake (right brake) To front brake (right brake) Drain (left, right brake) To pilot port (left brake)
STRUCTURE AND FUNCTION
BRAKE VALVE
BRAKE VALVE (LEFT)
Outline There are two brake valves installed in parallel under the front of the operator’s cab, and these are actuated by depressing the pedal. When the right pedal is depressed, oil is sent to the brake cylinders 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 transmission solenoid valve electrically and set the transmission to neutral.
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STRUCTURE AND FUNCTION Operation Brake applied (right brake valve) Upper portion When brake pedal (1) is depressed, the operating force is transmitted to spool (3) through rod (2) and spring (4). When spool (3) goes down, drain port a is closed, and the oil from the pump and accumulator flows from port A to port C and actuates the rear brake cylinder. Lower portion When brake pedal (1) is depressed, the operating force is transmitted to spool (3) through rod (2) and spring (4). When spool (3) goes down, spool (5) is also pushed 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 B and actuates the rear brake cylinder.
Brake applied (left brake pedal) When pedal (7) is depressed, spool (10) is pushed up by rod (8) and spring (9), and drain port c is closed. The oil from the pump and the accumulator flows from port E to port F. Port F of the left brake valve and port Pp of the right brake valve are connected by a hose, so the oil flowing to port F flows to pilot port Pp of the right brake valve. The oil entering pilot Pp enters port G from orifice d, and pushes pilot piston (11). The spring pushes spool (3) down, so the operation is the same as when the right brake valve is depressed.
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BRAKE VALVE
STRUCTURE AND FUNCTION
BRAKE VALVE
Applying brake when upper valve fails (right brake valve) Even if there is leakage of oil in the upper piping, spool (5) is moved down mechanically when pedal (1) is depressed, and the lower portion is actuated normally. The upper brake is not actuated. Applying brake when lower valve fails (right brake valve) Even if there is leakage of oil in the lower piping, the upper portion is actuated normally.
When actuation is balanced Upper portion When oil fills the rear brake cylinder and the pressure between port A and port C becomes high, the oil entering port H from orifice e of spool (3) pushes against spring (4). It pushes up spool (3) and shuts off the circuit between port A and port C. When this happens, drain port a stays closed, so the oil entering the brake cylinder is held and the brake remains applied.
Lower portion When spool (3) in the upper portion moves up and the circuit between port A and port C is shut off, oil also fills the front brake cylinder at the same time, so the pressure in the circuit between port B and port D rises. The oil entering port J from orifice f of spool (5) pushes up spool (5) by the same amount that spool (3) moves, and shuts off port B and port D. Drain port b is closed, so the oil entering the brake cylinder is held, and the brake is applied. The pressure in the space in the upper portion is balanced with the operating force of the pedal, and the pressure in the space in the lower portion is balanced with the pressure in the space in the upper portion. When spools (3) and (5) move to the end of their stroke, the circuits between ports A and C and between ports 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.
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STRUCTURE AND FUNCTION Brake released (right brake valve) Upper portion When brake pedal (1) is released and the operating force is removed from the top of the spool, the back pressure from the brake cylinder and the force of the spool return spring move spool (3) up. Drain port a is opened and the oil from the brake cylinder flows to the hydraulic tank return circuit to release the rear brake.
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 (5) 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.
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BRAKE VALVE
STRUCTURE AND FUNCTION
MEMORANDA
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STRUCTURE AND FUNCTION
CHARGE VALVE
CHARGE VALVE
A. ACC. PP. P. T.
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To PPC valve To brake valve To brake valve From pump Drain
Function The charge valve is actuated to maintain the oil pressure from the pump at the specified pressure and store it in the accumulator. When the oil pressure reaches the specified pressure, the oil from the pump is connected to the drain circuit to reduce the load on the pump.
STRUCTURE AND FUNCTION
1. 2. 3. 4. 5.
CHARGE VALVE
Valve body Main relief valve (R3) Relief valve (R1) PPC relief valve (R2) Relief valve (H1)
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STRUCTURE AND FUNCTION Operation 1. When no oil is being supplied to accumulator (cut-out condition) The pressure at port B is higher than the set pressure of the relief valve (R1), so piston (8) is forcibly pushed up by the oil pressure at port B. Poppet (6) is opened, so port C and port T are short circuited. The spring chamber at the right end of spool (15) is connected to port C of the relief valve (R1), so the pressure becomes the tank pressure. The oil from the pump enters port P, pushes spool (15) to the right at a low pressure equivalent to the load on spring (14), and flows from port A to the PPC valve. At the same time, it also passes through orifices (17), (18), and (16), and flows to the tank.
2. When oil is supplied to accumulator 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 contact, and port C and port T are shut off. The spring chamber at the right end of spool (15) is also shut off from port T, so the pressure rises, and the pressure at port P also rises in the same way. When the pressure at port P goes the pressure at port B (accumulator pressure), the supply of oil to the accumulator starts immediately. In this case, it is decided by the size (area) of orifice (17) and the pressure difference (equivalent to the load on spring (14)) generated on both sides of the orifice. A fixed amount is supplied regardless of the engine speed, and the remaining oil flows to port A.
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CHARGE VALVE
STRUCTURE AND FUNCTION
CHARGE VALVE
2) When cut-out pressure is reached When the pressure at port B (accumulator pressure) reaches the set pressure of the relief valve (R1), poppet (6) separates from valve seat (7), so an oil flow is generated and the circuit is relieved. When the circuit is relieved, a pressure difference is generated above and below piston (8), so piston (8) moves up, poppet (6) is forcibly opened, and port C and port T are short circuited. The spring chamber at the right end of spool (15) is connected to port C of the relief valve (R1), so the pressure becomes the tank pressure. The pressure at port P drops in the same way to a pressure equivalent to the load on spring (14), so the supply of oil to port B is stopped.
3. Safety relief valve (R3) If the pressure at port P (pump pressure) goes above the set pressure of the relief valve (R3), the oil from the pump pushes spring (3). Ball (11) is pushed up and the oil flows to the tank circuit, so this sets the maximum pressure in the brake circuit and protects the circuit.
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STRUCTURE AND FUNCTION
ACCUMULATOR (FOR BRAKE)
ACCUMULATOR (FOR BRAKE)
1. 2. 3. 4.
Function The accumulator is installed between the charge valve and the brake valve. It is charge with nitrogen gas between cylinder (3) and free piston (4), and uses the compressibility of the gas to absorb the pulse of the hydraulic pump or to maintain the braking force and to make it possible to operate the machine if the engine should stop.
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Valve Top cover Cylinder Piston
Specifications Gas used: Charge amount: Charging pressure:
Nitrogen gas 4,000 cc 3.4 ±0.15 MPa {35 ±1.5 kg/cm2} (at 50
STRUCTURE AND FUNCTION
SLACK ADJUSTER
SLACK ADJUSTER
1. 2. 3. 4. 5.
Bleeder Cylinder Check valve Piston Spring
A. Inlet port B. Outlet port
Function The slack adjuster is installed in the brake oil line from the brake valve to the brake piston. It acts to provide a fixed time lag when the brake is applied.
Specifications Piston actuation pressure: 0.01 +0.01 MPa {0.1 +0.1 kg/cm2} Check valve cracking pressure: 0.93 ±0.05 MPa {9.5 ±0.5 kg/cm2} Check valve closing pressure: 0.6 ±0.05 MPa {6.0 ±0.5 kg/cm2}
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STRUCTURE AND FUNCTION Operation 1. When brake pedal is depressed Before the brake is depressed, piston (4) is returned by the distance of stroke S (full stroke). When the brake pedal is depressed, the oil discharged from the brake valve flows from port P of the slack adjuster and is divided to the left and right cylinders (2), where it moves piston (4) by stroke S to the left and right.
When this is done, brake piston (7) moves by a distance of stroke S. In this condition, the closer the clearance between the brake piston and disc is to 0, the greater the braking force becomes.
If the brake pedal is depressed further, and the oil pressure discharged from the brake valve goes above the set pressure, check valve (3) opens and the pressure is applied to port C to act as the braking force. Therefore, when the brake is applied, the time lag is a fixed value.
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SLACK ADJUSTER
STRUCTURE AND FUNCTION
SLACK ADJUSTER
2. When brake pedal is released When the brake is released, piston (4) is returned by brake return spring (8) by an amount equivalent to the oil for stroke S, and the brake is released. In other words, return stroke T of brake piston (7) is determined by the amount of oil for stroke S of the slack adjuster. The time lag of the brake is always kept constant regardless of the wear of the brake disc.
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STRUCTURE AND FUNCTION
BRAKE
BRAKE
1. 2. 3. 4. 5. 6. 7. 8.
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Guide pin Return spring Cylinder Brake piston Outer gear (138 Teeth) Inner gear (105 Teeth) Plate Disc
Function The brakes are wet-type multiple disc brakes, and are fitted to all four wheels.
STRUCTURE AND FUNCTION
BRAKE
Operation When the brake pedal is depressed, the pressure oil from the brake valve moves brake piston (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.
When the brake pedal is released, the pressure at the back face of brake piston (4) is released, so the piston is moved to the left in the direction of the arrow by the force of return spring (2), and the brake is released.
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STRUCTURE AND FUNCTION
PARKING BRAKE CONTROL
PARKING BRAKE CONTROL
1. Parking brake switch 2. Parking brake emergency release switch 3. Transmission control valve Outline The parking brake is a wet-type multiple-disc brake built into the transmission. It is installed to the output shaft bearing, and uses the pushing force of a spring to apply the brake mechanically and hydraulic power to release the brake. When parking brake switch (1) installed in the operator’s compartment is switched ON, parking brake solenoid valve (4) installed to the transmission control valve (3) shuts off the oil pressure and applies the parking brake. When the parking brake switch is turned OFF, the oil pressure in the cylinder releases the parking brake.
When the parking brake is applied, the neutralizer
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4. Parking brake solenoid valve 5. Transmission (built-in parking brake)
relay shuts off the electric current to the transmission solenoid valve and keeps the transmission at neutral. Emergency release switch (2) for the parking brake is installed for use when moving the machine, if the machine has stopped (the parking brake is automatically applied) because of trouble in the engine or drive system.
STRUCTURE AND FUNCTION
PARKING BRAKE
PARKING BRAKE
Outline The parking brake is a wet-type multiple-disc brake. It is actuated mechanically by a spring and applies the braking force to output shaft (1) of the transmission. The pushing force of spring (5) pushes piston (2), Plate (4), and disc (3) into contact and applies the braking force to stop output shaft (1).
1. 2. 3. 4. 5.
Output shaft Piston Disc Plate Spring
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STRUCTURE AND FUNCTION
PARKING BRAKE SOLENOID VALVE
Operation Parking brake applied (solenoid deactivated) When the parking brake switch in the operator’s compartment is turned ON, the solenoid is turned OFF and spool (6) is pushed to the left by spring (5). When this happens, the passage between pump port P and parking brake port A is closed, and the pressure oil from the pump does not flow to the parking brake. At the same time, the pressure oil from the parking brake flows from port A to port T and is drained. As a result, the disc inside the parking brake is pushed by the spring and the parking brake is applied.
When the parking brake switch is turned OFF, the solenoid is turned ON and spool (6) is moved to the right. As a result, the pressure oil from the pump passes from port P through the inside of spool (6), flows to port A and then flows to the parking brake. At the same time, port To is closed, so the oil is not drained. As a result, the spring inside the parking brake is pushed back by the oil pressure and the parking brake is released.
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PARKING BRAKE SOLENOID VALVE
STRUCTURE AND FUNCTION
PARKING BRAKE SOLENOID VALVE
PARKING BRAKE EMERGENCY RELEASE SOLENOID VALVE
1. Valve assembly 2. Solenoid valve
A: B: C: T: P:
To parking brake From parking brake valve From pilot circuit Drain From brake (accumulator circuit)
Function The emergency release solenoid valve is installed between the transmission and the transmission control valve. If the engine breaks down and no oil pressure is supplied from the transmission pump, it is possible to actuate the solenoid for the parking brake release switch in the operator’s compartment. This allows the accumulator charge pressure in the brake circuit to flow to the parking brake cylinder.
Operation When the parking brake is emergency release turned ON, solenoid valve e pressure stored in the accumulator port P. The circuit is switched by pilot pressure, so the oil flows from port A to the parking brake, to release the parking brake.
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STRUCTURE AND FUNCTION
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MEMORANDA
STRUCTURE AND FUNCTION
HYDRAULIC PIPING
HYDRAULIC PIPING OUTLINE The hydraulic system consists of the work equipment circuit and the steering circuit. The work equipment circuit controls the movement of the bucket and attachment. The oil in hydraulic tank (5) is sent to the main control valve (1) by hydraulic pump (13). When the bucket and boom spools of the main control valve are at HOLD, the oil passes through the drain circuit of the main control valve, is filtered by the filter inside the hydraulic tank, and then returns to the tank. When the work equipment control levers are operated, the bucket or boom spool of the PPC valve (6) moves, and the spools of the main control valve are actuated by hydraulic pressure, so oil flows from the main control valve to boom cylinder (17) or bucket cylinder (2) to move the boom or bucket. Control of the maximum pressure in the hydraulic circuit is carried out by the relief valve inside the main control valve. A safety-suction valve si installed to the bucket cylinder circuit to protect the circuit. Accumulator (10) is installed in the PPC pilot circuit, so this makes it possible to lower the boom to the ground even when the engine si stopped. Hydraulic tank (5) is a pressurized sealed type and is equipped with a breather with relief valve. This compresses the inside of the tank and also prevents negative pressure, so this prevents cavitation of the pump.
1. 2. 3. 4. 5. 6. 7. 8. 9.
Main control valve Bucket cylinder Steering valve Orbit-Roll Hydraulic tank PPC valve Solenoid valve Switch, PPC pump Check
10. 11. 12. 13. 14. 15. 16. 17.
Accumulator Radiator Oil cooler Hydraulic pump Steering pump Cut-off valve Steering cylinder Boom cylinder
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STRUCTURE AND FUNCTION
WORK EQUIPMENT HYDRAULIC CIRCUIT DIAGRAM
WORK EQUIPMENT HYDRAULIC CIRCUIT DIAGRAM (MACHINES WITH STANDARD SPECIFICATIONS) 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13.
14. 15. 16. 17. 18.
19. 20. 21.
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Hydraulic tank Oil filter Breather Switch, PPC pump Torque converter charging pump Hydraulic pump Steering pump Strainer Accumulator charge valve Check valve Accumulator PPC valve Main control valve 13A. Main relief valve 13B. Bucket spool 13C. Safety valve with suction 13D. Unloader valve 13E. Float selector valve 13F. Boom spool 13G. Suction valve 13H. Slow return valve Boom cylinder Bucket cylinder Orbit-roll valve Stop valve Steering valve 18A. Demand spool 18B. Steering spool 18C. Steering relief valve 18D. Safety valve with suction Steering cylinder Cut-off valve Oil cooler
STRUCTURE AND FUNCTION
HYDRAULIC PIPING
REPLACE THIS PAGE WITH FOLDOUT 10-99 WORK EQUIPMENT HYDRAULIC CIRCUIT DIAGRAM (MACHINE WITH OPTIONAL SPECIFICATIONS)
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STRUCTURE AND FUNCTION
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MEMORANDA
STRUCTURE AND FUNCTION
MEMORANDA
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STRUCTURE AND FUNCTION
HYDRAULIC CIRCUIT SYSTEM
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HYDRAULIC CIRCUIT SYSTEM
STRUCTURE AND FUNCTION 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13.
14. 15. 16. 17. 18.
19. 20. 21.
HYDRAULIC CIRCUIT SYSTEM
Hydraulic tank Oil filter Breather Switch, PPC (brake) pump Torque converter charging pump Hydraulic pump Steering pump Filter Accumulator charge valve Check valve Accumulator PPC valve Main control valve 13A. Main relief valve 13B. Bucket spool 13C. Safety valve with suction 13D. Unloader valve 13E. Float selector valve 13F. Boom spool 13G. Suction valve 13H. Slow return valve Boom cylinder Bucket cylinder Orbit-roll valve Stop valve Steering valve 18A. Demand spool 18B. Steering spool 18C. Steering relief valve 18D. Safety valve with suction Steering cylinder Cut-off valve Oil cooler
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STRUCTURE AND FUNCTION
WORK EQUIPMENT LEVER LINKAGE
WORK EQUIPMENT LEVER LINKAGE
1. 2. 3. 4. 5.
Boom lever Kick-down switch Hold switch Bucket lever Attachment lever
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6. 7. 8. 9.
Solenoid valve for bucket lever Solenoid valve for boom lever Safety lever lock PPC valve
STRUCTURE AND FUNCTION
HYDRAULIC TANK
HYDRAULIC TANK
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STRUCTURE AND FUNCTION OPERATION OF OIL FILTER BY-PASS VALVE When the filter is clogged By-pass valve (1) opens and the oil returns directly to the tank without passing through the filter. By-pass valve set pressure: 125 kPa (1.27 kg/cm2)
When negative pressure is formed in the return circuit Valve (2) moves up and acts as a check valve. By-pass valve set pressure: 25.5 kPa (0.26 kg/cm2)
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HYDRAULIC TANK
STRUCTURE AND FUNCTION
HYDRAULIC TANK
BREATHER
1. 2. 3. 4.
Body Filter element Poppet Sleeve
Function Preventing negative pressure inside the tank The tank is a pressurized, sealed type, so negative pressure is formed inside the hydraulic tank when the oil level drops during operations. When this happens, the difference in pressure between the tank and the outside atmospheric pressure opens the poppet (3), and air from the outside is let into the tank to prevent negative pressure.
Preventing rise in pressure inside the tank When the hydraulic cylinders are being used, the oil level in the hydraulic circuit changes and the temperature rises. If the hydraulic pressure rises above set pressure, sleeve (4) is actuated to release the hydraulic pressure inside the tank.
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STRUCTURE AND FUNCTION
ACCUMULATOR (FOR PPC VALVE)
ACCUMULATOR (FOR PPC VALVE) 1. 2. 3. 4. 5. 6.
Gas plug Shell Poppet Holder Bladder Oil port
Specifications: Type of gas:
Nitrogen gas
Gas amount:
500 cc
Actuation Pressure: Maximum: 3.4 MPa (35 kg/cm2) Minimum: 1.2 MPa (12 kg/cm2)
Function The accumulator is installed between the accumulator charge valve and the PPC valve. Even if the engine stops when the boom is raised, it is possible to lower the boom and bucket under their own weight by using the pressure of the nitrogen gas compressed inside the accumulator to send the pilot oil pressure to the main control valve to actuate it.
Operation After the engine stops, if the PPC valve is at hold, chamber A inside the bladder is compressed by the oil pressure in chamber B. When the PPC valve is operated, the oil pressure in chamber B goes below 2.9 MPa (30 kg/cm2). When this happens, the bladder is expanded by the pressure of the nitrogen gas in chamber A, and the oil inside chamber B is used as the pilot pressure to actuate the main control valve.
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STRUCTURE AND FUNCTION
MEMORANDA
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STRUCTURE AND FUNCTION
PPC VALVE
PPC VALVE FOR BUCKET / BOOM
P. From PPC pump. P1. To TILT end of main control valve bucket spool. P2. To LOWER end of main control valve boom spool.
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P3. To RAISE end of main control valve boom spool. P4. To DUMP end of main control valve bucket. T. Drain.
STRUCTURE AND FUNCTION
1. 2. 3. 4. 5.
Bolt Piston Plate Collar Retainer
PPC VALVE
6. 7. 8. 9.
Centering spring Metering spring Valve Body
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STRUCTURE AND FUNCTION FOR OPTION
P. P2. P3. T.
From PPC pump. To main control valve attachment spool. To main control valve attachment spool. Drain.
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PPC VALVE
STRUCTURE AND FUNCTION
1. 2. 3. 4. 5.
Bolt Piston Plate Collar Retainer
PPC VALVE
6. 7. 8. 9.
Centering spring Metering spring Valve Body
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STRUCTURE AND FUNCTION OPERATION OF PPC VALVE (At neutral)
The oil from the PPC pump enters port P of the PPC valve, but the circuit is closed by spool (8), so the oil is drained from the relief valve (1). At the same time, the oil at port PA1 of the main control valve is drained from port f of spool (8). In addition, the oil at port PB1 is drained from port g of spool (10).
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PPC VALVE
STRUCTURE AND FUNCTION
PPC VALVE
FUNCTION OF PPC VALVE The ppc valve supplies pressure oil from the charging pump to the side face of the spool of each control valve according to the amount of travel of the control lever. This pressure oil actuates the spool.
Operation 1. Control lever at "hold". (Fig. 1) Ports PA1, PA4, PB1, and P1 are connected to drain chamber D through fine control hole (f) in valve (8).
2. Control lever operated slightly (fine control) (Fig. 2) When piston (2) starts to be pushed by plate (10), retainer (5) is pushed. Valve (8) is also pushed by spring (7) and moves down. When this happens, fine control hole (f) is shut off from drain chamber D. At almost the same time it is connected to pump pressure chamber PP, and the pilot pressure of the control valve is sent through fine control hole (f) to port P4. When the pressure at port P4 rises, Valve (8) is pushed back. Fine control hole (f) is shut off from pump pressure chamber PP. At almost the same time it is connected to drain chamber D, so the pressure at port P4 escapes to drain chamber D. Valve (8) moves up and down until the force of spring (7) is balanced with the pressure of port P4. The position of valve (8) and body (9) (when fine control hole (f) is midway between drain chamber D and pump pressure chamber PP) does not change until the head of valve (8) contacts the bottom of piston (2). Therefore, spring (7) is compressed in proportion to the travel of the control lever, so the pressure at port P4 also rises in proportion to the travel of the control lever. The spool of the control valve moves to a position where the pressure of port PA1 (same as pressure at port P4) and the force of the return spring of the control valve are balanced.
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STRUCTURE AND FUNCTION 3. Control lever moved back from slightly operated position to hold (Fine control) (Fig. 3) When plate (10) starts to be pushed back, piston (2) is pushed up by a force corresponding to the force of centering spring (6) and the pressure at port P4. At the same time, fine control hole (f) of valve (8) is connected to drain chamber D, so the oil at port P4 escapes. If the pressure at port 4P 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 camber D flows in from fine control hole (f1) of the valve which has not moved. The extra oil then flows through port P1 to chamber PB1.
4. Control lever operated to end of travel (Fig. 4) Plate (10) pushes piston (2) down, and piston (2) forcibly pushes in valve (8). Fine control hole (f) is shut off from drain chamber D, and is connected to pump pressure chamber PP. Therefore, pressure oil from the charging pump passes through fine control hole (f), and flows from port P4 to chamber PA1 to push the spool of the control valve. The oil returning from chamber PB1 flows from port 1P through fine hole (f1) to drain chamber D.
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PPC VALVE
STRUCTURE AND FUNCTION
PPC RELIEF VALVE
PPC RELIEF VALVE
1. 2. 3. 4. 5. 6.
Main valve Spring Valve seat Pilot poppet Spring 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 abnormal pressure is generated, the oil sent from the pump is relieved through this valve to protect the pump and circuit from damage.
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 of 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 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 in 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.
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STRUCTURE AND FUNCTION
CUT-OFF VALVE
CUT-OFF VALVE
1. 2. 3. 4.
Unload valve Check valve Cut-off valve Screen
C. P. T1. T2.
Port C (from hydraulic pump) Port P (From steering valve) Port T1 (to tank) Port T2 (to tank)
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Function The cut-off valve is installed between the switch pump and the main control valve. Depending on the operating condition, it switches the oil from the switch pump to the main control valve or to the drain circuit. The cut-off valve is operated by hydraulic pressure.
STRUCTURE AND FUNCTION
CUT-OFF VALVE
OPERATION OF CUT-OFF VALVE Cut-off operation conditions O: Cut-off (drain) X: Not actuated (to main control valve) More than 17.2 MPa (175 kg/cm2)
Less than 17.2 MPa (175 kg/cm2)
Kick-down switch “ON”
O
X
X
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.
2. When the work equipment valve is activated. 1) When the work equipment pump pressure is lower than the cut-off pressure. As when the work equipment valve is held, the oil at the switch pump (the oil from the steering valve) pushes up check valve (1), merges with the oil from the work equipment pump and flows to the work equipment valve.
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STRUCTURE AND FUNCTION 1) When the work equipment pump pressure 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 orifices 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.
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CUT-OFF VALVE
STRUCTURE AND FUNCTION
MEMORANDA
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STRUCTURE AND FUNCTION
MAIN CONTROL VALVE
MAIN CONTROL VALVE
PA1. PA2. PB1. PB2. P. P1. P2.
From PPC valve P4 From PPC valve P2 From PPC valve P1 From PPC valve P3 From pump From PPC valve P2 From PPC valve P3
A1. To bucket cylinder bottom end
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A2. To boom cylinder bottom end B1. To bucket cylinder head end B2. To boom cylinder head end D1. Drain port D2. Drain port T. Drain port
STRUCTURE AND FUNCTION
1. 2. 3. 4. 5.
Main relief valve Bucket spool return spring Boom spool return spring Boom spool Bucket spool
MAIN CONTROL VALVE
6. 7. 8. 9. 10.
Body Suction valve Unloader valve Safety valve (with suction) Float selector valve
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STRUCTURE AND FUNCTION
A1. A2. A3. B1. A2. A3.
To attachment cylinder To bucket cylinder bottom To boom cylinder bottom To attachment cylinder To bucket cylinder head To boom cylinder head
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MAIN CONTROL VALVE
D1. Drain port D2. Drain port P. From pump P1. From PPC valve P2 P2. From PPC valve P3 PA1. From option PPC valve
PA2. PA3. PB1. PB2. PB3. T.
From PPC valve P4 From PPC valve P2 From option PPC valve From PPC valve P1 From PPC valve P3 Drain port
STRUCTURE AND FUNCTION
1. 2. 3. 4. 5. 6.
Main relief valve Attachment spool return spring Bucket spool return spring Boom spool return spring Boom spool Bucket spool
MAIN CONTROL VALVE
7. 8. 9. 10. 11. 12.
Attachment spool Body Unloader valve Suction valve Safety valve (with suction) Float selector valve
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STRUCTURE AND FUNCTION
MAIN CONTROL VALVE
Outline The main control valve controls the actuation of the attachments and the bucket in the hydraulic system. It has a tandem circuit which gives priority to the bucket circuit. The oil from the pump enters port P. The maximum pressure is set by the main relief valve. The oil passes through the by-pass circuit of dump spool (5) and lift spool (4). It then flows from port T to the drain circuit, passes through the filter and returns to the tank. If the dump and lift spools are actuated, the oil flows to the dump and lift cylinders.
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However, the circuit gives priority to the bucket, so when the dump spool is being operated, even if the lift spool is operated, the lift arm will not move. There are two safety valves (with suction valves) (10) to protect the circuit if abnormal pressure is generated in the bucket circuit. If one of the two safety valves is acting as a relief valve, the other valve acts as a suction valve to make up for any lack of oil.
STRUCTURE AND FUNCTION
MEMORANDA
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STRUCTURE AND FUNCTION
MAIN CONTROL VALVE
RELIEF VALVE 1. 2. 3. 4. 5. 6.
Main valve Valve seat Pilot poppet Pilot poppet spring Adjustment screw Lock nut Set pressure:
Function The relief valve is installed to the inlet portion of the main control valve. If the oil goes above the set pressure, the relief valve drains the oil to the tank to set the maximum pressure for the work equipment circuit, and to protect the circuit.
Operation Port A is connected to the pump circuit and port B is connected to the drain circuit. The oil passes through the orifice of the main valve (1) and fills port B. Pilot poppet (3) is seated in valve seat (2). If the pressure port A and port B reaches the set pressure of pilot poppet spring (4), pilot poppet (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 port A and port 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 flows to the drain circuit to release the abnormal pressure. The set pressure can be varied by changing the tension of pilot poppet spring (4). To change the set pressure, remove cap nut, loosen lock nut (6) and turn adjustment screw (5), to adjust the set pressure as follows: Tighten to increase pressure Loosen to decrease pressure
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20.6 MPa (210 kg/cm2)
STRUCTURE AND FUNCTION
MAIN CONTROL VALVE
SAFETY VALVE (WITH SUCTION)
1. 2. 3. 4. 5. 6.
Suction valve Main valve Main valve spring Pilot piston Suction valve spring Valve body
Set pressure:
22.6 MPa (230 kg/cm2)
Function The safety valve is in the bucket cylinder circuit inside the main control valve. If any abnormal pressure is generated by any shock to the cylinder when the main control valve is at the neutral position, this valve relieves the abnormal pressure to prevent damage to the cylinder.
Operation 1. 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 relationship: d2 > d1 > d3 > d4. If abnormal pressure is created at port A, suction valve (1) is not actuated because of relationship d2 > d1 >, but relationship between port A and port C is d3 > d4 , so main valve (2) receives oil pressure equivalent to the difference between the areas of d3 and d4 . If the oil pressure reaches the force (set pressure) of main valve spring (3), main valve (2) is actuated, and the oil from port A flows to port B.
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STRUCTURE AND FUNCTION
MAIN CONTROL VALVE
2. Operation as suction valve If any negative pressure is generated at port A, port D is connected with port A, so there is also a negative pressure at port D. The tank pressure of port B is applied to port E, so the safety valve receives oil pressure a, which is equal to the difference in the area of d2 and d1 because of the tank pressure at port E. Therefore, oil pressure e moves the valve in the direction of opening, and oil pressure a acts to move suction valve (1) in the direction of closing. When the pressure at port A drops (and comes close to negative pressure), it becomes lower than hydraulic pressure e. The relationship becomes oil pressure e > oil pressure a + force of valve spring (5), and suction valve (1) opens to let the oil from port B flow into port A and prevent any negative pressure from forming at port A.
SUCTION VALVE
1. Main poppet 2. Sleeve 3. Spring
Function This valve acts to prevent any negative pressure 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 poppet (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.
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STRUCTURE AND FUNCTION FLOAT SELECTOR UNLOADER VALVE
VALVE
MAIN CONTROL VALVE AND
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 position.
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 setting valve fills chamber F and chamber E.
If the difference in pressure between port A and port B becomes greater than the specified pressure, float selector valve (2) is moved to the right, and port C and port D open. When port C opened, the oil pressure in chamber E drops, unload valve (4) is moved up in the direction of the arrow, and the oil from the pump flows to the drain circuit, and also flows to the rod end of the boom cylinders. The oil at the bottom end of the boom cylinders is connected to the drain circuit and forms the FLOAT position.
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STRUCTURE AND FUNCTION
MAIN CONTROL VALVE
BOOM SPOOL AT RAISE POSITION
Operation The oil from the pump enters port A and the maximum pressure is set by the relief valve (11). Bucket spool (1) is at HOLD, so the by-pass circuit is open. The oil at port A passes around the spool and flows to port B. Boom spool (2) is also at HOLD, so the by-pass circuit is open. The oil at port B passes around the spool and flows to port C in the drain circuit. From here it passes through the filter and returns to the tank.
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The oil from the PPC pump passes through check valve (13) and enters port L of the PPC valve. However, the boom and bucket levers are at the HOLD position, so the oil returns from PPC relief valve (12) to the hydraulic tank.
STRUCTURE AND FUNCTION
MAIN CONTROL VALVE
BOOM SPOOL AT RAISE POSITION
Operation When boom lever (3) is pulled, pressure oil from port L of the PPC valve flows to port N and port S. The oil in port T passes through port M and flows to the drain circuit. The pressure oil in port S pushes the push piston against the force of the spring and moves boom spool (2) to the RAISE position.
open check valve (10). The oil then flows from port H to port I, and goes to the bottom end of the cylinder. At the same time, the oil at the rod end of the cylinder flows from port K to drain port C, and returns to the tank. Therefore, the boom rises.
The oil flows from the pump through the by-pass circuit of the bucket spool, and then flows to the bypass circuit of boom spool (2). The by-pass circuit is closed by the spool, so the oil pushes
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STRUCTURE AND FUNCTION
MAIN CONTROL VALVE
BOOM SPOOL AT LOWER POSITION
Operation When boom lever (3) is pushed, pressure oil from port L of the PPC valve flows to port M and port T. In addition the oil at port S is connected to the drain circuit. The pressure oil at port T pushes the push piston against the force of the spring and moves boom spool (2) to the LOWER position The oil from the pump passes through the by-pass circuit of the bucket spool and flows to the by-pass circuit of boom spool (2). The by-pass circuit is closed by the spool, so the oil pushes open check
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valve (10). The oil then flows from port J to port K, and goes to the rod end of the cylinder. At the same time, the oil at the bottom end of the cylinder flows from port I to drain port C, and returns to the tank. Therefore, the boom goes down.
STRUCTURE AND FUNCTION
MAIN CONTROL VALVE
BOOM SPOOL AT FLOAT POSITION
Operation When boom lever (3) is pushed to the FLOAT position, the spool of the PPC valve moves further from the LOWER position to the FLOAT position. Pressure oil at port L flows to port M, and at the same time, it also flows to port T and port W. In addition, the pressurized oil at port S flows to port N. The pressure oil at port T pushes the push piston against the force of the spring and moves boom spool (2) to the LOWER position. If the pressure difference between port W and port X goes above the specified level, valve (7) moves to the right and opens ports C1 and C to connect them
to the drain circuit. When port C1 1 is connected to the drain circuit, unload valve (8) moves up, and the oil from the pump flows to the drain circuit. Therefore, the oil at the rod end of the cylinder flows from port K, and then flows from unload valves (8) to the drain circuit. At the same time, the oil at the bottom end of the cylinder flows from port I to port C, and then flows to the drain circuit. Therefore, the boom is set to the FLOAT condition.
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STRUCTURE AND FUNCTION
MAIN CONTROL VALVE
BUCKET SPOOL AT DUMP POSITION
Operation When bucket lever (4) is pushed, pressure oil from port L of the PPC valve flows to port V via port Q. In addition, the oil at port R is connected to the drain circuit. The pressure oil at port V pushes the push piston against the force of the spring and moves bucket spool (1) to the DUMP position. The by-pass circuit is closed by bucket spool (1), so the oil from port A pushes open check valve (9). The oil from check valve (9) then flows from port F and enters port G, and goes to the rod end of the cylinder.
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At the same time, the oil at the bottom end of the cylinder flows from port D to drain port C, and returns to the tank. Therefore, the bucket is dumped.
STRUCTURE AND FUNCTION
MAIN CONTROL VALVE
BUCKET SPOOL AT TILT POSITION
Operation When bucket lever (4) is pulled, the pressure oil at port L of the PPC valve flows to port R via port P. The oil in port V is connected to the drain circuit. The pressure oil at port R pushes the push piston against the force of the spring and moves bucket spool (1) to the TILT position. The by-pass circuit is closed by bucket spool (1), so the oil from port A pushes open check valve (9). The
oil from check valve (9) flows from port D to port E, and goes to the bottom end of the cylinder. At the same time, the oil at the rod end of the cylinder flows from port G to drain port C, and returns to the tank. Therefore, the bucket is tilted.
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STRUCTURE AND FUNCTION
WORK EQUIPMENT LINKAGE
WORK EQUIPMENT LINKAGE
1. 2. 3. 4. 5.
Bucket Bellcrank Bucket cylinder Boom cylinder Boom
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6. 7. 8. 9.
Bucket link Bucket hinge pin Cord ring Cord ring
STRUCTURE AND FUNCTION
WORK EQUIPMENT LINKAGE
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STRUCTURE AND FUNCTION
BUCKET
1. Bucket 2. Tooth 3. Corner tooth
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BUCKET
STRUCTURE AND FUNCTION
MEMORANDA
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STRUCTURE AND FUNCTION
BUCKET POSITIONER / BOOM KICK-OUT
BUCKET POSITIONER AND BOOM KICK-OUT
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STRUCTURE AND FUNCTION
BUCKET POSITIONER / BOOM KICK-OUT
Bucket positioner The bucket positioner is electrically actuated and is used to automatically obtain the optimum digging angle for the bucket. When the bucket is moved from the DUMP position to the TILT position, and it reaches the desired angle, the dump lever is automatically moved from the TILT position to the neutral. Lever (4) is secured by bolts to dump cylinder rod (3). A proximity switch (1) is fixed by bolts to the cylinder. When the bucket is moved from the DUMP position to the TILT position, the dump cylinder rod moves to the left. At the same time, lever (4) also moves to the left. When it reaches the desired position, lever (4) separates from proximity switch, and the bucket lever returns to neutral.
Boom kick-out The boom kick-out is electrically operated and acts to stop the lift arm. When the lift arm reaches the desired position before the maximum height, the lift arm lever is returned to neutral. Plate (5) is secured to the lift arm. A proximity switch (2) is fixed to the frame. When the lift arm is moved from the LOWER position to the RAISE position, the lift arm rises. When it reaches the desired position, the proximity switch and plate come into contact and the lift arm lever is returned to neutral.
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STRUCTURE AND FUNCTION
PROXIMITY SWITCH
PROXIMITY SWITCH Function Proximity switches are installed by a support to the boom and bucket cylinders. The lift arm RAISE position and the TILT BACK position can be selected to match the operating conditions. When these positions are reached, a pulse is generated from the
Operation of Proximity Switch BOOM RAISE When the boom is lower than the set position for the boom kick-out, the detection unit (steel plate) is on the sensing surface of the proximity switch. Electricity flows through the proximity switch. The relay switch is at OFF and the electric current of the magnet switch coil is shut off.
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switch, the electric current flows to a magnet and the lift or dump lever is returned to the hold position. When this happens, the main control valve is also returned to hold and the movement of the lift arm or bucket stops.
STRUCTURE AND FUNCTION
PROXIMITY SWITCH
When the boom lever is moved to the RAISE position, the lever cam and the cam follower keep the lift spool in the RAISE position, so the boom arm goes up.
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STRUCTURE AND FUNCTION
PROXIMITY SWITCH
Kick-out When the boom goes up and reaches the set position for the kick-out (that is, the detection unit (steel plate) is separated from the sensing surface of the proximity switch), the proximity switch and
relay circuit act to send electric current to the magnet coil. This actuates the magnet, the cam is pulled out of the cam detent, and the lift spool is returned to the neutral position by the return spring.
Action of proximity switch Position
Proximity switch actuation display
When detector is in position at detection surface of proximity switch
When detector is separated from detection surface of proximity switch
Lights up
Goes out
Proximity switch load circuit (relay switch circuit)
Current flows
Current shut off
Relay switch load circuit (Solenoid circuit)
Current flows
Current shut off
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STRUCTURE AND FUNCTION
PROXIMITY SWITCH
BUCKET "TILT" Hold When the bucket is dumped beyond the set position for the bucket leveler, the sensor (steel plate) is above the detection surface of the bucket proximity switch, so electric current flows in the proximity switch load circuit. The positioner relay is turned ON and the current for the solenoid is shut off.
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STRUCTURE AND FUNCTION Tilt When the bucket lever is moved to the TILT position, the bucket spool is held at the TILT position by the cam follower and cam on the lever, and the bucket tilts.
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PROXIMITY SWITCH
STRUCTURE AND FUNCTION
PROXIMITY SWITCH
Positioned When the bucket tilts and reaches the set position for the bucket leveler (that is, the detection unit (steel plate) is separated from the sensing surface of the proximity switch), the proximity switch and relay circuit act to send electric current to the magnet coil. This actuates the magnet, the cam is pulled out of the cam detent, and the dump spool is returned to the neutral position by the return spring.
Action of proximity switch Position
Proximity switch actuation display Positioner relay Solenoid (for bucket)
When sensor is in position at detection surface of proximity switch
When sensor is separated from detection surface of proximity switch
Lights up
Goes out
Current flows
Current shut off
Current shut off
Current flows
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STRUCTURE AND FUNCTION
CAB
1. 2. 3. 4.
Front glass Front wiper Rear wiper Door
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CAB
STRUCTURE AND FUNCTION
ROPS CANOPY
ROPS CANOPY
1. ROPS guard 2. Cab
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STRUCTURE AND FUNCTION
AIR CONDITIONER
AIR CONDITIONER AIR CONDITIONER PIPING
1. 2. 3. 4. 5.
Vent Window defroster Vent Dry receiver Air conditioner condenser
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6. 7. 8. 9.
Compressor Hot water inlet port Hot water outlet port Air conditioner unit
STRUCTURE AND FUNCTION
AIR CONDITIONER
AIR CONDITIONING (GENERAL) BASIC INFORMATION ON AIR CONDITIONERS UNITS RELATED TO REFRIGERATION Heat The kinetic energy of the molecular activity of a substance takes the form of heat. If a substance is given heat by any other substance, its temperature will rise. If heat is taken away by another body, the temperature will decrease. 1. Quantity of heat. If the heat is transferred from one substance to another, the temperatures of both substances will change. The amount of change in temperature will depend on the quantity of heat transferred. The quantity of heat is indicated in units of calories (cal) or kilocalories (Kcal). One cal denotes the quantity of heat required to raise the temperature of 1g of water by 1 degree. One Kcal denotes the quantity of heat required to raise the temperature of 1 kg of water by 1 degree. 2. Specific heat. The quantity of heat required to raise or lower the temperature of substance varies depending on the type, weight, and amount of change in temperature of the substance. The quantity of heat required to raise the temperature of one unit weight of a substance by 1 degree is called the "specific heat" of the substance. The unit of the specific heat is "kcal/kg C”. The specific heat is often indicated with a numerical value without the unit. The larger the specific heat of a substance, the more difficult it is for the substance to warm up and cool down. The specific heat of water is 1, the largest value of any solid or liquid. Substance
Specific heat (Kcal/kg
Water
1.0
Alcohol
0.57
Ice
0.49
Iron
0.11
Copper
0.09
Aluminum
0.21
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STRUCTURE AND FUNCTION Temperature When cooling or warming a substance, the units of warmth or coolness measurement are expressed as degrees C (Centigrade) or F (Fahrenheit). 1. Scales of temperature. The temperature at which water freezes at the standard barometric pressure (1 barometric pressure) (the "freezing point"): Centigrade . . . . . . . . . . . . . . . . 0 degree ( C) Fahrenheit . . . . . . . . . . . . . . . 32 degrees ( F) Temperature at which water boils at the standard barometric pressure (the "boiling point"): Centigrade . . . . . . . . . . . . . . . 100 degrees ( C) Fahrenheit . . . . . . . . . . . . . . . 212 degrees ( F) On the Centigrade scale, the scale is equally divided into 100 graduations ranging from 0 to 100 degrees. One graduation is 1 e below the freezing point (a sub-zero temperature) is indicated by a negative number, such as -a On the Fahrenheit scale, the scale is divided into 180 graduations ranging from 32 to 212 degrees. One graduation is 1 F is called sub-zero temperature and indicated by a negative number, such as -B F. Relationship between the Centigrade and the Fahrenheit scales: Centigrade and Fahrenheit temperatures can be converted according to the following formulas: Centigrade temperature ( Fahrenheit temperature (
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AIR CONDITIONER
STRUCTURE AND FUNCTION
AIR CONDITIONER
2. Absolute temperature (Kelvin scale) At zero degrees on the absolute scale ("absolute zero"), the molecular activity of all substances ceases. Absolute temperature, lowest temperature in the natural world, often is for theoretical studies. Relationships between the absolute temperature scale and the Centigrade and Fahrenheit temperature scales: 0 C is 273 e absolute temperature system. One degree in the Kelvin scale equals one degree in the Centigrade scale. On the Fahrenheit temperature scale, 0 s equivalent to 460 degree in the Rankine scale is equivalent to one degree on the Fahrenheit scale. Thus, their relationships are as follows: Absolute temperature ( 0 Absolute temperature ( 0 Pressure The force acting on a unit area is called "pressure". Normally, the force acting on a unit area of 1 cm² is indicated in unit of kg. Unit of pressure: kg/cm². 1. Absolute pressure. The pressure actually imposed on the wall of a vessel by the gas inside is called “absolute pressure”. The “complete vacuum pressure”, in which no molecular activity occurs, is defined as the zero pressure. The absolute pressure is used in the same manner as the absolute temperature when treating problems theoretically. The unit of absolute pressure is kg/cm² abs. 2. Gauge pressure. The pressure measured with a pressure gauge at zero barometric pressure is called the gauge pressure. This pressure indicates the difference between the absolute pressure and the atmospheric pressure. For a theoretical calculation, the gauge pressure must be converted into the absolute pressure. In most cases, pressure refers to the gauge pressure. The unit gauge pressure is kg/cm² g, which distinguishes it from ordinary pressure. 3. Atmospheric pressure. This is the pressure of the air. The standard atmospheric pressure is 1.03 kg/cm² abs. at sea level, equivalent to a mercury column of 760 mm (Hg) or to a water column of 10.3 m. The relationship between the absolute pressure and the gauge pressure is simple:Absolute pressure = Gauge pressure + Atmospheric pressure. Even if the gauge pressure of a gas in a container is zero, the gas is actually subject to a pressure of 1.03 kg/cm² abs.
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STRUCTURE AND FUNCTION 4. Vacuum and the degree of the vacuum. Normally, a pressure gauge has a red zone on its scale to indicate the pressure below 0 kg/cm². Any gas pressure indicated in the red zone is below the atmospheric pressure. The term "vacuum" refers to a given space filled with gas at a pressure below the atmospheric pressure. A “perfect vacuum” refers to a space completely empty of gas pressure (an absolute pressure of 0 kg/cm² abs). The degree of vacuum applies to the static pressure below the atmospheric pressure and is indicated in terms of absolute pressure in units of cm Hg. On the gauge scale, the atmospheric pressure is set at zero and the perfect vacuum is set at 76 cm Hg. To convert the reading, h cm Hg, of the vacuum gauge into the absolute pressure P kg/cm² abs., the following formula is used: P = 1.03 x (1 - h/76) In this case, the degree of vacuum is (76-h) cm Hg. Humidity The amount of water contained in the air is called the humidity. Humidity is generally classified into absolute humidity and relative humidity. 1. Absolute humidity. The absolute humidity is the weight of moisture per kg of dry air contained in the wet air, expressed in units of x kg/kg. Practically, an air diagram is used to indicate the weight of moisture contained in 1 kg of wet air. For example, if 30 g of moisture is contained in 1 kg of wet air, the absolute humidity on the air diagram is indicated as follows: Absolute humidity = 0.03 (kg)/1 (kg) = 0.03 kg/kg.
2. Relative humidity. The ratio between the water partial pressure P (kg/cm²) of the wet air and the max. partial pressure Ps contained in the water at that humidity (the water partial pressure of the saturated air) is called the "relative humidity". That is, Relative humidity = P/Ps x 100 (%). Generally, when we speak of humidity, we mean relative humidity. This is the humidity obtained from a home hygrometer or a weather forecast.
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AIR CONDITIONER
STRUCTURE AND FUNCTION
AIR CONDITIONER
PRINCIPLE OF COOLING 1. Why do coolers cool? We have all experienced the cold feeling when we are sweating and the wind blows, or when we put a liquid like alcohol on our skin. This feeling occurs because water and alcohol draw heat from the surrounding area when evaporating and turning into gas. If we express this another way, if we apply heat to a liquid it turns into gas. This is called evaporation latent heat. In a cooler, freon (R134a) is used instead of alcohol. When the liquid freon (R134a) turns into gas, it takes latent heat from its surroundings. However, if it is allowed to disperse as a gas, this is uneconomical. We need a device which can collect this gas and turn it back into liquid before evaporating it again, and then repeat this cycle continuously. A cooler is such a device. The fluid which turns into a liquid and then becomes a gas to cool the surroundings is called the refrigerant. 2. Refrigerator using evaporation latent heat The liquid refrigerant freon (R134a) is sent under high pressure through a valve where it is allowed to expand and is sent to the heat exchanger. The refrigerant takes heat from the air in the room (or cab) sucked in by low pressure vapor (moist vapor), turns into gas (super heated vapor) and is discharged. The air which has lost its heat is blown into the cooled room. This is the basic principle of the cooler, but using only this device to cool is uneconomical and not very practical. 3. Refrigeration method (Vapor compression) The refrigerant gas is compressed by a compressor (adiabatic compression) and changes to high temperature and high compression. It is then sent to the condenser and undergoes forced cooling in the condenser to be turned to liquid. If this liquefied refrigerant is expanded suddenly at the expansion valve, it changes into a low temperature and low pressure mist and flows inside the evaporator. The refrigerant, which enters the evaporator as a mist, passes through the fins of the evaporator and takes latent evaporation heat from the surrounding air. This causes it to evaporate and turn to its original gaseous condition. In this way it acts to cool the surrounding air.
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STRUCTURE AND FUNCTION 4. Refrigerating cycle The refrigerating cycle of an air conditioner consists of the compressor, condenser, expansion valve, and evaporator as shown in the diagram. Refrigerant is circulated in this sealed circuit (refrigeration cycle), and heat is transferred from the low temperature source (air inside the operator's compartment) to the high temperature source (outside air) to give the cooling. This is called the evaporation compression refrigeration system, the most widely used form of cooling used for bus coolers, room air conditioners, and small refrigerators. A) Flow of refrigerant 1) The liquid refrigerant which leaves the receiver is expanded suddenly at the expansion valve. It becomes a low temperature, low pressure mist and flows to the evaporator. 2) The refrigerant mist which flows into the evaporator takes heat from the air (air inside the operator's compartment) at the surface of the evaporator. It evaporates and is further heated, and is then sucked into the compressor as a gaseous refrigerant. The air inside the operator's compartment is sucked into the cooling unit by a fan, is cooled on the evaporator surface, and is then sent out into the operator's compartment again. 3) The gaseous refrigerant evaporated in the evaporator is sucked into the compressor. 4) The gaseous refrigerant is compressed in the compressor, and is then sent to the condenser at high temperature and high pressure. 5) In the condenser, the gaseous refrigerant is cooled. It becomes a liquid refrigerant again and flows to the receiver. By repeating the above steps (1) to (5), the heat is taken from the air at the surface of the evaporator, and heat is dissipated to the air at the surface of the condenser to produce cooling inside the operator's compartment. Note:
The temperature and pressure of the refrigerant vary according to the air flow and temperature of the front surface of the condenser.
In this way, the refrigerant circulates during the refrigeration cycle to carry out the refrigeration action. In refrigerators using the evaporation latent heat of the refrigerant at present used, if the gaseous refrigerant is not liquefied at near normal temperature, it cannot take evaporation latent heat from the surrounding material to carry out refrigeration (cooling).
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AIR CONDITIONER
STRUCTURE AND FUNCTION
AIR CONDITIONER
Generally speaking, for a gas to be liquefied, it must be pressurized. However, if it is cooled at the same time as being pressurized, it can be liquefied easily. For this reason, compressors and condensers are needed in the present refrigerating systems. B) Properties of R-134a Using R-134a as an example, let us explain how the refrigerant can be liquefied. High temperature (70 5 kg/cm²) gaseous refrigerant is compressed in the compressor. It then enters the condenser where it is cooled and liquefied. R-134a starts to liquefy at about 62 5 kg/cm², so the temperature of the refrigerant need only be brought below 62
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STRUCTURE AND FUNCTION
AIR CONDITIONER
C) Temperature and pressure in the refrigeration cycle
1. Receiver 2. Evaporator 3. Condenser
In the refrigeration cycle, the refrigerant transforms from a liquid to a gas (evaporation) and from a gas to a liquid (condensation). Both the temperature and pressure of the refrigerant vary throughout the refrigeration cycle. The figure above indicates variations of the temperature and pressure in the refrigeration cycle. (The numbers in the diagram are taken from the design values of a standard air conditioner, and are given only for reference. These values vary depending on the conditions for the actual cycle).
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4. Compressor 5. Blower 6. Expansion valve
STRUCTURE AND FUNCTION
AIR CONDITIONER
5. Heating cycle The heating cycle uses cooling water taken from the engine cooling system. A) The cooling water absorbs the heat from the engine, and its flow is controlled by the water valve to enter the heater core. B) In the heater core, the heat of the cooling water is transferred to the air at the surface of the core. C) The heat is sent by the blower to the operator's compartment. D) The cooling water which has given up its heat in the heater core returns to the engine. By repeating the above steps (A) to (B), the inside of the operator's compartment is heated.
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STRUCTURE AND FUNCTION REFRIGERANTS The refrigerant plays the most important role in the refrigeration cycle. Various kinds of refrigerants are available for various types of applications. The most critical characteristic of a refrigerant is the ease with it liquefies and vaporizes at normal or low temperatures. However, only a few kinds of refrigerants are used in air conditioners, depending on various conditions, such as the type of compressor, evaporation temperature (pressure), and condensation temperature (pressure). Ammonia and freon type gases, which satisfy the requirements, are widely used. Air conditioners usually use "freon type" gases because of their safety and the small size required for a refrigeration system. Freon-type gases Components in this system are compatible with Refrigerant 134a (CCL2F2 Dichlorodifluoromethane). Use of other refrigerants would not achieve performance characteristics, and more importantly, would, in most cases, chemically deteriorate components. SAFETY PRECAUTIONS WARNING! The refrigerant R-134a can be a fire and health hazard if handled incorrectly. Avoid contact with the substance and never expose it to extreme heat, sparks or open flame. The substance used in the air conditioning system, called R-134a is basically a safe, non-toxic refrigerant. However, when it is exposed to an open flame, it changes to a very highly poisonous and deadly phosgene gas. This phosgene gas will tarnish bright metal surfaces. The liquid refrigerant will boil (or vaporize at -29.8 (-21.7 F) at atmospheric pressure (or when it is exposed to the air). It also evaporates so rapidly that the gas may displace the oxygen in the area, if it happens to be a small enclosed area. Therefore, whenever the system is worked on, a safe practice would be to work on it in a well ventilated area. The refrigerant, when exposed to the air, is approximately -29 C (-21 F). Upon contact with the skin, the effect is just like frostbite. Treat the same as you would for frostbite. If the refrigerant contacts the eyes, immediately flush the eyes with water and continue to do so until the temperature is above the freezing point. Consult an eye specialist immediately. Blindness could result from an injury of this sort and it is highly recommended that safety goggles be worn whenever servicing the system
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AIR CONDITIONER
STRUCTURE AND FUNCTION
AIR CONDITIONER
If the air conditioning system must be discharged, do it out of doors or in a well ventilated area where no extreme heat or open flame is present. Release the refrigerant slowly as it will suck the oil from the compressor if the system is opened too fast. Always use the correct type of hoses for the air conditioning system. Do not use any hose which is not specified for refrigeration use. Never apply heat of any sort on any of the air conditioning hoses or components of the system while it is charged. The extra heat could cause the pressure of the refrigerant in the system to become excessive and cause a dangerous rupture. Be sure the pressurized refrigerant containers are never exposed to or stored in an area where the temperature could exceed 52 Do not discard empty refrigerant containers where they might be subjected to a temperature of 52 or higher. Do not add alcohol or other liquid driers to the system to prevent freeze-up. The desiccant in the dryer prefers alcohol to water and will discharge moisture to absorb alcohol. Refrigerant oil is the exception to the rule that water and oil do not mix. If left in an open container it will absorb moisture and may cause freeze-ups at the expansion valve or sludge build up. Use only refrigerant oil in the compressor. Remember: 1. Wear safety goggles. 2. Keep refrigerant away from heat, flame or sparks. 3. Do not smoke or have an open flame near when discharging refrigerant. 4. Work in a well ventilated area. 5. Avoid physical contact with refrigerant. REFRIGERATOR OIL (LUBE OIL) The lubricant used in air conditioners is generally called refrigerator oil. Its purpose in the compressor is to minimize wear of the piston, cylinder walls, and other frictional parts like bearings, and to prevent them from seizing by removing the heat created by friction. In addition, the substance helps prevent leakage of refrigerant by maintaining a uniform thin oil film on the contact surface of parts.
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STRUCTURE AND FUNCTION Freon type refrigerant dissolves in oil better than ammonia does. When the freon is dissolved in oil, the freezing point of the oil goes down, which causes no hindrance to the use of the oil at low temperatures. The flash point and the ignition point of the refrigerant oil are ordinarily 160 , respectively. The lube oil for air conditioners will contact refrigerant. Thus, the viscosity of the oil when mixed with refrigerant is an important factor in the selection of the refrigerant oil. The lube oil used in air conditioners is a mineral oil refined from petroleum, and various types are available. The refrigerant has a large effect on the durability of the compressor and therefore, the oil must conform to that specified for each compressor. Characteristics of SUNISO (SUNISO is a U.S. specification) refrigerator oil:. 1. Chemical stability The oil is resistant to chemical reactions with the refrigerant or any other substance in the system. 2. Thermal stability No carbon deposits are formed at high temperatures in the valve and delivery (discharge) portion of the compressor. 3. Low wax content The flocculent material does not separate from the oil-refrigerant mixture in the low-temperature portion of the refrigeration system. 4. Low pour point The oil in the refrigeration system does not freeze because the pour point is lower than the lowest temperature in the system. 5. High insulation resistance 6. Proper viscosity Excessive wear of the compressor is prevented because the proper viscosity is maintained even at high temperatures. Sufficient fluidity of the oil is maintained at low temperatures and a satisfactory oil film is formed at all times. 7. Cleanliness of oil No dust, or foreign matter that accelerate the deterioration of oil are mixed in the oil. Thus, the cylinder liners and bearings will not get flawed and oil grooves will not get clogged.
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AIR CONDITIONER
STRUCTURE AND FUNCTION
AIR CONDITIONING CONDENSER
AIR CONDITIONING CONDENSER FUNCTION In a refrigeration system, the job of the condenser is to convert the heated, high pressure gaseous refrigerant compressed in the compressor back into a liquid refrigerant. Heat at the same time dissipates into the atmosphere. An auxiliary fan helps force the heat exchange.
GENERAL DESCRIPTION In the condenser, the quantity of heat to be emitted from the gaseous refrigerant depends on the quantity of heat absorbed from the room air in the evaporator and the work to be done to compress the gas in the compressor. Accordingly, the effect of the heat radiation on the cooling effect is so large that the forced cooling is performed by two special cooling fans, in addition to the cooling fan for the engine radiator. This independent condenser helps prevent overheating of the engine and does not effect engine performance.
1. 2-Stage control of condenser fan motor The electric fan of the condenser is controlled to two speeds by the pressure of the refrigerant on the pressure side. If the pressure of the refrigerant on the high pressure side rises above 18 kg/cm², the pressure switch is turned ON and the fan motor runs at high speed. When the pressure of the refrigerant on the high pressure side drops below 14 kg/cm², the pressure switch is turned OFF and a resistor reduces the voltage to make the fan motor run at low speed. This extends the life of the fan motor, and also avoids the unnecessary use of electricity.
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STRUCTURE AND FUNCTION 2. Pressure switch This switches ON and OFF according to the pressure of the refrigerant. ON: 14 kg/cm² (199 psi) OFF: 18 kg/cm² (266 psi)
1) Pressure switch
3. Defrosting device Frost can build up on the evaporator fins if their temperature drops below freezing. Efficiency will suffer, so a thermistor has been provided, attached to the evaporator fins, to signal when the fins are too cold. If so, the controller will turn off the magnetic clutch, stopping the compressor.
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AIR CONDITIONING CONDENSER
STRUCTURE AND FUNCTION
AIR CONDITIONING CONDENSER
4. Magnetic clutch The compressor pulley incorporates a magnetic clutch to connect and disconnect from the engine. The clutch engages whenever current is supplied to its magnet stator coil (air conditioning is switched on). The drive belt then can power the compressor.
5. Electric fan motor This turns the electric fan and carries out the forced cooling of the condenser. 1) Fan
2) Fan motor
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STRUCTURE AND FUNCTION
AIR CONDITIONER COMPRESSOR The compressor is a pump to raise the pressure of the refrigerant. As the refrigerant pressure increases, so does its temperature, and the high temperature refrigerant gas then will condense rapidly in the condenser by releasing heat to the surroundings. The compressor illustrated here, a swash plate type, operates paired pistons on the swash plate. Rotation of the shaft and attached swash plate operates the pistons in their bores. The swash plate and shoes convert rotary motion of the shaft to reciprocating motion of the pistons.
Intake stroke: When the piston moves to the left, the right side of the piston draws the refrigerant through the suction valve while the discharge valve is held closed against the valve plate. Discharge stroke: When the piston moves to the left, the left side of the piston forces out the refrigerant through the discharge valve while the suction valve is held closed against the valve plate.
A shaft seal and seal plate seal the compressor shaft. The cutaway drawing illustrates a typical arrangement.
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AIR CONDITIONING CONDENSER
STRUCTURE AND FUNCTION
RECEIVER
RECEIVER WITH SIGHT GLASS (LIQUID TANK) The refrigerant liquified in the condenser is temporarily stored in this tank so that the refrigerant can be supplied to the evaporator according to the cooling load. A strainer is provided in the tank and the silica-gel is sealed on the external surface of the strainer. A sight glass and a fusible plug are provided in the top. The purpose of the strainer and silica-gel is to remove dust and water content from inside the refrigeration cycle. If water gets into the refrigeration cycle, functional parts will corrode and/or water can freeze in the small port of the expansion valve, and obstruct refrigerant flow.
1. 2. 3. 4.
Body Sight glass Drier Drier
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STRUCTURE AND FUNCTION 1. Fusible plug A fusible plug, also called a melt bolt, has a hole through its center which is filled with special solder that melts at 103 r cannot ventilate properly, and thoroughly dissipate the heat, the special solder in the fusible plug will melt. The refrigerant escapes to the open air before the pressure in the condenser and receiver can increase enough to damage them. When the special solder melts at 103 the pressure of the refrigerant is approx. 30 kg/cm².
2. Sight glass This small window allows observation of the refrigerant flowing through the refrigeration cycle. Generally, if air bubbles appear, the refrigeration system is lacking refrigerant. When no air bubbles are observed, the proper quantity of refrigerant is in the system. When there is no refrigerant in the system, no air bubbles will be seen.
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RECEIVER
STRUCTURE AND FUNCTION
AIR CONDITIONER UNIT
AIR CONDITIONER UNIT OUTLINE In this all-season-type air conditioner unit, the air is cooled and dehumidified through the evaporator and reheated to the proper temperature through the heater for a comfortable cab atmosphere. In hot weather, only the evaporator operates and in cold weather, mainly the heater operates. In other seasons, particularly rainy and humid weather, the heater and evaporator operate to dehumidify and heat the air. 1. BLOWER SWITCH Acts as the main switch and is used for controlling the air flow when cooling or heating. This switch controls the air flow to three levels: Low Medium High If the knob is turned to the OFF position, the air conditioner will stop. 2. AIR CONDITIONER SWITCH Switching when cooling (power for compressor) When the button is pressed, the switch is turned on and the pilot lamp lights up. When the button is pressed again, the switch is turned off and the pilot lamp goes out. If the air conditioner switch is turned on but the blower switch is still off, the air conditioner will not work (the pilot lamp does not light up). Turn the air conditioner switch on after turning the blower switch on. 3. TEMPERATURE CONTROL This lever controls the temperature during cooling or heating. Move the lever towards (left) the Cool position to lower the temperature; move the lever towards (right) the WARM position to raise the temperature. If the air conditioner switch and blower switch are turned on, and the lever is moved to the WARM position, the air conditioner will give dehumidifying and heating. 4. AIR SOURCE SELECTOR This lever switches the source of air during cooling or heating. FRESH (right - outside air is brought in) This is used for normal cooling and heating. Fresh air from the outside is used in addition to the air inside the operator's compartment. RECIRC (left - inside air is recirculated) This is used for quick cooling and heating. In this position, only the air inside the operator's compartment is used.
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STRUCTURE AND FUNCTION
ELECTRIC CIRCUIT DIAGRAM
AUTO-GREASING
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STRUCTURE AND FUNCTION
ELECTRIC CIRCUIT DIAGRAM
ELECTRONIC CONTROLLED SUSPENSION SYSTEM (E.C.S.S.)
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STRUCTURE AND FUNCTION
ELECTRIC CIRCUIT DIAGRAM
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STRUCTURE AND FUNCTION JOYSTICK STEERING REMOTE POSITIONER
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ELECTRIC CIRCUIT DIAGRAM
STRUCTURE AND FUNCTION
ELECTRIC CIRCUIT DIAGRAM
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STRUCTURE AND FUNCTION
MACHINE MONITOR SYSTEM
MACHINE MONITOR SYSTEM
1. 2. 3. 4.
Fuel level Engine water temperature Torque converter oil temperature Engine water temperature
OUTLINE The machine monitor system uses the sensors and other devices installed to various parts of the machine to observe the condition of the machine. It processes this information swiftly and displays it on the monitor panel to inform the operator of the condition of the machine. The machine monitor system consists of the main monitor, maintenance monitor, sensors, switches, relays, alarm buzzer, and power source. The displays can be broadly divided into the following: Cautions displayed on the monitors (abnormalities in the machine where an alarm is given), and normal conditions which are always displayed on the instrument panel (pilot lamps, readings for the gauges, speedometer, and service meter).
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5. 6. 7. 8.
Engine oil level Brake oil pressure Engine oil pressure Air cleaner clogging
There are also various switches built into the monitor panel which function to operate the machine. The main monitor uses the network wiring to send signals to the controller, and functions to display the following information: Shift indicator: 1st - 4th, N, F, R (F and R are optional). HOLD Failure action code, failure code, time elapsed since failure (failure data display mode).
STRUCTURE AND FUNCTION
MAIN MONITOR
MAIN MONITOR
1. Check lamp 2. Caution lamp 3. Caution items 3A. Ground driven steering actuated (option) 4. Pilot items 4A. Turn signal (left) 4B. Turn signal (right) 4C. High beam 4D. Shift indicator 4E. Speedometer
4F. Shift hold 4G. Parking brake 4H. Ground driven steering normal (option) 4I. Not used 4J. Failure action code 5. Switches 5A. Auto grease switch (option) 5B. Travel damper switch (option)
OUTLINE The main monitor has a display function for the speedometer and other gauges, and a switching function to control the electric components and controllers. There is one CPU (Central Processing Unit) installed internally, and this processes the signals from the sensors and outputs the display.
5C. Working lamp (front) switch 5D. Working lamp (rear) switch 5E. Transmission cut-off switch 5F. Auto shift, manual selector switch
A liquid crystal display and LEDs are used for the display. The switches are embossed sheet switches.
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STRUCTURE AND FUNCTION MAIN MONITOR DISPLAY FUNCTION
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MAIN MONITOR
STRUCTURE AND FUNCTION
MAIN MONITOR
MAIN MONITOR SWITCH FUNCTION Item
Function
Display
Actuation
Auto-greasing
Forced greasing is carried out while switch is being pressed when display is lighted up.
Lights up (goes out momentarily when switch is turned ON)
Auto-greasing control actuated (automatic greasing carried out at fixed interval)
Flashes (slowly)
Grease empty
Flashes (rapidly)
Abnormality in auto-greasing controller system
Goes out
Auto-greasing controller not installed
E.C.S.S. function is actuated or stopped each time switch is pressed
Lights up
E.C.S.S. function actuated
Goes out
E.C.S.S. function stopped
Front working lamp lights up or goes out each time switch is pressed when side lamps are lighted up
Lights up
Front working lamp lights up
Goes out
Front working lamp goes out
Rear working lamp lights up or goes out each time switch is pressed when side lamps are lighted up.
Lights up
Rear working lamp lights up
Goes out
Rear working lamp goes out
Transmission cut-off function is actuated or stopped each time switch is pressed
Lights up
Cut-off function actuated
Goes out
Cut-off function stopped
Auto shift mode switches to manual mode when switch is pressed
Lights up
Manual mode
Goes out
Auto shift mode
E.C.S.S.
Working lamp (front)
Working lamp (rear)
Transmission cut-off
Manual
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STRUCTURE AND FUNCTION
MAIN MONITOR
TROUBLE DATA DISPLAY MODE (When optional controller is installed) Item
Switch operation
Actuation
Method of switching to trouble data display mode
With engine stopped and starting switch turned ON, press 2nd switch from top on left side of main monitor (switch below ground driven steering display) and work lamp (front switch simultaneously for at least 5 seconds
All switch displays (LEDs) go out, and failure code is displayed on speedometer display and time elapsed since failure is displayed on failure action code display. 1) Failure code is two-digit display given in numbers or letters. The display for the failure now occurring flashes and the display for past failures lights up. 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 times are stored in memory for the failure codes.
Method of sending failure code
Press working lamp (front) switch
Failure code and time elapsed since failure change to next item
Clearing failure code
Press working lamp (rear) switch for at least 2 seconds
Failure code and time lapsed since failure being displayed are cleared. Failure code for problem now occurring (flashing display cannot be cleared.
Resetting from travel data display mode
Press 2nd switch from top on left side of main monitor (switch below ground driven steering display) and front working lamp switch simultaneously for at least 5 seconds, or start the engine.
Changes to normal display
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STRUCTURE AND FUNCTION
MAINTENANCE MONITOR
MAINTENANCE MONITOR
Outline The maintenance monitor has a display function for the caution items and gauges, and switch functions to control the work equipment controller. The m aintenance monitor consists of the monitor module, switch module, service meter, case, and other mechanisms.
The monitor module has a built-in CPU (Central Processing Unit). It processes the signal from the sensors, and carries out the display and output. A liquid crystal display and LEDs are used for the display portions. The switches are embossed sheet switches.
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STRUCTURE AND FUNCTION MAINTENANCE MONITOR DISPLAY FUNCTION
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MAINTENANCE MONITOR
STRUCTURE AND FUNCTION
MAINTENANCE MONITOR
MAINTENANCE MONITOR SWITCH FUNCTION Item
Function
Display
Remote boom positioner LOWER position setting
Sets stopping position in LOWER direction for remote boom positioner (boom position when switch is pressed is recorded)
Flashes (2.5 sec)
Remote boom positioner RAISE position setting
Sets stopping position in RAISE direction for remote boom positioner (boom position when switch is pressed is recorded)
Flashes (2.5 sec)
Selection of remote boom positioner RAISE/LOWER
Sets remote boom positioner in stopping direction (Switches function each time switch is pressed)
Goes out
Remote boom positioner function Off
RAISE lights up
Remote boom positioner RAISE stop function ON
LOWER lights up
Remote boom positioner LOWER stop function ON
RAISE, LOWER light up
Remote boom positioner RAISE/LOWER stop function ON
Goes out
Goes out
Actuation Sets stopping position Sets stopping position -
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STRUCTURE AND FUNCTION
AUTOMATIC TRANSMISSION SYSTEM
ALL-RANGE ELECTRONIC CONTROL AUTOMATIC TRANSMISSION SYSTEM OUTLINE OF SYSTEM
the all-range electronic control automatic transmission system consist of the transmission controller, directional and speed levers, engine speed sensor, speed sensor, and all-speed-range ECMV (transmission clutch modulation valve). The transmission controller controls the shifting to the appropriate speed range according to the lever position and travel speed signal. To reduce shock when shifting gear (engaging the clutch), all-speed-range ECMV carries out modulation control. A travel damper function and joystick steering control function are available as options, and these controls are possible if the function is installed to the machine. To improve durability, there is a safety function which prevents the machine from moving suddenly when the engine is started, and a transmission protection function which protects the clutch when the direction of travel is changed.
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The self-diagnostic function always observes the input and output condition, and displays the output condition on the two 7-segment LED displays on the transmission controller. There is also a failure detection function, and if any abnormality occurs, it displays a failure code. Depending on the condition, it also displays a failure action code on the main monitor and flashes the caution lamp to improve safety. The transmission controller has a communications function, and it sends the speed range (N, 1st-4th) data to the main monitor, which displays the speed range. (If the joystick mode is used, it also displays F and R.)
STRUCTURE AND FUNCTION
AUTOMATIC TRANSMISSION SYSTEM
SYSTEM STRUCTURE DIAGRAM
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STRUCTURE AND FUNCTION FUNCTION 1. Auto-shift function. Shifting the transmission up or down is carried out when the engine speed is above 1450 rpm. Shifting is decided by signals from the directional lever, speed lever, and travel speed sensor according to (Table 1 Automatic gear shift change point table) recorded in the memory of the transmission controller. 1) Speed lever (1st - 4th). This controls the maximum speed range (available speed range) for automatic gear shifting. Example: Speed lever at 4th: 2nd - 4th Speed lever at 2nd: 2nd only 2) Directional lever N position. To prevent the vehicle from moving accidentally, when the lever is at neutral position, only the 2nd clutch is engaged. 3) Directional lever F position. When the directional lever is operated from N to F, the transmission turns ON the F and 2nd ECMVs (F2). (Automatic start in 2nd) a) Shift up (when speed lever is at 4th) When the accelerator pedal is depressed to increase the engine speed and the travel speed rises, when the travel speed reaches approx. 9.3 km/h, the ECMV 3rd is turned ON, and at the same time, 2nd is turned OFF. (Shifting to F3) When the travel speed rises further to approx. 17.6 km/h, the ECMV 4th is turned ON, and at the same time, 3rd is turned OFF. (Shift to F4) b) Shift down (speed lever at 4th). When traveling in 4th, if the accelerator pedal is let back, and the travel speed comes down to approx. 15.6 km/h, the ECMV 3rd is turned ON, and 4th is turned OFF. (Shift to F3) When the travel speed goes down to approx. 9.8 km/h, the ECMV 2nd is turned ON, and 3rd is turned OFF. (Switches to F2) 4) Directional lever R position. Automatic gear shifting is carried out according to the travel speed between 2nd and 4th speeds (when the speed lever is at 4th) in the same way as when the speed lever is at the F position. 5) Skip shift. When coasting (in engine speed OFF mode) in 3rd or 4th speed with the accelerator pedal depressed, if the travel speed is less than 8 km/h, the gear shifts down to 2nd to make it easier to accelerate. If the travel speed is more than 8 km/h, the speed range is maintained, and when the engine speed goes above 1450
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AUTOMATIC TRANSMISSION SYSTEM rpm, the gear is shifted to a range that matches the travel speed. 6) Gear shift prevention interval. To prevent shift hunting after shifting gear, a time interval is set to maintain the speed range. The gear shift prevention interval differs according to the shift pattern. For details, see [Table 1 Automatic gear shift change point table].
2. Modulation control. The modulation control acts to reduce the shock when shifting gear (when engaging the clutch). It uses the data for the engine speed, transmission oil temperature, and gear shift pattern to control the clutch oil pressure (including the characteristics when starting) to match the condition of the hydraulic circuit to control all speed ranges to the optimum according to the data in the transmission modulation table stored in the transmission controller memory. In addition, to reduce the torque cut, it carries out modulation control of the ECMV at the side which switches OFF also. The transmission modulation data table is set for each transmission oil temperature. In addition, it has a learning function (transmission clutch piston data) to prevent any abnormal time lag when shifting gear.
3. HOLD function. When the HOLD switch is pressed, the speed range is held at the optimum speed range, and even if the travel speed goes down, the transmission does not shift down. However, when switching between forward and reverse, the transmission normally shifts down to 2nd according to the travel speed, and then shifts up to the HOLD shift range according to the travel speed and gear shifting conditions. (This prevents any unnecessary shift down when leveling ground, or when traveling downhill.)
STRUCTURE AND FUNCTION
AUTOMATIC TRANSMISSION SYSTEM
4. Kickdown function. When operator turns the kickdown switch ON, it overrides the auto shift and switches down forcibly to 1st if the conditions (speed range, travel speed) in [Table 1 Automatic gear shift change point table, 5. Kickdown] are fulfilled.
transmission shifts down to 2nd according to the deceleration. (For details, see Fig. 1 F-R selection gear shift pattern, table 1 Automatic gear shift change point table, 7. F-R selection.) b). Alarm buzzer. When the speed range control and travel fulfill the conditions for range III, the alarm buzzer sounds to warn the operator. (If the engine speed is above 1700 rpm and the travel speed is above 13 km/h, or the travel speed is above 14 km/h). (See Fig. 2 F-R selection alarm buzzer range.) 4). Manual shift. If the travel speed sensor is abnormal and it is impossible to detect the travel speed data, the transmission is set to manual (shift) mode.
5. Travel mode. 1). Manual mode (option). It is possible to switch between auto and manual shift. When using the manual mode, the gear is shifted according to the operation of the speed lever. When traveling in F2, it is also possible to use the kickdown function. 2). Joystick steering control function (option). a). If the machine is equipped with the joystick steering function, the operator can switch between steering wheel and joystick steering mode as desired. b). The transmission controller controls the signals from the travel system. (The steering system is controlled by the work equipment controller.) c). When switching the steering between steering wheel and joystick steering, always stop the machine first, return the speed lever to the N position, then switch the steering. When this is done, the transmission controller is set to the neutral safety condition to prevent the machine from suddenly moving.
6. Safety function. 1). Neutral safety. When the engine is started, if the directional lever is at any position other than N, the transmission controller keeps the transmission in neutral and prevents the machine from moving. If the N signal is input after the engine is started, the neutral safety is canceled. 2). Speed lever priority. It is possible to shift down immediately by operating the speed lever, so the engine can be used as a brake when traveling downhill. 3). Transmission protection. When traveling in 3rd or 4th speed, the travel speed is controlled and a warning buzzer sounds to protect the transmission when shifting between forward and reverse. a). Speed range control. When the speed range control and travel speed fulfill the conditions for range I, the transmission shifts down to 2nd. When the speed range control and travel speed fulfill the conditions for range II, the speed range is maintained and the
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STRUCTURE AND FUNCTION Table 1:
AUTOMATIC TRANSMISSION SYSTEM
Automatic gear shift change point table. Item
1. Basic shift change.
Speed range
Travel speed (Km/h)
Gear shift prevention interval
1
5.1 (5.3) or above
2
2
8.7 (9.2) or above
2
3
16.5 or above
1
4
Less than 14.5
1
3
Less than 9.2 (8.7)
2
2. Engine speed. (less than 1450 rpm)
4
Less than 1.0
o
3
Less than 1.0
0
3. Engine speed. (less than 1450 rpm 1450 rpm)
4
Less than 8.0
2
3
Less than 8.0
2
4. Shift when HOLD is ON.
1
5.1
0
2
8.7
0
3
16.5
0
2
Whole range
5
3
Less than 12.0
5
4
Less than 12.0
5
4 3 1
(Note 1)
5. Shift down when kickdown is ON.
6. FR selection (range I) (F (R
2
7. FR selection (range II) (F (R
(Note 2) 16.5 or above Less than 14.5 - 16.5
2
86.
16.5 or above Less than 8.7 - 16.5 Less than 8.7
0
FR selection (F (R
Note 1:
When the engine speed is less than 1900 rpm and the travel speed is less than 16 km/h, or the travel speed is less than 13 km/h.
Note 2:
When the travel speed is 1900 rpm or above and the travel speed is 13 km/h or above, or the travel speed is 16 km/h or above, the speed range maintained and the transmission shifts down to 2nd according to deceleration.
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STRUCTURE AND FUNCTION
AUTOMATIC TRANSMISSION SYSTEM
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STRUCTURE AND FUNCTION 7. Self-diagnostic function The transmission controller always observes the input and output signals of the automatic gear shifting system. It carries out self diagnosis and displays the results on the LEDs of the transmission controller. In addition, it sends the following data to the main monitor. Table 2:
AUTOMATIC TRANSMISSION SYSTEM 1) Normal display: Transmission controller LEDs display output range. 2) Failure code display: If an abnormality is detected, the nature of the failure is displayed as a code. For details of failure code, see Table 2 Failure code table.
Failure code table.
Code
Item
System
Main Monitor
Short Circuit
Disconnection
Action Code
10
Back-up alarm relay
O
O
None
11
None
-
-
-
12
F ECMV solenoid
O
O
Call
13
R ECMV solenoid
O
O
Call
14
1st ECMV solenoid
O
O
Call
15
2nd ECMV solenoid
O
O
Call
16
3rd ECMV solenoid
O
O
Call
17
4th ECMV solenoid
O
O
Call
18
None
-
-
-
19
Joystick direction switch
O
O
E00
20
Directional switch signal
O
O
Call
21
Range switch signal
O
O
None
22
Travel speed sensor
X
O
E00
23
Engine speed sensor
O
O
E00
24
Abnormality in memory (EEPROM)
-
-
None
25
Transmission oil temperature sensor
O
X
E01
26
F ECMV fill switch
O
X
Call
27
R ECMV fill switch
O
X
Call
28
1st ECMV fill switch
O
X
Call
29
2nd ECMV fill switch
O
X
Call
30
3rd ECMV fill switch
O
X
Call
31
4th ECMV fill switch
O
X
Call
32
F or R ECMV fill switch
X
O
E00
33
1st, 2nd, 3rd, or 4th ECMV fill switch
X
O
E00
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STRUCTURE AND FUNCTION 8. Communications function The transmission controller is equipped with a communications function using S-NET. It always maintains communications with the main monitor, and when the engine is started, it receives model, travel damper availability, and tire compensation data. When any abnormality occurs, it displays an action code on the main monitor according to the condition of the problem to warn the operator in order to increase safety. The failure code can recognize the codes recorded in the main monitor memory using the main monitor problem history mode. For details of operating the main monitor, see the section on the main monitor. 9. Travel damper (option) If the machine is equipped with a travel damper function, the operator can use this function by operating a switch. When the engine is started, the availability of the travel damper function is transmitted from the main monitor, and the troubleshooting function can also be actuated for the travel damper system.
TRANSMISSION CONTROLLER POWER SOURCE When the starting switch is turned ON and the supply voltage is more than 2OV, and +20V or more is supplied to the transmission controller solenoid power source input, it is possible to drive each solenoid valve. If the supply voltage is less than 19V, all outputs are turned OFF and the solenoids cannot carry out control (travel is impossible).
INPUT SIGNALS 1. Directional lever (F,N,R) signal This signal is a +24V/OPEN digital signal, and when it is normal, one of F, N, or R signals (+24V) is input. 2. Speed lever (lst - 4th) signal This signal is a +24V/OPEN digital signal and +24V is input for the signal for the lever position. 3. Kickdown switch This signal is a +24V/OPEN digital signal and +24V is input when the kickdown switch on the work equipment control lever is pressed. The switch operation is judged from the +24V starting signal from the OPEN condition at that point.
AUTOMATIC TRANSMISSION SYSTEM 4. FORWARD switch This signal is a +24V/OPEN digital signal and +24V is input when the HOLD switch on the work equipment control lever is pressed. The switch operation is judged from the +24V starting signal from the OPEN condition at that point. 5. Neutralizer relay signal This signal is a +24V/OPEN digital signal and +24V is input when the parking brake switch is pressed. When signal is OPEN, the transmission controller maintains the neutral condition. 6. Transmission cut-off signal This signal is a GND/OPEN digital signal, and when the transmission cut-off switch is operated (using the left brake), it changes to GND. When it is actuated, the transmission controller changes to the neutral output condition, and when it is restored, it sets to a suitable speed range for the travel speed at that point. 7. Manual mode signal This signal is a GND/OPEN digital signal, and when the manual mode switch is ON, GND is input. 8. Fill switch (F, R, 1st - 4th signals) This signal is a GND/OPEN digital signal, and is installed to each ECMV. The switch is operated by oil pressure. When the ECMV is on, GND is input. 9. Engine selection signal This signal is a GND/OPEN digital signal, and when the engine is started, the type of engine mounted is judged from this signal. (The speed conversion data is different.) Table 3 Engine selection signal table Input signal
Engine
Speed conversion data
GND
Cummins
118
10. Memory clear signal This signal is a GND/OPEN digital signal. It is normally OPEN. When clearing the memory, start the engine, then input OPEN N signals.
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STRUCTURE AND FUNCTION 11. Engine speed sensor signal This signal is a pulse signal, and it converts the pulses from the electromagnetic pickup sensor to rotation speed for control. When the engine speed is 1450 rpm or above, it is called the engine speed ON mode, and when the speed is less than 1450 rpm, it is called the engine speed OFF mode. Komatsu engine: Speed P (rpm) = Input frequency (Hz) x 60/6 Cummins engine: Speed P (rpm) = Input frequency (Hz) x 60/118 12. Travel speed sensor signal This signal is a pulse signal, and it converts the pulses from the electromagnetic pickup sensor to rotation speed for control. To convert to the travel speed, the tire compensation data (communications data from the main monitor) are added. In addition, the acceleration is also calculated to judge the travel speed for gear shifting. Speed P (rpm) = Input frequency (Hz) x 60/ 59 Travel speed V (km/h) = Speed P (rpm)/ (101.6 x tire compensation value k) or Travel speed V (km/h) = Input frequency (Hz)/(99.9 x tire compensation value k) 13. Transmission oil temperature sensor signal This signal is an analog signal and converts 0 - 5 V inside the controller to temperature. This is used for selecting the modulation table when shifting gear. 14. Communications signal (S-NET) This receives the following data set in the main monitor and is used for control. 1) Model selection It selects the automatic gear shift change point data table for each model to use for shifting gear. 2) Tire compensation data This adds the compensation value (covering a range from 0.86 to 1.14) to the speed data from the travel speed sensor to obtain an accurate travel speed. 3) Travel damper function selection This is a function selection signal and judges if the travel damper function exists. lt controls the travel damper system, including troubleshooting.
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AUTOMATIC TRANSMISSION SYSTEM OUTPUT SIGNALS 1. Transmission modulation valve (ECMV command current) This signal is an electrical output (O - 1A). There are six types of ECMV: R and F for direction, and lst, 2nd, 3rd, and 4th for each speed range. This valve is a pressure control valve and converts to a pressure matching the value of the current flowing to the solenoid. Therefore, it controls the oil pressure for the clutch selected for each speed range and controls the engagement of each independent clutch. In addition, only the 2nd clutch is actuated when the transmission is at neutral. Table 4:
Combination of speed ranges and ECMV
ECMV/ Speed range
F
F1
O
F2
O
F3
O
R
1st
2nd
3rd
4th
O O O
F4
O
N R1
O
R2
O
R3
O
R4
O
O O O O O = ON
2. Backup lamp relay signal This signal is a +24V digital (ON/OFF) output. It is actuated when the directional lever is placed at R and lights up the backup lamp and caution lamp. 3. F1 (cut-off) signal This signal is a +24V digital (ON/OFF) output. This signal is output when the kickdown is operated and sets the machine to Fl. 4. Engine speed signal This outputs a signal at the same cycle as the engine speed sensor signal input to the transmission controller.
STRUCTURE AND FUNCTION
AUTOMATIC TRANSMISSION SYSTEM
5. Communications signal (main monitor display data) For details of the display position and operation of the main monitor, see the section on the main monitor. 1) Speed range 1st speed range output: [1] 2nd speed range output: [2] 3rd speed range output: [3] 4th speed range output: [4] Neutral: [N] 2) F / R display F / R are displayed in the joystick steering mode (option). 3) HOLD display The pilot display is given on the main monitor when the HOLD function is ON.
LED DISPLAY When the engine is started, the display goes first to 1. “Program quality display mode”, and next to 2. “Output speed range display mode”. However, if any abnormality is detected, it goes immediately to the troubleshooting mode. 1. Program quality display mode. When the power source is on, it switches once every second.
2. Output speed range display mode. LED display X. Y. (Both dots are out) X: Direction ECMV drive condition FORWARD [F]: F, REVERSE [R]: A, Neutral: O Y: Speed range ECMV drive condition 1 - 4.
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STRUCTURE AND FUNCTION 3. Troubleshooting display mode (currently existing failure) A cycle of [E-(2 sec)], [Code (2 sec)] is repeated. 1) When there is one abnormal item.
2) When there are two abnormal items.
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AUTOMATIC TRANSMISSION SYSTEM
STRUCTURE AND FUNCTION
MEMORANDA
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STRUCTURE AND FUNCTION
TRANSMISSION CONTROLLER
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TRANSMISSION CONTROLLER
STRUCTURE AND FUNCTION
TRANSMISSION CONTROLLER
CONNECTOR SIGNALS CNC1
CNC3A
13
Direction N
1
Joystick N output
1
NC
14
Neutralizer relay
2
Buzzer signal
2
NC
15
Range SW 2
3
Relief solenoid
3
NC
16
Range SW 4
4
Engine speed output
4
NC
CNC4
5
Low pressure solenoid
5
NC
1
NC
6
GND
6
Pressure sensor power supply (+24v)
2
Engine speed
7
Power supply (+24V)
3
NC
7
potentio power supply 4
NC
8
NC 5
NC
9
NC 6
NC
10
ENC select 7
NC
11
T/M oil temp. Sensor 8
NC
12
NC 9
GND (for rotate sensor)
13
NC 10
NC
14
NC 11
Network (-)
15
NC 12
Network (-)
16
GND (for pressure sensor)
17
GND (for potentio)
18
NC
19
Jotstick ON/OFF SW
20
Pressure SW
8 9 10 11 12 13
F1 output Damper solenoid 5 High pressure solenoid Back lamp relay GND Power supply (+24V)
CNC2 1 2 3 4 5 6 7
Sol. power supply (+24V) ECMV 3 (+) NC
CNC5
ECMV 4 (+) NC NC ECMV F (+)
1
GND (for plus)
2
Speed
3
GND
4
GND
5
Kick down SW
6
T/M cut-off SW
7
Joystick N (NC)
8
Joystick F (NC)
9
Joystick R (NC)
10
GND (for plus)
11
Fill SW 3
12
Fill SW 4
13
Hold SW
14
Manual SW
15
Joystick N (NO)
16
Joystick F (NO)
17
Joystick R (NO)
CNC3B 8 9 10 11 12 13 14 15 16 17 18 19
ECMV R (+) 1
Pressure SW B
2
Fill SW F
3
Fill SW 1
4
NC
5
Direction F
6
Direction R
7
Range SW 1
8
Range SW 3
9
Damper SW
10
Fill SW R
11
Fill SW 2
12
NC
ECMV 1 (+) ECMV 2 (+) P GND Sol. power supply (+24V) ECMV 3 (-) NC ECMV 4 (-) NC ECMV F (-) ECMV R (-) ECMV 1 (-)
20
ECMV 2 (-)
21
P GND
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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.
Sensor detection item
Sensor method
When normal
When abnormal
Speedometer sensor
Electromagnetic
-
-
Engine oil level
Contact
ON
OFF
Radiator water level
Contact
ON
OFF
Engine oil pressure
Contact
OFF
ON
Engine water temperature
Resistance
-
-
Torque converter oil temperature
Resistance
-
-
Engine speed sensor
Electromagnetic
-
-
Fuel level sensor
Resistance
-
-
SPEEDOMETER SENSOR FUNCTION The speedometer sensor is installed to the transmission output gear. A pulse voltage is generated by the rotation of the gear teeth, and signal is sent to the machine monitor to display the travel speed.
1. Connector 2. Magnet 3. Case
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STRUCTURE AND FUNCTION
SENSORS
ENGINE SPEED SENSOR
1. 2. 3. 4. 5.
Magnet Terminal Case Boot Connector
FUNCTION The engine speed sensor is installed to the ring gear portion of the flywheel housing. A pulse voltage is generated by the rotation of the gear teeth, and a signal is sent to the controller and monitor panel.
ENGINE OIL PRESSURE SENSOR
1. 2. 3. 4. 5. 6.
Plug Contact ring Contact Diaphragm Spring Terminal
FUNCTION This sensor is installed to the engine block and the diaphragm detects the oil pressure. If the pressure goes below the specified pressure, the switch is turned ON, and a relay is actuated to turn the output OFF. This makes the maintenance monitor flash to warn of the abnormality. The caution lamp and alarm buzzer are also actuated at the same time to warn of the abnormality.
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STRUCTURE AND FUNCTION
SENSORS
RADIATOR WATER LEVEL SENSOR
1. Float 2. Sensor 3. Connector
FUNCTION The sensor is installed to the top of the radiator. 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.
ENGINE OIL LEVEL SENSOR
1. 2. 3. 4.
Connector Bracket Float Switch
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FUNCTION This sensor is installed to the side face of the oil pan. When the oil goes below the specified level, the float goes down ant the switch is turned OFF. This makes the maintenance monitor flash, and the check lamp to also light up at the same time to warn of the abnormality.
STRUCTURE AND FUNCTION
SENSORS
FUEL LEVEL SENSOR
1. 2. 3. 4. 5. 6. 7.
Connector Float Arm Body Spring Contact Spacer
FUNCTION The fuel level sensor is installed to the side face of the fuel tank. The float moves up and down as the level of the fuel changes. As the float moves up and down, the arm actuates a variable resistance, and this sends a signal to the maintenance monitor to display the fuel level. When the display the maintenance monitor reaches the specified level, the warning lamp flashes.
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STRUCTURE AND FUNCTION
SENSORS
ENGINE WATER TEMPERATURE SENSOR TORQUE CONVERTER OIL TEMPERATURE SENSOR
1. Connector 2. Plug 3. Thermistor
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FUNCTION These sensors are installed to the engine cylinder block and transmission case. The change in the temperature changes the resistance of the thermistor, and a signal is sent to the maintenance monitor to display the temperature. If the display on the maintenance monitor reaches the specified position, the lamp flashes and the buzzer sounds to warn of the abnormality.
STRUCTURE AND FUNCTION
MEMORANDA
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STRUCTURE AND FUNCTION
ENGINE STARTING CIRCUIT
ENGINE STARTING CIRCUIT
Function To ensure safety when starting the engine, the system is equipped with a neutral safety circuit. This makes it impossible for the engine to start if the directional lever is not at the N (Neutral) position. Operation When the directional lever is placed at the N (Neutral) position contacts of the directional lever switch are closed. In this condition, if the starting switch is turned to the START position, current flows in the following circuit. [1] Battery (+) starting switch terminal C terminal S directional lever switch terminal N the safety relay is closed.
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y
In addition, current flows from starting switch terminal BR o the battery relay switch is closed. This forms the following circuit. [2] Battery (+) terminal B relay terminal C and the engine starts.
y ,
If the directional lever is at any position other than N (Neutral), circuit [1] is not formed, and the engine does not start.
STRUCTURE AND FUNCTION
ENGINE STARTING CIRCUIT
a) Safety relay.
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STRUCTURE AND FUNCTION
ENGINE STOP CIRCUIT
ENGINE STOP CIRCUIT Operation When the starting is turned ON, electric current flows in the following circuit. [1] Battery (+) ing switch terminal BR ground connection. When electric current flows to the fuel cut solenoid, the fuel governor is put in the FREE position by the fuel control linkage. Fuel flows to the fuel injection pump and the engine starts.
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When the starting switch is turned OFF, circuit [1] is shut off, but the engine is rotating, so there is still voltage at terminal R of the alternator. For this reason, the following circuit is formed. [2] Alternator terminal R BR
l
The battery relay is maintained, but because of the diode inserted into the circuit, no electric current flows to the fuel cut solenoid, so the engine stops.
STRUCTURE AND FUNCTION
ETHER START CIRCUIT
ETHER START CIRCUIT
Function • The ether injection system delivers a 3cc shot of ether to the engine to aid in cold weather starting. Operation • With the lever in N (neutral) turn key to start position. This completes cranking circuit as described in engine starting section, and engine begins cranking. This also completes circuit from start switch “B” to start switch “R2" applying power to ether start switch. • Move ether start switch to ON position then release immediately (Do not hold it at ON position for more than 5 seconds. This will cause failure of ether start solenoid) This allows current to flow in the following circuit. Start switch terminal “R2" to ether start switch terminal “1" to ether start switch terminal “2" to ether solenoid “1" to ground. This actuates ether start solenoid, injecting ether.
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STRUCTURE AND FUNCTION
ELECTRIC TRANSMISSION CONTROL
ELECTRIC TRANSMISSION CONTROL
1. Transmission cut-off selector switch 2. Parking brake switch 3. Directional lever 4. Speed lever 5. Kick-down switch
6. Maintenance Monitor 7. Relays 8. Fuse boxes 9. Transmission controller 10. Transmission control valve
11. Speed sensor 12. Transmission cut-off switch 13. Brake valve (left) 14. Brake valve (right)
1
Selection of F, R, and N positions
Using directional lever
2
Selection of speed range
Using speed lever
3
Kick-down switch
When traveling in F2, it is possible to shift down to lst using this 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
5
Transmission cut-off selector function
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 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.
6
Neutralizer
To prevent seizure of the parking brake when traveling with the parking brake applied, the transmission is shifted to neutral when the parking brake is applied.
7
Neutral safety function
If the directional lever is not at the N position, the engine will not start 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.
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STRUCTURE AND FUNCTION
ELECTRIC TRANSMISSION CONTROL
COMBINATION SWITCH
OUTLINE The directional lever has three positions and the speed lever switch has four positions. As an individual part, the switch does not have a detent mechanism; the detent mechanism is in the combination switch. Each switch is positioned by two pins, and is secured to the body by three
screws. When each lever is operated to the desired position, the switch, which is interconnected by a shaft, acts to allow electric current to flow to that circuit only.
General locations, function 1
Directional lever switch
Switches between F, R, and N
2
Speed lever switch
Selects speed range
3
Speed lever stopper
Stopper used to prevent speed lever from entering 3rd or 4th during operations
4
Turn signal indicators
Direction indicator lamps used when turning left or right
5
Self cancel
Turn signal indicator lever automatically returns to central position after machines turns left or right
6
Lamp switch
Switches on clearance lamp, head lamp, parking lamp, etc.
7
Dimmer switch
Selects high beam for travel and low beam for passing
8
Hazard switch
Makes both left and right turn signal indicator lamps flash at the same time
9
Emergency flashing pilot lamp
Flashes at the same time as the emergency flashing lamp flashes
10
Parking brake switch
Applies or releases parking brake
10-199
STRUCTURE AND FUNCTION 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 amplification circuit. In the electric current amplification circuit, a signal is output to actuate the transmission.
10-200
ELECTRIC TRANSMISSION CONTROL
STRUCTURE AND FUNCTION
KICK-DOWN / HOLD SWITCH
KICK-DOWN / HOLD SWITCH
1. 2. 3. 4. 5.
KICK-DOWN SWITCH OPERATION The kick-down (shifting down from 2nd s actuated only when traveling in F2. When traveling in F2, if it is desired to shift down to 1st without operating the speed lever, operate the kick-down switch on the boom lever to ON to shift down to F1. After this, even if the kick-down switch is pressed, the transmission is kept at F1.
Kick-down switch Spring Spring Hold switch Wiring harness
HOLD SWITCH The hold switch is installed to the boom lever, and when the hold switch is pressed, the speed range displayed on the main monitor transmission indicator is held. Press the hold switch again to cancel.
Cancellation (or not actuated) When directional lever is at N When directional lever is at R When speed lever is not at 2nd When starting switch is OFF
10-201
STRUCTURE AND FUNCTION
KICK-DOWN ELECTRICAL CIRCUIT
KICK-DOWN ELECTRICAL CIRCUIT DIAGRAMS NORMAL OPERATION (When directional lever is at F and speed lever is at 2nd)
1. When directional lever is at F. If the directional lever is set to the F position,the electric currentflowsfrom battery (+) l lever terminals 1 - 2 r FORWARD CNC3B terminal 5, and then flows from CNC2 terminal 7 2 terminal 17 as the FORWARD output signal, and the FORWARD solenoid valve is actuated. If the parking brake is placed at the RELEASED position, electricity flows from battery (+) brake safety relay terminals 5 - 3 switch terminals 3 - 2 1 - 2 e neutralizer relay are connected.
10-202
2. When speed lever is at 2nd. When the speed lever is at the 2nd position,thesignal is inputtotransmission controller 2nd CNC3B terminal 15, and electricity flows as the 2nd signal from CNC2 terminal 10 CNC2 terminal 20, and the 2nd solenoid is actuated.
STRUCTURE AND FUNCTION
KICK-DOWN ELECTRICAL CIRCUIT
WHEN KICK-DOWN SWITCH IS OPERATED (Operation with speed lever at F2 position) (When kickdown switch is pressed ON)
When the kick-down switch is pressed, the main monitor network signal (-) enters from CNLO8 terminal 2 to controller CNC5 terminal 5. The kickdown circuit is formed inside the controller and the solenoid output signal flows from CNC2 terminal 7 and terminal 9 to the F solenoid and 1st solenoid, the solenoid valves are actuated, and the speed range is set to F1.
In this way, if the kick-down switch is pressed when the speed lever is at F2, the transmission is automatically shifted to F1. At the same time, the self-hold function of the kick-down circuit keeps the condition at F1 even if the switch is released or is pressed several times.
This kick-down circuit continues to be actuated even if the kick-down switch is returned. (Self-hold circuit)
10-203
STRUCTURE AND FUNCTION
KICK-DOWN ELECTRICAL CIRCUIT
KICK-DOWN SWITCH OPERATION CANCELED (When directional lever is set to N or R)
If the directional lever is operated to the R position, the contact of terminal F of the lever is turned off, so the electricity stops flowing from battery (+) speed lever switch terminals 1 - 2 n controller. The FORWARD circuit inside the transmission controller is opened, so electricity stops flowing to the kick-down circuit. As a result, the kick-down self-hold circuit is canceled and the 1 st solenoid stops actuating. (Even if the directional lever is set to the N position, the same operation as above is carried out and the kick-down circuit is canceled.) The FORWARD circuit is also opened, so the F solenoid also stops actuating.
10-204
When the directional lever is set to the R position, current flows from battery speed lever terminals 1 4 ransmission controller CNC3B terminal 6 CNC 2-8 terminal (Reverse circuit formations R (+) signal inside controller) r (-) CNC2 terminal 18, and the REVERSE solenoid valve is actuated. At the same time, electricity flows from transmission controller 2nd signal (+) CNC2 terminal 10 , and the 2nd solenoid valve is actuated to set to R2.
STRUCTURE AND FUNCTION
ELECTRIC PARKING BRAKE CONTROL
ELECTRIC CONTROL
PARKING
BRAKE
1. Parking brake emergency release switch 2. Neutralizer relay 3. Parking brake safety relay (parking brake emerge release relay) 4. Parking brake switch 5. Transmission control valve 6. Parking brake solenoid valve 7. Parking brake (built into transmission) 8. Parking brake emergency release valve 9. Charge valve 10. Accumulator
OUTLINE l The parking brake is a wet type multiple disc brake built into the transmission. When electricity flows to the parking brake solenoid valve, the oil pressure from the transmission pump is applied to the parking brake cylinder and releases the parking brake. l When the flow of electricity is stopped, the hydraulic pressure from the transmission pump is shut off. The hydraulic pressure inside the parking brake cylinder passes through the parking brake solenoid valve and is drained. The force of the brake spring then applies the parking brake.
8
7
6
5
s0w02111
1O-205
STRUCTURE
AND FUNCTION
Function 1. Applying and releasing parking brake The parking brake is applied or released by using the parking brake switch (combination switch). 2.
Automatic parking brake When the engine stops (when the starting switch is OFF), the parking brake is automatically applied to prevent the machine from running away when the operator is away from his seat.
3.
Emergency brake If the pressure in the oil pump should drop because of damage to the hydraulic circuit and the braking force can not be ensured, the parking brake is applied automatically to act as an emergency brake.
4.
Parking brake safety It is dangerous if the parking brake can be released simply by turning the starting switch ON after the automatic parking brake has been applied. Therefore, to ensure safety, the system is designed so the brake cannot be released unless the starting switch is turned ON and then the parking brake switch is also turned ON.
5.
Neutralizer The parking brake may seize if the machine is driven with the parking brake still applied. To prevent this problem, the caution lamp lights up and the alarm buzzer sounds to warn the operator of the mistaken operation. In addition to this, when the parking brake is applied, the transmission is forcibly shifted to neutral to make it impossible to drive the machine. However, the braking distance will become longer if the transmission is shifted to neutral when the emergency brake is applied. It may also be necessary to move the machine if it stops in places where it is prohibited to stop (such as on railway crossings). To overcome this, the circuit is designed so that the transmission is not shifted to neutral when the emergency brake is applied.
IO-206
ELECTRIC
6.
PARKING
BRAKE
CONTROL
Parking brake emergency release solenoid valve If the supply of pressure oil from the transmission pump should stop because of some failure, it is possible to actuate the emergency relief solenoid valve with the parking brake emergency release switch in the operators compartment. This sends the accumulator charge pressure in the brake piping to the parking brake cylinder to release the parking brake.
STRUCTURE AND FUNCTION
ELECTRIC PARKING BRAKE CONTROL
PARKING BRAKE EMERGENCY RELEASE SWITCH
EMERGENCY BRAKE SWITCH
10-207
STRUCTURE AND FUNCTION PARKING SAFETY RELAY NEUTRALIZER RELAY
10-208
ELECTRIC PARKING BRAKE CONTROL
STRUCTURE AND FUNCTION
ELECTRIC PARKING BRAKE CONTROL
OPERATION 1. Starting switch OFF
When the starting switch is turned OFF, the battery relay is opened, so electricity does not flow to the parking brake circuit. For this reason, if the starting switch is at the OFF position, no electric current flows to the parking brake solenoid valve, regardless of whether the parking brake switch is ON (applied) or OFF (released), so the parking brake is actuated. (Automatic parking brake)
10-209
STRUCTURE AND FUNCTION
ELECTRIC PARKING BRAKE CONTROL
2. Starting switch ON 2-1 When parking brake switch is ON (actuated) before starting switch is turned ON.
The electric current flows in circuit e battery + ground, so the battery relay is closed. When this happens, electric current flows in circuit battery + h terminal 1 - 3 ng brake safety relay terminal 1-2 the parking safety relay is actuated and safety relay terminals 3 - 5 are closed. When this happens, circuit e battery + y terminal 5 - 3 d. From this point, the parking safety relay is in the condition of circuit g switch is turned OFF.
10-210
In this condition, electric current does not flow to the parking brake solenoid valve, so the parking brake is actuated. In addition, in this condition, neutralizer relay terminals 3 and 5 are open, so electric current does not flow to the transmission directional circuit, and the transmission is shifted to neutral.
STRUCTURE AND FUNCTION
ELECTRIC PARKING BRAKE CONTROL
2-2 When parking brake switch is OFF (actuated) before starting switch is turned ON
Electric current flows in circuit starting switch relay coil the battery relay is closed. However, in this case, the parking brake switch is OFF (released), so the parking safety relay is not actuated. For this reason, the electric current does not flow to the parking brake solenoid valve, so after the automatic parking brake is applied, the parking brake is not released automatically even when the starting switch is turned ON.
In addition, the electric current does not flow to the transmission directional circuit, so the machine does not move.
10-211
STRUCTURE AND FUNCTION
ELECTRIC PARKING BRAKE CONTROL
3. Parking brake switch OFF (released) When the parking brake switch is turned from ON to OFF after the starting switch is turned ON
If the parking brake switch is turned from ON (actuated) to OFF (released), the circuit for terminals 2 and 3 of the parking brake switch is connected, and the parking brake safety relay is also actuated. For this reason, electric current flows in circuit parking brake safety relay e switch, and then flows to circuits n below.
10-212
This circuit is formed from the emergency brake switch arking brake solenoid valve ground, and the parking brake is released. This circuit is formed from the battery + battery relay neutralizer relay terminal 3 - 5 transmission directional circuit, so when the directional lever is operated, the machine will move.
STRUCTURE AND FUNCTION
ELECTRIC PARKING BRAKE CONTROL
4. Parking brake switch ON (actuated)
If the parking brake switch is turned ON (applied) after carrying out operations with the parking brake switch OFF (released), the circuit in the diagram above is formed. Electric current does not flow to the parking brake solenoid valve, so the oil pressure from the transmission pump to the parking brake cylinder is shut off. At the same time, the oil pressure inside the parking brake cylinder passes through the parking brake valve and is drained, so the parking brake is applied by the force of the spring.
In addition, at the same time, the neutralizer relay is reset, so the circuit between terminals 3 and 5 is opened, and no electricity flows to the transmission directional circuit, so the transmission is shifted to neutral. This kind of neutralizer relay shuts off the electric current going to the transmission solenoid valve when the parking brake is applied and shifts the transmission to neutral to prevent seizure of the parking brake if the operator should drive the machine with the parking brake still applied.
10-213
STRUCTURE AND FUNCTION
ELECTRIC PARKING BRAKE CONTROL
5. When main brake oil pressure drops (emergency brake actuated)
Operation If the oil pressure in the main brake line drops, the emergency brake switch installed to the accumulator is opened. For this reason, the electric current stops flowing to the parking brake solenoid valve, so the oil pressure inside the parking brake cylinder is drained and the parking brake is applied. However, in this case, the condition is different from the case where the parking brake switch is ON (applied), because there is electric current flowing to the neutralizer relay coil.
10-214
For this reason, electric current flows to the transmission directional circuit, and it is possible to engage the transmission clutch. In this way, it is possible to use the engine brake when the emergency brake is applied, so the braking distance becomes shorter. At the same time, if the emergency brake has been applied and it is necessary to move the machine (for example, if the emergency brake is applied when the machine is on a railway crossing), it is possible to move the machine by operating the transmission lever.
STRUCTURE AND FUNCTION
ELECTRIC PARKING BRAKE CONTROL
6. Parking brake emergency release
Operation If the machine should stop because of engine trouble, the oil pressure from the transmission pump to the parking brake cylinder is shut off and the parking brake is applied. When this happens, the oil pressure in the main brake line is stored in the accumulator. When the emergency release switch is turned on (released), the buzzer sounds, and at the same time, electric current flows to the emergency parking brake release solenoid valve.
The oil pressure stored in the accumulator in the main brake line then flows to the parking brake cylinder to release the parking brake. The emergency release switch should normally be kept at the OFF position and should be returned to the OFF position after the emergency release.
10-215
STRUCTURE AND FUNCTION
ELECTRIC PARKING BRAKE CONTROL
7. Function of parking brake neutralizer relay
OUTLINE When the parking brake is being actuated, the transmission is held at neutral to prevent the parking brakes from dragging if the machine is operated by mistake.
OPERATION 1. When the parking brake is actuated (ON), electricity flows from the battery relay g brake switch terminals 1 - 3 relay terminal 1 y relay coil is actuated, and safety relay terminals 3 and 5 are connected to form the circuit.
10-216
2. When the parking brake switch is OFF (released) and the engine is started, the circuit in Item 1 is not formed, so the parking brake switch must be turned ON. 3. When the parking brake is being actuated, electricity does not flow to the neutralizer relay coil, so neutralizer relay terminal 3 and terminal 5 are separated and no electricity flows to the transmission directional circuit. In this way, when the parking brake is applied, the transmission is held at neutral.
20 TESTING, ADJUSTING AND TROUBLESHOOTING Standard value table for engine - in chassis . . . 20-3 Standard value table for chassis . . . . . . . . . . . . . 20-4 Standard value table for electrical system . . . . . 20-9 Service tools for testing, adjusting & troubleshooting . . . . . . . . . . . . . . . . . . . . . . 20-22 Sketches of special tools . . . . . . . . . . . . . . . . . 20-23 Measuring engine speed . . . . . . . . . . . . . . . . . . 20-24 Measuring intake manifold pressure . . . . 20-25 Measuring intake air restriction . . . . . . . . . 20-26 Measuring engine lubricating oil pressure . 20-27 Measuring fuel filter inlet restriction . . . . . . 20-28 Measuring blow-by pressure . . . . . . . . . . . 20-29 Measuring exhaust back pressure . . . . . . . 20-30 Measuring coolant temperature . . . . . . . . . 20-31 Measuring and adjusting valve clearance 20-32 Alternator drive belt . . . . . . . . . . . . . . . . . . . . . . 20-33 Air conditioner belt . . . . . . . . . . . . . . . . . . . . . . . 20-34 Measuring exhaust temperature . . . . . . . . . . . . 20-35 Exhaust gas color . . . . . . . . . . . . . . . . . . . . . . . 20-36 Measuring engine stall speeds . . . . . . . . . . . . . 20-38 Measuring torque converter stall . . . . . . . . . . . 20-38 Measuring hydraulic stall . . . . . . . . . . . . . . . . . . 20-39 Measuring full stall . . . . . . . . . . . . . . . . . . . . . . . 20-39 Adjusting engine speed sensor . . . . . . . . . . . . . 20-40 Measuring shift levers . . . . . . . . . . . . . . . . . . . . 20-41 Measuring accelerator pedal . . . . . . . . . . . . . . 20-42 Measuring torque converter and transmission oil pressure . . . . . . . . . . . . . . 20-44 Flushing torque converter and transmission hydraulic circuit . . . . . . . . . . . 20-47 Moving machine when transmission valve fails . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-48 Testing and adjusting steering wheel . . . . . . . . 20-50 Steering oil pressure . . . . . . . . . . . . . . . . . . . . . 20-52 Steering stop valve . . . . . . . . . . . . . . . . . . . . . . 20-54 Measuring brake pedal . . . . . . . . . . . . . . . . . . . 20-55 Measuring brake performance . . . . . . . . . . . . . 20-56
Testing brake oil pressure . . . . . . . . . . . . . . . . . 20-57 Measuring brake disc wear . . . . . . . . . . . . . . . . 20-58 Parking brake performance . . . . . . . . . . . . . . . 20-59 Parking brake oil pressure . . . . . . . . . . . . . . . . 20-60 Parking brake disc wear . . . . . . . . . . . . . . . . . . 20-62 Manual release method for parking brake . . . . 20-63 PPC oil pressure . . . . . . . . . . . . . . . . . . . . . . . . 20-64 Adjusting PPC valve linkage . . . . . . . . . . . . . . . 20-66 Accumulator charge pressure . . . . . . . . . . . . . 20-67 Work equipment hydraulic pressure . . . . . . . . . 20-68 Releasing remaining pressure in hydraulic circuit . . . . . . . . . . . . . . . . . . . . . . 20-70 Adjusting work equipment lever linkage . . . . . . 20-71 Bleeding air . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-72 Bucket positioner . . . . . . . . . . . . . . . . . . . . . . . . 20-73 Boom positioner . . . . . . . . . . . . . . . . . . . . . . . . . 20-74 Transmission controller . . . . . . . . . . . . . . . . . . . 20-76 Adjusting main monitor (speed module) . . . . . . . . . . . . . . . . . . . . . 20-78 Points to remember when troubleshooting . . 20-202 Sequence of events in troubleshooting . . . . . 20-203 Points to remember when carrying out maintenance . . . . . . . . . . . . . . . . . . . . 20-204 Checks before troubleshooting . . . . . . . . . . . . 20-212 Handling connectors . . . . . . . . . . . . . . . . . . . . 20-213 Precautions when troubleshooting . . . . . . 20-214 Method of reading troubleshooting tables . . . . . . . . . . . . . . . . . . . . . . . . . 20-216 Air conditioner / heater (Denso) . . . . . . . . . . . 20-902 Visual and audible inspection . . . . . . . . . . 20-902 Troubleshooting with manifold gauge . . . 20-903 Troubleshooting the electrical circuit . . . . 20-907 Cooler circuit troubleshooting . . . . . . . . . 20-911
20-1
WARNING! When carrying out testing, adjusting, or troubleshooting, park the machine on level ground, insert the safety pins, and use blocks to prevent the machine from moving.
WARNING! When carrying out work together with other workers, always use signals and do not let unauthorized people near the machine.
WARNING! When checking the coolant level, always wait for the coolant to cool down. If the radiator cap is removed while the coolant is still hot, the coolant will spurt out and cause burns.
WARNING! Be careful not to get caught in the fan, fan belt or other rotating parts.
20-2
TESTING AND ADJUSTING
STANDARD VALUE TABLE FOR ENGINE
STANDARD VALUE TABLE FOR ENGINE - In Chassis
Item
Machine model
WA500-3L
Engine model
Cummins N14
Measure condition
Unit
High idle Engine speeds
Low idle
kW / rpm
Rated speed
Standard value for new machine
Service limit value
2300 ± 50
2300 ± 100
760 ± 50
760 ± 75
250 / 2100
250 / 2100
Intake manifold pressure
At T.C. stall and W.O.T (Wide Open Throttle)
mm Hg
1170 - 1500
1170 - 1500
Intake air restriction
At T.C. stall and W.O.T. at restriction indicator port
mm H 2O
New element: 380 Used Element: 635
635 max.
Lubricating oil pressure with SAE 15W-40 oil & coolant temperature in operating range
Minimum at low idle
kPa (kg/cm²)
70 (0.70)
70 (0.70)
Minimum at high idle
kPa (kg/cm²)
175 (1.75)
175 (1.75)
Fuel filter inlet restriction
Maximum restriction at high idle
mm Hg
New filter: 102 Used filter: 203
New filter: 102 Used filter: 203
Blow-by pressure
Coolant temperature in operating range: Service Tool orifice size: 7.67 mm At T.C. stall and W.O.T.
mm H 2O
305
460
Exhaust back pressure
Maximum at T.C. stall and W.O.T.
mm Hg
76
76
Coolant temperature
Maximum operating temperature at engine outlet
80 - 90
100 max.
Valve clearance
Engine cold: Intake valves Exhaust valves
mm
0.35 0.69
0.35 0.69
N (lbf)
620 (140)
270 - 490 (60 - 110)
mm
10 - 15
10 - 15
Alternator belt
Deflection when pressed with finger force of approx. 98 N (10 kg)
Air conditioner compressor belt tension
Deflection when pressed with finger force of approx. 98 N (10 kg)
For further detailed information, refer to Engine Shop Manual.
20-3
TESTING AND ADJUSTING
STANDARD VALUE TABLE FOR CHASSIS
STANDARD VALUE TABLE FOR CHASSIS Machine model
WA500-3L
Engine model
Cummins N14 Standard value for new machine
Service limit value
2140 ± 100
2140 ± 100
2180 ± 100
2180 ± 150
1820 ± 100
1820 ± 200
N (kg)
71.05 ± 2.45 (7.25 ± 0.25)
Max. 97 (10)
Operating angle: x1 x2
degree degree
48 34 - 35
Stopper height (L)
mm
60
Item Engine stall speeds: Torque converter Hydraulic Full
Measurement condition Coolant temperature in operating range Torque converter oil temperature in operating range Hydraulic oil at normal operating temperature
Accelerator pedal: Operating force
Item
Measurement condition
Shift lever operating force and stroke
Measure at center of lever knob
Directional lever operating force N-F N-R Speed lever operating force 1st - 2nd 2nd - 3rd 3rd - 4th Directional lever travel N-F N-R Speed lever travel 1st - 2nd -3rd -4th
20-4
Unit
rpm
---
Standard value for new machine
Service limit value
N (kg)
5.88 +4.9 / -2.94 (0.6 +0.5 / -0.3)
Max. 16.66 (1.7)
N (kg)
5.88 +4.9 / -2.94 (0.6 +0.5 / -0.3)
Max. 16.66 (1.7)
mm
35 ±10
35 ±20
mm
35 ±10
35 ±20
Unit
Engine stopped
TESTING AND ADJUSTING
Item
STANDARD VALUE TABLE FOR CHASSIS Standard value for new machine
Service limit value
0.39 ±0.1 (4 ±1)
0.39 ±0.1 (4 ±1)
0.83 ±0.1 (8.5 ±1)
0.83 ±0.1 (8.5 ±1)
3.28 ±0.2 (33.5 ±2) 3.48 ±0.15 (35.5 ±1.5)
3.28 ±0.2 (33.5 ±2) 3.48 ±0.15 (35.5 ±1.5)
3.23 ±0.15 (33 ±1.5) 3.53 ±0.15 (36 ±1.5)
3.23 ±0.15 (33 ±1.5) 3.53 ±0.15 (36 ±1.5)
0.21 ±0.08 (2.15 ±0.85)
0.21 ±0.08 (2.15 ±0.85)
Max. 2.5 Max. 4.0
-
mm
2 - 10
-
mm N (kg)
Max. 50 12.25 ±2.45 (1.25 ±0.25)
50-100 Max.19.6 (2.0)
Sec. Sec.
Max. 5.5 Max. 3.1
Max. 6.5 Max. 4.5
Engine speed: High idling
Turns
3.6 ±0.4
Max. 4.5
Engine speed: 1200 rpm
mm
25 ±2
-
Measurement condition
Unit
Oil pressure of torque converter and transmission. Torque converter outlet port oil pressure Torque converter inlet port oil pressure ECMV output (clutch) oil pressure 1st 2nd, 3rd, 4th, F-R Main relief valve Low idling
Torque converter oil temperature: 60-80 Engine speed: High idling
MPa kg/cm²
Manual switch ON
High idling
Lubrication pressure (oil cooler outlet port) Tire and wheel Fitting of wheel lock ring (A) (B) Clearance of wheel lock ring (C)
Steering wheel Steering wheel play Steering wheel operating force Operating time of steering wheel Low idle High idle Turning speed Clearance between front and rear frame
Tire inflation pressure Specified pressure
Road surface: Flat, horizontal, dry, paved surface: Hydraulic temp.: 45 55 Machine posture: Facing straight
20-5
TESTING AND ADJUSTING
Testing and measuring item Steering oil pressure Main relief oil pressure
STANDARD VALUE TABLE FOR CHASSIS
Measurement condition Hydraulic temperature: 45 - 55 Engine speed: High idle
Orbit-roll output pressure
Brake pedal Operating force
Engine speed: Low idle Hydraulic temperature: 45-55
Operating angle Play Accumulator Charge cut-in pressure Point where brake oil pressure warning lamp goes out
Brake performance
Drop in brake oil pressure
Wear of brake disc
20-6
Road surface: Flat, horizontal, dry, paved surface Speed when applying brakes: 20 km/h Time lag when pressing the pedal: 0.1 sec. Brake pedal operating force: 294 ±29.4 N (30 ±3 kg) Tire inflation pressure: Specified pressure Coolant temperature: Inside operating range Test pressure: 53 kg/cm²/5 min. Piston stroke
Service limit value 20.58 +0.98 / -0.29 (210 +10 / -3)
3.72 +0.39 / -0.19 (38 +4 / -2)
3.72 +0.39 / -0.19 (38 +4 / -2)
N (kg)
294 ±29.4 (30 ±3)
Max. 421.4 (43)
degree
45
-
mm
15 +1 / -0
-
5.88 +0.49 / -0 (60 +5 / -0)
5.88 +0.49 / -0 (60 +5 / -0)
9.8 +0.98 / -0 (100 +10 / -0)
9.8 +0.98 / -0 (100 +10 / -0)
kg/cm²
6.0 ±0.1 6.0 +0.4
6.0 ±0.1 6.0 +0.4
m
Max. 5
Max. 5
kg/cm²
Max. 5
Max. 5
mm
2.2-5.5
Max. 8.0
MPa kg/cm2
MPa kg/cm²
Coolant temperature: Inside operating range
Standard value for new machine 20.58 +0.98 / -0.29 (210 +10 / -3)
Engine speed: Low idle Hydraulic temperature: 45-55
Charge cut-out pressure Point where oil pressure is going up and then starts to go down Warning buzzer pressure Actuating starting Actuating stopping
Unit
TESTING AND ADJUSTING
Testing and measuring item
Parking brake performance
Thickness of pad Clearance between disc and pad Dump and lift control levers Lift arm control lever operating force Hold Raise Hold Lower Lower Float Dump control lever operating force Hold Hold Tilt
STANDARD VALUE TABLE FOR CHASSIS
Measurement condition
Unit
Tire inflation pressure: Specified pressure Road surface: Flat, dry, paved surface with 1/5 (11 Machine: In operating condition
No machine movement
With back plate Total of both side
mm
kg Hydraulic temperature: 45 - 55 Engine speed: Low idle Coolant temperature: Inside operating range
Lift arm control lever travel Hold Hold Hold
Service limit value
No machine movement
31.7
12.7
1.06 ±0.18
Max. 2.3
Max. 2.5 2-4 Max. 2.5 2-4 2-4
Max. 3.5 Max. 6 Max. 3.5 Max. 6 Max. 6
Max. 2.5 Max. 2.5 2-4
Max. 3.5 Max. 3.5 Max. 6
52 - 82 34 - 64 52 - 82
37 - 97 19 - 79 37 - 97
45 - 75 45 - 75
30 - 90 30 - 90
38 - 40 210 ±5
36 - 42 210 ±10
mm
Dump control lever travel Hold Hold
Relief oil pressure PPC valve Main control valve
Standard value for new machine
Coolant temperature: Inside operating range Hydraulic temperature: 45 - 55 Engine speed: High idle
kg/cm²
20-7
TESTING AND ADJUSTING
Testing and measuring item
STANDARD VALUE TABLE FOR CHASSIS
Measurement condition
Operating speeds Lift arm lifting time Lift arm lowering time Bucket dumping time Bucket tilt back time (Full stroke) Bucket tilt back time (Horizontal position of bucket)
Coolant temperature: Inside operating range Hydraulic temperature: 45 - 55 Engine speed: High idle Steering position: Neutral Bucket: empty
Hydraulic drift of lift arm and bucket Retraction of lift cylinder rod
Coolant temperature: Inside operating range Hydraulic temperature: 45 - 55 Stop engine, leave for 5 minutes, then measure for next 15 minutes. Lift arm horizontal Bucket horizontal Bucket: empty
Retraction of dump cylinder rod
Unit
sec.
mm
Bucket positioner Clearance of switch
Standard value for new machine
Service limit value
6.8 - 7.4 3.0 - 4.0 1.4 - 2.0
Max. 8.9 Max. 4.8 Max. 2.4
1.9 - 2.5
Max. 3.0
1.3 - 1.9
Max. 2.3
Max. 40
Max. 40
Max. 20
Max. 20
3-5
-
3-5
-
mm Boom kick-out Clearance of switch
20-8
TESTING AND ADJUSTING
STANDARD VALUE TABLE FOR ELECTRICAL SYSTEM
STANDARD VALUE TABLE FOR ELECTRICAL SYSTEM Name of component
Connector number
Inspection method
Measurement conditions
Judgement table If the condition is as shown in the table below, it is normal Between C1 (7), (13) - chassis
Power source
C1
Measure voltage
Between C2 (1), (12) - chassis 20 - 30 V Between C1 (7), (13) - (6), (12)
1. Turn starting switch OFF 2. Insert T-adapter 3. Turn starting switch ON
Transmission & Travel Damper Controller
Between C2 (1), (12) - (11), (21) If the condition is as shown in the table below, it is normal Power source (signal)
C3A
Measure voltage
Between (6) - (17) 20 - 30 V Between (6) - chassis If the condition is as shown in table below, the sensor is normal
Parking brake switch
CN L01
Measure voltage
Parking brake ON, Between (1) - (3),
20 - 30V
Parking brake OFF, Between (1) - (3),
Max. 1V
If condition is as shown in the table below, the sensor is normal ECMV solenoid (1st)
CN4 (male)
Measure resistance
Between (1) - (2)
5 - 15
Between (1), (2) - chassis
Min. 1 M
If the condition is as shown in the table below, the sensor is normal ECMV solenoid (2nd)
CN6 (male)
Measure resistance
Between (1) - (2)
5 - 15
Between (1), (2) - chassis
Min. 1 M
If the condition is as shown in the table below, the sensor is normal ECMV solenoid (3rd)
CN12 (male)
Measure resistance
Between (1) - (2)
5 - 15
Between (1), (2) - chassis
Min. 1 M
1. Turn starting switch OFF 2. Insert T-adapter 3. Turn starting switch ON 4. Apply parking brake 1. Turn starting switch OFF 2. Insert T-adapter 3. Turn starting switch ON
1. Turn starting switch OFF 2. Disconnect connector 3. Connect Tadapter 1. Turn starting switch OFF 2. Disconnect connector 3. Connect Tadapter 1. Turn starting switch OFF 2. Disconnect connector 3. Connect Tadapter
20-9
TESTING AND ADJUSTING
Name of component ECMV solenoid (4th)
Transmission & Travel Damper Controller
ECMV solenoid (F)
ECMV solenoid (R)
Connector number CN8 (male)
CN16 (male)
CN14 (male)
1st - CN5 (male)
STANDARD VALUE TABLE FOR ELECTRICAL SYSTEM
Inspection method Measure resistance
Measure resistance
Measure resistance
Measure resistance
2nd - CN7 (male)
If the condition is as shown in the table below, it is normal Between (1) - (2)
5 - 15
Between (1), (2) - chassis
Min. 1 M
If the condition is as shown in the table below, the sensor is normal Between (1) - (2)
5 - 15
Between (1), (2) - chassis
Min. 1 M
If the condition is as shown in the table below, it is normal Between (1) - (2)
5 - 15
Between (1), (2) - chassis
Min. 1 M
If the condition is as shown in the table below, it is normal
Speed lever at measurement position:
3rd - CN13 (male)
Between (1) - chassis
4th - CN9 (male)
Max. 1
Speed lever not at measurement position: Between (1) - chassis
ECMV fill switch F - CN17 (male)
Measurement conditions
Judgement table
Measure resistance
R - CN15 (male) Directional lever at measurement position: Max. 1
Directional lever not at measurement position: Between (1) - chassis
20-10
1. Turn starting switch OFF 2. Disconnect connector 3. Connect Tadapter
1. Turn starting switch OFF 2. Disconnect connector 3. Connect Tadapter
1. Turn starting switch OFF. 2. Disconnect connector. 3. Connect Tadapter. 4. Start engine. 5. Place directional lever at N. 6. Turn manual switch ON.
Min. 1
If the condition is as shown in the table below, it is normal
Between (1) - chassis
1. Turn starting switch OFF 2. Disconnect connector 3. Connect Tadapter
Min. 1
1. Turn starting switch OFF. 2. Disconnect connector. 3. Connect Tadapter. 4. Start engine. 5. Turn transmission cut-off (lamp OFF) 6. Turn parking brake switch OFF. 7. Depress brake.
TESTING AND ADJUSTING
Name of component Transmission oil temperature sensor
Transmission & Travel Damper Controller
Transmission oil temperature (controller)
Engine speed sensor
Engine speed (controller)
Connector number CN11 (male)
C2
E04 (male)
C4
STANDARD VALUE TABLE FOR ELECTRICAL SYSTEM
Inspection method Measure resistance
Measure resistance
Measure resistance
Measure voltage
If the condition is as shown in the table below, the sensor is normal Normal temperature (25 Between (1) - chassis
3.8 - 4.8
100 Between (1) - chassis
3.6 - 3.9
If the condition is as shown in the table below, it is normal Normal temperature (25 Between (11) - (17)
4.4 - 4.6
100 Between (11) - (17)
2.1 - 2.3
If the condition is as shown in the table below, the sensor is normal Between (1) - (2)
500 - 1000
Between (1) - (2) - chassis
Min. 1 M
If the condition is as shown in the table below, it is normal Measure with AC range Between (2) - (9)
Engine speed
___
CN3 (male)
Adjust
Measure resistance
Speed Adjust ___
Measurement conditions
Judgement table
Max. 0.5 V
If the condition is as shown in the table below, the sensor is normal 1.
Screw in until speed sensor contacts ring gear, then turn back 3/4 - 1 turn.
2.
Sensor should work normally when adjusted as above.
If the condition is as shown in the table below, it is normal Between (1) - (2)
500 - 1000
Between (1) - (2) - chassis
Min. 1 M
If the condition is as shown in the table below, the sensor is normal 1.
Screw in until speed sensor contacts ring gear, then turn back 3/4 - 1 turn.
2.
Sensor should work normally when adjusted as above.
1. Turn starting switch OFF 2. Disconnect connector 3. Connect Tadapter
1. Turn starting switch OFF 2. Disconnect connector 3. Connect Tadapter
1. Turn starting switch OFF 2. Disconnect connector 3. Connect Tadapter 1. Turn starting switch OFF 2. Disconnect connector 3. Start engine. ___
1. Turn starting switch OFF 2. Disconnect connector 3. Connect Tadapter ___
20-11
TESTING AND ADJUSTING
Name of component
Connector number
STANDARD VALUE TABLE FOR ELECTRICAL SYSTEM
Inspection method
Speed lever (1st)
If the condition is as shown in the table below, the sensor is normal
Directional lever (R)
Directional lever (N)
20-12
20 - 30 V
Speed lever not at 1st. Between (7) - chassis
Max. 1 V
Speed lever at 2nd. Between (15) - chassis
20 - 30 V
Speed lever not at 2nd. Between (15) - chassis
Max. 1 V
If the condition is as shown in the table below, the sensor is normal
C3B
Directional lever (F)
Speed lever at 1st. Between (7) - chassis
If the condition is as shown in the table below, it is normal
Speed lever (3rd)
Controller
Transmission & Travel Damper Controller
Speed lever (2nd)
Speed lever (4th)
Measurement conditions
Judgement table
Measure voltage
Speed lever at 3rd. Between (8) - chassis
20 - 30 V
Speed lever not at 3rd. Between (8) - chassis
Max. 1 V
If the condition is as shown in the table below, it is normal Speed lever at 4th. Between (16) - chassis
20 - 30 V
Speed lever not at 4th. Between (16) - chassis
Max. 1 V
If the condition is as shown in the table below, the sensor is normal Directional lever at F. Between (5) - chassis
20 - 30 V
Directional lever at F. Between (5) - chassis
Max. 1 V
If the condition is as shown in the table below, it is normal Directional lever at R. Between (6) - chassis
20 - 30 V
Directional lever not at R. Between (6) - chassis
Max. 1 V
If the condition is as shown in the table below, the sensor is normal Directional lever at N. Between (13) - chassis
20 - 30 V
Directional lever not at N. Between (13) - chassis
Max. 1 V
1. Turn starting switch OFF 2. Disconnect connector 3. Turn starting switch ON
TESTING AND ADJUSTING
Controller
Name of component S-NET (between transmission and main controller
Connector number C3B
STANDARD VALUE TABLE FOR ELECTRICAL SYSTEM
Inspection method Measure voltage
Transmission & Travel Damper Controller
If the condition is as shown in the table below, the sensor is normal
Between (4), (12) - chassis
Kick-down Switch
Hold Switch
Transmission cut-off switch
Power source
4-8V
If the condition is as shown in the table below, it is normal
L15 (male)
L12 (male)
C5
Measure resistance
Measure resistance
Measure voltage
Controller
Manual Switch
Measurement conditions
Judgement table
CN3 (male)
Measure voltage
Kick-down switch ON Between (1) - (2)
Max. 1
Kick-down switch OFF Between (1) - (2)
Min. 1 M
If the condition is as shown in the table below, the sensor is normal Hold switch ON Between (3) - (4)
Max. 1
Hold switch OFF Between (3) - (4)
Min. 1 M
If the condition is as shown in the table below, it is normal When operated normally Between (1) - (2)
Max. 1
When left brake is depressed Between (1) - (2)
Min. 1 M
If the condition is as shown in the table below, the sensor is normal Manual switch ON Between (14) -chassis
20 - 30 V
Manual switch OFF Between (14) -chassis
Max. 1 V
If the condition is as shown in the table below, it is normal Between (1) - (2) - chassis
Main Monitor
20 - 30 V Between (1) - (2) - (3) Charge (alternator)
L05
Measure voltage
If the condition is as shown in the table below, the sensor is normal Engine running (at above ½ throttle. Between (5) - (3)
28 ± 2 V
Starting switch ON Between (5) - (3)
Max. 1 V
1. Turn starting switch OFF 2. Insert Tadapter 3. Turn starting switch ON 1. Turn starting switch OFF 2. Disconnect connector 3. Connect Tadapter
1. Turn starting switch OFF 2. Disconnect connector 3. Connect Tadapter
1. Turn starting switch OFF 2. Disconnect connector 3. Connect Tadapter
1. Turn starting switch OFF 2. Insert Tadapter 3. Turn starting switch ON
1. Turn starting switch OFF 2. Insert Tadapter 3. Turn starting switch ON 1. Turn starting switch OFF 2. Insert Tadapter
* If the battery is old, or after starting in cold areas, the voltage may not rise for some time.
20-13
TESTING AND ADJUSTING
Name of component Directional switch (N)
Starting switch terminal C
Maintenance Monitor Related
Starting switch terminal C
Starting switch terminal BR
Connector number L05
L09 (male)
L04
L09 (male)
STANDARD VALUE TABLE FOR ELECTRICAL SYSTEM
Inspection method Measure voltage
Measure voltage
Measure voltage
Measure voltage
If the condition is as shown in the table below, the sensor is normal Directional lever at N Between (8) - (3)
20 - 30 V
Directional lever not at N Between (8) - (3)
Max. 1 V
If the condition is as shown in the table below, it is normal Starting switch at start Between (3) - chassis
20 - 30 V
Starting switch at OFF or ON Between (3) - chassis
Max. 1 V
If the condition is as shown in the table below, the sensor is normal Engine started Between (4) - (3)
20 - 30 V
Starting switch OFF or ON Between (4) - (3)
Max. 1 V
If the condition is as shown in the table below, it is normal Starting switch ON Between (2) - chassis Starting switch OFF Between (2) - chassis
Starting switch terminal BR
Parking brake indicator switch
Directional switch (F)
L07
CN19 (male)
L08
Measure voltage
Measure resistance
Measure voltage
20 - 30 V
Starting switch ON Between (2) - chassis
20 - 30 V
Starting switch OFF Between (2) - chassis
Max. 1 V
If the condition is as shown in the table below, it is normal Parking brake ON Between (1) - (2)
Max 1
Parking brake OFF Between (1) - (2) - chassis
Min. 1 M
If the condition is as shown in the table below, the sensor is normal
Directional lever not at F Between (7) - chassis
1. Turn starting switch OFF 2. Insert Tadapter 3. Turn starting switch ON
1. Turn starting switch OFF 2. Insert Tadapter
1. Turn starting switch OFF 2. Insert Tadapter
1. Turn starting switch OFF 2. Disconnect connector 3. Connect Tadapter
Max. 1 V
If the condition is as shown in the table below, the sensor is normal
Directional lever at F Between (7) - chassis
20-14
Measurement conditions
Judgement table
20 - 30 V Max. 1 V
1. Turn starting switch OFF 2. Insert Tadapter
1. Turn starting switch OFF 2. Disconnect connector 3. Connect Tadapter
1. Turn starting switch OFF 2. Insert Tadapter 3. Turn starting switch ON
TESTING AND ADJUSTING
Name of component Directional lever (R)
Power source
Connector number L08
L18
STANDARD VALUE TABLE FOR ELECTRICAL SYSTEM
Inspection method Measure voltage
Measure voltage
Measurement conditions
Judgement table If the condition is as shown in the table below, the sensor is normal Directional lever at R Between (8) - chassis
20 - 30 V
Directional lever not at R Between (8) - chassis
Max. 1 V
If the condition is as shown in the table below, it is normal Between (1), (2) - chassis 20 - 30 V Between (1), (2) - (3)
Maintenance Monitor Related
Engine water temperature sensor
Torque converter oil temperature sensor
E06 (male)
CN18 (male)
Measure resistance
Measure resistance
If the condition is as shown in the table below, the sensor is normal 50 Between (A) - (B)
Approx. 19
100 Between (A) - (B)
Approx. 3.6
If the condition is as shown in the table below, it is normal Normal temperature (25 Between (1) - (2) 130 Between (1) - (2)
Fuel level sensor
Radiator water level sensor
Engine oil pressure sensor
R07 (male)
G01 (male)
E11
Measure resistance
Measure resistance
Measure resistance
Approx. 40
1. Turn starting switch OFF 2. Insert Tadapter 3. Turn starting switch ON
1. Turn starting switch OFF 2. Insert Tadapter 3. Turn starting switch ON 1. Turn starting switch OFF 2. Disconnect connector 3. Connect Tadapter
1. Turn starting switch OFF 2. Disconnect connector 3. Connect Tadapter
Approx. 1.7
If the condition is as shown in the table below, the sensor is normal Float raised to stopper
Approx. 4
Float lowered to stopper
Approx. 85
If the condition is as shown in the table below, it is normal Water level normal Between (1) - (2)
Max 1
Water level low Between (1) - (2)
Min. 1 M
If the condition is as shown in the table below, the sensor is normal Engine oil pressure: Min. 0.13 MPa (1.3 kg/cm2(Start engine) Between (A) - (C)
Min. 1 M
Engine oil pressure: Max. 0.07 MPa (0.7 kg/cm2(Starting switch ON) Between (A) - (C)
Max. 1
1. Turn starting switch OFF 2. Disconnect connector 3. Drain fuel 4. Remove fuel level sensor 5. Connect Tadapter 1. Turn starting switch OFF 2. Disconnect connector 3. Connect Tadapter
1. Turn starting switch OFF 2. Disconnect connector 3. Connect Tadapter 4. Start engine
20-15
TESTING AND ADJUSTING
Name of component Brake accumulator low pressure switch
Connector number B08 (male) B13 (male)
STANDARD VALUE TABLE FOR ELECTRICAL SYSTEM
Inspection method Measure resistance
If the condition is as shown in the table below, the sensor is normal Accumulator pressure: Min. 5.39 ±0.49 MPa (55 ±5 kg/cm2) Between (1) - (2) Depress brake and lower accumulator pressure to below 4.41 ±0.49 MPa (45 ±5 kg/cm2) Between (1) - (2)
Maintenance Monitor Related
Charge (alternator)
L18
Measure voltage
Measurement conditions
Judgement table
Max. 1
Min. 1 M
If the condition is as shown in the table below, it is normal Engine running (at above 1/2 throttle) Between (12) -(3), (14) Starting switch ON Between (12) -(3), (14)
1. Turn starting switch OFF 2. Disconnect connector 3. Connect Tadapter
28 ±2 V
1. Turn starting switch OFF 2. Insert Tadapter 3. Start engine
Max. 1 V
*If the battery is old, or after starting in cold areas, the voltage may not rise for some time. Engine oil level sensor
Dust indicator
E10 (male)
E19 (male) E20 (female)
Measure resistance
Measure continuity
If the condition is as shown in the table below, the sensor is normal Oil level normal Between (1) - (2)
Max. 1
Oil level abnormal Between (1) - (2)
Min. 1 M
If the condition is as shown in the table below, it is normal Air cleaner normal Between E19 (1) - E20 (1) Air cleaner clogged or engine stopped - No continuity Between E19 (1) - E20 (1)
20-16
Continuity No continuity
1. Turn starting switch OFF 2. Disconnect connector 3. Connect Tadapter
Measurement conditions
TESTING AND ADJUSTING
STANDARD VALUE TABLE FOR ELECTRICAL SYSTEM
Check carefully that there is no one in the surrounding area before starting inspection. When carrying out operations during inspection, raise the work equipment control lever stand for operations, and lower it when traveling. Turn the starting switch OFF before inserting the T-adapter, or making any connections.
Name of component
Measurement conditions
Judgement table If the condition is as shown in Table 1, the monitor panel is normal
Maintenance Monitor Related
Table 1 (CHECK, CAUTION portion) Connector No.
CHECK, CAUTION portion
L18 (male)
Monitor item (input connector)
Measurement conditions
Display
Sensor signal input
Engine water level (8) - (3), (14)
Engine stopped, Starting switch ON
Flashing
15 - 20 V
OFF
Max. 1 V
Flashing
15 - 20 V
OFF
Max. 1 V
Flashing
15 - 20 V
OFF
Max. 1 V
Flashing
15 - 20 V
OFF
Max. 1 V
Flashing
Max. 10 V
OFF
Min. 12 V
Flashing
15 - 20 V
OFF
Max. 1 V
Engine oil level (13) - (3), (14) Engine oil pressure (10) - (3), (14) Brake oil pressure (11) - (3), (14) Battery charge (12) - (3), (14) Air cleaner (15) - (3), (14)
Engine stopped, Starting switch ON Start engine
Start engine
Start engine
Start engine
1. Connect Tadapter
20-17
TESTING AND ADJUSTING
Name of component
STANDARD VALUE TABLE FOR ELECTRICAL SYSTEM
Judgement table
Measurement conditions
Maintenance Monitor Related
Table 2 (Gauge portion)
Gauge portion
20-18
1. Turn starting switch OFF, then insert dummy resistance or measure resistance of sensor. 2. Turn starting switch ON and check display
TESTING AND ADJUSTING
Name of component Parking brake emergency cancel switch
Parking brake emergency cancel solenoid
L90
B14
B09, B10 (male)
Inspection method Measure voltage
Measure voltage
Measure resistance
Others
Emergency brake switch
Connector number
STANDARD VALUE TABLE FOR ELECTRICAL SYSTEM
If the condition is as shown in the table below, the sensor is normal Parking brake emergency cancel switch ON Between (1) -(2) and (3) - (4)
20 - 30 V
Parking brake emergency cancel switch OFF Between (1) -(2) and (3) - (4)
Max. 1 V
If the condition is as shown in the table below, it is normal Parking brake emergency cancel switch ON Between (1) -(2)
20 - 30 V
Parking brake emergency cancel switch ON Between (1) -(2)
Max. 1 V
If the condition is as shown in the table below, the sensor is normal Accumulator pressure: Min. 3.92 ±0.49 MPa (40 ±5 kg/cm2) Between B09 (1) - B10 (2) Depress brake and lower accumulator pressure to below 3.63 ±0.49 MPa (37 ±5 kg/cm2) Between B09 (1) - B10 (2)
Emergency brake switch
BR1
Measure voltage
Depress brake and lower accumulator pressure to below 3.63 ±0.49 MPa (37 ±5 kg/cm2) Between B09 (1) - B10 (2) F05
Measure voltage
Max. 1
1. Turn starting switch OFF 2. Insert Tadapter 3. Turn starting switch ON
1. Turn starting switch OFF 2. Insert Tadapter 3. Turn starting switch ON
1. Turn starting switch OFF 2. Disconnect connector 3. Connect Tadapter
Min. 1 M
If the condition is as shown in the table below, it is normal Accumulator pressure: Min. 3.92 ±0.49 MPa (40 ±5 kg/cm2) Between (7) - (8)
Bucket positioner proximity switch
Measurement conditions
Judgement table
20 - 30 V
1. Turn starting switch OFF 2. Insert Tadapter 3. Turn starting switch ON
Max. 1 V
If the condition is as shown in the table below, the sensor is normal
Between
When screwdriver is brought close
When screwdriver is not brought close
(1) - (2)
20 - 30 V
Max. 3 V
(1) - (3)
20 - 30 V
20 - 30 V
(2) - (3)
Max. 3 V
20 - 30 V
1. Turn starting switch OFF 2. Insert Tadapter 3. Turn starting switch ON
20-19
TESTING AND ADJUSTING
Name of component
F06
Inspection method Measure voltage
Others
Boom kick-out proximity switch
Connector number
STANDARD VALUE TABLE FOR ELECTRICAL SYSTEM
Boom kick-out solenoid
Bucket positioner solenoid
20-20
L16
L17
Measure resistance
Measure resistance
Measurement conditions
Judgement table If the condition is as shown in the table below, the sensor is normal
Between
When screwdriver is brought close
When screwdriver is not brought close
(1) - (2)
20 - 30 V
Max. 3 V
(1) - (3)
20 - 30 V
20 - 30 V
(2) - (3)
Max. 3 V
20 - 30 V
If the condition is as shown in the table below, it is normal Between (1), (2)
19 - 23
Between (1), (2) - chassis
Min. 1 M
If the condition is as shown in the table below, the sensor is normal Between (1), (2)
19 - 23
Between (1), (2) - chassis
Min. 1 M
1. Turn starting switch OFF 2. Insert Tadapter 3. Turn starting switch ON
1. Turn starting switch OFF 2. Disconnect connector 3. Connect Tadapter 1. Turn starting switch OFF 2. Disconnect connector 3. Connect Tadapter
TESTING AND ADJUSTING
Name of component Power source voltage
Connector number L28
STANDARD VALUE TABLE FOR ELECTRICAL SYSTEM
Inspection method Measure voltage
Measurement conditions
Judgement table If the condition is as shown in the table below, the sensor is normal. Between (8), (17), (18) - (9), (18)
Joystick R (right)solenoid
Joystick Controller
Joystick L (left) solenoid
Joystick neutral switch
CNR (male)
CNL (male)
NEUTRAL
Measure resistance
Measure resistance
Measure resistance
When actuated
20 - 30 V
When not actuated
Max. 1 V
If the condition is as shown in the table below, it is normal Between (1) - (2)
10 - 20
Between (1) - chassis
Min. 1 M
If the condition is as shown in the table below, the sensor is normal Between (1) - (2)
10 - 20
Between (1) - chassis
Min. 1 M
If the condition is as shown in the table below, it is normal Joystick neutral switch between (1) - (3) Not at N
Max. 1
1. Turn starting switch OFF 2. Insert Tadapter 3. Turn starting switch ON
1. Turn starting switch OFF 2. Disconnect connector 3. Connect Tadapter 1. Turn starting switch OFF 2. Disconnect connector 3. Connect Tadapter 1. Turn starting switch OFF 2. Disconnect connector 3. Connect Tadapter
At N Min. 1 M Between (1) - chassis Joystick potentiometer
L27
Measure voltage
If the condition is as shown in the table below, it is normal Between (20) - (9) When actuated
Joystick potentiometer
JS7 (male)
Measure resistance
0.5 - 4.5 V
If the condition is as shown in the table below, the sensor is normal Between (1) - (2)
0-5
Between (2) - (3)
4-5
Between (3) - (1)
0-5
1. Turn starting switch OFF 2. Insert Tadapter 3. Turn starting switch ON 1. Turn starting switch OFF 2. Disconnect connector 3. Connect Tadapter
20-21
TESTING AND ADJUSTING
SERVICE TOOLS AND TROUBLESHOOTING
SERVICE TOOLS FOR TESTING, ADJUSTING & TROUBLESHOOTING No.
Check or Measurement Item
Tool Description
Tool Number
Remarks
799-203-8001 799-203-9000 (Kit)
Digital display L: 60 - 20,000 rpm H: 60 - 19,999 rpm
1
Engine speeds
Digital Optical Tachometer
2
Intake manifold pressure
Pressure gauge
See Engine Shop Manual
3
Intake air restriction
Water manometer
See Engine Shop Manual
4
Lubricating oil pressure
Pressure gauge
See Engine Shop Manual
5
Fuel filter inlet restriction
Vacuum gauge
See Engine Shop Manual
6
Blow-by pressure
Tool, adapter & manometer
See Engine Shop Manual
7
Exhaust back pressure
Mercury manometer
See Engine Shop Manual
8
Coolant temperature
Digital temperature gauge
See Engine Shop Manual
9
Valve clearance
Feeler gauge
10
Alternator, fan & water pump drive belts
Tension gauge
ST-1138
Smoke detector
799-201-9000
11
Exhaust gas color Smoke meter
Commercially available
Brake test kit
793-520-1805
Nipple
793-520-1851
Push-pull scale
79A-264-0020
0 - 294.2 N (0 - 30 kg)
79A-264-0090
0 - 490.3 N (0 - 50 kg)
12
13
Brake oil pressure
Operating effort
Commercially available
14
Stroke, hydraulic drift
Scale
Commercially available
15
Work equipment speed
Stop watch
Commercially available
16
Measuring brake disc wear
Calipers
Commercially available
20-22
Discoloration 0-70% with standard color % x 1/10
TESTING AND ADJUSTING
Check or Measurement Item
No
SERVICE TOOLS AND TROUBLESHOOTING
Tool Description
Tool Number
Remarks
17
Moving machine when there is failure in transmission valve
Plate
793T-6851110
-
18
Measuring voltage, resistance value
Tester
79A-264-0210
-
T-adapter assembly
799-601-7400
-
799-601-7310
SWP12P
799-601-7320
SWP16P
799-601-7340
M8P
799-601-7380
JFC2P
19
Troubleshooting of wiring, harness, sensors
Adapter
SKETCHES OF SPECIAL TOOLS TOOL N Note:
Komatsu cannot accept any responsibility for special tools manufactured according to these sketches.
20-23
TESTING AND ADJUSTING
MEASURING ENGINE SPEEDS
MEASURING ENGINE SPEEDS When measuring engine speeds, one worker should measure the engine speed while the other sits in the operator's seat to operate the controls. Always check that the operation is safe, and use agreed upon signals. When removing or installing the measuring equipment, be careful not to touch any high temperature parts. Measure the engine speed under the following conditions. Coolant temperature: Within operating range Torque converter oil temperature: 70 to 90 Hydraulic oil temperature: 45 to 55 1.
Install the digital optical tachometer using the instructions supplied with it. When measuring engine speeds, be careful not to touch any high temperature parts or rotating parts.
2.
Start the engine, and measure the engine speed when it is set to the conditions for measuring. 1) Measuring low idle and high idle speeds. 2) Measure the speed at near the rated speed. When measuring speeds for items other than the above, such as torque converter stall, see the procedure for the item as described in this section.
20-24
TESTING AND ADJUSTING
MEASURING INTAKE MANIFOLD PRESSURE
MEASURING INTAKE MANIFOLD PRESSURE Refer to ENGINE SHOP MANUAL for tools and proper procedure.
20-25
TESTING AND ADJUSTING
MEASURING INTAKE AIR RESTRICTION
MEASURING INTAKE AIR RESTRICTION Refer to ENGINE SHOP MANUAL for tools and proper procedure.
20-26
TESTING AND ADJUSTING
MEASURING ENGINE LUBRICATING OIL PRESSURE
MEASURING ENGINE LUBRICATING OIL PRESSURE Refer to ENGINE SHOP MANUAL for tools and proper procedure.
20-27
TESTING AND ADJUSTING
MEASURING FUEL FILTER INLET RESTRICTION
MEASURING FUEL FILTER INLET RESTRICTION Refer to ENGINE SHOP MANUAL for tools and proper procedure.
20-28
TESTING AND ADJUSTING
MEASURING BLOW-BY PRESSURE
MEASURING BLOW-BY PRESSURE Refer to ENGINE SHOP MANUAL for tools and proper procedure.
20-29
TESTING AND ADJUSTING
MEASURING ENGINE BACK PRESSURE
MEASURING EXHAUST BACK PRESSURE Refer to ENGINE SHOP MANUAL for tools and proper procedure.
20-30
TESTING AND ADJUSTING
MEASURING COOLANT TEMPERATURE
MEASURING COOLANT TEMPERATURE Refer to ENGINE SHOP MANUAL for tools and proper procedure.
20-31
TESTING AND ADJUSTING
MEASURING & ADJUSTING VALVE CLEARANCE
MEASURING AND ADJUSTING VALVE CLEARANCE Refer to ENGINE SHOP MANUAL for tools and proper procedure.
20-32
TESTING AND ADJUSTING
ALTERNATOR DRIVE BELT
ALTERNATOR DRIVE BELT BELT TENSION CHART
Unit: N(lbf)
Belt tension
New tension
Used tension
620 (140)
270 - 490 (60 - 110)
Testing alternator belt tension. Belts will loosen during use. They must be adjusted to the values listed in the Belt Tension Chart. A belt is considered used if it has been in operation for 10 minutes or longer. Use the belt tension gauge, Part No. ST-1138. Check the belt tension. To adjust the alternator belt tension, see the "Engine Operation and Maintenance Manual"
20-33
TESTING AND ADJUSTING
AIR CONDITIONER BELT 1. Testing Measure deflection “c”of the belt when it is pushed with force of approximately 98 N (10 kg) at a point midway between the fan pulley and the air conditioner compressor pulley. Deflection “c”of belt (standard value): 10 - 15 mm
2. Adjusting 1) Loosen mount bolt and nut, and the adjustment plate bolt and nut. 2) Move the position of the air conditioner compressor to adjust the tension of the belt. 3) When the position of the air conditioner compressor is correct, tighten adjustment plate bolt and nut, and the mounting bolt and nut to secure it in position. 4) After adjusting the belt tension, repeat the testing procedure above to check that the tension is adjusted within the standard value.
20-34
AIR CONDITIONER BELT
TESTING AND ADJUSTING
MEASURING EXHAUST TEMPERATURE
MEASURING EXHAUST TEMPERATURE WARNING! The temperature sensor must be installed to the exhaust manifold, so if the machine has been operated, wait for the manifold temperature to drop before installing the sensor. Raise the coolant temperature to operating range before measuring the exhaust temperature.
Measurement procedure 1. When measuring the maximum value during troubleshooting. Carry out actual work and measure the maximum value during operation. Use the PEAK mode (it can store the maximum value in memory) of the temperature gauge function. NOTE: The exhaust temperature varies greatly according to the ambient temperature (temperature of the engine intake air), so if any abnormal value is obtained, carry out temperature compensation..
Compensation = Measured value + 2x (converted ambient temperature - actual ambient temperature). The converted ambient temperature is taken as 20 2. When measuring periodically (during preventive maintenance, etc.) 1) Raise the exhaust temperature by using full stall (torque converter stall + hydraulic pump relief). Standard value: Approximately 700
2) In the above condition, cancel the hydraulic relief, and carry out only torque converter stall. (The temperature will start to go down. If it goes up without going down, raise the set temperature shown in (1) of the right figure). 3) Note the stable temperature when the temperature starts to go down. If only torque converter stall is used when measuring the exhaust temperature, torque converter will overheat before a stable value is obtained.
20-35
TESTING AND ADJUSTING
EXHAUST GAS COLOR
EXHAUST GAS COLOR Measurement condition Coolant temperature: Inside operating range Valve clearance: Standard value
Special tools: No.
Part Number
Part Name
Qty.
A-1
799-201-9000
Handy smoke checker
1
A-2
Commercially available
Smoke checker
1
For tests in the field where there is no air or electricity available, use A-1; for tests in a repair shop, use A-2. Measuring with A-1 WARNING! When measuring the exhaust color, be careful not to touch the exhaust pipe. When measuring the exhaust color, warm the engine up thoroughly (oil temperature 60 1. Fit the filter paper in tool A-1. 2. Insert the exhaust gas suction port into the exhaust pipe, accelerate the engine suddenly, and operate the handle to catch the exhaust gas on the filter paper. 3. Remove the filter paper and compare it with the scale provided to judge the condition.
20-36
TESTING AND ADJUSTING
EXHAUST GAS COLOR
Measuring with A-2 WARNING! When measuring the exhaust color, be careful not to touch the exhaust pipe. When measuring the exhaust color, warm the engine up thoroughly (oil temperature 60 1. Insert probe (A) in outlet of exhaust pipe (1) and secure to exhaust pipe with clip. 2. Connect probe hose, connector hose of accelerator switch plug and air hose to tool A-2. The pressure of the air supply should be under 15 kg/cm². 3. Connect power cord to AC 100 V socket. Check that the power switch is OFF before connecting the cord.
20-37
TESTING AND ADJUSTING
MEASURING ENGINE STALL SPEEDS Measurement conditions Coolant temperature: Inside operating range Hydraulic oil temperature: 45 - 55 Torque converter oil temperature: 70 - 90 Check that the low and high idle speeds are at the standard value. Before measuring at each stall speed, install tachometer (A), using the instructions that came with it. Check that the engine speeds are the standard value. If any item is outside the permitted range, check for any looseness for play in the linkage. Apply the parking brakes and block the tires
1. Measuring torque converter stall 1). Start the engine and run at low idle. 2). Put the directional lever in FORWARD or REVERSE, and speed control lever in the highest speed range. 3) Using the brake, stop the machine and measure the engine speed when the engine when the accelerator pedal is fully depressed. Turn the transmission cut-off selector switch (1) to the OFF position, and use the left brake. (Check that the pilot lamp is OFF). Do not run at stall speed for more than 20 seconds, and do not let the torque converter oil temperature raise above 120 Turn the parking brake switch OFF (release).
20-38
MEASURING ENGINE STALL SPEEDS
TESTING AND ADJUSTING
MEASURING ENGINE STALL SPEEDS
2. Measuring hydraulic stall 1) Start engine and run at high idle. 2) Operate the dump or lift control lever to move the cylinder to the end of its stroke and actuate the relief valve of the main control valve. 3) Measure the engine at this point. Do not run the engine at stall speed for more than 20 seconds, and operate the control lever quickly.
3. Measuring full stall 1) Measure the engine speed when the torque converter stall and hydraulic stall are reached at the same time. Measure full stall when both the torque converter and hydraulic stall speeds are normal. If either stall speed is abnormal, correct and measure the stall speed again.
20-39
TESTING AND ADJUSTING
ADJUSTING ENGINE SPEED SENSOR 1. Engine speed sensor 1) Screw in until the tip of the sensor (1) contacts gear (2). 2) When sensor (1) contacts gear (2), turn back 1 turn. 3) Tighten locknut (3). Locknut: 49 ±4.9 Nm (5.0 ±0.5 kgm) Be particularly careful when handling the sensor wiring to ensure that no excessive force is brought to bear in the wiring. Be careful not to let the tip of the sensor be scratched, or let any foreign particles stick to it.
2. Transmission output shaft speed sensor Adjust transmission output shaft speed sensor (4) using the same procedure as for adjusting the engine speed sensor. However, in step 2, turn back 1/2 - 1 turn.
20-40
ADJUSTING ENGINE SPEED SENSOR
TESTING AND ADJUSTING
MEASURING SHIFT LEVERS
MEASURING SHIFT LEVERS Measurement conditions: Engine stopped Torque converter oil temperature: 60 - 80 Measure at center of lever knob
OPERATING FORCE OF SPEED LEVER Install push-pull scale l2 or a spring balance to the center of the control lever knob, and measure the operating force when the lever is pulled in the direction of operation. Carry out the measurement for each speed range.
TRAVEL OF SPEED LEVER Make a mark (1) at the center of the control lever knob, and measure the travel when the lever is operated in the direction of operation.
20-41
TESTING AND ADJUSTING
MEASURING ACCELERATOR PEDAL OPERATING FORCE 1. Measuring procedure 1) Put push-pull scale "A" in contact with the accelerator pedal at point 150 mm from pedal fulcrum "a". The center of push-pull scale n contact with a point 150 mm from the pedal fulcrum. 2) Start the engine, push the pedal in the direction of operation and measure the maximum value when pushing from low idle to the end of the pedal travel (high idling).
2. Testing and adjusting 1) Stop the engine. 2) Disconnect cable (1) at the bottom of the accelerator pedal, and check that plate (2) at the bottom of the pedal moves smoothly. 3) Connect the cable at the bottom of the pedal, then disconnect at the connection for the injection pump, and check that cable (3) moves smoothly. When performing this inspection, adjust or replace parts as necessary. Measure the operating force again and check that all measurements are within the standard values.
20-42
MEASURING ACCELERATOR PEDAL
TESTING AND ADJUSTING
MEASURING ACCELERATOR PEDAL
OPERATING ANGLE 1. Measuring procedure 1. Stop the engine. 2. Put angle gauge "A" in contact with the accelerator pedal, then measure the operating angle from low idle to high idle, and calculate operating angle a = a1 a2. 2. Adjusting procedure 1. Remove the cover under the cab, and open the inspection cover on the right side of the engine. 2. Loosen nut (1) and adjust bolt (2) so that mounting height "L" of the accelerator pedal stopper is within a range of 45 ± 5 mm. 3. Loosen locknut (4) and adjust length of cable (3) so that the fuel pump lever contacts the high idle stopper when the accelerator pedal is fully depressed (high idle). Check that the P.T. pump governor lever is in contact with the low idle stopper when the accelerator pedal is released (low idle). Adjust the travel of the governor lever with joint of cable (3). After completing the above adjustments, measure each part again to check that it is within the standard values.
20-43
TESTING AND ADJUSTING
TORQUE CONVERTER AND TRANSMISSION
MEASURING TORQUE CONVERTER AND TRANSMISSION OIL PRESSURE Measurement conditions Coolant temperature: Inside operating range. Torque converter oil temperature: 60 - 80 Engine speed: High idle Manual switch ON WARNING! Apply the parking brake and block the tires. 1. Measuring main relief pressure 1) Remove the cover at the front of the engine and the cover at the rear of the operator’s compartment. 2) Remove oil pressure measurement plug (PT1/8) (1), then install oil pressure gauge C1 (5.9 MPa {60 kg/cm2}). 3) Start the engine and measure the oil pressure with the engine at low idling and high idling.
2. Adjusting main relief valve CAUTION: Adjust the main relief valve with the engine stopped. If the main relief pressure is not within the standard value, adjust as follows: 1) Remove plug (1) and washer (2). 2) Remove inner spring (3) and outer spring (4). 3) Adjust by changing the thickness of shim (5). Standard shim thickness: 3.0 mm (0.5 x 6) Amount of adjustment for one shim: 0.04MPa (0.4 kg/cm2)
20-44
TESTING AND ADJUSTING
TORQUE CONVERTER AND TRANSMISSION
3. Measuring torque converter relief (inlet port) pressure 1) Remove the cover at the front of the engine and the cover at the rear of the operator’s compartment. 2) Remove oil pressure measurement plug (PT1/8) (1), then install oil pressure gauge C1 (5.9 MPa {60 kg/cm2}). 3) Start the engine and measure the oil pressure with the engine at high idling. (If the pressure is not affected by any adjustments, it may indicate possible need for repair.)
4. Measuring torque converter outlet port pressure 1) Remove the cover at the left side of the transmission. 2) Remove oil pressure measurement plug (1) at the bottom of the torque converter oil temperature sensor, then install oil pressure gauge C1 (5.9 MPa {60 kg/cm2}). 3) Start the engine and measure the oil pressure with the engine at high idling. (If the pressure is not affected by any adjustments, it may indicate possible need for repair.)
20-45
TESTING AND ADJUSTING
TORQUE CONVERTER AND TRANSMISSION
5. Measuring ECMV output (clutch) pressure 1) Remove the cover at the front of the engine and the cover at the rear of the operator’s compartment. 2) Remove the oil pressure measurement plug for the clutch to be measured. Plug for measuring 1st clutch pressure: (1) Plug for measuring 2nd clutch pressure: (2) Plug for measuring 4th clutch pressure: (3) Plug for measuring 3rd clutch pressure: (4) Plug for measuring reverse clutch pressure: (5) Plug for measuring forward clutch pressure: (6) : Gasket sealant (LG-5) 3) Install oil pressure gauge C1 (5.9 MPa {60 kg/cm2}). 4) Start engine and measure the 1st, 2nd, 3rd, and 4th clutch pressures under the following conditions at high idling. a) Leave the directional lever at neutral. b) Turn the main monitor manual switch ON. c) Place the gear shift lever at the speed range to be measured. 5) Start the engine and measure the forward and reverse clutch pressures under the following conditions at high idling. WARNING! Put blocks under the tires and depress the brake securely. a) Turn the transmission cut-off selector switch OFF (lamp off). b) Turn the parking brake switch OFF. c) Depress the brake. d) Turn the main monitor manual switch ON and place the gearshift lever in 4th. e) Keep the brake depressed and place the directional lever at F or R.
6. Measuring lubricating oil pressure (oil cooler outlet port) 1) Remove the cover at the left side of the rear frame. 2) Remove the oil pressure measurement plug (1), then, install oil pressure gauge C1 (5.9 MPa {60 kg/cm2}). 3) Start the engine and measure the oil pressure with the engine at high idling. (The pressure, not affected by adjustments, may indicate possible need for repair.)
20-46
TESTING AND ADJUSTING
TORQUE CONVERTER AND TRANSMISSION
FLUSHING TORQUE CONVERTER AND TRANSMISSION HYDRAULIC CIRCUIT Metal particles and other dirt in the torque converter and transmission hydraulic circuit will reduce the life of the torque converter and transmission, and will cause internal damage. To prevent this, flush the system to remove the dirt or metal particles in the hydraulic circuit. 1. Flush the circuit if the following conditions apply. 1) If there has been any breakage of the torque converter, transmission, or hydraulic equipment, and metal particles are circulating in the hydraulic circuit. 2) When the torque converter and transmission have been overhauled or repaired.
3) Repeat the procedure in 4-1, and run the engine at low idling for approximately 20 minutes.
5. Replace the flushing element. 1) Using the procedure in step 2-1, replace the flushing element with the standard element (424-16-11140). CAUTION! If the flushing element is used for a long time, there will be premature clogging, so always replace the flushing element with the standard element. 2) Add oil and check the level again.
2. Install the flushing element. 1) Drain the oil from the filter case. 2) Remove the two transmission oil filters, then install two flushing elements (561-15-55670). After flushing the system, assemble the parts that were removed, and the parts inside the case. 3. Fill the transmission case with oil. Add fresh oil through the oil filler port to the specified level, and run the engine to circulate the oil through the system. Then check the level again. Transmission case: 62
6. Replace the transmission fail safe filter. 1) Use a wrench to turn portion A of fail safe filter case (1) to remove it. If there is any dirt inside the filter case, wash the case. 2) Remove element (2) and replace with a new element. 3) Install new O-ring (3) to the outside circumference of the case. Coat the outside circumference of the Oring with a small amount of grease. 4) Install the case. Case: 39.2 Nm (4 kgm)
4. Carry out flushing as follows. 1) After starting the engine, run the engine for approximately 20 minutes at low idling without operating the speed lever or directional lever. From time to time, raise the engine speed to approximately 1500 rpm. If the ambient temperature is low and the engine coolant temperature gauge does not enter the green range, continue the warming-up operation longer. 2) Travel or carry out actual operations for at least 20 minutes. Use all the speed ranges (FORWARD, REVERSE, and 1st - 4th).
20-47
TESTING AND ADJUSTING
TORQUE CONVERTER AND TRANSMISSION
MOVING MACHINE WHEN TRANSMISSION VALVE FAILS If the machine cannot be moved because of a failure in any part of the transmission valve system (electrical system, solenoid valves, spools, etc.), it is possible to move the machine by installing plate N. WARNING! Plate N is only for emergency use when the machine cannot be moved by any other means because of a failure in the transmission control valve system. DO NOT install plate N to the ECMV except when there has been a failure and it is necessary to move the machine from a dangerous working area to a safe place for repairs. WARNING! When carrying out this operation keep strictly to the procedure and pay careful attention to safety when moving the machine. WARNING! To prevent the machine from moving, lower the work equipment completely to the ground, apply the parking brake, and put blocks under the tires. WARNING! Carry out the operation with the engine stopped. WARNING! Be careful not to burn yourself if the oil is hot.
1. Remove the cover at the bottom of the operator’s cab, and the cab at the bottom of the step on the left side. 2. Remove valve cover (1). Wash the area around the ECMV, clean and remove all dirt and mud. 3. Disconnect wiring connectors (2) through (13). For details of precautions when removing the wiring connectors, see DISASSEMBLY AND ASSEMBLY, REMOVAL OF TRANSMISSION CONTROL VALVE ASSEMBLY.
20-48
TESTING AND ADJUSTING
TORQUE CONVERTER AND TRANSMISSION
4. Depending on the direction for moving the machine (forward or reverse), remove the following 2 ECMV solenoids (14) and install plate N. FORWARD: F solenoid and 2nd solenoid REVERSE: R solenoid and 2nd solenoid If there is any mistake in the selection of the solenoid to remove, there is danger that the transmission may be damaged. Install plate N with the protruding surface facing the ECMV. Check also that there is an O-ring installed to the mating surface. Be careful not to let any dirt or mud get inside the removed solenoid or valve
5. Depress the left brake pedal securely. 6. Start the engine, release the parking brake, then release the brake pedal gradually to allow the machine to start, then move the machine. WARNING! Remove the blocks from under the tires.
WARNING! When the engine is started, the transmission is also engaged to start the machine. To ensure safety when starting the engine, check carefully that the direction of travel and area around the machine are safe, and always keep the brake pedal depressed when starting. WARNING! After moving the machine, stop the engine, apply the parking brake, put blocks under the tires.
20-49
TESTING AND ADJUSTING
TESTING AND STEERING WHEEL
ADJUSTING
MEASURING PLAY OF STEERING WHEEL Measurement conditions Engine speed: Stopped Machine posture: Facing straight forward
Method of measurement 1. Move the steering wheel 2 or 3 times lightly to the left and right, check that the steering mechanism is at the neutral position, then make a mark on the outside frame of the machine monitor. 2. Turn the steering wheel to the right, and make a mark at the position where the operating force starts to become heavy (when the steering valve lever starts to move). 3. Turn the steering wheel to the left in the opposite direction from Step 2, and make a mark at the point where the operating force becomes heavy (when the steering valve lever starts to move). Then measure the distance in a straight line between the marks made in Step 2 and Step 3.
MEASURING OPERATING FORCE OF STEERING WHEEL Measurement conditions Road surface: Flat, horizontal, dry paved surface Engine water temperature: Within green range on engine water temperature gauge Hydraulic oil temperature: 45 - 55 Tire inflation pressure: Specified pressure Engine speed: Low idling (bucket empty)
Measurement method 1. Install push-pull scale l2 to the steering wheel knob. 2. Start the engine. After starting the engine, raise the bucket approx. 400 mm and remove the safety bar. 3. Pull push-pull scale l2 in the tangential direction and measure the value when the steering wheel moves smoothly. Avoid measuring when the steering wheel starts to move.
20-50
STEERING WHEEL
TESTING AND ADJUSTING
STEERING WHEEL
MEASURING OPERATING TIME FOR STEERING WHEEL Measurement conditions Road surface: Flat, horizontal, dry paved surface Engine water temperature: Within green range on engine water temperature gauge Hydraulic oil temperature: 45 - 55 Tire inflation pressure: Specified pressure Engine speed: Low and high idling
Measurement method 1. Start the engine. After starting the engine, raise the bucket approx. 400 mm and remove the safety bar. 2. Operate the steering wheel to the end of its stroke to turn the machine to the left or right. 3. Measure the time taken to operate the steering wheel to the end of the stroke to the right (left). Operate the steering wheel as quickly as possible without using force. Carry out the measurements both at low idling and high idling, and to both the left and right.
20-51
TESTING AND ADJUSTING
STEERING OIL PRESSURE Hydraulic oil temperature: 45 - 55 CAUTION! Install the safety bar to the frame.
Measuring 1. Measuring steering relief pressure 1) Remove oil pressure measurement plug (PT1/8) (1) from the elbow at the right steering cylinder head end, then install oil pressure gauge Cl (39 MPa {400 kg/cm2}).
2) Start the engine, run the engine at high idling, then turn the steering wheel to the right and measure the pressure when the relief valve is actuated. When removing the oil pressure measurement plug on the left steering cylinder, turn the steering wheel to the left.
2.
Measuring steering pilot pressure 1) Disconnect pilot hose (2) or (3) from steering valve (1). 2) Install the adapter and oil pressure gauge (5.9 MPa {60 kg/cm2}) inside tool Cl. 3) Start the engine and measure the oil pressure when the steering wheel is turned with the engine running at high idling. Hose (2): Turn steering to right Hose (3): Turn steering to left
20-52
STEERING OIL PRESSURE
TESTING AND ADJUSTING 3.
STEERING OIL PRESSURE
Measuring Orbit-roll output pressure 1) Disconnect Orbit-roll output hose (1) or (2). 2) Install the adapter and oil pressure gauge (5-9 MPa {60 kg/cm2}) inside tool Cl. 3) Start the engine and measure the oil pressure when the steering wheel is turned with the engine running at high idling. Hose (1): Turn steering to right Hose (2): Turn steering to left
Adjusting WARNING! Always stop the engine before adjusting the pressure 1. Adjusting steering relief valve Loosen locknut (2) of steering relief valve (1), then turn adjustment nut (3) to adjust. Turn the adjustment screw to adjust the set pressure as follows. To INCREASE pressure, turn CLOCKWISE To DECREASE pressure, turn COUNTERCLOCKWISE Pressure adjustment for one turn of adjustment screw: Approx. 14.8 MPa (151 kg/cm2)
20-53
TESTING AND ADJUSTING
STEERING STOP VALVE Testing 1. Set the front and rear frames facing straight. 2. Check that locknut (2) of stopper bolt (1) is not loose. 3. Start the engine, and check that there is a clearance between the front frame stopper and rear frame stopper when the steering is turned to the right or left. CAUTION! stopped.
measure the clearance with the engine
Measure the clearance between the front frame and rear frame when steering stop valve contact surface (3) and stopper bolt (1) coming into contact and the turning stops. - Standard clearance a: 40±5 mm
Adjusting If the clearance between the front frame and rear frame is not within the standard value, adjust as follows. 1. Loosen locknut (2), tighten stopper bolt (1), and make sure that there is no contact with the steering stop valve. 2. Start the engine, run at low idling, then turn the steering wheel slowly to bring the front and rear frames into contact. When turning, be extremely careful not to get your arm or any other part of your body caught between the front and rear frames. 3. Stop the engine, then loosen the stopper bolt until it contacts the steering stop valve contact surface. 4. Set the front and rear frames facing straight. 5. Loosen stopper bolt (1) 8.5 turns, then tighten locknut (2). Carry out the procedure in Steps 1 - 5 to adjust both the left and right sides. 6. Start the engine, turn the machine, and check that clearance a between the front and rear frames is within the standard value for both the left and right and that the steering stopper valve and stopper bolt come into contact and the steering is stopped.
20-54
STEERING STOP VALVE
TESTING AND ADJUSTING
MEASURING BRAKE PEDAL
MEASURING BRAKE PEDAL Measurement conditions Engine water temperature: Within green range on engine water temperature gauge Engine speed: Low idling
Operating force of pedal 1. Install push gauge (1) to the operator's foot. Align the center of the push gauge with the center of the pedal. 2. Start the engine, run at low idling, and measure the operating force when the pedal is depressed.
Travel of pedal 1. Install push gauge (1) to the operator's foot. Align the center of the push gauge with the center of the pedal. 2. Start the engine, and measure pedal angle a1 when running at low idling, and pedal angel a2 when the pedal is depressed with a force of 30 kg. Install angle gauge (2) to the brake pedal when measuring.
Pedal play 1. Start the engine. 2. Push the brake pedal lightly by hand, and measure pedal angle a3 when the pedal starts to become heavy.
20-55
TESTING AND ADJUSTING
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. 2. Set the speed lever to the highest speed position and drive the machine. 3. When the travel speed reaches 20 km/h, depress the left brake pedal with the specified operating force. Before carrying out this operation, determine the run-up path and the point for applying the brakes, then apply the brakes when the machine reaches that point. Switch the transmission cut-off switch ON when carrying out this operation. 4. Measure the distance from the point where the brakes were applied to the point where the machine stopped. Repeat this measurement three times and take the average.
20-56
MEASURING BRAKE PERFORMANCE
TESTING AND ADJUSTING
TESTING BRAKE OIL PRESSURE
TESTING BRAKE OIL PRESSURE CAUTION! Put blocks securely under the tires
1. Inspecting brake oil pressure 1) Remove bleeder screw (1), then install oil pressure gauge tool l (39 MPa {400 kg/cm2}), the joint, bleeder screw, and nipple. 2) Connect hose (2) to the bleeder screw and bleed the air from the brake circuit. For details, see BLEEDING AIR. 3) Depress the left brake and measure the brake oil pressure.
2. Measuring drop in brake piston pressure 1) Remove bleeder screw (1), then install oil pressure gauge tool l (39 MPa {400 kg/cm2}), the joint, bleeder screw, and nipple. 2) Connect hose (2) to the bleeder screw and bleed the air from the brake circuit. For details, see BLEEDING AIR. 3) Stop the engine, depress the left brake pedal, leave for 5 min. with the oil pressure at 4.9 MPa (50 kg/c M2 }, and measure the drop in pressure. Be careful not to move the brake pedal for 5 minutes. After completing the operation, bleed the air from the brake circuit again.
20-57
TESTING AND ADJUSTING
MEASURING BRAKE DISC WEAR Brake oil pressure: 4.9 ±0.49 MPa (50 ±5 kg/cm2) CAUTION! Park the machine on horizontal ground and put blocks securely under the tires.
Measurement method 1. Remove plug (1). 2. Depress the brake pedal fully. 3. Use calipers M to measure depth a from the end face of the housing to the spring guide. When measuring, keep the brake pedal depressed. 4. Install a vinyl hose (3) to bleeder (2), then loosen the bleeder and drain the brake oil. After draining the brake oil, check that the brake piston has returned to the end of its stroke. 5. Measure depth b from the end face of the housing to the spring guide pin.
Calculating piston stroke S=a-b S=Max.3.9mm
20-58
MEASURING BRAKE DISC WEAR
TESTING AND ADJUSTING
PARKING BRAKE PERFORMANCE
PARKING BRAKE PERFORMANCE Measurement conditions Tire inflation pressure: Specified pressure Road surface: Flat, dry, paved surface with 1/5 (11 gradient. Machine: In operation condition
Measuring procedure 1. Start the engine, ser the machine facing in a straight line, then drive the machine up a 1/5 grade slope with the bucket empty. 2. Depress the brake, stop the machine, set the directional lever to the neutral position, then stop the engine. 3. Turn the parking brake switch ON, then slowly release the brake pedal, and the machine must not move at all. Carry out the measurement in two ways. Once with the machine facing uphill, and once more with the machine facing downhill.
20-59
TESTING AND ADJUSTING
PARKING BRAKE OIL PRESSURE 1. Measuring parking brake inlet port Torque converter oil temperature: 60 - 80 1) Remove the transmission side cover. 2) Remove oil pressure measurement plug (PT1/8) (1), then install oil pressure gauge Cl (5-9 MPa {60 kg/cm2}). 3) Turn the parking brake switch OFF. 4) Start the engine and measure with the engine running at low idling and high idling.
2. Measuring parking brake pilot pressure Torque converter oil temperature: 60 - 80 1) Remove the cover at the front of the engine and the cover at the top of the transmission. 2) Disconnect hose (1), then install adapter and oil pressure gauge in tool Cl (5.9 MPa {60 kg/cm2}). 3) Start the engine and measure at high idling.
20-60
PARKING BRAKE OIL PRESSURE
TESTING AND ADJUSTING
PARKING BRAKE OIL PRESSURE
3. Measuring parking brake solenoid valve output pressure Torque converter oil temperature: 60 - 80 1) Remove the cover at the front of the engine and the cover at the top of the transmission. 2) Disconnect hose (1), then install adapter and oil pressure gauge in tool Cl (5.9 MPa {60 kg/ cm2}). 3) Turn the parking brake switch OFF. 4) Start the engine and measure at high idling.
20-61
TESTING AND ADJUSTING
PARKING BRAKE DISC WEAR If the parking brake effect becomes weak, measure the wear of the parking brake disc as follows. CAUTION! To prevent the machine from moving, lower the work equipment completely to the ground and put blocks under the tires. CAUTION! Always stop the engine before carrying out this procedure.
1. Drain oil from the transmission case. Transmission case: 62
2. Remove one of two plugs (1) on each side. 3. Using calipers M, measure depth a from the end face of cage (2) to piston (3). Standard depth a: Max. 40.3 mm
4. If depth a is greater than the specified value, remove parking brake disc (4), and check thickness W of the disc. For details, see DISASSEMBLY AND ASSEMBLY, REMOVAL OF PARKING BRAKE DISC. Dimension W: Min. 3.2 ±0.1 mm If the thickness of the parking brake disc is below the standard value, replace it.
20-62
PARKING BRAKE DISC WEAR
TESTING AND ADJUSTING
MANUAL RELEASE PARKING BRAKE
MANUAL RELEASE METHOD FOR PARKING BRAKE
METHOD
FOR
The parking brake is controlled by hydraulic pressure, so if there should be any failure in the transmission and it becomes impossible to release the parking brake, it is possible to release it manually to move the machine. CAUTION! The manual release of the parking brake is designed only to move the machine from a dangerous working area to a safe place where repairs can be carried out. This method must not be used except when there has been a failure CAUTION! To prevent the machine from moving, lower the work equipment completely to the ground and put blocks under the tires. CAUTION! Always stop the engine before carrying out this procedure. 1. Remove two plugs (1). After releasing the parking brake, coat the plugs with gasket sealant (LG-5), then tighten the plugs. 2. Remove two cage mounting bolts (2), then screw them into the plug mount gradually in turn. When bolts (2) are screwed in, piston (3) is pulled and the parking brake is released.
20-63
TESTING AND ADJUSTING
PPC OIL PRESSURE Hydraulic oil temperature: 45 - 55 Measuring 1. Measuring PPC pump pressure 1) Remove the cover at the top of the pump. 2) Remove oil pressure measurement plug (PT1/8) (1), then install oil pressure gauge C1 (39 MPa {400 kg/cm2}). 3) Start the engine and measure the oil [pressure at high idling.
2. Measuring PPC valve basic pressure (orbit-roll basic pressure) 1) Disconnect hose (1), then install the adapter and oil pressure gauge (5.9 MPa {60 kg/cm2}) in tool C1. 2) Start the engine, run the engine at high idling, then operate the work equipment control lever and measure the oil pressure.
20-64
PPC OIL PRESSURE
TESTING AND ADJUSTING
PPC OIL PRESSURE
3. Measuring PPC valve output pressure CAUTION! Loosen the oil filler cap slowly to release the pressure inside the hydraulic tank. CAUTION! Operate the control levers several times to release the pressure in the PPC accumulator circuit.
1) Remove the main control valve cover. 2) Remove oil pressure detection plug (PT1/8) (1) of the circuit to be measured, then install oil pressure gauge C1 (5.9 MPa {60 kg/cm2}). Plug A: Boom LOWER, boom FLOAT Plug B: Boom RAISE Plug C: Boom DUMP Plug D: Boom TILT 3) Start the engine, run the engine at high idling, then operate the work equipment control lever and measure the oil pressure.
Adjusting 1. Adjusting PPC relief valve Loosen locknut (2) of PPC relief valve (1), then turn adjustment screw (3) to adjust. Turn the adjustment screw to adjust as follows: To INCREASE the pressure, turn clockwise. To DECREASE the pressure, turn counter clockwise. Amount of adjustment - for one turn of adjustment screw: 1.8 MPa (18.3 kg/cm2) Locknut: 83.4 ±4.9 Nm (18.3 ±0.5 kgm)
After completion of the adjustment, re-check the accumulator charge cut-in pressure and cut-out pressure again. Refer to ACCUMULATOR CHARGE PRESSURE, see page 20-67.
20-65
TESTING AND ADJUSTING
ADJUSTING PPC VALVE LINKAGE 1. Remove cover (1) at the bottom of the work equipment control lever. 2. Adjust dimension a from nut (1) of the PPC valve linkage to the top surface of the floor. Dimension a (target value): 54 mm 3. Loosen nuts (2) and (3), then adjust the installed height of trunnion (5) so that there is no play in lever (4). 4. After adjusting, tighten nuts (2) and (3).
20-66
ADJUSTING PPC VALVE LINKAGE
TESTING AND ADJUSTING
ACCUMULATOR CHARGE PRESSURE
ACCUMULATOR CHARGE PRESSURE Measuring Hydraulic oil temperature: 45 - 55 CAUTION! Stop the engine, then depress the brake pedal at least 100 times to release the pressure inside the accumulator circuit. 1. Disconnect accumulator inlet port hose (1), then install the adapter and oil pressure gauge (30 MPa {400 kg/cm2}) in tool C1. 2. Measure the accumulator charge cut-in pressure. Start the engine, run at low idling, and measure the oil pressure when the brake oil pressure warning pilot lamp on the maintenance monitor goes out. 3. Measure the accumulator charge cut-out pressure. After the accumulator charge cut-in, the pressure rises. Measure the oil pressure at the point where the oil pressure gauge indicator suddenly drops after rising.
Adjusting When the accumulator charge cut-out pressure is adjusted, the cut-in pressure also changes because of the valve area ratio. For this reason, there is no cut-in pressure adjustment nut. 1. Loosen locknut (2) of the accumulator charge cut-out valve (1), then turn adjustment screw (3) to adjust. Turn the adjustment screw to adjust as follows: To INCREASE the pressure, turn clockwise. To DECREASE the pressure, turn counter clockwise.
Amount of adjustment - for one turn of adjustment screw: 5.6 MPa (57 kg/cm2) Locknut: 10.78 ±0.98 Nm (1.1 ±0.1 kgm)
After completion of the adjustment, repeat the above procedure for test to check the accumulator charge cut-in pressure and cut-out pressure again.
20-67
TESTING AND ADJUSTING
WORK EQUIPMENT PRESSURE
WORK EQUIPMENT HYDRAULIC PRESSURE
HYDRAULIC
Hydraulic oil temperature: 45 - 55 CAUTION! Loosen the oil filler cap slowly to release the pressure inside the hydraulic tank.
1. Measuring work equipment relief pressure 1) Raise bucket portion a approx. 30 - 50 mm and set portion b in contact with the ground. 2) Stop the engine, then operate the work equipment control lever and check that the bottom surface of the bucket (both portion a and portion b) is in contact with the ground. After lowering the bucket to the ground, operate the work equipment control lever several times to release the remaining pressure in the piping. 3) Remove the cover at the top of the main control valve.
4) Remove oil pressure measurement plug (PT1/8) (1), then install oil pressure gauge C1 (39 MPa {400 kg/cm2}).
20-68
TESTING AND ADJUSTING
WORK EQUIPMENT HYDRAULIC PRESSURE
5) Start the engine, raise the lift arm approx. 400 mm, run the engine at high idling, tilt the bucket back, then measure the oil pressure when the relief valve is actuated. CAUTION! After measuring, repeat the procedure used when installing the oil pressure gauge to release the pressure inside the circuit, then remove the oil pressure gauge.
Adjusting 1. Adjusting work equipment relief valve. Loosen locknut (2) of work equipment relief valve (1), then turn adjustment screw (3) to adjust. Turn the adjustment screw to adjust as follows. To INCREASE the pressure, turn clockwise. To DECREASE the pressure, turn counter clockwise. Amount of adjustment for one turn of adjustment screw: 5.18 MPa {52.9 kg/cm2) Locknut: 39.2 ±9.8 Nm (4 ±1 kgm)
After completion of the adjustment, repeat the above procedure to measure the work equipment relief pressure again.
20-69
TESTING AND ADJUSTING
RELEASING REMAININ G PRESSURE IN HYDRAULIC CIRCUIT 1. Releasing remaining pressure between each hydraulic cylinder and control valve. If the piping between the hydraulic cylinder and the control valve is to be disconnected, release the remaining pressure from the circuit as follows: 1) Stop the engine. 2) Release the oil filler cap slowly to release the pressure inside the tank. 3) Operate the control levers. When the levers are operated 2 - 3 times, the pressure stored in the PPC accumulator is removed. Start the engine, run at low idling for approximately 5 minutes, then stop the engine and operate the control levers. Repeat the above operation 2 - 3 times to release all the remaining pressure. 2. Releasing remaining pressure in brake accumulator circuit. If the piping between the brake accumulator and emergency parking brake valve, between the accumulator and check valve, and between the accumulator and brake valve is to be disconnected, release the remaining pressure from the circuit as follows. 1) Stop the engine. 2) Depress the brake pedal at least 100 times to release the pressure inside the brake accumulator circuit. 3. Releasing remaining pressure PPC accumulator circuit. If the piping between the PPC accumulator and PPC valve is to be disconnected, release the remaining pressure from the circuit as follows: Repeat the above operation 2 - 3 times to release all the remaining pressure.
20-70
PRESSURE IN HYDRAULIC CIRCUIT
TESTING AND ADJUSTING
WORK EQUIPMENT LEVER LINKAGE
ADJUSTING WORK EQUIPMENT LEVER LINKAGE Always stop the engine before adjusting the work equipment lever linkage. Check that the operating effort of the work equipment control lever is within the standard value. 1. Do as follows to set solenoid (1) in a pulled condition. 1) Disconnect wiring connectors (F05) (2) and (F06) (3). F05: Proximity switch for bucket positioner F06: Proximity switch for boom kick-out 2) Connect a T-adapter, then connect the terminals between (1) and (2). Check that the solenoid is pulled l2 mm. 2. With the solenoid pulled, move solenoid (1) so that clearances a between boom lever cam (4) and boom lever cam follower (5) and between bucket lever cam (6) and bucket lever cam follower (7) are each 0 - 0.5 mm. Carry out the adjustment with the boom and bucket levers at the HOLD position. 3. Operate the boom lever and adjust distance c between the pins of rod (8) so that clearance b between the notches at both ends of boom lever cam (4) and boom lever cam follower (5) is 0 - 1 mm. Distance c between pins of rod (8): 337 mm 4. Operate the bucket lever and adjust distance c between the pins of rod (8) so that clearance d between the notches (1 place) bucket lever cam (6) and bucket lever cam follower (7) is 0 - 1 mm. Distance c between pins of rod (8): 337 mm
20-71
TESTING AND ADJUSTING
BLEEDING AIR CAUTION! Put blocks securely under the tires
1. Bleeding air from brake system 1) Remove cap (1) of the bleeder screw, insert a vinyl hose into the screw, and insert the other end in a container. 2) Start the engine. 3) Depress the brake pedal, then loosen the bleeder screw and bleed the air. This operation is carried out with two workers. One worker operates the brake pedal while the other bleeds the air from the bleeder screw. When depressing the brake pedal, use the left pedal. 4) When no more air bubbles come out with the fluid from the hose, depress the pedal fully and tighten the bleeder screw while the oil is still flowing. Repeat the operation to bleed the air from the other cylinders, and after completing the operation, check the level in the oil tank and add more oil if necessary. To bleed the air completely, bleed the air first from the cylinder which is farthest from the brake pedal.
2. Bleeding air from the hydraulic cylinders. 1) Start the engine and run at idling for approximately 5 minutes. 2) Run the engine at low idling, the raise and lower the boom 4 - 5 times in succession. Operate the piston rod to a point approximately 100 mm before the end of its stroke. Do not relieve the circuit under any circumstances. 3) Run the engine at full throttle and repeat step 2). After that, run the engine at low idling, and operate the piston rod to the end of its stroke to relieve the circuit. 4) Repeat steps 2) and 3) to bleed the air from the bucket cylinder. When the cylinder has been replaced, bleed the air before connecting the piston rod.
20-72
BLEEDING AIR
TESTING AND ADJUSTING
BUCKET POSITIONER
BUCKET POSITIONER Hydraulic oil temperature: 45 - 55 Testing 1. Start the engine, operate the bucket and actuate proximity switch (1), then stop the engine and measure clearance a between the proximity switch and angle (2). Standard clearance a: 3 - 5 mm 2. Run the engine at mid-range speed (1500 rpm), actuate the proximity switch, and check that the bucket angle is 0 - 1 e bucket is lowered to the ground. Measure dimension b between the center of the proximity switch to the tip of the angle. Measure three times and take the average. Standard dimension b: 15 mm
Adjusting 1. If dimension a is not within the standard value, adjust as follows: 1) Adjust mounting nut (4) so that clearance c between the tip of the switch protector (3) and the sensing surface of proximity switch (1) is the standard value. standard clearance c: 0.5 - 1.0 mm Mounting nut: 17.15 ±2.45 Nm (1.75 ±0.25 kgm)
2) Adjust with washer (5) and shim (6) so that clearance a between the sensing surface of proximity switch (1) and angle (2) is the standard value. Adjust with shim (6) so that clearance a is within the standard value for the whole stroke of the angle. Secure in position, making sure that the center of proximity switch sensing surface and the angle do not move away from the center. After adjusting, operate the bucket lever and check that the proximity switch is actuated normally. 2. If the bucket angle and dimension b are not within the standard value, move the switch protector (3) to adjust.
20-73
TESTING AND ADJUSTING
BOOM POSITIONER Hydraulic oil temperature: 45 - 55 CAUTION! Always be sure to apply the safety lock to work equipment control lever. Testing 1. Start the engine, operate the boom lever to actuate proximity switch (1), then stop the engine and measure dimension a between the center of proximity switch (1) and the top of plate (2). Standard clearance a: 0 - 5 mm 2. Measure dimension b between the proximity switch sensing surface and the plate. Standard dimension b: 3 - 5 mm
Adjusting 1. If the dimension a is not within the standard value, move the plate to adjust. 2. If dimension b is not within the standard value, adjust proximity switch mounting nut (3). Mounting nut: 17.15 ±2.45 Nm (1.75 ±0.25 kgm)
After adjusting, operate the boom lever and check that the proximity switch is actuated normally.
20-74
BOOM POSITIONER
TESTING AND ADJUSTING
BOOM POSITIONER
Proximity switch actuation pilot lamp (red) The proximity switch is equipped with a pilot lamp which shows when it is being actuated, so use this when adjusting.
Proximity switch actuation pilot lamp
Lights up
Detector position
When detector is positioned at detection surface of proximity switch
Goes out
When detector has moved away from detection surface of proximity switch
Bucket positioner
Boom kick-out
20-75
TESTING AND ADJUSTING
TRANSMISSION CONTROLLER The transmission controller is equipped with a learning function to self compensate so that it provides a constant gear shifting feeling to match the changes in the transmission clutches occurring with the wear. If the transmission is overhauled or replaced, the transmission controller keeps the control command values learned to match the previous transmission. For this reason, transmission shock or abnormal noise may occur. After operating the machine for a short time, the controller will learn to match the condition of the new transmission and will gradually return to the normal condition, but if it is desired to reset the condition quickly and to carry out learning again, it is possible to reset the learning data and to carry out initial learning as follows. 1. Method for resetting learning control data Do as follows to return all the previously learned control data in the controller to the default values. 1) Check that the starting switch is at the OFF position. 2) Remove the cover at the right side of the work equipment control box. 3) Disconnect wiring connector (C3B) (1) and connect T-adapter P to the controller only (leave the harness hanging). 4) Turn the starting switch ON. Do not start the engine. 5) Short circuit between terminals No. (1) to (16) for at least one second, then return them to free condition.
2. Initial learning method To adjust the controller learning control data for each clutch from the default settings to the optimum values, first carry out the above Step 1 "Method of resetting learned control data”, then do as follows. 1) Stall the torque converter. For details, see MEASURING ENGINE SPEED. 2) Operate the speed lever and directional lever as follows. N Operate the levers with the engine running at low idling, the transmission cut-off selector switch at OFF, and the manual switch at ON.
20-76
TRANSMISSION CONTROLLER
TESTING AND ADJUSTING
TRANSMISSION CONTROLLER
it is possible to carry out this operation with the left brake pedal depressed fully, so there is no need to travel. 3) When the torque converter oil temperature gauge rises to the 2nd level on the maintenance monitor, return the engine to low idling. Target value for torque converter oil temperature: 40 - 50 There is no problem If the oil temperature gauge goes down to the 1st level. 4) Operate the speed lever and directional lever twice in succession as follows:
N Operate the levers with the engine running at low idling, the transmission cutoff selector switch at OFF, and the manual switch at ON. Hold for the following periods of time for each speed range. Speed range 4 only: 3 seconds Other speed ranges: 2 seconds After carrying out the gear shifting operation in Step 2), if the engine is stopped before carrying out the gear shifting operation in Step 4), repeat Step 2) again. It is possible to carry out this operation with the left brake pedal depressed fully, so there is no need to travel.
CAUTION! Check that the area around the machine is safe and depress the left brake securely when shifting gear.
20-77
TESTING AND ADJUSTING
ADJUSTING MAIN MONITOR
ADJUSTING MAIN MONITOR (SPEED MODULE) The speedometer on the main monitor is a common part for all machines, and the input signal for the travel speed differs according to the machine, so it is necessary to adjust the monitor for use with the particular model. In addition, the tire diameter also differs according to the type of tire fitted, so it is necessary to adjust to give the correct travel speed. It is also necessary to change the switches if the optional E.C.S.S. (Electronically Controlled Suspension System) is installed.
Adjustment procedure Turn off the power, then remove the machine monitor and adjust the switches at the back of the speedometer. 1. Setting machine model 1) Remove the rubber caps from dip switches (1), (2) and (3) at the back of the speedometer. 2) When the rubber cap is removed, a rotary switch can be seen inside. Using a flat-headed screwdriver, turn this switch to adjust it to the settings in the table below.
Tire size
Switch 1 Model selection
Switch 2 Speedometer correction
Switch 3 Tachometer input selection
km per hour
mile per hour
26.5-25
5
D
7
0
29.5-25
5
D
4
0
20-78
TESTING AND ADJUSTING
ADJUSTING MAIN MONITOR
3) When the cap is removed from dip switch (4) at the back of the speedometer, an ON/OFF switch can be seen. Adjust the setting if the E.C.S.S. (Electronically Controlled Suspension System) is installed Switch number
Switch 4 W/O E.C.S.S.
With E.C.S.S.
1
ON
ON
2
ON
ON
3
ON
OFF
4
OFF
OFF
4) After completing the adjustment, fit the rubber caps securely and install the main monitor.
Reference: Amount of correction for switch (2) Switch position
0
1
2
3
4
5
6
7
Amount of correction (%)
+14
+12
+10
+8
+6
+4
+2
0
Switch position
8
9
A
B
C
D
E
F
Amount of correction (%)
0
-2
-4
-6
-8
-10
-12
-14
20-79
TESTING AND ADJUSTING
20-80
MEMORANDA
TABLE OF CONTENTS
TROUBLESHOOTING
TROUBLESHOOTING Points to remember when troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Sequence of events in troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Points to remember when carrying out maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Checks before troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Handling connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Precautions when troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Method of reading troubleshooting tables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Preventing recurrence of trouble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Connector types and mounting locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Connection table for connector pin numbers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Explanation of functions of electric control mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Transmission control system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Main monitor system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Maintenance monitor system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ECSS (Electronically Controlled Suspension System) control system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Joystick steering control system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Method of displaying action and failure code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Chart of action codes and failure codes, and re-enaction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Transmission controller LED display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Method of using judgement table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Method of using judgement charts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Method of using matrix troubleshooting tables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
20-202 20-203 20-204 20-212 20-213 20-214 20-216 20-218 20-220 20-229 20-240 20-240 20-244 20-248 20-252 20-256 20-258 20-260 20-263 20-264 20-266 20-268
20-201
TROUBLESHOOTING
POINTS TO REMEMBER WHEN TROUBLESHOOTING
POINTS TO REMEMBER WHEN TROUBLESHOOTING WARNING!
Stop the machine in a level place, and check that the safety pin, blocks, and parking brake are securely fitted.
WARNING!
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.
WARNING!
If the radiator cap is removed when the engine is hot, hot coolant may spurt out and cause burns, so wait for the engine to cool down before starting troubleshooting.
WARNING!
Be extremely careful not to touch any hot parts or to get caught in any rotating parts.
WARNING!
When disconnecting wiring, always disconnect the negative (-) terminal of the battery first.
WARNING!
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, an important point is to understand the structure and function of the machine. 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.
2.
3.
When carrying out troubleshooting, do not hurry to disassemble the components. If components are disassembled immediately after a failure occurs: Parts that have no connection with the failure or other unnecessary parts will be disassembled. It will become impossible to find the cause of the failure. It will also cause a waste of man hours, parts, or oil and grease. At the same time, it will also lose the confidence of the user or operator. For this reason, when carrying out troubleshooting, it is necessary to carry out thorough prior investigation and to carry out troubleshooting in accordance with the fixed procedure. Points to ask the user or operator. 1. Have any other problems occurred apart from the problem that has been reported? 2. Was there anything strange about the machine before the failure occurred? 3. Did the failure occur suddenly, or were there problems with the machine condition before this? 4. Under what conditions did the failure occur? 5. Had any repairs been carried out before the failure? When were these repairs carried out? 6. Has the same kind of failure occurred before? Check before troubleshooting. 1. Check the oil level. 2. Check for any external leakage of oil from the piping or hydraulic equipment. 3. Check the travel of the control levers. 4. Check the stroke of the control valve spool.
20-202
5.
Other maintenance items can be checked externally, so check any item that is considered to be necessary. 4. Confirming the failure. 1. Confirm the extent of the failure yourself, and judge whether to handle it as a real failure or as a problem with the method of operation, etc. When operating the machine to reenact the troubleshooting symptoms, do not carry out any investigation or measurement that may make the problem worse. 5. Troubleshooting 1. Use the results of the investigation and inspection in Steps 2 - 4 to narrow down the causes of the failure, then use the troubleshooting flowchart to locate the position of the failure exactly. 2. The basic procedure for troubleshooting is as follows. 1. Start from the simple points. 2. Start from the most likely points. 3. Investigate other related parts or information. 6. Measures to remove root cause of failure. 1. Even if the failure is repaired, if the root cause of the failure is not repaired, the same failure will occur again. 2. To prevent this, always investigate why the problem occurred. Then, remove the root cause.
POINTS TO REMEMBER WHEN TROUBLESHOOTING
TROUBLESHOOTING
SEQUENCE OF EVENTS IN TROUBLESHOOTING
20-203
TROUBLESHOOTING
POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE
POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE To maintain the performance of the machine over a long period, and to prevent failures or other troubles before they occur, correct operation, maintenance and inspection, troubleshooting and repairs must be carried out. This section deals particularly with correct repair procedures for mechanics and is aimed at improving the quality of repairs. For this purpose, it gives sections on “Handling electric equipment”and “Handling hydraulic equipment”(particularly gear oil and hydraulic oil).
Points to remember when handling electric equipment 1.
Handling wiring harnesses and connectors. Wiring harnesses consist of wiring connecting one component to another component, connectors used for connecting and disconnecting one wire from another wire, and protectors or tubes used for protecting the wiring. Compared with other electrical components fitted in boxes or cases, wiring harnesses are more likely to be affected by the direct effects of rain, water, heat or vibration. Furthermore, during inspection and repair operations, they are frequently removed and installed again, so they are likely to suffer deformation or damage. For this reason, it is necessary to be extremely careful when handling wiring harnesses.
a.
Main failures occurring in wiring harness. i. Defective contact of connectors (defective contact between male and female). Problems with defective contact are likely to occur because the male connector is not properly inserted into the female connector, or because one or both of the connectors is deformed or the position is not correctly aligned, or because there is corrosion or oxidization of the contact surfaces.
20-204
POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE ii.
Defective crimping or soldering of connectors. The pins of the male and female connectors are in contact at the crimped terminal or soldered portion, but if there is excessive force brought to bear on the wiring, the plating at the joint will peel and cause improper connection or breakage.
iii.
Disconnections in wiring. If the wiring is held and the connectors are pulled apart, or components are lifted with a crane with the wiring still connected, or a heavy object hits the wiring, the crimping of the connector may separate, or the soldering may be damaged, or the wiring may be broken.
iv.
High-pressure water entering connector. The connector is designed to make it difficult for water to enter (drip-proof structure), but if high pressure water is sprayed directly on the connector, water may enter the connector, depending on the direction of the water jet. Since the connector is designed to prevent water from entering, but at the same time, if water does enter, it is difficult for it to be drained. Therefore, it water should get into the connector, the pins will be short-circuited by the water, so if any water gets in, immediately dry the connector or take other appropriate action before passing electricity through it.
TROUBLESHOOTING
20-205
TROUBLESHOOTING v.
2.
POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE
Oil or dirt stuck to connector. If oil or grease is stuck to the connector and an oil film is formed on the mating surface between the male and female pins, the oil will not let the electricity pass, so there will be defective contact. If there is oil or grease stuck to the connector, wipe it off with a dry cloth or blow dry with compressed air and spray it with a contact restorer. When wiping the mating portion of the connector, be careful not to use excessive force or deform the pins. If there is oil or water in the compressed air, the contacts will become even dirtier, so remove the oil and water from the compressed air completely before cleaning with compressed air. Removing, installing, and drying connectors and wiring harnesses. a. Disconnecting connectors i. Hold the connectors when disconnecting. When disconnecting the connectors, hold the connectors and not the wires. For connectors held by a screw, loosen the screw fully, then hold the male and female connectors in each hand and pull apart. For connectors which have a lock stopper, press down the stopper with your thumb and pull the connectors apart. Never pull with one hand. b. When removing from clips i. When removing a connector from a clip, pull the connector in a parallel direction to the clip. If the connector is twisted up and down or to the left or right, the housing may break.
20-206
POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE c.
d.
TROUBLESHOOTING
Action to take after removing connectors i. After removing any connector, cover it with a vinyl bag to prevent any dust, dirt, oil or water from getting in the connector portion. If the machine is left disassembled for a long time, it is particularly easy for improper contact to occur, so always cover the connector. Connecting connectors i. Check the connector visually ii. Check that there is no oil, dirt, or water stuck to the connector pins (mating portion). iii. Check that there are no deformation, defective contact, corrosion, or damage to the connector pins. iv. Check that there is no damage or breakage to the outside of the connector. If there is any oil, water, or dirt stuck to the connector, wipe it off with a dry cloth. If any water has got inside the connector, warm the inside of the wiring with a dryer, but be careful not to make it too hot as this will cause short circuits. If there is any damage or breakage, replace the connector. v. Fix the connector securely vi. Align the position of the connector correctly, then insert it securely. vii. For connectors with lock stopper, push in the connector until the stopper clicks into position. viii. Correct any protrusion of the boot and any misalignment of the wiring harness. ix. For connectors fitted with boots, correct any protrusion of the boot. In addition, if the wiring harness is misaligned, or the clamp is out of position, adjust it to its correct position. If the connector cannot be corrected easily, remove the clamp and adjust the position. x. If the connector clamp has been removed, be sure to return it to its original position. Check also that there are no loose clamps.
20-207
TROUBLESHOOTING e.
POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE
Drying wiring harness. If there is any oil or dirt on the wiring harness, wipe it off with a dry cloth. Avoid washing it in water or using steam. If the connector must be washed in water, do not use high-pressure water or steam directly on the wiring harness. If water gets directly on the connector, do as follows. i. Disconnect the connector and wipe off the water with a dry cloth. If the connector is blown dry with compressed air, there is the risk that oil in the air may cause defective contact, so remove all oil and water from the compressed air before blowing with air.
ii.
Dry the inside of the connector with a dryer. If water gets inside the connector, use a dryer to dry the connector. Hot air from the dryer can be used, but regulate the time that the hot air is used in order not to make the connector or related parts too hot, as this will cause deformation or damage to the connector.
iii.
Carry out a continuity test on the connector. After drying, leave the wiring harness disconnected and carry out a continuity test to check for any short circuits between pins caused by water. After completely drying the connector, blow it with contact restorer and reassemble.
20-208
POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE 3.
TROUBLESHOOTING
Handling control box a. The control box contains a microcomputer and electronic control circuits. These control all of the electronic circuits on the machine, so be extremely careful when handling the control box. b. Do not open the cover of the control box unless necessary.
c. d. e.
Do not place objects on top of the control box. Cover the control connectors with tape or a vinyl bag. Never touch the connector contacts with your hand. During rainy weather, do not leave the control box in a place where it is exposed to rain.
i.
ii.
Do not place the control box on oil, water, or soil, or in any hot place, even for a short time. (Place it on a suitable dry stand). Precautions when carrying out arc welding . When carrying out arc welding on the body, disconnect all wiring harness connectors connected to the control box. Fit an arc welding ground close to the welding point.
Points to remember when troubleshooting electric circuits 1. 2. 3. 4.
Always turn the power OFF before disconnecting or connecting connectors. Before carrying out troubleshooting, check that all the related connectors are properly inserted. Disconnect and connect the related connectors several times to check. Always connect any disconnected connectors before going on to the next step. If the power is turned ON with the connectors still disconnected, unnecessary abnormality displays will be generated. When carrying out troubleshooting of circuits (measuring the voltage, resistance, continuity, or current), move the related wiring and connectors several times and check that there is no change in the reading of the tester. If there is any change, there is probably defective contact in that circuit.
20-209
TROUBLESHOOTING
POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE
Points to remember when handling hydraulic equipment With the increase in pressure and precision of hydraulic equipment, the most common cause of failure is dirt (foreign material) in the hydraulic circuit. When adding hydraulic oil, or when disassembling or assembling hydraulic equipment, it is necessary to be particularly careful. 1. Be careful of the operating environment. Avoid adding hydraulic oil, replacing filters, or repairing the machine in rain or high winds, or in places where there is a lot of dust. 2. Disassembly and maintenance work in the field. If disassembly or maintenance work is carried out on hydraulic equipment in the field, there is danger of dust entering the equipment. It is also difficult to confirm the performance after repairs, so it is desirable to use a unit exchange. Disassembly and maintenance of hydraulic equipment should be carried out in a specially prepared dust proof workshop, and the performance should be confirmed with special test equipment.
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 entering. If the opening is left open or is blocked with a rag, there is a danger of dirt entering or of the surrounding area being made dirty by leaking oil. 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.
4.
Do not let any dirt or dust get in during refilling operations. Always keep the oil filler and the area around it clean, and always use clean pumps and oil containers. If an oil cleaning device is used, it is possible to filter out the dirt that has collected during storage.
20-210
POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE 5.
Change hydraulic oil when the temperature is high. When hydraulic oil or other oil is warm, it flows easily. In addition, the sludge can also be drained out easily from the circuit together with the oil, so it is best to change the oil when it is still warm. When changing the oil, as much as possible of the old hydraulic oil must be drained out. (Drain the oil from the hydraulic tank; also drain the oil from the filter and from the drain plug in the circuit.) If any old oil is left, the contaminants and sludge in it will mix with the new oil and will shorten the life of the hydraulic oil.
6.
Flushing operations. After disassembling and assembling the equipment, or changing the oil, use flushing oil to remove the contaminants, sludge, and old oil from the hydraulic circuit. Normally, flushing is carried out twice: primary flushing is carried out with flushing oil and secondary flushing is carried out with the specified hydraulic oil.
7.
Cleaning operations. After repairing the hydraulic equipment (pump, control valve, etc.) or when running the machine, carry out oil cleaning to remove the sludge or contaminants in the hydraulic oil circuit. The oil cleaning equipment is used to remove the ultra fine (about 3µ) particles that the filter built into the hydraulic equipment cannot remove, so it is an extremely effective device,
TROUBLESHOOTING
20-211
TROUBLESHOOTING
CHECKS BEFORE TROUBLESHOOTING
CHECKS BEFORE TROUBLESHOOTING xxxxxxxx
xxxxxxxxx
Checks before starting
Lubricating oil, cooling water
Item
1. 2. 3. 4. 5. 6. 7. 8.
Item
Electrical Equipment
9. 10. 11. 12.
Other check items
Add fuel Clean, drain Add oil Clean, drain
-----
Add oil Add oil Add water Clean or replace
Check for loose or corroded battery terminals Check for loose or corroded alternator terminals Check for loose or corroded stating motor terminals Check operation of instruments
--
Tighten or replace
--
Tighten or replace
--
Tighten or replace
--
Repair or replace
-----
Repair Repair Bleed air Repair or replace
Check for abnormal noise or smell Check for oil leakage Bleed air from system Check parking brake and wheel brakes
Electrical components
17.
Check battery voltage (engine stopped) Check level of battery electrolyte Check for discolored, burnt, or bare wires Check for missing wiring clamps, hanging wires Checks for water leaking onto wiring (checks carefully water leakage at connectors and terminals) Check for broken or corroded fuses Check alternator voltage (engine running at over ½ throttle) (If the battery charge is low, the voltage may be approximate, 25V immediately after starting.) Sound of actuation of battery relay (when switch starting is turned ON, OFF)
21.
22. 23.
24.
20-212
-----
13. 14. 15. 16.
20.
Remedy
Check fuel level Check for dirt or water in fuel Check hydraulic oil level Check hydraulic oil filter (Torque converter, transmission oil) Check brake oil level Check engine oil level Check cooling water level Check condition of dust indicator
Hydraulic mechanical components
18. 19.
Standard value
24 - 26 V
Replace
---
Add or replace Replace
--
Repair
--
Disconnect connector and dry connection
-28.5 - 29.5 V
Replace Replace
Replace --
HANDLING CONNECTORS
TROUBLESHOOTING
HANDLING CONNECTORS 1.
When removing connectors from 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.
2.
When disconnecting male and female connectors, release the lock and pull in a parallel direction with both hands. Never try to pull apart with one hand.
3.
When the wiring harness clamp of the connector has been removed, always return it to its original condition and check that is no looseness of the clamp.
20-213
TROUBLESHOOTING
PRECAUTIONS WHEN TROUBLESHOOTING
PRECAUTIONS WHEN TROUBLESHOOTING b.
1. SAFETY Stop the machine on level ground, and check that the safety pins and parking brake are correctly applied, and that the tires are blocked.
c. d.
When working in groups, use agreed upon signals and do not allow unauthorized persons near machine.
e. f.
Be careful not to get burned by hot parts or get caught in rotating parts. 2) Always disconnect the cable from the negative (-) terminals of the battery before disconnecting any wiring. Always release the pressure before removing the plugs or caps of any place under hydraulic or air pressure, and connect all measuring tools correctly.
a. b. c. d. 3)
2.
METHODS FOR TROUBLESHOOTING Just because a failure occurs, do not immediately start to disassemble the machine.
a.
The machine may be disassembled in such a way that the problem cannot be located, so the cause of the problem will be unknown.
b.
Was there anything unusual before the machine broke down? Did the breakdown occur suddenly, or had there been signs of trouble before? What was the machine doing when break down occurred? Had the machine been repaired before the breakdown? If so, who carried out the repair, and when? Had the same kind of failure occurred before? Check the following items which can be checked simply by visual checks etc. Check oil level. Check for leakage of oil from piping or hydraulic equipment. Check travel of control levers. Check stroke of spool in control valves. Reenact the failure and check the condition of the machine (particular conditions at the time of failure). Ask the user or operator if the decision about the failure was made based on measured values, or by comparison, or by feeling. Compare extent of failure with standard values. Check safety before carrying out any check. Did not make any check or measurement that will make the condition worse.
As a result, 4) The customer and operator will lose confidence in you. Time will be wasted, and unnecessary costs will be incurred for excess parts and greasing. To avoid these problems, use the following procedure when troubleshooting. 1)
Ask the customer and operator the following questions about the breakdown. a. Have there been any other problems apart from the one reported?
20-214
Try to locate the possible causes for the failure. The transmission system consists of the transmission itself, the transmission control valve, and the transmission electrical control. In particular, when trouble occurs in the transmission system, the probable location of the failure can be divided as follows; Transmission itself, or transmission control valve. Transmission electric control.
HANDLING CONNECTORS To decide which of the two is the location of the failure, refer to “JUDGMENT ON POWER TRAIN”. 5)
Carry out troubleshooting using the troubleshooting charts. There are the following two types of troubleshooting charts. 1.
TROUBLESHOOTING TABLE POWER TRAIN STEERING SYSTEM BRAKE AND AIR SYSTEM WORK EQUIPMENT SYSTEM
2.
TROUBLESHOOTING FLOW CHART ELECTRICAL SYSTEM
TROUBLESHOOTING When removing parts, check their condition of mounting, and distinguish between front and rear, left and right, and top and bottom. Check the match marks, or make match marks to prevent mistakes when installing. If part cannot be removed even when the nuts and bolts have been removed, do not use excessive force to remove it. Check the part to see if there is any problem with it and remove the problem before trying to disassemble the part. When installing or assembling, clean off all dust and dirt and repair any scratches or dents. Remove all grease or oil before coating with gasket sealant.
The troubleshooting charts consist of: 1) Items which can be checked easily. 2) Items which are likely to be the cause of such failures. Follow theses charts to carry out troubleshooting. At the same time, do not forget the following points. Check related items. Check that there are no other failures or breakdowns. 6)
Investigate causes of breakdown Even if the breakdown is repaired, if the original cause of the problem is not removed, the same breakdown will occur again. To investigate and remove the original cause, see "Actions to take to prevent failures from occurring again".
3.
PRECAUTIONS WHEN REMOVING, INSTALLING, DISASSEMBLING OR ASSEMBLING PARTS DURING TROUBLESHOOTING Carry out the various testing and adjusting while observing the items on quality control given in "Testing and Adjusting".
20-215
TROUBLESHOOTING METHOD OF READING TROUBLESHOOTING TABLES DESCRIPTION OF SYMBOLS USED IN TROUBLESHOOTING TABLES The following symbols are used in the "Remedy" column to indicate the method of eliminating the cause of a fault. X: Replace A: Adjusting C: Clean METHOD OF READING TROUBLESHOOTING TABLE The symbol o in the table is inserted only for causes which can be diagnosed. If a cause cannot be diagnosed, the corresponding box is left blank. If the result of problem 1 using the troubleshooting table shown at right is abnormal, the cause of the trouble can be assumed to lie between "a" and "d". Because it is not passible to make a problem regarding "e", it is necessary to perform the next problem (owing to the possibility of a multiple fault). If the result of problem 1 is normal, the cause of the fault does not lie between "a" and "d". In such a case, before diagnosing the causes as "e", however, carry out a check by means of problem 2 or 5. If now the result of problem 1 is abnormal and the result of problem 2 normal, the cause is one of "a", "b" or "d". In addition, if the result of problem 3 is abnormal, the cause will be narrowed down to one of "b" or "d". To determine which of "b" or "d" is the actual cause, perform problem 4. If the result of problem is abnormal, blacken out the corresponding o in the table and then perform the next problem on these causes in order to narrow the likely causes. Example 1: Problem 1 Problem 2 Problem 3 Problem 4
20-216
METHOD OF READING TABLES Example 2: Problem 1 Problem 2 the cause of the fault is "b". In example 2, it is evident that the cause is "e" without carrying out problem 2, however problem 2 is performed by way of an additional check.
METHOD OF READING TABLES
TROUBLESHOOTING
Example 3:
Problem 1
Abnormal
Problem 2
Abnormal
Problem 3
Normal
From the table of example 3, the cause is one of "a", "c" and "e".
Example 4:
Problem 1
Abnormal
Problem 2
Normal
From table of example 4, the cause is one of "a", "b", or "d".
Continue problems
Problem 3
Abnormal
Problem 4
Abnormal
Problem 5
Normal
From table of example 4-1, the cause is "a" or "d".
As can be seen from the above examples, it is not necessary to perform all the problems. Also, looking at a particular cause, no matter how many marks there are in the column corresponding to that cause, it will cause to be an actual cause if there is even one o mark in the same column.
20-217
TROUBLESHOOTING
PREVENTING RECURRENCE OF TROUBLE
PREVENTING RECURRENCE OF TROUBLE The troubleshooting table is used to establish the direct cause of damage or breakdown of a part or piece of equipment. It is not able to establish the root cause of the damage or failure, however. Also, this table only describes the action to be taken with the particular part or piece of equipment. It does not mention what action should be taken to prevent a recurrence of the root cause. In order to remove the root cause of a fault so as to prevent a recurrence, carefully investigate the real cause while referring to the following items. Regarding the method of checking and adjusting each part or piece of equipment, refer to "Testing and Adjusting" in the Shop Manual. HYDRAULIC EQUIPMENT 1. Oil checks The fundamental cause of almost all faults occurring in hydraulic equipment is the inclusion of water, air or other foreign matter in the oil. Accordingly, it is necessary to check the oil to see whether or not it contains any of the above substances, and then take appropriate action. 1)
2)
20-218
Oil checks Check for water contamination. Check the oil for possible water contamination by means of a diesel engine oil checker or a hot plate. Check for contamination of other foreign matter. Remove the drain plug and filter, then check the bottom of the tank and also the filter to see if any foreign matter has collected there. Check the degree of contamination by means of a contamination checker. Viscosity check Check the viscosity of the oil using a viscometer in order to confirm whether or not the oil is satisfactory. Check of contamination point If, as a result of the above checks, it is discovered that the oil is contaminated by water or other foreign matter, it is necessary to find out where the contamination is occurring and also to take steps to prevent it.
Water: Sand:
Oil storage tank, breather, etc. Oil replenishing or replacing method, etc. Rubber: Cylinder packing, etc. Metal: Wear or damage to hydraulic equipment such as pump and motor, as well as transmission and torque converter, etc. 3)
2.
Oil cleaning and replacement If a large amount of metal particles or other foreign matter is discovered in the oil, either wash the oil using an oil refresher or replace it. If the oil is contaminated by water, it is not possible to remove the water by means of an oil refresher. When washing the oil, also wash or replace the strainer and replace the filter.
Cleaning fragments of damaged parts If a part becomes damaged, fragments may pass into the oil line. It is thus necessary to wash the oil. In addition, disassemble and wash such parts as valves and cylinders which are liable to collect metal fragments and other foreign matter, thus helping to prevent a recurrence of faults due to such fragments becoming lodged in various parts of the engine or hydraulic equipment.
TROUBLESHOOTING
CONNECTOR ARRANGEMENT DIAGRAM
20-219
CONNECTOR ARRANGEMENT DIAGRAM
20-219-1
TROUBLESHOOTING
TROUBLESHOOTING
CONNECTOR TYPES AND MOUNTING LOCATION
CONNECTOR TYPES AND MOUNTING LOCATIONS The address column in the table below shows the address in the connector arrangement diagram. Connector Number
Type
No. of pins
A4
X
2
Air servo motor
W5
A5
M
2
Thermistor
U1
A6
SWP
6
Air mix servo motor
V2
A7
M
6
Blower motor and resistor
V2
A8A
S
10
Intermediate connector (air conditioner relay)
V2
A8B
S
8
Intermediate connector (air conditioner relay)
V2
A9
KES 0
4
Blower relay (Main)
W3
A10
KES 0
4
Blower relay (Hi)
W3
A11
KES 0
4
Blower relay (M2)
W3
A12
KES 0
4
Condenser relay
W3
A13
KES 0
4
Blower relay (M1)
W2
A14
X
2
M6 switch
W4
A14
KES 0
4
Condenser relay (Hi)
W4
2
Hi / Lo switch
W5
A15
Place of use
Address
A15
KES 0
4
Magnet clutch relay
W2
A16
SWP
12
Air conditioner controller
R1
A17
SWP
16
Air conditioner controller
R1
A18
SWP
8
L.H. detection servo motor
A19
SWP
8
R.H. detection servo motor
AF1
X
2
Solenoid 1 (relief)
E1
AF2
X
2
Solenoid 2 (Hi)
F1
AF3
X
2
Solenoid 3 (Lo)
F1
AF4
X
2
Solenoid 4 (selector)
E1
AF5
X
2
Solenoid 5 (charge)
B3
AF6
X
2
Boom bottom pressure switch
B3
AF7
X
2
Charge pressure switch
B2
B01
X
2
Condenser (upper)
F9
B03
KES 1
2
Window washer
M5
B04
KES 1
2
Window washer
K4
20-220
CONNECTOR TYPES AND MOUNTING LOCATION
TROUBLESHOOTING
Connector Number
Type
No. of pins
B05
KES 1
2
Diode
B06
KES 1
2
Diode
B07
X
2
Condenser (lower)
F8
B08
X
2
Brake accumulator low pressure switch
I2
B09
X
2
Emergency brake switch
F7
B10
X
2
Emergency brake switch
F7
B11
X
1
Condenser (upper)
F9
B12
X
1
Condenser (lower)
F9
B13
X
2
Brake accumulator low pressure switch
I2
B14
X
2
Parking brake emergency release solenoid
F8
BOOM
X
3
Boom proximity switch
BR1
SWP
14
Intermediate connector (washer, condenser)
J3
C01
M
6
Front wiper motor
Q1
9
Radio
Q3
C02
Place of use
Address
C03
M
2
Front working lamp
R8
C04
M
2
Front working lamp
T9
4
Warning lamp switch
R9
C05 C06
KES 1
2
Room lamp
T9
C07
M
4
Rear wiper motor
W8
C1
MIC
13
Transmission and ECSS controller
a5
C2
MIC
21
Transmission and ECSS controller
a3
C3A
AMP040
20
Transmission and ECSS controller
Y4
C3B
AMP040
16
Transmission and ECSS controller
Y4
C4
AMP040
12
Transmission and ECSS controller
Y4
C5
MIC
17
Transmission and ECSS controller
Y3
CH1
AMP
13
For T-adapter connection
CH2
AMP
21
For T-adapter connection
CL1
S
12
Intermediate connector (working lamp, radio)
Q2
CL2
S
10
Intermediate connector (air conditioner)
Q2
CL3
M
6
Intermediate connector (air conditioner)
Q1
CN3
X
2
Speed sensor
H1
CN4
JFC
2
1st solenoid
D7
20-221
TROUBLESHOOTING
CONNECTOR TYPES AND MOUNTING LOCATION
Connector Number
Type
No. of pins
CN5
X
1
1st fill switch
C8
CN6
JFC
2
2nd solenoid
D7
CN7
X
1
2nd fill switch
C9
CN8
JFC
2
4th solenoid
D7
CN9
X
1
4th fill switch
D9
CN10
X
2
Parking brake solenoid
E7
CN11
X
2
Transmission oil temperature sensor
I2
CN12
JFC
2
3rd solenoid
E7
CN13
X
1
3rd fill switch
D9
CN14
JFC
2
R solenoid
E8
CN15
X
1
R fill switch
D9
CN16
JFC
2
F solenoid
E8
CN17
X
1
F fill switch
E9
CN18
X
2
Torque converter oil temperature sensor
I2
CN19
X
2
Parking brake indicator switch
I2
CNL
X
2
Joystick solenoid (L)
S1
CNR
X
2
Joystick solenoid (R)
T1
D01
KES 1
2
Diode
D02
KES 1
2
Diode
D1
KES 1
2
Diode
D2
KES 1
2
Diode
E01
-
1
Slow blow fuse
M3
E02
-
1
Slow blow fuse
M2
E04
X
3
Engine speed sensor
K3
1
Engine water temperature sensor (Standard specification)
L8 L4
E05
Place of use
Address
E06
X
2
Engine water temperature sensor (Standard specification)
E07
-
1
Heater relay
E08
-
1
Heater relay
I9
E09
-
1
Heater relay
H9
E10
X
1
Engine oil level sensor
L4
E11
-
1
Engine oil pressure sensor
G9
20-222
CONNECTOR TYPES AND MOUNTING LOCATION
TROUBLESHOOTING
Connector Number
Type
No. of pins
Place of use
Address
E12
X
1
Air conditioner compressor
J9
E13
X
2
Starting motor
L4
E15
-
1
Alternator terminal B
M7
E16
-
1
Alternator terminal R
M6
E17
-
1
Alternator terminal E
M6
E19
1-pin connector
1
Dust indicator
H9
E20
1-pin connector
1
Dust indicator
H9
E23
KES 1
2
Diode
ECSS
SWP
8
Intermediate connector
E7
ER1
SWP
14
Intermediate connector (air conditioner, engine water temperature sensor)
J3
EST
X
3
Remove when installing emergency steering
F01
M
3
Head lamp (RH)
D6
F02
M
3
Front combination lamp (RH)
D6
F03
M
3
Front combination lamp (LH)
B1
F04
M
3
Head lamp (LH)
B1
F05
X
3
Proximity switch for bucket
B4
F06
X
3
Proximity switch for boom kick-out
E6
F07
-
1
Horn
D6
F08
-
1
Horn
G1
F09
-
1
Horn
G1
F10
-
1
Horn
C6
F11
X
2
Switch pump cut-off solenoid
G1
F12
KES 1
2
Diode
F21
X
2
Boom RAISE switch
B4
F22
X
2
Boom LOWER switch
B5
F23
X
2
Boom lever detent switch
B4
F26
X
2
Damping solenoid
B5
F30
X
3
Boom cylinder oil pressure sensor
FR1
X
10
Intermediate connector (head lamp)
H1
20-223
TROUBLESHOOTING
CONNECTOR TYPES AND MOUNTING LOCATION
Connector Number
Type
No. of pins
FR2
X
4
Intermediate connector (boom, bucket SIG)
FR5
SWP
6
Intermediate connector
FS1
L
2
Power source
W6
FS2
S
12
Fuse
W6
FS3
M
6
Fuse
W7
FS4
L
2
Power source
W7
FS5
M
6
Fuse
W7
FS6
M
4
Fuse
W7
G01
X
2
Coolant level
K9
G02
M
2
Working lamp (RH)
K9
G03
M
2
Working lamp (LH)
K9
GE01
SWP
8
Rack sensor
GER1
SWP
8
Intermediate connector
GER2
SWP
6
Intermediate connector
GLR1
SWP
8
Intermediate connector
GLR2
SWP
6
Intermediate connector
GR1
X
4
Intermediate connector (working lamp)
GRE
SWP
6
Grease
GVN
M
6
Model selection connector
HEAT
M
2
Intermediate connector
JS1
S
1
Buzzer
W5
JS3
1-pin connector
1
Cut-off switch power source
W5
JS4
1-pin connector
2
Cut-off switch GND
W5
JS5
KES 1
2
Joystick ON-OFF switch
Q8
JS6
X
3
Neutral switch
W4
JS8
KES 0
5
Caution relay
a7
JS9
KES 0
5
Solenoid cut relay
a8
JS10
KES 0
5
Selector switch
a8
JS11
KES 0
3
Steering neutral interlock relay
Z9
JS12
M
8
Intermediate connector (joystick switch)
U1
20-224
Place of use
Address H1
L8
CONNECTOR TYPES AND MOUNTING LOCATION
TROUBLESHOOTING
Connector Number
Type
No. of pins
Place of use
Address
JS14
M
8
Intermediate connector (joystick lever switch)
U1
JSA (male)
1-pin connector
1
Intermediate connector (neutral)
W3
JSB (male)
1-pin connector
1
Intermediate connector (neutral)
W4
JSC
1-pin connector
1
Neutral
S1
JSD
1-pin connector
1
Neutral
S1
L01
SWP
6
Parking brake switch
Q5
L02
SWP
6
Light and dimmer switch
Q5
L03
SWP
6
Turn signal and hazard switch
Q4
L04
SWP
14
F/R and speed switch
Q3
L05
AMP040
20
Main monitor
Q4
L06
AMP040
16
Main monitor
Q4
L07
AMP040
12
Main monitor
Q4
L08
AMP040
8
Main monitor
Q4
L09
M
4
Starting switch
Q3
L10
S
10
Wiper switch
Q3
L12
X
2
Transmission cut-off switch
U1
L13
X
3
Accelerator potentiometer
R1
L14
X
3
Accelerator limit switch
R1
L15
M
4
Kick-down and hold switch
Q7
L16
KES 1
2
Boom kick-out solenoid
Q7
L17
KES 1
2
Bucket positioner solenoid
Q6
L18
AMP040
16
Maintenance monitor
Q6
L19
AMP040
8
Maintenance monitor
Q6
L20
AMP040
16
Maintenance monitor
Q8
L21
KES 1
2
Maintenance monitor
Q7
L22
KES 1
22
Maintenance monitor
Q7
L23
10
Engine throttle controller
L24
18
Engine throttle controller
L25
24
Engine throttle controller
20-225
TROUBLESHOOTING
CONNECTOR TYPES AND MOUNTING LOCATION
Connector Number
Type
No. of pins
L26
MIC
21
Work equipment and joystick controller
T1
L27
MIC
20
Work equipment and joystick controller
T1
L28
MIC
16
Work equipment and joystick controller
U1
L32
M
2
Intermediate connector (power source, GND)
Q5
L33
M
2
Intermediate connector (boom kick-out output)
Q6
L34
S
8
Intermediate connector (network, buzzer output)
S1
L42
1-pin connector
1
Caution buzzer
T9
L43
1-pin connector
1
Caution buzzer
U9
L44
KES 0
6
Wiper relay
V8
L46
KES 1
3
Flasher unit
V9
L48
KES 0
5
Bucket relay
Z6
L49
KES 0
5
Boom relay
a7
L52
KES 0
5
Hazard relay
Y6
L53
KES 0
5
Stop lamp relay
Y6
L54
KES 0
5
Back-up lamp relay
a7
L55
KES 0
5
Horn relay
a8
L56
KES 0
5
Spare relay
a9
L57
KES 0
5
Neutral relay
X6
L58
KES 0
5
Neutralizer relay
X8
L59
KES 0
5
Parking brake safety relay
Z9
L60
KES 0
6
Front working lamp relay
a9
L61
KES 0
6
Rear working lamp relay
a9
L62
KES 0
5
Engine stop relay
Y9
L63
1-pin connector
1
Horn switch
Q5
L64
KES 0
5
Engine oil pressure relay
X9
L75
KES 1
4
Pressure release switch
V8
L80
KES 0
5
Dust indicator relay
Y9
L81
X
2
Stop lamp switch
T1
L82
KES 0
5
Switch pump cut-off relay
L90
KES 1
4
Parking brake emergency release switch
20-226
Place of use
Address
W6
CONNECTOR TYPES AND MOUNTING LOCATION
TROUBLESHOOTING
Connector Number
Type
No. of pins
L91
KES 0
5
ECSS relay
LGL
S
16
Intermediate connector
LGL2
M
2
Intermediate connector
LM1
S
10
MDC monitor panel
LR1
S
12
Intermediate connector (lamp)
B7
LR2
SWP
14
Intermediate connector(air conditioner, washer)
A7
LR4
SWP
14
Intermediate connector (monitor related)
A7
LR5
X
4
Intermediate connector (power source, GND)
B6
LR6
L
2
Intermediate connector (power source)
A6
LR11
SWP
14
Intermediate connector (boom switch)
E7
M01
MIC
20
MDC monitor panel (not used)
M02
MIC
9
MDC monitor panel (not used)
M03
MIC
20
MDC monitor panel (not used)
M04
L
2
MDC monitor controller (not used)
M05
M
4
Intermediate connector
M07
M
4
Cancel, sub total switch
M08
1-pin connector
1
Printer power source
M09
1-pin connector
1
Printer GND
M13
M
3
Intermediate connector
M15
1-pin connector
1
Intermediate connector
M16
MIC
16
MDC monitor controller
M17
MIC
8
MDC monitor controller
M20
KES 1
2
Resistor
M21
KES 1
2
Resistor
MR1
SWP
8
Intermediate connector
OP1
1-pin connector
1
Fuse outlet
OP2
1-pin connector
1
Fuse outlet (power source)
R01
KES 1
2
Diode
R02
KES 1
2
Diode
20-227
Place of use
Address Y9
W6
20-227
TROUBLESHOOTING
CONNECTOR TYPES AND MOUNTING LOCATION
Connector Number
Type
No. of pins
R03
KES 1
2
Diode
R04
KES 1
2
Diode
R07
X
2
Fuel level sensor
K4
R08
M
6
Rear combination lamp (LH)
M6
R09
M
6
Rear combination lamp (RH)
J9
R11
Terminal
1
Battery
L8
R12
Terminal
1
Battery relay
K1
R13
Terminal
1
Battery relay
L1
R15
Terminal
1
Slow blow fuse
M4
R17
Terminal
2
Slow blow fuse
M1
R18
1-pin connector
1
License lamp
M7
R19
1-pin connector
1
License lamp (GND)
M8
R20
X
1
Battery electrolyte level sensor
RES
KES 1
2
Resistance
SEL1
M
2
Engine select
Q3
SEL2
M
2
Joystick function selection
Q2
TM1
SWP
14
Intermediate connector (transmission)
B6
TM2
SWP
16
Intermediate connector (transmission)
A6
20-228
Place of use
Address
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
TROUBLESHOOTING
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS The terms male and female refer to the pins, while the terms male housing and female housing refer to the mating portion of the housing.
20-229
TROUBLESHOOTING
20-230
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
20-231
TROUBLESHOOTING
TROUBLESHOOTING
20-232
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
20-233
TROUBLESHOOTING
TROUBLESHOOTING
20-234
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
20-235
TROUBLESHOOTING
TROUBLESHOOTING
20-236
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
20-237
TROUBLESHOOTING
TROUBLESHOOTING
20-238
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
MEMORANDA
20-239
TROUBLESHOOTING
TROUBLESHOOTING
EXPLANATION OF FUNCTIONS OF ELECTRIC CONTROL MECHANISM
EXPLANATION OF FUNCTIONS OF ELECTRIC CONTROL MECHANISM TRANSMISSION CONTROL SYSTEM
20-240
EXPLANATION OF FUNCTIONS OF ELECTRIC CONTROL MECHANISM 1. Function of equipment at input end. (1) F/R switch. This detects the condition of operation of directional lever and inputs it to the controller as a digital (ON-OFF) signal. (On machines equipped with joystick, the signal from the joystick switch is also input.) (2) Speed range switch. This detects the condition of operation of speed lever and inputs it to the controller as a digital (ON-OFF) signal. (3) Manual selector switch. This detects the condition of operation of the manual selector switch and inputs it to the controller as a digital (ON-OFF) signal. (4) Transmission cut-off selector switch. This detects the condition of operation of the transmission cut-off switch, and controls the signal of the ON-OFF signal from CUT-OFF oil pressure switch to the controller signal. (5) Hold switch. This detects the condition of operation of the hold switch or shift up switch (when using the joystick) and inputs it to the controller as a digital (ON-OFF) signal. (6) Kick-down switch. This detects the condition of operation of the kick-down switch or shift-down switch (when using the joystick) and inputs it to the controller as a digital (ON-OFF) signal. (7) Engine speed sensor. This detects the speed of the engine flywheel as the engine speed and inputs it to the controller as a pulse (rotation) signal. (8) Cut-off oil pressure switch. This detects the condition of operation of the left brake pedal from the brake circuit oil pressure, and inputs it to the controller as a digital (ON-OFF) signal. (When the main monitor cut-off switch is ON.) (9) Speed sensor. This detects the speed of the transmission output shaft as the travel speed and inputs it to the controller as a pulse (rotation) signal. (The speed sensor is also used with the main monitor system.)
20-241
(10)
TROUBLESHOOTING
Transmission oil temperature sensor. This detects the temperature of the transmission oil and inputs it to the controller as a analog (resistance) signal.
(11)
Speed range switch. (F, R, 1st, 2nd, 3rd, 4th) This detects the condition of actuation of the ECMV flow detection valve and inputs it to the controller as a digital (ON-OFF) signal.
(12)
Neutralizer relay. This detects the condition of actuation of the parking brake and inputs it to the controller as a digital (ON-OFF) signal.
2. Limit function of controller (outlet port). Auto-shift function: This calculates the optimum speed range from the signals from the switches and sensors, and outputs it to the ECMV as an analog (current) signal in order to shift up or down. Modulation control function: This calculates the optimum modulation pattern from the signals from the switches and sensors in order to reduce the shock when shifting up or down, and outputs it to the ECMV of both the clutch to be engaged and the clutch to be disengaged as an analog (current) signal. Hold function: When the hold switch is turned ON, it outputs a signal to the ECMV to stop the auto-shift and hold it at the same speed range. Kick-down function: When the kick-down switch is turned ON, if it matches the control conditions, the signal is output to the ECMV to shift down to 1st.
TROUBLESHOOTING
EXPLANATION OF FUNCTIONS OF ELECTRIC CONTROL MECHANISM
Manual shift function: When the manual shift is turned ON, the signal is output to the ECMV to shift the speed to the selected speed range with the shift lever. For machines with joysticks, when operating in the manual mode, the hold switch becomes the shift-up switch and the kickdown switch becomes the shift-down switch, so the transmission is shifted up or down within the range of the speeds selected by the speed range switch (the range of speeds between 1st and the selected speed range). Parking brake neutralizer function: To prevent seizure of the parking brake, the signal from the neutralizer relay stops the out-put of the directional signal to the ECMV and holds the transmission at neutral even if the directional lever is operated to F or R. Back-up lamp drive function: The signal from the directional switch is sent to the back-up lamp relay as a digital (ONOFF) signal. Buzzer function: The signal is sent through the main monitor to the alarm buzzer as a digital (ON-OFF) signal according to the condition of the input signal. Self-diagnostic function: The controller always observes the directional switch, speed range switch, speed sensor, engine speed sensor, transmission oil temperature sensor, the 6 ECMV fill switches at the input side, and the 8 ECMV solenoids at the output side to check that no abnormality occurs in the back-up lamp relay systems.
20-242
Network communication with main monitor: 1) The controller communicates the actuated speed range through the network. 2) The controller communicates the actuated F/R position through the network. (Machines with joystick.) 3) It communicates the condition of actuation of the hold mode through the network. 4) If any abnormality is detected by the selfdiagnostic function, it communicates the details of the abnormality through the network. 3. Functions of output equipment. 1) ECMV solenoid valve. (F, R, 1st, 2nd, 3rd, 4th) The solenoid receives the signal from the controller, is driven, and controls the transmission clutch oil pressure. 2) Back-up lamp relay. The relay receives the signal from the controller, is driven, and turns the power for the back-up lamp relay ON-OFF. 4. Main monitor display. For details, see MAIN MONITOR.
EXPLANATION OF FUNCTIONS OF ELECTRIC CONTROL MECHANISM -MEMORANDA-
20-243
TROUBLESHOOTING
TROUBLESHOOTING MAIN MONITOR SYSTEM
20-244
EXPLANATION OF FUNCTIONS OF ELECTRIC CONTROL MECHANISM
EXPLANATION OF FUNCTIONS OF ELECTRIC CONTROL MECHANISM 1. Functions of equipment at input end 1) Parking brake oil pressure switch This detects the condition of actuation of the parking brake and inputs it to the main monitor as a digital (ON-OFF) signal. 2) Engine speed sensor. This detects the speed of the engine flywheel as the engine speed and inputs it to the main monitor as a pulse (rotation) signal. 3) Speed sensor. This detects the speed of the transmission output shaft as the travel speed and inputs it to the main monitor as a pulse (rotation) signal. (The speed sensor is also used with the transmission control system.) 4) Engine water temperature sensor. This detects the temperature of the engine cooling water and inputs it to the main monitor as an analog (resistance) signal. 5) Transmission directional switch. This detects the condition of operation of the directional lever to the “N”position and inputs it to the main monitor as a digital (ON-OFF) signal. (The transmission directional switch is also used for the transmission control system.) 6) Emergency steering detection switch. This detects the condition of actuation of the emergency steering hydraulic circuit and inputs into the main monitor as a digital (ONOFF) signal. 7) Turn signal, hazard switch. This detects the condition of operation of the turn signal and hazard switch, and inputs it to the main monitor as a digital (ON-OFF) signal. 8)
Dimmer switch. This detects the condition of operation of the dimmer switch and inputs it to the main monitor as a digital (ON-OFF) signal.
TROUBLESHOOTING
10) Preheating relay. Optional equipment, detects actuation of the relay from the secondary outlet voltage of the preheating relay, and inputs it to the main monitor as a digital (ON-OFF) signal. 11) Maintenance monitor. CHECK lamp signal. This inputs the CHECK lamp drive signal (the output signal from the maintenance monitor) to the main monitor as a digital (ON-OFF) signal. CAUTION lamp signal. This inputs the CAUTION lamp drive signal (the output signal from the maintenance monitor) to the main monitor as a digital (ON-OFF) signal. Lamp synchronous signal. This inputs the lamp synchronous signal (the output signal from the maintenance monitor) to the main monitor as a digital (ON-OFF) signal. 12) Starting switch. Terminal BR. This detects the condition of operation of the starting switch to the ON position and inputs it to the main monitor as a digital (ON-OFF) signal. Terminal C. This detects the condition of operation of the starting switch to the START position and inputs it to the main monitor through the neutral relay as a digital (ON-OFF) signal. 13) Alternator (terminal R). This detects the condition of electricity generated by the alternator and inputs it to the main monitor as an analog (voltage) signal. 2. Network communication with controllers. With transmission, ECSS controller. 1) The speed range (1 - 4) now being used is communicated.
9) Head lamp relay/rear lamp relay. This detects the condition of actuation of the relay from the secondary outlet voltage of the head lamp relay and rear lamp relay, and inputs it to the main monitor as a digital (ONOFF) signal.
20-245
20-245
TROUBLESHOOTING
3.
EXPLANATION OF FUNCTIONS OF ELECTRIC CONTROL MECHANISM
2) The directional position (F, N, R) now being selected is communicated (machines with joystick). 3) When the hold function is actuated, the actuation signal is communicated. 4) If any abnormality occurs in the transmission control system or ECSS control system, the details of the abnormality are communicated.
Turn signal pilot lamp function: The left or right turn signal pilot lamps are made to flash (in the case of hazard the lamps on both sides flash) by the signal from the turn signal and hazard switch. Hi beam pilot lamp function: When the Hi beam is used, the Hi beam pilot lamp is lighted up by the signal from the dimmer switch.
With work equipment, joystick controller: If any abnormality occurs in the transmission control system or joystick control system, the details of the abnormality are communicated.
CHECK lamp function: The CHECK lamp is made to flash by the CHECK lamp signal from the maintenance monitor. When this happens, the flashing of the lamp on the maintenance monitor and the flashing of the CHECK lamp are synchronized by the flash synchronous signal from the maintenance monitor. CAUTION lamp function: The CAUTION lamp is made to flash by the CAUTION lamp signal from the maintenance monitor. When this happens, the flashing of the lamp on the maintenance monitor and the flashing of the CAUTION lamp are synchronized by the flash synchronous signal from the maintenance monitor. Emergency steering indicator function: The emergency steering pilot lamp is made to flash by the signal from the emergency steering detection switch. ECSS switch function (machines equipped with ECSS): For details, see ECSS CONTROL SYSTEM. Working lamp switch function (front, rear): The condition of operation of the working lamp switch is output to the working lamp relay as a digital (ON-OFF) signal. At the same time, the indicator is lighted up by the signal from the working lamp relay.
Functions of main monitor Self-check function: When the starting switch is turned ON, all lamps and meters light up for 3 seconds and the alarm buzzer sounds for 1 second to carry out a self check. (If the starting switch is turned to the START position during the 3 seconds of the self check, the self check stops.) Speedometer function: The speedometer is displayed on the meter portion by the signal from the speed sensor. (When the system is set to the tachometer display specification, the tachometer is displayed on the meter portion by the signal from the engine speed sensor.) Transmission shift indicator function: The speed range or directional N is displayed on the shift indicator portion by the network communication from the transmission and ECSS controller. Transmission directional indicator function: (Machines with joystick) The directional F or R is displayed at the bottom of the speedometer portion by the network communication from the transmission and ECSS controller. (Even on machines with joystick, the directional N is displayed on the shift indicator portion.) Hold indicator function When the hold mode is actuated, the hold indicator is lighted up by the network communication from the transmission and ECSS controller.
2-246
EXPLANATION OF FUNCTIONS OF ELECTRIC CONTROL MECHANISM
TROUBLESHOOTING
Parking brake dragging warning function: If the directional lever (switch) is set to the F or R position when the parking brake is still applied (ON), the CAUTION lamp flashes and the alarm buzzer sounds intermittently. Action code and failure code display function: If an abnormality signal is received by network communication from the controllers, the action code (normally displayed) or failure code (when failure code is displayed) are displayed on the speedometer portion. At the same time, when the abnormality code is received, the total hours of operation of the machine is calculated by the signal from the alternator terminal R, and this is displayed as the elapsed time since failure on the failure mode display. 4. Functions of equipment at output end. 1) Alarm buzzer: This receives the signal from the main monitor and generates the alarm sound. (The alarm buzzer is also used for the maintenance monitor system.) 2) Front, rear working lamp relay: This receives the signal from the controller and switches the power for the front or rear working lamp relay ON-OFF according to the switching of the relay.
20-247
TROUBLESHOOTING
EXPLANATION OF FUNCTIONS OF ELECTRIC CONTROL MECHANISM
MAINTENANCE MONITOR SYSTEM
2-248
EXPLANATION OF FUNCTIONS OF ELECTRIC CONTROL MECHANISM 1. Functions of equipment at input end. 1) Fuel level sensor: This detects the fuel level in the fuel tank and inputs it to the maintenance monitor as an analog (resistance) signal. 2) Engine water temperature sensor: This detects the temperature of the engine cooling water and inputs it to the maintenance monitor as an analog (resistance) signal. 3) Torque converter oil temperature sensor: This detects the temperature of the torque converter oil and inputs it to the maintenance monitor as an analog (resistance) signal. 4) Engine water level switch: This detects the level of the engine cooling water in the radiator reservoir tank and inputs it to the maintenance monitor as a digital (ON-OFF) signal.
TROUBLESHOOTING
9) Alternator (terminal R): This detects the condition of generation of electricity by the alternator and inputs it to the maintenance monitor as an analog (electricity generation) signal. 10) Starting switch (terminal C): This detects the condition of operation of the starting switch to the START position and inputs it through the neutral relay to the maintenance monitor as a digital (ON-OFF) signal. 2. Control functions of maintenance monitor. Self-check function: When the starting switch is turned ON, all lamps and meters light up for 3 seconds and the alarm buzzer sounds for 1 second to carry out a self check. (If the starting switch is turned to the START position during the 3 seconds of the self check, the self check stops.)
5) Engine oil level switch: This detects the level of the oil in the engine oil pan and inputs it to the maintenance monitor as a digital (ON-OFF) signal.
Fuel gauge: The fuel gauge is displayed and the pilot lamp flashes or goes out according to the signal from the fuel level sensor.
6) Brake accumulator low-pressure switch: This detects the oil pressure in the wheel brake accumulator circuit and inputs it to the maintenance monitor as a digital (ON-OFF) signal.
Engine water temperature gauge: The engine water temperature gauge is displayed and the pilot lamp flashes or goes out according to the signal from the engine water temperature sensor.
7) Engine oil pressure switch: This detects the engine oil pressure inputs it to the maintenance monitor as a digital (ONOFF) signal.
Torque converter oil temperature gauge: The torque converter oil temperature gauge is displayed and the pilot lamp flashes or goes out according to the signal from the torque converter oil temperature sensor.
8) Air cleaner clogging switch: This detects the clogging condition of the air cleaner and inputs it to the maintenance monitor as a digital (ON-OFF) signal.
Engine water level pilot lamp: The pilot lamp flashes or goes out according to the signal from the engine water level sensor.
20-249
TROUBLESHOOTING
EXPLANATION OF FUNCTIONS OF ELECTRIC CONTROL MECHANISM
Engine oil level pilot lamp: The pilot lamp flashes or goes out according to the signal from the engine oil level sensor. Brake oil pressure caution lamp: The caution lamp flashes or goes out according to the signal from the brake accumulator low-pressure switch. Engine oil pressure caution lamp: The caution lamp lights up, flashes, or goes out according to the signal from the engine oil pressure switch. Battery charge caution lamp: The caution lamp lights up, flashes, or goes out according to the signal from alternator terminal R. Air cleaner clogging caution lamp: The caution lamp flashes or goes out according to the signal from the air cleaner clogging sensor. Service meter: The service meter is driven by the signal from the engine oil pressure switch. Output to main monitor: The CHECK lamp signal, CAUTION lamp signal, and flash synchronous signal are output to the main monitor as a digital (ONOFF) signal according to the condition of the input signal. Alarm buzzer function: The digital (ON-OFF) signal is output to the alarm buzzer according to the condition of the input signal.
2-250
3.
Functions of equipment at output end. 1) Main monitor: This receives the signal from the maintenance monitor and makes the CHECK lamps or CAUTION lamps flash. 2) Alarm buzzer: This receives the signal from the maintenance monitor and makes the alarm buzzer sound. (The alarm buzzer is also used for the main monitor system.)
EXPLANATION OF FUNCTIONS OF ELECTRIC CONTROL MECHANISM
TROUBLESHOOTING
-MEMORANDA-
20-251
TROUBLESHOOTING
EXPLANATION OF FUNCTIONS OF ELECTRIC CONTROL MECHANISM
ECSS (Electronically Controlled Suspension System) CONTROL SYSTEM This system has functions in the transmission controller, and judges the function by the select signal from the main monitor when the engine is started.
2-252
EXPLANATION OF FUNCTIONS OF ELECTRIC CONTROL MECHANISM 1. Functions of equipment at input end 1) ECSS actuation switch: This detects the condition of actuation of the ECSS switch and inputs it to the controller as a digital (ON-OFF) signal. 2) Output speed range signal: This detects the condition of the output speed range. (The ECSS system carries out control with the same controller as the transmission control system, so the speed range switch signal is also used inside the controller.) 3) Speed sensor: This detects the speed of the transmission output shaft as the travel speed (speed) and inputs it to the controller as a pulse (rotation) signal. (The ECSS system carries out control with the same controller as the transmission control system, so the speed sensor signal is also used inside the controller.) 4) Charge oil pressure switch: This detects the basic oil pressure of the damper circuit and inputs it to the controller as a digital (ON-OFF) signal. 5) Boom bottom oil pressure switch: This detects the oil pressure of the boom cylinder bottom circuit and inputs it to the controller as a digital (ON-OFF) signal. 6) Pressure release switch: This switch is the drive power to the selector solenoid (SOL4) by the operation of the pressure release switch. (The signal from the pressure release switch does not pass through the controller, and is output directly to the selector solenoid (SOL4). It is actuated at the same time has the normal return solenoid valve (SOL1).) 2.
Control function of controller Damper function: To prevent pitching and bouncing of the bucket, the input signals from the switches and sensors are output as a digital (ON-OFF)
TROUBLESHOOTING signal to the relief solenoid (SOL1), Highpressure solenoid (SOL2), Low-pressure solenoid (SOL3), and pressure release solenoid (SOL4).
Accumulator charge function: To prevent the oil pressure in the accumulator circuit from dropping and the boom from going down when the damper function is actuated, the signal from the charge oil pressure sensor is output to the charge solenoid (SOL5) as a digital (ONOFF) signal. Pressure release function: The pressure release switch signal drives the pressure release solenoid (SOL4) to release the remaining pressure in the boom cylinder circuit during the disassembly and assembly operation. (The pressure release switch signal does not pass through the controller; it can be input directly to the pressure release solenoid (SOL4).) Self-diagnostic function: The controller always observes the system to check that no abnormality has occurred in the systems for the four solenoids at the output end. Network communication with main monitor: If the self-diagnostic function detects any abnormality, it communicates the details of the abnormality through the network. (The ECSS system carries out control with the same controller as the transmission control system, so the network communication circuit is used in both systems.) 3. Functions of equipment at output end. 1) Return solenoid valve (SOL1): This receives the signal from the controller and the solenoid is driven to open or close the circuit between the boom cylinder head circuit and the hydraulic tank.
20-253
TROUBLESHOOTING
EXPLANATION OF FUNCTIONS OF ELECTRIC CONTROL MECHANISM
2) High-pressure solenoid valve (SOL2): This receives the signal from the controller and the solenoid is driven to open or close the circuit between the boom cylinder bottom circuit and the high-pressure accumulator. 3) High-pressure solenoid valve (SOL3): This receives the signal from the controller and the solenoid is driven to open or close the circuit between the boom cylinder bottom circuit and the low-pressure accumulator. 4) Pressure release check solenoid valve (SOL4): The return solenoid valve (SOL1) and the pressure release check solenoid valve (SOL4) are turned ON-OFF through the relay. The valve receives the signal from the controller or the pressure release switch, and the solenoid is driven to open or close the circuit between the boom cylinder bottom circuit and the damper (high-pressure, lowpressure accumulator) circuit. 5) Accumulator pressure solenoid valve (SOL5): This receives the signal from the controller, and the solenoid is driven to open or close the circuit between the hydraulic pump circuit and the damper (high-pressure, low-pressure accumulator) circuit. 4.
Main monitor display For details, see MAIN MONITOR SYSTEM.
2-254
EXPLANATION OF FUNCTIONS OF ELECTRIC CONTROL MECHANISM
TROUBLESHOOTING
-MEMORANDA-
20-255
TROUBLESHOOTING
EXPLANATION OF FUNCTIONS OF ELECTRIC CONTROL MECHANISM
JOYSTICK STEERING CONTROL SYSTEM
2-256
EXPLANATION OF FUNCTIONS OF ELECTRIC CONTROL MECHANISM This section describes only the items related to steering in the joystick steering control system. For details of the transmission, see TRANSMISSION CONTROL SYSTEM.
Buzzer drive function: If any abnormality occurs in the system, this turns the digital (ON-OFF) signal to the caution relay OFF and actuates the buzzer. Self-diagnostic function: The controller always observes the condition to check that there is no abnormality in the joystick potentiometer and joystick neutral switch systems at the input end and the left and right steering solenoids, solenoid cut relay, and caution relay systems at the output end. Network communication with main monitor: If the self-diagnostic function detects any abnormality, it communicates the details of the abnormality to the main monitor through the network. (The joystick control system carries out control with the same controller as the work equipment control system, so the network communication circuit is used in both systems.)
1. Functions of equipment at input end. 1) Joystick ON-OFF switch: This detects the condition of operation of the joystick ON-OFF switch and inputs it to the controller as a digital (ON-OFF) signal. 2) System cut-off switch: This detects the slide position of the joystick lever stand and inputs it to the controller as a digital (ON-OFF) signal. 3) Joystick neutral switch: This detects the neutral position of the steering lever and inputs it to the controller as a digital (ON-OFF) signal. 4) Joystick potentiometer: This detects the angle of operation of the steering lever and inputs it to the controller as an analog (current) signal. 2.
TROUBLESHOOTING
3.
Control functions of controller. System cut-off function: This actuates or stops the system according to the signals from the system cutoff switch and joystick ON-OFF switch. Joystick neutral interlock function When starting the engine, if the joystick is not at the neutral position, the engine cannot be started. Steering function: This calculates the signal from the steering potentiometer and outputs an analog (current) signal corresponding to this to the left and right steering solenoids. Solenoid stop function: If any abnormality occurs in the system, this outputs a signal to the solenoid cut relay as a digital (ON-OFF) signal.
Functions of equipment at output end 1) Left, right steering solenoid valve This receives the signal from the controller and drives the solenoid to control the solenoid valve output pressure effortlessly. 2) Steering neutral interlock relay: This receives the signal from the controller and drives the solenoid to drive the neutral safety relay when the engine is started. 3) Solenoid cut relay: This receives the signal from the controller and drives the solenoid to switch the circuit at the return side of the steering solenoid ONOFF. 4) Caution relay: This receives the signal from the controller and drives the relay to switch the alarm buzzer circuit ON-OFF.
4.
Main monitor display For details, see MAIN MONITOR SYSTEM.
20-257
TROUBLESHOOTING
EXPLANATION OF FUNCTIONS OF ELECTRIC CONTROL MECHANISM
METHOD OF DISPLAYING ACTION AND FAILURE CODE 1. Outline The speedometer display on the main monitor is used to display the troubleshooting for each control system. The nature of the troubleshooting is displayed as the failure action code, failure code, and the time elapsed since failure. The signals between the main monitor and each controller are transmitted in serial through the network circuit. (Only the engine controller uses a special parallel signal.) 2. Display of failure action code This code informs the operator directly of the abnormality, and takes action, such as stopping the machine immediately. There are three types of action code: EOO, EON + CALL (EON and CALL are displayed alternately), and CALL. If a failure occurs suddenly, one of these codes is shown on the speedometer display. 3. Failure code and time elapsed since failure The failures detected by each controller are changed to a code and displayed. It is possible to tell from this code which system in which controller has failed, so carry out troubleshooting for the applicable controller. 4. Saving failure code The transmission controller writes the failure codes to memory. 1) A total of 9 failure codes can be saved in memory. 2) The data that is saved to memory is as follows: A) Failure code B) Time elapsed since failure (up to 1000 hours) 3) The failures are saved in the order that they occur. If a failure code already exists in the memory, the repeat failure code is not saved.
2-258
4) If there are already 9 items in memory, and a 10th failure occurs, the oldest item is deleted and the new item is saved. It is possible to display the failure code and time elapsed since failure for items saved in memory by operating the main monitor set switch.
EXPLANATION OF FUNCTIONS OF ELECTRIC CONTROL MECHANISM
TROUBLESHOOTING
5. Switch operation procedure actuation Switch operation Trouble data memory mode display 1) Stop engine 2) Turn starting switch ON 3) Push operation mode switch (1) and head lamp switch (2) simultaneously and keep pressed for at least 5 seconds.
Going to next failure code 4) Press head lamp switch (2).
Clearing failure code 5) Keep rear lamp switch (3) pressed for at least 2 seconds.
Quitting trouble data memory display mode 6) Push operation mode switch (1) and head lamp switch (2) simultaneously and keep pressed for at least 5 seconds. Or start the engine.
Actuation
The failure code is displayed on the speedometer display and the time elapsed since failure is displayed on the action code display. If there is no failure, the speedometer display shows [CC] and the action code display shows [0000].
The failure code and time elapsed since failure are displayed in turn (when this is done, the failure code for the latest failure is displayed first). If the failure still exists, the display flashes; if the failure has been restored, the display lights up. The failure and elapsed time on the display are cleared. If the failure still exists, the failure code is not cleared.
The display returns to the normal display.
20-259
TROUBLESHOOTING
CHART OF ACTION CODES, FAILURE CODES, AND RE-ENACTION
CHART OF ACTION CODES, FAILURE CODES, AND RE-ENACTION After an error occurs, turn the starting switch OFF, and if the display goes out, it is possible to re-enact the problem as follows. For details of the method of displaying the action codes and failure codes, see METHOD OF DISPLAYING SELF DIAGNOSIS (ERROR CODE) AND SAVING TO MEMORY. Re-enaction marks Turn starting switch ON (with engine stopped) Start engine Carry out operation to actuate actuator. 1. Transmission controller 1) Transmission control system. Main monitor action code
None
Failure code
Item
Failed system Short circuit
Disconnection
Re-enaction Short circuit
Memory
Alarm buzzer
Disconnection
10
Back-up lamp relay
O
O
O
X
12
F ECMV solenoid
O
O
O
O
13
R ECMV solenoid
O
O
O
O
14
1st ECMV solenoid
O
O
O
O
15
2nd ECMV solenoid
O
O
O
O
16
3rd ECMV solenoid
O
O
O
O
17
4th ECMV solenoid
O
O
O
O
E00
19
Joystick directional switch
O
O
O
X
CALL
20
Directional switch signal
O
O
O
O
None
21
Range switch signal
O
O
O
X
22
Travel speed sensor
X
O
O
O
23
Engine speed sensor
O
O
O
X
None
24
EEP ROM abnormality
O
X
E01+CALL
25
Transmission oil temperature sensor
O
O
CALL
E00
2-260
O
X
EXPLANATION OF FUNCTIONS OF ELECTRIC CONTROL MECHANISM Main monitor action code
Failure code
Item
Failed system Short circuit
Disconnection
TROUBLESHOOTING Re-enaction Short circuit
Memory
Alarm buzzer
Disconnection
26
F ECMV fill switch
O
X
O
O
27
R ECMV fill switch
O
X
O
O
28
1st ECMV fill switch
O
X
O
O
29
2nd ECMV fill switch
O
X
O
O
30
3rd ECMV fill switch
O
X
O
O
31
4th ECMV fill switch
O
X
O
O
32
F, R ECMV fill switch
X
O
O
X
33
1st, 2nd, 3rd, 4th ECMV fill switch
X
O
O
X
CALL
E00
E23 (short circuit engine speed sensor) can only be detected if the machine is traveling at 4 km/h (3 mp/h) or more.
20-261
TROUBLESHOOTING
CHART OF ACTION CODES, FAILURE CODES, AND RE-ENACTION
2) ECSS control system Main monitor action code
None
Failure code
Item
Failed system Short circuit
Disconnection
Re-enaction Short circuit
Memory
Alarm buzzer
Disconnection
d0
Solenoid 1 (relief)
O
O
O
X
d1
Solenoid 2 (high pressure)
O
O
O
X
d2
Solenoid 3 (high pressure)
O
O
O
X
d3
Solenoid 5 (high pressure)
O
O
O
X
2. Joystick controller Main monitor action code
None
CALL
E00
Failure code
Item
Failed system Short circuit
Disconnection
Re-enaction Short circuit
Memory
Alarm buzzer
Disconnection
56
Back-up lamp relay
O
O
O
X
57
F ECMV solenoid
O
O
O
O
58
R ECMV solenoid
O
O
O
O
59
1st ECMV solenoid
O
O
O
O
60
2nd ECMV solenoid
O
O
O
O
61
3rd ECMV solenoid
O
O
O
O
62
4th ECMV solenoid
O
O
O
O
63
Joystick directional switch
O
O
O
O
E59 and E60 cannot be distinguished, so they are issued at the same time. Disconnection cannot be detected for E56. It is always ON and is called up when there is a failure warning.
2-262
EXPLANATION OF FUNCTIONS OF ELECTRIC CONTROL MECHANISM
TROUBLESHOOTING
3. Action code table. Action code
Transmission control system Problem system
E00
E01 + CALL
CALL
Action of machine
Disconnection in travel speed sensor system
Automatic gear shifting not carried out (changes to manual gear shifting)
Disconnection, short circuit, or abnormality in engine speed sensor system
Engine speed taken as 2100 rpm (there is shock when shifting gear)
Disconnection in fill switch
Clutch engaged with out fill signal (there is shock when shifting gear)
Short circuit in transmission oil temperature sensor
Joystick control system Problem system Disconnection, short circuit with ground, or short circuit in joystick FNR signal system
__
__
Action of machine
Action buzzer
Shifts to neutral (possible to switch to manual)
__
Normal manual gear shifting possible
No
__
__
Short with ground in fill switch
Shifts to neutral, travel impossible (modulation output OFF)
__
__
Disconnection, short circuit with ground, or short circuit in shift lever system
Shifts to neutral, travel impossible (controller input judged as N)
__
__
Disconnection, short circuit with ground, or short circuit in F,R ECMV solenoid system
Shifts to neutral, travel impossible (ECMV output OFF)
Disconnection, short circuit with ground, or short circuit in speed range ECMV solenoid system
Shifts to neutral, travel impossible (ECMV output OFF)
Normal operation possible but there is shock when shifting gear Normal operation possible but there is shock when shifting gear
__
Suitable gear shifting data for transmission oil temperature cannot be selected (there is shock when shifting gear)
Action by operator
Yes
Travel under own power possible, move to safe place then call for service Stop machine immediately, turn starting switch OFF, then call for service
Yes __
__
__
__
20-263
TROUBLESHOOTING
CHART OF ACTION CODES, FAILURE CODES, AND RE-ENACTION
TRANSMISSION CONTROLLER LED DISPLAY The transmission controller uses two 7-segment LEDs to display the internal condition of the controller and input/output errors. The display shows two characters at the same time, and changes these in turn to give the display. When the engine is started, “Program part No. display mode" appears, followed by "Output speed range display mode". If there is any abnormality in the controller, it changes to "Troubleshooting mode". The failure mode is saved to memory by the main monitor. Method of displaying failure codes for transmission controller
Table 1 (Output speed range display mode)
2-264
Display
Content
Display
Content
0. 1.
NEUTRAL, 1st
F. 4.
FORWARD, 4th
0. 2.
NEUTRAL, 2nd
A. 1.
REVERSE, 1st
0. 3.
NEUTRAL, 3rd
A. 2.
REVERSE, 2nd
0. 4.
NEUTRAL, 4th
A. 3.
REVERSE, 3rd
F. 1.
FORWARD, 1st
A. 4.
REVERSE, 4th
F. 2.
FORWARD, 2nd
F. F.
Neutral safety condition
F. 3.
FORWARD, 3rd
TROUBLESHOOTING
MEMORANDA
-MEMORANDA-
20-265
TROUBLESHOOTING
MEMORANDA
METHOD OF USING JUDGEMENT TABLE This judgement table is a tool to determine if the problem with the machine is caused by an abnormality in the electrical system or by an abnormality in the hydraulic or mechanical system. The symptoms are then used to decide which troubleshooting table (E-00, H-00, etc.) matches the symptoms. The judgement table is designed so that it is easy to determine from the self-diagnostic display which troubleshooting table to go to. The abnormality display given by the monitor panel leads directly to troubleshooting of the monitor system (M00, K-00, C-00). (See troubleshooting of the machine monitor system) [Method of using judgement table] A 0 mark is put at the places where the failure mode and self-diagnostic display match, so check if an error code is displayed on the graphic display portion of the monitor panel. If an error code is displayed: Go to the troubleshooting code at the bottom of the judgement table (E-00, etc.). If there is a problem but no error code is displayed: Go to the troubleshooting code on the right of the judgement table (H-00). For failure modes where no 0 mark is given, go directly to the troubleshooting code on the right of the judgement table.
2-266
TROUBLESHOOTING
MEMORANDA
-MEMORANDA-
20-267
TROUBLESHOOTING
METHOD OF USING TROUBLESHOOTING CHARTS
METHOD OF USING JUDGEMENT CHARTS 1.
Category of troubleshooting code number Troubleshooting Code No.
2.
Component
S-00
Troubleshooting of engine system
T-00
Troubleshooting of transmission controller system
M-00
Troubleshooting of main monitor system
K-00
Troubleshooting of maintenance monitor system
E-00
Troubleshooting of electrical system
H-00
Troubleshooting of hydraulic, mechanical system
D-00
Troubleshooting of ECSS
J-00
Troubleshooting of joystick steering controller system
Method of using troubleshooting table 1) Troubleshooting code number and problem: The top left of the troubleshooting chart gives the troubleshooting code number and the problem with the machine. 2) Distinguishing conditions: Even with the same problem, the method of troubleshooting may differ according to the model, component, or problem. In such cases, the troubleshooting chart is further divided into sections marked with small letters (for example, a), b)), so go to the appropriate section to carry out troubleshooting. If the troubleshooting table is not divided into sections, start troubleshooting from the first check item. 3) General precautions: When using the troubleshooting chart, precautions that apply to all items are given at the top of the page and marked with The precautions marked the check inside the box. 4) Method of following troubleshooting chart: Check or measure the item inside E= , and according to the answer follow either the YES line or the NO line to go to the next box. (Note: The number written at the top right corner of the box is an index number; it does not indicate the order to follow.) Following the YES or NO lines according to the results of the check or measurement will lead finally to the Cause column. Check the cause and take the action given in the Remedy column on the right. Below the box there are the methods for inspection or measurement, and the judgement values. If the judgement values below the box are correct or the answer to the question inside the box 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 box 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). 5)
6)
2-268
Troubleshooting tools: When carrying out the troubleshooting, prepare the necessary troubleshooting tools. For details, see TOOLS FOR TESTING, ADJUSTING, AND TROUBLESHOOTING. Installation position, pin number: A diagram or chart is given for the connector type, installation position, and connector pin number connection. When carrying out troubleshooting, see this chart for details of the connector pin number and location for inspection and measurement of the wiring connector number appearing in the troubleshooting flow chart.
METHOD OF USING TROUBLESHOOTING CHARTS
TROUBLESHOOTING
1) C-11 Monitor does not display abnormality, but warning lamp (CHECK lamp, CAUTION lamp) lights up. 2)
Before carrying out troubleshooting, check that there is no abnormality display on the main monitor. Before carrying out troubleshooting, check that all the related connectors are properly inserted. Always connect any disconnected connectors before going on to the next step.
3) Division into a) CHECK lamp, and b) CAUTION lamp. 4) Main flow. a) CHECK lamp.
b) CAUTION lamp.
C-11
Related electrical circuit diagram.
20-269
TROUBLESHOOTING
METHOD OF USING MATRIX TROUBLESHOOTING TABLES
METHOD OF USING MATRIX TROUBLESHOOTING TABLES The troubleshooting tables use the same method as for other troubleshooting table (YES/NO type) to locate the causes of failures in the machine. The troubleshooting tables are divided broadly into categories for the main components, such as the steering system and work equipment hydraulic system. Follow the procedure given below and carry out troubleshooting to locate the problems accurately and swiftly. Step 1. Questioning the operator The questions to ask the operator are given below the failure symptom. If the answers to the questions match the information given, follow the arrow to reach the probable cause of the failure. Consider the contents of the questions and consult the table while proceeding to Steps 2 and 3 to grasp the true cause.
1.
STEERING does not work symptom [Example]
Ask the operator about the following points. Did the steering suddenly stop working? Breakage in steering equipment Had the steering gradually been becoming heavy? Internal wear of steering equipment, defective seal Checks before starting [Example]
Step 2. Checks before troubleshooting Before starting the main troubleshooting and measuring the hydraulic pressure, first check the Checks before Starting items, and check for oil leakage and loose bolts. These checks may avoid time wasted on unnecessary troubleshooting. The items given under Checks before Starting are items which must be considered particularly for that symptom before starting troubleshooting. Step 3. Using cross-reference table 1) Operate the machine to carry out the checks in the troubleshooting item column. Mark the items where the results match the symptom. It is not necessary to follow the troubleshooting checks in order; follow an order which is easiest to carry out troubleshooting. 2)
Find the appropriate cause from the cause column. If the symptom appears, the that line indicate the possible causes. (For item No. 2 in the table on the right, the possible causes are c or e.) If there is only one : Carry out the other troubleshooting items (where the same cause is marked with ), check if the symptom appears, then repair. If there are two : Go on to Step 3) to narrow down the possible causes.
20-270
Is the oil level in the hydraulic tank correct? Is the type of oil correct? Is there any leakage of oil from the steering valve or Orbit-roll? Has the safety bar been removed from the frame?
METHOD OF USING MATRIX TROUBLESHOOTING TABLES 3)
Operate the machine and check the troubleshooting items other than those in 1). Operate the machine and check the items in the same way as in 1), and if the symptom appears, mark that item. (In the chart on the right, the symptom appears again for item 5).
4)
Find the appropriate cause from the cause column. In the same way as in Step 2), if the symptom appears, the marks on that line indicate the possible causes. (For item No. 5 in the table on the right, the possible causes are b or e.)
5)
Narrow down the possible causes. There is one common cause among the causes located in Steps 2) and 4). (One cause marked appears on the line for both items.) This cause is common to both the symptoms in troubleshooting Steps 1) and 3). The causes which are not common to both troubleshooting items (items which are not marked for both symptoms) are unlikely causes, so ignore them. (in the example given on the right, the causes for Troubleshooting Item 2 are c or e, and the cause for Troubleshooting Item 5 are b or e, so cause e is common to both.)
6)
Repeat the operations in Steps 3), 4) and 5) until one cause (one common cause) remains. If the causes cannot be narrowed down to one cause, narrow the causes down as far as possible.
7)
Remedy If the causes are narrowed down to one common cause, take the action given in the remedy column. The symbols given in the remedy column indicate the following: X: Replace,
TROUBLESHOOTING
: repair, A: Adjust, C: Clean
20-271
TROUBLESHOOTING
METHOD OF USING MATRIX TROUBLESHOOTING TABLES
MEMORANDA
20-272
TABLE OF CONTENTS
TROUBLESHOOTING
TROUBLESHOOTING OF TRANSMISSION CONTROLLER SYSTEM (T MODE)
Judgement table tor transmission controller system related parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Action taken by controller when abnormality occurs and problems on machine . . . . . . . . . . . . . . . . . . . . . . . . Electrical circuit diagram for transmission controller system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T- 1 Failure code [10] (Short circuit, disconnection, short circuit with power source in back-up lamp relay) is displayed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T- 2 Failure code [12] (Short circuit, disconnection, short circuit with power source in F solenoid) is displayed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T- 3 Failure code [13] (Short circuit, disconnection, short circuit with power source in R solenoid) is displayed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T- 4 Failure code [14] (Short circuit, disconnection, short circuit with power source in 1st solenoid) is displayed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T- 5 Failure code [15] (Short circuit, disconnection, short circuit with power source in 2nd solenoid) is displayed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T- 6 Failure code [16] (Short circuit, disconnection, short circuit with power source in 3rd solenoid) is displayed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T- 7 Failure code [17] (Short circuit, disconnection, short circuit with power source in 4th solenoid) is displayed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T- 8 Failure code [19] (Short circuit, disconnection in joystick directional switch system) is displayed . . . . T- 9 Failure code [201 (Short circuit, disconnection in directional switch system) is displayed . . . . . . . . . . T-10 Failure code [211 (Short circuit, disconnection in range switch system) is displayed . . . . . . . . . . . . . . T-11 Failure code [221 (Disconnection in travel speed sensor system) is displayed . . . . . . . . . . . . . . . . . . T-12 Failure code [231 (Short circuit, disconnection in engine speed sensor system) is displayed . . . . . . . T-13 Failure code [241 (Short circuit, disconnection in EEP ROM) is displayed . . . . . . . . . . . . . . . . . . . . . . T-14 Failure code [251 (Short circuit in transmission oil temperature system) is displayed . . . . . . . . . . . . . T-15 Failure code [26] (Short circuit in F ECMV fill switch system) is displayed . . . . . . . . . . . . . . . . . . . . . . T-16 Failure code [27] (Short circuit in R ECMV fill switch system) is displayed . . . . . . . . . . . . . . . . . . . . . . T-17 Failure code [281 (Short circuit in 1st ECMV fill switch system) is displayed . . . . . . . . . . . . . . . . . . . . T-18 Failure code [291 (Short circuit in 2nd ECMV fill switch system) is displayed . . . . . . . . . . . . . . . . . . . T-19 Failure code [301 (Short circuit in 3rd ECMV fill switch system) is displayed . . . . . . . . . . . . . . . . . . . .
20-354 20-356 20-364 20-366 20-367 20-368 20-369 20-370 20-371 20-372 20-373 20-374 20-378 20-381 20-382 20-383 20-384 20-385 20-385 20-386 20-386 20-387
20-351
TROUBLESHOOTING T-20 T-21 T-22 T-23 T-24 T-25 T-26 T-27 T-28 T-29 T-30 T-31 T-32 T-33 T-34 T-35 T-36 T-37
TABLE OF CONTENTS
Failure code [311 (Short circuit in 4th ECMV fill switch system) is displayed . . . . . . . . . . . . . . . . . . . . Failure code [32] (Short circuit in F or R ECMV fill switch system) is displayed . . . . . . . . . . . . . . . . . . Failure code [33] (Short circuit in 1st, 2nd, 3rd, or 4th ECMV fill switch system) is displayed . . . . . . . Hold switch system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Kick-down switch system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Transmission cut-off signal system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Neutralizer relay signal system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Buzzer signal system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Network system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Transmission controller power source system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Short circuit in travel speed sensor system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Disconnection in transmission oil temperature sensor system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Disconnection in F ECMV fill switch system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Disconnection in R ECMV fill switch system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Disconnection in 1st ECMV fill switch system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Disconnection in 2nd ECMV fill switch system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Disconnection in 3rd ECMV fill switch system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Disconnection in 4th ECMV fill switch system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
20-352
20-387 20-388 20-390 20-392 20-392 20-393 20-394 20-395 20-396 20-397 20-398 20-399 20-400 20-400 20-401 20-401 20-402 20-402
MEMORANDA
TROUBLESHOOTING
20-353
TROUBLESHOOTING JUDGEMENT TABLE FOR TRANSMISSION CONTROLLER SYSTEM
JUDGEMENT TABLE FOR TRANSMISSION CONTROLLER SYSTEM RELATED PARTS
20-354
JUDGEMENT TABLE FOR TRANSMISSION CONTROLLER SYSTEM TROUBLESHOOTING
20-355
TROUBLESHOOTING ACTION TAKEN BY CONTROLLER WHEN ABNORMALITY OCCURS
ACTION TAKEN BY CONTROLLER WHEN ABNORMALITY OCCURS AND PROBLEMS ON MACHINE (1) TRANSMISSION CONTROLLER SYSTEM
20-356
ACTION TAKEN BY CONTROLLER WHEN ABNORMALITY OCCURS TROUBLESHOOTING
20-357
TROUBLESHOOTING ACTION TAKEN BY CONTROLLER WHEN ABNORMALITY OCCURS
20-358
ACTION TAKEN BY CONTROLLER WHEN ABNORMALITY OCCURS TROUBLESHOOTING
20-359
TROUBLESHOOTING ACTION TAKEN BY CONTROLLER WHEN ABNORMALITY OCCURS
20-360
ACTION TAKEN BY CONTROLLER WHEN ABNORMALITY OCCURS TROUBLESHOOTING
20-361
TROUBLESHOOTING ACTION TAKEN BY CONTROLLER WHEN ABNORMALITY OCCURS
20-362
ACTION TAKEN BY CONTROLLER WHEN ABNORMALITY OCCURS TROUBLESHOOTING
20-363
TROUBLESHOOTING
ELECTRICAL CIRCUIT DIAGRAM FOR TRANSMISSION CONTROLLER
ELECTRICAL CIRCUIT DIAGRAM FOR TRANSMISSION CONTROLLER SYSTEM
20-364
ELECTRICAL CIRCUIT DIAGRAM FOR TRANSMISSION CONTROLLER
TROUBLESHOOTING
20-365
TROUBLESHOOTING
T-1
Failure code [10] (Short circuit, disconnection, short circuit with power source in back-up lamp relay) is displayed
This troubleshooting is carried out when there is still an abnormality, so when disconnecting the connector and inserting the T-adapter, or when removing the T-adapter and returning the connector to its original position, if the error code is no longer displayed on the monitor display, the problem has been removed. Before carrying out troubleshooting, check that all the related connectors are properly inserted. Always connect any disconnected connectors before going on to the next step.
T-1 Related electrical circuit diagram
20-366
T-1
T-2
TROUBLESHOOTING
T-2
Failure code [12] (Short circuit, disconnection, short circuit with power source in F solenoid) is displayed
This troubleshooting is carried out when there is still an abnormality, so when disconnecting the connector and inserting the T-adapter, or when removing the T-adapter and returning the connector to its original position, if the error code is no longer displayed on the monitor display, the problem has been removed. Before carrying out troubleshooting, check that all the related connectors are properly inserted. Always connect any disconnected connectors before going on to the next step.
T-2 Related electrical circuit diagram
20-367
TROUBLESHOOTING
T-3
Failure code [13] (Short circuit, disconnection, short circuit with power source in R solenoid) is displayed
This troubleshooting is carried out when there is still an abnormality, so when disconnecting the connector and inserting the T-adapter, or when removing the T-adapter and returning the connector to its original position, if the error code is no longer displayed on the monitor display, the problem has been removed. Before carrying out troubleshooting, check that all the related connectors are properly inserted. Always connect any disconnected connectors before going on to the next step.
20-368
T-3
T-4
TROUBLESHOOTING
T-4
Failure code [14] (Short circuit, disconnection, short circuit with power source in 1st solenoid) is displayed
This troubleshooting is carried out when there is still an abnormality, so when disconnecting the connector and inserting the T-adapter, or when removing the T-adapter and returning the connector to its original position, if the error code is no longer displayed on the monitor display, the problem has been removed. Before carrying out troubleshooting, check that all the related connectors are properly inserted. Always connect any disconnected connectors before going on to the next step.
20-369
TROUBLESHOOTING
T-5
Failure code [15] (Short circuit, disconnection, short circuit with power source in 2nd solenoid) is displayed
This troubleshooting is carried out when there is still an abnormality, so when disconnecting the connector and inserting the T-adapter, or when removing the T-adapter and returning the connector to its original position, if the error code is no longer displayed on the monitor display, the problem has been removed. Before carrying out troubleshooting, check that all the related connectors are properly inserted. Always connect any disconnected connectors before going on to the next step.
20-370
T-5
T-6
TROUBLESHOOTING
T-6
Failure code [16] (Short circuit, disconnection, short circuit with power source in 3rd solenoid) is displayed
This troubleshooting is carried out when there is still an abnormality, so when disconnecting the connector and inserting the T-adapter, or when removing the T-adapter and returning the connector to its original position, if the error code is no longer displayed on the monitor display, the problem has been removed. Before carrying out troubleshooting, check that all the related connectors are properly inserted. Always connect any disconnected connectors before going on to the next step.
20-371
TROUBLESHOOTING
T-7
Failure code [17] (Short circuit, disconnection, short circuit with power source in 4th solenoid) is displayed
This troubleshooting is carried out when there is still an abnormality, so when disconnecting the connector and inserting the T-adapter, or when removing the T-adapter and returning the connector to its original position, if the error code is no longer displayed on the monitor display, the problem has been removed. Before carrying out troubleshooting, check that all the related connectors are properly inserted. Always connect any disconnected connectors before going on to the next step.
20-372
T-7
T-8
TROUBLESHOOTING
T-8
Failure code [19] (Short circuit, disconnection in joystick directional switch system) is displayed
This troubleshooting is carried out when there is still an abnormality, so when disconnecting the connector and inserting the T-adapter, or when removing the T-adapter and returning the connector to its original position, if the error code is no longer displayed on the monitor display, the problem has been removed. Before carrying out troubleshooting, check that all the related connectors are properly inserted. Always connect any disconnected connectors before going on to the next step.
20-373
TROUBLESHOOTING
T-9
Failure code [20] (Short circuit, disconnection in directional switch system) is displayed
This troubleshooting is carried out when there is still an abnormality, so when disconnecting the connector and inserting the T-adapter, or when removing the T-adapter and returning the connector to its original position, if the error code is no longer displayed on the monitor display, the problem has been removed. Before carrying out troubleshooting, check that all the related connectors are properly inserted. Always connect any disconnected connectors before going on to the next step.
20-374
T-9
T-9
TROUBLESHOOTING
20-375
TROUBLESHOOTING T-9
20-376
Related electrical circuit diagram
T-9
MEMORANDA
TROUBLESHOOTING
MEMORANDA
20-377
TROUBLESHOOTING
T-10
T-10
Failure code [21] (Short circuit, disconnection in range switch system) is displayed
This troubleshooting is carried out when there is still an abnormality, so when disconnecting the connector and inserting the T-adapter, or when removing the T-adapter and returning the connector to its original position, if the error code is no longer displayed on the monitor display, the problem has been removed. Before carrying out troubleshooting, check that all the related connectors are properly inserted. Always connect any disconnected connectors before going on to the next step.
20-378
T-10
TROUBLESHOOTING
20-379
TROUBLESHOOTING T-10
20-380
Related electrical circuit diagram
T-10
T-11
T-11
TROUBLESHOOTING
Failure code [22] (Disconnection in travel speed sensor system)is displayed
This troubleshooting is carried out when there is still an abnormality, so when disconnecting the connector and inserting the T-adapter, or when removing the T-adapter and returning the connector to its original position, if the error code is no longer displayed on the monitor display, the problem has been removed. Before carrying out troubleshooting, check that all the related connectors are properly inserted. Always connect any disconnected connectors before going on to the next step.
20-381
TROUBLESHOOTING
T-12
T-12
Failure code [23] (Short circuit, disconnection in engine speed sensor system) is displayed
This troubleshooting is carried out when there is still an abnormality, so when disconnecting the connector and inserting the T-adapter, or when removing the T-adapter and returning the connector to its original position, if the error code is no longer displayed on the monitor display, the problem has been removed. Before carrying out troubleshooting, check that all the related connectors are properly inserted. Always connect any disconnected connectors before going on to the next step.
20-382
T-13
T-13
TROUBLESHOOTING
Failure code [24] (Short circuit, disconnection in EEP ROM) is displayed
This troubleshooting is carried out when there is still an abnormality, so when disconnecting the connector and inserting the T-adapter, or when removing the T-adapter and returning the connector to its original position, if the error code is no longer displayed on the monitor display, the problem has been removed. Before carrying out troubleshooting, check that all the related connectors are properly inserted. Always connect any disconnected connectors before going on to the next step.
20-383
TROUBLESHOOTING
T-14
T-14
Failure code [25] (Short circuit in transmission oil temperature system) is displayed
This troubleshooting is carried out when there is still an abnormality, so when disconnecting the connector and inserting the T-adapter, or when removing the T-adapter and returning the connector to its original position, if the error code is no longer displayed on the monitor display, the problem has been removed. Before carrying out troubleshooting, check that all the related connectors are properly inserted. Always connect any disconnected connectors before going on to the next step.
20-384
T-15, T-16
T-15
TROUBLESHOOTING
Failure code [26] (Short circuit in F ECMV fill switch system) is displayed
This troubleshooting is carried out when there is still an abnormality, so when disconnecting the connector and inserting the T-adapter, or when removing the T-adapter and returning the connector to its original position, if the error code is no longer displayed on the monitor display, the problem has been removed. Before carrying out troubleshooting, check that all the related connectors are properly inserted. Always connect any disconnected connectors before going on to the next step.
T-16
Failure code [27] (Short circuit in R ECMV fill switch system) is displayed
This troubleshooting is carried out when there is still an abnormality, so when disconnecting the connector and inserting the T-adapter, or when removing the T-adapter and returning the connector to its original position, if the error code is no longer displayed on the monitor display, the problem has been removed. Before carrying out troubleshooting, check that all the related connectors are properly inserted. Always connect any disconnected connectors before going on to the next step.
20-385
TROUBLESHOOTING
T-17
T-17, T-18
Failure code [28] (Short circuit in 1st ECMV fill switch system) is displayed
This troubleshooting is carried out when there is still an abnormality, so when disconnecting the connector and inserting the T-adapter, or when removing the T-adapter and returning the connector to its original position, if the error code is no longer displayed on the monitor display, the problem has been removed. Before carrying out troubleshooting, check that all the related connectors are properly inserted. Always connect any disconnected connectors before going on to the next step.
T-18
Failure code [29] (Short circuit in 2nd ECMV fill switch system) is displayed
This troubleshooting is carried out when there is still an abnormality, so when disconnecting the connector and inserting the T-adapter, or when removing the T-adapter and returning the connector to its original position, if the error code is no longer displayed on the monitor display, the problem has been removed. Before carrying out troubleshooting, check that all the related connectors are properly inserted. Always connect any disconnected connectors before going on to the next step.
20-386
T-19, T-20
T-19
TROUBLESHOOTING
Failure code [30] (Short circuit in 3rd ECMV fill switch system) is displayed
This troubleshooting is carried out when there is still an abnormality, so when disconnecting the connector and inserting the T-adapter, or when removing the T-adapter and returning the connector to its original position, if the error code is no longer displayed on the monitor display, the problem has been removed. Before carrying out troubleshooting, check that all the related connectors are property inserted. Always connect any disconnected connectors before going on to the next step.
T-20
Failure code [31] (Short circuit in 4th ECMV fill switch system) is displayed
This troubleshooting is carried out when there is still an abnormality, so when disconnecting the connector and inserting the T-adapter, or when removing the T-adapter and returning the connector to its original position, if the error code is no longer displayed on the monitor display, the problem has been removed. Before carrying out troubleshooting, check that all the related connectors are properly inserted. Always connect any disconnected connectors before going on to the next step.
20-387
TROUBLESHOOTING
T-21
T-21
Failure code [32] (Short circuit in F or R ECMV fill switch system) is displayed
This troubleshooting is carried out when there is still an abnormality, so when disconnecting the connector and inserting the T-adapter, or when removing the T-adapter and returning the connector to its original position, if the error code is no longer displayed on the monitor display, the problem has been removed. Before carrying out troubleshooting, check that all the related connectors are properly inserted. Always connect any disconnected connectors before going on to the next step.
20-388
MEMORANDA
TROUBLESHOOTING
MEMORANDA
20-389
TROUBLESHOOTING
T-22
T-22
Failure code [33] (Short circuit in 1st, 2nd, 3rd, or 4th ECMV fill switch system) is displayed
This troubleshooting is carried out when there is still an abnormality, so when disconnecting the connector and inserting the T-adapter, or when removing the T-adapter and returning the connector to its original position, if the error code is no longer displayed on the monitor display, the problem has been removed. Before carrying out troubleshooting, check that all the related connectors are properly inserted. Always connect any disconnected connectors before going on to the next step.
20-390
T-22
TROUBLESHOOTING
20-391
TROUBLESHOOTING
T-23
T-23, T-24
Hold switch system
Before carrying out troubleshooting, check that all the related connectors are properly inserted. Always connect any disconnected connectors before going on to the next step. Always turn the starting switch OFF before disconnecting the connector or connecting the T-adapter (or socket).
T-24
20-392
Kick-down switch system
TROUBLESHOOTING
T-23, T-24
20-393
TROUBLESHOOTING
T-25
Transmission cut-off signal system
Before carrying out troubleshooting, check that all the related connectors are properly inserted. Always connect any disconnected connectors before going on to the next step. Always turn the starting switch OFF before disconnecting the connector or connecting the T-adapter (or socket).
20-394
T-25
TROUBLESHOOTING
T-26
T-26
Neutralizer relay signal system
Check that the parking brake works normally. Before carrying out troubleshooting, check that all the related connectors are properly inserted. Always connect any disconnected connectors before going on to the next step. Always turn the starting switch OFF before disconnecting the connector or connecting the T-adapter.
20-395
TROUBLESHOOTING
T-27
Buzzer signal system
Check that the main monitor and alarm buzzer work normally. Before carrying out troubleshooting, check that all the related connectors are properly inserted. Always connect any disconnected connectors before going on to the next step. Always turn the starting switch OFF before disconnecting the connector or connecting the T-adapter (or socket).
20-396
T-27
TROUBLESHOOTING
T-28
T-28
Network system
Before carrying out troubleshooting, check that all the related connectors are properly inserted. Always connect any disconnected connectors before going on to the next step. Always turn the starting switch OFF before disconnecting the connector or connecting the T-adapter (or socket).
20-397
TROUBLESHOOTING
T-29
Transmission controller power source system
Check that fuse 11 @ is normal. Before carrying out troubleshooting, check that all the related connectors are properly inserted. Always connect any disconnected connectors before going on to the next step. Always turn the starting switch OFF before disconnecting the connector or connecting the T-adapter (or socket).
20-398
T-29
TROUBLESHOOTING
T-30
T-30
Short circuit in travel speed sensor system
Before carrying out troubleshooting, check that all the related connectors are properly inserted. Always connect any disconnected connectors before going on to the next step.
20-399
TROUBLESHOOTING
T-31
Disconnection in transmission oil temperature sensor system
Before carrying out troubleshooting, check that all the related connectors are properly inserted. Always connect any disconnected connectors before going on to the next step.
20-400
T-31
TROUBLESHOOTING
T-32
T-32, T-33
Disconnection in F ECMV fill switch system
Before carrying out troubleshooting, check that all the related connectors are properly inserted. Always connect any disconnected connectors before going on to the next step.
T-33 Disconnection in R ECMV fill switch system Before carrying out troubleshooting, check that all the related connectors are properly inserted. Always connect any disconnected connectors before going on to the next step.
20-401
TROUBLESHOOTING
T-34
Disconnection in 1st ECMV fill switch system
Before carrying out troubleshooting, check that all the related connectors are properly inserted. Always connect any disconnected connectors before going on to the next step.
T-35
Disconnection in 2nd ECMV fill switch system
Before carrying out troubleshooting, check that all the related connectors are properly inserted. Always connect any disconnected connectors before going on to the next step.
20-402
T-34, T-35
TROUBLESHOOTING
T-36
T-36, T-37
Disconnection in 3rd ECMV fill switch system
Before carrying out troubleshooting, check that all the related connectors are properly inserted. Always connect any disconnected connectors before going on to the next step.
T-37
Disconnection in 4th ECMV fill switch system
Before carrying out troubleshooting, check that all the related connectors are properly inserted. Always connect any disconnected connectors before going on to the next step.
20-403
TROUBLESHOOTING
20-404
T-36, T-37
TABLE OF CONTENTS
TROUBLESHOOTING
TROUBLESHOOTING OF MAIN MONITOR SYSTEM (M MODE)
Trouble data display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Electrical circuit diagram for machine monitor system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Electrical circuit diagram for lamp and horn system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Electrical circuit diagram for turn signal and hazard system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M- 1 Main monitor does not work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M- 2 When starting switch is turned ON and engine is started immediately, all lamps stay lighted up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M- 3 Speedometer display does not work properly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M- 4 Abnormality in shift indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . a) Displays N even when directional lever is at F . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . b) Displays N even when directional lever is at R . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . c) Does not display N even when directional lever is at N, and displays R when directional lever is at F . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . d) Does not display N even when directional lever is at N, and displays R when directional lever is at F . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . e) Does not display 1st - 4th . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M- 5 High beam does not light up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M- 6 Turn signal display does not light up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . a) L.H. turn signal display does not light up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . b) R.H. turn signal display does not light up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M- 7 Abnormality in parking display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . a) Parking lamp display does not light up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . b) Parking lamp display stays lighted up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M- 9 Night lighting does not light up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M-10 Abnormality in front working lamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . a) Neither monitor display nor front working lamp light up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . b) Working lamp lights up but monitor display does not light up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . c) Monitor display lights up but working lamp does not light up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M-11 Abnormality in rear working lamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . a) Neither monitor display nor rear working lamp light up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . b) Working lamp lights up but monitor display does not light up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . c) Monitor display lights up but working lamp does not light up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
20-453 20-456 20-458 20-459 20-460
M-12
20-474
Abnormality in transmission cut-off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . a) When monitor switch (transmission cut-off switch) is pressed, cut-off function is not switched and display does not change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . b) When monitor switch (transmission cut-off switch) is OFF, monitor display goes out but cut-off function is actuated when pedal is depressed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . c) When monitor display is turned off (transmission cut-off switch turned OFF), cut-off function is always actuated . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . d) Cut-off function is always actuated regardless of monitor display (transmission cut-off switch ON or OFF) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . e) Monitor display lights up (transmission cut-off switch turned ON), but
20-461 20-462 20-463 20-463 20-463 20-463 20-464 20-464 20-465 20-466 20-466 20-466 20-467 20-467 20-467 20-469 20-470 20-470 20-470 20-470 20-472 20-472 20-472 20-472
20-474 20-474 20-474 20-474
20-451
TROUBLESHOOTING M-13
M-14
M-15
M-16 M-17
M-18 M-19
M-20
M-21
M-22
M-23
20-452
TABLE OF CONTENTS
cut off function is not actuated . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Abnormality in parking brake dragging warning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . a) When parking brake is applied, buzzer sounds (intermittently) and caution lamp flashes even when directional lever is at N . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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 . . . . . . . . . . . . . . . . . . . . . . When parking brake dragging warning is given, buzzer and caution lamp are actuated continuously, or they are not actuated . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . a) Actuated continuously . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . b) Not actuated . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Abnormality in buzzer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . a) Buzzer does not sound when starting switch is at ON (for 3 seconds) (during self-check) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . b) Buzzer always sounds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Condition of monitor switches is not stored in memory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Abnormality in failure display mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . a) Does not enter failure display mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . b) Count for time elapsed since failure in failure display mode does not advance . . . . . . . . . . . . . . . . . Buzzer is not made to sound by transmission controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Abnormality in emergency steering normal display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . a) Emergency steering normal display does not light up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . b) Emergency steering normal display stays lighted up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Abnormality in emergency steering actuation display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . a) Emergency steering actuation display does not light up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . b) Emergency steering actuation display stays lighted up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Abnormality in auto-greasing system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . a) Forced greasing cannot be carried out . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . b) Monitor display flashes rapidly (2 times/sec) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . c) When no more grease remains, monitor display flashes rapidly (2 times/sec) . . . . . . . . . . . . . . . . . . d) Monitor display flashes slowly (1time/sec), confirm that grease is not empty . . . . . . . . . . . . . . . . . . . e) Monitor display goes out . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Abnormality in ECSS system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . a) Display does not change when switch is pressed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . b) Monitor display lights up but ECSS function does not work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Failure code is not sent to main monitor (abnormality in network) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
20-475 20-476 20-476 20-476 20-478 20-478 20-478 20-479 20-479 20-479 20-480 20-481 20-481 20-481 20-482 20-483 20-483 20-483 20-484 20-484 20-484 20-486 20-486 20-486 20-486 20-487 20-487 20-488 20-488 20-488 20-489
TROUBLE DATA DISPLAY
TROUBLESHOOTING
TROUBLE DATA DISPLAY 1.
Outline The speedometer display on the main monitor is used to display the troubleshooting for each control system. The nature of the troubleshooting is displayed as the failure action code, failure code, and the time elapsed since failure. The signals between the main monitor and each controller are transmitted in serial through the network circuit. (Only the engine controller uses a special parallel signal.)
2.
Display of failure action code This code informs the operator directly of the abnormality, and takes action, such as stopping the machine immediately. There are three types of action codes: E00, E01 + CALL (E01 and Call are displayed alternately), and CALL. If a failure occurs suddenly, one of these codes is shown on the speedometer display.
3.
Failure code and time elapsed since failure The failures detected by each controller are changed to a code and displayed. It is possible to tell from this code which system in which controller has failed, so carry out troubleshooting for the applicable controller. For failure that have occurred and been reset, the failure code and the time elapsed since the failure are displayed to make it easy to check failures that are not occurring at present. The failure codes for failures that are now occurring flash, and codes for failures that are not occurring light up. For details of the method of operating and transferring data to the trouble data display mode, see STRUCTURE AND FUNCTION for the main monitor. Note: If the engine is not stopped, it is impossible to switch to the trouble data display mode, so the codes for failures which can only be detected when the engine is operating light up. For the correspondence between the failure codes for each controller and the failed system, see item 4.
20-453
TROUBLESHOOTING 4.
TROUBLE DATA DISPLAY
Action code table
Action code
Transmission control system
ECSS control system
Action of machine
Problem system
Action of machine
Disconnection in travel speed sensor system
Automatic gear shifting not carried out (changes to manual gearshifting)
__
__
Normal manual gear shifting possible
Disconnection, short circuit, or abnormality in engine speed sensor system
Engine speed taken as 2100 rpm (there is shock when shifting gear)
__
Normal operation possible but there is shock when shifting gear
__
No Disconnection in fill switch
CALL
20-454
Action by operator
Problem system
E00
E01 + CALL
Action Buzzer
Clutch engaged with out fill signal (there is shock when shifting gear)
Short circuit in transmission oil temperature sensor
Suitable gearshifting data for transmission oil temperature can not be selected (there is shock when shifting gear)
Short circuit with ground in fill switch
Shifts to neutral, travel impossible (modulation output OFF)
Disconnection, short circuit with ground, or short circuit in shift lever system
Shifts to neutral, travel impossible (controller input judged as N)
Disconnection, short circuit with ground, or short circuit in F, R ECMV solenoid system
Shifts to neutral, travel impossible (ECMV output OFF)
Disconnection, short circuit with ground, or short circuit in speed range solenoid system
Shifts to neutral, travel impossible (ECMV output OFF)
__
Normal operation possible but there is shock when shifting gear
__
__
Yes
Travel under own power if possible, move to safe place then call for service
__
__
__
__ Yes
Stop machine immediately, turn starting switch OFF, then call for service
__
__
__
__
__
TROUBLE DATA DISPLAY Action code
Joystick control system Problem system
E00
E01 + CALL CALL
TROUBLESHOOTING
Disconnection, short circuit with ground, or short circuit in joystick FNR signal system
Action Buzzer
Action by operator
Action of machine
Shifts to neutral (possible to switch to manual)
__
__
__
__
__
__
No
Normal manual gear shifting possible
__
__
__
__
__
__
__
__
20-455
TROUBLESHOOTING ELECTRICAL CIRCUIT DIAGRAM FOR MACHINE MONITOR SYSTEM
ELECTRICAL CIRCUIT DIAGRAM FOR MACHINE MONITOR SYSTEM
20-456
ELECTRICAL CIRCUIT DIAGRAM FOR MACHINE MONITOR SYSTEM
TROUBLESHOOTING
20-457
TROUBLESHOOTING
ELECTRICAL CIRCUIT DIAGRAM FOR LAMP AND HORN SYSTEM
ELECTRICAL CIRCUIT DIAGRAM FOR LAMP AND HORN SYSTEM
20-458
ELECTRICAL CIRCUIT DIAGRAM FOR TURN SIGNAL/HAZARD SYSTEM
TROUBLESHOOTING
ELECTRICAL CIRCUIT DIAGRAM FOR TURN SIGNAL AND HAZARD SYSTEM
20-459
TROUBLESHOOTING
M-1
Main monitor does not work
Before carrying out troubleshooting, check that all the related connectors are properly inserted. Always connect any disconnected connectors before going on to the next step.
20-460
M-1
M-2
M-2
TROUBLESHOOTING
When starting switch is turned ON and engine is started immediately, all lamps stay lighted up
Before carrying out troubleshooting, check that all the related connectors are properly inserted. Always connect any disconnected connectors before going on to the next step.
20-461
TROUBLESHOOTING
M-3
Speedometer display does not work properly
Before carrying out troubleshooting, check that all the related connectors are properly inserted. Always connect any disconnected connectors before going on to the next step. Check that the gap between the speed sensor and gear is normal.
20-462
M-3
M-4
M-4
TROUBLESHOOTING
Abnormality in shift indicator
Before carrying out troubleshooting, check that all the related connectors are properly inserted. Always connect any disconnected connectors before going on to the next step. Check that the transmission shifts.
20-463
TROUBLESHOOTING
20-464
M-4
M-5
M-5
TROUBLESHOOTING
High beam does not light up
Before carrying out troubleshooting, check that all the related connectors are properly inserted. Always connect any disconnected connectors before going on to the next step. Before starting troubleshooting, check that the lamp bulb is not blown.
20-465
TROUBLESHOOTING
M-6
Turn signal display does not light up
Before carrying out troubleshooting, check that all the related connectors are properly inserted. Always connect any disconnected connectors before going on to the next step. Before starting troubleshooting, check that the lamp bulb of the turn signal indicator on the monitor is not blown.
20-466
M-6
M-7
M-7
TROUBLESHOOTING
Abnormality in parking display
Before carrying out troubleshooting, check that all the related connectors are properly inserted. Always connect any disconnected connectors before going on to the next step.
20-467
TROUBLESHOOTING
M-8 -MEMORANDA-
20-468
M-9
M-9
TROUBLESHOOTING
Night lighting does not light up
Before carrying out troubleshooting, check that all the related connectors are properly inserted. Always connect any disconnected connectors before going on to the next step. Before starting troubleshooting, check that the lamp bulbs are not blown. Check that fuse 1-6 is normal. If it is blown, check for a short circuit with the chassis ground in the wiring harness between FS2 (female) (5) and L05 (female) (16).
20-469
TROUBLESHOOTING
M-10
Abnormality in front working lamp
Before carrying out troubleshooting, check that all the related connectors are properly inserted. Always connect any disconnected connectors before going on to the next step. Before starting troubleshooting, check that the monitor lighting is lighted up.
20-470
M-10
M-10 M-10
TROUBLESHOOTING Related electrical circuit diagram
20-471
TROUBLESHOOTING
M-11
Abnormality in rear working lamp
Before carrying out troubleshooting, check that all the related connectors are properly inserted. Always connect any disconnected connectors before going on to the next step. Before starting troubleshooting, check that the monitor lighting is lighted up.
20-472
M-11
M-11 M-11
TROUBLESHOOTING Related electrical circuit diagram
20-473
TROUBLESHOOTING
M-12
Abnormality in transmission cut-off
Before carrying out troubleshooting, check that all the related connectors are properly inserted. Always connect any disconnected connectors before going on to the next step.
20-474
M-12
M-12
TROUBLESHOOTING
20-475
TROUBLESHOOTING
M-13
Abnormality in parking brake dragging warning
Before carrying out troubleshooting, check that all the related connectors are properly inserted. Always connect any disconnected connectors before going on to the next step.
20-476
M-13
M-13 M-13
TROUBLESHOOTING Related electrical circuit diagram
20-477
TROUBLESHOOTING
M-14
When parking brake dragging warning is given, buzzer and caution lamp are actuated continuously, or they are not actuated
Before carrying out troubleshooting, check that all the related connectors are properly inserted. Always connect any disconnected connectors before going on to the next step.
20-478
M-14
M-15
M-15
TROUBLESHOOTING
Abnormality in buzzer
Before carrying out troubleshooting, check that all the related connectors are properly inserted. Always connect any disconnected connectors before going on to the next step.
20-479
TROUBLESHOOTING
M-16
Condition of monitor switches is not stored in memory
Before carrying out troubleshooting, check that all the related connectors are properly inserted. Always connect any disconnected connectors before going on to the next step.
20-480
M-16
M-17
M-17
TROUBLESHOOTING
Abnormality in failure display mode
Before carrying out troubleshooting, check that all the related connectors are properly inserted. Always connect any disconnected connectors before going on to the next step.
20-481
TROUBLESHOOTING
M-18
Buzzer is not made to sound by transmission controller
Before carrying out troubleshooting, check that all the related connectors are properly inserted. Always connect any disconnected connectors before going on to the next step.
20-482
M-18
M-19
M-19
TROUBLESHOOTING
Abnormality in emergency steering normal display
Before carrying out troubleshooting, check that all the related connectors are properly inserted. Always connect any disconnected connectors before going on to the next step.
20-483
TROUBLESHOOTING
M-20
Abnormality in emergency steering actuation display
Before carrying out troubleshooting, check that all the related connectors are properly inserted. Always connect any disconnected connectors before going on to the next step.
20-484
M-20
M-20
TROUBLESHOOTING
-MEMORANDA-
20-485
TROUBLESHOOTING
M-21
Abnormality in auto-greasing system
Before carrying out troubleshooting, check that all the related connectors are properly inserted. Always connect any disconnected connectors before going on to the next step.
20-486
M-21
M-21
TROUBLESHOOTING
20-487
TROUBLESHOOTING
M-22
Abnormality in ECSS system
Before carrying out troubleshooting, check that all the related connectors are properly inserted. Always connect any disconnected connectors before going on to the next step. ECSS : Electronic Controlled Suspension System.
20-488
M-22
M-23
M-23
TROUBLESHOOTING
Failure code is not sent to main monitor (abnormality in network)
Before carrying out troubleshooting, check that all the related connectors are properly inserted. Always connect any disconnected connectors before going on to the next step. Set dipswitch 3 at the rear of the main monitor to 'F". MDC: Multiple Display and Condition.
20-489
TROUBLESHOOTING
M-23 -MEMORANDA -
20-490
TABLE OF CONTENTS
TROUBLESHOOTING
TROUBLESHOOTING OF MAINTENANCE MONITOR SYSTEM (K MODE)
Electrical circuit diagram for machine monitor system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . a) No lamps on maintenance monitor light up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . b) Some lamps do not light up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . K-2 When starting switch is turned ON, all lamps on maintenance monitor light up but do not go out (even after 3 seconds) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . K- 3 When engine is started immediately after starting switch is turned ON (within 3 seconds), no lamps on maintenance monitor go out . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . K- 4 When starting switch is turned ON (engine stopped), CHECK items flash . . . . . . . . . . . . . . . . . . . . . . . . . . . . a) Engine oil level display flashes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . b) Engine water level display flashes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . K- 5 When starting switch is turned ON (engine started), CAUTION items flash . . . . . . . . . . . . . . . . . . . . . . . . . . . a) Engine oil pressure display flashes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . b) Battery charge level display flashes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . c) Brake oil pressure display flashes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . d) Air cleaner display flashes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . K- 6 CAUTION items are flashing but caution buzzer does not sound . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . K-7 There is no abnormality in monitor display but caution buzzer sounds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . K-8 CAUTION items are flashing but warning lamp (CHECK lamp, CAUTION lamp) does not flash . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . a) CHECK lamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . b) CAUTION lamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . K- 9 There is no abnormality in maintenance monitor display but warning lamp (CHECK lamp, CAUTION lamp) lights up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . a) CHECK lamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . b) CAUTION lamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . K-10 Night lighting does not light up when lamp switch is turned ON (only lighting of maintenance monitor does not light up) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . K-11 Night lighting lights up even when lamp switch is OFF, night lighting stays lighted up . . . . . . . . . . . . . . . . . . . K-12 Service meter does not work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
20-504 20-506 20-506 20-506 20-507 20-508 20-509 20-509 20-510 20-511 20-511 20-512 20-513 20-514 20-515 20-516 20-517 20-517 20-517 20-518 20-518 20-518 20-519 20-520 20-521
20-501
TROUBLESHOOTING K-13 K-14
20-502
TABLE OF CONTENTS
Service meter is running even when engine is stopped . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Abnormality in gauge items . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . a) Abnormality in fuel gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . b) Abnormality in engine water temperature gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . c) Abnormality in torque converter oil temperature gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
20-521 20-522 20-522 20-523 20-524
MEMORANDA
TROUBLESHOOTING
20-503
TROUBLESHOOTING
ELECTRICAL CIRCUIT DIAGRAM FOR MACHINE MONITOR SYSTEM
ELECTRICAL CIRCUIT DIAGRAM FOR MACHINE MONITOR SYSTEM
20-504
ELECTRICAL CIRCUIT DIAGRAM FOR MACHINE MONITOR SYSTEM
TROUBLESHOOTING
20-505
TROUBLESHOOTING
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
before carrying out troubleshooting, check that all the related connectors are properly inserted. Always connect any disconnected connectors before going on to the next step.
20-506
K-1
K-2
K-2
TROUBLESHOOTING
When starting switch is turned ON, all lamps on maintenance monitor light up but do not go out (even after 3 seconds)
Before carrying out troubleshooting, check that all the related connectors are properly inserted. Always connect any disconnected connectors before going on to the next step.
20-507
TROUBLESHOOTING
K-3
When engine is started immediately after starting switch is turned ON (within 3 seconds), no lamps on maintenance monitor go out
Before carrying out troubleshooting, check that all the related connectors are properly inserted. Always connect any disconnected connectors before going on to the next step.
20-508
K-3
K-4
K-4
TROUBLESHOOTING
When starting switch is turned ON (engine stopped), CHECK items flash
Before carrying out troubleshooting, check that all the related connectors are properly inserted. Always connect any disconnected connectors before going on to the next step. a)
Engine oil level display flashes Before starting troubleshooting, check the engine oil level to make sure it is correct.
20-509
TROUBLESHOOTING
20-510
K-4
K-4 b)
TROUBLESHOOTING
Engine water level display flashes Before starting troubleshooting, check the engine water level again. (Check that the water level is correct).
20-511
TROUBLESHOOTING
K-5
When starting switch is turned ON (engine started), CAUTION items flash
Before carrying out troubleshooting, check that all the related connectors are properly inserted. Always connect any disconnected connectors before going on to the next step.
20-512
K-5
K-5
20-513
TROUBLESHOOTING
TROUBLESHOOTING
20-514
K-5
K-5
20-515
TROUBLESHOOTING
TROUBLESHOOTING
K-6
K-6
CAUTION items are flashing but caution 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 to the next step. check that fuse 1-10 is normal. If it is blown, check for a short circuit with the chassis ground in the wiring harness between fuse 1-10 - FS2 (9) - L42.
20-516
TROUBLESHOOTING
K-7
There is no abnormality in monitor display but caution buzzer sounds
Before carrying out troubleshooting, check that there is no abnormality display on the main monitor. Before carrying out troubleshooting, check that all the related connectors are properly inserted. Always connect any disconnected connectors before going on to the next step.
20-517
K-7
TROUBLESHOOTING
K-8
CAUTION items are flashing but warning lamp (CHECK lamp, CAUTION lamp) does not flash
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 to the next step.
20-518
K-8
TROUBLESHOOTING
K-9
There is no abnormality in maintenance monitor display but warning lamp (CHECK lamp, CAUTION lamp) lights up
Before carrying out troubleshooting, check that there is no abnormality display on the main monitor. Before carrying out troubleshooting, check that all the related connectors are properly inserted. Always connect any disconnected connectors before going on to the next step
20-519
K-9
TROUBLESHOOTING
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 to the next step.
20-520
K-10
TROUBLESHOOTING
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 to the next step.
20-521
K-11
TROUBLESHOOTING
K-12
Service meter does not work
Before carrying out troubleshooting, check that all the related connectors are properly inserted. Always connect any disconnected connectors before going on to the next step.
K-13
Service meter is running even when engine is stopped
Before carrying out troubleshooting, check that all the related connectors are properly inserted. Always connect any disconnected connectors before going on to the next step.
20-522
K-12, K-13
K-14
K-14
TROUBLESHOOTING
Abnormality in gauge items
Before carrying out troubleshooting, check that all the related connectors are properly inserted. Always connect any disconnected connectors before going on to the next step. a)
20-523
Abnormality in fuel gauge Before carrying out troubleshooting, check the fuel level and make sure the level is correct.
TROUBLESHOOTING b)
Abnormality in engine water temperature gauge
20-524
K-14
K-14 c)
Abnormality in torque converter oil temperature gauge
20-525
TROUBLESHOOTING
TABLE OF CONTENTS
TROUBLESHOOTING
TROUBLESHOOTING OF ELECTRICAL SYSTEM (E MODE) Electrical circuit diagram for power supply, engine starting / stop system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Electrical circuit diagram for parking brake system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Electrical circuit diagram for lamp and horn system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Electrical circuit diagram for boom kick-out and bucket positioner system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Electrical circuit diagram for transmission controller system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E- 1 Engine does not start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . a) Starting motor does not turn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . b) Starting motor turns . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E- 2 Engine does not stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E- 3 Engine stops when machine is traveling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E- 4 Not used E- 5 Parking brake does not have effect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . a) Parking brake has no effect when parking brake switch is turned ON (actuated) . . . . . . . . . . . . . . . b) Parking brake has no effect when brake pressure drops (Does not work as emergency brake) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E- 6 Parking brake is applied when machine is traveling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E- 7 Parking brake is released when starting switch is turned ON . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E- 8 Transmission does not change to neutral when parking brake is applied (But parking brake works normally) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E- 9 Kick-down switch does not work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . a) Kick-down switch does not work (shift works correctly during normal gear shift operations) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . b) Kick-down is not canceled . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-10 Boom kick-out cannot be used . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-11 Abnormality in bucket positioner function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-12 Abnormality in lighting up of front working lamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-13 Abnormality in lighting up of rear working lamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-14 Abnormality in transmission cut-off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-15 Abnormality in parking brake dragging warning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-16 Abnormality in buzzer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
20-551
20-552 20-553 20-554 20-555 20-556 20-558 20-558 20-562 20-564 20-564 20-567 20-567 20-567 20-568 20-570 20-570 20-572 20-572 20-573 20-574 20-578 20-581 20-581 20-581 20-581 20-581
TROUBLESHOOTING
ELECTRICAL CIRCUIT DIAGRAMS
ELECTRICAL CIRCUIT DIAGRAM FOR POWER SUPPLY, ENGINE STARTING / STOP SYSTEM
20-552
ELECTRICAL CIRCUIT DIAGRAMS
20-553
TROUBLESHOOTING
TROUBLESHOOTING
ELECTRICAL CIRCUIT DIAGRAMS
ELECTRICAL CIRCUIT DIAGRAM FOR PARKING BRAKE SYSTEM
20-554
ELECTRICAL CIRCUIT DIAGRAMS
TROUBLESHOOTING
ELECTRICAL CIRCUIT DIAGRAM FOR LAMP AND HORN SYSTEM
20-555
TROUBLESHOOTING
ELECTRICAL CIRCUIT DIAGRAMS
ELECTRICAL CIRCUIT DIAGRAM FOR BOOM KICK-OUT AND BUCKET POSITIONER SYSTEM
20-556
ELECTRICAL CIRCUIT DIAGRAMS
TROUBLESHOOTING
ELECTRICAL CIRCUIT DIAGRAM FOR TRANSMISSION CONTROLLER SYSTEM
20-557
TROUBLESHOOTING
20-558
ELECTRICAL CIRCUIT DIAGRAMS
E-1
E-1
TROUBLESHOOTING
Engine does not start
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 CNOA( ). 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. a)
Starting motor does not turn
20-559
TROUBLESHOOTING
20-560
E-1
E-1
TROUBLESHOOTING
20-561
TROUBLESHOOTING
20-562
E-1
E-1 b)
TROUBLESHOOTING
Starting motor turns
20-563
TROUBLESHOOTING
20-564
E-1
E-1
E-2
TROUBLESHOOTING
Engine does not stop
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 CNOA( ). 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.
E-3
Engine stops when machine is traveling
Check if the starting motor turns. If it does not turn, check E-1, a) Starting motor does not turn.
20-565
TROUBLESHOOTING E-1, E-2, E-3
20-566
Related electrical circuit diagram
E-2, E-3
E-1, E-2, E-3
TROUBLESHOOTING
-MEMORANDA-
20-567
TROUBLESHOOTING
E-5
E-4
Parking brake does not have effect
When carrying out troubleshooting of the brake system, stop the machine on flat ground. 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 CNOA(). 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.
20-568
E-6
E-6
TROUBLESHOOTING
Parking brake is applied when machine is traveling
When carrying out troubleshooting of the brake system, stop the machine on flat ground. 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 CNOA( ). 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.
20-569
TROUBLESHOOTING
20-570
E-6
E-6
E-7
TROUBLESHOOTING
Parking brake is released when starting switch is turned ON
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 CNOL( ). 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.
E-8
Transmission does not change to neutral when parking brake is applied (but parking brake works normally)
20-571
TROUBLESHOOTING E-6, E-7, E-8
20-572
Related electrical diagram
E-7, E-8
E-9
TROUBLESHOOTING
E-9 Kick-down switch does not work 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 CNOA( ). 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. a)
Kick-down switch does not work (shift works correctly during normal gear shift operations)
20-573
TROUBLESHOOTING b)
Kick-down is not canceled
20-574
E-9
E-10
E-10
TROUBLESHOOTING
Boom kick-out cannot be used
Before carrying out troubleshooting, check that all the related connectors are properly inserted. Always connect any disconnected connectors before going on to the next step. Check that fuse I (10) is normal. If it is blown, check for a short circuit with the ground in the wiring harness between fuse I (10) - FS2 (10) - L49 (3) - LR2 (1) - FR2 (1) - F06 (female) (1), or FS2 (10) - L32 (1) - L33 (1) - L40 (female) (1)
20-575
TROUBLESHOOTING
20-576
E-10
E-10 E-10
TROUBLESHOOTING Related electrical circuit diagram
20-577
TROUBLESHOOTING
E-10 -MEMORANDA -
20-578
E-11
E-11
TROUBLESHOOTING
Abnormality in bucket positioner function
Before carrying out troubleshooting, check that all the related connectors are properly inserted. Always connect any disconnected connectors before going on to the next step. Check that fuse I (10) is normal. If it is blown, check for a short circuit with the ground in the wiring harness between fuse I (10) - FS2 (10) - L48 (1), (3), or FS2 (10) - LR2 (1) - FR2 (1) - F05 (female) (1)
Figure 284
20-579
TROUBLESHOOTING
20-580
E-11
E-11 E-11
TROUBLESHOOTING Related electrical circuit diagram
20-581
TROUBLESHOOTING
E-12
Abnormality in lighting up of front working lamp Go to Troubleshooting M-10.
E-13
Abnormality in lighting up of rear working lamp Go to Troubleshooting M-11
E-14
Abnormality in transmission cut-off Go to Troubleshooting M-12.
E-15
Abnormality in parking brake dragging warning Go to Troubleshooting M-13, M-14.
E-16
Abnormality in buzzer Go to Troubleshooting M-15, M-18.
20-582
E-11
E-12, E-13, E-14, E-15, E-16
TROUBLESHOOTING -MEMORANDA -
20-583
TABLE OF CONTENTS
TROUBLESHOOTING
TROUBLESHOOTING OF HYDRAULIC AND MECHANICAL SYSTEM (H MODE) Power train H- 1 H- 2
Machine does not start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Travel speed is slow, thrusting power is weak, lacks power on slopes, Does not shift gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H- 3 Excessive shock when starting machine of shifting gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H- 4 Excessive time lag when starting machine of shifting gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H- 5 Torque converter oil temperature is high . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Steering system H- 6 Steering does not turn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H- 7 Steering does not turn (machine with joystick) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H- 8 Turning, response of steering is poor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H- 9 Turning, response of steering is poor (machine with joystick) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H-10 Steering is heavy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H-11 Joystick is heavy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H-12 Steering wheel shakes or jerks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H-13 Steering shakes or there is excessive shock (machine with joystick) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H-14 Turning radius is different between left and right at maximum steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Brake system H-15 Wheel brakes do not work or braking effect is poor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H-16 Wheel brakes are not released or brakes drag . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H-17 Parking brake does not work or braking effect is poor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H-18 Parking brake is not released or brake drags (including emergency release system) . . . . . . . . . . . . . . . . . . . . Work equipment H-19 Neither boom nor bucket move . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H-20 Both boom and bucket are slow or lack power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H-21 Boom does not move . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H-22 Not used H-23 Boom is slow or boom lacks power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H-24 Not used H-25 Boom cannot be set to FLOAT or cannot be released from FLOAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H-26 Boom drops momentarily when control lever is operated from HOLD to RAISE . . . . . . . . . . . . . . . . . . . . . . . . H-27 Not used H-28 Excesseve hydraulic drift of boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H-29 Bucket does not move . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H-30 Bucket is slow or lacks power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H-31 Excesseve hydraulic drift of bucket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H-32 ECSS does not work, and there is pitching and bouncing (machines with ECSS) . . . . . . . . . . . . . . . . . . . . . .
20-602 20-605 20-609 20-611 20-613 20-614 20-615 20-616 20-618 20-620 20-620 20-621 20-622 20-623 20-624 20-626 20-627 20-628 20-629 20-630 20-631 20-633 20-635 20-635 20-637 20-638 20-639 20-640 20-641
20-601
TROUBLESHOOTING
H-1
H- 1 Machine does not start Ask the operator the following questions. Did the problem suddenly start? Yes = Clutch seized, part broken Was there any abnormal noise when this happened? Where did the noise come from? Checks before troubleshooting Does the main monitor function properly? Is any failure code for the electrical system displayed on the main monitor?
20-602
Is the transmission oil level correct? Is the type of oil correct? Is the transmission oil deteriorated? Does the oil smell of burning? Is the transmission filter or strainer clogged? Is there any damage or leakage of oil that can be seen externally? Is the drive shaft broken? Is the wheel brake or parking brake locked?
H-1
TROUBLESHOOTING
20-603
TROUBLESHOOTING
H-1
Method of determining defective clutch and ECMV (check using failure code) For details of the method for checking the failure code display, see 'Method of displaying action code and failure code' and 'Action code and failure code table and re-enaction" When replacing the ECMV and carrying out troubleshooting, remove all mud and dirt from around the ECMV, then wash it and tighten the mounting bolts to the specified tightening torque. Carry out the following troubleshooting with the manual mode for starting the engine.
20-604
H-2
H-2
TROUBLESHOOTING
Travel speed is slow, thrusting power is weak, lacks power on slopes, does not shift gear
Ask the operator the following questions. Did the problem suddenly start? Yes = Related equipment broken Was there any abnormal noise when this happened? Where did the noise come from? Did the problem gradually appear? Yes = Wear of related parts, defective seal Checking for abnormalities Measure digging operations and speed when traveling on level ground and on slopes, and check if there is actually an abnormality or whether it is just the feeling of the operator. Checks before troubleshooting Is the failure code for the electrical system displayed on the monitor? Is the transmission oil level correct? Is the type of oil correct? Is the transmission filter or strainer clogged? Is there any oil leaking from the joints of the piping or valves around the torque converter or transmission? Is there any dragging of the wheel brake or parking brake? Is the tire inflation pressure and tread pattern correct? Is the method of operation correct? Note: If it is judged that there is a drop in the engine performance, go to troubleshooting of the engine system (S mode).
20-605
TROUBLESHOOTING
20-606
H-2
H-2
TROUBLESHOOTING
20-607
TROUBLESHOOTING
H-2
Method of determining defective clutch and ECMV (check using failure code) For details of the method for checking the failure code display, see 'Method of displaying action code and failure code" and 'Action code and failure code table and re-enaction" When replacing the ECMV and carrying out troubleshooting, remove all mud and dirt from around the ECMV, then wash it and tighten the mounting bolts to the specified tightening torque. Carry out the following troubleshooting with the manual mode for starting the engine.
20-608
H-3
H-3
TROUBLESHOOTING
Excessive shock when starting machine or shifting gear
Ask the operator the following questions. Did the problem suddenly start? Yes = Related equipment broken Was there any abnormal noise when this happened? Where did the noise come from? Did the problem gradually appear? Yes = Wear of related parts, defective seal Checking for abnormalities Is the travel speed slow, is the thrusting force weak, does the machine lack power when traveling uphill, is it impossible to shift gear, or are there any other abnormalities occurring at the same time? Yes = Carry out Troubleshooting H-2
Checks before troubleshooting Is the failure code for the electrical system displayed on the monitor? Is the transmission oil level correct? Is the type of oil correct? Is the transmission filter or strainer clogged? Is there any oil leaking from the joints of the piping or valves around the torque converter or transmission?
Defective operation of solenoid or defective operation of pressure control valve spool and flow detector valve spool caused by dirt. Go to “Method of determining defective clutch and ECMV (check using failure code)”.
20-609
TROUBLESHOOTING
H-3
Method of determining defective clutch and ECMV (check using failure code) For details of the method for checking the failure code display, see 'Method of displaying action code and failure code" and "Action code and failure code table and re-enaction" When replacing the ECMV and carrying out troubleshooting, remove all mud and dirt from around the ECMV, then wash it and tighten the mounting bolts to the specified tightening torque. Carry out the following troubleshooting with the manual mode for starting the engine.
20-610
H-4
H-4
TROUBLESHOOTING
Excessive time lag when starting machine or shifting gear
Ask the operator the following questions. Did the problem suddenly start? Yes = Related equipment broken Was there any abnormal noise when this happened? Where did the noise come from? Did the problem gradually appear? Yes = Wear of related parts, defective seal Checking for abnormalities Is the travel speed slow, is the thrusting force weak, does the machine lack power when traveling uphill, is it impossible to shift gear, or are there any other abnormalities occurring at the same time? Yes = Carry out Troubleshooting H-2
Checks before troubleshooting Is the failure code for the electrical system displayed on the monitor? Is the transmission oil level correct? Is the type of oil correct? Is the transmission filter or strainer clogged? Is there any oil leaking from the joints of the piping or valves around the torque converter or transmission?
Defective operation of solenoid or defective operation of pressure control valve spool and flow detector valve spool caused by dirt in the spool. Go to “Method of determining defective clutch and ECMV (check using failure code)”.
20-611
TROUBLESHOOTING
H-4
Method of determining defective clutch and ECMV (check using failure code) For details of the method for checking the failure code display, see "Method of displaying action code and failure code" and 'Action code and failure code table and re-enaction" When replacing the ECMV and carrying out troubleshooting, remove all mud and dirt from around the ECMV, then wash it and tighten the mounting bolts to the specified tightening torque.
20-612
H-5
H-5
TROUBLESHOOTING
Torque converter oil temperature is high
Ask the operator the following questions. Does oil temperature rise during torque converter stall and go down when there is no load? Yes = Improper selection of transmission range Does oil temperature rise only when carrying out scooping work? Yes = Improve method of operation
Checks before troubleshooting Are the radiator water level and fan belt tension correct? Is the transmission oil level correct? Is the type of oil correct? Is the transmission filter or strainer clogged? Note:
Checking for abnormalities Measure the torque converter oil temperature. Is it actually high? No = Defective oil transmission gauge
If it is judged that there is a drop in the engine performance, go to troubleshooting of the engine system (S mode).
20-613
TROUBLESHOOTING
H-6
H-6
Steering wheel does not turn
Ask the operator the following questions. Did the problem suddenly start? Yes = Related equipment broken Was there any abnormal noise when this happened? Where did the noise come from?
Checks before troubleshooting Is the oil level in the hydraulic tank correct? Is the type of oil correct? Is the steering shaft broken? Is the stop valve stopper properly adjusted? Has the safety bar been removed from the frame?
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.
20-614
H-7
H-7
TROUBLESHOOTING
Steering does not turn [machine with joystick]
Ask the operator the following questions. Did the problem suddenly start? Yes = Related equipment broken Was there any abnormal noise when this happened? Where did the noise come from?
Checks before troubleshooting Is the oil level in the hydraulic tank correct? Is the type of oil correct? Is the steering shaft broken? Is the stop valve stopper properly adjusted? Has the safety bar been removed from the frame? Is the operation of the steering and the steering mode switch correct?
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.
20-615
TROUBLESHOOTING
H-8
- MEMORANDA -
20-616
H-8
H-8
TROUBLESHOOTING
Turning, response of steering is poor
Ask the operator the following questions. Did the problem suddenly start? Yes = Related equipment broken Was there any abnormal noise when this happened? Where did the noise come from? Did the problem gradually appear? Yes = Wear of related parts, defective seal
Checks before troubleshooting Is the oil level in the hydraulic tank correct? Is the type of oil correct?
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.
20-617
TROUBLESHOOTING
H-8 -MEMORANDA -
20-618
H-9
H-9
TROUBLESHOOTING
Turning, response of steering is poor [machine with joystick]
Ask the operator the following questions. Did the problem suddenly start? Yes = Related equipment broken Was there any abnormal noise when this happened? Where did the noise come from? Was there previously any symptom, such as difficulty in steering? Yes = Wear of related equipment, defective seal
Checks before troubleshooting Is the oil level in the hydraulic tank correct? Is the type of oil correct?
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.
20-619
TROUBLESHOOTING
H-9
- MEMORANDA -
20-620
H-9
TROUBLESHOOTING
20-621
TROUBLESHOOTING
H-10
H-10, H-11
Steering is heavy
Checking for abnormalities Is the steering difficult to turn? Yes = Go to H-8 or H-9 Measure the operating effort and turning speed, and check the STANDARD VALUE TABLE to see if they are abnormal.
Checks before troubleshooting Is the oil level in the hydraulic tank correct? Is the type of oil correct? Is the tire inflation pressure correct?
Ask the operator the following questions. Did the problem suddenly start? Yes = Related equipment broken Was there previously any symptom, such as heavy steering? Yes = Wear of related equipment, defective seal
H-11
Joystick steering is heavy (machines equipped with joystick)
Causes and remedy Abnormality of joystick (X) (The joystick is an electrically operated lever, so if the operating effort is large, the abnormality is in the joystick).
20-622
H-12
H-12
TROUBLESHOOTING
Steering wheel shakes or jerks
Checking for abnormalities Is the steering difficult to turn? Yes = Go to H-8 Is there any abnormal noise from around the steering equipment?
Checks before troubleshooting Is the steering wheel play correct? Is there any abnormality in the connection between the steering shaft and the Orbit-roll? Is the tire inflation pressure correct?
20-623
TROUBLESHOOTING
H-13
Steering shakes or there is excessive shock [machine with joystick]
Checking for abnormalities Is the steering difficult to turn? Yes = Go to H-9 Is there any abnormal noise from around the steering equipment?
20-624
H-13
Checks before troubleshooting Is any failure code for the electrical system displayed on the main monitor? Is the steering wheel play correct? Is there any abnormality in the connection between the steering shaft and the Orbit-roll? Is the tire inflation pressure correct?
H-14
H-14
TROUBLESHOOTING
Turning radius is different between left and right at maximum steering
Causes and Remedy Defective adjustment of stop valve (
20-625
TROUBLESHOOTING
H-15
H-15
Wheel brakes do not work or braking effect is poor
Checking for abnormalities Measure the actual brake performance, and check if there is actually an abnormality or whether it is just the feeling of the operator. For details, see TESTING AND ADJUSTING, Measuring brake performance. Ask the operator the following questions. Did the problem suddenly start? Yes = Related equipment broken Was there any abnormal noise when this happened? Where did the noise come from? Did the problem gradually appear? Yes = Wear of related parts, defective seal
Checks before troubleshooting Is the oil level in the hydraulic tank correct? Is the type of oil correct? Is the brake pedal play correct? Is there any leakage of oil from the brake tube? Is there any deformation of the tube? Is the tire inflation pressure and tread pattern correct?
The PPC pump is used for the wheel brake actuation pressure in the same way as for the work equipment circuit and steering circuit, so if any abnormality is felt in the wheel brake, check the condition of actuation of the work equipment and steering also. (The circuit set pressure is different).
20-626
H-15
TROUBLESHOOTING
20-627
TROUBLESHOOTING
H-16
Wheel brakes are not released or brakes drag
Ask the operator the following questions. Did the problem suddenly start? Yes = Related equipment broken Was there any abnormal noise when this happened? Where did the noise come from?
20-628
H-16
Checks before troubleshooting Does the brake pedal come back fully? Is the parking brake still applied?
H-17
H-17
TROUBLESHOOTING
Parking brake does not work or braking effect is poor
Ask the operator the following questions. Did the problem suddenly start? Yes = Related equipment broken Was there any abnormal noise when this happened? Where did the noise come from? Did the problem gradually appear? Yes = Wear of related parts, defective seal
Checks before troubleshooting Is parking brake emergency release switch open? (Normally it is open) Is parking brake mechanical release operation being carried out?
20-629
TROUBLESHOOTING
H-18
H-18
Parking brake is not released or brake drags (including emergency release system)
Checking for abnormalities is there any abnormality in the power train system? Yes = Carry out Troubleshooting H-1 - H-4 (Power train hydraulic system)
The power train main relief pressure is used for the parking brake release pressure, so if any abnormality is felt in the parking brake release system, check the condition of actuation of the power train (the emergency release circuit uses the wheel brake circuit presure).
20-630
H-19
H-19
TROUBLESHOOTING
Neither boom nor bucket move
Ask the operator the following questions. Did the problem suddenly start? Yes = Related equipment broken Was there any abnormal noise when this happened? Where did the noise come from?
Checks before troubleshooting Is the oil level in the hydraulic tank correct? Is the type of oil correct?
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.
20-631
TROUBLESHOOTING
H-20
H-20
Both boom and bucket are slow or lack power
Ask the operator the following questions. Did the problem suddenly start? Yes = Related equipment broken Was there any abnormal noise when this happened? Where did the noise come from? Did the problem gradually appear? Yes = Wear of related parts, defective seal
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.
20-632
H-21
H-21
TROUBLESHOOTING
Boom does not move
Ask the operator the following questions. Did the problem suddenly start? Yes = Related equipment broken Was there any abnormal noise when this happened? Where did the noise come from?
20-633
TROUBLESHOOTING
H-22 -MEMORANDA -
20-634
H-23
H-23
TROUBLESHOOTING
Boom is slow or boom lacks power
Ask the operator the following questions. Did the problem suddenly start? Yes = Related equipment broken Was there any abnormal noise when this happened? Where did the noise come from? Did the problem gradually appear? Yes = Wear of related parts, defective seal
20-635
TROUBLESHOOTING
H-24 -MEMORANDA -
20-636
H-25, H-26
H-25
Boom cannot be set to FLOAT or cannot be released from FLOAT
Ask the operator the following questions. Did the problem suddenly start? Yes = Related equipment broken Was there any abnormal noise when this happened? Where did the noise come from? Did the problem gradually appear? Yes = Wear of related parts, defective seal
H-26
TROUBLESHOOTING
Checks before troubleshooting Can other operations of boom (RAISE, HOLD, LOWER) be carried out normally?
Boom drops momentarily when control lever is operated from HOLD to RAISE
Checking for abnormalities With the engine running at low idling, if the boom control lever is gradually moved from HOLD to RAISE, the boom moves down momentarily under its own weight. If the control lever is operated fully to the RAISE position, the condition becomes normal. Causes and Remedy Defective slow return check valve for control valve boom spool (X) or (
20-637
TROUBLESHOOTING
H-27 -MEMORANDA -
20-638
H-28
H-28
TROUBLESHOOTING
Excessive hydraulic drift of boom
Ask the operator the following questions. Did the problem suddenly start? Yes = Related equipment broken Was there any abnormal noise when this happened? Where did the noise come from? Did the problem gradually appear? Yes = Wear of related parts, defective seal
Note:
Before starting troubleshooting, the PPC accumulator must be charged, so run the engine at low idling for 5 - 10 seconds, then stop the engine.
20-639
TROUBLESHOOTING
H-29
Bucket does not move
Ask the operator the following questions. Did the problem suddenly start? Yes = Related equipment broken Was there any abnormal noise when this happened? Where did the noise come from?
20-640
H-29
H-30
H-30
TROUBLESHOOTING
Bucket is slow or lacks power
Ask the operator the following questions. Did the problem suddenly start? Yes = Related equipment broken Was there any abnormal noise when this happened? Where did the noise come from? Did the problem gradually appear? Yes = Wear of related parts, defective seal
20-641
TROUBLESHOOTING
H-31
H-31
Excessive hydraulic drift of bucket
Ask the operator the following questions. Did the problem suddenly start? Yes = Related equipment broken Did the problem gradually appear? Yes = Wear of related parts, defective seal
Note:
20-642
Before starting troubleshooting, the PPC accumulator must be charged, so run the engine at low idling for 5 - 10 seconds, then stop the engine.
H-32
H-32
TROUBLESHOOTING
ECSS does not work, and there is pitching and bouncing [machines with ECSS]
Ask the operator the following questions Did the problem suddenly start? Yes = Related equipment broken Was there any abnormal noise when this happened? Where did the noise come from? Did the problem gradually appear? Yes = Wear of related parts, defective seal
Checks before troubleshooting Is operation of ECSS switch correct?
20-643
TROUBLESHOOTING
H-32 -MEMORANDA -
20-644
TABLE OF CONTENTS
TROUBLESHOOTING
TROUBLESHOOTING OF ECSS (ELECTRONICALLY CONTROLLED SUSPENSION SYSTEM) (D MODE) Judgement table for controller electrical system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Electrical circuit diagram for ECSS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-1 ECSS does not work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . a) Error code [d0] is displayed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . b) Error code [d1] is displayed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . c) Error code [d2] is displayed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . d) Error code [d3] is displayed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . e) No abnormality display is given . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-2 ECSS cannot be canceled . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
20-652 20-654 20-655 20-656 20-656 20-657 20-657 20-659 20-662
20-651
TROUBLESHOOTING
JUDGEMENT TABLE FOR CONTROLLER ELECTRICAL SYSTEM
JUDGEMENT TABLE FOR CONTROLLER ELECTRICAL SYSTEM ECSS CONTROL SYSTEM Failure code
Abnormal system
Nature of abnormality 1) 2)
d0
sol 1 (relief) and sol 14 relay
3) 4) 1) 2)
d1
sol 2 (high pressure)
3) 4) 1) 2)
d2
sol 3 (low pressure)
3) 4) 1) 2)
d3
sol 5
3) 4)
20-652
Defective sol 1 and sol 14 relays. Short circuit with power source, short circuit with ground, defective contact, or disconnection in wiring harness between transmission controller C1 (female) (3) and ECSS relay L90 (1). Defective contact or disconnection in wiring harness between sol 1 and sol 14 relay L90 (female) (2) and chassis ground. Defective transmission controller. Defective sol 2. Short circuit with power source, short circuit with ground, defective contact, or disconnection in wiring harness between transmission controller C1 (female) (10) - ECSS (2) - AF2 (1). Defective contact or disconnection in wiring harness between sol 2 connector AF2 (female) (2) and chassis ground. Defective transmission controller. Defective sol 3. Short circuit with power source, short circuit with ground, defective contact, or disconnection in wiring harness between transmission controller C1 (female) (5) - ECSS (3) - AF3 (1). Defective contact or disconnection in wiring harness between sol 3 connector AF3(female) (2) and chassis ground. Defective transmission controller. Defective sol 5. Short circuit with power source, short circuit with ground, defective contact, or disconnection in wiring harness between transmission controller C1 (female) (9) - ECSS (7) - AF5 (1). Defective contact or disconnection in wiring harness between sol 5 connector AF5 (female) (2) and chassis ground. Defective transmission controller.
JUDGEMENT TABLE FOR CONTROLLER ELECTRICAL SYSTEM Condition when normal (Voltage, current, resistance)
Action by controller when abnormality is detected
TROUBLESHOOTING
Problem that appears on machine when there is abnormality
1) Resistance of relay coil: 200 - 400 2) Resistance of wiring harness between transmission controller C1 (female) (3) and ECSS relay L90 (female) (1): Max. 1 3) Voltage between transmission controller C1 (3) and chassis ground: Less than 1 V (Command OFF); 20 V or above (Command ON). 4) Resistance of wiring harness between ECSS relay L90 (female) (2) and chassis ground: Max. 1 1) Resistance of solenoid: 30 - 80 2) Voltage between transmission controller C1 (10) and chassis ground at neutral: Less than 1 V. 3) Resistance between transmission controller C1 (female) (10) and chassis ground: Min. 1 M 4) Resistance of wiring harness between transmission controller C1 (female) (10) - ECSS (2) - AF2 (1): Less than 1 5) Resistance between sol 2 connector AF2 (2) - chassis ground: Less than 1 1) Resistance of solenoid: 30 - 80 2) Voltage between transmission controller C1 (5) and chassis ground at neutral: Less than 1 V. 3) Resistance between transmission controller C1 (female) (5) and chassis ground: Min. 1 M 4) Resistance of wiring harness between transmission controller C1 (female) (5) - ECSS (3) - AF3 (1): Less than 1 5) Resistance between sol 3 connector AF3 (2) - chassis ground: Less than 1 1) Resistance of solenoid: 30 - 80 2) Voltage between transmission controller C1 (9) and chassis ground at neutral: Less than 1 V. 3) Resistance between transmission controller C1 (female) (9) and chassis ground: Min. 1 M 4) Resistance of wiring harness between transmission controller C1 (female) (9) - ECSS (7) - AF5 (1): Less than 1 5) Resistance between sol 5 connector AF5 (2) - chassis ground: Less than 1
Troubleshooting code
D-1 a)
D-1 b)
ECSS function: OFF
Swaying (pitching, bouncing) of machine when traveling at high speed (2nd - 4th) D-1 c)
D-1 d)
20-653
TROUBLESHOOTING
ELECTRICAL CIRCUIT DIAGRAM FOR ECSS
ELECTRICAL CIRCUIT DIAGRAM FOR ECSS
20-654
D-1
D-1
TROUBLESHOOTING
ECSS does not work
Before carrying out troubleshooting, check that all the related connectors are properly inserted. Always connect any disconnected connectors before going on to the next step. Carry out troubleshooting with the starting switch ON. Check that the ECSS switch on the main monitor is ON.
20-655
TROUBLESHOOTING
20-656
D-1
D-1
TROUBLESHOOTING
20-657
TROUBLESHOOTING D-1 a), b), c), d) Related electrical circuit diagram
20-658
D-1
D-1 e)
TROUBLESHOOTING
No abnormality display is given (1) Does not work at all Before starting troubleshooting, check that the main monitor dipswitch is set to ON for ECSS function.
20-659
TROUBLESHOOTING
20-660
D-1
D-1
TROUBLESHOOTING
20-661
TROUBLESHOOTING
D-2
ECSS cannot be canceled
Before carrying out troubleshooting, check that all the related connectors are properly inserted. Always connect any disconnected connectors before going on to the next step.
20-662
D-2
TABLE OF CONTENTS
TROUBLESHOOTING
TROUBLESHOOTING OF JOYSTICK STEERING CONTROLLER SYSTEM (J MODE) Judgement table for joystick controller system related parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Action taken by controller when abnormality occur . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Electrical circuit diagram for joystick system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . J- 1 Failure code [56] (short circuit, disconnection in caution relay output) is displayed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . J- 2 Failure code [57] (short circuit in steering right solenoid (detected when output) is displayed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . J- 3 Failure code [58] (short circuit in steering left solenoid (detected when output) is displayed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . J- 4 Failure code [59] (short circuit in steering right solenoid (HOT end) is displayed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . J- 5 Failure code [60] (short circuit in steering left solenoid (HOT end) is displayed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . J- 6 Failure code [61] (short circuit, disconnection in steering solenoid cut relay output) is displayed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . J- 7 Failure code [62] (short circuit, disconnection in joystick steering neutral signal) is displayed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . J- 8 Failure code [63] (short circuit, disconnection in joystick steering lever potentiometer system) is displayed (Not used) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . J- 9 Abnormality in power source, voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . J-10 Abnormality in joystick steering ON-OFF signal system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . J-11 Disconnection in steering right solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . J-12 Disconnection in steering left solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
20-702 20-704 20-708 20-709 20-710 20-711 20-712 20-713 20-714 20-715 20-716 20-717 20-718 20-719 20-720
20-701
TROUBLESHOOTING
JUDGEMENT TABLE FOR JOYSTICK CONTROLLER SYSTEM
JUDGEMENT TABLE FOR JOYSTICK CONTROLLER SYSTEM RELATED PARTS
20-702
JUDGEMENT TABLE FOR JOYSTICK CONTROLLER SYSTEM
TROUBLESHOOTING
-MEMORANDA-
20-703
TROUBLESHOOTING
ACTION TAKEN BY CONTROLLER WHEN ABNORMALITY OCCUR
ACTION TAKEN BY CONTROLLER WHEN ABNORMALITY OCCUR JOYSTICK CONTROLLER SYSTEM Failure code
Abnormal system
Nature of abnormality 1) 2)
56
Joystick caution relay system 3) 4)
57
Steering (R) (right) sol. System
Defective caution relay Short circuit with ground, defective contact, or disconnection in wiring harness between work equipment controller L28 (female) (13) and JS8 (1) Defective contact or disconnection in wiring harness between caution relay J8 (female) (2) and chassis ground Defective work equipment controller
1) 2) 3)
Defective R sol Defective steering solenoid cut relay Short circuit in wiring harness between work equipment controller L26 (female) (6) and (16) Short circuit with ground, defective contact, or disconnection in the following wiring harness: 4) Wiring harness between work equipment controller L26 (female) (6) and R (2) 5) Wiring harness between work equipment controller L26 (female) (16) and JS9 (3) 6) Wiring harness between steering solenoid cut relay JS9 (5) and R (1) 7) Defective work equipment controller 1) 2) 3)
58
Steering (L) (left) sol. System
59
Short circuit with power source in wiring harness between steering (R) (right) sol. System
Defective L sol Defective steering solenoid cut relay Short circuit in wiring harness between work equipment controller L26 (female) (7) and (16) Short circuit with ground, defective contact, or disconnection in the following wiring harness: 4) Wiring harness between work equipment controller L26 (female) (7) and L (2) 5) Wiring harness between work equipment controller L26 (female) (16) and JS9 (3) 6) Wiring harness between steering solenoid cut relay JS9 (5) and L (1) 7) Defective work equipment controller 1) 2) 3)
60
Short circuit with power source in wiring harness between steering (L) (left) sol. System
1) 2) 3)
20-704
Defective R sol Short circuit with power source in wiring harness between work equipment controller L26 (female) (6) and R (2) Defective work equipment controller Defective L sol Short circuit with power source in wiring harness between work equipment controller L26 (female) (7) and L (2) Defective work equipment controller
ACTION TAKEN BY CONTROLLER WHEN ABNORMALITY OCCUR Condition when normal (voltage, current, resistance)
TROUBLESHOOTING
Action by controller when abnormality is detected
Problem that appears on machine when there is abnormality
1) Joystick caution relay: ON (voltage between L28 (15) and chassis ground: 20 - 30 V) 2) Resistance of relay coil between work equipment controller L28 (female) (13) and J chassis ground: 200 - 400 3) Resistance of wiring harness between work equipment controller L28 (female) (13) and caution relay JS8 (female) (1): Less than 1 4) Resistance of wiring harness between caution relay JS8 (female) (2) and chassis ground: Less than 1
Caution output: OFF
Joystick caution actuated
1) Steering solenoid cut relay: ON (voltage between L26 (8) and chassis groung: 20 - 30 V) 2) Resistance of steering R solenoid: 10 - 20 3) Resistance between work equipment controller L26 (female) (6), (16) and chassis ground: Min. 1M Resistance of the following wiring harness: Less than 1 4) Wiring harness between work equipment controller L26 (female) (6) - R (female) (2) 5) Wiring harness between work equipment controller L26 (female) (16) - JS9 (female) (3) 6) Wiring harness between steering solenoid cut relat JS9 (female) (5) and L (female (1)
Steering R, L solenoid output: OFF and steering solenoid cut relay output: OFF and caution relay: OFF
1) Steering solenoid cut relay: ON (voltage between L26 (8) and chassis groung: 20 - 30 V) 2) Resistance of steering L solenoid: 10 - 20 3) Resistance between work equipment controller L26 (female) (7), (16) and chassis ground: Min. 1M Resistance of the following wiring harness: Less than 1 4) Wiring harness between work equipment controller L26 (female) (7) - L (female) (2) 5) Wiring harness between work equipment controller L26 (female) (16) - JS9 (female) (3) 6) Wiring harness between steering solenoid cut relat JS9 (female) (5) and L (female (1)
Steering R, L solenoid output: OFF and steering solenoid cut relay output: OFF and caution relay: OFF
Joystick lever at neutral Voltage between work equipment controller L26 (female) (6) and chassis ground: Less than 1 V
Steering R, L solenoid output: OFF and steering solenoid cut relay output: OFF and caution relay: OFF
Impossible to use joystick and joystick caution actuated
Joystick lever at neutral Voltage between work equipment controller L26 (female) (6) and chassis ground: Less than 1 V
Steering R, L solenoid output: OFF and steering solenoid cut relay output: OFF and caution relay: OFF
Impossible to use joystick and joystick caution actuated
Troubleshooting code
J-1
Impossible to use joystick and joystick caution actuated J-2
Impossible to use joystick and joystick caution actuated J-3
J-4
J-5
20-705
TROUBLESHOOTING Failure code
ACTION TAKEN BY CONTROLLER WHEN ABNORMALITY OCCUR
Abnormal system
Nature of abnormality
Steering sol. cut relay system
1) Defective steering sol relay 2) Short circuit with ground, defective contact, or disconnection in wiring harness between work equipment controller L26 (female) (8) and JS9 (1) 3) Defective contact or disconnection in wiring harness between NEUTRAL SW (1) and chassis ground 4) Defective work equipment controller
62
Joystick neutral SW system
1) Defective joystick neutral SW 2) Short circuit with ground, defective contact, or disconnection in wiring harness between work equipment controller L27 (female) (17) - D01 (2), (1) - NEUTRAL SW (3) 3) Defective contact or disconnection in wiring harness between NEUTRAL SW (1) and chassis ground 4) Defective work equipment controller
63
Joystick potentiometer system
61
20-706
1) Defective boom angle potentiometer 2) Short circuit with power source, short circuit with ground, defective contact, or disconnection in wiring harness between work equipment controller L27 (female) (20) and JS7 (1) 3) Short circuit with power source, short circuit with ground, defective contact, or disconnection in wiring harness between work equipment controller L27 (female) (9) and JS7 (2) 4) Short circuit with power source, short circuit with ground, defective contact, or disconnection in wiring harness between work equipment controller L27 (female) (10) and JS7 (3) 5) Defective work equipment controller
ACTION TAKEN BY CONTROLLER WHEN ABNORMALITY OCCUR Condition when normal (voltage, current, resistance)
TROUBLESHOOTING
Action by controller when abnormality is detected
Problem that appears on machine when there is abnormality
Resistance between work equipment controller L27 (female) (17) and chassis ground: Min. 1 M Less than 1
Steering R, L solenoid output: OFF and steering solenoid cut relay output: OFF and caution relay: OFF
Impossible to use joystick and joystick caution actuated
Voltage between work equipment controller L27 (female) (20) and L27 (9): 0.5 - 4.5 V (voltage when joystick is at neutral: Approx. 2.5 V)
Steering R, L solenoid output: OFF and steering solenoid cut relay output: OFF and caution relay: OFF
Impossible to use joystick and joystick caution actuated
1) Steering solenoid cut relay: ON (voltage between L26 (8) and chassis ground: 20 - 30 V) 2) Resistance of relay coil between work equipment controller L28 (female) (8) and chassis ground: 200 - 400 3) Resistance of wiring harness between work equipment controller L28 (female (8) and JS9 (female) (1) 4) Resistance of wiring harness between steering solenoid cut relay JS9 (female) (2) and chassis ground: Less than 1
Steering R, L solenoid output: OFF and steering solenoid cut relay output: OFF and caution relay: OFF
Impossible to use joystick and joystick caution actuated
Troubleshooting code
J-6
J-7
J-8
20-707
TROUBLESHOOTING
ELECTRICAL CIRCUIT DIAGRAM FOR JOYSTICK SYSTEM
ELECTRICAL CIRCUIT DIAGRAM FOR JOYSTICK SYSTEM
20-708
J-1
TROUBLESHOOTING
J-1
Failure code [56] (Short circuit, disconnection in caution relay output) is displayed
Before carrying out troubleshooting, check that all the related connectors are properly inserted. When the joystick steering lever is not being used, leave it at the neutral position and turn the joystick steering selector switch ON. Always connect any disconnected connectors before going on to the next step. Always turn the starting switch OFF before disconnecting any connector
20-709
TROUBLESHOOTING
J-2
J-2
Failure code [57] (Short circuit in steering right solenoid (detected when output)) is displayed
This troubleshooting is carried out when there is still an abnormality, so when disconnecting the connector and inserting the T-adapter, or when removing the T-adapter and returning the connector to its original position, if the failure code is no longer displayed on the monitor display, the problem has been removed. Before carrying out troubleshooting, check that all the related connectors are properly inserted. Always connect any disconnected connectors before going on to the next step. When the joystick steering lever is not being used, leave it at the neutral position and turn the joystick steering selector switch ON.
20-710
J-3
TROUBLESHOOTING
J-3
Failure code [58] (Short circuit in steering left solenoid (detected when output)) is displayed
This troubleshooting is carried out when there is still an abnormality, so when disconnecting the connector and inserting the T-adapter, or when removing the T-adapter and returning the connector to its original position, if the failure code is no longer displayed on the monitor display, the problem has been removed. Before carrying out troubleshooting, check that all the related connectors are properly inserted. Always connect any disconnected connectors before going on to the next step. When the joystick steering lever is not being used, leave it at the neutral position and turn the joystick steering selector switch ON.
20-711
TROUBLESHOOTING
J-4
J-4
Failure code [59] (Short circuit in steering right solenoid (HOT end) is displayed
Before carrying out troubleshooting, check that all the related connectors are properly inserted. When the joystick steering lever is not being used, leave it at the neutral position and turn the joystick steering selector switch ON. Always connect any disconnected connectors before going on to the next step.
20-712
J-5
TROUBLESHOOTING
J-5
Failure code [60] (Short circuit in steering left solenoid (HOT end) is displayed
Before carrying out troubleshooting, check that all the related connectors are properly inserted. When the joystick steering lever is not being used, leave it at the neutral position and turn the joystick steering selector switch ON. Always connect any disconnected connectors before going on to the next step. Always turn the starting switch OFF before disconnecting any connector to connect the T-adapter (or socket adapter).
20-713
TROUBLESHOOTING
J-6
J-6
Failure code [61] (Short circuit, disconnection in steering solenoid cut relay output) is displayed
This troubleshooting is carried out when there is still an abnormality, so when disconnecting the connector and inserting the T-adapter, or when removing the T-adapter and returning the connector to its original position, if the failure code is no longer displayed on the monitor display, the problem has been removed. Before carrying out troubleshooting, check that all the related connectors are properly inserted. Always connect any disconnected connectors before going on to the next step. When the joystick steering lever is not being used, leave it at the neutral position and turn the joystick steering selector switch ON.
20-714
J-7
TROUBLESHOOTING
J-7
Failure code [62] (Short circuit, disconnection in joystick steering neutral signal) is displayed
Before carrying out troubleshooting, check that all the related connectors are properly inserted. When the joystick steering lever is not being used, leave it at the neutral position and turn the joystick steering selector switch ON. Always connect any disconnected connectors before going on to the next step.
20-715
TROUBLESHOOTING
MEMORANDA
-MEMORANDA-
20-716
J-9
TROUBLESHOOTING
J-9
Abnormality in power source, voltage
Before carrying out troubleshooting, check that all the related connectors are properly inserted. Check that fuse I (11) is normal. When the joystick steering lever is not being used, leave it at the neutral position and turn the joystick steering selector switch ON. Always connect any disconnected connectors before going on to the next step.
20-717
TROUBLESHOOTING
J-10
J-10
Abnormality in joystick steering ON-OFF signal system
Before carrying out troubleshooting, check that all the related connectors are properly inserted. Check that fuse I (11) is normal. When the joystick steering lever is not being used, leave it at the neutral position and turn the joystick steering selector switch ON. Always connect any disconnected connectors before going on to the next step.
20-718
J-11
J-11
TROUBLESHOOTING
Disconnection in steering right solenoid
Before carrying out troubleshooting, check that all the related connectors are properly inserted. Always connect any disconnected connectors before going on to the next step. When the joystick steering lever is not being used, leave it at the neutral position and turn the joystick steering selector switch ON.
20-719
TROUBLESHOOTING
J-12
J-12
Disconnection in steering left solenoid
Before carrying out troubleshooting, check that all the related connectors are properly inserted. Always connect any disconnected connectors before going on to the next step. When the joystick steering lever is not being used, leave it at the neutral position and turn the joystick steering selector switch ON.
20-720
TABLE OF CONTENTS
TROUBLESHOOTING
TROUBLESHOOTING OF MDC (MULTIPLE DISPLAY AND CONDITION) MONITOR SYSTEM (C MODE) Electrical circuit diagram for MDC (Multiple Display and Condition) monitor system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Electrical circuit diagram for machine monitor system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C- 1 When engine is running, engine oil level display shows “Abnormal” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C- 2 When engine is running, battery electrolyte level display shows “Abnormal” . . . . . . . . . . . . . . . . . . . . . . . . . . . C- 3 Abnormality in engine coolant level display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . a) Display shows “Abnormal” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . b) Display shows “Disconnection” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . c) Display shows “Short circuit” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C- 4 Abnormality in brake oil pressure display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . a) When engine is running, display shows “Abnormal” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . b) Display shows “Disconnection” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . c) Display shows “Short circuit” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C- 5 Abnormality in engine oil pressure display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . a) When engine is running, display shows “Abnormal” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . b) When engine is stopped or running, display shows “Disconnection” . . . . . . . . . . . . . . . . . . . . . . . . . c) Only when engine is stopped, display shows “Disconnection” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . d) Display shows “Short circuit” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C- 6 When starting switch is at “ON”(engine started), battery charge display shows “Abnormal” . . . . . . . . . . . . . . C- 7 When starting switch is at “ON”(engine started), air cleaner display shows “Abnormal” . . . . . . . . . . . . . . . . . C- 8 CAUTION item display shows “Abnormal”, but alarm buzzer does not sound . . . . . . . . . . . . . . . . . . . . . . . . . C- 9 Monitor display does not show “Abnormality”, but alarm buzzer sounds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-10 CAUTION item display shows “Abnormal”, but warning lamp (CHECK lamp, CAUTION lamp) does not flash . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . a) CHECK lamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . b) CAUTION lamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-11 Monitor display does not show any abnormality, but warning lamp (CHECK lamp, CAUTION lamp) lights up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . a) CHECK lamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . b) CAUTION lamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-12 Service meter does not work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-13 Service meter is running when engine is stopped . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-14 Abnormality in fuel gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . a) Display shows “Disconnection”or low fuel level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . b) Display always shows FULL and does not go down . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-15 Abnormality in engine coolant temperature gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . a) Display shows “Short circuit” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . b) Display always shows lowest level and does not go up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
20-804 20-806 20-808 20-809 20-810 20-810 20-810 20-810 20-812 20-812 20-813 20-813 20-814 20-814 20-814 20-814 20-815 20-816 20-817 20-818 20-819 20-820 20-820 20-820 20-821 20-821 20-821 20-822 20-822 20-823 20-823 20-823 20-824 20-824 20-824
20-801
TROUBLESHOOTING C-16
C-17
C-18 C-19
C-20 C-21
C-22
C-23 C-24
C-25
C-26
C-27 C-28 C-29
20-802
TABLE OF CONTENTS
Abnormality in torque converter oil temperature gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . a) Display shows “Short circuit” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . b) Display always shows lowest level and does not go up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . When starting switch is turned ON, monitor is not actuated (KOMATSU is not displayed . . . . . . . . . . . . . . . . a) Main monitor CHECK lamps do not light up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . b) Main monitor CHECK lamps light up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Does not switch to working memory (engine running) mode, or switches to check before starting mode when engine is running . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Abnormality in MDC monitor display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . a) Display color is abnormal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . b) Display flickers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Even when switch is operated, nothing functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Does not switch to TV/video mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . a) Stays at PARKING BRAKE APPLIED display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . b) Display does not light up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Abnormality in memory data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . a) Load meter data is not saved to memory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . b) Maintenance time is not saved to memory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Engine speed stays at 0 rpm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pressure sensor display shows “Disconnection” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . a) Sensor power source display also shows “Abnormal”. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . b) Only pressure sensor display shows “Disconnection” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Load meter cannot weigh load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . a) Cannot carry out calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . b) Can carry out calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Abnormality in lever switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . a) Sub-total switch does not work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . b) Cancel switch does not work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Printer does not print out . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Abnormality in antenna system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Abnormality in speaker system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . a) Abnormality in right speaker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . b) Abnormality in left speaker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
20-825 20-825 20-825 20-826 20-826 20-827 20-828 20-829 20-829 20-829 20-830 20-832 20-832 20-834 20-836 20-836 20-836 20-837 20-838 20-838 20-838 20-839 20-839 20-840 20-841 20-841 20-841 20-842 20-843 20-844 20-844 20-844
MEMORANDA
TROUBLESHOOTING
20-803
TROUBLESHOOTING
ELECTRICAL CIRCUIT DIAGRAM FOR MDC MONITOR SYSTEM
ELECTRICAL CIRCUIT DIAGRAM FOR MDC (MULTIPLE DISPLAY AND CONDITION) MONITOR SYSTEM
20-804
ELECTRICAL CIRCUIT DIAGRAM FOR MDC MONITOR SYSTEM
TROUBLESHOOTING
20-805
TROUBLESHOOTING ELECTRICAL CIRCUIT DIAGRAM FOR MACHINE MONITOR SYSTEM
ELECTRICAL CIRCUIT DIAGRAM FOR MACHINE MONITOR SYSTEM
20-806
ELECTRICAL CIRCUIT DIAGRAM FOR MACHINE MONITOR SYSTEM TROUBLESHOOTING
20-807
TROUBLESHOOTING
C-1
When engine is running, engine oil level display shows "Abnormal'
Before starting troubleshooting, check the engine oil level again. (The engine oil level must be correct.) Before carrying out troubleshooting, check that all the related connectors are properly inserted. Always connect any disconnected connectors before going on to the next step.
20-808
C-1
C-2
C-2
TROUBLESHOOTING
When engine is running, battery electrolyte level display shows "Abnormal"
Check that the cell where the battery electrolyte level sensor is installed is normal.
20-809
TROUBLESHOOTING
C-3
Abnormality in engine coolant level display
Before starting troubleshooting, check the engine coolant level again. (The engine coolant level must be correct.) Before carrying out troubleshooting, check that all the related connectors are properly inserted. Always connect any disconnected connectors before going on to the next step.
20-810
C-3
C-3
TROUBLESHOOTING
20-811
TROUBLESHOOTING
C-4
Abnormality in brake oil pressure display
Before carrying out troubleshooting, check that all the related connectors are properly inserted. Always connect any disconnected connectors before going on to the next step.
20-812
C-4
C-4
TROUBLESHOOTING
20-813
TROUBLESHOOTING
C-5
Abnormality in engine oil pressure display
Before carrying out troubleshooting, check that all the related connectors are properly inserted. Always connect any disconnected connectors before going on to the next step.
20-814
C-5
C-5
TROUBLESHOOTING
20-815
TROUBLESHOOTING
C-6
When starting switch is at ON (engine started), battery charge display shows "Abnormal"
Before carrying out troubleshooting, check that all the related connectors are properly inserted. Always connect any disconnected connectors before going on to the next step.
20-816
C-6
C-7
TROUBLESHOOTING
C-7 When starting switch is at ON (engine started), air cleaner display shows "Abnormal" Before carrying out troubleshooting, check that all the related connectors are properly inserted. Always connect any disconnected connectors before going on to the next step. Check that the air cleaner is not clogged.
20-817
TROUBLESHOOTING
C-8
C-8
CAUTION item display shows “Abnormal”, but alarm buzzer does not sound
The buzzer does not sound for CHARGE or AIR CLEANER. Before carrying out troubleshooting, check that all the related connectors are properly inserted. Always connect any disconnected connectors before going on to the next step. Check that fuse 1-10 is normal. If it is blown, check for a short circuit with the chassis ground in the wiring harness between fuse 1-10 - FS2 (9) - L42 (1).
20-818
C-9
C-9
TROUBLESHOOTING
Monitor display does not show “Abnormal”, but alarm buzzer sounds
Before carrying out troubleshooting, check that there is no abnormality display on the main monitor. Before carrying out troubleshooting, check that all the related connectors are properly inserted. Always connect any disconnected connectors before going on to the next step.
20-819
TROUBLESHOOTING
C-10
CAUTION item display shows “Abnormal”, but warning lamp (CHECK lamp, CAUTION lamp) does not flash
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 to the next step.
20-820
C-10
C-11
C-11
TROUBLESHOOTING
Monitor display does not show any abnormality, but warning lamp (CHECK lamp, CAUTION lamp) lights up
Before carrying out troubleshooting, check that there is no abnormality display on the main monitor. Before carrying out troubleshooting, check that all the related connectors are properly inserted. Always connect any disconnected connectors before going on to the next step.
20-821
TROUBLESHOOTING
C-12
Service meter does not work
Before carrying out troubleshooting, check that all the related connectors are properly inserted. Always connect any disconnected connectors before going on to the next step.
C-13
Service meter is running when engine is stopped
Before carrying out troubleshooting, check that all the related connectors are properly inserted. Always connect any disconnected connectors before going on to the next step.
20-822
C-12, C-13
C-14
C-14
TROUBLESHOOTING
Abnormality in fuel gauge
Before starting troubleshooting, check the fuel level again. Before carrying out troubleshooting, check that all the related connectors are properly inserted. Always connect any disconnected connectors before going on to the next step.
20-823
TROUBLESHOOTING
C-15
Abnormality in engine water temperature gauge
Before carrying out troubleshooting, check that all the related connectors are properly inserted. Always connect any disconnected connectors before going on to the next step.
20-824
C-15
C-16
C-16
TROUBLESHOOTING
Abnormality in torque converter oil temperature gauge
Before carrying out troubleshooting, check that all the related connectors are properly inserted. Always connect any disconnected connectors before going on to the next step.
20-825
TROUBLESHOOTING
C-17
When starting switch is turned to ON, monitor is not actuated (KOMATSU is not displayed)
Before carrying out troubleshooting, check that all the related connectors are properly inserted. Always connect any disconnected connectors before going on to the next step.
20-826
C-17
C-17 b)
TROUBLESHOOTING
Main monitor CHECK lamps light up Check that the WAITING display on the remote control receiver portion of the monitor is flashing. It will flash if the chamber temperature is high, so in this case, lower the chamber temperature.
20-827
TROUBLESHOOTING
C-18
20-828
Does not switch to working memory (engine running) mode, or switches to check before starting mode when engine is running
C-18
C-19
C-19
TROUBLESHOOTING
Abnormality in MDC monitor display
20-829
TROUBLESHOOTING
C-20
Even when switch is operated, nothing functions
Before starting troubleshooting, check that there is no mistake in the operation of the switch. Before carrying out troubleshooting, check that all the related connectors are properly inserted. Always connect any disconnected connectors before going on to the next step.
+
20-830
C-20
C-20
TROUBLESHOOTING - MEMORANDA -
20-831
TROUBLESHOOTING
C-21
Does not switch to TV/video mode
Before carrying out troubleshooting, check that all the related connectors are properly inserted. Always connect any disconnected connectors before going on to the next step. After turning the starting switch ON, keep the TV/video mode switch pressed for at least 2 seconds. If the parking brake switch (indicator switch) is not ON, the system does not switch to this mode.
20-832
C-21
C-21
TROUBLESHOOTING
20-833
TROUBLESHOOTING
20-834
C-21
C-21
TROUBLESHOOTING
20-835
TROUBLESHOOTING
C-22
Abnormality in memory data
Before carrying out troubleshooting, check that all the related connectors are properly inserted. Always connect any disconnected connectors before going on to the next step.
20-836
C-22
C-23
C-23
TROUBLESHOOTING
Engine speed stays at 0 rpm
Before carrying out troubleshooting, check that there is no abnormality display on the main monitor. Before carrying out troubleshooting, check that all the related connectors are properly inserted. Always connect any disconnected connectors before going on to the next step.
20-837
TROUBLESHOOTING
C-24
Pressure sensor display shows "Disconnection"
Before carrying out troubleshooting, check that all the related connectors are properly inserted. Always connect any disconnected connectors before going on to the next step.
20-838
C-24
C-25
C-25
TROUBLESHOOTING
Load meter cannot weigh load
Before carrying out troubleshooting, check that all the related connectors are properly inserted. Always connect any disconnected connectors before going on to the next step.
20-839
TROUBLESHOOTING
20-840
C-25
C-26
C-26
TROUBLESHOOTING
Abnormality in lever switch
Before carrying out troubleshooting, check that all the related connectors are properly inserted. Always connect any disconnected connectors before going on to the next step.
20-841
TROUBLESHOOTING
C-27
Printer does not print out
Check that the printer power is switched on. Check that the paper is set properly and that the platen lever is lowered. Before carrying out troubleshooting, check that all the related connectors are properly inserted. Always connect any disconnected connectors before going on to the next step.
20-842
C-27
TROUBLESHOOTING AIR CONDITIONING
C-28
TROUBLESHOOTING
Abnormality in antenna system
Before carrying out troubleshooting, check that all the related connectors are properly inserted. Always connect any disconnected connectors before going on to the next step.
20-843
TROUBLESHOOTING
C-29
Abnormality in speaker system
Before carrying out troubleshooting, check that all the related connectors are properly inserted. Always connect any disconnected connectors before going on to the next step.
20-844
C-29
TROUBLESHOOTING AIR CONDITIONING
TROUBLESHOOTING
TROUBLESHOOTING AIR CONDITIONING Air conditioner / heater (Denso) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Visual and audible inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Troubleshooting with manifold gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Troubleshooting the electrical circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cooler circuit troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Wiring diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
20-902 20-902 20-903 20-907 20-911 20-919
20-901
TROUBLESHOOTING
AIR CONDITIONER / HEATER (DENSO) TROUBLESHOOTING Visual and Audible Inspection Is the drive belt loose? Are condenser fins blocked or clogged -- covered with dirt or dust (condenser and air conditioner efficiency both will suffer)? Is the air filter clogged (clogged air filter will reduce air flow and lower the cooling capacity)? Are oil stains present in the refrigeration cycle connections and joints (stains are evidence of compressor oil, usually accompanied by refrigerant)? Does the system contain the correct refrigerant quantity as seen in the sight glass (only a small quantity of bubbles appear)? Is the system louder than usual (abnormal noise)?
Component
Check these items
Compressor
Shaft, cylinder head
Magnetic clutch
Worn or damaged bearing Contact between stator and rotor Loose mounting screw on stator
Blower motor
Upside down blower motor Loose blower mounting
V-belt
Improper tension
Idle pulley
Worn mounting Worn or damaged bearing
Piping parts
Improper fastening or mounting of bracket or clamp Incorrect clearance.
20-902
AIR CONDITIONER / HEATER
AIR CONDITIONER / HEATER
TROUBLESHOOTING
Troubleshooting with manifold gauge (refrigeration cycle) Trouble often can be detected and diagnosed for repair with the help of a manifold gauge. The manifold gauge unit indicates the refrigeration system pressure on both sides (high and low pressure sides) simultaneously on the two dials. NOTE:
Be sure air has been purged from the charging hoses of the manifold gauge by using the refrigerant pressure in the system.
Normal Conditions After engine warm-up, check the following conditions: Engine speed 1500 rpm A/C inlet temperature 30-35 Blower speed HI Temperature control Maximum cooling NOTE:
Gauge indications before A/C operation, both high and low pressure sides: 5-8 kg/cm² (0.5 0.8 Mpa).
(B) Insufficient refrigerant Problem
Cause
Check and remedy
Pressure low on both low pressure side and the high pressure side
Quantity of refrigerant is too small.
-Check for gas leak and repair.
Bubbles visible in sight glass Air output is not cool
Replenish refrigerant.
Gas leakage
If pressure near 0, evacuate air after repairing leak.
20-903
TROUBLESHOOTING
AIR CONDITIONER / HEATER
(C ) Refrigerant fails to circulate (system clogged) Problem
Cause
Check and remedy
Vacuum is immediately indicated on low pressure side (completely clogged).
Clogging of A/C system.
-Check condition of receiver, expansion valves, etc. -A temperature difference occurs between IN and OUT of the defective parts. -Evacuate air after repair.
Vacuum gradually indicated on low pressure side (partially clogged). (D) Moisture in system Problem
Cause
Check and remedy
Normal operation at first; vacuum on low pressure side is indicated after time.
Moisture in expansion valve freezes.
-Check condition of expansion valve, etc. -Replace receiver (or dryer) -Evacuate air after repair.
20-904
AIR CONDITIONER / HEATER
TROUBLESHOOTING
(E) Compressor failure Problem
Cause
Check and remedy
Pressure on low pressure side is high; pressure on high pressure side is low.
Compressor defect.
-Check compressor condition. -Compressor unit is cool to the touch if there is a compression malfunction.
When the A/C is turned off, the low and high pressure sides quickly equalize.
(F) Excessive refrigerant or insufficient condenser cooling Problem
Cause
Check and remedy
Pressure high on both sides. Bubbles not visible in the sight glass. Poor cooling performance.
Excessive refrigerant.
-Check refrigerant quantity and slowly vent excess if overcharged. -Check and repair condenser fan. -Check engine cooling system
Poor condenser cooling.
20-905
TROUBLESHOOTING
AIR CONDITIONER / HEATER
(G) Air in the system Problem
Cause
Check and remedy
Pressure high on both sides. Low pressure is hot to the touch. Bubbles are visible in the sight glass.
Air has entered the system.
-Replace the refrigerant. -Evacuate the air after the repair.
(H) Expansion valve opens too far Problem
Cause
Check and remedy
Pressure is high on both sides. Frost (condensation) appears on low pressure side piping.
Expansion valve fault (problem frequently occurs after replacing expansion valves).
-Check condition of expansion valves. -Check the temperature sensing bulb condition and installation.
20-906
AIR CONDITIONER / HEATER
TROUBLESHOOTING
Troubleshooting the electrical circuit The flow charts on the following pages break down air conditioning problems into two categories: blower-related problems and cooling equipment related problems. Check for blower troubles first, including such items as gauge fuse, circuit breaker, heater relay, blower motor, blower resistor, and blower switch. Then check other air conditioning electrical components like air conditioner fuse and switch, magnetic clutch and relay, sensors and wiring (input to amplifier) and amplifier. Cooler circuit troubleshooting steps are shown on the next flow chart. Blower troubleshooting Start the engine and allow it to run at idle speed with the vehicle stationary. Follow the steps as shown in the chart. Descriptions of the inspection metthods can be found on the pages that follow the flow chart.
20-907
TROUBLESHOOTING
20-908
AIR CONDITIONER / HEATER
AIR CONDITIONER / HEATER
TROUBLESHOOTING
Electrical circuit checks Heater relay (steps 4 and 5) Turn on the ignition switch and check input voltage at terminal 5 and 3. If no voltage (0V), there should be open circuit between heater relay and gauge fuse, or between heater relay and the battery. Inspect the continuity with a circuit tester or ohmmeter. Repair or replace as necessary. Standard:
terminal No. 1-3 terminal No. 2-4 terminal No. 4-5
continuity continuity no continuity
Applying the battery voltage between terminal Nos. 1 and 3, check continuity between terminal 4 and 5 (point is closed). Blower switch (step 6) If the blower doesn’t operate correctly, remove the blower switch connector and check the continuity between the terminals with each switch position. If all conditions are good reconnect the blower switch. Check continuity between the heater relay terminals and the blower switch terminals as follows. (a) Check continuity between the heater relay terminal 1 and blower switch terminal 12, and between blower switch terminal 9 and vehicle ground. (b) Check the resistance betwen the heater relay terminal 4 and blower switch terminal 9 with each blower switch position. When changing blower switch position from OFF to HI, the resistance value should change from a high value to a low value.
20-909
TROUBLESHOOTING
AIR CONDITIONER / HEATER
Consult this troubleshooting flow chart for procedures to check the cooler equipment after problems with the blower circuit have been ruled out. Details about the procedures appear on the pages that follow.
20-910
AIR CONDITIONER / HEATER
TROUBLESHOOTING
Cooler circuit troubleshooting Air Conditioner switch Step 1-2 Turn on the blower switch and air conditioner switch, check the voltage of the amplifier at terminal 10. If 12 volts is not present (battery voltage), the wiring between the air conditioner fuse and the amplifier input terminals is faulty (open circuit) or the A/C swtich is defective.
Magnetic clutch relay Step 4 and 4-1 Check that continuity exists between terminal no. 1 and 3 but not between terminals 2 and 4. Apply the battery voltage between terminal 1 and 3, check the continuity between terminals 2 and 4 (the point is closed).
20-911
TROUBLESHOOTING
AIR CONDITIONER / HEATER
Condenser fan operation circuit Step 2-2 Turn on the blower switch and A/C switch. Then inspect the condenser fan operation . Conditions A/C switch
Mag. clutch
ON or OFF
OFF
Coolant temp. ( below 83 above 90
ON
ON
ON
ON
Refrigerant pressure (kg/cm²)
Fan speed
Stop below 12.5
below 83
HI LO
below 83
above 15.5
above 90
below 12.5
HI
above 15.5 Under the low coolant temperature and low thermal load (low room and ambient temperature) conditions, the fan rotates at low speed with the magnetic clutch on, while as the coolant temperature increases, the fan starts high speed rotation. In the case of high thermal load, the fan rotates at high speed also. Check four relays used in the condenser fan operation. (a) Engine main relay (identical to the heater relay) (b) Condenser fan relay (3), identical to magnetic clutch relay. (c) Condenser fan relay (2) differs slightly from the heater relay in the terminal layout. Check continuity as follows: continuity between terminals 5 and 2, 1 and 3. No continuity between terminals 1 and 4. Applying the battery voltage between terminals 5 and 2, check the continuity between terminals 1 and 4 (point is closed). Note that the diode permits current flow between terminal 5 and terminal 2 in only one direction.
20-912
AIR CONDITIONER / HEATER
TROUBLESHOOTING
If the thermistor signal is wrong, check the resistance of the termistor. Its resistance characteristics are shown in the illustration.
Idle speed check When the air conditioner switch is turned ON, the idle speed should increase. Make sure the speed change
20-913
TROUBLESHOOTING
20-914
AIR CONDITIONER / HEATER
AIR CONDITIONER / HEATER
TROUBLESHOOTING
Troubleshooting Setup: Abbreviations: Controller on Temp. 60 Defrost “off”, Fan on high (A) Problem - EO error message display on the controller: Possible Cause
Inspection
Remedy
1. Open EC power circuit
Check the EC circuit breaker for power, voltage, and continuity
a) Repair the wiring b) Replace open circuit breaker
2. Defective EC relay (circuit)
Check for output voltage on the yellow wire, at the relay coil. Check the voltage and continuity across the relay contacts.
a) Repair the connections / wiring b) Replace the defective relay
3. Open EC voltage detection circuit
Check for input voltage on the brown wire, at the controller.
a) Repair the wiring or connector
4. Improper wiring installation
Applicable to systems without an EC
a) See note #3
5. Defective controller
Check for output voltage on the yellow wire, at the controller.
a) Replace the controller
(B) Problem - E1 error message display on the controller: Possible Cause
Inspection
Remedy
1. Abnormal A/C refrigerant pressure(s). * Cool weather operation may cause low pressure short cycling
Check the refrigerant pressures with gauges.
2. Opened compressor clutch circuit
Check for output voltage on the green wire at the compressor. Check the wire connections. Check for continuity across the pressure switch(es) and thermostat. Check the continuity of the clutch solenoid to ground.
a) Repair the connections/wiring b) Replace the defective switch(es) or the thermostat c) Replace the defective compressor clutch
3. Opened pressure switch detection circuit
Check for an input voltage on the tan wire, at the controller.
a) Repair the connections/ wiring
4. Defective controller
Check for output voltage on the green wire, at the controller.
a) Replace the controller
High side greater than: 320 psig (R12), or 350 psig (R134a). Low side less than: 3 - 6 psig.*
a) Check the condenser operation for air and refrigerant blockage b) Leak check system, repair the leaks and recharge the system c) Relocate the low pressure switch to the evaporator outlet
20-915
TROUBLESHOOTING
AIR CONDITIONER / HEATER
(B) Problem continued False E1 error message / cold weather charging problems: (Occurs particularly when vapor charging in cold weather)
1.
E1 error message may occur during charging when the low pressure switch (LPS) opens at 3 psig. The suction side pressure must rise above 45 psig to reset the E1 error message.
2.
When the system is fully charged, the E1 error message should not appear under normal operating conditions.
3.
In order to continue charging, by-pass the LPS, turn the controller “off”then “on”, and set the controller to 60 This will reset the controller and force into the air conditioning mode.
4.
If the LPS can’t be easily reached, disconnect the clutch wire at the compressor, and run a hot wire directly to the compressor clutch solenoid. Take care not to short out the controller clutch circuit.
5.
E1 error message may occur while charging, when the compressor is wired hot.
(C) Problem - No Heat Possible Cause
Inspection
Remedy
1. Opened heat solenoid circuit. Poor connection, loss of voltage.
Check for an output voltage on the white wire, at the heat solenoid valve. Check the solenoid continuity to ground.
a) Repair connections/wiring
2. Defective heat solenoid or improper installation.
Check for coolant blockages in the heat solenoid valve and hoses. Check the direction of coolant flow (feel the hoses).
a) Repair or replace the valve. b) Reverse the coolant hoses to the valve.
3. Defective controller
Check for output voltage on the white wire, at the controller.
a) Replace the controller
20-916
AIR CONDITIONER / HEATER
TROUBLESHOOTING
(D) Problem - No display, the blower fan will not turn off, when the power is turned on. Possible Cause 1. Fan wires shorted to ground or vehicle chassis
Inspection Disconnect the controller from the external harness, Individually check the continuity of the orange and black fan wires to ground, in the external harness.
Remedy a) Unground and repair the shorted wiring.
(E) Problem - Compressor clutch will not engage, unless defrost button is pushed. Possible Cause
Inspection
Remedy
1. Defective preset thermostat inside evaporator. Opened preset thermostat circuit. Broken thermostat wiring. Evaporator coil temperature too cold for a/c operation.
Push, hold defrost / temperature decrease buttons simultaneously. Check display for “OP”or “CL”readout. Disconnect red leads, and check for continuity across thermostat terminals.
a) If “CL”, go to step 2. b) If “OP”, repair connections or wiring to preset thermostat. c) Replace preset thermostat.
2. Ambient cab temperature too cool (below 60
Set controller at 68-70 Warm-up ambient temperature probe with fingers or heat gun.
a) Verify if compressor clutch will pull in or not. b) If not go to step 3.
3. Opened ambient cab temperature probe (thermistor)
Push, hold temp. Decrease/increase buttons simultaneously. Display will read 40F if probe is defective. Disconnect the controller, check for continuity across black probe leads. Check resistance of thermistor.
a) If display reads 49F, at room temperature, replace thermistor. b) Repair connections/wiring. c) If 10K ohms +/- 20%, thermistor is good. If 100K-1M ohms, replace thermistor.
Notes: 1.
Wire colors may vary with installation. Refer to the wiring schematic.
2.
For 24V controllers, resistor (R17) must be clipped and removed from the circuit board. (Refer to figure below) If the resistor is not clipped on the 24V system, the controller display will light up, but the blower fan will not turn on.
20-917
TROUBLESHOOTING
AIR CONDITIONER / HEATER
3.
For air conditioning systems that do not use an electric condenser, the blue and brown wires must be connected together, on the external harness. The brown wire must be connected to the battery voltage, or the EO error message will result.
4.
Care must be taken during installation, not to pinch or cut wiring from the controller. Shorted wiring may result in damage to the controller.
5.
Improper probe location of the evaporator coil thermostat sensor, or ambient cab temperature sensor, may cause short cycling of the compressor.
6.
Eagle climate controllers are designed to use normally closed heat solenoid valves.
7.
Disconnect the vehicle battery leads, if a machine is to be inactive, or put into storage, for a period of a week or more. The current drain from the controller’s memory may result in a dead vehicle battery. An optional ignition relay may be installed to disable the controller’s memory function, when the key switch is turned off.
20-918
AIR CONDITIONER / HEATER
TROUBLESHOOTING
WIRING DIAGRAM
NOTES: 1. 2. Wire Chart Socket
Position the ambient temperature probe near waist high level, out of air flow and sun load. Insert the sensing tube from present thermostat down into the evaporator coil, parallel to the coil face, between the 1st and 2nd rows, to a depth of the coil height minus 1 inch. CONNECTOR DETAIL Size
Color
Wire function
1
10GA
Red
Battery positive in
2
18GA
Red
½ evap coil thermostat in
3
18GA
Black
½ ambient thermistor in
4
18GA
Red
½ evap coil thermostat in
5
N/A
N/A
Not used
6
18GA
Black
½ ambient thermistor in
7
14GA
Orange
Fan positive out
8
16GA
Dk. Green
Clutch out
9
18GA
Dk. Blue
Ignition switch in
10
14GA
Black
Fan negative out
11
18Ga
Brown
Condenser blown fuse in
12
16GA
White
Heat solenoid out
13
18GA
Tan
Pressure switch detect in
14
16GA
Yellow
Condenser fan relay out
15
12GA
Black
Battery negative in
16
N/A
N/A
Not used
20-919
TROUBLESHOOTING
AIR CONDITIONER / HEATER
Sensor circuit
Servomotors
Body ground
Wire harness
Problem
Fuses
No.
Connectors
Main inspection areas
Others inspection items
1
Fuse blows easily
2
No blower operation
Heater relay, blower motor, blower resistor, blower switch
3
Blower speed does not change
Blower resistor, blower switch
4
No compressor operation
Magnetic clutch and relay, compressor, heater relay, A/C switch, A/C amplifier
5
A/C lamp doesn’t light
Engine speed signal lines, A/C amplifier, A/C switch
6
A/C lamp flashes (only for compressor with lock sensor)
Compressor, drive belt, A/C amplifier, magnetic clutch
7
No A/C operation (cooled air does not come out)
8
Cab temperature does not decrease (insufficient cooling).
Water temperature switch (for variable compressor type) A/C amplifier
9
Warm air doesn’t come out.
Engine coolant volume, A/C temperature control , heater radiator
10
No condenser fan operation.
Relays (for condenser fan, radiator fan), condenser fan motor, condenser fuse
11
No engine idle speed increase when A/C switch is turned on.
Idle-up actuator, vacuum hose line, air conditioner amplifier
20-920
30 DISASSEMBLY AND ASSEMBLY Precautions when carrying out operation . . . . . . . . . . . 30-3 Special tool list . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-6 Sketches of special tools . . . . . . . . . . . . . . . . . . . . . . 30-11 Starting motor assembly . . . . . . . . . . . . . . . . . . . . . . 30-14 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-14 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-14 Alternator assembly . . . . . . . . . . . . . . . . . . . . . . . . . . 30-15 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-15 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-15 Engine oil cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-16 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-16 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-16 Fuel injection pump assembly . . . . . . . . . . . . . . . . . . 30-17 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-17 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-17 Water pump assembly . . . . . . . . . . . . . . . . . . . . . . . . 30-18 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-18 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-18 Injector assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-19 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-19 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-19 Turbocharger assembly . . . . . . . . . . . . . . . . . . . . . . . 30-20 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-20 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-20 After cooler assembly . . . . . . . . . . . . . . . . . . . . . . . . . 30-22 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-22 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-23 Cylinder head assembly . . . . . . . . . . . . . . . . . . . . . . . 30-24 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-24 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-26 Radiator assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-29 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-30 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-31 Damper assembly Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-32 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-32 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-33 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-36 Torque converter and transmission Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-41 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-44 Disconnection . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-45 Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-45 Torque converter Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-46 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-50 Transmission Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-58 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-75 Transfer assembly Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-92 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-96 Parking brake assembly Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-92
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-104 Transmission control valve (ECMV assembly) Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-108 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-108 Disassembly of center support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-110 Assembly of center support . . . . . . . . . . . . . . . . . . . 30-112 Disassembly of drive shaft. . . . . . . . . . . . . . . . . . . . . 30-115 Assembly of drive shaft . . . . . . . . . . . . . . . . . . . . . . 30-118 Removal of front axle assembly . . . . . . . . . . . . . . . . 30-121 Installation of front axle assembly . . . . . . . . . . . . . . 30-122 Removal of front differential assembly . . . . . . . . . . . 30-123 Installation of front differential assembly . . . . . . . . . 30-125 Removal of rear axle assembly . . . . . . . . . . . . . . . . 30-126 Installation of rear axle assembly . . . . . . . . . . . . . . . 30-131 Removal of rear differential assembly . . . . . . . . . . . 30-132 Installation of rear differential assembly . . . . . . . . . . 30-133 Disassembly of differential gear assembly . . . . . . . . 30-134 Fine disassembly of pinion assembly . . . . . . . . . . . . 30-136 Fine disassembly of differential gear case assembly . . . . . . . . . . . . . . . . . . . . . . . . . 30-137 Fine assembly of differential gear case assembly . . . . . . . . . . . . . . . . . . . . . . . . . 30-138 Disassembly of final drive assembly . . . . . . . . . . . . . 30-146 Assembly of final drive assembly . . . . . . . . . . . . . . 30-149 Removal of orbit-roll assembly . . . . . . . . . . . . . . . . . 30-153 Installation of orbit-roll assembly . . . . . . . . . . . . . . . 30-153 Disassembly of orbit-roll assembly . . . . . . . . . . . . . . 30-154 Assembly of orbit-roll assembly . . . . . . . . . . . . . . . . 30-159 Removal of steering cylinder assembly . . . . . . . . . . 30-166 Installation of steering cylinder assembly . . . . . . . . . 30-167 Disassembly of steering cylinder assembly . . . . . . . 30-168 Assembly of steering cylinder assembly . . . . . . . . . 30-170 Removal of steering valve assembly . . . . . . . . . . . . 30-172 Installation of steering valve assembly . . . . . . . . . . . 30-174 Removal of brake valve assembly . . . . . . . . . . . . . . 30-175 Installation of brake valve assembly . . . . . . . . . . . . . 30-176 Removal of slack adjuster assembly . . . . . . . . . . . . 30-177 Installation of slack adjuster assembly . . . . . . . . . . . 30-177 Disassembly of slack adjuster . . . . . . . . . . . . . . . . . 30-178 Assembly of slack adjuster . . . . . . . . . . . . . . . . . . . 30-179 Removal of brake assembly (front, rear) . . . . . . . . . 30-180 Installation of brake assembly (front, rear) . . . . . . . . 30-180 Disassembly of brake assembly (front, rear) . . . . . . 30-181 Assembly of brake assembly (front, rear) . . . . . . . . 30-184 Removal of hydraulic pump (switch & PPC, loader, torque converter-transmission, steering) assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-188 Installation of hydraulic pump (switch & PPC, loader, torque . . . . . . . . . . . . . . . . . . . . . 30-189 Removal of hydraulic tank assembly . . . . . . . . . . . . 30-190 Installation of hydraulic tank assembly . . . . . . . . . . . 30-191 Removal of hydraulic filter assembly . . . . . . . . . . . . 30-192 Installation of hydraulic filter assembly . . . . . . . . . . . 30-192
30-1
DISASSEMBLY AND ASSEMBLY Removal of PPC valve assembly . . . . . . . . . . . . . . . Installation of PPC valve assembly . . . . . . . . . . . . . Disassembly of PPC valve assembly . . . . . . . . . . . . Assembly of PPC valve assembly . . . . . . . . . . . . . . Removal of main control valve assembly . . . . . . . . . Installation of main control valve assembly . . . . . . . Assembly of main control valve . . . . . . . . . . . . . . . . Removal of bucket cylinder assembly . . . . . . . . . . . Installation of bucket cylinder assembly . . . . . . . . . . Removal of boom cylinder assembly . . . . . . . . . . . . Installation of boom cylinder assembly . . . . . . . . . . Disassembly of boom and bucket cylinders assembly . . . . . . . . . . . . . . . . . . . . . . Assembly of boom and bucket cylinders assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal of center hinge pin . . . . . . . . . . . . . . . . . . Installation of center hinge pin . . . . . . . . . . . . . . . . . Removal of work equipment . . . . . . . . . . . . . . . . . . Installation of work equipment assembly . . . . . . . . . Removal of bulkhead assembly . . . . . . . . . . . . . . . . Installation of bulkhead assembly . . . . . . . . . . . . . . Installation of engine hood assembly . . . . . . . . . . . . Removal of floor frame assembly . . . . . . . . . . . . . . . Installation of floor frame assembly . . . . . . . . . . . . . Removal of counterweight . . . . . . . . . . . . . . . . . . . Installation of counterweight . . . . . . . . . . . . . . . . . . Removal of fuel tank assembly . . . . . . . . . . . . . . . . Installation of fuel tank assembly . . . . . . . . . . . . . . . Removal of cab assembly . . . . . . . . . . . . . . . . . . . . Installation of cab assembly . . . . . . . . . . . . . . . . . . . Removal of air conditioner unit assembly . . . . . . . . . . . . . . . . . . . . . . . . . . Installation of air conditioner unit assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal of air conditioner condenser assembly . . . . . . . . . . . . . . . . . . . . . Installation of air conditioner condenser assembly . . . . . . . . . . . . . . . . . . . . . Removal of receiver tank . . . . . . . . . . . . . . . . . . . . . Installation of receiver tank . . . . . . . . . . . . . . . . . . . . Removal of air conditioner compressor assembly . . . . . . . . . . . . . . . . . . . . Installation of air conditioner compressor assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
30-2
TABLE OF CONTENTS 30-193 30-193 30-194 30-194 30-195 30-197 30-202 30-206 30-207 30-208 30-209 30-210 30-212 30-215 30-221 30-225 30-229 30-230 30-231 30-232 30-233 30-235 30-236 30-236 30-237 30-238 30-239 30-241 30-242 30-243 30-244 30-244 30-245 30-245 30-246 30-246
DISASSEMBLY AND ASSEMBLY
PRECAUTIONS WHEN CARRYING OUT OPERATION
PRECAUTIONS WHEN CARRYING OUT OPERATION When carrying out removal or installation (disassembly or assembly) of units, be sure to following general precautions. 1. Precautions when carrying out removal work. If the coolant contains anti-freeze, dispose of it correctly. After disconnecting hoses or tubes, cover them or fit blind plugs to prevent dirt or dust from entering. When draining oil, prepare a container of adequate size to catch the oil. Confirm the match marks showing th e installation position, and make match marks in the necessary places before removal to prevent any mistake when assembling. To prevent any excessive force from being applied to the wiring, always hold connectors when disconnecting. Do not pull the wires.
Fit wires and hoses with tags to show thei r installation position to prevent any mistake when installing. Check the number and thickness of the shims, and keep in a safe place. When raising components, be sure to use lifting equipment with ample strength. When using forcing screws to remove any components, tighten the forcing screws uniformly in turn. Before removing any unit, clean the surrounding area. Fit a cover to prevent any dust or dirt from entering after removal.
Precautions when handling piping during disassembly. Fit the following blind plugs into the piping after disconnecting it during disassembly operations. 1) Hoses and tubes using sleeve nuts. Nominal number
Plug (nut end)
Sleeve nut (elbow end)
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)
2) Split flange type hoses and tubes. Nominal number
Flange (hose end)
Sleeve head (tube end)
Split flange
04
07379-00400
07378-10400
07371-40400
05
07379-00400
07378-10500
07371-30500
30-3
DISASSEMBLY AND ASSEMBLY
PRECAUTIONS WHEN CARRYING OUT OPERATION
3) If the part is not under hydraulic pressure, the following corks can be used Nominal number
Part Number
06
Dimensions D
d
L
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
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
22
07049-02228
22
18.5
28
24
07049-02430
24
20
30
27
07049-02734
27
22.5
34
2. Precautions when carrying out installation work. Tighten all bolts and nuts (sleeve nuts) to the specified (KES) torque. Install the hoses without twisting or interference. Replace all gaskets, O-rings, cotter pins, and lock plates with new parts. Bend the cotter pins and lock plates securely. When coating with adhesive, clean the part and remove all oil and grease, then coat the threaded portion with two - three drops of adhesive. When coating with gasket sealant, clean the surface and remove all oil and grease, check that there is no dirt or damage, then coat uniformly with gasket sealant.
Clean all parts, and correct any damage, dents, burrs, or rust. Coat rotating parts and sliding parts with engine oil. When press fitting parts, coat the surface with anti-friction compound (LM-P). After fitting snap rings, check that the snap ring is fitted securely in the ring groove. When connecting wiring connectors, clean the connector to remove all oil, dirt, or water, then connect securely. When using eye bolts, check that there is no deformation or deterioration, screw them in fully, and align the direction of the hook. When tightening split flanges, tighten uniformly in turn to prevent excessive tightening on one side.
When operating the hydraulic cylinders for the first time after reassembling cylinders, pumps and other hydraulic equipment removed for repair, always bleed the air as follows: 1. Start the engine and run at low idling. 2. Operate the work equipment control lever to operate the hydraulic cylinder four - five times, stopping the cylinder 100 mm from the end of its stroke.
30-4
DISASSEMBLY AND ASSEMBLY
PRECAUTIONS WHEN CARRYING OUT OPERATION
3. Next, operate the steering, bucket, and boom cylinders to the end of their stroke three - four times, stop the engine, loosen air bleed plug (1), bleed the air from the hydraulic tank, then tighten plug (1) again. 4. Raise the engine speed, repeat Step 3 to bleed the air, and repeat this operation until no more air comes out from the plug. 5. After doing this, run the engine at normal speed. When using the machine for the first time after repair or long storage, follow the same procedure.
3. Precautions when completing the operation. If the coolant has been drained, tighten the drain valve, and add water to the specified level. Run the engine to circulate the water through the system. Then check the water level again. If the hydraulic equipment has been removed and installed again, add engine oil to the specified level. Run the engine to circulate the oil through the system. Then check the oil level again. If the piping or hydraulic equipment have been removed, always bleed the air from the system after reassembling the parts. For details, see TESTING AND ADJUSTING, Bleeding air. Add the specified amount of grease (molybdenum disulfide grease) to the work equipment parts.
30-5
DISASSEMBLY AND ASSEMBLY
SPECIAL TOOL LIST
SPECIAL TOOL LIST Tools with part number 790T-000-0000 cannot be supplied (they are items to be locally manufactured). Necessity: Cannot be substituted, should always be used. Extremely useful if available, can be substituted with commercially available part. New/remodel: N: Tools with new part numbers, newly developed for this model. R: Tools with upgraded part numbers, remodeled from items already available for other models. Blank: Tools already available for other models, used without any modification. Tools marked O in the sketch column are tools introduced in special sketches (See SKETCHES OF SPECIAL TOOLS). Component
Symbol
Installation of engine cylinder head
Installation of engine front seal, rear seal
Part Name
Nece Qty New/ Sketch Nature of work, remarks ssity remodel
1
790-331-1110
Wrench
1
1
795-521-1110
Push tool
1
2 2
790-101-5221
Grip
1
3
01010-51225
Bolt
1
4
01050-31640
Bolt
3
1
795-931-1210
Sleeve jig
1
3 2
795-931-1220
Sleeve jig
1
3
01050-31625
Bolt
3
4
01050-31645
Bolt
3
1
793T-615-1230
Push tool
1
N
O
1 2
793T-615-1240
Spacer
1
N
O
3
790-101-5421
Grip
1
4
01010-51240
Bolt
1
790-102-1871
Wrench
1
1
790-201-2730
Spacer
1
2
791-520-4140
Screw
1
3 3
02215-11622
Nut
2
4
01643-32780
Washer
2
5
790-101-2102
Puller (294.2 kN {30 ton})
1
6
79-101-1102
Pump
1
A
Assembly of damper
Part No.
2 B
Disassembly, assembly of PTO
30-6
Tightening of head assembly
Press fitting of front seal
Press fitting of rear seal
Press fitting of oil seal and dust seal
Removal, installation of round nut
Press fitting of PTO gear bearing inner race
DISASSEMBLY AND ASSEMBLY Component
Disassembly, assembly of torque converter assembly
Symbol
C
Part No.
SPECIAL TOOL LIST Part Name Repair stand
Necessity
Qty
New/ remodel
Sketch
1
790-501-5200
2
790-901-2110 Bracket
1
3
790-310-2160 Plate
1
799-301-1500 Oil leak tester
1
Checking actuation of clutch piston
1 796-514-2000 Remover
1
2 796-515-2140 Adapter
1
Removal of No.3 planet gear shaft
1
2 Disassembly, assembly of transmission assembly
Nature of work, remarks
790-201-1702 Push tool kit D
1 1 Press fitting of No.3, No.4 carrier bushing
1741 4 1 5021 1 Disassembly, assembly of Orbit-roll assembly
790-452-1200 Pilot ring tool
1
Centering of body and upper cover
790-452-1100 Installer set
1
Press fitting of spacer
1 790-520-2510 Bracket
1
2 790-520-2610 Plate
1
Removal, installation of differential assembly
1 F 2
Removal, installation of differential assembly
1
790-501-5000 Repair stand
1
100V
790-501-5200 Repair stand
1
220V, 240V
1 2
H Disassembly, assembly of differential assembly
2 790-901-2110 Bracket
1
3 793-310-2160 Plate
1
1 793T-622-1120 Push tool
1
N
O
2 793T-622-1130 Spacer
1
N
O
3 790-101-5421 Grip
1
4 01010-51240
1
3 Bolt
1 792-525-1000 Micrometer
1
2 792-525-1230 Adapter
2
4
Press fitting of dust seal and oil seal of coupling cage
Adjusting preload of bearing
30-7
DISASSEMBLY AND ASSEMBLY Component
Symbol
5
Part No.
SPECIAL TOOL LIST Part name
Necessity
Qty
New/ remodel
Sketch
N
O
1 793T-622-1110
Plate
1
2 790-101-5421
Grip
1
3 01010-51240
Bolt
1
Fixture
3
N
1 793-520-1805
Brake tester
1
N
2 793-520-1851
Nipple
1
N
1 793-520-2680
Installer
1
2 791-580-1600
Push tool
1
793T-622-1150
6
Press fitting of oil seal of outer drum
7
Disassembly, assembly of final drive assembly
3
1
4
4
5
1
6
4
7
8
8
4
9
4
Disassembly, assembly of brake assembly
30-8
9
O
Removal, installation of wheel hub Checking leakage of brake oil
Installation of floating seal (gear end)
8 H
Nature of work, remarks
10 792-530-1630
Stud
4
1 793-520-2680
Installer
1
2 793-622-1200
Push tool
1
N
3
4
N
4
1
N
5
1
6
4
7
4
8
4
9
4
Installation of floating seal (hub end)
DISASSEMBLY AND ASSEMBLY Component
Symbol
1
Part No.
SPECIAL TOOL LIST Part name
793-520-2630
Bar
2
2
793-520-2640
Push tool
1
3
793-520-2530
Guide
1
4
790-101-2300
Push puller
1
5
1
Nature of work, remarks
Press fitting of bearing of top center hinge portion
2 790-101-2102
8
790-101-1102
Pump
1
1
793-520-2550
Guide
1
2
01010-31480
Bolt
2
3
01643-31445
Washer
2
4
793-520-2640
Push tool
1
5
790-101-2102
Puller (294.2 kN {30 ton})
1
6
790-101-1102
Pump
1
Repair stand
1
790-502-1003 or 790-502-2000
2
790-101-1102
Pump
1
2
790-330-1100
Wrench assembly
1
Removal, installation of cylinder head
3
790-302-1290
Socket (width across flats 60 mm)
1
Removal, installation of nut
790-201-1500
Push tool
1
1
4
Sketch
7
K
U
New/ remodel
Puller (294.2 kN {30 ton})
2
Disassembly, assembly of hydraulic cylinder assembly
Qty
1
6 Removal, installation of center hinge
Necessity
1
Press fitting of bearing of bottom center hinge portion
1
1
Press fitting of dust seal
2
1
Steering cylinder
3
1
Boom cylinder
4
1
Bucket cylinder
5
1
6
1
All cylinders
30-9
DISASSEMBLY AND ASSEMBLY Component
Symbol 1
SPECIAL TOOL LIST
Part No.
Part name
790-201-1702
Push tool kit
Necessity Qty
New/ remodel
Sketch
Nature of work, remarks
1
Press fitting of roll bushing
2
1
Steering cylinder
3
1
Boom cylinder
4
1
Bucket cylinder
5
1
6
1
5
All cylinders Disassembly, assembly of hydraulic cylinder U assembly
1
790-720-1000
Expander
1
2
796-720-1660
Ring
1
3
07281-01159
Clamp
1
4
796-720-1690
Ring
1
5
07281-02169
Clamp
1
6
796-720-1720
Ring
1
7
07281-02429
Clamp
1
1
790-102-2303
Wrench assembly
1
2
790-102-4300
Wrench assembly
1
3
790-102-4310
Pin
1
1
790-720-1000
Expander
1
2
796-720-1660
Ring
1
3
07281-01159
Clamp
1
792-610-1700
Charging tool assembly
1
1
799-703-1200
Service tool kit
1
2
799-703-1100
3
799-703-1110
4
799-703-1120
5
799-703-1400
Expansion of piston ring
Steering cylinder
6
Boom cylinder
Bucket cylinder
1
Disassembly, assembly of accumulator assembly 2
X 3
Charging air conditioner with gas
30-10
4
Vacuum pump
Gas leak tester
Removal, installation of round head
Expansion of piston ring
Charging with N2 gas
1
110V
1
220V
1
240V
1
DISASSEMBLY AND ASSEMBLY
SKETCHES OF SPECIAL TOOLS
SKETCHES OF SPECIAL TOOLS Note: H3-2
Komatsu cannot accept any responsibility for special tools manufactured according to these sketches.
H6
30-11
DISASSEMBLY AND ASSEMBLY H5-1
H3-1
30-12
SKETCHES OF SPECIAL TOOLS
DISASSEMBLY AND ASSEMBLY
DISASSEMBLY AND ASSEMBLY
B1-2
B1-1
30-13
DISASSEMBLY AND ASSEMBLY
STARTING MOTOR ASSEMBLY REMOVAL OF WARNING! 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. WARNING! Disconnect the cable from the negative (-) terminal of the battery.
1. Remove catch, open side cover, then remove two side covers. 2. Disconnect connector (1) and wire (2). 3. Remove ground connection (3), then remove starting motor assembly (4). 4. For details, see Cummins Engine "Troubleshooting and repair manual.”
INSTALLATION OF 1. Fit gasket and install starting motor assembly (4), then tighten together with ground connection (3). 2. Connect wire (2) and connector (1). 3. Install cover, close two side covers, then lock with catch. 4. Connect cable to negative (-) terminal of battery. 5. For details, see Cummins Engine "Troubleshooting and repair manual.”
30-14
STARTING MOTOR ASSEMBLY
DISASSEMBLY AND ASSEMBLY
ALTERNATOR ASSEMBLY
ALTERNATOR ASSEMBLY REMOVAL OF WARNING! 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. WARNING! Disconnect the cable from the negative (-) terminal of the battery. 1. Remove catch, then open side cover. 2. Disconnect wires (1, 2 and 3). 3. Remove bolt (4) of adjustment plate, then loosen mounting bolt and nut (5). 4. Remove adjustment plate (6). 5. Move alternator assembly towards lower position to loosen belt tension, then remove belt (7). 6. Remove mounting bolt and nut, then remove alternator assembly. 7. For details, see Cummins Engine "Troubleshooting and repair manual.” INSTALLATION OF 1. Install alternator assembly (8), then partially tighten mounting bolt and nut (5). 2. Fit belt (7) in pulley groove and install. 3. Install adjustment plate (6), and partially tighten bolt (4) of adjustment plate. 4. Insert a bar between the alternator assembly and cylinder block, raise the alternator and adjust the belt tension. The belt should deflect about 15mm when pushed with a finger pressure of 6kg at a point midway between the alternator and the fan pulley. 5. Tighten the adjustment plate bolt, and the alternator assembly bolt and nut. 6. Connect wires (3, 2 and 1). 7. Close cover, then lock with catch. 8. Connect cable to negative (-) terminal of battery. 9. For details, see Cummins Engine "Troubleshooting and repair manual.”
30-15
DISASSEMBLY AND ASSEMBLY
ENGINE OIL COOLER REMOVAL OF WARNING! 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. Remove catch, then open left engine side cover. 2. Loosen drain valve (1), and drain the cooling water. If the coolant contains antifreeze, dispose of it correctly. 3. Remove the turbocharger oil supply tube (3) and the by-pass filter return tube (4). 4. Remove the cover and the water transfer tube (2). 5. Remove the full flow and by-pass filters (5). 6. Remove the oil cooler assembly, then remove the remaining bolts from the support. 7. For details, see Cummins Engine "Troubleshooting and repair manual.”
INSTALLATION OF 1. 2. 3. 4.
Install the oil cooler support. Install the oil cooler assembly (6). Install the cover and the water transfer tube (2). Install the turbocharger oil supply tube (3), and the by-pass filter return tube (4). 5. Install the full flow and by-pass filters (5). 6. For details, see Cummins Engine "Troubleshooting and repair manual.”
30-16
ENGINE OIL COOLER
DISASSEMBLY AND ASSEMBLY
FUEL INJECTION ASSEMBLY
FUEL INJECTION PUMP ASSEMBLY
PUM P
REMOVAL WARNING! 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. Remove the three engine side covers on the left side. 2. Disconnect wire (1) to the fuel shut-off valve. 3. Remove control rod (2). 4. Disconnect the fuel inlet hose (3) and the air supply hose (4). 5. Remove fuel tubing (5, 6, and 7). 6. Remove fuel pump (8). 7. For details, see Cummins Engine "Troubleshooting and repair manual.”
INSTALLATION OF 1. Install fuel pump (8), then install the drive spider coupling. 2. Install fuel tubing (5, 6, and 7). 3. Connect the fuel inlet hose (3) and air supply hose (4). 4. Connect fuel shut-off valve wire (1). 5. Install control rod (2). 6. Install the three engine side covers, then lock with catch. 7. For details, see Cummins Engine "Troubleshooting and repair manual.”
30-17
DISASSEMBLY AND ASSEMBLY
WATER PUMP ASSEMBLY REMOVAL OF WARNING! 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. Remove radiator assembly (see removal of radiator) 2. Remove water pump belt (1). 3. Remove fan hub (2), and the water pump idler pulley assembly (3). 4. Remove fan hub support bracket (4). 5. Remove air compressor coolant outlet tube (5). 6. Remove thermostat by-pass tube (6). 7. Remove coolant inlet transfer connection (7) from the water pump. 8. Remove water pump assembly (8). 9. For details, see Cummins Engine "Troubleshooting and repair manual.”
INSTALLATION OF 1. Install water pump assembly (8) with a new gasket. 2. Install coolant inlet transfer connection (7) with a new gasket. 3 Install coolant outlet tube (5), and the thermostat by-pass tube (6). 4. Install fan hub support bracket (4). 5. Install fan hub (2), and the water pump idler pulley (3). 6. Install water pump belt (1). 7. For details, see Cummins Engine "Troubleshooting and repair manual.”
30-18
WATER PUMP ASSEMBLY
DISASSEMBLY AND ASSEMBLY
INJECTOR ASSEMBLY
INJECTOR ASSEMBLY REMOVAL WARNING! 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. Preparatory work Remove engine side covers, hood, and exhaust pipe. Remove cylinder head assembly, injector assembly, muffler, intake connector, and air cleaner assembly, then disconnect all injectors. 1. Remove mounting bolt (1) of the head cover, then remove head cover (2). 2. Loosen adjusting screw locknut (3) and move the injector push rod to the side. 3. Remove the injector link. 4. Remove injector hold down clamp (4). 5. Using injector puller (Cummins part #3376497), remove injectors (5). 6. For details, see Cummins Engine "Troubleshooting and repair manual.”
INSTALLATION OF Replace the three o-rings on each injector. 1. Install injectors (5) in the cylinder head injector bore. 2. Install injector hold down clamp (4). 3. Install the injector link in each injector. 4. Align the push rod with the injector rocker lever, turn the adjusting screw, and tighten locknut (3). 5. Install rocker lever head cover (2), and mounting bolts (1). 6. For details, see Cummins Engine "Troubleshooting and repair manual.”
30-19
DISASSEMBLY AND ASSEMBLY
TURBOCHARGER ASSEMBLY REMOVAL OF WARNING! 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. Preparatory work Remove hood, engine side covers, and exhaust muffler. To remove exhaust muffler and air cleaner assembly 1. Disconnect inlet connector (1). 2. Disconnect oil supply tube (2), and drain tube (3). 3. Remove mount bolts (4), and remove turbocharger assembly (5).
INSTALLATION OF Replace gaskets and o-rings with new. 1. Fit new gasket and install turbocharger assembly (5), then tighten turbocharger mounting bolts (4). 2. Fit new gasket, connect drain tube (2), and supply tube (3). 3. Fit new o-ring and gasket, install inlet connector (1). 4. Install exhaust muffler, hood, and side covers.
30-20
TURBOCHARGER ASSEMBLY
DISASSEMBLY AND ASSEMBLY
MEMORANDA - MEMORANDA -
30-21
DISASSEMBLY AND ASSEMBLY
AFTER COOLER ASSEMBLY REMOVAL OF WARNING! 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. Engine hood and radiator grille. a) Remove exhaust pipe (1), remove radiator grille (2). b) Refer to REMOVAL OF ENGINE HOOD ASSEMBLY. 2. Ether injector. a) Remove ether injector (3), and bracket (4). 3. Draining water. a) Open radiator drain valve (5), and drain coolant. b) Open after cooler drain valve (6), and drain coolant. If the coolant contains antifreeze, dispose of it properly. 4. Crossover connection. b) Remove air crossover connection (7). 5. Hoses and hose clamps. a) Loosen hose clamps (8). b) Remove after cooler inlet hose (9), and outlet hose (10). c) Remove air compressor air inlet tube (11), and after cooler signal tube (12). d) Remove any other hoses which are attached to the after cooler assembly. 6. After cooler assembly. a) Remove after cooler assembly (13), and mounting bolts. 7. For details, see Cummins Engine "Troubleshooting and repair manual.”
30-22
AFTER COOLER ASSEMBLY
DISASSEMBLY AND ASSEMBLY
AFTER COOLER ASSEMBLY
INSTALLATION OF 1. After cooler assembly. a) Install the guide studs (14) in the cylinder head, then install the after cooler assembly (13). 2. Hoses and clamps. a) Install after cooler inlet hose (9), and outlet hose (10), and tighten the hose clamps (8). b) Install air compressor air inlet tube (11), and after cooler signal tube (12). c) Remove any other hoses which are attached to the after cooler assembly. 3. Crossover connection. a) Install air crossover connection (7). 4. Ether injector. a) Install ether injector (3), and bracket (4). 5. Refilling coolant. a) Close radiator drain valve (5), and after cooler drain valve (6) b) Add coolant through the radiator filler neck to the specified level. Run the engine to circulate the coolant through the system. Then check the coolant level again. Coolant:
81 21.4 gal.
6. Hood and engine side covers. a) Install left and right hand engine side covers. b) Install hood (2), and exhaust pipe (1). 7. For details, see Cummins Engine "Troubleshooting and repair manual.”
30-23
DISASSEMBLY AND ASSEMBLY
CYLINDER HEAD ASSEMBLY
CYLINDER HEAD ASSEMBLY REMOVAL OF WARNING! 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. Engine hood and radiator grille. a) Remove exhaust pipe (1), remove grille (2). b) Refer to REMOVAL OF ENGINE ASSEMBLY. a) Remove exhaust pipe (1), remove grille (2). b) Refer to REMOVAL OF ENGINE ASSEMBLY.
radiator HOOD radiator HOOD
2. Draining coolant. 1) Open radiator drain valve (3), and drain coolant. If the coolant contains antifreeze, dispose of it properly. 3. Bracket. 1) Disconnect fuel control cable bracket (4).
4. Drain tube. 1) Remove muffler drain tube (5). 5. Muffler. 1) Remove exhaust pipe (6), then loosen the pipe clamps. 2) Disconnect aspirator pipe (7), then remove clamp (8). 3) Sling muffler (9), then lift off.
30-24
DISASSEMBLY AND ASSEMBLY
CYLINDER HEAD ASSEMBLY
6. Intake connector assembly 1) Disconnect aspirator intermediate hose (10). 2) Remove mounting bolts (11), loosen connector clamp (13), then remove intake connector (12).
7. Air cleaner assembly. 1) Remove air cleaner mounting band. 2) Remove intake connector bracket mounting bolts (14). 3) Sling air cleaner assembly (15), then remove air cleaner and intake connector as one unit. Air cleaner assembly:
35 kg (77 lb)
8. Cylinder heads. 1) Remove after cooler assembly (16). 2) Remove turbocharger assembly (17).
3) Remove exhaust manifold (18). 4) Remove water manifold (19). 5) For details, see Cummins Engine "Troubleshooting and repair manual.”
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DISASSEMBLY AND ASSEMBLY INSTALLATION OF 1. Cylinder head assembly. 1) Install new head gaskets on the dowel pins in the cylinder block. Make sure the side of the gasket marked "TOP" is facing up. 2) For details, see Cummins Engine "Troubleshooting and repair manual.”
3) 4) 5) 6)
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Install water manifold (19). Install exhaust manifold (18). Install turbocharger assembly (17). Install after cooler assembly (16).
CYLINDER HEAD ASSEMBLY
DISASSEMBLY AND ASSEMBLY
CYLINDER HEAD ASSEMBLY
2. Air cleaner assembly. 1) Sling air cleaner assembly and intake connector as one unit, then install the air cleaner assembly (15). 2) Tighten the intake connector bracket mounting bolts (14). 3) Secure the air cleaner mounting band.
3. Intake connector assembly. 1) Install a new gasket, then install the air intake connector (12), tighten mounting bolts (11), and install connector clamp (13). 2) Connect aspirator intermediate hose (10).
4. Muffler. 1) Sling the muffler assembly (9), then install. 2) Connect aspirator pipe (7), then install clamp (8). 3) Install exhaust pipe (6), then tighten the pipe clamps.
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DISASSEMBLY AND ASSEMBLY 5. Drain tube. 1) Connect the muffler drain tube (5). 6. Bracket. 1) Connect fuel control cable bracket (4).
7. Refilling coolant. 1) Close radiator drain valve (5), and after cooler drain valve (6) 2) Add coolant through the radiator filler neck to the specified level. Run the engine to circulate the coolant through the system. Then check the coolant level again. Coolant:
81 21.4 gal.
8. Engine hood and radiator grille. 1) Install hood, refer to INSTALLATION OF ENGINE HOOD ASSEMBLY. 2) Install radiator grille (2), and exhaust pipe (1).
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CYLINDER HEAD ASSEMBLY
DISASSEMBLY AND ASSEMBLY
MEMORANDA
MEMORANDA
30-29
DISASSEMBLY AND ASSEMBLY
RADIATOR ASSEMBLY REMOVAL OF WARNING! 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. Loosen the oil cap slowly to release the pressure inside the hydraulic tank. Then operate the control levers several times to release the remaining pressure in the hydraulic piping. 1. Remove engine hood assembly, see “REMOVAL OF ENGINE HOOD ASSEMBLY”. 2. Open radiator drain valve (1), and drain coolant. If the coolant contains antifreeze, dispose of it properly. Coolant:
88 23.23 gal.
3. Disconnect aeration hose (2) and return hose (3). 4. Disconnect make-up line (4). 5. Remove fan guard (5). 6. Disconnect radiator outlet hose (6). 7. Disconnect torque converter cooler outlet and inlet hoses (7). 8. Disconnect hydraulic cooler outlet and inlet hoses (8).
9. Remove cover (9) at front bottom of radiator. 10. Loosen radiator mounting bolts (10).
30-30
RADIATOR ASSEMBLY
DISASSEMBLY AND ASSEMBLY
RADIATOR ASSEMBLY
11. Sling radiator assembly (11) and remove mounting bolt (10). Disconnect supports from radiator, loosen supports at frame, and rotate out of way.
12. Lift off radiator assembly. Sling the radiator assembly, and lift off while moving radiator to the rear. Be careful, and make sure the cooling fan does not interfere with the radiator core. Radiator assembly: 330 kg (728 lb.)
INSTALLATION OF Carry out installation in the reverse order to removal. Install so that the clearances between the fan and fan guard at the left and right, and the top and bottom are the same. Add coolant through the radiator filler neck to the specified level. Coolant:
88 23.23 gal.
Add transmission oil through the oil filler to the specified level. Run the engine to circulate the oil and coolant through the system. Recheck oil and coolant levels again.
30-31
DISASSEMBLY AND ASSEMBLY
DAMPER ASSEMBLY
DAMPER ASSEMBLY REMOVAL OF WARNING! 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. Remove engine hood assembly. For details, see REMOVAL OF ENGINE HOOD. 2. Remove bulkhead assembly. For details, see REMOVAL OF BULKHEAD. 3. Disconnect switch pump suction tube (1) and outlet hose (2), then remove switch pump + PPC pump (3). 4. Disconnect hydraulic pump suction tube (4) and outlet tube (5), then remove hydraulic pump (6). 5. Disconnect steering pump outlet hose (7), remove tube (8) at pump end. 6. Disconnect damper lubrication tubes (9) and (10). 7. Disconnect drive shaft (11). (Refer to note “A”). 8. Pull out flange (12). 9. Remove mounting bolt (13). Remove the mounting bolt, insert a guide bolt, then sling the cover and push the cover out with forcing screws. 10. Lift off cover assembly (14). Cover:
32 kg (71 lb)
11. Sling damper assembly (15), then remove mounting bolt (16) and insert guide bolt. Pull out the damper assembly using forcing screws. Damper assembly:
60 kg (132 lb)
INSTALLATION OF Carry out installation in the reverse order to removal. Note A: Mounting bolts:
DISASSEMBLY OF 1. Cover assembly.
30-32
110.7 ± 12.7 Nm (11.3 ± 1.3 kgm) (81.5 ± 9 lbf.ft)
1) Remove elbows (1) and (2).
DISASSEMBLY AND ASSEMBLY
DAMPER ASSEMBLY
2) Remove mounting bolts, then using forcing screws, remove cover (3). Tighten the two forcing screws uniformly.
3) Remove oil seal (4) and o-ring (5) from cover (3).
4) Turn over cover (6), then pull out shaft (7). Cover: 29 kg (64 lb)
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DISASSEMBLY AND ASSEMBLY 5) Remove snap rings (8) and bearing (9) from shaft (7).
6) Remove snap rings (10). (11), and oil seal (12) from cover (6).
2. Damper. 1) Remove spacer (14).
2) Using forcing screws, remove flange (13). Tighten the two forcing screws evenly.
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DAMPER ASSEMBLY
DISASSEMBLY AND ASSEMBLY
DAMPER ASSEMBLY
3) Remove inner body (15) and rubber (16).
4) Remove snap ring (17) and oil seal (18) from the inner body.
5) Remove flange (20) from outer body (19). Screw in the mounting bolts, then tap with a hammer to remove.
30-35
DISASSEMBLY AND ASSEMBLY ASSEMBLY OF 1. Damper assembly. 1) Install flange (20) at bottom of outer body (19). Contact surface of flange and outer body: Gasket sealant (LG-4).
2) Press fit oil seal (18) in the inner body (15), then assemble snap ring (17). Fit the snap ring securely in the groove. Set the oil seal with the sleeve on the snap ring side, and fit it close in contact with the snap ring. Inside surface portion (hatched portion) of inner body (15): Lithium base molybdenum disulphide extreme pressure grease. Fill the circumference uniformly with grease.
Lip of oil seal: Lithium base molybdenum disulphide extreme pressure grease. Brand of Lithium base molybdenum disulphide extreme pressure grease. Kyoto Oil Malleolus No.2 or equivalent. Show Shell Sunlight TB-2 or equivalent. Nippon Sekiyu Molytex No.2 or equivalent.
3) Assemble inner body (15) in outer body (19), then assemble rubber (16). Whole surface of rubber: Grease (G2-LI)
Outer surface of inner body: Grease (G2-LI) Inner surface of outer body: Grease (G2-LI) Between inner body and rubber: Grease (G2-LI)
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DAMPER ASSEMBLY
DISASSEMBLY AND ASSEMBLY
DAMPER ASSEMBLY
Fill clearance "b" at four places evenly with 270g of grease.
4) Install flange (13), and tighten mounting bolts. Contact surface of flange and outer body: Gasket sealant (LG-4). Mounting bolts: 66.6 ±6.9 Nm (6.8 ±0.7 kgm) (49 ±5 lbf.ft.)
2. Cover assembly. 1) Fit snap ring (11), then fit snap ring (10) after press fitting the oil seal (12) in cover (6). Press fit the oil seal with the lip face on the bearing side. 2) Assem ble snap rings (8) and bearing (9) to shaft (7). Bearing portion "C" (hatched portion): Lithium base molybdenum disulphide extreme pressure grease.
Do not leave any space when filling with grease. Brand of Lithium base molybdenum disulphide extreme pressure grease. Kyoto Oil Malleolus No.2 or equivalent. Show Shell Sunlight TB-2 or equivalent. Nippon Sekiyu Molytex No.2 or equivalent.
30-37
DISASSEMBLY AND ASSEMBLY 3) Press fit shaft (7) into cover (6).
4) Press fit oil seal (4) into cover (3), and install oring (5). Oil seal portion "d" (hatched portion): Lithium base molybdenum disulphide extreme pressure grease. Brand of Lithium base molybdenum disulphide extreme pressure grease. Kyoto Oil Malleolus No.2 or equivalent. Show Shell Sunlight TB-2 or equivalent. Nippon Sekiyu Molytex No.2 or equivalent.
30-38
DAMPER ASSEMBLY
DISASSEMBLY AND ASSEMBLY
DAMPER ASSEMBLY
5) Set cover (3) on mounting position, and tighten the mounting bolts.
6) Install elbows (1) and (2). Elbow (1) and (2): Thread tightener (LT-2). Elbow (1): 3.9 ±1.0 Nm (0.4 ±0.1 kgm) (3.0 ±0.7 lbf.ft)
Be careful of the direction of elbow (2).
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DISASSEMBLY AND ASSEMBLY 3. Greasing. 1) Assemble damper to the engine, and connect the grease hose, then fill the inside of the damper with grease (310g) from portion "e". Damper portion "e" (hatched portion): Lithium base molybdenum disulphide extreme pressure grease.
Brand of Lithium base molybdenum disulphide extreme pressure grease. Kyodo Oil Molylex No.2 or equivalent. Showa Shell Sunlight TB-2 or equivalent. Nippon Sekiyu Molytex No.2 or equivalent.
30-40
DAMPER ASSEMBLY
DISASSEMBLY AND ASSEMBLY
TORQUE CONVERTER TRANSMISSION
TORQUE CONVERTER, TRANSMISSION
AND
REMOVAL OF WARNING! 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. Loosen the oil cap slowly to release the pressure inside the hydraulic tank. Then operate the control levers several times to release the remaining pressure in the hydraulic piping. 1. Drain oil. Hydraulic oil:
120 31.7 gal.
Transmission:
62 16.4 gal.
2. Remove bulkhead assembly. For details, see REMOVAL OF BULKHEAD ASSEMBLY. 3. Remove floor frame assembly. For details, see REMOVAL OF FLOOR FRAME ASSEMBLY. 4. Remove drive shaft between switch + PPC pump, loader pump, and engine - torque converter. For details, see REMOVAL OF HYDRAULIC PUMP ASSEMBLY 5. Disconnect drive shaft (1) between transmission and rear differential at the transmission end. (Refer to note “A”). 6. Disconnect drive shaft (2) between transmission and center support at the differential end. (Refer to note “A”).
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DISASSEMBLY AND ASSEMBLY 7. Disconnect hose (3) from oil cooler on left side of transmission and hose (4) leading to transmission valve. 8. Disconnect transmission oil outlet tube (5)
9. Disconnect hoses (6) and (7) leading to steering valve at right side of transmission. 10. Disconnect hose (8) to loader control valve.
11. Disconnect hydraulic tank outlet hose (9). 12. Remove clamps (10) and (11), then remove tube (12).
13. Disconnect hoses (13) and (14) leading to emergency brake valve from transmission control valve. 14. Disconnect grease supply hose (15) at bottom of transmission support.
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TORQUE CONVERTER, TRANSMISSION
DISASSEMBLY AND ASSEMBLY
TORQUE CONVERTER, TRANSMISSION
15. Disconnect connectors (16), (17), and (18) at bottom left of floor frame. (LR1 - 6 and TM1, 2). 16. Disconnect (19) at left side of center of machine. (FR1, 2).
17. Remove filler tube (20).
18. Remove two mount bolts (21) at torque converter end. (Refer to note “B”). 19. Disconnect parking brake hose (22) at bottom left of transfer. 20. Remove four mount bolts (23) at transfer end. (Refer to note “B”). 21. Raise transmission assembly (24) and remove cushion.
22. Remove mounting bolts (26), then remove bracket (27). (Refer to note “C”). Remove the bracket and move the transmission assembly to the left while slowly raising the assembly.
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DISASSEMBLY AND ASSEMBLY INSTALLATION OF Carry out installation in the reverse order to removal. Adjust the mount at the transfer end as shown i n the diagram to the right. Note “A”: Drive shaft: 110.7 ±12.7 Nm (11.3 ±1.3 kgm) (81.0 ±9.0 lbf.ft) Note “B”: Mount bolt: 744.8 ±83.3 Nm (76.0 ±8.5 kgm) (549.0 ±61.0 lbf.ft)
Note “A”: Bracket mounting bolts: 274.4 ±29.4 Nm (28.0 ±3.0 kgm) (202.0 ±22.0 lbf.ft) Refilling hydraulic tank and transmission case with oil. Add oil through oil filler to the specified level. Run the engine to circulate the oil through the system. Then check the oil level again.
30-44
TORQUE CONVERTER, TRANSMISSION
DISASSEMBLY AND ASSEMBLY
TORQUE CONVERTER, TRANSMISSION
DISCONNECTION OF 1. Remove torque converter and transmission assembly. For details, see REMOVAL OF TORQUE CONVERTER, TRANSMISSION ASSEMBLY. 2. Disconnect suction tube (1). 3. Remove flange (2). 4. Remove tube (3) between torque converter and transfer.
5. Remove support (4). 6. Disconnect connector (5). 7. Remove mounting bolts (6), then lift off torque converter assembly (7). Using a lever block set, set with the torque converter end at the top. After setting the assembly in position, check that it is stable, before removal of the lifting tool.
CONNECTION OF Carry out connection in the reverse order to disconnection. Note “A”: Input shaft seal ring:
G2-LI
Make the protrusion from the shaft equal. Be careful when pushing in. If the assembly is pushed in by force, the seal ring (8) may be damaged. Torque converter mounting bolts: 110.7 ±12.7 Nm (11.3 ±1.3 kgm) (81.0 ±9.0 lbf.ft)
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DISASSEMBLY AND ASSEMBLY
TORQUE CONVERTER ASSEMBLY DISASSEMBLY OF 1. Disconnect torque converter and PTO assembly from transmission assembly. For details, see DISCONNECTION OF TORQUE CONVERTER, TRANSMISSION ASSEMBLY.
2. PTO assembly 1) Set tool C to torque converter and PTO assembly (1). 2) Remove holder (2) and coupling (3).
3) Using eye bolts “a”, sling PTO assembly. 4) Using forcing screw “b”, lift off PTO assembly (4).
5) Disassemble PTO assembly as follows. I) Remove retainer (5). ii) Remove oil seal (6) from retainer (5). iii) Remove bearing (7).
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TORQUE CONVERTER ASSEMBLY
DISASSEMBLY AND ASSEMBLY
TORQUE CONVERTER ASSEMBLY
iv) Using tool B2, remove nut (8). v) Using puller “d”, push out gear (9). At this point, put in contact with the bearing outer race and push the gear out. Do not remove the gear.
vi) Remove bearing (10a). vii) Using snap ring pliers, remove snap ring (11) viii) Remove spacer (12).
ix) Using gear puller “e”, pull out outer races (13a) and (13b) approx. 10 mm. x) Remove gear (9), then remove outer races (13a) and (13b) and spacer (14). xi) Remove spacer (40) and bearing (10b) from gear (9).
3. Turbine case assembly 1) Leave two pump mounting bolts (15) on diagonally opposite sides and remove other mounting bolts. 2) Set with case at top and remove remaining two mounting bolts. 3) Using eye bolt “c” , remove turbine and case assembly (16).
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DISASSEMBLY AND ASSEMBLY 4) Disassemble turbine and case assembly as follows. I) Remove shaft (17) and gear (18). ii) Using snap ring pliers, remove snap ring (19). iii) Remove spacer (20).
iv) lnsert two round bars “f” from l hole and remove turbine assembly (21). Push the inner race of the bearing with a forcing screw.
v)
Using snap ring pliers, remove snap ring (23) from case (22). vi) Using push tool “g”, remove bearing (24).
4. Stator 1) Remove snap ring (25). 2) Remove stator (26).
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TORQUE CONVERTER ASSEMBLY
DISASSEMBLY AND ASSEMBLY
TORQUE CONVERTER ASSEMBLY
5. Stator shaft, pump assembly. 1) Remove 10 mounting bolts (27). 2) Remove stator shaft and pump assembly (28) from housing (29).
3) Disassemble stator shaft and pump assembly as follows. I) Remove two plugs (31) of stator shaft (30).
ii)
Using round bar (h), knock out bearing inner race from hole where plug has been removed, then remove pump assembl y (32).
iii) Remove bolts, then remove retainer (33), pump (34), and guide (35). iv) Remove bearing (36) from guide (35).
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DISASSEMBLY AND ASSEMBLY ASSEMBLY OF 1. Stator shaft, pump assembly. 1) Assemble stator shaft and pump assembly as follows: I) Using push tool (j), press fit bearing (36) (outside diameter: 120 mm) to guide (35). After press fitting the bearing, apply drops (6 cc) of engine oil (EO10-CD or EO30-CD) and rotate 10 times.
ii)
Align with oil groove and install guide (35) and retainer (33) to pump (34). Mounting bolt:
Thread tightener (LT-2)
Mounting bolt:
59 - 74 Nm (6 - 7.5 kgm) (43.5 - 54.6 lbf.ft)
iii) Install seal ring (39) to stator shaft (30). Apply grease to the seal ring and make the protrusion from the shaft uniform.
iv) Using push tool (k), press fit pump assembly (32) to stator shaft (30).
30-50
TORQUE CONVERTER ASSEMBLY
DISASSEMBLY AND ASSEMBLY v)
TORQUE CONVERTER ASSEMBLY
Install two plugs (31) to stator shaft (30). Do not coat the plugs with adhesive. Plug:
3 - 6 Nm (0.3 - 0.6 kgm) (2.2 - 4.4 lbf.ft)
2) Set housing (29) to tool C. 3) Install stator shaft and pump assembly (28). Mounting bolt:
Thread tightener (LT-2)
Mounting bolt:
59 - 74 Nm (6 - 7.5 kgm) (43.5 - 54.6 lbf.ft)
2. Stator. 1) Install stator (26). 2) Using snap ring pliers, install snap ring (25).
3. Turbine case assembly. 1) Assemble turbine case assembly as follows: i) Using push tool (g), press fit bearing (24) to case (22). ii) Using snap ring pliers, install snap ring (23).
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DISASSEMBLY AND ASSEMBLY iii) Using push tool (1), press fit turbine assembly (21) to case (22). Support the inner race of the case bearing and press fit the turbine assembly. After press fitting, apply drops (6 cc) of engine oil (EO10-CD or EO30-CD) and rotate 10 times.
iv) Install spacer (20). v) Using snap ring pliers, install snap ring (19). vi) Using push tool (m), press fit inner race (37) to shaft (17).
vii) Install gear (18) and shaft (17) to case (22).
30-52
Mounting bolt:
Thread tightener (LT-2)
Mounting bolt:
59 - 74 Nm (6 - 7.5 kgm) (43.5 - 54.6 lbf.ft)
TORQUE CONVERTER ASSEMBLY
DISASSEMBLY AND ASSEMBLY
TORQUE CONVERTER ASSEMBLY
2) Using eyebolt (c), install turbine and case assembly (16), then tighten 24 mounting bolts (15). Mounting bolt:
Thread tightener (LT-2)
Mounting bolt:
49 - 59 Nm (5 - 6 kgm) (36 - 43.5 lbf.ft)
4. PTO assembly. 1) Assemble PTO assembly as follows: i) Using push tool (n), press fit bearing (10b) (inside diameter: 50 mm) to gear (9).
ii)
Set gear (9) to each pump mount portion of housing (38). Gear (spline portion): Grease (G2-LI)
iii) Using push tool (p), press fit outer race (13b) (outside diameter: 90 mm). Be careful of the mounting direction.
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DISASSEMBLY AND ASSEMBLY iv) Install spacer (14).
v)
Using push tool (p), press fit outer race (13a) (outside diameter: 90 mm). Be careful of mounting direction.
vi) Fit spacer (40), the using puller (q), press fit bearing (10a) (inside diameter: 50 mm).
vii) Install spacer (12). viii) Using snap ring pliers, install snap ring (11).
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TORQUE CONVERTER ASSEMBLY
DISASSEMBLY AND ASSEMBLY
TORQUE CONVERTER ASSEMBLY
ix) Using tool B2, tighten mounting nut (8). Mounting nut:
Thread tightener (LT-2)
Mounting nut:
392 - 441 Nm (40 - 45 kgm) (289 - 325 lbf.ft)
After tightening the mounting nut, apply drops (6 cc) of engine oil (EO10-CD or EO30-CD) to bearings (10a) and (10b) and rotate 10 times. Then check the tightening torque of the mounting nut again. x)
Using push tool (r), press fit bearing (7) (outside diameter: 130 mm) to coupling mount portion of housing (38). After tightening the mounting nut, apply drops (6 cc) of engine oil (EO10-CD or EO30-CD) to bearings (7) and rotate 10 times.
xi) Using push tool, press fit oil seal (6) to retainer (5). Lip of oil seal:
Grease (G2-LI)
Coat the oil seal press-fitting surface of the retainer with gasket sealant (LG-5). When coating with gasket sealant, coat the hole in the housing thinly, and wipe off all gasket sealant that is squeezed out.
xii) Fit O-ring and install retainer (5). O-ring: Grease (G2-LI) 2) Fit O-ring, then using eyebolts (a), install PTO assembly (4). O-ring: Grease (G2-LI)
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DISASSEMBLY AND ASSEMBLY 3) Fit O-ring and install coupling (3) and holder (2). O-ring: Grease (G2-LI)
30-56
Mounting bolt:
Thread tightener (LT-2)
Mounting bolt:
157 - 196 Nm (16 - 20 kgm) (116 - 145 lbf.ft)
TORQUE CONVERTER ASSEMBLY
DISASSEMBLY AND ASSEMBLY
TORQUE CONVERTER ASSEMBLY - MEMORANDA -
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DISASSEMBLY AND ASSEMBLY
TRANSMISSION ASSEMBLY DISASSEMBLY OF 1. Torque converter and PTO assembly. Disconnect torque converter and PTO assembly. For details, see DISCONNECTION OF TORQUE CONVERTER, TRANSMISSION ASSEMBLY.
2. Cover. Remove cover (1) from top of transmission control valve. 3. Main relief valve. Remove main relief valve (3).
4. Transmission control valve. 1) Remove wiring harness (4). Disconnect the ECMV solenoid connector. For details, see REMOVAL OF TRANSMISSION CONTROL VALVE ASSEMBLY (ECMV ASSEMBLY). 2) Remove parking brake hose (5). 3) Lift off transmission control valve assembly (6). Remove the bolts at the positions marked by arrows in the diagram on the right.
5. Lubrication tube. Remove lubrication tube (7) from front of transfer. 6. Sleeves. Using eyebolt “a”, remove four sleeves (8) (length: 74mm) and 1 sleeve (9) (length: 79mm).
30-58
TRANSMISSION ASSEMBLY
DISASSEMBLY AND ASSEMBLY
TRANSMISSION ASSEMBLY
7. Transmission, transfer assembly. 1) Using eyebolts “b” and chain block, raise transmission and transfer assembly (10), then set on block “c” with transfer assembly at bottom.
2) Using eyebolts “d”, sling transmission assembly (11), then using forcing screw “e”, disconnect from transfer assembly.
8. Transmission assembly. 1) Remove 6 mounting bolts (12) from output shaft end of transmission case assembly (11).
2) Set transmission case assembly (11) on block “c”. 3) Remove 15 mounting bolts (13) from input shaft of transmission case assembly (11).
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DISASSEMBLY AND ASSEMBLY 4) Remove two tie bolts (14) shown in diagram on the right, and install eyebolts “f”. 5) Lift off transmission assembly (16) from transmission case (15), and set to “g”.
9. Checking actuation of clutch piston. 1) Install four sleeves (8) and 1 sleeve (9) to transmission assembly (16). 2) Using tool D1, check actuation of piston before disassembling. 3) After checking actuation of piston, remove four sleeves (8) and 1 sleeve (9).
10. Input shaft, No. 1 carrier, housing assembly. 1) Remove remaining 10 tie bolts (14). 2) Using eyebolts “h”, remove input shaft and No. 1 carrier and housing assembly (17), and put on block “c”.
3) Disassemble input shaft, No. 1 carrier and housing assembly (17) as follows: i) Using snap ring pliers, remove snap ring (19). ii) Remove No. 2 sun gear (20).
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TRANSMISSION ASSEMBLY
DISASSEMBLY AND ASSEMBLY
TRANSMISSION ASSEMBLY
iii) Support housing (21), then using push tool “i”, push input shaft (22) with press and remove. iv) Using snap ring pliers, remove snap ring (166) from input shaft (22). v) Remove seal ring (167).
vi) Using snap ring pliers, remove snap ring (25). Remove from the bearing inner race end.
vii) Support housing (21), then using push tool “j”, push No. 1 carrier assembly (26) with press and remove. viii) Remove spacer (27).
ix) Using snap ring pliers, remove snap ring (169). x) Remove bearing (170). xi) Remove seal ring (171).
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DISASSEMBLY AND ASSEMBLY 4) Disassemble No. 1 carrier assembly as follows: i) Remove snap ring (23). ii) Remove No. 1 ring gear (24). iii) Remove shaft (29) and ball (173) from No. 1 carrier. Be careful not to lose ball (173). iv) Remove two thrust washers (174), needle bearing (175), and planetary gear (176).
v)
Remove sun gear (30) and spacer (31).
vi) Using push tool “k”, remove spacer and bearing assembly (32). vii) Using snap ring pliers, remove snap ring (33) from spacer and bearing assembly (32). viii) Using push tool “l”, remove bearing (34).
ix) Using snap ring pliers, remove snap ring (36) from No. 1 carrier. x) Using push tool “m”, remove bearing (37).
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TRANSMISSION ASSEMBLY
DISASSEMBLY AND ASSEMBLY
TRANSMISSION ASSEMBLY
11. No 1 spring. Remove No. 1 spring (38).
12. No 1 plates, springs, No 1 discs. Remove four No. 1 plates (39), 20 springs (41), and four No. 1 discs (40).
13. Guide pins, plate. Remove five guide pins (42) and plate (43).
14. Valve, spring. Remove valve (44) and spring (45).
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DISASSEMBLY AND ASSEMBLY 15. No 1, No 2 piston, housing assembly. 1) Using eyebolts “n”, lift off No. 1 and No. 2 piston and housing assembly (46). Tap with a copper hammer to pull out the dowel pin, then remove. When raising the housing assembly, be careful not to drop the No. 2 piston. 2) Using eyebolt “o”, remove No. 1 piston (48) from No. 1 housing (47). 3) Turn over No. 1 housing, then remove No. 2 piston (52).
4) Remove seal ring (49) from No. 1 piston (48). 5) Remove seal ring (53) from No. 2 piston (52).
6) Remove seal rings (50) and (51) from No. 1 housing (47).
16. Plate. Remove plate (54). 17. No. 2 springs. Remove 10 No. 2 springs (164).
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TRANSMISSION ASSEMBLY
DISASSEMBLY AND ASSEMBLY
TRANSMISSION ASSEMBLY
18. No. 2 discs, springs, No. 2 plates. Remove four No. 2 discs (55), 20 springs (56), and four No. 2 plates (57).
19. Spacer. 1) Using snap ring pliers, remove snap ring (58). 2) Remove spacer (59).
20. No. 2 carrier, housing assembly. 1) Using eyebolts “p”, lift off No. 2 carrier and housing assembly (60). 2) Using snap ring pliers, remove snap ring (61) from bearing inner end.
3) Support No. 2 housing assembly (62), then using push tool “q”, push No. 2 carrier assembly (63) with press and remove. Push the No. 2 carrier.
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DISASSEMBLY AND ASSEMBLY 4) Disassemble No. 2 housing assembly (62) as follows: i) Using snap ring pliers, remove snap ring (64). ii) Support No. 2 housing (65), then using push tool “r”, push bearing (66) with press and remove.
iii) Remove seal ring (67) from No. 2 housing (65).
5) Disassemble No. 2 carrier assembly (63) as follows: i) Remove spacer (68). ii) Remove ring gear (69).
iii) Insert thin rods into four holes (70) for removing snap ring, then push snap ring (71), and remove No. 2 carrier assembly (163) from ring gear (72).
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TRANSMISSION ASSEMBLY
DISASSEMBLY AND ASSEMBLY
TRANSMISSION ASSEMBLY
iv) Remove shaft (73) and ball (74) from No. 2 carrier (163). Be careful not to lose ball (74). v) Remove two thrust washers (75), needle bearing (76), and planetary gear (77).
21. No. 3 springs. Remove 10 No. 3 springs (78). 22. No. 3 discs, springs, No. 3 plates. Remove three No. 3 discs (79), 20 springs (80), and two No. 3 plates (81).
23. No 3 piston. 1) Remove No. 3 piston (82). 2) Remove seal ring (158). 24. Guide pins. Remove five guide pins (162). 25. No. 3 ring gear. Remove No. 3 ring gear (83).
26. No. 3, No. 4 housing, No. 4 piston assembly. 1) Using eyebolts “s”, liftoff No. 3 and No. 4 housing and piston assembly (159). Tap with a copper hammer to pull out the dowel pin, then remove. 2) Turn over No. 3 and No. 4 housing (84), and remove No. 4 piston (86).
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DISASSEMBLY AND ASSEMBLY 3) Remove seal ring (87) from No. 4 piston (86). 4) Remove two seal rings (85) from No. 3 and No. 4 housing (84).
27. No. 4 springs. Remove 10 No. 4 springs (88). 28. No. 4 discs, springs, No. 4 plates. Remove three No. 4 discs (89), 15 springs (90), and two No. 4 plates (91).
29. No. 3, No. 4 carrier assembly. 1) Using bar “t”, push up No. 3 and No. 4 carrier assembly (92) and remove.
2) Disassemble No. 3 and No. 4 carrier assembly as follows: i) Using tool D2, pull out No. 3 shaft (93) and remove. Be careful not to lose ball (94). ii) Remove two thrust washers (95), needle bearing (96), and No. 3 planetary gear (97).
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TRANSMISSION ASSEMBLY
DISASSEMBLY AND ASSEMBLY
TRANSMISSION ASSEMBLY
iii) Using round bar, knock pin (98) into No. 4 shaft (99). iv) Using round bar “u”, knock out No. 4 shaft (99) from No. 3 carrier end and remove.
v)
Remove two thrust washers (100), needle bearing (101), and No. 4 planetary gear (102).
vi) Using push tool “v”, push bearing (103) with press and remove.
vii) Remove bushing (161). viii) Remove No. 3 and No. 4 seal ring (104).
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DISASSEMBLY AND ASSEMBLY 30. No. 4 sun gear. 1) Using snap ring pliers, remove snap ring (105). 2) Remove spacer (106) and No. 4 sun gear (107).
31. No. 4 ring gear. 1) Remove snap ring (108). 2) Remove No. 4 ring gear (109).
32. No. 5 housing, No. 5 piston assembly. 1) Using eyebolts “w”, lift off No. 5 housing and No. 5 piston assembly (110). When raising the housing, be careful not to drop the No. 5 piston. 2) Using eyebolt “o”, remove No. 5 piston (112) from No. 5 housing (181).
3) Remove seal ring (113) from No. 5 piston (112). 4) Remove seal ring (111) from No. 5 housing (110).
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TRANSMISSION ASSEMBLY
DISASSEMBLY AND ASSEMBLY
TRANSMISSION ASSEMBLY
33. No. 5 plate. Remove No. 5 plate (114). 34. No. 5 springs. Remove 10 No. 5 springs (115). 35. No. 5 discs, springs, No. 5 plate. Remove two No. 5 discs (116), 10 springs (117), and No. 5 plate (118).
36. Guide pins. Remove 5 guide pins (119). 37. No. 5 ring gear. Remove No. 5 ring gear (120). 38. No. 5 plate. Remove No. 5 plate (121).
39. No. 5 carrier assembly. 1) Remove nine mounting bolts (122). 2) Remove No. 5 carrier assembly (123). Tap with a copper hammer to pull out the dowel pin, then remove. 3) Remove spacer (124) from No. 5 carrier assembly (123).
4) Disassemble No. 5 carrier assembly (123) as follows. i) Using snap ring pliers, remove snap ring (182).
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DISASSEMBLY AND ASSEMBLY ii)
Remove shaft (125) and ball (126). Be careful not to Iose baII (126). iii) Remove two thrust washers (127), needle bearing (128), and planetary gear (129). 40. No. 5 sun gear. Remove No. 5 sun gear (130).
41. Spring, pin. Remove spring (131) and pin (132). 42. No. 6 discs, springs, No. 6 plates. Remove three No. 6 discs (133), 15 springs (134), and two No. 6 plates (135).
43. No. 6 piston. 1) Remove No. 6 piston (136). 2) Remove seal ring (156).
44. Guide pins. Remove five guide pins (153). 45. Seal ring. Remove seal ring (154) from housing (149).
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TRANSMISSION ASSEMBLY
DISASSEMBLY AND ASSEMBLY
TRANSMISSION ASSEMBLY
46. No 6 hub. Remove No. 6 hub (137).
47. Output shaft. 1) Support cage, then push output shaft (139) with press and remove. 2) Remove two seal rings (140) from output shaft (139).
48. Cage assembly. 1) Using snap ring pliers, remove snap ring (142). 2) Support No. 6 housing assembly (143), then using push tool “x”, push cage assembly (144) with press and remove.
3) Using push tool “nn”, push bearing (145) with press and remove from cage (146). 4) Remove two seal rings (147).
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DISASSEMBLY AND ASSEMBLY 49. No. 6 housing assembly. 1) Using snap ring pliers, remove snap ring (148).
2) Using push tool “y”, remove bearing (150), bushing (151), and ball (152) from housing (149). Be careful not to lose ball (152).
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TRANSMISSION ASSEMBLY
DISASSEMBLY AND ASSEMBLY
TRANSMISSION ASSEMBLY
TRANSMISSION ASSEMBLY ASSEMBLY OF 1. No. 6 housing assembly. 1) Using push tool “z”, press fit bearing (150) to No. 6 housing (149). 2) Using push tool “aa”, press fit bushing (151) and ball (152) to No. 6 housing (149).
3) Using snap ring pliers, install snap ring (148). 2. Cage assembly. 1) Install two seal rings (147) to cage (146). Seal ring:
Grease (G2-LI)
2) Using push tool “bb”, No. 6 housing assembly (143) to cage assembly (144) with press. Push the inner race of bearing (150).
3) Using snap ring pliers, install snap ring (142). 3. Output shaft. 1) Install two seal rings (140) to output shaft (139). Seal ring:
Grease (G2-LI)
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DISASSEMBLY AND ASSEMBLY 2) Using push tool “cc”, press fit bearing (145) to output shaft (139) with press. 3) Set No. 6 housing assembly (143) to “g”. 4) Using push tool “dd”, press fit output shaft and bearing assembly (155). Push bearing (145) of the output shaft.
4. Seal ring. Install seal ring (154) to No. 6 housing (149). Set the groove of the seal ring facing the direction receiving the pressure. Seal ring:
Grease (G2-LI)
5. Guide pin. Install guide pin (153).
6. No. 6 piston. 1) Install seal ring (156) to No. 6 piston (136). Set the groove of the seal ring facing the direction receiving the pressure. Seal ring:
Grease (G2-LI)
7. No. 6 gear. 1) Install No. 6 gear (137).
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TRANSMISSION ASSEMBLY
DISASSEMBLY AND ASSEMBLY
TRANSMISSION ASSEMBLY
2) Install No. 6 piston (136).
8. No. 6 plates, springs, No. 6 discs. Install two No. 6 plates (135), 15 springs (134), and three No. 6 discs (133). 9. Pin, spring. Install pin (132) and spring (131).
10. No. 5 sun gear. Install No. 5 sun gear (130). 11. No. 5 carrier assembly. 1) Assemble No. 5 carrier assembly as follows: i) Assemble needle bearing (128) to planetary gear (129), put washers (127) to both ends, then set to No. 5 carrier. Align the center of each part with the shaft hole. ii) Install shaft (125) and ball (126). Check that the gear rotates smoothly.
2) Using snap ring pliers, install snap ring (182).
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DISASSEMBLY AND ASSEMBLY 3) Align position of dowel pin and install No. 5 carrier assembly (123). Tap with a copper hammer to knock in the dowel pin. 4) Install 9 mounting bolts (122). Mounting bolt:
Thread tightener (LT-2)
Mounting bolt:
157 - 177 Nm (16 - 18 kgm) (116 - 131 lbf)
5) Assemble spacer (124). 12. No. 5 housing assembly. 1) Assemble No. 5 housing assembly as follows: i) Install No. 5 ring gear (120) to No. 5 plate (121). ii) lnstall guide pins (119). iii) Install two No. 5 discs (116), 10 springs (117), and No. 5 plate (118). iv) Install 10 No. 5 springs (115). v) Install No. 5 plate (114). vi) Install seal ring (113) to No. 5 piston (112). Set the groove of the seal ring facing the direction receiving the pressure. Seal ring:
Grease (G2-LI)
vii) Install seal ring (111) to No. 5 housing (181). Set the groove of the seal ring facing the direction receiving the pressure. Seal ring:
Grease (G2-LI)
viii) Install No. 5 piston (112) to No. 5 housing.
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TRANSMISSION ASSEMBLY
DISASSEMBLY AND ASSEMBLY
TRANSMISSION ASSEMBLY
ix) Align position of dowel pin and install No. 5 housing and No. 5 piston assembly (110). Be careful not to drop the No. 5 piston. Tap with a copper hammer to knock in the dowel pin.
2) Fit clamps “ee” to No. 5 housing assembly (157) to hold in position. 3) Using eyebolts “w”, install No. 5 housing assembly (157).
13. No. 4 ring gear. 1) Install No. 4 ring gear (109). 2) Install snap ring (108).
14. No. 4 discs, springs, No. 4 plates. Install three No. 4 discs (89), 15 springs (90), and two No. 4 plates (91). 15. Springs. Install 10 springs (88).
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DISASSEMBLY AND ASSEMBLY 16. No. 4 piston. Install seal ring (87) to No. 4 piston (86). Set the groove of the seal ring facing the direction receiving the pressure. Seal ring:
Grease (G2-LI)
17. No. 3 piston. Install seal ring (158) to No. 3 piston (82). Set the groove of the seal ring facing the direction receiving the pressure. Seal ring:
Grease (G2-LI)
18. No. 3, No. 4 housing. 1) Install two seal rings (85) to No. 3 and No. 4 housing (84). Set the groove of the seal ring facing the direction receiving the pressure. Seal ring:
Grease (G2-LI)
2) Install No. 3 piston (82) and No. 4 piston (86) to No. 3 and No. 4 housing (84). 3) Using eyebolts “s”, lift off No. 3 and No. 4 housing assembly (159). When raising the housing, be careful not to drop the No. 4 piston. Tap with a copper hammer to knock in the dowel pin. 19. No. 4 sun gear, spacer. 1) Install No. 4 sun gear (107) and spacer (106). 2) Using snap ring pliers, install snap ring (105).
20. No. 3, No. 4 carrier assembly. 1) Assemble No. 3 and No. 4 carrier assembly as follows: i) Install seal ring (104) to No. 3 and No. 4 carrier (160). Seal ring:
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Grease (G2-LI)
TRANSMISSION ASSEMBLY
DISASSEMBLY AND ASSEMBLY ii)
TRANSMISSION ASSEMBLY
Using tool D3, press fit bushing (161) to No. 3 and No. 4 carrier (160).
iii) Using push tool “ee”, press fit bearing (103) to No. 3 and No. 4 carrier (160).
iv) Assemble needle bearing (101) to No. 4 planetary gear (102), put thrust washers (100) to both ends, then set to No. 4 carrier. Align the center of each part with the shaft hole. v) Align roll pin hole and install No. 4 shaft (99). The deviation between the position of the No. 4 shaft and carrier roll pin hole must be less than 0.2 mm. vi) Install roll pin (98). Install so that the side of the roll pin with the slit is facing the planetary gear. vii) Assemble needle bearing (96) to No. 3 planetary gear (97), and put thrust washers (95) to both ends, then set to No. 4 carrier. viii) Install No. 3 shaft (93) and ball (94). Check that the gear rotates smoothly.
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DISASSEMBLY AND ASSEMBLY 2) Install No. 3 and No. 4 carrier assembly (92). Put plate “ff” to No. 3 and No. 4 carrier assembly (92), then press fit the bearing inner race portion to the output shaft.
21. No. 3 ring gear. Install No. 3 ring gear (83). 22. Guide pins. Install guide pins (162).
23. No. 3 discs, springs, No. 3 plates. Install three No. 3 discs (79), 20 springs (80), and two No. 3 plates (81). 24. No. 3 springs. Install 10 No. 3 springs (78).
25. No. 2 carrier, housing assembly. 1) Assemble No. 2 carrier assembly as follows: i) Set snap ring to No. 2 carrier (163) and install ring gear (72). ii) Set snap ring (71) in groove of ring gear (72).
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TRANSMISSION ASSEMBLY
DISASSEMBLY AND ASSEMBLY
TRANSMISSION ASSEMBLY
iii) Assemble needle bearing (76) to planetary gear (77), put thrust washers (75) to both ends, then set to No. 2 carrier. Align the center of each part with the shaft hole. iv) Install shaft (73) and ball (74). Check that the gear rotates smoothly.
v)
Install spacer (68) and ring gear (69) to No. 2 carrier assembly.
2) Assemble No. 2 housing assembly as follows: i) Install seal ring (67) to No. 2 housing (65). Seal ring:
Grease (G2-LI)
ii)
Support No. 2 housing (65), then using push tool “gg”, press fit bearing (66) with press. iii) Using snap ring pliers, install snap ring (64).
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DISASSEMBLY AND ASSEMBLY 3) Support No. 2 carrier assembly (63), then using push tool “hh”, press fit No. 2 housing assembly (62) with press. Press fit the bearing inner race.
4) Using snap ring pliers, install snap ring (61). 5) Using eyebolts “p”, lift off No. 2 carrier and housing assembly (60).
26. Spacer. 1) Install spacer (59). 2) Using snap ring pliers, install snap ring (58).
27. No. 2 plates, springs, No. 2 discs. Install four No. 2 plates (57), 20 springs (56), and four No. 2 discs (55).
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TRANSMISSION ASSEMBLY
DISASSEMBLY AND ASSEMBLY
TRANSMISSION ASSEMBLY
Assemble discs (55), springs (56), and plates (57) in the order shown in the diagram.
28. No. 2 springs. Install 10 No. 2 springs (164). 29. Plate. Install plate (54).
30. No. 1 piston, housing assembly. 1) Install seal ring (49) to No. 1 piston (48). Set the groove of the seal ring facing the direction receiving the pressure. Seal ring:
Grease (G2-LI)
2) Install seal ring (53) to No. 2 piston (52). Set the groove of the seal ring facing the direction receiving the pressure. Seal ring:
Grease (G2-LI)
3) Install seal rings (50) and (51) to No. 1 housing (47). Set the groove of the seal ring facing the direction receiving the pressure. Seal ring:
Grease (G2-LI)
4) Install No. 1 piston (48) and No. 2 piston (52) to No. 1 housing (47).
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DISASSEMBLY AND ASSEMBLY 5) Using eyebolts “n”, lift off No. 1 piston and housing assembly (46). When raising the housing assembly, be careful not to drop the No. 2 piston. Tap with a copper hammer to knock in the dowel pin.
31. Spring, valve. Install spring (45) and valve (44).
32. No. 1 carrier assembly. 1) Using push tool “ii”, press fit bearing (37) to No. 1 carrier (165). 2) Using snap ring pliers, install snap ring (36).
3) Assemble needle bearing (175) to planetary gear (176), put thrust washers (174) to both ends, then set to No. 1 carrier. Align the center of each part with the shaft hole. 4) Install shaft (29) and ball (173). Check that the gear rotates smoothly. 5) Set No. 1 ring gear (24) to No. 1 carrier assembly. 6) Using snap ring pliers, install snap ring (23).
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TRANSMISSION ASSEMBLY
DISASSEMBLY AND ASSEMBLY
TRANSMISSION ASSEMBLY
33. Input shaft. 1) Install seal ring (167) to input shaft (22). Seal ring:
Grease (G2-LI)
2) Using snap ring pliers, install snap ring (166). 3) Support No. 1 carrier assembly (26), then using push tool “i”, press fit input shaft (22) with press. Press fit until snap ring (166) of the input shaft contacts the bearing.
34. Spacer, sun gear. Install spacer (31) and sun gear (30). 35. Bearing, spacer. 1) Using push tool “jj”, press fit bearing (34) to spacer (136).
2) Using push tool “kk”, press fit spacer and bearing assembly (32). After assembling, check that the bearing rotates easily. 3) Using snap ring pliers, install snap ring (33).
36. No. 2 sun gear. 1) Install No. 2 sun gear (20). 2) Using snap ring pliers, install snap ring (19). 37. Input shaft, No. 1 carrier assembly. Raise input shaft and No. 1 carrier assembly (1 68) and install.
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DISASSEMBLY AND ASSEMBLY 38. Guide pins. Install five guide pins (42). 39. Plate. Install plate (43).
40. No. 1 plates, springs, No. 1 discs. Install four No. 1 plates (39), 20 springs (41), and four No. 1 discs (40).
Assemble in the order shown in the diagram.
41. No. 1 springs. Install 10 No. 1 springs (38).
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TRANSMISSION ASSEMBLY
DISASSEMBLY AND ASSEMBLY
TRANSMISSION ASSEMBLY
42. Housing. 1) Install seal ring (171) to housing (21). Seal ring:
Grease (G2-LI)
2) 3) 4) 5)
Using push tool “al”, press fit bearing (170). Using snap ring pliers, install snap ring (169). Install spacer (27) to No. 1 carrier assembly. Install housing (21). Fit eyebolt “an” to the input shaft, then fit the wire, apply slight tension to the wire, and press fit the housing. 6) Using snap ring pliers, install snap ring (25). 7) Install 10 tie bolts (14). Tie bolt:
157 - 177 Nm (16 - 18 kgm) (116 - 131 lbf)
Do not install the two tie bolts at the position where the eyebolts are installed. 43. Checking actuating condition and travel of piston. 1) Install four sleeves (8) and 1 sleeve (9) to transmission assembly (16). 2) Using tool D1, check actuating condition and travel of piston. Air pressure: 0.29 - 0.49 MPa (3 - 5 kg/cm) (42 - 71 psi) (mm) Piston
Travel
No. 1
4
No. 2
5.5
No. 3
3.5
No. 4
4.5
No. 5
3
No. 6
4.2
3) Remove four sleeves (8) and 1 sleeve (9) from transmission assembly (16).
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DISASSEMBLY AND ASSEMBLY 44. Transmission assembly. 1) Install dowel pin (171) from output shaft end. 2) Install eyebolts “f”at positions shown by arrows in diagram on right. 3) Put transmission case (15) on block “c”. 4) Raise transmission assembly (16) and install to transmission case (15). Align the position of the mounting bolt hole on the top of the transmission. Check that dowel pin (171) has entered the transmission case. 5) Remove eyebolts “f”, and install remaining two tie bolts (14). Tie bolt:
157 - 177 Nm (16 - 18 kgm) (116 - 131 lbf)
6) Install six mounting bolts (12) to output shaft end. 7) Install 15 mounting bolts (13) to input shaft end. Mounting bolt:
Thread tightener (LT-2)
Mounting bolt:
98 - 123 Nm (10 - 12.5 kgm) (72 - 91 lbf)
45. Transmission case assembly. 1) Set transfer assembly (172) to block “c”. 2) Fit O-ring, then using eyebolts “d”, raise transmission case (11) and install. Mounting bolt:
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98 - 123 Nm (10 - 12.5 kgm) (72 - 91 lbf)
TRANSMISSION ASSEMBLY
DISASSEMBLY AND ASSEMBLY
TRANSMISSION ASSEMBLY
46. Sleeves. Fit O-ring and install four sleeves (8) (length: 74mm) and 1 sleeve (9) (length: 79mm). O-ring: Grease (G2-LI) 47. Lubrication tube. Install lubrication tube (7) to transfer.
48. Transmission control valve. 1) Fit O-ring to transmission case and valve seat, then raise transmission control valve assembly (6) and install. Tighten the mounting bolts in the positions shown in the diagram on the right. Check that there is an O-ring fitted to the rear of the transmission case. 2) Install parking brake hose (5). 3) Install wiring harness (4). Install the ECMV solenoid connector. For details, see INSTALLATION OF TRANSMISSION CONTROL VALVE (ECMV ASSEMBLY). 49. Main relief valve. Fit O-ring and install main relief valve (3). Mounting bolt:
44 - 54 Nm (4.5 - 5.5 kgm) (33 - 40 lbf)
50. Cover. Install cover (1) to top of transmission control valve. 51. Torque converter, PTO assembly. Connect torque converter and PTO assembly to transmission assembly. For details, see CONNECTION OF TORQUE CONVERTER AND TRANSMISSION ASSEMBLY.
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DISASSEMBLY AND ASSEMBLY
TRANSFER ASSEMBLY DISASSEMBLY OF 1. Transmission. Remove transmission assembly from transfer. For details, see DISASSEMBLY OF TRANSMISSION ASSEMBLY. 2. Parking brake assembly. Remove parking brake assembly. For details, see DISASSEMBLY OF PARKING BRAKE ASSEMBLY. 3. Input shaft cage assembly. 1) Using forcing screws “a”, remove input shaft cage assembly (1). 2) Remove shims (2). Check the number and thickness of the shims at each mounting position, and keep in a safe place.
4. Input shaft gear assembly. 1) Remove input shaft gear assembly (3). 2) Remove bearings (4) and (5) from input shaft gear assembly (6).
5. Outer race. 1) Using push tool “b”, remove outer race (7) from input shaft cage (34). 2) Remove outer race (35).
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TRANSFER ASSEMBLY
DISASSEMBLY AND ASSEMBLY
TRANSFER ASSEMBLY
6. Strainer. 1) Remove cover (8).
2) Remove spring (9). 3) Remove strainer (10).
7. Intermediate shaft cage assembly. 1) Turn over transfer. 2) Using forcing screws “c”, remove intermediate cage assembly (11) and shims (12). Check the number and thickness of the shims at each mounting position, and keep in a safe place.
8. Intermediate shaft gear assembly. 1) Remove intermediate shaft gear assembly (14). 2) Remove two bearings (16) from intermediate shaft gear (15).
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DISASSEMBLY AND ASSEMBLY 9. Outer race. 1) Remove outer race (13) from intermediate cage (32). 2) Remove outer race (17) from transfer case.
10. Coupling. Remove holder (18) and coupling (19).
11. Cover. 1) Using forcing screws “c”, remove cove r assembly (22) and shims (23). 2) Remove dust seal (25) and oil seal (26) from cover(35).
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TRANSFER ASSEMBLY
DISASSEMBLY AND ASSEMBLY
TRANSFER ASSEMBLY
12. Output shaft. Using tool D4, remove output shaft (20) and spacer (21).
13. Cage. 1) Using forcing screws “d”, remove cage and bearing assembly (27). 2) Using push tool “e”, remove outer races (28a) and (28b), collar (28c), and bearings (28d) and (28e) from cage (29). The two bearings are not interchangeable, so keep them as separate sets.
14. Spacer. Remove spacer (30). 15. Output shaft gear. Remove output shaft gear (31).
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DISASSEMBLY AND ASSEMBLY
TRANSFER ASSEMBLY ASSEMBLY OF 1. Outer race. Using push tool “f”, press fit outer race (17) to transfer case.
2. Intermediate shaft gear assembly. 1) Using push tool “g”, press fit two bearings (16) to intermediate shaft gear. 2) Install intermediate gear assembly (14).
3. Intermediate shaft cage assembly. 1) Using push tool “h”, press fit outer race (13) to intermediate shaft cage (32).
2) Fit O-ring and install shims (12) and intermediate shaft cage assembly (11). Standard shim thickness: 2 mm O-ring: Grease (G2-LI)
4. Adjusting preload of intermediate shaft bearing. 1) Remove cover (33).
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TRANSFER ASSEMBLY
DISASSEMBLY AND ASSEMBLY
TRANSFER ASSEMBLY
2) Using tool D6 and torque wrench, measure preload of intermediate shaft. 3) Adjust shims as follows: i) Adjust with shims (12) so that preload is 0.29 - 0.54 Nm (0.03 - 0.055 kgm). ii) After adjusting, add a further 0.1 mm o f shim. There are four types of shim thickness: t=0.15, t=0.2, t=0.3, and t=1.0 Check that there is no play in the gear. If there is any play, adjust the shims again. 4) After adjusting preload, remove intermediate shaft cage assembly (11), shims (12), and intermediate shaft gear assembly (14).
5. Outer race. 1) Using push tool “i”, press fit outer race (35) to transfer case. 2) Using push tool “i”, press fit outer race (7) to input shaft cage (34). 6. Input shaft gear assembly. 1) Using push tool “j”, install bearings (4) and (5) to input shaft gear (6). 2) Install input shaft gear assembly (3).
7. Input shaft cage assembly. Install shims (2) and input shaft cage assembly (1). Standard shim thickness: 2 mm
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DISASSEMBLY AND ASSEMBLY 8. Adjusting preload of input shaft bearing. Using tool D7 and torque wrench, measure preload of input shaft. If measurement is not within standard, adjust with shim (2). Preload standard value: 0.1 - 0.98 Nm (0.01 0.1 kgm) There are four types of shim thickness: t=0.15, t=0.2, t=0.3, and t=1.0 Check that there is no play in the gear. If there is any play, adjust the shims again. Reference: Standard value for preload when assembling input shaft and intermediate shaft (measure at input shaft end): 0.2 - 1.27 Nm (0.02 - 0.13 kgm) 9. Output shaft gear. Assemble output shaft gear (31) to transfer case. 10. Spacer. Install spacer (30).
11. Outer race. Using push tool “k”, press fit outer race (28a) to cage (29). 12. Output shaft. Assemble output shaft (20) and spacer (21), and support with block “l”.
13. Cage assembly. Fit O-ring and install cage assembly (36). O-ring: Grease (G2-LI)
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TRANSFER ASSEMBLY
DISASSEMBLY AND ASSEMBLY
TRANSFER ASSEMBLY
14. Bearing. 1) Using tool D5, press fit bearing (28d). 2) Press fit bearing (28e) in same way.
15. Outer race. 1) Install collar (28c). 2) Using push tool “l”, press fit outer race (28b). 16. Cover. 1) Using push tool, press fit oil seal (26) and dust seal (27) to cover (37). Oil seal:
Grease (G2-LI)
Oil seal press-fitting surface: Gasket sealant (Three Bond 1110B) When coating with gasket sealant, coat the inside surface of the hole in the housing thinly, and wipe off all the gasket sealant that is squeezed out. Dust seal:
Grease (G2-LI)
2) Adjust shims as follows: i) Fit O-ring and install shims (23) and cover assembly (22). Do not tighten the mounting bolts. O-ring: Grease (G2-LI) ii)
Put feeler gauge between shims (23) and cover assembly (22) and measure clearance, adjust number of shims so that clearance is 0.05 - 0.10 mm, then tighten mounting bolts. Standard shim thickness: 0.25 mm
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DISASSEMBLY AND ASSEMBLY 17. Coupling. 1) Install coupling (19). 2) Fit O-ring and install holder (18). O-ring: Grease (G2-LI) Mounting bolt:
Thread tightener (LT-2)
Mounting bolt: 662 - 829 Nm (67.5 - 84.5 kgm) (488 - 611 lbf)
18. Intermediate shaft gear assembly. Install intermediate shaft gear assembly again. For details, see steps 2, 3, and 4. Assemble the shims adjusted in step 4.
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TRANSFER ASSEMBLY
DISASSEMBLY AND ASSEMBLY
PARKING BRAKE
PARKING BRAKE ASSEMBLY DISASSEMBLY OF 1. Transmission. Disconnect transmission assembly from transfer. For details, see DISASSEMBLY OF TRANSMISSION ASSEMBLY. 2. Coupling. Remove holder (1) and coupling (2).
3. Sleeve. 1) Remove flange (3). 2) Using eyebolt “I”, remove sleeve (4).
4. Parking brake assembly. 1) Remove 12 mounting bolts (5). Do not remove four mounting bolts (6). 2) Using forcing screws “a”, disconnect parking brake assembly (7).
3) After removing forcing screws “a”from parking brake assembly (7), fit eyebolts “b”and lift off.
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DISASSEMBLY AND ASSEMBLY 5. Cover assembly. 1) Remove cover assembly (8). 2) Disassemble cover assembly as follows” i) Remove dust seal (9) and oil seal (10). ii) Remove bearing (11). iii) Remove dowel pin (29).
6. Springs. Remove 18 outer springs (12) and 18 inner springs (13).
7. Spacer assembly. 1) Remove spacer assembly (14). 2) Using push tool “c”, remove inner race (15) from spacer (16).
8. Piston. 1) Using eyebolts “d”, lift off piston (17). 2) Remove seal rings (18) and (19).
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PARKING BRAKE
DISASSEMBLY AND ASSEMBLY
PARKING BRAKE
9. Snap ring. Using snap ring pliers, install snap ring (20). 10. Plates, springs, discs. Remove 9 plates (21), 8 springs (22), and 8 discs (23).
11. Gear. Remove gear (24). 12. End plate. Remove end plate (25).
13. Housing. Using snap ring pliers, install snap ring (26) from housing (27).
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DISASSEMBLY AND ASSEMBLY
PARKING BRAKE ASSEMBLY ASSEMBLY OF 1.
Cover. 1) Assemble cover assembly as follows: i) Using push tool “f”, press fit bearing (11). ii) Install two dowel pins (29). iii) Using push tool, press fit oil seal (10) and dust seal (9). Oil seal: Grease (G2-LI) Oil seal press-fitting surface: Gasket sealant (Three Bond 1110B) Dust seal:
Grease (G2-LI)
When coating with gasket sealant, coat the inside surface of the mount thinly, and wipe off all the gasket sealant that is squeezed out. 2.
Spacer assembly. 1) Using push tool “e”, press fit inner race (15) to spacer (16). 2) Install spacer assembly (14) to cover assembly (8).
3.
Springs. Install 18 outer springs (12) and 18 inner springs (13) to cover assembly (8).
4.
Piston. 1) Install seal rings (18) and (19) to piston (17). Set the groove of the seal ring facing the direction shown in the diagram on the right. Seal ring: 2)
Grease (G2-LI)
Set piston (17) on outer spring (12) and inner spring (13). Align the position of the hole in piston (17) and dowel pin (27) of the cover assembly.
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PARKING BRAKE
DISASSEMBLY AND ASSEMBLY
PARKING BRAKE
5. Housing. 1) Using snap ring pliers, install snap ring (20) to housing (27). 2) Fit O-ring and install housing (27) to cover assembly (8), then tighten four mounting bolts (6). Be careful not to twist the piston against housing (27), and tighten the bolts uniformly a little at a time.
6. Plugs. 1) Remove two plugs (28). 2) Tighten two mounting bolts of parking brake assembly together with washers to mounting portion of plug (28). Tighten the bolts a little at a time in turn. The piston is pulled when the bolts are tightened.
7. Gear. Install gear (24). Be careful of the direction of mounting.
8. Plates, springs, discs. Install 9 plates (21), 8 springs (22), and 8 discs (23).
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DISASSEMBLY AND ASSEMBLY 9. End plate. Install end plate (25). 10. Snap ring. Using snap ring pliers, install snap ring (26). 11. Mounting bolts. Remove two mounting bolts installed in Step 6 - 2), then install two plugs (28). Loosen the two mounting bolts a little at a time in turn. Plug:
Gasket sealant (LG-5)
12. Parking brake assembly. Using eyebolts “b”, fit O-ring, raise parking brake assembly (7) and install. When installing, gradually mesh the spline on the inside of spacer assembly (14) and gear (24) with the spline of the output shaft, and install. O-ring: Grease (G2-LI) Mounting bolt:
Thread tightener (LT-2)
Mounting bolt: 98 - 123 Nm (10 - 12.5 kgm) (72 - 91 lbf) 13. Sleeve. 1) Fit O-ring and install sleeve (4). O-ring: Grease (G2-LI) 2) Fit O-ring and install flange (3).
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PARKING BRAKE
DISASSEMBLY AND ASSEMBLY
PARKING BRAKE
14. Coupling. 1) Install coupling (2). 2) Fit O-ring and install holder (1). O-ring: Grease (G2-LI) Mounting bolt:
Thread tightener (LT-2)
Mounting bolt: 662 - 829 Nm (67.5 - 84.5 kgm) (488 - 661 lbf)
15. Transmission. Connect transmission assembly and transfer. For details, see ASSEMBLY OF TRANSMISSION ASSEMBLY.
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DISASSEMBLY AND ASSEMBLY
TRANSMISSION CONTROL VALVE ASSEMBLY (ECMV ASSEMBLY) REMOVAL WARNING! 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. Remove cover (1) between bulkhead and cab. 2. Remove transmission top cover (2). 3. Disconnect solenoid connector (3) and fill connector (4). When disconnecting the solenoid connector, hold the ECMV body lightly with one hand, and hold the connector housing with the other hand as shown in the diagram on the right. Then lift up the connector housing lightly in direction A and in this condition, pull it in direction B to disconnect.
4. Remove four mounting bolts (5), then remove ECMV assembly (6).
INSTALLATION Carry out installation in the reverse order to removal. Clean around the valve before installing the ECMV assembly. When fitting the solenoid connector, align the lock and guide as shown in the diagram on the right, and push in. Do not twist when inserting. ECMV assembly mounting bolt: 31.4 ± 3.9 Nm (3.2 ± 0.4 kgm) (23 ± 3 lbf)
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TRANSMISSION CONTROL VALVE ASSEMBLY
DISASSEMBLY AND ASSEMBLY
CENTER SUPPORT ASSEMBLY
CENTER SUPPORT ASSEMBLY REMOVAL WARNING! 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. Disconnect center drive shaft (1) from center support. Set a block under the drive shaft when removing. Center drive shaft: 36.4 kg (80.1 lb) 2. Sling front drive shaft (2) and disconnect from center support. Front drive shaft: 44 kg (97 lb)
3. Disconnect grease tube.
4. Sling center support (4), remove mounting bolts, then remove. If there are shims between the center support and frame, check the number and thickness of the shims and use as a guide when assembling. Center support: 43 kg (94.8 lb)
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DISASSEMBLY AND ASSEMBLY Carry out installation in the reverse order to removal.
Center drive shaft mounting bolt: 110.7 ± 12.7 Nm)(800.7 ± 91 lbf ft)
Front drive shaft mounting bolt : 110.7 ± 12.7 Nm)(800.7 ± 91 lbf ft)
Center support mounting bolt 548.8 ± 58.8 Nm)(405.1 ± 43.4 lbf ft)
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CENTER SUPPORT ASSEMBLY
DISASSEMBLY AND ASSEMBLY
CENTER SUPPORT ASSEMBLY
DISASSEMBLY OF CENTER SUPPORT 1. Coupling Remove center bolt (1), then remove retainer (2), O-ring (3), and coupling (4).
2. Retainer Remove mounting bolts (5) or retainer. Remove all mounting bolts while rotating coupling.
3. Shaft 1) Set shaft case assembly (6) on press stand. 2) Push out shaft (7) with press. Be careful because the shaft will fall out suddenly.
3) Remove spacer (8), bearing cone (9) and retainer (5) from shaft.
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DISASSEMBLY AND ASSEMBLY 4. Oil seal 1) Remove oil seal (10 )and O-ring (11) from retainer.
2) Remove oil seal (12) from case. 5. Case Remove bearing cone (13) and bearing outer race (14) and (15).
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CENTER SUPPORT ASSEMBLY
DISASSEMBLY AND ASSEMBLY
ASSEMBLY SUPPORT
OF
CENTER SUPPORT ASSEMBLY
CENTER
1. Bearing outer race Assemble bearing outer race (14) and (15), in case (16).
2. Oil seal Assemble oil seal (10) in retainer (5). Outer circumference of oil seal Grease (G2-LI)
3. Bearing cone Assemble retainer (5) shaft and press fit bearing cone (9). After assembling bearing, check that there is no clearance at tip of shaft. Assemble spacers. Lip of seal : Grease (G2-LI) Inner circumference of bearing Grease (G2-LI)
4. Case 1) Assemble O-ring (11) in retainer. Insert O-ring completely in groove.
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DISASSEMBLY AND ASSEMBLY 2) Stand shaft and insert case (16). Fill “a" and "b" of case and inner circumference of oil seal completely with grease.
5. Retainer Secure retainer (5) in case. Be careful that O-ring does not get caught or damaged when installing. Mounting bolt: 65.7 ± 6.9 Nm)(48.5 ± 5.1 lbf ft)
6. Bearing seal 1) Press fit bearing (13) to shaft. 2) Assemble oil seal (12) in case. Dimension of seal press fit and outer edge of case:± 0.5 mm Seal: Grease (G2-LI)
7. Coupling Assemble coupling (4), install O-ring (3) and retainer (2), and secure center bolt (1). Center bolt: 931 ± 98 Nm (687.1 ± 7.2 lbf ft)
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CENTER SUPPORT ASSEMBLY
DISASSEMBLY AND ASSEMBLY
CENTER SUPPORT ASSEMBLY
8. Inspection of end play Check that end play is within specified range. End play: Less than 0.22 mm If end play is “0", with the seal and bearing coated with grease check that the free rotating torque is less than 3.9 Nm (0.4 kgm).
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DISASSEMBLY AND ASSEMBLY
DISASSEMBLY OF DRIVE SHAFT 1. Shaft 1) Remove shaft (2) Make match marks a before removing to ensure that the direction of the spider assembly does not change.
Cover (1) and (1A) is caulked with a punch at four places, so it must not be remove d unless necessary. When removing cover (1) and (1A) be extremely careful not to damage cover (1), (1A) and yoke (3). When removing the caulking, raise the caulking with a screwdriver.
2) Remove mounting bolts (4), then remove spider assembly (5). Make match marks on yoke and spider.
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DRIVE SHAFT
DISASSEMBLY AND ASSEMBLY
DRIVE SHAFT
3) Remove bearing caps (6) from spider assembly. Remove strap (7) of cap.
4) When replacing bearing (8), seal (9), and derling washer (10) from bearing cap (6), replace whole cap assembly.
2. Yoke 1) Remove mounting bolts (11) from yoke (3), then remove spider assembly (12). Stamp match marks on the yoke and spider.
2) Remove bearing caps (13) from spider assembly.
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DISASSEMBLY AND ASSEMBLY 3) When replacing bearing (14), seal (15), and derling washer (16) from bearing cap (13) replace whole cap assembly.
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DRIVE SHAFT
DISASSEMBLY AND ASSEMBLY
DRIVE SHAFT
ASSEMBLY OF DRIVE SHAFT 1. Yoke 1) Install bearing (14), and seal (15) to bearing cap (13). Bearing, seal : Grease (G2-LI)
2) Assemble derling washer (16), and bearing cap (13) to spider assembly (12) Be careful not to damage bearing with heat when welding strap. Bearing cap: Grease (G2-LI)
3) Assemble spider assembly (12) to yoke (3). Carefully align match marks. Clean the mounting face of the bearing cap by wiping with a clean cloth. Mounting bolts : 142.2 ± 9.8 Nm (104.9 ± 7.2 lbf ft)
2. Shaft 1) Assemble bearing (8) and seal (9) in bearing cap (6). Bearing seal : Grease (G2-LI)
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DISASSEMBLY AND ASSEMBLY 2) Assemble derling washer (10 )and bearing cap (6) to spider assembly (5). Be careful not to damage bearing with heat when welding strap. Bearing cap: Grease (G2-LI)
3) Assemble spider assembly (5) to shaft (2). Carefully align match marks. Clean the mounting face of the bearing cap by wiping with a clean cloth. Mounting bolt: 142.2 ± 9.8 Nm (104.9 ± 70.8 lbf ft)
4) Align match marks “a”, then install shaft (2) to yoke (3). Check that the direction of the spider assembly is the same. If the spline is worn, replace the whole drive shaft assembly. Spline: Grease (G2-LI)
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DRIVE SHAFT
DISASSEMBLY AND ASSEMBLY
DRIVE SHAFT
5) lf cover (1) and (1A) has been removed, do as follows. Front and rear drive shaft. Insert seal and retainer to cover (1) and shaft (2), assemble cover (1), then caulk with a punch on diagonally opposite sides. Center drive shaft. Insert shaft (2) to cover (1A), assemble cover (1A), then caulk with a punch on diagonally opposite sides.
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DISASSEMBLY AND ASSEMBLY
REMOVAL OF ASSEMBLY
FRONT
FRONT AXLE ASSEMBLY
AXLE
WARNING! Stop the machine on level ground, install the safety bar on the frame, and put blocks under the wheels to prevent the machine from moving. 1. Insert block n top face (1) of left and right rear axle housings and frame (2). 2. Start engine, operate work equipment to raise front axle, then set block er front frame on left and right sides and operate work equipment to lower frame. Check that the front wheels can be removed, then lower the work equipment to the ground. 3. Sling left and right wheels (3), remove hub nuts, then lift off. Tire, wheel: 660 kg (1452 lb)
4. Disconnect front drive shaft (4) at differential end.
Make counter marks to act as a guide when assembling.
5. Disconnect brake tube (5) from slack adjuster. 6. Remove brake tubes (6) and (7). Seal the brake system with blind plugs after disconnecting the piping.
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DISASSEMBLY AND ASSEMBLY
FRONT AXLE ASSEMBLY
7. Sling one side of front axle assembly (8) and set garage jack to other side. 8. Remove mounting bolts (9). 9. Operate crane and garage jack to lower the axle assembly. Be careful not to let the slack adjuster on top of the axle housing hit the frame. Front axle assembly: 1,850 kg (4070 lb) 10. Pull out front axle assembly from chassis.
INSTALLATION OF FRONT AXLE ASSEMBLY Carry out installation procedure in reverse order to remove.
Hub nut: 470.4 ± 49.0 Nm (347.2 ± 36.2 lbf ft)
Drive shaft mounting bolt: 110.7 ± 12.7 Nm (81.7 ± 9.4 lbf ft)
Axle mounting bolt: 2744.0 ± 294.0 Nm (2025 ± 217 lbf ft)
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FORWARD
FRONT DIFFERENTIAL ASSEMBLY
REMOVAL OF F R O NT DIFFERENTIAL ASSEMBLY WARNING! Stop the machine on level ground, install the safety bar on, the frame, and put blocks under the wheels to prevent the machine from moving. 1. Remove drain plugs (1) and (2), and drain oil.
Axle oil : 78 2. Operate work equipment to raise front axle, then set stand under left side of axle. 3. Sling left wheel (3), then remove hub nut and lift off. Tire, wheel: 660 kg (1452 lb)
4. Remove left and right final drive covers (4).
5. Using forcing screws approx. 200 mm together with sun gear (6).
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)
FORWARD
FRONT DIFFERENTIAL ASSEMBLY
6. Remove front drive shaft (7). Sling the drive shaft and lower it slowly.
7. Remove two mounting bolts of differential (8), and install guide bolt Screw in the guide bolt fully and check that all the threads have entered the hole. First, screw in the guide bolt, then remove the remaining mounting bolts. 8. Set lever block ntial case (9), and set so that differential assembly does not fall over. Fit both ends of a lever block to the front frame inspection window. 9. Pull out differential (8) approx. 20 mm from axle housing (10) along guide bolts. Be careful not to damage the O-ring. 10. Install tools H1-1 and H1-2 to garage jack, and insert between differential and axle housing, then install differential to tool H1-1. 11. Adjust lever block and height of jack, and remove differential assembly slowly. Differential assembly: 282 kg (620.4 lb) 12. Operate jack and pull out differential assembly (8) to outside of chassis. 13. Remove O-ring (11).
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FORWARD
INSTALLATION OF FRONT DIFFERENTIAL ASSEMBLY Carry out installation in the reverse order to remove.
Drain valve 151.9 ± 24.5 Nm (112.1 ± 18.1 lbf ft)
Hub nut: 470.4± 49.0 Nm (347.2 ± 36.2 lbf ft)
Drive shaft mounting bolt: 110.7 ± 12.7 Nm (74.5 ± 9.4 lbf ft)
Differential mounting bolt: 548.8 ± 58.8 Nm (405.1 ± 43.5 lbf ft) Refilling with oil (axle) Add oil through the oil filler to the specified level.
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FRONT DIFFERENTIAL ASSEMBLY
DISASSEMBLY AND ASSEMBLY
REMOVAL OF ASSEMBLY
REAR
REAR AXLE ASSEMBLY
AXLE
WARNING! Stop the machine on level ground, install the safety bar on the frame, and put blocks under the wheels to prevent the machine from moving. 1. Jack up chassis, set block under rear frame, and support bottom of counterweight with stand
2. Sling left and right wheels (1), then remove hub nut and lift off. Tire, wheel: 660 kg (1452 lb)
3. Disconnect rear drive shaft (2) from rear axle. Rear drive shaft: 37 kg (81.4 lb)
4. Disconnect hose (3) between brake pedal and slack adjuster at slack adjuster end. 5. Disconnect tubes (4) and (5) between slack adjuster and left and right wheel brakes. Be sure to remove the brake tube before removing the axle. There is danger that it may be crushed.
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DISASSEMBLY AND ASSEMBLY 6. Disconnect grease tubes (6) and (7) from axle support at rear end.
7. Disconnect grease tube (8) from axle support at front end. Remove the clamps of the brake hose from the support.
8. Secure axle support and rear axle with chain.
9. Remove mounting bolts, then using garage jack to maintain balance, lower axle assembly. Rear axle assembly: 1,710 kg (3762 lb) 10. Pull out rear axle assembly (9) from chassis. Support both ends of the axle with jacks.
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REAR AXLE ASSEMBLY
DISASSEMBLY AND ASSEMBLY
REAR AXLE ASSEMBLY
11. Remove front support (10) from rear axle. Be careful not to damage the packing. Front support: 95 kg (209 lb)
12. Remove packings (11) and (12) from front support.
13. Remove bushing (13) from front support. Remove all dirt and oil from the bushing mounting surface inside the front support.
14. Sling rear support, and remove thrust cap (14).
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DISASSEMBLY AND ASSEMBLY 15. Remove thrust washer (15), thrust plate (16), and thrust washer (17) from rear axle.
16. Lift off rear support (18). Rear support: 115 kg (253 lb)
17. Remove packing (19) from rear support.
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DISASSEMBLY AND ASSEMBLY
REAR AXLE ASSEMBLY
18. Remove bushing (20) from rear support. Remove all dirt and oil from the bushing mounting surface inside the rear support.
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DISASSEMBLY AND ASSEMBLY
REAR AXLE ASSEMBLY
INSTALLATION OF REAR AXLE ASSEMBLY Installation is the reverse of removal procedure.
Hub nut: 471 ± 49 Nm (347.2 ±36 lbf ft) Drive shaft mounting bolt: 110.7 ± 12.7 Nm (745 ± 7.9 lbf ft) Rear support mounting bolt: 1,568 ± 196 Nm (1157.3 ± 144.7 lbf ft) Soak a cloth with primer for Loctite Prism adhesive, then wipe the adhesion surface at the bushing end. Adhesion surface at rear support end: Instant adhesive Loctite Prism 411 (approx. 3g) Install the bushing within five minutes of coating it with primer. Do not mix the primer with adhesive whe n using it. Be careful to install the packing with the lip facing in the correct direction. Lip of packing: Grease (G2-LI) Rear axle mount portion: Grease (G2-LI)
Front support mounting bolt: 1,568 ± 196 Nm (1157.3 ± 144.7 lbf ft) Coat the bushing the same as the rear axle. Lip of packing: Grease (G2-LI) Front axle mount portion: Grease LI)
(G2-
Thrust cap mounting bolt: 279.3 ± 29.4 Nm (206.14 ± 21.7 lbf ft)
Thrust plate mounting bolt: 279.3 ± 29.4 Nm (206.14 ± 21.7 lbf ft)
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DISASSEMBLY AND ASSEMBLY
DIFFERENTIAL ASSEMBLY
REMOVAL OF REAR DIFFERENTIAL ASSEMBLY WARNING! Stop the machine on level ground, install the safety bar on the frame, and put blocks under the wheels to prevent the machine from moving. 1. Remove rear axle assembly from chassis. For details, see REMOVAL OF REAR AXLE ASSEMBLY. Do not remove the rear support from the rear axle. 2. Remove plug (1) and drain axle oil. Set so that the drain plug is at the bottom. Axle oil: 78 3. Remove cover (2).
4. Using forcing screws, pull out drive shaft (3). Pull the drive shaft out approx. 200 mm (7.8 in).
5. Using eyebolts, lift off rear differential assembly (4).
Rear differential assembly: 282 kg (620.4 lb) Remove the O-ring from the housing mating surface.
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DISASSEMBLY AND ASSEMBLY
INSTALLATION OF REAR DIFFERENTIAL ASSEMBLY Carry out installation in the reverse order to remove.
Differential mounting bolt: Thread tightener (LT-2) Differential mounting bolt: 548.8 ± 58.8 Nm (405.1 ± 43.4 lbf ft) Adjusting shims on shaft Adjust the shims on the shaft if the differential assembly or axle housing have been replaced. 1) Tighten mounting bolts of shaft (5) uniformly, then measure clearance a between axle housing and shaft. (Do not assemble the shims. Tighten th e mounting bolts to 3.9 ± 0.1 Nm (2.89 lbf ft).) 2) Add 0.1 ± 0.05 mm to the measurement fo r clearance a, then select a shim within that range and assemble it. Shim thickness: Clearance a + (0.1 ± 0.05 mm) Mounting bolt: 112.7 ± 9.8 Nm (83.18 ± 7.2 lbf ft)
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DIFFERENTIAL ASSEMBLY
DISASSEMBLY OF DIFFERENTIAL GEAR ASSEMBLY 1. Set differential assembly (1) on special tools H2-1, H2-2, and H-3. Differential assembly: 230kg (506 lb)
2. Pinion assembly 1) Remove case (2).
2) Remove oil seal (3) and dust seal (3A) from case.
3) Screw in jack screw (D (Thread dia. = 18 mm, Pitch = 1.75 mm), and lift out pinion assembly (4). Check number of shims (5).
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DISASSEMBLY AND ASSEMBLY 3. Differential gear case assembly 1) Remove left and right locks (6), and with a bar, turn nut (7) until it become loose.
2) Remove mounting bolts (9) of cap (8).
3) Remove nut and lift out differential gear case assembly (10).
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DIFFERENTIAL ASSEMBLY
DISASSEMBLY AND ASSEMBLY
DIFFERENTIAL ASSEMBLY
FINE DISASSEMBLY OF PINION ASSEMBLY 4. Bearing, collar, cage 1) Support cage (11), push shaft with press and tack out pinion.
2) Remove bearing (12) and collar from cage.
3) Remove outer races (13) and (14) from cage (11).
5. Pinion, bearing 1) Remove snap ring (15), then remove bearing (16). 2) Remove bearing (17).
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DISASSEMBLY AND ASSEMBLY
FINE DISASSEMBLY OF DIFFERENTIAL GEAR CASE ASSEMBLY 6. Bevel gear (large) Remove mounting bolts, using eye-bolts (2) (Thread dia. = 16 mm, Pitch = 2.0 mm), lift of f bevel gear (18).
7. Bevel gear (small) Remove thrust plate (19) and bevel gear (20). 8. Pinion gear, cross shaft Remove pinion gear (21), cross shaft (22), and washer (23) as one unit.
9. Bevel gear (small) Remove bevel gear (24) and thrust plate. 10. Bearing Remove bearing (26) from case (25).
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DISASSEMBLY AND ASSEMBLY
FINE ASSEMBLY DIFFERENTIAL GEAR ASSEMBLY
DIFFERENTIAL ASSEMBLY
OF CASE
1. Bearing Using press fit kit (3) (120 mm inner diameter), press fit bearing (26) to case (25).
2. Bevel gear (small) Install thrust and small bevel gear (24) in case. Align thrust with dowel pin and install.
3.
Pinion gear, cross shaft Assemble pinion gear (21) and washer (23) with cross shaft (22). Align washer groove with dowel pin of case and install.
4. Bevel gear (small) Install bevel gear (20) and thrust plate (19).
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DISASSEMBLY AND ASSEMBLY
DIFFERENTIAL ASSEMBLY
5. Bevel gear (large) Using eye-bolts (2) (thread dia. = 16 mm, Pitch = 2.0 mm), lift and install bevel gear (18). Align pin hole of thrust and dowel pin on case side and install.
FINE ASSEMBLY ASSEMBLY
OF
PINION
6. Bearing 1) Using press fit kit (4) (26 mm inner diameter). Install pinion bearing (17).
2) Using press fit kit (5) (55mm inner diameter), install bearing (16). Rotating surface of bearing: Engine oil (EO30-CD) 3) Install snap ring (15).
7. Cage 1) Install outer races (14) and (13). 2) lnstall cage (11) to pinion assembly.
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DISASSEMBLY AND ASSEMBLY
DIFFERENTIAL ASSEMBLY
8. Collar Install collar (27). 9. Bearing Using press fit kit (4) (76 mm inner diameter), install bearing (12).
ASSEMBLY OF DIFFERENTIAL ASSEMBLY Set differential case on special tools Hl-I, H2-2, and H2-3. 10. Pinion assembly 1) Assemble shims (5) removed whe n disassembled. Standard shims thickness: 2.1 mm. 2) Using eye-bolts (5) (Thread dia.=12mm, Pitch 1.75 mm), install pinion assembly (4). 3) Remove oil seal (3) and dust seal (3A) to case. Lip of oil seal : Grease (G2-LI) Rear Lip of dust seal: Grease (G2-LI)
4) Fit O-ring to case, and install case (2). Mounting bolt: 279.3 ± 29.4 Nm (206.14 ± 21.7 lbf ft) Mounting bolt: Thread tightener (LT2)
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DISASSEMBLY AND ASSEMBLY 5) Insert coupling (28), fit O-ring and tighten holder. Mounting bolt: Thread tightener (LT-2) Mounting bolt: 921 ± 98 Nm (607.6 ± 72.3 lbf ft) Fit the balancer (6) to bolt hole of coupling, and measure the rotating torque. Rotating torque: Max. 50.0 N (11.22 lb)
11 Differential gear assembly Sling differential gear assembly (10) and install case.
12. Nut, cap 1) Align nut (7) with differential case groove and install.
2) Install cap (8) and tighten (9). Mounting bolt: Thread tightener (LT-2) Mounting bolt: Check match marks on bearing cup before installing. Rotate bevel gear 20 - 30 times to settle in, then tighten bolt.
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DIFFERENTIAL ASSEMBLY
Bearing pre-load adjustment steps are as follows. 1) Install tool H4-1 and H4-2 to cap on both sides.
2) Measure clearance "a" between tool H4-2 with tool H4-1.
3) Add 0.26 ± 0.07 mm to measuremen t dimension and set scale on tool H4-1. The added dimension becomes the amount of bending of the case, given before pre-load and given after pre-load. 4) Tighten adjusting nut with bar until increased amount becomes 0.26 ± 0.07 mm.
Caution for pre-load adjustment When adjusting nut is overtightened (in case the amount of increased bending surpasses the standard measurement), return adjusting nut to position before adjusting. Then, while rotating bevel gear, lightly tap bearing cap and bevel gear with plastic hammer, and check that there is no clearance in position b.
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DISASSEMBLY AND ASSEMBLY 13. Adjusting tooth contact, backlash Adjust the backlash, and at the same time adjus t tooth contact. 1) Adjust backlash as follows: i) Movement of bevel gear is done with adjusting nut (7). At this time, so as not to change pre-load pressurization of bearing, turn nuts on both sides, the same amount each, in same direction. ii) Put dial gauge (3) in vertical contact with forward and reverse sides of outer edge of bevel gear tooth face, and while turning adjusting nut, adjust until gauge meter fluctuation becomes 0.3 - 0.4 mm. Measure at three or four places, and keep the pinion gear fixed when measuring. 2) Adjust tooth contact as follows: i) Adjust bevel pinion by adjusting shims between differential case and bearing cage. ii) Adjusting tooth contact For details, see ADJUSTING TOOTH CONTACT.
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DISASSEMBLY AND ASSEMBLY
DIFFERENTIAL ASSEMBLY
3) Adjusting tooth contact Coat face 7 or 8 teeth of bevel pinion lightly with red lead (minimum). Hold the bevel gear by hand to act as a brake, rotate the pinion gear forward and backward and inspect the pattern left on the teeth.
When adjusting the driven gear do not change the pre-load of the bearing. Turn the left and right adjusting nut, the same amount each (check by the number of notches), in the same direction.
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DISASSEMBLY AND ASSEMBLY 14. Lock After adjusting tooth contact and backlash, install lock (6). Mounting bolt: Thread tightener (LT-2)
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DIFFERENTIAL ASSEMBLY
DISASSEMBLY AND ASSEMBLY
FINAL DRIVE ASSEMBLY
DISASSEMBLY OF FINAL DRIVE ASSEMBLY WARNING! Stop the machine on level ground, install the safety bar on the frame, and put blocks under the wheels to prevent the machine from moving. 1. Tire assembly Loosen hub nut, raise chassis with work equipment or jack, insert support stand under axle, then sling tire assembly, remove hub nuts, and lift off tire assembly (1). Tire assembly: 660 kg (1452 lb) 2. Draining oil 1) Remove drain plug (2) and drain oil. Set so that the drain plug is at the bottom. Axle oil: 78
d
rear) 3. Cover Remove mounting bolts (3), then remove cover (4). 4. Drive shaft Screw in bolt (1) (Thread dia.=12 mm, Pitch = 1.75 mm) in drive shaft, then pull out drive shaft assembly (5) and remove.
5. Planetary carrier assembly Remove mounting bolts (6), then using eyebolt (2) (Thread dia.=12 mm, Pitch=1.75 mm), lift of f planetary carrier assembly (7). Use a bar to adjust the position of the center of gravity when removing. Planetary carrier assembly: 90 kg (198.42 lb)
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DISASSEMBLY AND ASSEMBLY 6. Ring gear 1) Using tool H6, secure wheel hub (8) and brake housing (9). Install tool H6 at three places at equal distances. Do not remove tool H6 until assembly Step 3.
2) Remove mounting bolts (10), then remove retainer (11) and ring gear (12). Check the number and thickness of shims on the inside of the retainer. Ring gear: 50 kg (110 lb)
7. Disassembly of planetary carrier Using press, pull out shaft (13), then remove pinion gear (14). Lock ball (15) is fitted in the shaft, so be careful not to lose the ball. Write the serial number on the case and be careful not to mix the removed parts with other parts. The bearings and other parts have settled as a set, so make identification marks and be careful not to mix with other parts.
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DISASSEMBLY AND ASSEMBLY
FINAL DRIVE ASSEMBLY
8. Disassembly of ring gear 1) Remove lock plates (18) from ring gear hub (17), then remove ring gear (19) 2) Pull out bearing (20) from ring gear hub (17).
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DISASSEMBLY AND ASSEMBLY
ASSEMBLY OF FINAL DRIVE ASSEMBLY 1. Assembly of ring gear 1) Press fit bearing (20) on ring gear hub (17). After press fitting the bearing, check that there is not clearance between the rib and bearing. 2) Set ring gear hub (17) on ring gear (19), then install lock plates (18). Install the lock plates with the wider ones on the inside. Remove all grease and oil from the bolt. Mounting bolt: Thread tightener (LT-2) Mounting bolt: 31.4 ± 2.9 Nm (23.1 ± 2.2 lbf ft)
2. Assembly of planetary carrier Set pinion gear (14) in carrier case, insert ball (15) in shaft (13), then press fit. Press fit so that the hole for the lock ball is on the outside circumference, then stop with the hole at the front and align the holes. After press fitting the shaft, check that the gear rotates smoothly.
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DISASSEMBLY AND ASSEMBLY
FINAL DRIVE ASSEMBLY
3. Wheel bearing adjustment 1) Insert ring gear assembly (12) in axle housing, fit retainer (11) tighten temporarily with mounting bolts (10), and remove tool H6.
Measure thickness "b" of retainer before installing. Do not insert shims in the retainer when tightening temporarily. Rotate the wheel hub 20 - 30 times and tighten the bolts to a uniform torque. Mounting bolt: 78.4 ± 4.9 Nm (57.9 ± 3.6 lbf ft)
2) Using a depth micrometer or dial gauge, insert through measuring hole of retainer (21) and measure clearance "a" from retainer to face of housing. ure at two places and take the average. 0.3 mm added to measured valu e difference C = a - b, becomes shim thickness. the smallest number of shims whic h gives the required thickness.
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DISASSEMBLY AND ASSEMBLY 3) After installing tool H6 to brake housing and wheel hub, remove retainer, insert the required number of shims and retainer, then tighten mounting bolts. When assembling shims, after installing tool H6, always tighten the mounting bolts uniformly to the specified tightening torque. Mounting bolt: Thread tightener (LT-2) Mounting bolt: 279.5± 29.4 Nm (206.1 ± 21.7 lbf ft) 4. Planetary carrier Fit O-ring, using eye-bolts (2) ( Thread dia. = 12 mm, Pitch = 1.75 mm) sling planetary carrier assembly (7), set in mounting position and tighten mounting bolts (6). Because balance is bad, adjust the center of gravity with a bar and install.
5. Axle shaft Screw in bolt (D (Thread dia. = 12 mm, Pitch= 1.75 mm) in axle shaft and insert axle shaft assembly (5). If the position of the sun gear does not match, rotate the wheel hub to align.
6. Cover Fit O-ring, install final drive cover (4), then tighten mounting bolts (3). Mounting bolt: 68.6 ± 9.8 Nm (50.6 ± 7 lbf ft)
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FINAL DRIVE ASSEMBLY
DISASSEMBLY AND ASSEMBLY
FINAL DRIVE ASSEMBLY
7. Refilling with oil Tighten drain plug (2), then remove level plug, and add oil through oil filter to specified level. Set the machine so that the level plug of the final drive is at the bottom when refilling with oil. Axle oil: Approx. 78
8. Tire assembly Raise tire assembly (1), set to wheel hub, and tighten temporarily with wheel nuts. Then jack up chassis with work equipment and jack, remov e stand under axle, lower chassis to ground and tighten wheel nuts to specified torque. Wheel nut: 470 ± 49.0 Nm (347.4 ± 36.2 lbf ft) (Width across flats: 30 mm)
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DISASSEMBLY AND ASSEMBLY
REMOVAL OF ORBIT-ROLL ASSEMBLY WARNING! Stop the machine on level ground and turn the steering fully to the right. Then stop the engine and put blocks under the wheels to prevent the machine from moving. 1. Remove cover (1) from steering column. 2. Remove joint lock bolt (2). 3. Disconnect four hoses (3). Mark the hoses and their destinations to facilitate reassembly.
4. Remove three mounting bolts (4), then remove Orbit Roll assembly (5). 5. Remove joint lock bolt (6), then remove joint assembly (7). 6. Remove bolt (8), then remove bracket (9).
INSTALLATION OF ORBIT-ROLL ASSEMBLY Carry out installation in the reverse order to removal.
Joint lock bolt: 55.9 ± 7.8 Nm (41.2 ± 5.8 lbf ft) Bracket mounting bolt : 51.9 ± 7.8 Nm (38.3 ± 5.8 lbf ft)
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DISASSEMBLY AND ASSEMBLY
ORBIT-ROLL ASSEMBLY
DISASSEMBLY OF ORBIT-ROLL ASSEMBLY Ensure a clean working environment. 1. Dirt or debris in the hydraulic system will cause premature wear and erratic operation. Keep all dirt and dust out of the hydraulic circuit. 2. Use a clean work bench when disassembling or assembling the equipment. 3. Remove dirt from the exterior of the unit before disconnecting any piping. 4. Always wipe dirt off the unit before placing it on the work bench. After disassembling, wash with a clean petroleum-base solvent, and blow dry with clean air. Always ensure that there are no impurities in the solvent or air. If any other solvent is used, it may lead to deterioration of the rubber seal. Never wipe any part with a cloth or apply steam to the unit. The solvent is flammable. Keep flames and sparks away. PREPARATORY WORK 1) Fit blind plugs in the five ports in the valve body, clean the outside, then remove the blind plugs. 2) Install tube nut (1) to one of the ports. 3) Install in a vise (2) with the end cover at the top. Do not clamp the valve body directly in the vise, which could damage or break the unit. 1. Remove 7 mounting bolts (1), insert screwdriver between end cover assembly (2) and sleeve (3), then remove end cover assembly (2). After removing, check that there is no damage to the edge of the hole in the end cover.
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DISASSEMBLY AND ASSEMBLY 2. Remove commutator (5) and washer (6). Do not remove pin (4).
3. Using two mounting bolts (1), remove commutator ring (7) and manifold (8). 4. Using two mounting bolts (1), remove rotor set (9) and wear plate (10) in the same way as commutator ring and manifold.
5. Insert screwdriver between sleeve (3) and valve body (11), then remove sleeve (3). 6. Remove drive link(12).
7. Remove ball (13). 8. Remove rod (14), roller (15), rod (16), and spring (17).
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DISASSEMBLY AND ASSEMBLY
ORBIT-ROLL ASSEMBLY
9. Install in vise with input shaft (18) at the top, and make counter marks with a punch in upper cover (19) and valve body (11). 10. Remove four mounting bolts (20), then grip input shaft (18), move it up, and remove input shaft, upper cover, and valve spool assembly (23).
The valve spool is fitted in the body with an extremely small clearance, so if a horizontal force is applied, it will be impossible to remove it. When removing the valve spool from the housing, never apply any excessive force.
11. Remove upper cover assembly (22) from input shaft and valve spool assembly (23), then remove shim (24) and spacer (25). Check the number and thickness of the shims, and keep in a safe place.
12. Remove seal (26) and snap ring (27), then remove spacer (28), seal (29), and seal ring (30) from upper cover (19).
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DISASSEMBLY AND ASSEMBLY Seal (29) and seal ring (30) may form one unit.
13. Remove snap ring (31), thrust washer (32), thrust bearing (33), thrust washer (34), and wave washer (35) from input shaft (18).
14. Use punch pin (3) (3.0 mm dia, 16 mm length), to remove needle roller (36) from input shaft (18).
Cushion the input shaft with a wooden block to prevent damage when striking with the hammer.
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DISASSEMBLY AND ASSEMBLY
ORBIT-ROLL ASSEMBLY 15. Set valve spool (37) facing bottom, then remove torsion bar (38) and spacer (39) from input shaft and valve spool assembly. Do not remove needle roller (40) from the torsion bar.
16. Set valve spool (37) facing bottom, then rotate input shaft (18) until drive link (41) comes out. 17. Set valve spool (37) facing bottom, then rotate input shaft (18) clockwise to a point where ball comes out. Ball (42) may come out by itself, so be careful not to lose it.
Do not remove ball retaining spring (43) unless it is to be replaced. When removing it, hold the flat end with pliers and pull up until it comes completely out from valve spool (37). When doing this, be careful not to damage the outside of the valve spool or the control edge.
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DISASSEMBLY AND ASSEMBLY
ASSEMBLY OF ORBIT-ROLL ASSEMBLY Before assembly, wash all parts with clean petroleum based solvent and dry with air. Never wipe with a cloth. Check carefully that there is no debris or paint on the edge of the lapped surface. If there are no special instructions, do not coat any parts with oil when assembling. 1. Set thrust washer (34), thrust bearing (33), and thrust washer (32) to input shaft (18), and install snap ring (31). 2. Install wave washer (35) to thrust bearing (33) and thrust washer (34). 3. Install ball (42) inside valve spool (37).
4. To mesh the groove and ball, rotate counterclockwise and insert input shaft (18) into valve spool (37). Keep the spool horizontal when doing this.
5. Fit center portion of torsion bar (38) between thrust washer (34) and valve spool (37).
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ORBIT-ROLL ASSEMBLY
DISASSEMBLY AND ASSEMBLY
ORBIT-ROLL ASSEMBLY
The positioning of the valve spool and input shaft is carried out by inserting the torsion bar.
6. Check spline of input shaft (18) and drive link (41), and align spline of valve spool (37), then install drive link (41). If the drive link and input shaft do not mesh, rotate the input shaft slightly to carry out the meshing. When inserting the drive link, make sure that the torsion bar is securely held in position. If the drive link is assembled correctly, there will be a clearance of 8.89 mm between the thrust washer and valve spool. If the relationship between the spool, drive link, and input shaft is not correct, the steering unit will not work properly.
7. Measure diameter L of pin (40) of torsion bar (38) at several points and check that the difference does not exceed 0.025 mm. 8. Set spacer (39) to torsion bar (38), then insert in valve spool and input shaft assembly (23).
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DISASSEMBLY AND ASSEMBLY 9. Using pin (3) (outside diameter: 3 mm), align pin hole of input shaft (18) and torsion bar (38). 10. Using pin (1), knock pin (36) 0.8 mm in from end face of input shaft.
11. Install spacer (25) on valve spool and input shaft. If there is a lip at one end inside the spacer, install so that the lip surface is facing the wave washer. 12. Install input shaft and valve spool assembly (23) to valve body (11). The clearance is extremely small, so if any sideways pressure is applied during assembly, it will not work properly. 13. Set shim (24) on top of thrust washer, fit seal, align counter marks of upper cover (19), then install and tighten mounting bolts (20) temporarily.
14. Set tool F1 in position, and install so that valve body and upper cover are centered. 15. Tighten mounting bolts (20) and remove tool F1. Mounting bolt : 27.4 ± 2.5 Nm (19.9 ±1.8 lbf ft)
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DISASSEMBLY AND ASSEMBLY
ORBIT-ROLL ASSEMBLY
16. Measure width several places and check that the difference does not exceed 0.025 mm.
17. Pull input shaft down, align drive link (12) with spline of valve spool, then rotate spool so that end face of spool and valve body are level with each other.
18. Align pin (40) and drive link (12) and install.
19. Using depth gauge (6), measure installed height h of end face of valve body and valve spool.
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DISASSEMBLY AND ASSEMBLY h = Within 0.063 mm..... Not necessary to adjust shim. If installed height h = 0.064 mm or more, repea t Steps -12 through 19 to adjust the shim height so that h = Within 0.063 mm.
20. Install ball (13). 21. Set rod (17) to spring (16), then fit to valve body (11) and install roller (15) and rod (14). 22. Fit seal to valve body.
23. Before installing rotor, check rotor as follows. 1) Set the pin end of end cover assembly at top and spline end of rotor assembly (9) at bottom, then check that rotor rotates freely inside stator.
2) Measure thickness of rotor and stator, and check that the difference is less than 0.18 mm. 3) Using feeler gauge (7), check that the clearance of the rotor from the stator is less than 0.18 mm.
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ORBIT-ROLL ASSEMBLY
24. Using guide pin (8), install wear plate (10), rotor assembly (9), and manifold (8). 25. Fit seal to end cover assembly (2).
26. Set sleeve (3) and end cover assembly (2) in position, tighten mounting bolts (1) uniformly, then install sleeve, and remove end cover assembly.
27. Fit washer (6) to end cover assembly (2), and install commutator (5). Install the commutator so that the concav e part is at the end cover assembly end.
Determine the position so that the oval hole of the commutator is in line with one of the bolt holes of the end cover assembly.
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DISASSEMBLY AND ASSEMBLY 28. Install commutator ring (7). 29. Rotate input shaft so that tip of drive shaft is aligned with oval hole in commutator. 30. Set end cover assembly (2) on sleeve (3), then tighten five mounting bolts uniformly. Mounting bolt: 6.9 ± 0.6 Nm (60.7 ± 5.2 lbf in)
31. Set input shaft end facing top, then install seal ring (30) and seal (29). Install the seals from the small diameter end. Seal ring (30) and seal (29) are stuck together and are supplied as one unit. Coat the new seal with oil and install from the lip end. When doing this, coat the inside with a small amount of grease.
32. Using tool F2, install spacer (28) from small diameter end. 33. Install snap ring (27). 34. Fit seal (26) to input shaft, and fit to upper cover.
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DISASSEMBLY AND ASSEMBLY
STEERING CYLINDER
REMOVAL OF STEERING CYLINDER ASSEMBLY WARNING! Stop the machine on level ground, install the safety bar on the frame, and put blocks under the wheels to prevent the machine from moving.
1. Remove bolts (1), loosen bolt (2), then rotate cover (3) carefully towards rear of machine. Rotate the cover using bolt (2) as the fulcrum. The operating space is confined, so be extremely careful when carrying out the operation.
2. Disconnect bottom hose (4). 3. Disconnect grease tube (5). 4. Remove mounting bolt (6), then pull out pin (7). Note the number and thickness of the shims to use as a guideline when assembling.
5. Disconnect head hose (8).
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DISASSEMBLY AND ASSEMBLY 6. Remove mounting bolt (9), then pull out pin (10). Note the number and thickness of the shims to use as a guideline when assembling. 7. Using lever block, lift off steering cylinder (11). Carry out the removal operation for the cylinder using two workers. Be careful not to damage the cylinder rod. Steering cylinder : 47 kg (103.4 lb)
INSTALLATION OF STEERING CYLINDER ASSEMBLY Carry out installation in the reverse order to removal. WARNING! When aligning the position of the pin hole, use a bar. Never insert your fingers in the pin hole. Adjust the shims so that the clearance is specified value. Clearance a + b = Less than 1.0 mm (The specified value is the same for both the rod end and the bottom end.)
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STEERING CYLINDER ASSEMBLY
DISASSEMBLY AND ASSEMBLY
STEERING CYLINDER ASSEMBLY
DISASSEMBLY OF STEERING CYLINDER ASSEMBLY 1. Set cylinder assembly (1) in tool U1. 2. Raise lock of cylinder head (2), then using tool U2, remove cylinder head (2) from cylinder.
3. Pull cylinder head and piston rod assembly (3) out from cylinder (4), then lift off. Oil will come out when the piston rod assembly is removed from the cylinder, so catch it in a container. 4. Remove cylinder (4) from tool U1.
5. Set cylinder head and piston rod assembly in tool U1, and, using power wrench (1) and socket U3, loosen nut (5). Power wrench: x 16 Socket U3: Width across flats: 60 mm
6. Remove nut (5), then remove piston assembly (6), and cylinder head assembly (7) from rod (8).
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DISASSEMBLY AND ASSEMBLY 7. Disassembly of piston assembly 1) Remove wear ring (9). 2) Remove piston ring (10) from piston (11). 8. Disassembly of cylinder head assembly 1) Remove snap ring (16), then remove dust seal (17).
2) 3) 4) 5) 6)
Remove rod packing (18). Remove buffer ring (19). Remove O-ring (20) and backup ring (21). Remove O-ring (22). Remove bushing (23) from cylinder head (24).
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STEERING CYLINDER ASSEMBLY
DISASSEMBLY AND ASSEMBLY
STEERING CYLINDER ASSEMBLY
ASSEMBLY OF STEERING CYLINDER ASSEMBLY Clean all parts, and check for dirt or damage. Coat the sliding surfaces of all parts with engine oil before installing. Be careful not to damage the rod packing, dust seals or O-ring when assembling. 1. Assembly of cylinder head assembly 1) Using tool U5, press fit bushing (23) to cylinder head (24). Be extremely careful not to deform the bushing when press fitting. 2) Install buffer ring (19). 3) Install rod packing (18). Be careful to install rod packing (18) facing in the correct direction. 4) Using push tool, install dust seal (17) to cylinder head (24). 5) Install snap ring (16). 6) Install O-ring (22). 7) Install backup ring (21) and O-ring (20). Do not try to force the backup ring into position. Warm it in water (50 - 60 2. Assembly of piston assembly 1) Using tool U6-1, expand piston ring (10). Place the piston ring on the expander and turn the handle 8 - 10 times to expand the ring. 2) Remove piston ring (10) from tooI U6-1, and assemble on piston (11).
3) Fit tooI U6-2, on piston ring, then using clamp U6-3, contact piston ring. 4) Assemble wear ring (9).
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DISASSEMBLY AND ASSEMBLY 3. Set piston rod (8) in tool U1. 4. Assemble cylinder head assembly (7) and piston assembly (6) no rod, then fit nut (5).
5. Using power wrench (1) and socket U3 tighten nut (5). Piston nut:
Power of power wrench (1)
X16
Width across flats of nut (5)
60 mm
Tightening torque of nut
1,765 ± 176 Nm (1302 ±132 lbf ft)
6. Remove piston rod and head assembly from tool U1. 7. Set cylinder (4) in tool U1. 8. Raise piston rod and head assembly (3), and assemble in cylinder (4).
9. Using tool U2, tighten cylinder head nut (2). Cylinder head nut: 932.0 ± 93.2 Nm (687.1 ± 68.7 lbf ft) 10. Bend lock into notch on cylinder side. 11. Remove cylinder assembly from tool U1.
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STEERING CYLINDER ASSEMBLY
DISASSEMBLY AND ASSEMBLY
STEERING VALVE
REMOVAL OF STEERING VALVE ASSEMBLY WARNING! Stop the machine on level ground and turn the steering fully to the right. Then stop the engine and put blocks under the wheels to prevent the machine from moving. 1. Remove bolt (1), Ioosen bolt (2),then rotate cover (3) carefully towards rear of machine. Rotate the cover using bolt (2) as the fulcrum. The operating space is confined, so be extremely careful when carrying out the operation. 2. Remove side cover (4).
3. Remove mounting bolts (5), and disconnect bracket (6). 4. Remove mounting bolts (7), and disconnect bracket (8).
5. Disconnect hose (9) between cut-off valve and hydraulic tank. 6. Disconnect hoses (10) and (11) between cut-off valve and loader circuit. 7. Disconnect hose (12) between steering valve and cut-off valve. Hose (12) is at the rear of the cut-off valve.
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DISASSEMBLY AND ASSEMBLY 8. Disconnect tubes (13) between steering valve and steering cylinder. 9. Disconnect tube, (14) between steering valve and hydraulic tank.
10. Disconnect hose (15) between stop valve and steering valve. 11. Disconnect hose (16) between stop valve and steering valve. It is connected to both ends of the steering valve.
12. Disconnect hose (17) between steering valve and steering pump. 13. Disconnect tube (18) between switch pump and steering valve. 14. Disconnect hose (19) between steering valve and cut-off valve. 15. Remove mounting bolt (20).
16. Using guide bolt (1), pull out steering valve assembly (21) together with bracket approx. 200 mm to center of machine. Remove the cut-off valve at this point.
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STEERING VALVE
DISASSEMBLY AND ASSEMBLY
STEERING VALVE
17. Lift off steering valve assembly (21) together with bracket.
INSTALLATION OF STEERING VALVE ASSEMBLY Carry out installation in the reverse order to removal.
Install the cut-off valve after lowering the steering valve assembly together with the bracket to the mounting position. After installing the cut-off valve, use the guide bolt to move close to the frame and install.
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DISASSEMBLY AND ASSEMBLY
REMOVAL OF BRAKE VALVE ASSEMBLY WARNING! Stop the machine on level ground and put blocks under the wheels to prevent the machine from moving. 1. Remove clamp (1) at front of brake valve. 2. Disconnect hose (2) between valve and hydraulic tank. 3. Disconnect hoses (3) and (4) between accumulator and valve. Fit a wrench to the joint to stop it from turning. 4. Remove hoses (5) between R.H. brake valve and slack adjuster. 5. Remove clamp (6). 6. Disconnect hose (7) between R.H. brake valve and L.H. brake valve. 7. Disconnect hose (8) between valve and hydraulic tank. 8. Disconnect hose (9) between accumulator and valve. 9. Remove pedal (10).
10. Pull out snap pin (11), then pull out pin (12). Be careful not to lose L-shaped pin (13).
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BRAKE VALVE
DISASSEMBLY AND ASSEMBLY
BRAKE VALVE
11. Remove mounting bolts (14), then remove brake valve assembly (15). Carry out the operation with two workers and remove the valve assembly from under the floor plate.
INSTALLATION OF BRAKE VALVE ASSEMBLY Reverse the removal procedure to install a brake valve assembly.
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DISASSEMBLY AND ASSEMBLY
REMOVAL OF SLACK ADJUSTER ASSEMBLY WARNING! Stop the machine on level ground and put blocks under the wheels to prevent the machine from moving. 1. Remove cover (1) on top of front frame.
2. Disconnect tube (2) between brake valve and slack adjuster. 3. Disconnect tube (3) between slack adjuster and left and right brake pistons. 4. Remove mounting bolts, then remove slack adjuster (4). The operating space is confined, so be extremely careful when carrying out the operation.
INSTALLATION OF SLACK ADJUSTER ASSEMBLY Carry out installation in the reverse order to removal.
Tube: 80.9 ± 12.3 Nm (60 ± 9.4 lbf ft)
Tube: 68.6 ± 9.8 Nm (50.6 ± 7.2 lbf ft)
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SLACK ADJUSTER
DISASSEMBLY AND ASSEMBLY
SLACK ADJUSTER
DISASSEMBLY OF SLACK ADJUSTER 1. Bleeder Remove bleeder (2) from body (1).
2. Cylinder Remove mounting bolts, then disconnect body (1) and cylinder (4) together with bracket (3). WARNING! There is spring tension inside the cylinder, so hold the contact surfaces and be careful when removing.
3. Piston 1) Remove spring (5) and O-ring (6). 2) Remove piston (7), then remove O-ring Use a rod of 10 mm diameter and pus h out the piston slowly. Be careful not to damage the thread with the rod.
4. Poppet Do not disassemble the poppet unless necessary. If it is disassembled, replace the whole cylinder assembly. 1) Remove cover (8) from cylinder (4), then remove plug (9), spring (10) and poppet (11). When removing the poppet, blow in air from the oil hole in the cylinder. Hold the oil port of the cylinder by hand, and do not pump in air suddenly. Be careful not to change the combination of poppet (11) and cylinder (4). When replacing, replace the poppet and cylinder as an assembly. 2) Remove O-ring (12) from poppet.
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DISASSEMBLY AND ASSEMBLY
ASSEMBLY OF SLACK ADJUSTER 1. Poppet 1) Fit O-ring (12) on poppet (11). 2) Install poppet (11), spring (10), plug (9) and cover (8), then assemble cylinder (4).
2. Piston 1) Install O-ring (13) on piston (7). 2) Insert piston (7) in cylinder (4). Check that the piston moves smoothly.
3. Cylinder 1) Install O-ring (6) and spring (5) in cylinder. Installed load of spring 43.1 Nm (4.4 kg) (9.68 lb) 2) Install body (1) and cylinder (4) together with bracket (3).
4. Bleeder Install bleeder (2).
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SLACK ADJUSTER
DISASSEMBLY AND ASSEMBLY
BRAKE
REMOVAL OF BRAKE ASSEMBLY (FRONT, REAR) WARNING! Stop the machine on level ground, install the safety bar on the frame, and put blocks under the wheels to prevent the machine from moving. 1. Remove final drive assembly. For details, see DISASSEMBLY OF FINAL DRIVE ASSEMBLY. 2. Disconnect brake tube (1). 3. Set tooI H6 in position, and sling brake and wheel hub assembly, remove mounting bolts (2), then lift off brake and wheel hub assembly (3). Brake, wheel hub assembly: 280 kg (617.3 lb)
4. Remove bearing (5) and retainer (6) from axle (4).
INSTALLATION OF BRAKE ASSEMBLY (FRONT, REAR) •
Carry out installation in the reverse order to removal.
Brake tube: 68.6 ± 9.8 Nm (50.6 ± 7.2 lbf ft)
Mounting bolt: Thread tightener (LT-2) Brake, wheel hub mounting bolt: 548.8± 58.8 Nm (405.1 ± 43.4 lbf ft)
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DISASSEMBLY AND ASSEMBLY
DISASSEMBLY OF BRAKE ASSEMBLY (FRONT, REAR) 1. Cylinder Using eye-bolt (1) (Thread dia. = 16 mm, Pitch = 2.0 mm), lift out cylinder (1).
Disassemble cylinder with following steps: 1) Screw in eye-bolts (1) (Thread dia.=16 mm, Pitch 2.0 mm), push in spring with bar (2), then pull out pin (2). 2) Remove spring (3) and shaft (4).
3)
Remove piston (5).
2. Plate, disc 1) Remove plate (6).
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BRAKE
DISASSEMBLY AND ASSEMBLY
BRAKE
2) Remove disc (7). When removing the disc and plates, put match marks on the inner gear and disc, and outer gear and plate before removing. The discs are made of soft material, so b e careful not to damage them during removal. Remove discs and plates alternately.
3. Gear assembly 1) Remove tool H6.
2) Using eyebolt (3) (Thread dia.=12 mm, Pitch =1.75 mm), lift off gear (8). 3) Remove plate (9) from gear (8).
4) Remove floating seal (10) and oil seal (11) from gear (8).
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DISASSEMBLY AND ASSEMBLY 4. Floating seal, outer race 1) Remove floating seal (12) from hub (13). 2) Remove outer races (14) and (15) from hub (13).
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BRAKE
DISASSEMBLY AND ASSEMBLY
BRAKE
ASSEMBLY OF BRAKE ASSEMBLY (FRONT, REAR) 1. Outer race, floating seal 1) Using push tool (4), press fit outer race (15) to hub (13). 2) Using push tool (5), press fit outer race (14 ) to hub (13).
3) Using tooI H9, install floating seal (12) to hub (13). Seal contact surface: Engine oil (EO30-CD) Assemble O-ring (12) to floating seal. Use alcohol to completely remove any white blooming from the surface of the O-ring. Remove all oil and grease from the floating seal and hub O-ring contact surface. Tighten tool H9 uniformly to prevent twisting of the floating seal O-ring. After press fitting, measure height at four places around the circumference and check that the difference in dimension t at all four places is within 1 mm.
2. Gear assembly 1) Using tool H5, install oil seal (11) to gear (8). Lip of oil seal: Grease (G2-LI) Mating surface of oil seal hub: Thread tightener (Loctite #648)
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DISASSEMBLY AND ASSEMBLY 2) Using tooI H8, install floating seal (10) to gear (8). Seal contact surface: Engine oil (E030-CD) Assemble O-ring (10) to floating seal. Use alcohol to completely remove any white blooming from the surface of the O-ring. Remove all oil and grease from the floating seal and retainer O-ring contact surface. Tighten tool H8 uniformly to prevent twisting of the floating seal O-ring. After press fitting, measure height t at four places around the circumference and check that the difference in dimension t at all four places is within 1 mm.
3. Assemble plate (9), then using eyebolt (3) (Thread dia.=12 mm, Pitch= 1.75 mm), raise gear (8) and install.
4. Install tool H6.
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BRAKE
DISASSEMBLY AND ASSEMBLY
BRAKE
5. Disc, plate 1) Install disc (7).
2) Install plate (6). Align notched portion of outer teeth of plate and assemble. Align the counter marks on the disc and inner gear, and plate and outer gear, then assemble the plates and discs in turn.
6. Cylinder Assemble cylinder with following steps: 1) Set piston (5) at bottom.
2) Install shaft (4) and spring (3). 3) Screw in eye-bolts (1) (Thread dia. = 6 mm, Pitch = 2.0 mm), push in spring with bar (2), then install pin (2).
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DISASSEMBLY AND ASSEMBLY 4) Fit O-ring and using eye-bolts (1) (Thread dia. = 16 mm, Pitch = 2.0 mm), match with guide bolt (i) and lift and install cylinder assembly (1). Mounting bolt: Thread tightener (LT-2) Mounting bolt: 176.5 ± 19.6 Nm (130.2 ± 14.5 lbf ft)
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BRAKE
DISASSEMBLY AND ASSEMBLY
HYDRAULIC PUMP
REMOVAL OF HYDRAULIC PUMP (SWITCH & PPC, LOADER, TORQUE CONVERTER-TRANSMISSION, STEERING) ASSEMBLY WARNING! Stop the machine on level ground and put blocks under the wheels to prevent the machine from moving. 1. Remove engine hood assembly. For details, see REMOVAL OF ENGINE HOOD ASSEMBLY. 2. Remove bulkhead assembly. For details, see REMOVAL OF BULKHEAD ASSEMBLY. 3. SWITCH+PPC pump assembly 1) Disconnect hose (1) and tube (2). 2) Remove mounting bolt (3). 3) Lift off pump assembly (4).
4. Loader pump assembly 1) Remove bolts (5), and disconnect tube (6) together with hose. 2) Disconnect hose (7).
3) Remove U-bolts (8), then remove bracket (9). 4) Remove bolt (10), then remove tube (11). 5) Remove bolt (12), then remove pump assembly (13). 6) Disconnect tube (14).
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DISASSEMBLY AND ASSEMBLY 5. Steering pump assembly 1) Remove drive shaft assembly (15).
2) Disconnect tube (16). 3) Remove bolt (17), then remove pump assembly (18).
6. Transmission, torque converter pump assembly 1) Disconnect hose (18). 2) Disconnect tube(19). 3) Remove mounting bolt (20), then remove pump assembly (21).
INSTALLATION OF HYDRAULIC PUMP (SWITCH & PPC, LOADER, TORQUE CONVERTER-TRANSMISSION, STEERING) ASSEMBLY •
Carry out installation in the reverse order to removal.
Drive shaft: 110.7 ± 12.7 Nm (81.0 ± 9.4 lbf ft)
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HYDRAULIC PUMP
DISASSEMBLY AND ASSEMBLY
HYDRAULIC TANK
REMOVAL OF HYDRAULIC TANK ASSEMBLY WARNING! Stop the machine on level ground, install the safety bar on the frame, and put blocks under the wheels to prevent the machine from moving.
• •
WARNING! Loosen the oil filler cap slowly to release the pressure inside the hydraulic tank. Then operate the steering wheel and control levers several times to release the remaining pressure in the hydraulic piping. Remove cover (1). Loosen plug (2) on top of the hydraulic tank filter and bleed the air from tank.
1. Remove plug (3), then loosen valve (4) and drain hydraulic oil. Hydraulic oil: 175
2. Sling ladder floor (5), then remove mounting bolts and lift off. Be careful of the center of gravity when lifting off the ladder floor. Ladder floor: 90 kg (198 lb)
3. Disconnect main suction tube (6). 4. Disconnect return tube (7) from cooler. 5. Disconnect main return tube (8).
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DISASSEMBLY AND ASSEMBLY 6. Disconnect hose (9) between brake valve and hydraulic tank.
7. Disconnect stop valve, charge valve, PPC, Orbit-roll, and drain hoses (10).
8. Sling hydraulic tank, then remove mounting bolts (11) and (12).
9. Lift off hydraulic tank assembly (13). Hydraulic tank assembly: 240 kg (308 lb)
INSTALLATION OF HYDRAULIC TANK ASSEMBLY •
Carry out installation in the reverse order to removal.
Plug: 11.8 ± 1.0 Nm (8.7 ± 7.2 lbf ft)
Hydraulic tank bolt: 277.3± 32.3 Nm (205 ± 23.9 lbf ft)
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HYDRAULIC TANK
DISASSEMBLY AND ASSEMBLY
HYDRAULIC FILTER
REMOVAL OF HYDRAULIC FILTER ASSEMBLY WARNING! Loosen the oil filler cap slowly to release the pressure inside the hydraulic tank. 1. Remove cover (1). 2. Loosen plug (2) and bleed air from tank, then remove mounting bolts, and remove cover (3).
WARNING! The cover is under pressure from a spring. Remove the cover slowly and carefully. 3. Remove spring (4). 4. Remove bypass valve (5).
5. Remove filter (6).
INSTALLATION OF HYDRAULIC FILTER ASSEMBLY •
Carry out installation in the reverse order to removal.
Plug: 11.8 ± 1.0 Nm (8.7 ± 7.2 lbf ft)
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DISASSEMBLY AND ASSEMBLY
REMOVAL OF PPC VALVE ASSEMBLY WARNING! Stop the machine on level ground, install the safety bar on the frame, and put blocks under the wheels td prevent the machine from moving. WARNING! Loosen the oil filler cap slowly to release the pressure inside the hydraulic tank. Then operate the steering wheel and control levers several times to release the remaining pressure in the hydraulic piping. • Open cover (1). • Loosen plug (2) on top of the hydraulic tank filter and bleed the air from tank. 1. Remove console box cover (3) on right side of operator's seat. 2. Disconnect rods (4). 3. Disconnection of hoses from PPC valve 1) Disconnect hoses P1 (5) and P4 (6) for bucket control 2) Disconnect hoses P3 (7) and P2 (8) for boom control 3) Disconnect hose (9) from PPC pump 4) Remove eyebolt (10) of return hose leading to hydraulic tank. After disconnecting the hoses, fit tags to distinguish them. 4. Remove mounting bolts (11), then remove PPC valve assembly (12).
INSTALLATION OF PPC VALVE ASSEMBLY •
Carry out installation in the reverse order to removal.
Plug: 11.8 ± 1.0 Nm (8.7 ± 7.2 lbf ft)
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PPC VALVE
DISASSEMBLY AND ASSEMBLY
PPC VALVE
DISASSEMBLY OF PPC VALVE ASSEMBLY 1. Remove bolt (1). 2. Remove plate (2). 3. Remove seal (3), then remove collar (4). 4. Remove valve assembly and center spring (7) from valve body (10). 5. Remove collar (11), then remove retainer (6), shim (12), and spring (8) from valve (9).
ASSEMBLY OF PPC VALVE ASSEMBLY 1. Push shim (12), spring (8), and retainer (6) into valve (9), and install collar (11). 2. Install center spring (7) and valve assembly to valve body (10). 3. Install spool (5). 4. Fit O-ring and install collar (4). 5. Install seal (3). 6. Fit plate (2) and install bolt (1). Bolt: 44.1 ± 4.9 Nm (325.5 ± 36.2 lbf ft)
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DISASSEMBLY AND ASSEMBLY
REMOVAL OF MAIN CONTROL VALVE ASSEMBLY WARNING! Stop the machine on level ground, install the safety bar on the frame, and put blocks under the wheels to prevent the machine from moving. WARNING! Loosen the oil filler cap slowly to release the pressure inside the hydraulic tank. Then operate the steering wheel and control levers several times to release the remaining pressure in the hydraulic piping. 1. Open cover (1). 2. Loosen plug (2) on top of the hydraulic tank filter and bleed air from tank. 3. Remove bucket cylinder assembly. For details, see REMOVAL OF BUCKET CYLINDER ASSEMBLY. 4. Remove bolt (3), then remove cover (4).
5. Remove bolt (5), and loosen bolt (6), then rotate cover (7) carefully to right. Rotate the cover on the right side of the chassis to the left. Rotate the cover using bolt (6) as the fulcrum. The operating space is confined, so be extremely careful when carrying out the operation.
6. Disconnect hose (13) for bucket spool between PPC valve (P1) and main control valve (PB1).
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MAIN CONTROL VALVE
DISASSEMBLY AND ASSEMBLY
MAIN CONTROL VALVE
7. Disconnect hose (14) for boom spool between PPC valve (P3) and main control valve (PB2). 8. Disconnect hose (15) for bucket spool between PPC valve (P4) and main control valve (PA1). 9. Disconnect hose (16) for boom spool between PPC valve (P2) and main control valve (PA2). Remove the hose clamp. After disconnecting the hose, move it to the rear of the machine. After disconnecting the hoses, fit tags to distinguish them. 10. Disconnect hose (17) between main control valve and hydraulic tank.
11. Remove tube (18) between main control valve and bucket cylinder together with hose. 12. Remove tube (19) between main control valve and boom cylinder. 13. Disconnect tube (20) from manifold. 14. Remove bracket (21) of tube.
15. Disconnect hose (22) between steering valve and main control valve from main control valve. 16. Disconnect tube (23) between hydraulic tank and main control valve from main control valve.
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DISASSEMBLY AND ASSEMBLY 17. Remove tube (24) between main control valve and bucket cylinder together with hose. 18. Disconnect tube (25) between main control valve and boom cylinder from main control valve. Loosen the tube clamp.
19. Remove mounting bolts and rotate main control valve (26) 90
20. Using eyebolts, lift off main control valve. Be careful of the slack adjuster bleed screw when removing. Main valve: 91 kg (200.2 lb)
INSTALLATION OF MAIN CONTROL VALVE ASSEMBLY Carry out installation in the reverse order to removal.
Plug: 11.8 ± 1.0 Nm (8.68 ± .7 lbf ft) To refill with oil (hydraulic tank), add oil through oil filler to the specified level. Run the engine to circulate the oil through the system. Then check the oil level again.
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MAIN CONTROL VALVE
DISASSEMBLY AND ASSEMBLY
MAIN CONTROL VALVE
DISASSEMBLY OF MAIN CONTROL VALVE
1. Spool assembly
1)
Remove sleeve (1), then remove case (2).
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DISASSEMBLY AND ASSEMBLY 2) 3) 4) 5)
Remove spring (3) and retainer (4). Remove spring (5) and retainer (6). Remove piston (7), spring (8), and spacer (9). Remove spool assembly (10). Disassemble spool assembly. Remove plugs (12) and (13) from spool (11).
2. Main relief valve 1) Remove main relief valve assembly (14). Disassemble main relief valve assembly. i) Loosen nut (15), and pull out adjustment screw (16), then remove retainer (17), spring (18), spacer (19), and poppet (20) Before loosening nut (15), measure the protrusion of screw (16) from the end face of the nut. ii) Loosen nut (21), then remove holder (22), seat (23), and backup ring (24). iii) Remove snap ring (25), then remove retainer (26), valve (27), and spring (28) from sleeve (29). iv) Remove backup ring (30) from sleeve. If there is any abnormality in the sleeve or valve, replace as an assembly. 3. Safety valve assembly with suction Remove safety valve assembly (31). The safety valve cannot be adjusted when it is on the machine, so do not disassemble it.
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MAIN CONTROL VALVE
DISASSEMBLY AND ASSEMBLY
MAIN CONTROL VALVE
4. Suction valve assembly Remove suction valve assembly (32). Disassemble suction valve assembly (32). i) Remove valve (33) together with seal (34). ii) Remove seal (34) from valve (33). iii) Remove spring (35) from sleeve (36). If there is any abnormality in the sleeve or valve, replace as an assembly.
5. Selector valve assembly Remove selector valve assembly (37). 1) Remove sleeve (38) together with seat (39). Seat (39) is press fitted to sleeve (38) (press fitting load: 1,177 - 7,845 N (120 800 kg), so if there is any abnormality replace as an assembly. (The same applies for the sleeve.) 2) Remove nipple (40), then remove shim (41), spring (42), and piston (43). Check the number and thickness of the shims, and keep in a safe place. 6. Check valve assembly 1) Remove plate (44), then remove spring (45) and check valve (46). 2) Remove flange (47), then remove spring (48), seal (49), and valve (50).
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DISASSEMBLY AND ASSEMBLY
MAIN CONTROL VALVE
MEMORANDA
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DISASSEMBLY AND ASSEMBLY
MAIN CONTROL VALVE
ASSEMBLY OF MAIN CONTROL VALVE
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DISASSEMBLY AND ASSEMBLY 1. Check valve assembly 1) Assemble valve (50), seal (49), and spring (48) in valve body (51), then fit O-ring and install flange (47). Flange surface: Thread tightener (LT-2) 2) Assemble check valve (46) and spring (45) in valve body, then fit O-ring and install plate (44). 88.2 ± 9.8 Nm (65.1 ± 7.2 lbf ft) 2. Selector valve assembly Assemble selector valve assembly. 1) Assemble piston (43), spring (42), and shim (41) in sleeve (38), then fit O-ring and install nipple (40). Nipple: 22.1 ± 2.5 Nm (162.5 ± 18.1 lbf ft) Fit O-ring and install selector valve assembly (37). Selector valve 68.6 ± 9.8 Nm (50.6 ± 7.2 lbf ft) 3. Suction valve assembly Assemble suction valve assembly. i) Assemble spring (35) in sleeve (36). ii)
Assemble seal (34) in valve (33), and install to sleeve (36).
Fit O-ring and install suction valve assembly (32). Suction valve assembly: 186.2 ± 9.8 Nm (130.2 ± 7.2 lbf ft) 4. Safety valve assembly with suction Fit O-ring and install safety valve assembly (31). Safety valve : 186.2 ± 9.8 Nm (130.2 ± 7.2 lbf ft)
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MAIN CONTROL VALVE
DISASSEMBLY AND ASSEMBLY
MAIN CONTROL VALVE
5. Main relief valve assembly Assemble main relief valve. i) Install backup ring (30) and O-ring to sleeve (29). ii) Assemble spring (28), valve (27), and retainer (26) in sleeve (29), and install snap ring (25). iii) Fit backup ring (24) and O-ring, and assemble seat (23) in sleeve. iv) Screw nut (21) into holder (22), then fit O-ring and assemble in sleeve, and tighten nut. Holder: 39.2 ± 9.8 Nm (28.9 ± 7.2 lbf ft) Nut thread Thread tightener (LT-2) Nut: 152.0 -± 24.5 Nm (112.1 ± 18.1 lbf ft) v)
Assemble poppet (20), spacer (19), spring (18), and retainer (17), and screw in adjustment screw (16). Adjus t protrusion from end face of nut (15) to same dimension as at time of disassembly, then tighten with nut (15). Nut thread: Thread tightener (LT-2) Nut: 39.2 ± 4.9 Nm (28.9 ± 3.6 lbf ft)
Fit O-ring and install main relief valve assembly (14). Main relief valve assembly: 323.6 ± 44.1 Nm (238.7 ± 32.5 lbf ft) 6. Spool assembly Assembly of spool assembly. Install plugs (13) and (12) to spool (11). Nut thread: Tightener (LT-2) Nut: 24.5 ± 4.9 Nm (18.1 ± 3.6 lbf ft) 1) Assemble spool assembly (10) in valve body. 2) Assemble spacer (9), spring (8), and piston (7). 3) Assemble retainer (6), spring (5), retainer (4), and spring (3), then fit O-ring and install case (2) and sleeve (1).
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DISASSEMBLY AND ASSEMBLY
REMOVAL OF BUCKET CYLINDER ASSEMBLY WARNING! Stop the machine on level ground, install the safety bar on the frame, and put blocks under the wheels to prevent the machine from moving. WARNING! Pressure in the hydraulic system must be released. Loosen the oil filler cap slowly to release pressure inside the hydraulic tank. Operate steering wheel and control levers several times to release the remaining pressure in the hydraulic piping. 1. Disconnect connector (1) for bucket positioner. 2. Disconnect grease tube (2) from bottom pin. 3. Disconnect head hose (3). 4. Disconnect bottom hose (4).
5. Sling cylinder then remove lockbolt, and remove head pin (5).Sling from two points and be careful of the center of gravity.
6. Remove lock bolt, then remove bottom pin (6). If there are shims, check the number and thickness of the shim.
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BUCKET CYLINDER
DISASSEMBLY AND ASSEMBLY
BUCKET CYLINDER
7. Remove bucket cylinder assembly (7). Be careful not to damage the cylinder rod. Bucket cylinder assembly: 286 kg (629.2 lb)
INSTALLATION OF BUCKET CYLINDER ASSEMBLY Carry out installation in the reverse order to removal.
When aligning the pin hole at the bottom end, assemble shims so that the total clearance between the cylinder and frame is within the specified value, then assemble pin (6) and lock with the bolt. Clearance a + b = Less than 1.0 mm
WARNING! Align the position of the pin hole with a bar. Never insert a finger in the pin hole.
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DISASSEMBLY AND ASSEMBLY
REMOVAL OF BOOM CYLINDER ASSEMBLY WARNING! Stop the machine on level ground, install the safety bar on the frame, and put blocks under the wheels to prevent the machine from moving. WARNING! Loosen the oil filler cap slowly to release the pressure inside the hydraulic tank. Then operate the steering wheel and control levers several times to release the remaining pressure in the hydraulic piping. 1
Lift off fender (1). Fender: 25 kg (55 lb)
2. Sling boom cylinder, then remove lock bolt, and remove pin (3). Start the engine and operate the control lever to retract the cylinder rod of the cylinder where the pin has been removed. After stopping the engine, release the remaining pressure from the hydraulic piping.
3. Disconnect head hose (4) and bottom hose (5).
4. Fit lifting tool to bottom of boom cylinder (2), then use lever block (1) to pull out to rear of machine. 5. Using forcing screws, remove bottom pin (6) If there are shims, check the number and thickness of the shim.
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BOOM CYLINDER
DISASSEMBLY AND ASSEMBLY
BOOM CYLINDER
6. Lift off boom cylinder assembly (2). Be careful not to damage the cylinder rod. Boom cylinder assembly: 272 kg (598.4 lb)
INSTALLATION OF BOOM CYLINDER ASSEMBLY Carry out installation in the reverse order to removal.
When aligning the pin hole at the bottom end, assemble shims so that the total clearance between the cylinder and frame is within the specified value, then assemble pin (6) and lock with the bolt. Clearance a + b = Less than 1.0 mm WARNING! When aligning the position of the pin hole, use a bar. Never insert your fingers in the pin hole.
30-209
DISASSEMBLY AND ASSEMBLY
DISASSEMBLY OF BOOM AND BUCKET CYLINDERS ASSEMBLY 1. Set cylinder assembly (1) tool U1. 2. Remove mounting bolts (2) of cylinder head.
3. Pull cylinder head and piston rod assembly (3) out from cylinder (4), then lift off. Oil will come out when the piston rod assembly is removed from the cylinder, so catch it in a container.
4. Remove piston bolts (5), then remove spacer (6), piston assembly (7) and cylinder head assembly (8).
5. Remove O-ring (10) and backup ring (11) from piston rod (9).
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BOOM AND BUCKET CYLINDERS
DISASSEMBLY AND ASSEMBLY
BOOM AND BUCKET CYLINDERS
6. Disassembly of piston assembly Remove wear ring (12) and piston ring (13) from piston (14).
7. Disassembly of cylinder assembly 1) Remove O-ring (15 )and back up ring(16). 2) Remove snap ring, then remove dust seal (17).
3) Remove rod packing (18). 4) Remove bushing (19).
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DISASSEMBLY AND ASSEMBLY
ASSEMBLY OF BOOM AND BUCKET CYLINDERS ASSEMBLY Clean all parts, and check for dirt or damage. Coat the sliding surfaces of all parts with engine oil before installing. Be careful not to damage the U-packings, dust seals or O-ring when assembling.
1. Assembly of cylinder head assembly 1) Using push tooI U5, press fit bushing (19) on cylinder head (20). Be careful not to deform the bushing when press fitting. 2) Assemble rod packing (18). Be careful to install the rod packing facing in the correct direction. 3) Assemble buffer ring (21). 4) Assemble backup ring (16) and O-ring (15) in order. Do not try to force the backup ring into position. Heat the backup ring in warm water (50
5) Using push tool U4, install dust seal (17) to cylinder head, then secure with snap ring.
30-212
BOOM AND BUCKET CYLINDERS
DISASSEMBLY AND ASSEMBLY
BOOM AND BUCKET CYLINDERS
2. Assembly of piston assembly 1) Using tool U6-1, expand piston ring (13). Set the piston ring on the expander and turn the handle 8 - 11 times to expand the ring. 2) Remove piston ring from tool U6-1, and assemble on piston (14). 3) Fit tools U6-2, on piston ring, then using clamp U6-3, compress piston ring. 4) Assemble wear ring (12) on piston.
3. Assemble O-ring (10) and backup ring (11) on piston rod (9).
4. Assemble cylinder head assembly (8) and piston assembly (7) on piston rod. Coat backup ring (11) with grease so that it does not stick out, and assemble carefully. 5. Assemble spacer (6), then tighten piston bolts (5). Piston bolt : 176.5 ± 19.6 Nm (130.2 ± 14.5 lbf ft) Piston bolt: Adhesives (LT-2)
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DISASSEMBLY AND ASSEMBLY 6. Set cylinder (4) in tool U1, then raise piston rod and head assembly (3), and assemble in cylinder (4).
Tighten cylinder head mounting bolts (2). Cylinder head mounting bolt: 662 ± 74 Nm (501 ± 542.5 lbf ft) Remove cylinder assembly (1) from tool U1.
30-214
BOOM AND BUCKET CYLINDERS
DISASSEMBLY AND ASSEMBLY
CENTER HINGE PIN
REMOVAL OF CENTER HINGE PIN Warning! Stop the machine on level ground, install the safety bar on the frame, and block the wheels to prevent the machine from moving. Warning! Loosen the oil filler cap slowly to release the pressure inside the hydraulic tank. Then operate the steering wheel and control levers several times to release the remaining pressure in the hydraulic piping. 1. Open cover (1) and loosen plug (2) on top of hydraulic tank to prevent oil from flowing out from tank.
2. Remove bolt (3), then remove cover (4).
3. Remove plug (5), then loosen valve (6) and drain hydraulic oil. When draining thehydraulic oil, drain to the level of the bottom of each pipe. Hydraulic oil : 140 piping)
f
4. Remove covers (7) and (8) at bottom of cab.
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DISASSEMBLY AND ASSEMBLY 5. Remove left and right steering cylinder pins (9). If there are shims between the pin and frame, check the number and thickness. 6. Remove guard (10), then remove center drive shaft (11). Center drive shaft assembly: 31 kg (68.2 lb) 7. Disconnect hose (12) between brake valve and slack adjuster.
8. Disconnect connectors (13) FR1 and (14) FR2. Disconnect the clamps under the floor.
9. Disconnect hoses (15) and (16) between steering valve and stop valve at steering valve end.
10. Disconnect hose (17) between steering valve and oil cooler. 11. Disconnect hose (18) between work equipment control valve and hydraulic tank. 12. Disconnect hose (19) between work equipment control valve and loader pump.
30-216
CENTER HINGE PIN
DISASSEMBLY AND ASSEMBLY
CENTER HINGE PIN
13. Disconnect bypass hose (20) from hydraulic circuit at top of tank. 14. Disconnect hoses P1 (21) and P4 (22) for bucket control. 15. Disconnect hoses P3 (23) and P2 (24) for boom control. Disconnect the clamps at the rear frame end.
16. Using hydraulic jack to rear frame, insert block (1) while adjusting height. Put support stands (2) under the left and right side of the frame. 17. Put support stand (2) under counterweight.
18. Using jack under front frame, insert block (3).
19. Remove mounting bolts, then remove retainer (25). If there are shims between the retainer and frame, check the number and height.
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DISASSEMBLY AND ASSEMBLY 20. Adjust height carefully so that lower hinge pin (26) can be removed easily by hand.
21. Remove spacer (27).
22. Remove mounting bolts, then remove retainer (28).
23. Using puller, remove upper hinge pin (29) and spacer(30).
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CENTER HINGE PIN
DISASSEMBLY AND ASSEMBLY
CENTER HINGE PIN
24. Remove safety bar, then pull out front frame towards front and disconnect frame. Be careful not to let the spacer at the top of the lower hinge get caught in the rear frame. Carry out the operation carefully and pay attention to maintaining the balance. Move approx. 100 mm (3.9 in) at a time.
25. Remove mounting bolts, then remove retainer (31). If there are shims between the retainer and frame, check the number and thickness.
26. Remove dust seal (32) from retainer (31).
27. Remove spacer (33) and dust seal (34) from front frame.
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DISASSEMBLY AND ASSEMBLY 28. Remove bearing (35).
29. Remove retainer (36). If there are shims between the retainer and frame, check the number and thickness.
30. Remove dust seal (37) from retainer. Remove dust seal (38) at the frame end.
31. Remove bearing (39).
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CENTER HINGE PIN
DISASSEMBLY AND ASSEMBLY
CENTER HINGE PIN
INSTALLATION OF CENTER HINGE PIN Carry out installation in the reverse order to removal.
Plug: 11.8 ± 1.0 Nm (8.68 ± .7 lbf ft)
Adjust the shims so that the clearance is the specified value. Clearance a + b = Less than 1.0 mm
Drive shaft mounting bolt: 110.7 ± 12.7 Nm (752.2 ± 94 lbf ft)
Outer circumference of hinge pin: Grease (G2-LI) Measure clearance c between the retainer and frame at four places on the inside circumference, and select a shim thickness to make the value 0.08 - 0.18 mm less than the measured value. When adjusting the shim, temporarily tighten the retainer mounting bolts to act as a stopper. When tightening the mounting bolts, first tighten the retainer mounting bolts to the specified torque, then tighten the pin mounting bolts. After selecting the shim, assemble the retainer to the specified torque. Remove all oil and grease from the mounting bolts and mount holes. Mounting bolt: Thread tightener (Loctite 262) Mounting bolt (48) when adjusting shims: 276.3 ± 29.4 Nm (206 ± 21.7 lbf ft) Mounting bolt (48): 276.3 ± 29.4 Nm (206 ± 21.7 lbf ft) Mounting bolt (49) when adjusting shims 382.2 ± 34.3 Nm (282.1 ± 25.3 lbf ft)
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DISASSEMBLY AND ASSEMBLY
Assemble spacer (30), insert upper hinge (29), then tap three times with a copper hammer to settle the parts. Never coat spacer (30) with grease. Outer circumference of hinge pin Grease (G2-LI) Mounting bolt (46): Thread tightener (Loctite 262) Mounting bolt (46): 176.4 ± 19.6 Nm (130.2 ± 14.5 lbf ft) Mounting bolt (47): 176.4 ± 19.6 Nm (130.2 ± 14.5 lbf ft) Grease on spacer (28) may prevent the mounting bolts being tightened to the specified tightening torque. Remove any grease and tighten again.
Use tool K2 to press fit the bearing and spacer to the frame. Make sure the bearing is not at an angle. Fill the inside of the bearing with grease. When assembling the bearing, be sure to assemble the spacer. The clearance of the bearing is adjusted, so do not change the combination of bearing and spacer. When replacing, replace as a set. Press fit so that the lip of the dust seal is facing the outside. Lip of oil seal: Grease (G2-LI) Measure clearance a between retainer (31) and hinge at four places on the inside circumference, and select a shim thickness to make the value 0.08 - 0.18 mm less tha n the measured value. After selecting the shim, assemble the retainer to the specified torque. Mounting bolt (when adjusting shims): 98.0 ± 9.8 Nm (72.3 ± 7.2 lbf ft) Mounting bolt: 176.4 ± 19.6 Nm (130.2 ± 14.5 lbf ft)
30-222
CENTER HINGE PIN
DISASSEMBLY AND ASSEMBLY
CENTER HINGE PIN
Using tool K1, press fit the bearing and spacer to the frame. When press fitting the bearing, be careful that the bearing is not at an angle. Fill the inside of the bearing with grease. When assembling the bearing, be careful not to forget to assemble the spacer. The clearance of the bearing is adjusted, so do not change the combination of bearing and spacer. When replacing, replace as a set. Press fit so that the lip of the dust seal is facing the outside. Lip of oil seal: Grease (G2-LI) Measure clearance a between retainer (36) and the hinge at four places on the inside circumference, and select a shim thickness to make the value 0.08 - 0.18 mm less than the measured value. After selecting the shim, assemble the retainer to the specified torque. Mounting bolt (when adjusting shims): 58.8 ± 5.9 Nm (43.4 ± 4.3 lbf ft) Mounting bolt: 176.4 ± 19.6 Nm (130.2 ± 14.5 lf ft) After completion of mounting the hinge pin, fill with oil and bleed the air. 1) Tighten the plug on the top of the hydraulic tank filter, then add hydraulic oil through oil filler to the specified level. Plug on top of filter 11.8 ± 1.0 Nm (8.7 ± .7 lbf ft) Hydraulic oil: Approx. 140 Run the engine to circulate the oil through the system. Then check the oil level again. 2) Bleed the air from the brake system. For details, see TESTING AND ADJUSTING.
30-223
DISASSEMBLY AND ASSEMBLY
REMOVAL OF WORK EQUIPMENT Warning! Stop the machine on level ground, install the safety bar on the frame, block the wheels to prevent the machine from moving. 1. Remove mounting pin (1) of bucket link. Remove cord ring. Tie the bucket link to the tilt lever with wire. Mounting pin: 25 kg (55 lb) 2. Remove mounting pin (2) of bucket hinge. Remove cord ring. Warning! Use a bar to align the pin holes. Never use your fingers. Mounting pin: 25 kg (55 lb) 3. Move machine to rear and disconnect bucket.
4. Temporarily sling bucket cylinder (3), pull pin (4), then disconnect cylinder rod and tilt lever. Attach lifting tool to bucket cylinder and secure in the rear. Bucket cylinder: 285 kg (627 lb) Mounting pin: 30 kg (66 lb)
5. Attach lever block (1) to boom cylinder (5), pull machine to rear and remove mounting pin (6). Boom cylinder: 272 kg (598.4 lb)
Mounting pin: 25 kg (55 lb)
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WORK EQUIPMENT
DISASSEMBLY AND ASSEMBLY
WORK EQUIPMENT
6. Temporarily sling bellcrank (7) and bucket link, remove mounting pin (8), then lift out from boom (9). Remove with the bucket link still fitted. Three technicians are necessary for removal of mounting pin operation. Bellcrank and bucket link: 615 kg (1365 lb) Mounting pin: 59 kg (129.8 lb)
7. Temporarily sling bucket link (10), remove mounting pin (11), then lift out from bellcrank (7). Remove cord ring. Bucket link: 103 kg (226.6 lb) Mounting pin: 25 kg (55 lb) Note the number of shims at this location for reference when installing.
8. Remove boom kickout switch (13).
9. Temporarily sling boom (9), pull out mounting pin of boom, then lift out boom. Shims are installed at connecting point of front frame and boom, so check the number of shims. Boom: 2,025 kg (4455 lb) Mounting pin: 35 kg (77 lb)
30-225
DISASSEMBLY AND ASSEMBLY 10. Pull out dust seal (14) and bushing (15) from boom (9).
11. Pull out dust seal (16) and bushing (17) from bellcrank (7)
30-226
WORK EQUIPMENT
DISASSEMBLY AND ASSEMBLY
WORK EQUIPMENT
12. Pull out dust seal (18) and bushing (19) from bucket link (10).
After long use, wear can make the pin difficult to remove. A puller (pin puller jig) such as the one shown here can be helpful when removing a pin.
30-227
DISASSEMBLY AND ASSEMBLY
INSTALLATION OF WORK EQUIPMENT ASSEMBLY Carry out installation in the reverse order to removal.
Clearance g + h = Less than 1.0 mm Be careful not to get cord ring (22) caught.
Clearance e + f = Less than 1.0 mm Be careful not to get cord ring (21) caught.
Secure the bucket link and bellcrank with wire. Insert shims so that the clearance is equal on the left and right. Clearance c + d = Less than 1.0 mm Be careful not to get cord ring (20) caught.
Align the hole in the boom mount and the front frame, then insert shims to make th e clearance equal on the left and right. Clearance a + b = Less than 1.0 mm After assembling the pin, set the support stand to the tip of the boom. Grease each pin.
30-228
WORK EQUIPMENT
DISASSEMBLY AND ASSEMBLY
BULKHEAD
REMOVAL OF BULKHEAD ASSEMBLY Warning! Stop the machine on level ground and put blocks under the wheels to prevent the machine from moving. 1. Remove engine hood assembly (1). For details, see REMOVAL OF ENGINE HOOD ASSEMBLY. 2. Remove bulkhead left side cover (2). Disconnect the connector (BR1) at the bottom at the engine end of the left side of the bulkhead. Reach in at the point marked by the arrow, and disconnect the connector (BR1).
3. Remove bulkhead hood (3). 4. Remove floor plate (4). 5. Remove covers (5) and (6).
6. Disconnect hose (7) at receiver tank end. 7. Disconnect hose (8) at condenser end. Disconnect the accelerator control cable at the fuel pump end.
30-229
DISASSEMBLY AND ASSEMBLY 8. Disconnect brake hoses (9), (10), and (11). 9. Disconnect emergency brake valve connecting hoses (12), (13), and (14).
10. Disconnect accumulator charge valve connecting hoses (15), (16), and (17). 11. Disconnect PPC pump connecting hose (18). 12. Disconnect PPC accumulator inlet hose (19). 13. Disconnect window washer hoses (20). 14. Disconnect transmission breather (21). After disconnecting the hoses, fit tags to distinguish them. 15. Remove four mounting bolts (22) and (23). 16. Lift off bulkhead assembly (24). Bulkhead assembly: 220 kg (484 lb)
INSTALLATION OF BULKHEAD ASSEMBLY Install the hoses without twisting or interference. When installing the hoses, be careful not to let dirt, dust, or moisture get inside the hoses. Using a gas charger (X3), charge with new freon gas (R134a).
30-230
BULKHEAD
DISASSEMBLY AND ASSEMBLY
ENGINE HOOD
REMOVAL OF ENGINE HOOD ASSEMBLY Warning! Stop the machine on level ground, set the parking brake to the PARKING position, and block wheels to prevent the machine from moving. Open the left and right inspection covers. 1. Remove exhaust tube (1). 2. Remove radiator grille (2). Remove the baffle plate on both sides of the radiator. 3. Disconnect head lamp connector (3). 4. Disconnect water level sensor connector (4). 5. Remove six mounting bolts (5) and four mounting bolts (6). 6. Remove radiator support (7).
7. Lift off engine hood (8). There are clamps for the air conditioner hoses at two places inside the engine hood on the right, so disconnect them. Use a lever block to maintain the balance when lifting off. Engine hood assembly: 470 kg (1034 lb)
INSTALLATION OF ENGINE HOOD ASSEMBLY Carry out installation in the reverse order to removal.
30-231
DISASSEMBLY AND ASSEMBLY
REMOVAL OF FLOOR FRAME ASSEMBLY Warning! Stop the machine on level ground, install the safety bar on the frame, and block the wheels to prevent the machine from moving. 1. Remove cab assembly. For details, see REMOVAL OF CAB ASSEMBLY. 2. Remove left and right ladders (1) and (2). Ladder: 90 kg (198 lb) 3. Remove floor plate (4) and cover (3) of bulkhead. 4. Disconnect wiring connectors (5) (TM1, 2, LR16). 5. Disconnect ground connection (6).
6. Disconnect hoses (7) between brake valve and slack adjuster. 7. Disconnect hose (9) between Orbit-roll (8) and hydraulic tank. 8. Disconnect hose (10) between Orbit-roll (8) and accumulator. 9. Disconnect hoses (11) between Orbit-roll (6) and stop valve.
10. Disconnect return hose (12) between Orbit-roll valve and hydraulic tank. 11. Disconnect return hose (13) coming from PPC valve. 12. Disconnect return hose (14) coming from brake valve. After disconnecting the hose, install a blind plug to prevent contamination.
30-232
FLOOR FRAME
DISASSEMBLY AND ASSEMBLY
FLOOR FRAME
13. Remove mounting bolts (15), then remove brake hose bracket (16). 14. Disconnect PPC hoses (17). The hoses are fitted with self-seal couplings. 15. Disconnect hose (18) from accumulator.
16. Disconnect accumulator charge valve connecting hoses (19) and (20). 17. Disconnect PPC accumulator connecting hose (21). 18. Disconnect two window washer hoses (22). 19. Disconnect two hoses (23) from brake valve.
20. Disconnect air conditioner compressor hose (24). There are hose clamps at two places inside the engine hood. Remove the hose clamps. 21. Remove clamp (25) and joint (26), then remove accelerator cable (27).
22. Disconnect heater hoses (28) and (29). Hose (29) is installed under the connector at the suction end of the water pump. Drain the coolant.
30-233
DISASSEMBLY AND ASSEMBLY
FLOOR FRAME
23. Remove floor frame mount mounting nuts (30 ) (four places). 24. Lift off floor frame assembly (31). Check that all the clamps and wiring harnesses have been disconnected. Floor frame assembly: 280 kg (617 lb)
INSTALLATION OF FLOOR FRAME ASSEMBLY Carry out installation in the reverse order to removal.
Install the hoses interference.
without
twisting
or
When installing the hoses, be careful to prevent dirt, dust, or moisture from getting inside the hoses. Using a gas charger (X3), charge with new freon gas (R134a).
Mount nut: 277.3 ± 32.3 Nm (202.5 ± 23.9 lbf ft) Refilling with coolant Tighten radiator drain valve and add coolant through water filler to the specified level. Run the engine to circulate the coolant through the system. Then check the water level again.
30-234
DISASSEMBLY AND ASSEMBLY
COUNTERWEIGHT
REMOVAL OF COUNTERWEIGHT Warning! Stop the machine on level ground, install the safety bar on the frame, and block the wheels to prevent the machine from moving. 1. Sling counterweight (19), then remove mounting bolts, and lift off.
When lifting off the counterweight, be careful to maintain the balance. Counterweight: 1,500 kg (3,300 lb)
INSTALLATION OF COUNTERWEIGHT Carry out installation in the reverse order to removal.
Counterweight mounting bolt: 1,568 ± 196 Nm (1157 ± 144 lbf ft)
30-235
DISASSEMBLY AND ASSEMBLY
FUEL TANK
REMOVAL OF FUEL TANK ASSEMBLY Warning! Stop the machine on level ground, install the safety bar on the frame, and block the wheels to prevent the machine from moving. 1. Loosen drain valve (1) and drain fuel. Check the fuel level before draining. Fuel (when full): 486
)
2. Remove engine oil drain valve (2) from fuel tank. 3. Disconnect hose (3) between injection pump and fuel tank. 4. Disconnect hose (4) between fuel tank and feed Pump. 5. Disconnect spill hose (5).
6. Disconnect connector (6) for fuel level sensor. 7. Remove hoses (7) of blow-by and muffler.
8. Sling fuel tank assembly (8), then remove mounting bolts and slowly lower the tank. Put a pallet under the tank, then be careful to maintain the balance of the tank assembly, and lower it on to the pallet. Fuel tank assembly: 246 kg (541.2 lb) Before pulling out the fuel tank assembly, remove breather tube (9). The bottom surface of the tank is not flat, and there is danger that it may slip, so be extremely careful when handling it.
30-236
DISASSEMBLY AND ASSEMBLY
FUEL TANK
INSTALLATION OF FUEL TANK ASSEMBLY Carry out installation in the reverse order to removal.
Fuel tank mounting bolt: 931.0 ± 98.0 Nm (686 ± 72 lbf ft) Be careful of breather tube (9) when raising the tank.
30-237
DISASSEMBLY AND ASSEMBLY
REMOVAL OF CAB ASSEMBLY Warning! Stop the machine on level ground, install the safety bar on the frame, and block the wheels to prevent the machine from moving. 1. Remove covers (1) at bottom of floor frame.
2. Remove right cover (2) inside cab.
3. Disconnect electric wiring connectors (3). 4. Disconnect window washer hose (4).
5. Remove two steering post lock bolts (5).
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CAB ASSEMBLY
DISASSEMBLY AND ASSEMBLY
CAB ASSEMBLY
6. Remove plastic mounting bolts and pull up rubber boot (6) at bottom of steering post.
7. Remove four bolts (7), then tip steering post over fully towards operator's seat. At the same time, set the column tilt lever to the unlock position and tip the steering column over fully toward the operator's seat.
8. Remove two cab mounting bolts (8) and four mounting bolts (9) each at intermediate position and rear.
9. Raise cab assembly (10) slowly and keep horizontal when lifting off. Be careful that there is no interference with the electric wiring at the rear right of the floor frame. Cover the steering post and plastic cover with a sheet to prevent any damage.
30-239
DISASSEMBLY AND ASSEMBLY
INSTALLATION OF CAB ASSEMBLY Carry out installation in the reverse order to removal.
When installing the cab assembly, be sure to install the seal. Coat the seal uniformly with adhesive.
Seal: Adhesive (Cemedyne 366E)
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CAB ASSEMBLY
DISASSEMBLY AND ASSEMBLY
AIR CONDITIONER UNIT
REMOVAL OF AIR CONDITIONER UNIT ASSEMBLY Warning! Stop the machine on level ground, install the safety bar on the frame, and block the wheels to prevent the machine from moving. Warning! Disconnect the cable from the negative (-) terminal of the battery. 1. Remove cab assembly. For details, REMOVAL OF CAB ASSEMBLY.
see
2. Remove connector (1) 3. Install freon gas collector and regenerator to plug (2), and collect refrigerant. 4. Remove operator's seat (3). Operator's seat assembly: 40 kg (88 lb)
5. Remove rear console box (4). 6. Remove console box cover (5). 7. Remove console box (6).
8. Disconnect connector (7) (CL3). 9. Disconnect connector (8) (CL2). 10. Disconnect tubes (9). 11. Disconnect heater hoses (10).
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DISASSEMBLY AND ASSEMBLY 11. Remove mounting bolt (11), then remove air conditioner unit assembly (12). Pull the unit out to the left and remove it.
INSTALLATION OF AIR CONDITIONER UNIT ASSEMBLY Carry out installation in the reverse order to removal. Using a gas charger (X3), charge with new freon gas (R134a).
30-242
AIR CONDITIONER UNIT
DISASSEMBLY AND ASSEMBLY
AIR CONDITIONER UNIT
REMOVAL OF AIR CONDITIONER CONDENSER ASSEMBLY Warning! Stop the machine on level ground and block the wheels to prevent the machine from moving. 1. Disconnect connector (1) (E1 2). 2. Install freon gas collector and regenerator to plugs (2), and collect refrigerant. 3. Remove bulkhead cover (3). 4. Disconnect connectors (4) (B07 and B12). 5. Disconnect hose (5) between condenser and air conditioner compressor. Always fit a wrench to the condenser end. 6. Disconnect connectors (6) (B01 and B11). 7. Disconnect hose (7) between top and bottom condensers. 8. Disconnect hose (8) between receiver tank and condenser. 9. Remove mounting bolts (9), then remove condenser assembly (10).
INSTALLATION OF AIR CONDITIONER CONDENSER ASSEMBLY Carry out installation in the reverse order to removal.
Install the hoses without twisting or interference. When installing the hoses, be careful not to let dirt, dust, or moisture get inside the hoses. Using a gas charger (X3), charge with new freon gas (R134a).
30-243
DISASSEMBLY AND ASSEMBLY
REMOVAL OF RECEIVER TANK Warning! Stop the machine on level ground and block the wheels to prevent the machine from moving. 1. Disconnect connector (1) (E12). 2. Install freon gas collector and regenerator to plugs (2), and collect refrigerant.
3. Remove bulkhead cover (3).
4. Disconnect hose (4) between air conditioner compressor and receiver tank 5. Disconnect hose (5) between receiver tank and condenser. 6. Remove U-bolts (6), then remove receiver tank assembly (7).
INSTALLATION OF RECEIVER TANK Install the hoses without twisting or interference. When installing the hoses, be careful not to let dirt, dust, or moisture get inside the hoses. Using a gas charger (X3), charge with new freon gas (R134a).
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AIR CONDITIONER UNIT
DISASSEMBLY AND ASSEMBLY
AIR CONDITIONER UNIT
REMOVAL OF AIR CONDITIONER COMPRESSOR ASSEMBLY Warning! Stop the machine on level ground and block the wheels to prevent the machine from moving. 1. Disconnect connector (1) (E12). 2. Install freon gas collector and regenerator to plugs (2), and collect refrigerant.
3. Loosen adjustment bolt (3) and lock bolt (4), then remove belt (5) and remove from compressor.
4. Disconnect hoses (6). 5. Remove four mounting bolts (7), then remove air conditioner compressor assembly (8).
INSTALLATION OF AIR CONDITIONER COMPRESSOR ASSEMBLY Carry out installation in the reverse order to removal.
Install the hoses without twisting or interference. When installing the hoses, be careful not to let dirt, dust, or moisture get inside the hoses. Using a gas charger (X3), charge with new freon gas (R134a).
30-245
DISASSEMBLY AND ASSEMBLY
AIR CONDITIONER UNIT
MEMORANDA
30-246
40 Enginemount
MAINTENANCE
mount
TorqueconverterandPTO
..........................................................................
....................................................................................
........................................................................................
Main relief, torque converter Lubricationreliefvalve Driveshaft
relief valve.
Differential
...6 ...8 ..I 0 ..I 4
.................................................................
.............................................................................
......................................................................................
Centersupport
.
........................................................................
.........................................................................................
Transmission
.
..................................................................................
Torqueconverterchargingpump
Transfer
2
..............................................................................
Transmission Damper
STANDARD
................................................................................... ......................................................................................
16 ..I
7
..I
8
..I
9
..Z 0
Final drive .......................................................................................
..2 4
Axlemount
..2 6
......................................................................................
Centerhingepin
..................................................................................
..2 8
Steering column
..................................................................................
..3 0
Steering pump
...................................................................................
..3 1
Steeringvalve......................................................................................3 Steeringcylindermount
............................................................................
2 ..3 3
Brakevalve........................................................................................3 Slackadjuster.. Brake
..................................................................................
..........................................................................................
Parking brake
....................................................................................
4 ..3 8 ..4 0 ..4 2
Hydraulicpump.....................................................................................4 Switchand
PPCpump
.............................................................................
4 ..4 5
PPCvalve..
.....................................................................................
..4 6
Cut-offvalve
.....................................................................................
..4 8
Maincontrolvalve...................................................................................5 Hydrauliccylinders.. Bucketlinkage
..............................................................................
0 ..5 4
......................................................................................
Bucket............................................................................................5 Bucketpositionerandboomkick-out ROPSCab
..................................................................
......................................................................................
8 ..5 9 ..6 0
40-I
MAINTENANCE
STANDARD
ENGINE MOUNT
ENGINE MOUNT
El LlZAD066 Unit: mm No. 1
40-2
Check item Clearance
between engine mounting
bracket and adjusting
bolt
Criteria
Remedy
3.0 - 7.0
Adjust
MAINTENANCE
STANDARD
TRANSMISSION
TRANSMISSION
MOUNT
MOUNT
B-B
SDW02122
Unit: mm No 1
Check item Thickness
of shim for
mounting
Criteria Shim thickness:
Remedy
0.5mm
(Decide the shim thickness
so that the misalignment
between the
damper output shaft and input shaft is less than 2.0mm). 2
Clearance
between
stopper and bracket
There must be a clearance
of at least 2mm between the stopper and
Adjust
bracket around the whole circumference.
40-3
MAINTENANCE
STANDARD
TORQUE CONVERTER
CHARGING
PUMP
TORQUE CONVERTER CHARGING PUMP
’
6p-l
277.0 '-31.ONm (28.25 '-3.25kgmI
SEW02124
Unit: mm I
I
No
I
1
Check item
Criteria
I
I I
Clearance
1
I
2
between
gear case and
Standard clearance
side plate, gear
I
Clearance
Remedy
I
between
inside diameter
I Clearance
limit
0.10 - 0.15
0.19
0.06 - 0.149
0.20
of
Replace
plain bearing and outside diameter of gear shaft
3
1 Insertion depth of pin I
14 +o/-0.5
Rotating torque of spline shaft
ti
6.9 - 11.8 Nm (0.7 - 1.2 kgm} Revolution
Pressure
Standard
Repair limit
(rpm)
MPa
discharge
discharge
{kg/cm?
(P/min)
(Plmin)
2500
3.5 MPA (35.9)
40-4
192
176
MAINTENANCE
STANDARD
MEMORANDA
40-5
MAINTENANCE
STANDARD
DAMPER
DAMPER
A-A 7
8 SDWO2123
40-6
MAINTENANCE
STANDARD
DAMPER Unit: mm
No
Check item Clearance
1
between
bearing
Criteria Standard
Tolerance
size
and shaft.
Shaft 40
2
Clearance
between
bearing
80
and housing. 3
Clearance
betweenbearing
75
and shaft. 4
Clearance
between
bearing
130
and cover. 5
Clearance
between
retainer
135
and cover.
Wear of surface in coupling
95
and oil seal. 7
Wear of surface in shaft and seal.
8
Backlash of spline (shaft,
Standard
Clearance
clearanc e
limit
-0.009
0
-0.003
-0.034
-0.012
-0.034
0
-0.03
-0.030
-0.013
+0.012
0
-0.027
-0.007
-0.015
-0.007
0
+.018
0.007
-0.018
+.007
0.036
-0.014
+0.04
0.014
-0.054
0
0.094
Tolerance
0
0.05
0.035
0 -0.013
Standard size 6
Hole
Remedy
Replace 0.025
0.05
0.13
Repair limit
-0.12
-0.087 105
0
-0.12
-0.087 0.071 - 0.177
coupling, and body).
40-7
MAINTENANCE
TORQUE CONVERTER
STANDARD
AND PTO
TORQUE CONVERTER AND PTO
/ ,
m
66 5*7.5Nm (6. 75* 0. 75kd
SKW02125 Unit:
Standard 1
Remedy
Criteria
Check item
No
inside diameter of seal ring surface of retainer
Tolerance
Repair limit Repair
size 120
+0.035 0
120.5
chrome plating or replace
2
Inside diameter
of seal ring surface of sleeve
65
+0.025
65.1
0 Width 3
Width and thickness
3.95
0
ring
4.6
*O.l
Thickness 4
40-8
3.55
-0.1
of seal
Backlash of PTO gear (Drive gear)
0.18 - 0.49
4.14
Replace
mm
MAINTENANCE
STANDARD
MEMORANDA
40-9
MAINTENANCE
STANDARD
TRANSMISSION
TRANSMISSION
SKW02126
40-I 0
MAINTENANCE
STANDARD
TRANSMISSION Unit: mm
No
1
Installation
No. 1 clutch spring (X 10)
load
utch spring (X 10)
No. 4 clutch spring (10 17.5 kg)
each) 5
No. 5 clutch spring (X 10)
39.8
16.4 kg1
101.0 N
32.5
86.3 N
37.4
(10.3 kg} 6
No. 6 clutch spring (10
39.8
(8.8 kg)
77.5 N
34.2
65.7 N
37.4
17.9 kg)
each) Thickness of 4 discs and 3 plates for No. 1 clutch
Standard
16.7 kg)
Tolerance
Repair limit
35
50.26
31.8
Thickness of 4 discs and 3 plates for No. 2 clutch
35
kO.26
31.8
Thickness of 3 discs and 2 plates for No. 3 clutch
25
io.22
22.6
Thickness of 3 discs and 2 plates for No. 4 clutch
25
*to.22
22.6
Thickness of assembled No. 5 clutch
2 discs and 1 plates for
15
*0.17
13.4
12
Thickness of assembled No. 6 clutch
3 discs and 2 plates for
25
rto.22
22.6
13
Thickness of 1 disc
5
*to.1
4.2
14
Thickness of 1 plate
5
Zto.1
4.5
size
9
15
Clearance
between
I transmission
input shaft bearing and housing
Standard size 90
16
Clearance
between transmission
72
outout shaft bearina and carrier 17
Clearance
between transmission
output shaft bearing and housing
Replace
I
100
Tolerance
Standard
Clearance
clearance
Limit +0.037
Shaft
Hole
0
+0.016
+0.031
-0.015
-0.006
-0.006
0
+0.016
+0.026
-0.013
-0.006
-0.006
0
+0.016
+0.031
-0.015
-0.006
-0.006
+0.031
+0.037
40-I 1
MAINTENANCE
STANDARD
TRANSMISSION
SKW02127
40-12
MAINTENANCE
TRANSMISSION
STANDARD
Unit: mm No. 1
Check item Wear of seal ring for input
Criteria
I
I Width
I
I Standard size
shaft
I
Remedy
I Tolerance
I
I Reoair limit
-0.01
Thickness
3.0
-0.03
2.6
3.5
*0.1
3.35
-0.01 2
Wear of seal ring for output shaft
3
Backlash between
Width
4.0
-0.03
3.5
Thickness
5.1
*0.12
4.95
No. 1 sun gear and planet
0.13 - 0.32
No. 1 planet gear and ring
0.15 - 0.38
No. 2 sun gear and planet
0.13 - 0.32
No. 2 planet gear and ring
0.15 - 0.38
No. 3 sun gear and planet
0.12 - 0.30
No. 3 planet gear and ring
0.15 - 0.38
No. 4 sun gear and planet
0.13 - 0.32
No. 4 planet gear and ring
0.15 - 0.38
No. 5 sun gear and planet
0.14 - 0.35
No. 5 planet gear and ring
0.15 - 0.38
gear 4
Backlash between gear inside teeth
Replace 5
Backlash between gear
6
Backlash between gear inside teeth
7
Backlash between gear
8
Backlash between gear inside teeth
9
Backlash between gear
10
Backlash between gear inside teeth
11
Backlash between gear
12
Backlash between gear inside teeth
I
40-I 3
I
3 14
45*63Nm 6*8.5bd
_
10.3* 12.3Nm 1.25* 1.25ka
40-14
MAINTENANCE
STANDARD
TRANSFER
Unit: mm No
Check item
Criteria Standard size
1
Clearance
between
85
2
3
4
Clearance
Clearance
Clearance
Clearance
between
between
between
between
drive gear bearing and cage
drive gear bearing and cage
150
150
idler gear and bearing
drive gear bearing and case
95
170
(cover) Clearance
7
8
9
Clearance
Clearance
Clearance
between
between
between
between
80
output shaft and bearing
output shaft bearing and cage
140
spacer and bearing
output shaft bearing and
95
170
housing 10
Coupling oil seal contact surface
Tolerance Shaft
drive gear and bearing
Standard
Remedy Standard
Hole
clearance
+0.045
0
-0.023
+0.023
-0.020
-0.065
0
-0.012
0.006
-0.018
-0.052
-0.052
0
0
0.018
-0.018
-0.040
-0.040
+0.059
0
-0.037
-0.037
-0.020
-0.079
0
0
0.025
-0.025
-0.040
-0.040
+0.039
0
-0.020
-0.020
-0.015
-0.054
0
-0.012
0.006
-0.018
-0.052
-0.052
+0.045
0
-0.023
+0.023
-0.020
-0.065
0
-0.012
0.013
-0.025
-0.052
-0.052
Tolerance
_ Replace
Repair limit
size 0
95
94.8
-0.087 11
Clearancebetweencageandcase
2 (Shim)
Preload: 0.1 - 1.0 Nm (0.01 - 0.1 kgm} (Drive gear as individual
12
Clearance
between
cover and case
2 (Shim)
Adjust
part)
Preload: 0.3 - 0.55 Nm (0.03 - 0.055 kgm} Then add 0.1 mm of shim (idler gear as individual
13
Clearance
between
cage and cover
0.25 (Shims)
part)
Preload: 0.5 - 1 .O Nm (0.05 - 0.1 kgm} (Output shaft as individual
14
Backlash between
drive gear and idler gear
0.17 - 0.44
15
Backlash between
idler gear and driven gear
0.17 - 0.44
part)
Replace
40-I 5
MAINTENANCE
STANDARD
MAIN RELIEF, TORQUE CONVERTER
RELIEF VALVE
MAIN RELIEF, TORQUE CONVERTER RELIEF VALVE
A-A
SDWO2129 Unit: mm No 1
Check item Clearance
between main
relief valve and valve body
Standard size 25
2
Clearance converter
between torque
Remedv
Criteria
22
relief valve and
Tolerance
Standard
Clearance
clearance
limit
Shaft
Hole
-0.035
+0.013
0.035
-0.045
0
0.058
-0.035
+0.013
0.035
-0.045
0
0.058
0.08
0.08
valve body 3
Main relief valve spring (outer)
Standard
size
Repair limit
Free
Installa-
Installation
Free
Length
tion
load
Length
Installation
Replace load
length 128
75.3
509 N (51.9
4
Main relief valve spring
108
75.3
(inner) 5
Main relief valve spring
402 N
50
42
153N
483 N (49.3 kg}
104.8
(41 .O kg}
{I 5.6 kg}
40-I 6
124.2
kg}
382 N (39.0 kg}
48.5
145 N (14.8 kg}
MAINTENANCE
LUBRICATION
STANDARD
LUBRICATION
RELIEF VALVE
RELIEF VALVE
SDWO2130
Unit: mm No
Criteria
Check item
Remedv Repair limit
Standard size Free Length 1
Lubrication valve spring
relief 26
Installation
Installation
length
load
23.7
11.8 N (1.2 kg)
Free Length
Installation
load Replace
25.2
10.8 N (1.1 kg}
40-I 7
MAINTENANCE
STANDARD
DRIVE SHAFT
DRIVE SHAFT
_I, 47 ~~____yf~Y&-’ d‘\y-’
---_-
__-_ _ __-.
40-I 8
’ .
MAINTENANCE
STANDARD
CENTER SUPPORT
CENTER SUPPORT 6
5
SEW02132 Unit: mm No.
Check item
Criteria Standard
Tolerance
size
1
Clearance
between
case
140
and bearing 2
Clearance
between
case
130
and bearing 3
Clearance
between
cou-
80
pling shaft and bearing 4
Clearance
between cou-
75
Standard
Standard
Clearance
clearance
limit -0.015
Shaft
Hole
0
-0.036
-0.018
-0.018
-0.061
-0.061
0
-0.036
-0.018
-0.018
-0.061
-0.061
+0.051
0
0.032
+0.032
-0.015
0.066
+0.051
0
0.032
-0.015
0.066
+0.032
pling shaft and bearing
Remedy
size
Tolerance
-0.015
0.029
Replace
0.029
Repair limit Repair
95 5
Wear of oil seal surface
6
Wear of oil seal surface
0
-0.18
chrome plating or
-0.087
replace 105
0
-0.18
-0.087 7
End play of coupling shaft
Preload max. 3.9 Nm (0.4 kgm}
Replace
40-I 9
MAINTENANCE
STANDARD
DIFFERENTIAL
DIFFERENTIAL
13
14
15
i2
40-20
MAINTENANCE
STANDARD
DIFFERENTIAL Unit: mm T
No.
Check item
Criteria Standard
Tolerance
size 1
2
Clearance
of side bearing (outer race) in
differential
gear assembly
Clearance
of side bearing (inner race) in differ-
120
Clearance
of pinion shaft bearing (outer race)
4
Clearance
of pinion shaft bearing (inner race)
5
Clearance
of pinion shaft bearing (inner race)
Clearance
of pilot bearing (outer race)
171.45
8
of pilot bearing (inner race)
Clearance
between differential
0
+0.054
0.014
-0.025
+0.014
0.079
+0.045
0
-0.023
+0.023
-0.020
-0.065
+0.025
+0.026
0.026
0
-0.014
-0.039
11 120
I 1
Replace
0 -0.015
I
Clearance
I
+0.034
I
1 +0.012 I
I
1 +0.010
1
0.012
I
0.049
carrier and cage 1
9
clearance
Hole
I Clearance
Standard
Shaft
180
ential aear assemblv 3
remedy
-0.060
I
I
0.106
between spider and differential pinion
bushina 10
Backlash of bevel gear
11
Backlash of differential
12
End olav of pinion aear
13
Free rotating torque of bevel gear
14
Rear face runout of bevel gear
15 G -
Standard thickness
0.30 - 0.41 aear
of shims for stop shaft
0.30 - 0.41 Max. 0.064 Max. 8.34 Nm 10.85 kam\ 0.1 Clearance
Replace
“a” +(O.l f 0.05)
40-2 1
MAINTENANCE
DIFFERENTIAL
STANDARD
r 277*32Nm :28.25* 3.25kpml 927* .94.5*
\
103Nm 10.5koml
-+QV-T-Z
II
I
_I
SOW02352
40-22
MAINTENANCE
STANDARD
DIFFERENTIAL
Unit: mm No.
1
Check item
Thickness
of side gear washer
Criteria
Remedy
Standard size
Tolerance
Repair limit
4
+0.05
3.8
-0.05 2
Thickness
3
Wear of oil seal surface
of pinion gear washer
1.5
100
+O.OQ
1.35
Replace
0 -0.087
40-23
MAINTENANCE
FINAL DRIVE
STANDARD
FINAL DRIVE
SOW02135
Unit: mm No
Criteria
Check item Standard
Tolerance
size
1
Clearance
between
plane-
55
tary shaft and bearing 2
Clearance
ring gear
between
190
hub and bearing
Shaft
Hole
+0.015 +0.002
0 -0.015
Remedy Standard
Clearance
clearance
limit
-0.002 -0.030
-
-
+0.033
0
-0.004
+0.004
-0.030
-0.063
Standard size
Tolerance
Repair limit
22
+O.l /-0.1
21.5
3
Thickness of spacer
4
Backlash between
planet gear and sun gear
0.18 - 0.43
5
Backlash between
planet gear and ring gear
0.18 - 0.54
6
Thickness of shim for wheel hub
40-24
Replace
2.0
Replace
MAINTENANCE
STANDARD
MEMORANDA
40-25
MAINTENANCE
STANDARD
AXLE MOUNT
AXLE MOUNT
\
‘-.____--
/.’ 1569*196Nm ~160~20bnl
3 217*32Nm I28.25*3.25bml
4 I I A-A
40-26
__/
/*
.---
ill’
-5 P stlwoz136
MAINTENANCE
STANDARD
AXLE MOUNT
I Init. mm
No.
Check item
Criteria Standard
Tolerance
size
1
Clearance
of shaft and hole
310
front support side (after press
Remedy Standard
Clearance
clearance
limit 1.6
Shaft
Hole
-0.056
+0.489
0.056
-0.137
0
0.626
+2.300
+0.089
-0.800
0
-0.056
+0.481
fitting bushing) 2
Clearance
of shaft and hole
320.2
front support side (before installing bushing) 3
Clearance
of shaft and hole
Replace 260
rear support side (after press fitting bushing) 4
Clearance
of shaft and hole
270.2
rear support side (before
-0.137
-0.008
+2.300
+0.081
+0.800
0
0.048
1.6
(see note)
0.618
installing bushing)
Thickness
of wear plate
Standard size
Tolerance
20
-0.10
Repair limit
-0.25 Thickness
* Note:
of wear plate
5
+O.l -0.3
Thickness of rear bushing
5
*0.1
Thickness of front bushing
5
*O.l
Replace
The bushings must be in contact with the support at both the front and rear.
40-27
MAINTENANCE
CENTER HINGE PIN
STANDARD
CENTER HINGE PIN
m
5&6*5.9Nm (6.0i0.6kra)
(Yhsn
17
A
m ~$~!~~!$?I,
40-28
277.0*31.9& (26.25*3.25kaml
(When adjust (Final
value)
ina
shim) SDWO2353
MAINTENANCE
STANDARD
CENTER HINGE PIN Unit: mm
No.
Check item
Criteria Standard
Remedy
Tolerance
Standard
size
1
Clearance
between
lower hinge
clearance
100
pin and rear frame 2
Clearance
between
lower hinge
100
pin and spacer (small) 3
Clearance
between
lower hinge
100
pin and bearing 4
Clearance
between
lower hinge
100
pin and spacer (large) 5
Clearance
between
rear frame and
130
spacer (large) 6
Clearance
between front frame
Clearance
between
upper hinge
100
pin and rear frame 8
Clearance
between
upper hinge
100
pin and bearing 9
Clearance
between front frame
Clearance
between
rear frame and
125
bushing 11
Clearance
at press fitted part of
115
seal of upper hinge pin 12
Clearance
at press fitted part of
135
seal of lower hinge pin
13
14
-0.036
+0.054
0.036
-0.058
0
0.112
-0.036
+0.054
0.036
-0.058
0
0.112
-0.036
0
0.016
-0.058
-0.020
0.058
-0.036
+0.054
0.036
-0.058
0
0.112
-0.043
+0.063
0.043
-0.106
0
0.169
0
-0.048
-0.023
-0.025
-0.088
-0.088
-0.036
+0.054
0.036
-0.058
0
0.112
-0.036
0
0.016
-0.058
-0.020
0.058
160
and lower hinge bearing 10
Hole
155
and upper hinge bearing 7
Shaft
0
-0.050
-0.025
-0.025
-0.090
-0.090
-0.043
+0.063
0.043
-0.084
0
0.146
+0.280
+0.054
-0.126
+0.180
0
-0.28
+0.310
+0.063
-0.147
+0.210
0
-0.31
Standard size
Tolerance
Height of lower hinge spacer (small)
35
*0.1
Height of lower hinge spacer
101.5
*0.1
Replace
(large) 15
Shim thickness for lower hinge and
2.3
retainer 16
Shim thickness for lower hinge and
1.6 Adjust
retainer 17
Shim thickness for upper hinge
1.6
and retainer
40-29
MAINTENANCE
STANDARD
STEERING
COLUMN
STEERING COLUMN
D-D
-__-__-__ ----__-__
SDWO2138 Unit: mm No.
Check item
Criteria
Remedy
I
I Standard
Tolerance
Standard
size 1
Clearance
between
and column bushing
40-30
steering shaft
19
Clearance Shaft
Hole
0
+0.150
0.05
-0.080
+0.050
0.23
Replace
MAINTENANCE
STANDARD
STEERING
PUMP
STEERING PUMP
A-A
I
SEW02124
I
No.
Check item
Criteria
Clearance
between gear case
mm
Remedy
Standard clearance 1
Init.
Clearance
0.10 - 0.15
0.19
0.06 - 0.149
0.20
limit
and side plate, gear 2
Clearance
between
inside diame-
Replace
ter of plain bearing and outside diameter of gear shaft 3
Insertion depth of pin
4
Rotating torque of spline shaft Discharge EOI O-CD
14 +o/-0.5 0.7 - 1.2 kgm Revolution
Discharge
Standard
Repair limit
(RPM)
pressure
discharge
discharge
(kg/cm’)
@/min.)
@/min.)
210
184
170
45” - 55” 2500
-
40-31
MAINTENANCE
STANDARD
STEERING
VALVE
STEERING VALVE
4
I
I No.
1
SLW01253
Unit: mm
I Check item
Criteria
Remedy
Standard size
1
Steering spool return spring
Free
Installed
length
length
37.2
Repair limit Installed load
32.0
Free
Load
length
limit
56.9 N
45.1 N
15.8 kg1 2
Load check valve spring
20.9
13.2
9.3 i4.9 N (0.95 kO.5 kg}
3
4
5
Demand spool return spring
Relief valve spring
Check valve return spring
75.2
24.0
21.6
68.5
22.19
17.0
40-32
-
7.8 N IO.8 kg)
136.3 N
111.8 N
{I 3.9 kg}
{I 1.4 kg}
182.4 N
145.1 N
(18.6 kg)
(14.8 kg}
2.3 N 1
14.6 kg1
(0.23 kg}
1.8 N
1 (0.18 kg}
Replace
MAINTENANCE
STEERING
STANDARD
CYLINDER
MOUNT
STEERING CYLINDER MOUNT
a
3
I
b'
A
I
A-A SDWO2140
Unit: mm Remedy
Criteria
Check item
No.
Standard
Tolerance
Standard
clearance
size
1
Clearance
between
bushing connection
mounting
pin and
60
of steering
Shaft
Hole
0
+0.200
0.100
-0.074
+O.lOO
0.248
0
+0.200
0.100
-0.074
+O.lOO
0.248
cylinder rod and frame 2
Clearance
between
mounting
bushing at connection
pin and
60
of steering
Replace
cylinder bottom and frame
3
Connection
of steering cylinder and
front frame 4
Connection rear frame
Width of
Width of
boss
hinge
70 +0.8
74 *I
Standard clearance (Clearance
a + b)
2.2 - 5.0
0 of steering cylinder and
70 -0.5
Max. 1.0 after adjusting shim
74 il
3.0 - 5.5
0
40-33
MAINTENANCE
STANDARD
BRAKE VALVE
BRAKE VALVE (RIGHT)
SOW02141
40-34
MAINTENANCE
No
STANDARD
BRAKE VALVE Unit: mm
r
Check item
1 Remedv
Criter Standard
Tolerance
size 1
Clearance
between
Standard
Clearance
clearance
limit
0.25
pedal
mount hole and bracket
Shaft
Hole
-0.025
+O.l
0.175
-0.075
0
0.025
-0.025
+O.l
0.175
-0.075
0
0.025
hole
IO
Clearance
between
roller
and pin
IO
0.25 Replace
Standard size Outside diameter
Tolerance
I
Repair limit
of roller 30
4
I I
0
~
Control spring
5
6
Return spring
8
Return spring
16.7 N
28
{I .7 kg}
40-35
MAINTENANCE
STANDARD
BRAKE VALVE
(LEFT)
SDWD2142
40-36
MAINTENANCE
STANDARD
BRAKE VALVE Unit: mm
No
T
Check item
Criter
Standard
Remedv
Tolerance
size 1
Clearance
between
Standard
Clearance
clearance
limit
0.25
pedal
mount hole and bracket
Shaft
Hole
-0.025
+O.l
0.175
-0.075
0
0.025
-0.025
+0.1
0.175
-0.075
0
0.025
hole
10
2
Clearance
between
roller
and pin
-I--10
Standard size
3
Outside diameter
of roller
I
0.25 Replace
1
Tolerance
Repair limit
I 29.2
Standard Size
4
Control spring
Repair limit
Free length
Test height
Test load
Free length
34
21.8
93.2 N
33
Test load
19.5 kg) 5
Control spring
46.3
34.3
459.0 N
45.3
(46.8 kg} 6
Return spring
86.2
58
60.8 N
78
16.2 kg) 7
Spring
17
15
69.6 N
16.2
(7.1 kg) 8
Return spring
31.5
19.5
16.7 N
28
40-37
MAINTENANCE
STANDARD
SLACK ADJUSTER
SLACK ADJUSTER
SEW02143
No.
Criteria
Check item Standard
Remedy
Tolerance
size Shaft 1
Clearance
between
Unit: mm
Standard
Clearance
clearance
Limit
Hole
body and
oiston Replace
Free
Test
Test
Free
Test
length
length
load
length
load
198
38
43.2 N 14.4 kg)
39.2
1
33
1
66.7 N
1
-
1
-
40-38
L
MAINTENANCE
STANDARD
MEMORANDA
40-39
MAINTENANCE
BRAKE
STANDARD
BRAKE
I
/I: ! 14J ’
___-_-___-_____________-_I
b_----____-_____-__-____
I+
/
40-40
--kL/~ ---___
__--
:
7’ i.J
MAINTENANCE
STANDARD
BRAKE Unit: mm
No.
Check item
Criteria
Remedy
Standard size
1
Return spring
Repair limit
Free
Install
Install
Free
Install
length
length
load
length
load
80.2
69.9
600.2 N
72.2
539.4 N
(61.2 kg} Standard size
155 kg)
Tolerance
Repair limit
2
Thickness
of plate
3
Thickness
of disc
4
Total thickness of plates
2.3
kO.08
2.0
3.8
*to.1
4.6
38.8
kO.98
35.0
42.0
+0.097
and discs 5
Wear of piston seal contact surface
6
0
Wear of piston seal contact
38.3
+0.089
surface 7
Replace
0
Backlash between outer
0.21 - 0.65
gear and plate 8
Backlash between
inner
0.31 - 0.74
gear and disc
40-41
MAINTENANCE
STANDARD
PARKING
BRAKE
PARKING BRAKE
SDWcl2145
Unit: mm No.
Check item
Criteria
Remedy
Standard size 1
Parking brake spring (outside)
Repair limit
Free
Install
Install
Free
Install
length
length
load
length
load
77.7
54.0
1425 &22 N
69.9
(145.2 Q.2 kg} 2
Parking brake spring
77.8
54.0
(inside)
535 k5.3 N
70.0
(54.6 55.4 kg} Standard size
Tolerance
1258 N (128.3 kg} 482 N (49.1 kg} Repair limit
3
Separate
Thickness
4.0
of plate
*0.05
3.9
0.15
0.6
3.2
*o. 1
35.0
0.45
+0.175
0.235
Distortion Thickness 4
Brake
Depth of lining
disc
groove Thickness lining
5
40-42
Load of wave spring
0 if
0.7
+0.075
Replace
MAINTENANCE
STANDARD
MEMORANDA
40-43
MAINTENANCE
HYDRAULIC
STANDARD
PUMP
HYDRAULIC PUMP SAR(4)-160
.6Nm
sDwo2146 Unit: mm Remedy
Criteria
Check item
10.
Clearance
Standard size 1
Clearance
between gear case
0.11 - 0.16
0.19
0.06 - 0.140
0.20
limit
and side plate gear 2
Clearance
between
inside
Replace
diameter of plain bearing and outside diameter of gear shaft 3
14
Insertion depth of pin
0 -0.5
4
9.8 - 14.7 Nm
Rotating torque of spline shaft
{I .O - 1.5 kgm}
Discharge:
Revolution
Discharge
Standard
Repair limit
(rpm)
pressure
Discharge
Discharge
MPa {kg/cm’)
(PI min.)
@/min.)
328
303
Oil: EOIO-CD Temperature:
45 - 55°C
20.6 2,200
40-44
12101
-
MAINTENANCE
STANDARD
SWITCH, PPC PUMP
SWITCH, PPC PUMP SAR(3)-63 + SAR(I)-28
I-
SAR(3)-63
SAR(l)-28
I.
A-A
SOW02147 Unit: mm
UIICZCIR
“V.
1
Clearance
1LsilII
between gear
case and side plate gear
2
Clearance
between
“I
,LG,
IQ
I\FillE”J
Model
Standard clearance
Clearance
limit
SAR(3) - 63
0.10 - 0.15
0.19
SAR(l)
- 28
0.10 - 0.15
0.19
SAR(3) - 63
0.06 - 0.149
0.20
0.064 - 0.119
0.20
Model
Standard size
Tolerance
SAR(3) - 63
10
inside diameter of plain bearing and outside
Replace SAR(l)
- 28
diameter of gear shaft 3
Insertion depth of pin
0 -0.5
SAR(l)
- 28
10
0 -0.5
4
Rotating torque of spline
SAR(3) - 63
6.9 - 11.8 Nm
shaft
(0.7 - 1.2 kgm} SAR(l)
- 28
2.0 - 4.9 Nm (0.2 - 0.5 kgm}
Model
Discharge Oil: EOI O-CD Temperature:
Revolution (rpm)
45 - 55°C SAR(3) - 63
2,500
Discharge
Standard
Repair limit
pressure
discharge
discharge
MPa {kg/cm?
(P/min)
(P/min)
20.6
145
134
67
60
1210) SAR(l)
- 28
2,500
3.7 1381
40-45
MAINTENANCE
STANDARD
PPC VALVE
PPC VALVE FOR BUCKET, BOOM
SEW02148 Unit: mm No.
Check item
Criteria Standard size
1
Centering
spring
Remedy Repair limit
Free length
Installed
Installed
X O.D.
length
load
load
52.8 X 12.3
36.0
29.4 N
23.5 N
damaged
(3.0 kg)
12.4 kg}
deformed
39.2 N
31.4 N
14.0 kg)
13.2 kg)
(bucket DUMP, boom
Free length
Installed
LOWER) 2
Centering
pin (bucket
52.8 X 12.3
36.0
TILT, boom RAISE) 3
Metering spring
31.4 x 7.4
29.4
16.7 N Il.7
40-46
kg)
13.7 N Il.4
kg)
Replace spring if or
MAINTENANCE
PPC VALVE
STANDARD
OPTION
SEW02149
Unit: mm No.
Remedv
Check item Repa r limit
Standard size
1
2
3
Centering
Centering
spring
pin
Metering spring
Free length
Installed
Installed
X O.D.
length
load
load
52.8 X 12.3
36.0
29.4 N
31.4 N
damaged
(3.0 kg)
(3.2 kg)
deformed
39.2 N
23.5 N
14.0 kg)
12.4 kg)
16.7 N
13.7 N
52.8 X 12.3
31.4 x 7.4
36.0
29.4
Free length
Installed
Replace spring if or
40-47
MAINTENANCE
STANDARD
CUT-OFF VALVE
CUT-OFF VALVE
A-A
Qq
34.3*4.9Nm (3.5*0.5lmd
n
B
n
n
L B-B SDW02150
Unit: mm No.
I
1
Check item
I I I
Criteria Standard size Free length
1
2
40-48
Unload valve spring
Check valve spring
1 I
I
36.95
33
Repair limit
Installed
Installed
length
load
load
3.0
35.3 N
26.4 N
(3.6 kg1
(2.9 kg)
16.7 N
1.4 N
(0.17 kg}
(0.14 kg}
2.0
Remedy
Free length
Installed
Replace
MAINTENANCE
STANDARD
MEMORANDA
40-49
MAINTENANCE
MAIN CONTROL VALVE
STANDARD
MAIN CONTROL VALVE 2-SPOOL VALVE
10
-5
-kg.
186.3*
9.8Nm
‘6
11 \
SEW02151
40-50
MAINTENANCE
STANDARD
MAIN CONTROL VALVE
Unit: mm No.
1
Check item
Criteria
T
Standard size T
Bucket spool return
Free length
Installed length
64.4
62.2
spring (Large) Bucket spool return
14.9
18.6
spring (Small) Boom spool return
64.4
62.7
spring (Large) 4
Boom spool return
18.6
15.2
spring (Small) 5
Boom spool return
89.2
82.0
spring (Large) 6
Boom spool return
42.0
42.0
82.4
82.0
Remedv
-
Installed load
Repair limit
Free length
Installed load
190N
152 N
{I9.4 kg)
(15.5 kg}
112.8 N
90 N
{I 1.5 kg}
(9.2 kg)
149 N
119.6 N
(15.2 kg}
(12.2 kg}
104N
83.4 N
(10.6 kg}
(8.5 kg)
616 N
554N
(62.8 kg}
(56.5 kg} Replace
0
spring (Small) 7
Bucket spool return spring (Large)
8
Bucket spool return
182.4 N
163.8 N
(18.6 kg}
(16.7 kg}
42.0
42.0
0
52.3
38.0
86.3 N
68.6 N
18.8 kg)
17.0 kg1
spring (Small) 9
10
11
Main valve spring
Check valve spring
Suction valve spring of
78.2
52.0
27.9
18.0
safety valve 12
13
Suction valve spring
Float selector valve
27.9
18.0
53.0
42.1
spring 14
15
Unloader valve spring
Relief valve poppet
82.7
47
49.3
43.3
spring
18.8 N
14.7 N
{I .92 kg}
(1.5 kg)
6.9 N
5.9 N
(0.70 kg}
IO.6 kg)
6.9 N
5.9 N
(0.70 kg)
IO.6 kg1
137 N
123.6 N
(14.0 kg)
(12.6 kg}
49 N
39 N
15.0 kg1
14.0 kg)
209.9
N
167.7 N
(21.4 kg}
(17.1 kg}
-
40-51
MAINTENANCE
STANDARD
MAIN CONTROL VALVE
3-SPOOL VALVE
__
I
17 \
m
68.6*9.8Nm ,('i'bmt
cv /
22.1*2.5Nm (2.25*0.25kpm)
SEW02152
40-52
MAINTENANCE
STANDARD
MAIN CONTROL VALVE Unit: mm 1 Remedy
Boom spool return spring Replace Boom spool return s
16
17
18
19
Suction valve spring
27.9
Float selector valve spring
53.0
Unloader valve spring
82.7
Relief valve poppet spring
49.3
18.0
42.1
47
43.3
6.9 N
5.9 N
(0.70 kg}
(0.6 kg)
137N
123.6 N
(14.0 kg}
{I 2.6 kg}
49 N
39 N
16.0 kg1
14.0 kg1
209.9 N
167.7 N
j21.4 kg)
(17.1 kg)
40-53
MAINTENANCE
STANDARD
HYDRAULIC
CYLINDERS
STEERING
HYDRAULIC
CYLINDERS
CYLINDER
(Width across flats: 60 n
BOOM CYLINDER
SOW02154
BUCKET CYLINDER ?
40-54 0
4
MAINTENANCE
STANDARD
HYDRAULIC
CYLINDERS
Unit: mm No.
f
Check item
Criteria
Name of
Std.
cylinder
size
Steering
55
T
TRemedv
-
T
Tolerance Shaft
Hole
-0.030
Standard
Clearance
Clearance
limit 0.327
-L
Clearance
between rod
and bushing Boom
110
Bucket
Clearance
between
piston rod mounting and diameter of hole
120
Steering
+0.151
0.036
-0.076
+0.006
0.227
-0.036
+0.274
0.096
-0.090
+0.060
0.364
-0.043
+0.203
0.091
-0.106
+0.048
0.309
0
+o. 174
0.100
-0.074
+o. 100
0.248
60
pin Boom
120
0.469
0.469
Replace
1.0
+o. 1 0
Bucket
120
+0.307 +0.220
3
Clearance
between
Steering
cylinder bottom mounting pin and bushing
0
+0.174
0.100
-0.074
+O.lOO
0.248
60
Boom
120
1.0
+0.307 +0.220
Bucket
120
+0.307 +0.220
4
Cylinder bore
1
Standard size 110
Steering
Tolerance
Repair limit
0 +0.15
Boom
I
200
0 +0.2
225
0 +0.2
-
40-55
MAINTENANCE
BUCKET LINKAGE
STANDARD
BUCKET LINKAGE
a
b
b
Section A-A
b
a Section D-D
'b Section E-E
"
Section F-F
b
8
7
r
Section G-G
40-56
a'
-b
'b Section H-H
Section J-J
MAINTENANCE
STANDARD
BUCKET LINKAGE Unit: mm
No.
Check item
Criteria Tolerance
Standard size
1
Clearance between pin and bushing
110
Remedy
I
I
I
Shaft
Hole
-0.036
+0.307
Standard
Clearance
clearance
limit
0.256
1.0
at boss ends and bucket link. 2
Clearance between pin and bushing at joint of and bucket
3
Replace, also if
Clearance between pin and bushing at joint of and frame
4
Clearance between pin and bushing
120
at joint of bucket cylinder bottom
-0.090
+0.220
0.397
other
-0.036
+0.307
0.256
parts are
-0.090
+0.220
0.397
biting into pin.
and frame 5
Clearance between pin and bushing at joint of bucket cylinder rod and lever
6
Clearance between pin and bushing at joint of tilt lever and
7
Clearance between pin and bushing at joint of boom cylinder bottom and frame
8
Clearance between pin and bushing
120
at joint of boom cylinder rod and
-0.036
+0.307
0.256
-0.090
+0.220
0.397
1.0
Width between
Width
Standard clearance
bosses
of hinge
(Clearance a + b)
143
140
3.0
153
150
3.0
180
176.8
3.2
Joint of bucket cylinder and frame 9
Insert 10
Joint of and frame
11
Joint of and bucket
shims on both sides to make
12
Joint of bucket link and bucket
145
142
3.0
13
Joint of tilt lever and bucket link
144
142
2.0
on both
240
237
3.0
left and
143
140
3.0
sides less
clearance
14
Joint of tilt lever and
15
Joint of bucket lever and bucket
right than
cylinder
1.5mm 16
Joint of boom cylinder and boom
17
Joint of boom cylinder and frame
125
122
3.0
40-57
MAINTENANCE
STANDARD
BUCKET
BUCKET
/
Section
1
A-A
Section
B-B
‘2 L17CZO25
Unit: mm No
Criteria
1
Wear of bucket tooth
2
Thickness
of shims for tooth (Clearance
between
tooth and bucket) 3
Tightening
torque of mounting
bolt for bucket tooth
4
Tightening
torque of mounting
bolt for corner tooth
40-58
Remedy
Standard size
Repair limit
61
23
Replace
MAINTENANCE
STANDARD
BUCKET POSITIONER
BUCKET POSITIONER
AND BOOM KICK-OUT
AND BOOM KICK-OUT
View
1
Section
Z
A-A
L17DV004 Unit: mm
No
Check item
1
Clearance
of bucket positioner
2
Clearance
of boom kick-out switch
3
Tightening
torque of mounting
bolt for adjuster
4
Tightening
torque of mounting
bolt for switch
Criteria
Remedy
switch 3-5
Adjust
9.Ok3.5 kgm 1.85.2 kgm
Retighten
40-59
MAINTENANCE
STANDARD
ROPS CAB
ROPS CAB
* !r #;’ ;;
----_
-1--j-K __LT_
.-__A-
“,/
$7
SDWO2159
40-60
Komatsu America International Company 440 North Faitwav Drive I Vernon Hills, IL 66061-8112 U.S.A. 1 Attn: Technical Publications 1 Fax No. (847) 970-4186
PROPOSAL
I
FOR MANUAL REVISION
I
FOR INTERNAL NAME OF COMPANY:
1
USE ONLY
No. PMR LOCATION: PHONE NO: DATE:
DEPARTMENT: NAME: VlANUAL NAME: MANUAL NO: MACHINE MODEL: j/N IF APPLICABLE: ‘AGE NO:
‘ROBLEM:
Attach photo or sketch. If more space is needed, use another sheet. FOR INTERNAL CORRECTIVE
HPFMRI
081696
USE ONLY
ACTION:
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