SEBM002307
MACHINE MODEL
SERIAL NUMBER
GD825A-2
11001 and up
• This shop manual may contain attachiments and optional equipment that are not available in your area. Please consult your local Komatsu distributor for those items you may require. Materials and specifications are subject to change without notice. • GD825A-2 mount the S6D140-1 and S6D140E-2 engine. For details of the engine, see the 6D140-1 and 6D140-2 Series Engine Shop Manual.
00-1 (7)
The affected pages are indicated by the use of the following marks. It is requested that necessary actions be taken to these pages according to the table below.
Mark
Indication
Action required
Q
Page to be newly added
Add
q
Page to be replaced
Replace
( )
Page to be deleted
Discard
Pages having no marks are those previously revised or made aditions.
LIST OF REVISED PAGES Mark
Page
q 00-1 q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q q
00-2 00-2-1 00-2-2 00-2-3 00-2-4 (00-2-5) 00-3 00-4 00-5 00-6 00-7 00-8 00-9 00-10 00-11 00-12 00-13 00-14 00-15 00-16 00-17 00-18 00-19 00-20 00-21 00-22 00-23 00-24 00-25 00-26 00-27 00-28 00-29 00-30 00-31 00-32 00-33 00-34 00-35 00-36
Revision Mark number
(7) (2) (7) (7) (7) (7) (6) (6) (6) (6) (6) (6) (6) (6) (6) (6) (6) (6) (6) (6) (6) (6) (6) (6) (6) (6) (6) (6) (6) (6) (6) (6) (6) (6) (6) (6) (6) (6) (6) (6)
q q q q q
Page
Revision Mark number
00-37 00-38 00-39 00-40 00-41
(6) (6) (6) (6) (6)
01-1 01-2 01-3 01-4 01-5 01-6 01-7 01-8 01-9
(2) (2) (2) (2) (2) (2) (2) (2) (2)
10-1 10-2 10-3 10-4 10-5 10-6 10-7 10-7-1 10-7-2 10-8 10-10 10-11 10-11-1 10-11-2 10-12 10-13 10-14 10-15 10-16 10-17 10-18 10-19 10-20 10-21 10-22
(2) (2)
(2) (2) (2) (2) (2) (4) (4) (2) (6) (4) (6) (4) (2)
Page
10-23 10-24 10-25 10-26 10-27 10-28 10-29 10-29-1 10-29-2 10-29-3 10-29-4 10-29-5 10-29-6 10-29-7 10-29-8 10-29-9 10-29-10 10-29-11 10-29-12 10-29-13 10-29-14 10-30 10-31 10-31-1 10-31-2 10-31-3 10-31-4 10-31-5 10-31-6 10-32 10-33 10-34 10-35 10-36 10-37 10-39 10-40 10-41 10-42 10-43 10-44
Revision Mark number
(2) (4) (2) (2) (2) (2) (2) (2) (2) (2) (2) (2) (2) (2) (2) (2) (2) (2) (4) (2) (4) (4)
(2) (2) (2) (2) (6) (6) (2)
(2)
Page
10-45 10-46 10-47 10-48 10-49 10-50 10-51 10-51-1 10-51-2 10-51-3 10-52 10-52-1 10-53 10-54 10-55 10-57 10-58 10-59 10-60 10-61 10-62 10-63 10-64 10-65 10-66 10-67 10-68 10-69 10-70 10-71 10-72 10-73 10-74 10-75 10-76 10-77 10-78 10-79 10-79-1 10-79-2 10-79-3
Revision Mark number
(2) (2) (2)
(2) (4) (6) (6) (2) (2)
(2) (2)
(4) (4)
(2) (2) (2) (2) (2) (2) (2) (2)
Revision number
Page
10-79-4 10-80 10-80-2 10-80-3 10-80-4 10-80-6 10-80-7 10-80-8 10-80-10 10-80-11 10-80-12 10-81-1 10-81-2 10-81-3 10-82 10-83 10-84 10-85 10-86 10-87 10-88 10-89 10-90 10-91 10-92 10-93 10-94 10-95 10-96 10-97 10-97-1 10-97-2 10-98 10-99 10-100 10-100-1 10-100-2 10-100-3 10-100-4 10-101 10-102
(2) (2) (2) (2) (2) (2) (2) (2) (2) (2) (2) (1) (1) (1) (2)
(2)
(2) (2) (2) (2) (2)
(2) (2) (2) (2) (2)
00-2-1 (7)
Mark
Page
10-103 10-104 10-105 10-106 10-107 10-108 10-109 10-110 10-111 10-112 10-113 10-113-1 10-113-2 10-113-3 10-113-4 10-114 10-115 10-116 10-117 10-118 10-119 10-120 10-120-1 10-120-2 10-120-3 10-120-4 10-121 10-122 10-123 10-123-1 10-124 10-125 10-126 10-128 10-129 10-130 10-131 10-132 10-134 10-135 10-136 10-136-1 10-137 10-138 10-140 10-141 10-141-2 10-142 10-142-1 10-143 10-144
00-2-2 (7)
Revision Mark number
(2) (2) (2) (2) (2) (2) (2) (2) (2) (2) (2) (2) (2) (2) (2) (2) (2) (6) (6) (6) (6) (6) (6) (6) (6) (6) (2) (2) (2) (2) (2) (2) (2) (2) (4) (4) (6) (6) (2) (2) (4) (2) (6) (4) (6) (6) (6)
Page
Revision Mark number
10-145 10-146-1 10-146-3 10-146-5 10-146-7 10-146-9 10-146-11 10-147 10-148 10-149 10-150 10-151 10-152 10-153 10-154 10-155 10-155-1 10-155-2 10-155-3 10-156 10-156-1 10-157 10-158 10-159 10-160 10-161 10-162 10-163 10-164 10-165 10-166 10-166-1 10-166-2 10-167 10-168 10-169 10-170 10-171 10-172 10-173
(2) (6) (6) (6) (6) (6) (6) (2) (2) (2) (2) (2) (4) (2) (2) (2) (4) (4) (4) (6) (6) (2) (2) (2) (2) (2) (2) (2) (2) (2) (4) (6) (6) (2) (2) (2) (4) (6) (6) (6)
20-1 20-2 20-3 20-3-1 20-4 20-5 20-6 20-7 20-7-1 20-8
(2) (3) (3) (3) (3) (3) (3) (5)
Page
20-9 20-10 20-11 20-12 20-13 20-13-1 20-14 20-15 20-16 20-17 20-18 20-19 20-19-1 20-20 20-21 20-22 20-23 20-23-1 20-24 20-25 20-26 20-27 20-28 20-29 20-30 20-31 20-32 20-33 20-34 20-35 20-36 20-37 20-38 20-39 20-40 20-41 20-42 20-43 20-44 20-45 20-46 20-47 20-48 20-49 20-50 20-51 20-52 20-53 20-54 20-55 20-55-1
Revision Mark number
(5) (2) (2) (2) (2) (2) (5)
(2) (2)
(2) (5) (5) (5)
(6) (6)
(5)
(2) (2) (2) (2) (2) (2) (6) (2) (2) (2) (5) (2) (2) (5) (5) (5) (5) (5) (5) (5) (5) (5)
q q q q q q q q q q q q q q q q q q q q q q
Page
20-56 20-57 20-58 20-59 20-59-1 20-59-2 20-60 20-60-1 20-60-2 20-60-3 20-60-4 20-60-5 20-60-6 20-60-8 20-60-9 20-60-10 20-60-49 20-60-50 20-60-51 20-60-52 20-60-53 20-60-54 20-60-55 20-60-56 20-60-57 20-60-59 20-60-60 20-60-61 20-60-62 20-60-63 20-60-64 20-60-65 20-60-66 20-60-67 20-60-68 20-60-69 20-60-70 20-60-71 20-60-72 20-60-73 20-60-74 20-60-75 20-60-76 20-60-77 20-60-78 20-60-79 20-60-80 20-60-81 20-60-82 20-60-83 20-60-84
Revision Mark number
(2) (2) (4) (2) (2) (4) (2) (2) (2) (2) (4) (2) (2) (4) (4) (4) (4) (4) (4) (6) (4) (4) (6) (6) (6) (6) (6) (6) (6) (7) (7) (7) (7) (7) (7) (7) (7) (7) (7) (7) (7) (7) (7) (7) (7) (7) (7) (7) (7) (7) (7)
q q q q q q q q q q q q q q q q q
Page
Revision number
20-60-85 20-60-86 20-60-87 20-60-88 20-60-89 20-60-90 20-60-91 20-60-92 20-60-93 20-60-94 20-60-95 20-60-96 20-60-97 20-60-98 20-60-99 20-60-100 20-60-101 20-60-102 20-60-103 20-60-104 20-60-105 20-60-106 20-60-107 20-61 20-62 20-63 20-64 20-65 20-66 20-67 20-68 20-69 20-70 20-71 20-72 20-73 20-74 20-75 20-76 20-77 20-78 20-79 20-80 20-81 20-82 20-83 20-84 20-85 20-85-1 20-86 20-87
(7) (7) (7) (7) (7) (7) (7) (7) (7) (7) (7) (7) (7) (7) (7) (7) (7) (5) (5) (5) (5) (5) (5) (2)
(2)
(4) (4) (4)
Mark
Page
20-88 20-89 20-90 20-90-1 20-91 20-92 20-92-1 20-93 20-94 20-95 20-96 20-97 20-98 20-99 20-101 20-102 20-103 20-104 20-105 20-105-1 20-106 20-107 20-108 20-109 20-110 20-110-1 20-111 20-112 20-112-1 20-113 20-114 20-115 20-116 20-151 20-152 20-153 20-154 20-155 20-156 20-157 20-158 20-159 20-160 20-161 20-162 20-163 20-164 20-165 20-166 20-167 20-168
Revision Mark number
(4) (4) (4) (4) (4)
(4) (2) (2) (2) (2) (4) (4) (2) (4) (4) (2) (4) (4) (2) (4) (4) (2) (2) (2) (2) (4) (2) (2) (2) (2) (2) (2) (2) (2) (2) (2) (2) (2) (2) (2) (2) (2) (2)
Page
20-169 20-170 20-171 20-172 20-173 20-174 20-175 20-175-1 20-176 20-177 20-178 20-179 20-180 20-181 20-182 20-183 20-184 20-185 20-186 20-187 20-188 20-189 20-190 20-191 20-192 20-193 20-201 20-202 20-204 20-205 20-206 20-207 20-208 20-209 20-210 20-211 20-212 30-1 30-1-1 q 30-1-2 q 30-1-3 30-1-4 30-1-5 30-1-6 30-2 30-3 30-4 30-4-1 30-4-2 30-5
Revision Mark number
(2) (2) (2) (2) (4) (4) (4) (4) (4) (4) (4) (4) (4) (4) (4) (4) (4) (4) (4) (4) (4) (4) (4) (4) (4) (4) (2) (2) (2) (2) (2) (2) (2) (2) (2) (2) (2) (6) (6) (6) (6) (6) (6) (6) (7) (7) (2) (2) (2) (2)
Page
30-6 30-7 30-8 30-9 30-10 30-11 30-12 30-13 30-14 30-15 30-16 30-17 30-18 30-18-1 30-19 30-20 30-21 30-22 30-23 30-24 30-25 30-26 30-27 30-28 30-28-1 30-29 30-30 30-31 30-32 30-33 30-34 30-35 30-36 30-37 30-38 30-39 30-40 30-41 30-42 30-43 30-44 30-45 30-45-1 30-45-2 30-45-3 30-45-4 30-45-5 30-45-6 30-45-7 30-45-8 30-46
Revision Mark number
(2) (2) (1) (1) (1) (1) (1) (1) (1) (1) (1) (1) (2) (2) (1) (1) (1) (1) (1) (1) (1) (1) (1) (2) (2) (1) (1) (1) (1) (1) (1) (3) (2) (1) (1) (1) (1) (1) (1) (1) (1) (1) (2) (2) (2) (2) (2) (2) (2) (2) (1)
Page
30-47 30-48 30-49 30-50 30-51 30-52 30-53 30-54 30-55 30-56 30-57 30-58 30-59 30-60 30-61 30-62 30-63 30-64 30-65 30-66 30-67 30-68 30-69 30-70 30-71 30-72 30-73 30-74 30-75 30-76 30-77 30-78 30-79 30-80 30-81 30-82 30-83 30-84 30-85 30-86 30-87 30-88 30-89 30-90 30-91 30-92 30-93 30-94 30-95 30-96 30-97
Revision Mark number
(1) (1) (1) (1) (1) (1) (1) (1) (1) (1) (1) (1) (4) (4) (4) (1) (1) (1) (1) (1) (1) (1) (1) (1) (1) (4) (4) (4) (4) (1) (1) (1) (4) (1) (1) (1) (1) (1) (1) (1) (1) (1) (1) (1) (1) (1) (1) (1) (1) (1) (1)
Revision number
Page
30-98 30-99 30-100 30-101 30-102 30-103 30-104 30-105 30-106 30-107 30-108 30-109 30-110 30-111 30-112 30-113 30-114 30-115 30-116 30-117 30-118 30-119 30-120 30-121 30-122 30-123 30-124 30-124-1 30-125 30-126 30-127 30-128 30-129 30-130 30-131 30-132 30-133 30-134 30-135 30-136 30-137 30-138 30-139 30-140 30-141 30-142 30-143 30-144 30-145 30-146 30-147
(1) (1) (1) (1) (1) (1) (1) (1) (1) (1) (1) (1) (1) (1) (1) (1) (1) (1) (1) (1) (1) (1) (1) (1) (6) (6) (6) (6) (1) (1) (1) (1) (1) (1) (1) (1) (1) (1) (1) (1) (2) (1) (1) (2) (1) (1) (1) (1) (1) (1) (1)
00-2-3 (7)
Mark
Page
30-148 30-149 30-150 30-151 30-152 30-153 30-154 30-155 30-156 30-157 30-158 30-159 30-160 30-161 30-162 30-163 30-164 30-165 30-166 30-167 30-168 30-169 30-170 30-171 30-172 30-173 30-174 30-175 30-176 30-177 30-178 30-179 30-180 30-181 30-182 30-183 30-184 30-185 30-186 30-187 30-188 30-189 30-190 30-191 30-192 30-193 30-194 30-194-1 30-194-2 30-194-3 30-194-4
00-2-4 (7)
Revision Mark number
(1) (1) (1) (1) (1) (1) (1) (1) (1) (1) (1) (1) (1) (1) (1) (1) (1) (1) (1) (1) (1) (1) (1) (1) (1) (1) (1) (1) (1) (1) (1) (2) (1) (1) (1) (1) (1) (1) (2) (1) (1) (2) (1) (1) (1) (1) (1) (2) (2) (2) (2)
Page
30-194-5 30-194-6 30-194-7 30-194-8 30-194-9 30-194-10 30-195 30-196 30-197 30-198 30-199 30-200 30-201 30-202 30-203 30-204 30-205 30-205-1 30-205-2 30-205-3 30-205-4 30-205-5 30-205-6 30-205-7 30-205-8 30-206 30-207 30-207-1 30-207-2 30-208 30-209 30-210 30-211 30-212 30-213 30-214 30-214-1 30-214-2 30-214-3 30-214-4 30-214-5 30-214-6 30-214-7 30-214-8 30-215 30-215-1 30-216 30-217 30-218 30-219 30-220
Revision Mark number
(2) (2) (2) (2) (2) (2) (1) (1) (1) (1) (1) (1) (6) (6) (6) (6) (6) (6) (6) (6) (6) (6) (6) (6) (6) (2) (2) (2) (2) (2) (1) (1) (2) (2) (2) (2) (6) (2) (2) (2) (2) (2) (2) (2) (2) (2) (2) (2) (1) (2) (1)
Page
Revision Mark number
30-221 30-222 30-223 30-223-1 30-223-2 30-223-3 30-223-4 30-223-5 30-224 30-225 30-226 30-227 30-228 30-229 30-230 30-231 30-232 30-233 30-234 30-235 30-236 30-237 30-238 30-239 30-240 30-241 30-242 30-243 30-244 30-245 30-246 30-247
(2) (2) (2) (2) (2) (2) (6) (2) (2) (1) (1) (1) (1) (2) (2) (2) (2) (2) (2) (2) (2) (2) (2) (5) (5) (6) (6) (6) (6) (6) (6) (6)
40-1 40-2 40-3 40-3-1 40-3-2 40-4 40-5 40-6 40-7 40-8 40-9 40-9-1 40-9-2 40-10 40-10-1 40-11 40-12 40-13
(2) (4) (4) (6) (4) (6) (4) (2) (2) (2) (2) (2) (2) (6)
Page
40-14 40-15 40-15-1 40-15-2 40-16 40-17 40-18 40-19 40-20 40-21 40-21-1 40-21-2 40-22 40-23 40-23-1 40-23-2 40-24 40-26 40-27 40-27-1 40-27-2 40-28 40-29 40-29-1 40-29-2 40-30 40-31
Revision Mark number
(4) (6) (6)
(2) (2) (2) (2) (2) (2) (2) (2) (2) (2) (2) (2) (2) (2) (2) (2) (2) (2) (2) (6)
Page
Revision number
Safety notice
(Rev. 2008/08)1
Important safety notice Proper service and repair are extremely important for safe machine operation. The service and repair techniques recommended by Komatsu and described in this manual are both effective and safe. Some of these techniques require the use of tools specially designed by Komatsu for the specific purpose. To prevent injury to workers, the symbol k is 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. 1.
General precautions k Mistakes in operation are extremely dangerous. Read the Operation and Maintenance Manual carefully before operating the machine. In addition, read this manual and understand its contents before starting the work. 1) Before carrying out any greasing or repairs, read all the safety labels stuck to the machine. For the locations of the safety labels and detailed explanation of precautions, see the Operation and Maintenance Manual. 2) 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, water, or oil on the floor. Smoke only in the areas provided for smoking. Never smoke while working. 3) When carrying out any operation, always wear safety shoes and helmet. Do not wear loose work clothes, or clothes with buttons missing. q Always wear safety glasses when hitting parts with a hammer. q Always wear safety glasses when grinding parts with a grinder, etc. 4) When carrying out any operation with 2 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 warning signs in the operator's compartment. 5) Only qualified workers must carry out work and operation which require license or qualification. 6) Keep all tools in good condition, learn the correct way to use them, and use the proper ones of them. Before starting work, thoroughly check the tools, machine, forklift, service car, etc.
7)
8) 9)
If welding repairs are needed, always have a trained and experienced welder carry out the work. When carrying out welding work, alw ays wear welding gloves, apron, shielding goggles, cap and other clothes suited for welding work. Before starting work, warm up your body thoroughly to start work under good condition. Avoid continuing work for long hours and take rests at proper intervals to keep your body in good condition. Take rests in specified safe places.
Safety points 1 Good arrangement 2 Correct work clothes 3 Following work standard 4 Making and checking signs 5
Prohibition of operation and handling by unlicensed workers
6 Safety check before starting work 7
Wearing protective goggles (for cleaning or grinding work)
8
Wearing shielding goggles and protectors (for welding work)
9 Good physical condition and preparation 10
Precautions against work which you are not used to or you are used to too much
00(6)
3
2.
3.
00(6)
Preparations for work 1) Before adding oil or making any repairs, park the machine on a hard and level ground, and apply the parking brake and block the wheels or tracks to prevent the machine from moving. 2) Before starting work, lower the work equipment (blade, ripper, bucket, etc.) to the ground. If this is not possible, insert the lock 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. 3) When disassembling or assembling, support the machine with blocks, jacks, or stands before starting work. 4) 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 m a c h i n e . N e v e r j u m p o n o r o ff t h e machine. If it is impossible to use the handrails, ladders or steps, use a stand to provide safe footing.
6)
Precautions during work 1) Before disconnecting or removing components of the oil, water, or air circuits, first release the pressure completely from the circuit. When removing the oil filler cap, a drain plug, or an oil pressure pickup plug, loosen it slowly to prevent the oil from spurting out. 2) The coolant and oil in the circuits are hot when the engine is stopped, so be careful not to get scalded. Wait for the oil and coolant to cool before carrying out any work on the oil or water circuits. 3) Before starting work, stop the engine. When working on or around a rotating part, in particular, stop the engine. When checking the machine without stopping the engine (measuring oil pressure, revolving speed, temperature, etc.), take extreme care not to get rolled or caught in rotating parts or moving parts. 4) Before starting work, remove the leads from the battery. Always remove the lead from the negative (–) terminal first. 5) When raising a heavy component (heavier than 25 kg), use a hoist or crane. Before starting work, check that the slings (wire ropes, chains, and hooks) are free from damage. Always use slings which have ample capacity and install them to proper places. Operate the hoist or crane slowly to prevent the component from hitting any other part. Do not work with any part still raised by the hoist or crane.
11)
4
7)
8)
9) 10)
12)
13) 14) 15)
16)
When removing a cover which is under internal pressure or under pressure from a spring, always leave 2 bolts in diagonal positions. Loosen those bolts gradually and alternately to release the pressure, and then remove the cover. When removing components, be careful not to break or damage the electrical wiring. Damaged wiring may cause electrical fires. When removing piping, stop the fuel or oil from spilling out. If any fuel or oil drips onto the floor, wipe it up immediately. Fuel or oil on the floor can cause you to slip and can even start fires. As a general rule, do not use gasoline to wash parts. Do not use it to clean electrical parts, in particular. Be sure to assemble all parts again in their original places. Replace any damaged parts and parts which must not be reused 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 operated. 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. In addition, check t h a t c o n n e c t i n g pa r ts a r e c o r r e c t l y installed. When assembling or installing parts, always tighten them to the specified 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. When aligning 2 holes, never insert your fingers or hand. Be careful not to get your fingers caught in a hole. When measuring hydraulic pressure, check that the measuring tools are correctly assembled. Take care when removing or installing the tracks of track-type machines. When removing the track, the track separates suddenly, so never let anyone stand at either end of the track. If the engine is operated for a long time in a place which is not ventilated well, you may suffer from gas poisoning. Accordingly, open the windows and doors to ventilate well.
4.
Precautions for sling work and making signs 1) Only one appointed worker must make signs and co-workers must communicate with each other frequently. The appointed sign maker must make specified signs clearly at a place where he is well seen from the operator's seat and where he can see the working condition easily. The sign maker must always stand in front of the load and guide the operator safely. q Do not stand under the load. q Do not step on the load. 2) Check the slings before starting sling work. 3) Keep putting on gloves during sling work. (Put on leather gloves, if available.) 4) Measure the weight of the load by the eye and check its center of gravity. 5) Use proper sling according to the weight of the load and method of slinging. If too thick wire ropes are used to sling a light load, the load may slip and fall. 6) Do not sling a load with 1 wire rope alone. If it is slung so, it may rotate and may slip out of the rope. Install 2 or more wire ropes symmetrically. k Slinging with 1 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. 7) Limit the hanging angle to 60°, as a rule. Do not sling a heavy load with ropes forming a wide hanging angle from the hook. When hoisting a load with 2 or more ropes, the force subjected to each rope will increase with the hanging angle. The table below shows the variation of allowable load in kN {kg} when hoisting is made with 2 ropes, each of which is allowed to sling up to 9.8 kN {1,000 kg} vertically, at various hanging angles. When the 2 ropes sling a load vertically, up to 19.6 kN {2,000 kg} of total weight can be suspended. This weight is reduced to 9.8 kN {1,000 kg} when the 2 ropes make a hanging angle of 120°. If the 2 ropes sling a 19.6 kN {2,000 kg} load at a lifting angle of 150°, each of them is subjected to a force as large as 39.2 kN {4,000 kg}.
8)
When installing wire ropes to an angular load, apply pads to protect the wire ropes. If the load is slippery, apply proper material to prevent the wire rope from slipping. 9) Use the specified eyebolts and fix wire ropes, chains, etc. to them with shackles, etc. 10) Apply wire ropes to the middle portion of the hook. q Slinging near the tip of the hook may cause the rope to slip off the hook during hoisting. The hook has the maximum strength at the middle portion.
11) Do not use twisted or kinked wire ropes. 12) When lifting up a load, observe the following. q Wind in the crane slowly until wire ropes are stretched. When settling the wire ropes with the hand, do not grasp them but press them from above. If you grasp them, your fingers may be caught. q After the wire ropes are stretched, stop the crane and check the condition of the slung load, wire ropes, and pads.
00(6)
5
If the load is unstable or the wire rope or chains are twisted, lower the load and lift it up again. q Do not lift up the load slantingly. 13) When lifting down a load, observe the following. q When lifting down a load, stop it temporarily at 30 cm above the floor, and then lower it slowly. q Check that the load is stable, and then remove the sling. q Remove kinks and dirt from the wire ropes and chains used for the sling work, and put them in the specified place.
13) If the hoist stops because of a power failure, turn the power switch OFF. When turning on a switch which was turned OFF by the electric shock prevention earth leakage breaker, check that the devices related to that switch are not in operation state. 14) If you find an obstacle around the hoist, stop the operation. 15) After finishing the work, stop the hoist at the specified position and raise the hook to at least 2 m above the floor. Do not leave the sling installed to the hook.
q
5.
6.
00(6)
Precautions for using mobile crane a Read the Operation and Maintenance Manual of the crane carefully in advance and operate the crane safely. Precautions for using overhead hoist crane k When raising a heavy part (heavier than 25 kg), use a hoist, etc. In Disassembly and assembly, the weight of a part heavier than 25 kg is indicated after the mark of 4. 1) Before starting work, inspect the wire ropes, brake, clutch, controller, rails, over wind stop device, electric shock prevention earth leakage breaker, crane collision prevention device, and power application warning lamp, and check safety. 2) Observe the signs for sling work. 3) Operate the hoist at a safe place. 4) Check the direction indicator plates (east, west, south, and north) and the directions of the control buttons without fail. 5) Do not sling a load slantingly. Do not move the crane while the slung load is swinging. 6) Do not raise or lower a load while the crane is moving longitudinally or laterally. 7) Do not drag a sling. 8) When lifting up a load, stop it just after it leaves the ground and check safety, and then lift it up. 9) Consider the travel route in advance and lift up a load to a safe height. 10) Place the control switch on a position where it will not be an obstacle to work and passage. 11) After operating the hoist, do not swing the control switch. 12) Remember the position of the main switch so that you can turn off the power immediately in an emergency.
6
7.
Selecting wire ropes 1) Select adequate ropes depending on the weight of parts to be hoisted, referring to the table below.
Wire ropes (Standard “Z” twist ropes without galvanizing) (JIS G3525, No. 6, Type 6X37-A) Nominal Allowable load diameter of rope mm kN ton 10 8.8 0.9 12 12.7 1.3 14 17.3 1.7 16 22.6 2.3 18 28.6 2.9 20 35.3 3.6 25 55.3 5.6 30 79.6 8.1 40 141.6 14.4 50 221.6 22.6 60 318.3 32.4
a
The allowable load is one-sixth of the breaking strength of the rope used (Safety coefficient: 6).
8.
Precautions for disconnecting and connecting hoses and tubes in air conditioner circuit 1) Disconnection k For the environment, the air conditioner of this machine uses the refrigerant (air conditioner gas: R134a) which has fewer factors of the depletion of the ozone layer. However, it does not mean that you may discharge the refrigerant into the atmosphere as it is. Be sure to recover the refrigerant when disconnecting the refrigerant gas circuit and then reuse it. a Ask professional traders for collecting and filling operation of refrigerant (R134a). a Never release the refrigerant (R134a) to the atmosphere. k If the refrigerant gas gets in your eyes or contacts your skin, you may lose your sight and your skin may be frozen. Accordingly, put on safety glasses, safety gloves and safety clothes when recovering or adding the refrigerant. Refrigerant gas must be recovered and added by a qualified person. 2)
a
Example of O-ring (Fitted to every joint of hoses and tubes)
a
For tightening torque, see the precautions for installation in each section of "Disassembly and assembly".
Connection 1] When installing the air conditioner circuit hoses and tubes, take care that dirt, dust, water, etc. will not enter them. 2] When connecting the air conditioner hoses and tubes, check that O-rings (1) are fitted to their joints. 3] Check that each O-ring is not damaged or deteriorated. 4] When connecting the refrigerant piping, apply compressor oil for refrigerant (R134a) (DENSO: ND-OIL8, VA L E O T H E R M A L S Y S T E M S : ZXL100PG (equivalent to PAG46)) to its O-rings.
00(6)
7
How to read the shop manual q q q
1.
1
Some attachments and optional parts in this shop manual may not be delivered to certain areas. If one of them is required, consult KOMATSU distributors. Materials and specifications are subject to change without notice. Shop manuals are divided into the “Chassis volume” and “Engine volume”. For the engine unit, see the engine volume of the engine model mounted on the machine.
Composition of shop manual This shop manual contains the necessary technical information for services performed in a workshop. For ease of understanding, the manual is divided into the following sections. 00. Index and foreword This section explains the shop manuals list, table of contents, safety, and basic information. 01. Specification This section explains the specifications of the machine. 10. Structure, function and maintenance standard This section explains the structure, function, and maintenance standard values of each component. The structure and function sub-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. The maintenance standard sub-section explains the criteria and remedies for disassembly and service. 20. Standard value table This section explains the standard values for new machine and judgement criteria for testing, adjusting, and troubleshooting. This standard value table is used to check the standard values in testing and adjusting and to judge parts in troubleshooting. 30. Testing and adjusting This section explains measuring instruments and measuring methods for testing and adjusting, and method of adjusting each part. The standard values and judgement criteria for testing and adjusting are explained in Testing and adjusting. 40. Troubleshooting This section explains how to find out failed parts and how to repair them. The troubleshooting is divided by failure modes. The “S mode” of the troubleshooting related to the engine may be also explained in the Chassis volume and Engine volume. In this case, see the Chassis volume. 50. Disassembly and assembly This section explains the special tools and procedures for removing, installing, disassembling, and assembling each component, as well as precautions for them. In addition, tightening torque and quantity and weight of coating material, oil, grease, and coolant necessary for the work are also explained. 90. Diagrams and drawings (chassis volume)/Repair and replacement of parts (engine volume) q Chassis volume This section gives hydraulic circuit diagrams and electrical circuit diagrams. q Engine volume This section explains the method of reproducing, repairing, and replacing parts.
2.
Revision and distribution Any additions, revisions, or other change of notices will be sent to KOMATSU distributors. Get the most up-to-date information before you start any work.
00(6)
8
3.
4.
Filing method File by the brochures in the correct order of the form number printed in the shop manual composition table. q
Revised edition mark When a manual is revised, the ones and tens digits of the form number of each brochure is increased by 1. (Example: 00, 01, 02 …)
q
Revisions Revised brochures are shown in the shop manual composition table.
Symbols Important safety and quality portions are marked with the following symbols so that the shop manual will be used practically. Symbol
Remarks
k
Safety
a
Caution
4
Special technical precautions or other precautions for preserving standards are necessary when performing work.
Weight
3
Weight of parts of component or parts. Caution necessary when selecting hoisting wire, or when working posture is important, etc.
Tightening torque
2
5.
Item
Coat
5
Oil, coolant
6
Drain
Special safety precautions are necessary when performing work.
Places that require special attention for tightening torque during assembly. Places to be coated with adhesives, etc. during assembly. Places where oil, etc. must be added, and capacity. Places where oil, etc. must be drained, and quantity to be drained.
Units In this shop manual, the units are indicated with International System of units (SI). For reference, conventionally used Gravitational System of units is indicated in parentheses { }.
00(6)
9
Explanation of terms for maintenance standard
1
The maintenance standard chapter explains the criteria for replacing or reusing products and parts in the machine maintenance work. The following terms are used to explain the criteria. 1.
Standard size and tolerance q To be accurate, the finishing size of parts is a little different from one to another. q To specify a finishing size of a part, a temporary standard size is set and an allowable difference from that size is indicated. q The above size set temporarily is called the “standard size” and the range of difference from the standard size is called the “tolerance”. q The tolerance with the symbols of + or – is indicated on the right side of the standard size. Example: Standard size
Tolerance –0.022 –0.126
120 a
The tolerance may be indicated in the text and a table as [standard size (upper limit of tolerance/lower limit of tolerance)]. Example) 120 (–0.022/–0.126)
q
Usually, the size of a hole and the size of the shaft to be fitted to that hole are indicated by the same standard size and different tolerances of the hole and shaft. The tightness of fit is decided by the tolerance. Indication of size of rotating shaft and hole and relationship drawing of them
q
Example: Standard size 60
00(6)
10
Tolerance Shaft –0.030 –0.076
Hole +0.046 +0
2.
Standard clearance and standard value The clearance made when new parts are assembled is called the “standard clearance“, which is indicated by the range from the minimum clearance to the maximum clearance. q When some parts are repaired, the clearance is generally adjusted to the standard clearance. q A value of performance and function of new products or equivalent is called the “standard value“, which is indicated by a range or a target value. q When some parts are repaired, the value of performance/function is set to the standard value.
5.
q
3.
Standard interference q When the diameter of a hole of a part shown in the given standard size and tolerance table is smaller than that of the mating shaft, the difference between those diameters is called the “interference”. q The range (A – B) from the difference (A) between the minimum size of the shaft and the maximum size of the hole to the difference (B) between the maximum size of the shaft and the minimum size of the hole is the “standard interference”. q After repairing or replacing some parts, measure the size of their hole and shaft and check that the interference is in the standard range.
4.
Repair limit and allowable value or allowable dimension q The size of a part changes because of wear and deformation while it is used. The limit of changed size is called the “repair limit”. q If a part is worn to the repair limit, it must be replaced or repaired. q The performance and function of a product lowers while it is used. A value which the product can be used without causing a problem is called the “allowable value” or “allowable dimension”. q If a product is worn to the allowable value, it must be checked or repaired. Since the permissible value is estimated from various tests or experiences in most cases, however, it must be judged after considering the operating condition and customer's requirement.
6.
Clearance limit q Parts can be used until the clearance between them is increased to a certain limit. The limit at which those parts cannot be used is called the “clearance limit”. q If the clearance between the parts exceeds the clearance limit, they must be replaced or repaired. Interference limit The allowable maximum interference between the hole of a part and the shaft of another part to be assembled is called the “interference limit”. q The interference limit shows the repair limit of the part of smaller tolerance. q If the interference between the parts exceeds the interference limit, they must be replaced or repaired. q
00-
11 (6)
Handling of electric equipment and hydraulic component
1
To maintain the performance of the machine over a long period, and to prevent failures or other troubles before they occur, correct “operation“, “maintenance and inspection“, “troubleshooting“, and “repairs” must be carried out. This section deals particularly with correct repair procedures for mechatronics and is aimed at improving the quality of repairs. For this purpose, it gives sections on “Handling electric equipment” and “Handling hydraulic equipment” (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. 2.
Main failures occurring in wiring harness 1) 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. The corroded or oxidized contact surfaces may become shiny again (and contact may become normal) by connecting and disconnecting the connector about 10 times. 2)
00(6)
12
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.
3)
Disconnections in wiring If the wiring is held and the connectors are pulled apart, or components are lifted with a crane with the wiring still connected, or a heavy object hits the wiring, the crimping of the connector may separate, or the soldering may be damaged, or the wiring may be broken.
4)
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. Accordingly, take care not to splash water over the connector. 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, if water should get into the connector, the pins will be shortcircuited by the water, so if any water gets in, immediately dry the connector or take other appropriate action before passing electricity through it.
5)
Oil or dirt stuck to connector If oil or grease are 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 it dry with compressed air and spray it with a contact restorer. a When wiping the mating portion of the connector, be careful not to use excessive force or deform the pins. a 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.
00-
13 (6)
3.
Removing, installing, and drying connectors and wiring harnesses 1) Disconnecting connectors 1] Hold the connectors when disconnecting. When disconnecting the connectors, hold the connectors. 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. a Never pull with one hand. 2] q
00(6)
14
When removing from clips Both of the connector and clip have stoppers, which are engaged with each other when the connector is installed.
q
When removing a connector from a clip, pull the connector in a parallel direction to the clip for removing stoppers. a If the connector is twisted up and down or to the left or right, the housing may break.
3]
Action to take after removing connectors After removing any connector, cover it with a vinyl bag to prevent any dust, dirt, oil, or water from getting in the connector portion. a If the machine is left disassembled for a long time, it is particularly easy for improper contact to occur, so always cover the connector.
2)
Connecting connectors 1] Check the connector visually. Check that there is no oil, dirt, or water stuck to the connector pins (mating portion). Check that there is no deformation, defective contact, corrosion, or damage to the connector pins. Check that there is no damage or breakage to the outside of the connector. a 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. a If there is any damage or breakage, replace the connector. 2] Fix the connector securely. Align the position of the connector correctly, and then insert it securely. For connectors with the lock stopper, push in the connector until the stopper clicks into position. 3] Correct any protrusion of the boot and any misalignment of the wiring harness. For connectors fitted with boots, correct any protrusion of the boot. In addition, if the wiring harness is misaligned, or the clamp is out of position, adjust it to its correct position. a If the connector cannot be corrected easily, remove the clamp and adjust the position. q If the connector clamp has been removed, be sure to return it to its original position. Check also that there are no loose clamps.
00-
15 (6)
3)
00(6)
16
Heavy duty wire connector (DT 8-pole, 12pole) Disconnection (Left of figure) While pressing both sides of locks (a) and (b), pull out female connector (2). Connection (Right of figure) 1] Push in female connector (2) horizontally until the lock clicks. Arrow: 1) 2] Since locks (a) and (b) may not be set completely, push in female connector (2) while moving it up and down until the locks are set normally. Arrow: 1), 2), 3) a Right of figure: Lock (a) is pulled down (not set completely) and lock (b) is set completely. (1): Male connector (2): Female connector (a), (b): Locks
q
Disconnection
q
Connection (Example of incomplete setting of (a))
4)
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. 1] Disconnect the connector and wipe off the water with a dry cloth. a 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 o i l an d w at e r f r o m t h e c om pressed air before blowing with air. 2] Dry the inside of the connector with a dryer. If water gets inside the connector, use a dryer to dry the connector. a 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. 3] 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. a After completely drying the conn e c t o r, b l o w i t w i t h c o n ta c t restorer and reassemble.
00-
17 (6)
4.
Handling controller 1) The controller contains a microcomputer and electronic control circuits. These control all of the electronic circuits on the machine, so be extremely careful when handling the controller. 2) Do not place objects on top of the controller. 3) Cover the control connectors with tape or a vinyl bag. Never touch the connector contacts with your hand. 4) During rainy weather, do not leave the controller in a place where it is exposed to rain. 5) Do not place the controller on oil, water, or soil, or in any hot place, even for a short time. (Place it on a suitable dry stand). 6) Precautions when carrying out arc welding When carrying out arc welding on the body, disconnect all wiring harness connectors connected to the controller. Fit an arc welding ground close to the welding point.
5.
Points to remember when troubleshooting electric circuits 1) Always turn the power OFF before disconnecting or connecting connectors. 2) Before carrying out troubleshooting, check that all the related connectors are properly inserted. a Disconnect and connect the related connectors several times to check. 3) Always connect any disconnected connectors before going on to the next step. a If the power is turned ON with the connectors still disconnected, unnecessary abnormality displays will be generated. 4) When carrying out troubleshooting of circuits (measuring the voltage, resistance, continuity, or current), move the related wiring and connectors several times and check that there is no change in the reading of the tester. a If there is any change, there is probably defective contact in that circuit.
00(6)
18
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 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 check the performance after repairs, so it is desirable to use unit exchange. Disassembly and maintenance of hydraulic equipment should be carried out in a specially prepared dustproof workshop, and the performance should be checked 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 danger of dirt entering or of the surrounding area being made dirty by leaking oil so never do this. Do not simply drain oil out onto the ground, but 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 Be careful not to let any dirt or dust get in when refilling with hydraulic oil. Always keep the oil filler and the area around it clean, and also use clean pumps and oil containers. If an oil cleaning device is used, it is possible to filter out the dirt that has collected during storage, so this is an even more effective method.
00-
19 (6)
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 3 m) particles that the filter built in the hydraulic equipment cannot remove, so it is an extremely effective device.
00(6)
20
Handling of connectors newly used for engines a
1.
Mainly, following engines are object for following connectors. q 95E-5 q 107E-1 q 114E-3 q 125E-5 q 140E-5 q 170E-5 q 12V140E-3 Slide lock type (FRAMATOME-3, FRAMATOME-2) q 95 – 170, 12V140 engines q Various pressure sensors and NE speed sensor Examples) Intake air pressure sensor in intake manifold: PIM (125, 170, 12V140 engines) Oil pressure sensor: POIL (125, 170, 12V140 engines) Oil pressure switch (95, 107, 114 engines) Ne speed sensor of flywheel housing: NE (95 – 170, 12V140 engines) Ambient pressure sensor: PAMB (125, 170, 12V140 engines)
2.
1
Pull lock type (PACKARD-2) 95 – 170, 12V140 engines q Various temperature sensors Example) Intake air temperature sensor in intake manifold: TIM Fuel temperature sensor: TFUEL Oil temperature sensor: TOIL Coolant temperature sensor: TWTR, etc. Disconnect the connector by pulling lock (B) (on the wiring harness side) of connector (2) outward.
q
Disconnect connector (1) according to the following procedure. 1) Slide lock (L1) to the right. 2) While pressing lock (L2), pull out connector (1) toward you. a Even if lock (L2) is pressed, connector (1) cannot be pulled out toward you, if part A does not float. In this case, float part A with a small screwdriver while press lock (L2), and then pull out connector (1) toward you.
00-
21 (6)
3.
Push lock type q 95, 107, 114 engines Example) Fuel pressure sensor in common rail (BOSCH-03) Disconnect connector (3) according to the following procedure. 1) While pressing lock (C), pull out connector (3) in the direction of the arrow. q
q
114 engine
107 engine
a
2)
00(6)
22
If the lock is on the underside, use flat-head screwdriver [1] since you cannot insert your fingers. While pressing up lock (C) of the connector with flat-head screwdriver [1], pull out connector (3) in the direction of the arrow.
q
107, 114 engines Example) Intake air pressure/temperature sensor in intake manifold (SUMITOMO-04)
3)
While pressing lock (D), pull out connector (4) in the direction of the arrow.
q
4)
95, 125 – 170, 12V140 engines While pressing lock (E) of the connector, pull out connector (5) in the direction of the arrow. Example) Fuel pressure sensor in common rail: PFUEL etc. (AMP-3)
4.
Turn-housing type (Round green connector) 140 engine Example) Intake air pressure sensor in intake manifold (CANNON-04): PIM etc.
q
1)
Disconnect connector (6) according to the following procedure. 1] Turn housing (H1) in the direction of the arrow. a When connector is unlocked, housing (H1) becomes heavy to turn. 2] Pull out housing (H1) in the direction of the arrow. a Housing (H1) is left on the wiring harness side.
2)
Connect the connector according to the following procedure. 1] Insert the connector to the end, while setting its groove. 2] Turn housing (H1) in the direction of the arrow until it “clicks”.
Example) Injection pressure control valve of fuel supply pump: PCV (SUMITOMO-2)
Example) Speed sensor of fuel supply pump: G (SUMITOMO-3) a Pull the connector straight up.
00-
23 (6)
How to read electric wire code a
1
The information about the wires unique to each machine model is described in Troubleshooting section, Relational information of troubleshooting.
In the electric circuit diagram, the material, thickness, and color of each electric wire are indicated by symbols. The electric wire code is helpful in understanding the electric circuit diagram. Example: AEX
0.85
L - - - Indicates blue, heat-resistant, low-voltage wire for automobile, having nominal No. of 0.85 Indicates color of wire by color code. Color codes are shown in Table 3. Indicates size of wire by nominal No. Size (Nominal No.) is shown in Table 2. Indicates type of wire by symbol. Type, symbol, and material of wire are shown in Table 1. (Since AV and AVS are classified by size (nominal No.), they are not indicated.)
1.
Type, symbol, and material AV and AVS are different in only thickness and outside diameter of the cover. AEX is similar to AV in thickness and outside diameter of AEX and different from AV and AVS in material of the cover.
(Table 1) Type
Symbol
Low-voltage wire for automobile
AV
Thin-cover low-voltage wire for automobile
AVS
Heat-resistant low-voltAEX age wire for automobile
00(6)
24
Material Conductor Insulator Conductor
Annealed copper for electric appliance Soft polyvinyl chloride Annealed copper for electric appliance
Insulator
Soft polyvinyl chloride
Conductor
Annealed copper for electric appliance Heat-resistant crosslinked polyethylene
Insulator
Using temperature range (°C)
Example of use General wiring (Nominal No. 5 and above)
–30 to +60 General wiring (Nominal No. 3 and below) General wiring in extremely –50 to +110 cold district, wiring at high-temperature place
2.
Dimensions
(Table 2) Nominal No. 0.5f (0.5) 0.75f (0.85) 1.25f (1.25) 2f 2 3f 3 5 Number of strands/Diam- 20/0.18 7/0.32 30/0.18 11/0.32 50/0.18 16/0.32 37/0.26 26/0.32 58/0.26 41/0.32 65/0.32 eter of strand Conductor Sectional 0.51 0.56 0.76 0.88 1.27 1.29 1.96 2.09 3.08 3.30 5.23 area (mm2) d (approx.) 1.0 1.2 1.5 1.9 1.9 2.3 2.4 3.0 AVS Standard 2.0 2.2 2.5 2.9 2.9 3.5 3.6 – CovAV Standard – – – – – – – 4.6 er D AEX Standard 2.0 2.2 2.7 3.0 3.1 – 3.8 4.6
Nominal No. Number of strands/Diameter of strand Conductor Sectional area (mm2) d (approx.) AVS Standard CovAV Standard er D AEX Standard
8
15
20
30
40
50
60
85
100
50/0.45
84/0.45
41/0.80
70/0.80
85/0.80
7.95
13.36
20.61
35.19
42.73
54.29
63.84
84.96
109.1
3.7 – 5.5 5.3
4.8 – 7.0 7.0
6.0 – 8.2 8.2
8.0 – 10.8 10.8
8.6 – 11.4 11.4
9.8 – 13.0 13.0
10.4 – 13.6 13.6
12.0 – 16.0 16.0
13.6 – 17.6 17.6
108/0.80 127/0.80 169/0.80 217/0.80
“f” of nominal No. denotes flexible”.
00-
25 (6)
3.
Color codes table
(Table 3) Color Code B Br BrB BrR BrW BrY Ch Dg G GB GL Gr GR GW GY L LB Lg LgB LgR
Color of wire Black Brown Brown & Black Brown & Red Brown & White Brown & Yellow Charcoal Dark green Green Green & Black Green & Blue Gray Green & Red Green & White Green & Yellow Blue Blue & Black Light green Light green & Black Light green & Red
Color Code LgW LgY LR LW LY O P R RB RG RL RW RY Sb Y YB YG YL YR YW
Color of wire Light green & White Light green & Yellow Blue & Red Blue & White Blue & Yellow Orange Pink Red Red & Black Red & Green Red & Blue Red & White Red & Yellow Sky Blue Yellow Yellow & Black Yellow &Green Yellow & Blue Yellow & Red Yellow & White
Remarks: In a color code consisting of 2 colors, the first color is the color of the background and the second color is the color of the marking. Example: “GW” means that the background is Green and marking is White.
4.
Types of circuits and color codes
(Table 4) Type of wire Charge Ground Start Light Instrument Signal Type of circuit Others
00(6)
26
AVS or AV R B R RW Y G L Br Lg O Gr P Sb Dg Ch
AEX
–
R B R D Y G L
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
–
WG
–
–
–
–
–
–
–
–
–
–
–
–
–
–
RB YR GW LW BrW LgR
RY YB GR LR BrR LgY
RG YG GY LY BrY LgB
RL YL GB LB BrB LgW
–
–
–
–
–
–
–
–
–
–
– –
–
YW GL
– – – –
Gr Br –
Precautions when carrying out operation
1
[When carrying out removal or installation (disassembly or assembly) of units, be sure to follow the general precautions given below when carrying out the operation.] 1. q q q q q q q q q q
a
Precautions when carrying out removal work If the coolant contains antifreeze, dispose of it correctly. After disconnecting hoses or tubes, cover them or fit plugs to prevent dirt or dust from entering. When draining oil, prepare a container of adequate size to catch the oil. Confirm the match marks showing the installation position, and make match marks in the necessary places before removal to prevent any mistake when assembling. To prevent any excessive force from being applied to the wiring, always hold the connectors when disconnecting the connectors. Do not pull the wires. Fit wires and hoses with tags to show their installation position to prevent any mistake when installing. Check the number and thickness of the shims, and keep in a safe place. When raising components, be sure to use lifting equipment of ample strength. When using forcing screws to remove any components, tighten the forcing screws uniformly in turn. Before removing any unit, clean the surrounding area and fit a cover to prevent any dust or dirt from entering after removal. Precautions when handling piping during disassembly Fit the following plugs into the piping after disconnecting it during disassembly operations. 1) Face seal type hoses and tubes Nominal number 02 03 04 05 06 10 12 2)
Sleeve nut (elbow end)
07376-70210 07376-70315 07376-70422 07376-70522 07376-70628 07376-71034 07376-71234
02789-20210 02789-20315 02789-20422 02789-20522 02789-20628 07221-21034 07221-21234
Split flange type hoses and tubes Nominal number 04 05
3)
Plug (nut end)
Flange (hose end)
Sleeve head (tube end)
Split flange
07379-00400 07379-00500
07378-10400 07378-10500
07371-30400 07371-30500
If the part is not under hydraulic pressure, the following corks can be used. Nominal number
Part Number
06 08 10 12 14 16 18 20 22 24
07049-00608 07049-00811 07049-01012 07049-01215 07049-01418 07049-01620 07049-01822 07049-02025 07049-02228 07049-02430
D 6 8 10 12 14 16 18 20 22 24
27
07049-02734
27
Dimensions d L 5 8 6.5 11 8.5 12 10 15 11.5 18 13.5 20 15 22 17 25 18.5 28 20 30 22.5
34
00-
27 (6)
2. q q q q q q q q q q q q q
a
a
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 and fix them with intermediate clamps, if there are any. 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 2 – 3 drops of adhesive. When coating with gasket sealant, clean the surface and remove all oil and grease, check that there is no dirt or damage, then coat uniformly with gasket sealant. Clean all parts, and correct any damage, dents, burrs, or rust. Coat rotating parts and sliding parts with engine oil. When press fitting parts, coat the surface with anti-friction compound (LM-P). After fitting snap rings, check that the snap ring is fitted securely in the ring groove. When connecting wiring connectors, clean the connector to remove all oil, dirt, or water, then connect securely. When using eyebolts, check that there is no deformation or deterioration, screw them 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 idle. 2) Operate the work equipment control lever to operate the hydraulic cylinder 4 – 5 times, stopping the cylinder 100 mm from the end of its stroke. 3) Next, operate the hydraulic cylinder 3 – 4 times to the end of its stroke. 4) After doing this, run the engine at normal speed. When using the machine for the first time after repair or long storage, follow the same procedure.
3.
Precautions when completing the operation 1) Refilling with coolant, oil and grease q If the coolant has been drained, tighten the drain valve, and add coolant to the specified level. Run the engine to circulate the coolant through the system. Then check the coolant level again. q 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. q If the piping or hydraulic equipment have been removed, always bleed the air from the system after reassembling the parts. a For details, see Testing and adjusting, “Bleeding air”. q Add the specified amount of grease (molybdenum disulphide grease) to the work equipment parts. 2) Checking cylinder head and manifolds for looseness Check the cylinder head and intake and exhaust manifold for looseness. If any part is loosened, retighten it. q For the tightening torque, see “Disassembly and assembly”. 3) Checking engine piping for damage and looseness Intake and exhaust system Check the piping for damage, the mounting bolts and nuts for looseness, and the joints for air suction and exhaust gas leakage. If any part is loosened or damaged, retighten or repair it. Cooling system Check the piping for damage, the mounting bolts and nuts for looseness, and the joints for coolant leakage. If any part is loosened or damaged, retighten or repair it. Fuel system Check the piping for damage, the mounting bolts and nuts for looseness, and the joints for fuel leakage. If any part is loosened or damaged, retighten or repair it.
00(6)
28
4)
5)
Checking muffler and exhaust pipe for damage and looseness 1] Visually check the muffler, exhaust pipe and their mounting parts for a crack and damage. If any part is damaged, replace it. 2] Check the mounting bolts and nuts of the muffler, exhaust pipe and their mounting parts for looseness. If any bolt or nut is loosened, retighten it. Checking muffler function Check the muffler for abnormal sound and sound different from that of a new muffler. If any abnormal sound is heard, repair the muffler, referring to “Troubleshooting” and “Disassembly and assembly”.
00-
29 (6)
Method of disassembling and connecting push-pull type coupler k k
1
Before carrying out the following work, loosen the oil filler cap of the hydraulic tank gradually to release the residual pressure from the hydraulic tank. Even if the residual pressure is released from the hydraulic tank, some hydraulic oil flows out when the hose is disconnected. Accordingly, prepare an oil receiving container.
Type 1 1.
Disconnection 1) Hold adapter (1) and push hose joint (2) into mating adapter (3). (Fig. 1) a The adapter can be pushed in about 3.5 mm. a Do not hold rubber cap portion (4). 2) After hose joint (2) is pushed into adapter (3), press rubber cap portion (4) against adapter (3) until it clicks. (Fig. 2) 3) Hold hose adapter (1) or hose (5) and pull it out. (Fig. 3) a Since some hydraulic oil flows out, prepare an oil receiving container.
2.
Connection 1) Hold hose adapter (1) or hose (5) and insert it in mating adapter (3), aligning them with each other. (Fig. 4) a Do not hold rubber cap portion (4). 2) After inserting the hose in the mating adapter perfectly, pull it back to check its connecting condition. (Fig. 5) a When the hose is pulled back, the rubber cap portion moves toward the hose about 3.5 mm. This does not indicate abnormality, however.
00(6)
30
Type 2 1.
2.
Disconnection 1) Hold the tightening portion and push body (7) straight until sliding prevention ring (6) contacts contact surface (a) of the hexagonal portion at the male end. (Fig. 6) 2) While holding the condition of Step 1), turn lever (8) to the right (clockwise). (Fig. 7) 3) While holding the condition of Steps 1) and 2), pull out whole body (7) to disconnect it. (Fig. 8)
Connection Hold the tightening portion and push body (7) straight until sliding prevention ring (6) contacts contact surface (a) of the hexagonal portion at the male end. (Fig. 9)
q
00-
31 (6)
Type 3 1.
Disconnection 1) Hold the tightening portion and push body (9) straight until sliding prevention ring (8) contacts contact surface (b) of the hexagonal portion at the male end. (Fig. 10) 2) While holding the condition of Step 1), push cover (10) straight until it contacts contact surface (b) of the hexagonal portion at the male end. (Fig. 11) 3) While holding the condition of Steps 1) and 2), pull out whole body (9) to disconnect it. (Fig. 12)
2.
Connection q Hold the tightening portion and push body (9) straight until the sliding prevention ring contacts contact surface (b) of the hexagonal portion at the male end. (Fig. 13)
00(6)
32
Standard tightening torque table 1.
1
Table of tightening torques for bolts and nuts a Unless there are special instructions, tighten metric nuts and bolts to the torque below. a
The following table applies to the bolts in Fig. A.
Thread diameter of bolt mm 6 8 10 12 14 16 18 20 22 24 27 30 33 36 39 a
Tightening torque Nm 11.8 – 14.7 27 – 34 59 – 74 98 – 123 157 – 196 245 – 309 343 – 427 490 – 608 662 – 829 824 – 1,030 1,180 – 1,470 1,520 – 1,910 1,960 – 2,450 2,450 – 3,040 2,890 – 3,630
kgm 1.2 – 1.5 2.8 – 3.5 6.0 – 7.5 10.0 – 12.5 16 – 20 25 – 31.5 35 – 43.5 50 – 62 67.5 – 84.5 84 – 105 120 – 150 155 – 195 200 – 250 250 – 310 295 – 370
The following table applies to the bolts in Fig. B.
Thread diameter of bolt mm 6 8 10 12 a Fig. A
Width across flats mm 10 13 17 19 22 24 27 30 32 36 41 46 50 55 60
Width across flats mm 10 12 14 17
Tightening torque Nm 5.9 – 9.8 13.7 – 23.5 34.3 – 46.1 74.5 – 90.2
kgm 0.6 – 1.0 1.4 – 2.4 3.5 – 4.7 7.6 – 9.2
a Fig. B
Remarks: The widths across flats against the thread diameters of flanged bolts (marks with "*") in Fig. A are the ones indicated in the table for bolts shown in Fig. B. (Values of tightening torques shown in the table for Fig. A are applied.)
00-
33 (6)
2.
Table of tightening torques for split flange bolts a Unless there are special instructions, tighten split flange bolts to the torque below.
Thread diameter of bolt mm 10 12 16
3.
Width across flats mm 14 17 22
Tightening torque Nm kgm 59 – 74 6.0 – 7.5 98 – 123 10.0 – 12.5 235 – 285 23.5 – 29.5
Table of tightening torques for O-ring boss piping joints a Unless there are special instructions, tighten O-ring boss piping joints to the torque below.
Nominal No. 02 03,04 05,06 10,12 14
4.
Thread diameter mm 14 20 24 33 42
Width across flats mm
Tightening torque Nm {kgm} Range Target 35 – 63 { 3.5 – 6.5} 44 { 4.5} 84 – 132 { 8.5 – 13.5} 103 {10.5} Varies depending on type of connec- 128 – 186 {13.0 – 19.0} 157 {16.0} tor. 363 – 480 {37.0 – 49.0} 422 {43.0} 746 – 1,010 {76.0 – 103} 883 {90.0}
Table of tightening torques for O-ring boss plugs a Unless there are special instructions, tighten O-ring boss plugs to the torque below. Nominal No. 08 10 12 14 16 18 20 24 30 33 36 42 52
00(6)
34
Thread diameter mm 8 10 12 14 16 18 20 24 30 33 36 42 52
Width across flats mm 14 17 19 22 24 27 30 32 32 – 36 – –
Tightening torque Nm {kgm} Range Target 5.88 – 8.82 {0.6 – 0.9} 7.35 {0.75} 9.81 – 12.74 {1.0 – 1.3} 11.27 {1.15} 14.7 – 19.6 {1.5 – 2.0} 17.64 {1.8} 19.6 – 24.5 {2.0 – 2.5} 22.54 {2.3} 24.5 – 34.3 {2.5 – 3.5} 29.4 {3.0} 34.3 – 44.1 {3.5 – 4.5} 39.2 {4.0} 44.1 – 53.9 {4.5 – 5.5} 49.0 {5.0} 58.8 – 78.4 {6.0 – 8.0} 68.6 {7.0} 93.1 – 122.5 { 9.5 – 12.5} 107.8 {11.0} 107.8 – 147.0 {11.0 – 15.0} 127.4 {13.0} 127.4 – 176.4 {13.0 – 18.0} 151.9 {15.5} 181.3 – 240.1 {18.5 – 24.5} 210.7 {21.5} 274.4 – 367.5 {28.0 – 37.5} 323.4 {33.0}
5.
Table of tightening torques for hoses (taper seal type and face seal type) a Unless there are special instructions, tighten the hoses (taper seal type and face seal type) to the torque below. a Apply the following torque when the threads are coated (wet) with engine oil.
Nominal No. of hose
Width across flats
02
19
03 04 05 06 (10) (12) (14)
6.
22 24 27 32 36 41 46 55
Tightening torque Nm {kgm} Range 34 – 54 { 3.5 – 5.5} 34 – 63 { 3.5 – 6.5} 54 – 93 { 5.5 – 9.5} 59 – 98 { 6.0 – 10.0} 84 – 132 { 8.5 – 13.5} 128 – 186 {13.0 – 19.0} 177 – 245 {18.0 – 25.0} 177 – 245 {18.0 – 25.0} 197 – 294 {20.0 – 30.0} 246 – 343 {25.0 – 35.0}
Target
44 { 4.5} 74 { 7.5} 78 { 8.0} 103 {10.5} 157 {16.0} 216 {22.0} 216 {22.0} 245 {25.0} 294 {30.0}
Taper seal Thread size (mm) – 14 – 18 22 24 30 33 36 42
Face seal Nominal No. – Thread Number of diameter (mm) threads, type of (Reference) thread 9/16-18UN 14.3 – – 11/16-16UN 17.5 – – 13/16-16UN 20.6 1-14UNS 25.4 1-3/16-12UN 30.2 – – – – – –
Table of tightening torques for face seal joints a Tighten the face seal joints (sleeve nut type) made of plated steel pipes for low pressure service to be used for engines etc. to the torque shown in the following table. a Apply the following torque to the face seal joint while their threaded parts are coated with engine oil (wetted).
Outer diameter of pipe (mm)
Width across flats (mm)
8 10 12 15 (16) 22 (20)
19 22 24 (27) 30 (32) 36
Tightening torque Nm {kgm} Range
Target
14 – 16 {1.4 – 1.6} 24 – 27 {2.4 – 2.7} 43 – 47 {4.4 – 4.8} 60 – 68 {6.1 – 6.8} 90 – 95 {9.2 – 9.7}
15 {1.5} 25.5 {2.6} 45 {4.6} 64 {6.5} 92.5 {9.4}
Face seal Thread diameter Nominal No. – (mm) Number of threads, (Reference) type of thread 9/16-18UN 14.3 11/16-16UN 17.5 13/16-16UN 20.6 1-14UN 25.4 1-3/16-12UN 30.2
Reference: The face seal joints of the dimensions in ( ) are also used, depending on the specification.
7.
Table of tightening torques for 102, 107 and 114 engine series (Bolts and nuts) a Unless there are special instructions, tighten the metric bolts and nuts of the 102, 107 and 114 engine series to the torque below. Tightening torque Bolts and nuts
Thread size mm 6 8 10 12 14
Nm 10 ± 2 24 ± 4 43 ± 6 77 ± 12 —
kgm 1.02 ± 0.20 2.45 ± 0.41 4.38 ± 0.61 7.85 ± 1.22 —
00-
35 (6)
8.
Table of tightening torques for 102, 107 and 114 engine series (Eye joints) a Unless there are special instructions, tighten the metric eye joints of the 102, 107 and 114 engine series to the torque below. Thread size mm 6 8 10 12 14
9.
kgm 0.81 ± 0.20 1.02 ± 0.20 1.22 ± 0.20 2.45 ± 0.41 3.67 ± 0.51
Table of tightening torques for 102, 107 and 114 engine series (Taper screws) a Unless there are special instructions, tighten the taper screws (unit: inch) of the 102, 107 and 114 engine series to the torque below. Material Thread size (inch) 1/16 1/8 1/4 3/8 1/2 3/4
00(6)
Tightening torque Nm 8±2 10 ± 2 12 ± 2 24 ± 4 36 ± 5
36
Tightening torque In cast iron or steel In aluminum Nm kgm Nm kgm 15 ± 2 1.53 ± 0.20 5±1 0.51 ± 0.10 20 ± 2 2.04 ± 0.20 15 ± 2 1.53 ± 0.20 25 ± 3 2.55 ± 0.31 20 ± 2 2.04 ± 0.20 35 ± 4 3.57 ± 0.41 25 ± 3 2.55 ± 0.31 55 ± 6 5.61 ± 0.61 35 ± 4 3.57 ± 0.41 75 ± 8 7.65 ± 0.82 45 ± 5 4.59 ± 0.51
Conversion table
1
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 (A), and then draw a horizontal line from (A). 2) Locate the number 5 in the row across the top, take this as (B), then draw a perpendicular line down from (B). 3) Take the point where the 2 lines cross as (C). This point (C) gives the value when converting from millimeters to inches. Therefore, 55 mm = 2.165 inches.
2.
Convert 550 mm into inches. 1) The number 550 does not appear in the table, so divide it by 10 (move the decimal point one place to the left) to convert it to 55 mm. 2) Carry out the same procedure as above to convert 55 mm to 2.165 inches. 3) The original value (550 mm) was divided by 10, so multiply 2.165 inches by 10 (move the decimal point one place to the right) to return to the original value. This gives 550 mm = 21.65 inches.
(B)
Millimeters to inches
(A)
0 10 20 30 40
0 0 0.394 0.787 1.181 1.575
1 0.039 0.433 0.827 1.220 1.614
2 0.079 0.472 0.866 1.260 1.654
3 0.118 0.512 0.906 1.299 1.693
4 0.157 0.551 0.945 1.339 1.732
50 60 70 80 90
1.969 2.362 2.756 3.150 3.543
2.008 2.402 2.795 3.189 3.583
2.047 2.441 2.835 3.228 3.622
2.087 2.480 2.874 3.268 3.661
2.126 2.520 2.913 3.307 3.701
5 0.197 0.591 0.984 1.378 1.772 (C) 2.165 2.559 2.953 3.346 3.740
6 0.236 0.630 1.024 1.417 1.811
1 mm = 0.03937 in 7 8 9 0.276 0.315 0.354 0.669 0.709 0.748 1.063 1.102 1.142 1.457 1.496 1.536 1.850 1.890 1.929
2.205 2.598 2.992 3.386 3.780
2.244 2.638 3.032 3.425 3.819
2.283 2.677 3.071 3.465 3.858
2.323 2.717 3.110 3.504 3.898
00-
37 (6)
Millimeters to inches 1 mm = 0.03937 in 8 9 0.315 0.354 0.709 0.748 1.102 1.142 1.496 1.536 1.890 1.929
0 10 20 30 40
0 0 0.394 0.787 1.181 1.575
1 0.039 0.433 0.827 1.220 1.614
2 0.079 0.472 0.866 1.260 1.654
3 0.118 0.512 0.906 1.299 1.693
4 0.157 0.551 0.945 1.339 1.732
5 0.197 0.591 0.984 1.378 1.772
6 0.236 0.630 1.024 1.417 1.811
7 0.276 0.669 1.063 1.457 1.850
50 60 70 80 90
1.969 2.362 2.756 3.150 3.543
2.008 2.402 2.795 3.189 3.583
2.047 2.441 2.835 3.228 3.622
2.087 2.480 2.874 3.268 3.661
2.126 2.520 2.913 3.307 3.701
2.165 2.559 2.953 3.346 3.740
2.205 2.598 2.992 3.386 3.780
2.244 2.638 3.032 3.425 3.819
1 kg = 2.2046 lb 6 7 8 9 13.23 15.43 17.64 19.84 35.27 37.48 39.68 41.89 57.32 59.53 61.73 63.93 79.37 81.57 83.78 85.98 101.41 103.62 105.82 108.03
2.283 2.677 3.071 3.465 3.858
2.323 2.717 3.110 3.504 3.898
Kilogram to pound
0 10 20 30 40
0 0 22.05 44.09 66.14 88.18
1 2.20 24.25 46.30 68.34 90.39
2 4.41 26.46 48.50 70.55 92.59
3 6.61 28.66 50.71 72.75 94.80
4 8.82 30.86 51.91 74.96 97.00
5 11.02 33.07 55.12 77.16 99.21
50 60 70 80 90
110.23 132.28 154.32 176.37 198.42
112.44 134.48 156.53 178.57 200.62
114.64 136.69 158.73 180.78 202.83
116.85 138.89 160.94 182.98 205.03
119.05 141.10 163.14 185.19 207.24
121.25 143.30 165.35 187.39 209.44
0 10 20 30 40
0 1 2 0 0.264 0.528 2.642 2.906 3.170 5.283 5.548 5.812 7.925 8.189 8.454 10.567 10.831 11.095
3 0.793 3.434 6.076 8.718 11.359
4 1.057 3.698 6.340 8.982 11.624
1 l = 0.2642 U.S.Gal 5 6 7 8 9 1.321 1.585 1.849 2.113 2.378 3.963 4.227 4.491 4.755 5.019 6.604 6.869 7.133 7.397 7.661 9.246 9.510 9.774 10.039 10.303 11.888 12.152 12.416 12.680 12.944
50 60 70 80 90
13.209 15.850 18.492 21.134 23.775
14.001 16.643 19.285 21.926 24.568
14.265 16.907 19.549 22.190 24.832
14.529 17.171 19.813 22.455 25.096
123.46 145.51 167.55 189.60 211.64
125.66 147.71 169.76 191.80 213.85
127.87 149.91 171.96 194.01 216.05
130.07 152.12 174.17 196.21 218.26
Liters to U.S. Gallons
00(6)
38
13.473 16.115 18.756 21.398 24.040
13.737 16.379 19.020 21.662 24.304
14.795 17.435 20.077 22.719 25.361
15.058 17.700 20.341 22.983 25.625
15.322 17.964 20.605 23.247 25.889
15.586 18.228 20.870 23.511 26.153
Liters to U.K. Gallons 1 l = 0.21997 U.K.Gal 6 7 8 9 1.320 1.540 1.760 1.980 3.520 3.740 3.950 4.179 5.719 5.939 6.159 6.379 7.919 8.139 8.359 8.579 10.119 10.339 10.559 10.778
0 10 20 30 40
0 0 2.200 4.399 6.599 8.799
1 0.220 2.420 4.619 6.819 9.019
2 0.440 2.640 4.839 7.039 9.239
3 0.660 2.860 5.059 7.259 9.459
4 0.880 3.080 5.279 7.479 9.679
5 1.100 3.300 5.499 7.699 9.899
50 60 70 80 90
10.998 13.198 15.398 17.598 19.797
11.281 13.418 15.618 17.818 20.017
11.438 13.638 15.838 18.037 20.237
11.658 13.858 16.058 18.257 20.457
11.878 14.078 16.278 18.477 20.677
12.098 14.298 16.498 18.697 20.897
12.318 14.518 16.718 18.917 21.117
12.528 14.738 16.938 19.137 21.337
0 10 20 30 40
0 0 72.3 144.7 217.0 289.3
1 7.2 79.6 151.9 224.2 296.6
2 14.5 86.8 159.1 231.5 303.8
3 21.7 94.0 166.4 238.7 311.0
4 28.9 101.3 173.6 245.9 318.3
5 36.2 108.5 180.8 253.2 325.5
6 43.4 115.7 188.1 260.4 332.7
7 50.6 123.0 195.3 267.6 340.0
50 60 70 80 90
361.7 434.0 506.3 578.6 651.0
368.9 441.2 513.5 585.9 658.2
376.1 448.5 520.8 593.1 665.4
383.4 455.7 528.0 600.3 672.7
390.6 462.9 535.2 607.6 679.9
397.8 470.2 542.5 614.8 687.1
405.1 477.4 549.7 622.0 694.4
412.3 484.6 556.9 629.3 701.6
12.758 14.958 17.158 19.357 21.557
12.978 15.178 17.378 19.577 21.777
kgm to ft.lb 1 kgm = 7.233 ft.lb 8 9 57.9 65.1 130.2 137.4 202.5 209.8 274.9 282.1 347.2 354.4 419.5 491.8 564.2 636.5 708.8
426.8 499.1 571.4 643.7 716.1
100 110 120 130 140
723.3 730.5 737.8 745.0 752.2 759.5 766.7 773.9 781.2 788.4 795.6 802.9 810.1 817.3 824.6 831.8 839.0 846.3 853.5 860.7 868.0 875.2 882.4 889.7 896.9 904.1 911.4 918.6 925.8 933.1 940.3 947.5 954.8 962.0 969.2 976.5 983.7 990.9 998.2 1005.4 1012.6 1019.9 1027.1 1034.3 1041.5 1048.8 1056.0 1063.2 1070.5 1077.7
150 160 170 180 190
1084.9 1157.3 1129.6 1301.9 1374.3
1092.2 1164.5 1236.8 1309.2 1381.5
1099.4 1171.7 1244.1 1316.4 1388.7
1106.6 1179.0 1251.3 1323.6 1396.0
1113.9 1186.2 1258.5 1330.9 1403.2
1121.1 1193.4 1265.8 1338.1 1410.4
1128.3 1200.7 1273.0 1345.3 1417.7
1135.6 1207.9 1280.1 1352.6 1424.9
1142.8 1215.1 1287.5 1359.8 1432.1
1150.0 1222.4 1294.7 1367.0 1439.4
00-
39 (6)
kg/cm2 to lb/in2
0 10 20 30 40
0 0 142.2 284.5 426.7 568.9
1 14.2 156.5 298.7 440.9 583.2
2 28.4 170.7 312.9 455.1 597.4
3 42.7 184.9 327.1 469.4 611.6
4 56.9 199.1 341.4 483.6 625.8
5 71.1 213.4 355.6 497.8 640.1
6 85.3 227.6 369.8 512.0 654.3
1 kg/cm2 = 14.2233 lb/in2 7 8 9 99.6 113.8 128.0 241.8 256.0 270.2 384.0 398.3 412.5 526.3 540.5 554.7 668.5 682.7 696.9
50 60 70 80 90
711.2 853.4 995.6 1,138 1,280
725.4 867.6 1,010 1,152 1,294
739.6 881.8 1,024 1,166 1,309
753.8 896.1 1,038 1,181 1,323
768.1 910.3 1,053 1,195 1,337
782.3 924.5 1,067 1,209 1,351
796.5 938.7 1,081 1,223 1,365
810.7 953.0 1,095 1,237 1,380
825.0 967.2 1,109 1,252 1,394
839.2 981.4 1,124 1,266 1,408
100 110 120 130 140
1,422 1,565 1,707 1,849 1,991
1,437 1,579 1,721 1,863 2,005
1,451 1,593 1,735 1,877 2,020
1,465 1,607 1,749 1,892 2,034
1,479 1,621 1,764 1,906 2,048
1,493 1,636 1,778 1,920 2,062
1,508 1,650 1,792 1,934 2,077
1,522 1,664 1,806 1,949 2,091
1,536 1,678 1,821 1,963 2,105
1,550 1,693 1,835 1,977 2,119
150 160 170 180 190
2,134 2,276 2,418 2,560 2,702
2,148 2,290 2,432 2,574 2,717
2,162 2,304 2,446 2,589 2,731
2,176 2,318 2,460 2,603 2,745
2,190 2,333 2,475 2,617 2,759
2,205 2,347 2,489 2,631 2,773
2,219 2,361 2,503 2,646 2,788
2,233 2,375 2,518 2,660 2,802
2,247 2,389 2,532 2,674 2,816
2,262 2,404 2,546 2,688 2,830
200 210 220 230 240
2,845 2,987 3,129 3,271 3,414
2,859 3,001 3,143 3,286 3,428
2,873 3,015 3,158 3,300 3,442
2,887 3,030 3,172 3,314 3,456
2,901 3,044 3,186 3,328 3,470
2,916 3,058 3,200 3,343 3,485
2,930 3,072 3,214 3,357 3,499
2,944 3,086 3,229 3,371 3,513
2,958 3,101 3,243 3,385 3,527
2,973 3,115 3,257 3,399 3,542
00(6)
40
Temperature Fahrenheit-Centigrade conversion: A simple way to convert a Fahrenheit temperature reading into a Centigrade temperature reading or vice versa is to enter the accompanying table in the center (boldface column) of figures. These figures refer to the temperature in either Fahrenheit or Centigrade degrees. When convert from Fahrenheit to Centigrade degrees, consider the center column to be a table of Fahrenheit temperatures and read the corresponding Centigrade temperature in the column at the left. When convert from Centigrade to Fahrenheit degrees, consider the center column to be a table of Centigrade values, and read the corresponding Fahrenheit temperature on the right.
°C
°F
°C
°F
°C
°F
°C
1°C = 33.8°F °F
–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
177.8 179.6 181.4 183.2 185.0
–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-
41 (6)
01
GENERAL
Specification dimension drawings ............... Specifications.. ................................................ Weight table .................................................. Fuel, coolant and lubricants ........................
01-2 01-4 01-7 01-8
01-l 0
SPECIFICATION
GENERAL
SPECIFICATION
DIMENSION
DIMENSION
DRAWINGS
DRAWINGS Unit: mm
Serial No.: 11001 - 12050
-
-I
c
0
c c
0 -
SWG00332
01-2 0
GENERAL
SPECIFICATION
DIMENSION
DRAWINGS
Serial No.: 12051 and up
Unit: mm
c
0
c c
a P
01-3 0
GENERAL
SPECIFICATIONS
SPECIFICATIONS
Machine Serial
model
G D825A-2
No.
f
11001 - 12000
12001-
12050
12051 and up
kg
29,680
29,680
Load on front wheel
kN {kg1
78.9 {8,040)
78.9 (8,040)
78.9 (8,040)
Load on rear wheel
kN (kg1
212.2 121,640)
212.2 (21,640)
212.2 (21,640)
Overall
weight
29,680
Overall
length
mm
11,470
11,470
11,470
Overall
width
mm
3,310
3,310
3,310
Overall
height (to top of cab)
mm
3,550
3,550
3,550
Overall
height (to tip of muffler)
mm
2,605
2,605
2,605
mm
7,100
7,100
7,100
mm
1,840
1,840
1,840
(front)
mm
2,620
2,620
2,620
(rear)
mm
2,620
2,620
2,620
mm
440
440
440
1st
km/h
4.0
4.0
4.0
2nd
km/h
5.4
5.4
5.4
Wheelbase Distance
between
tandem Tread
Ground
clearance
Forward
Reverse t
Drawbar
pull
Gradeability Min. turning Static stability
01-4 0
centers of
wheels
radius
3rd
km/h
8.0
8.0
8.0
4th
km/h
11.5
11.5
11.5
5th
km/h
15.8
15.8
15.8
6th
km/h
21.4
21.4
21.4
7th
km/h
31.3
31.3
31.3
8th
km/h
44.9
44.9
44.9
1st
km/h
4.3
4.3
4.3
2nd
km/h
5.8
5.8
5.8
3rd
km/h
8.5
8.5
8.5
4th
km/h
12.2
12.2
12.2
5th
km/h
16.9
16.9
16.9
6th
km/h
22.8
22.8
22.8
7th
km/h
33.4
33.4
33.4
8th
km/h
47.9
47.9
47.9
tN {kg)
169.85 {17,320)
169.85 {17,320}
169.85 (17,320)
deg
24
24
24
m
7.9
7.9
7.9
deg
35
35
35
GENERAL
SPECIFICATIONS
Machine Serial
1
model No.
Model
G D825A-2
3
4-cycle, water-cooled,
Type
vertical,
in-line,
direct injection
type,
ith turbocharger No. of cylinders
- Bore x stroke
mm
6-140x165
6-140x165
6-140x
15.24 {I 5,240I
15.24 {I 5,240)
15.24 {I 5,240)
165
Piston displacement
.Q{cc1
Flywheel
:W/rprr
209/2,100
209/2,100
209/2,100
-iP/rpm
{280/2,100)
~280/2,1001
{280/2,100)
lm/rpn
1,255/l ,400
1,255/l ,400
1,255/l ,400
:gm/rprr
{128/1,4001
{I 28/l ,400)
{128/l ,400}
horsepower
Max. torque
Low idling
rpm
2,350
2,350
2,350
High idling
rpm
650
650
650
g/kWh
201
208
208
g/HPhl
{I501
11551
{I 551
Min. fuel consumption
Starting
ratio
24V, 11 kW
motor
24V, 50A
Alternator Battery
12V, 160Ahx2 Planetary
gear type, power disc clutch,
multiple actuated,
Transmission
force
lubrication
feed,
deduction
Spiral bevel
gear
Tandem U 3 _ z 5 2 q
5
ij t z
Fullv
leaning
angle
Y
deg
14.5
Type Steering Max.
I Fully hydraulic
angle
q
ii
Elliott
Hydraulic
Leaning Max.
tandem
transmission
Reverse
Type
and planetary
articulating
angle
gear
reduction
floating,
Chain
device
pump
8 speeds,
8 speeds
gear
2-stage 3ear axle
gear
forward
reverse
shift type,
hydraulically
14.5
type
tvoe type angle
type
I
14.5
type (Orbit-roll)
deg
50
50
50
deg
25
25
25
01-5 0
GENERAL
SPECIFICATIONS
Machine
model
Serial
No.
Size
Inflation
G D825A-2
pressure
11001 - 12000
12001-
(front)
18.00-25-12PR
23.5-25-l
2PR
23.5-25-l
2PR
(rear)
18.00-25-i
23.5-25-l
2PR
23.5-25-l
2PR
(front,
rear
2PR
12050
12051 and up
kPa
240
240
240
:kg/cm?
(2.45)
(2.45)
{2.45}
Rear 4-wheel Main brake
braking
Wet type, multiple
disc
Air actuated Transmission Parking
brake
Dry-type,
output
released Dimensions
(length
(arc height) Dimensions
x height
mm
of cutting
4,928
800
x
4,928
(695) x 25
x thickness) edge
mm
shaft braking
disc type, spring actuated, bv air x
800
4,877
(695) x 25
x
a60
(750) x 25
2,438 x 203 x 19 i 1,438 x 203 x 19 i !,438 x 254 x 25 - 2 pieces
- 2 pieces
- 2 pieces
mm
490
420
450
mm
680
680
950
(left)
mm
1,920
1,920
1,920
Max. side shift distance (right
mm
2,070
2,070
2,070
Turning
angle
deg
360
360
360
Digging
angle
(max.)
deg
a4
a4
115
(min.)
deg
25
25
63
Max. lifting height (from ground) Max. lowering
depth
(from ground) Max. side shift distance
Parallelogram
Type Shank
Standard
to install 7)
149 {15,2001
149 {15,200)
Ripping width
mm
2,978
2,978
2,978
Max. lifting height
mm
675
615
615
mm
480
deg
42.3
of ripper
149 {15,2001
/
kN {kg1
Weight
1
3 (possible
type
(from ground) Max.
lowering
depth
I
480
(from ground)
-
Ripping
01-6 0
angle
52
52
WEIGHT TABLE
GENERAL
WEIGHT TABLE a
Thus . weight
table
is for use when
handling
components
or when
transporting
the machine. Unit:
Machine
Engine
assembly
Radiator
Final drive Tandem Front
(dry)
assembly
(dry)
assembly
drive
axle
(except
assembly
(each)
assembly leaning
Front frame Rear frame
cylinder
and steering
assembly assembly
Operator’s
compartment
assembly
(incl. control) ROPS cab assembly (OPT, High ROPS cab assembly) Drawbar
assembly
Blade assembly Circle rotation
assembly
Wheel assembly Power tilt cylinder Leaning
cylinder
assembly assembly
Blade lift cylinder Drawbar
assembly
shift cylinder
Blade shift cylinder Steering Articulate
11001 - 12000
(dry)
assembly
Transmission
No.
(dry)
assembly
Fuel tank
GD825A-2
model
Serial
cylinder (dry)
Hydraulic
tank (dry)
Hydraulic
pump
Transmission
pump
Circle rotation Ripper assembly
assembly
motor
12001-12050
12051 and up
1,360
1,360
1,360
183
183
183
298
298
298
1,147
1,147
1,147
1,802
1,802
1,802
1,242
1,242
1,242
1,024
1,024
1,085
2,982
2,982
2,982
2,093
2,093
2,093
300
300
300
1,000
1,040
1,040
1,125
1,090
1,090
1,160
1,160
1,320
1,540
1,540
1,600
278
278
300
530
530
530
83
83
83
26
26
26
cylinder)
158x2
158 x 2
160 x2
72
72
74
106
106
105
15 x2
cylinder
Ripper cylinder
assembly
kg
15 x 2
15 x2
72
72
72
130
130
130
53
53
53
106
106
106
12
12
12
55
55
15
2,025
2,025
2,025
01-7 0
GENERAL
FUEL, COOLANT
FUEL, COOLANT
AND
LUBRICANTS
AND LUBRICANTS
Serial No.: 11001 - 12050
UND OF FLUID
RESERVOIR
AMBIENT -22 .30
-4 -20
14 -10
32 0
TEMPERATURE 50 10
68 20
CAPACITY 104 40
86 30
122°F 50°C
Specified
(J?)
Refill
34 (36)
Engine oil pan
+ Transmission
case
25 Engine oil
Final drive case
63
Tandem case (each)
57 95
Front axle housing Hydraulic
t
system
Circle rotation (Brake case)
gear case
Circle rotation (Gear case)
gear case
Fuel tank
Cooling
system
80 0.18
Gear oil
16
Diesel fuel
500
Coolant
Add antifreeze z ASTM
NOTE: (I) When fuel sulphur content is less than 0.5%, change oil in the oil pan every periodic maintenance hours described in this manual. Change oil according to the following table if fuel sulphur content is above 0.5%.
Fuel sulphur
content
Change interval of oil in engine oil pan
0.5 to 1.0%
l/2 of regular
interval
Above
l/4 of regular
interval
ASTM: SAE: API:
1.0%
j8 (78.5)
D975 No.1
-
1: Serial No. 12001 - 12050
(2) When starting the engine in an atmospheric temperature of lower than O‘C, be sure to use engine oil of SAEIOW, SAEIOW-30 and SAE15W-40, even though an atmospheric temperature goes up to 10°C more or less in the day time. (3) Use API classification CD as engine oil and if API classification CC, reduce the engine oil change interval to half.
American Society of Testing and Material Society of Automotive Engineers American Petroleum Institute
Specified capacity: Total amount of oil including oil for components Refill capacity: Amount of oil needed to refill system during normal
01-8 0
(
-
and oil in piping. inspection and maintenance.
GENERAL
Serial
FUEL, COOLANT
AND
No.: 12051 and up
RESERVOIR
AMBIENT -22
-4
14
TEMPERATURE
32
50
68
86
CAPACITY 104
122°F
Transmission
Refill
40
36
35
25
case Engine oil
Final drive case
63
Tandem case (each)
120
Front axle housing
0.9
Hydraulic
140
system
Circle rotation Brake case
Gear oil
system
Coolant
Add antifreeze
s ASTM
NOTE: (I) When fuel sulphur content is less than 0.5%, change oil in the oil pan every periodic maintenance hours described in this manual. Change oil according to the following table if fuel sulphur content is above 0.5%.
Fuel sulphur
content
c
Change interval of oil in engine oil pan
)
1
I
57 95
L +
10
Diesel fuel
Fuel tank
Cooling
+
gear cast
l
(k?)
Specifiec
Engine oil pan
ASTM: SAE: API:
LUBRICANTS
80 8
500
t 78.5
L
D975 No.1
(2) When starting the engine in an atmospheric temperature of lower than OX, be sure to use engine oil of SAEIOW, SAEIOW-30 and SAE15W-40, even though an atmospheric temperature goes up to 10°C more or less in the day time. (3) Use API classification CD as engine oil and if API classification CC, reduce the engine oil change interval to half.
American Society of Testing and Material Society of Automotive Engineers American Petroleum Institute
Specified capacity: Total amount of oil including oil for components Refill capacity: Amount of oil needed to refill system during normal
and oil in piping. inspection and maintenance.
10
STRUCTURE AND FUNCTION
General .......................................................... IO- 2 Power train diagram .................................... IO- 3 Joint ............................................................... IO- 4 HYDROSHIFT transmission and transfer piping ...................................................... IO- 5 Hydraulic circuit for power train ................ IO- 6 Hydraulic circuit diagram for power train ............................................. IO- 7 PTO (Power Take Off) .................................. IO- 8 HYDROSHIFT transmission and transfer .................................................... IO-I 0 Transmission control valve ......................... IO-16 Transmission control ................................... 1O-30 inching control ............................................. IO-32 Drive shaft .................................................... . 1o-33 Final drive, differential lock and unlock piping.. ........................................ IO-34 Final drive ..................................................... 1O-36 Tandem drive ............................................... 1o-39 Steering piping ............................................. IO-41 Steering circuit system ................................ IO-42 Steering circuit diagram.. ............................ 1o-43 Steering valve.. ............................................. IO-44 Double relief valve ....................................... 1O-48 Check valve.. ................................................. IO-49 Emergency steering system ........................ IO-50 Front axle ...................................................... IO-51 Wheel ............................................................ 1O-52 Disc brake ..................................................... IO-53 Parking brake.. .............................................. 1o-55 Brake air piping ............................................ 1 O-56 Brake air circuit system ............................... 1O-58 Brake air circuit diagram ............................. 1o-59 Air drier ......................................................... 1O-60 Air governor ................................................. 1 O-62 Air tank .......................................................... 1 O-64 Safety valve .................................................. 1O-64 Automatic drain valve ............................... IO- 65 Check valve.. ............................................... IO- 67 Brake valve ................................................. IO- 68
Parking brake system ................................ IO- 72 Parking brake solenoid valve.. .................. IO- 72 Exhaust valve ............................................. IO- 74 Spring cylinder ........................................... IO- 75 Hydraulic control piping ............................ IO- 76 Hydraulic circuit system ............................ IO- 80 Hydraulic circuit diagram ........................ 10-80-2 Closed center load sensing system (CLSS) .................................................. 10-81-I Hydraulic pump.. ........................................ IO- 82 Priority flow divider valve ......................... IO- 87 Surge pressure absorbing valve .............. IO- 93 Hydraulic control valve.. ............................ IO- 96 Pressure compensating mechanism of hydraulic control valve ................... IO- 98 Blade lift speed adjustment mechanism ........................................ 10-100-4 Pilot check valve ......................................... IO-102 Pilot check valve (with safety valve). ..... ..lO-10 4 Circle rotation motor ................................. IO-106 Blade accumulator system ........................ IO-109 Blade float system ..................................... IO-I 11 Drawbar and lifter ...................................... IO-I 12 Blade ......................................................... 1 O-l 13-3 Lifter bracket control piping.. .................... IO-I 14 Circle rotation gear .................................... IO-I 15 Rear mount ripper ...................................... IO-I 17 Hydraulic control linkage .......................... IO-I 18 Main frame ................................................. IO-120 Air conditioner ......................................... 10-120-1 Electrical wiring diagram .......................... IO-121 Monitor panel, cluster gauge and pilot lamp ............................................. IO-125 Electrical circuit diagram ........................... IO-128 Electronic vehicle monitoring system (EVMS) .................................................. IO-147 Transmission control system .................... IO-153 Sensors ....................................................... IO-156 Engine starting circuit ................................ IO-162 Engine stopping circuit .............................. IO-168
10-l 0
GENERAL
4
5
El F23507003
The power produced by diesel engine (I) goes to HYDROSHIFT transmission (3) through joint (2). Transmission (31, with a planetary gear mechanism and a hydraulic control unit combined, allows an easy selection of eight forward speeds and eight reverse speeds. Through drive shaft (41, the power is transmitted from the transmission to the final drive (5). Here, final drive (5) directs the power to the right and left, and the power is transmitted to the left and right tandem drives (6). Tandem drive (6) transmits the power to the wheel by a chain and the machine travels.
1o-2
1. 2. 3. 4. 5. 6.
Engine Joint HYDROSHIFT transmission Drive shaft Final drive Tandem drive
POWER
TRAIN
DIAGRAM
F23501004
1. Engine 2. Joint 3. PTO (Power
Take Off)
4. HYDROSHIFT
transmission
5. Transfer 6. Parking
brake
7. Drive shaft 8. Final drive 9. Tandem
drive
10. Tire P,
Hydraulic
P,
Transmission
pump
P,
Differential
pump lock pump
1o-3 0
JOINT
Engine
f
-.. T ---2
c
13
F23501007
1o-4
1.
Engine flywheel
2.
Plate
3.
Tube
4.
PTO input
shaft
_-_--_$ - - _.-
f
c----q - __i--i_~.-=& /l-
r-n YI
I
2
r-.
- - *_-,-y_
1. Transfer 2.
HYDROSHIFT
3.
Transmission
control
4.
Transmission
filter pump
5.
Transmission
6.
Engine
7.
Radiator
8.
Oil cooler
.
The
oil
mission .
valve
in transmission pump
The oil from mission
235CD02001
transmission
filter
(5) through transmission
by
trans-
the strainer. pump
(5) flows
(4), and transmission
(3). Then the oil flows be cooled
(2) is sucked
to oil cooler
to trans-
control
(8) in radiator
and to the transmission
to lubricate
valve (7) to it.
1o-5
HYDRAULIC
CIRCUIT FOR POWER TRAIN
Engine running, gear shift lever in NEUTRAL Serial No.: 11001 - 12012, 12016 - 12018 R
F
4th
3rd
2nd
1st
L
H
235FO2001
1O-6 0
STRUCTURE
AND
HYDRAULIC Serial
FUNCTION
HYDRAULIC
CIRCUIT DIAGRAM
No.: 11001 - 12012,
CIRCUIT
DIAGRAM
FOR POWER TRAIN
FOR POWER TRAIN
12016 - 12018
0. 29-3 04HPa 13-3lks/cm'l t----t------6
4th
1. OGMPa
(10. Bka/cm'i II I !________ i
3rd
)I( LL
0 29HPa _
1. 2. 3. 4. 5. 6. 7. 8.
Transmission case Strainer Transmission pump Transmission filter Priority valve Modulating valve Quick return valve Pilot oil filter
,;!
9. Pilot reducing 10. Transmission
11. 12. 13. 14. 15. 16.
valve lubrication
Oil cooler Transmission lubrication Oil cooler bypass valve Inching valve F-R clutch spool 4th clutch spool
relief valve
17. 18. 19. 20. 21. 22. 23.
3rd clutch spool 2nd clutch spool 1st clutch spool High clutch spool Low clutch spool Emergency spool Solenoid valve
1o-7 0
STRUCTURE
AND
HYDRAULIC
FUNCTION
HYDRAULIC
CIRCUIT
FOR POWER TRAIN
CIRCUIT FOR POWER TRAIN
Engine running, gear shift lever in NEUTRAL Serial No.: 12013 - 12015, 12019 and up
SWG00336
1o-7- 1 0
STRUCTURE
AND
HYDRAULIC Serial
HYDRAULIC
FUNCTION
CIRCUIT DIAGRAM
No.: 12013 - 12015,
CIRCUIT
DIAGRAM
FOR POWER TRAIN
FOR POWER TRAIN
12019 and up
0.29-3.04HPa 13-3lka/cm'l
1 47HPa il5ks/cm'l
& 5
L--J
t--j
I.OGMPa (IO Bkefcm'l -___p~-~-~-----------__ 9
I--_-dI II )I( LL
0 49MPa 15ks/cm'l
SWG00335
1. Transmission 2. 3. 4. 5. 6. 7. 8.
case Strainer Transmission pump Transmission filter Priority valve Modulating valve Quick return valve Pilot oil filter
9. Pilot reducing valve 10. Transmission lubrication 11. Oil cooler 12. Transmission lubrication 13. Oil cooler bypass valve 14. Inching valve 15. F-R clutch spool 16. 4th clutch spool
relief valve
17. 18. 19. 20. 21. 22. 23.
3rd clutch spool 2nd clutch spool 1st clutch spool High clutch spool Low clutch spool Emergency spool Solenoid valve
10-7-2 0
PTO (Power
Take Off)
2 B-B
235FO2003
1,
A-A
1 O-8
F2350
1008-2
1.
Input shaft
2.
Idler gear
3.
Pump drive
4.
Transmission
gear pump
5.
Transmission
control
valve
STRUCTURE
AND
FUNCTION
HYDROSHIFT
HYDROSHIFT
TRANSMISSION
TRANSMISSION
AND TRANSFER
AND TRANSFER
Serial No.: 11001 - 12012,12016 - 112018
B-B A-A
c-c 235FO2004
2 l
The oil in the transmission mission
pump
through
is sucked
strainer
The oil from
the transmission
transmission
filter,
(2).
10-10 0
by the trans-
(3). pump
and transmission
1.
Breather
2.
Transmission
flows
to the
3.
Strainer
control
valve
4.
Drain plug
control
valve
HYDROSHIFT TRANSMISSION AND TRANSFER
023502
STRUCTURE AND FUNCTION
10-12 (6)
HYDROSHIFT TRANSMISSION AND TRANSFER
023502
STRUCTURE AND FUNCTION
10-14 (6)
TRANSMISSION
CONTROL VALVE
Serial No.:11001 - 12012,12016-12018
235coo2039
1.
Connector
A.
Inching
2.
Lower
valve
B.
Main pressure
3.
Upper
valve
C.
Priority
D.
Oil cooler
E.
Lubricating
10-16 0
pressure
pick-up pick-up
pressure bypass
pick-up pressure
pressure
pick-up
pick-up
UPPER VALVE
-iid
r-71
1.
Housing
2.
Inching
3. . huick
valve return
4.
Modulating
5.
Priority
6.
Oil cooler
valve valve
valve bypass
valve
235CDO2040
\ 4
1 Y-Y
OUTLINE l
The oil from
the transmission
pump
enters
and
through
valve
(5). It is then
passes
divided
into
two
and the other valve
valve
The
oil flowing
trols
the pilot
tional
lines:
to pilot
one to the clutch reducing
(5) acts to control
reducing l
priority
reducing
valve
the two
(12) is the priority to pilot pressure
and speed
each spool
valve
spools.
port A, pistons,
(12). Priority
lines so that
pilot
valve
(12) con-
used to actuate
the direc-
The oil regulated through
The
by pilot
the orifice
other
return
ing valve
(4) and quick
clutch
pressure
when
actuating 3rd,
change .
oil line flows
and quick
2nd,
circuit.
reducing
(12) presses
l
4th,
valve
to
modulating
(3). The action return
smoothly.
valve
valve
(3) raises the
This reduces
the shock
the FORWARD,
REVERSE
High
speed
and
Low
(4)
of modulat-
and Ist,
clutches
to
gear.
Lubrication
valve
(14) controls
the
lubrication
oil
inside the transmission.
in
and fills the spool.
10-17
LOWER VALVE
235CD02041
7. High clutch
spool
8. 2nd spool 9. Low clutch
spool
10. 4th spool 11. 1st spool 12. Pilot reducing
valve
13. F-R spool 14. Lubrication 15. 3rd wool
lo-18
valve
SOLENOID
VALVE
\
6
I I
7
8
9
1‘1
Section X-X
\
10
F23501302
1. Valve
STRUCTURE l
The
transmission
the transmission control
valve.
together
When
ed, the solenoid spool
solenoid
valve with
is actuated
inside the transmission
to
the transmission
the gear shift
valve
is installed
valve.
body
2. 2nd solenoid
valve
3. 4th solenoid
valve
lever is operat-
4. 1 st solenoid
valve
and moves
5. L solenoid
valve
6. H solenoid
valve
the
7. 3rd solenoid
valve
8. F solenoid
valve
9. R solenoid
valve
10. Emergency
manual
spool
1 1. Connector
10-19
PRIORITY VALVE
Function . Priority
valve
ure required oil to pilot any other
(1) ensures
the minimum
for pilot reducing reducing
valve
valve
oil press-
(2) and sends
(2) with
priority
over
circuit.
Operation l
When
the oil pressure
cm2), the
oil from
is below
pump
flows
priority
valve
and also into port
ducing
valve.
Since
lower,
the priority
the flow
to ports
sult, the oil from pilot reducing
1.47 MPa (15 kg/ to port
valve
moves
on port
valve
reA is
to the left, causing
A and C to be shut the pump
A on the
B on the pilot
the oil pressure
To each transmission spool
To modulating valve
off. As a re-
is delivered
only to the
circuit.
423FO33
l
When
the oil pressure
kg/cm2), pet
the hydraulic
spring
priority
valve
(3) push
is more
than
pressure back
spring
(1) to the right.
port C to the clutch
spool.
(4) and
When
port A and port C are connected, from
1.47 MPa (15
and force
To modulating valve
To each transmission spool
of popmove
this happens,
and the oil flows
-
Pi lot oil filter
423FO34
1O-20
PILOT REDUCING VALVE
Function l
The pilot
reducing
ure needed
valve
to actuate
acts to control
the press-
the transmission
spools.
Operation l
The oil from
the pump
ter and enters
port
The oil passes through the orifice
passes through
A of pilot port
of transmission
the pilot fil-
reducing
valve
B and enters spool
(1).
through
(2) to fill the in-
side of port C.
’
valve
423 FO30
l
When
the
urized
oil flows
valve
urized
from
inside
port
orifice
“a”
C rises, of pilot
press-
reducing
(1) and goes to port D.
As a result, right,
pressure
pilot
reducing
valve
(I) moves
to the
and ports A and B are shut off, so the pressoil
at port
C is maintained
at the
same
pressure.
423FO29
10-21
Function
of pilot circuit
This pilot valve pressure: drain
possible
port
at
drain
pressure
generated
pressure
as the primary
high as the primary valve
secondary
the specified
at the Neutral
pressure
valve
secondary
If the reducing
a at the
to obtain
For example, ondary
as a reducing
1.47 MPa (15 kg/cm*);
1.06 MPa (10.8 kg/cm2). have
drain
functions
reducing
position, port
pressure.
valve
does not
side,
it is im-
pressure.
if there
is no sec-
a, theoretically
at the secondary side because
primary pressure:
the
side is the same
(Actually, of leakage
it is not as from
the
spool.)
F23501306
1o-22
MODULATING
VALVE
AND
QUICK
RETURN
VALVE
Function l
The modulating together
to raise the transmission
smoothly.
In this
when shifting eration same
way.
operator time,
they
reduce
the
in the power
fatigue
operator
is reduced,
comfort
C Shifting
clutch pressure
speed range, and prevent
of peak torque
result,
(kg/cm”)
valve and quick return valve act
gear
I
shock
the gen-
train. As a and
at the
and the durability
of the power train are increased.
(Set)
Time
11
Immediately
after
shifting
423FO35
gear (Point A on Fig. 423FO35)
erection and speed spool
To pilot reducing
F23501303
Operation l
The
oil sent from
valve
(I)
modulating return “a”
the pump
through valve
valve
of quick
flows A,
return
in pressure
between
port B and port
C. The quick return valve moves to the right and the oil flows to clutch (5). In addition,
orifice
return valve
(3) and flows
to the
is opened,
has been actuated.
it passes through
difference
priority through
through
oil passes valve
from
passes
port B of quick
(21, and enters
(3). The
clutch pistion, which er when
port
orifice
when quick
to the right, drain port D
and the pressurized
oil at the rear of
piston (4) flows to the drain circuit.
Howev-
“a” it creates
(3) moves
a
1 O-23
2)
Clutch
pressure
rising
(Point
B on Fig. 423FO35)
Direction
and Speed SpOOl
I
pilot
reducing
Ive
To oil cooler F23501304
Operation l
As the pressure
pressure
at the clutch
piston
at port C also rises. Quick
(3) is pushed
rises, the
return valve
back to the left and drain port D is
closed. The oil from the pump flows from to the flows
clutch
piston,
and
at the
from orifice “b” through
same
port C time
it
quick return valve
(3) and enters port E. The oil at port E acts on the modulating
piston
(4). It pushes
piston
(4) to the rig ht.
1 O-24
back spring
(61 and moves
At
the
same
time,
the
orifice
through
modulating
valve
(2).
pressurized and
enters
oil also passes poppet
It moves modulating
(7)
of
valve
(2) to the left and some of the oil at port A flows to port G.
3)
Completion
of rise in clutch
pressure
(Point C on Fig. 423FO35)
Direction and speed spool
i
pilot reducing Ive
To
oil cooler
’
To inching valve 235FO2005
Operation l
The oil entering (4). When
port
the piston
the rise in pressure pressure
reaches
to push
stops. When
this happens,
the set pressure
In addition,
(4), so the oil at port A passes
through connected
the
of the modulat-
ing valve.
The oil at port
piston
the end of its stroke,
by piston
port G and flows l
E continues reaches
port F and port G are closed through
to the oil cooler.
E is connected
the throttle
to the inching
(the modulating
with the inching
valve
valve
is inter-
valve).
1 o-25
OIL
COOLER
BYPASS
VALVE
FUNCTION l
The
oil cooler
pressure stant
bypass
valve
of the oil entering
pressure.
the specified
It drains
acts to maintain the oil cooler
the
the
To each transmission
spool
at a con-
oil if it goes
above
pressure.
OPERATION l
The
oil from
valve
(I)
the
and
then enters
pump
passes
actuates
through
modulating
port A and flows
priority
valve
(2). It
to the oil cooler.
-2
-1
To transmission lubrication
From pump F7.3501307
l
If the
oil
at
pressure,
it
port passes
cooler
bypass
moves
oil cooler
result,
the oil from
flowing specified
to
the
valve
A goes
port
the
orifice
(3) and enters
bypass oil
above
through valve
port
of
spool
oil
B. It then
(3) to the left. As a
A is drained,
cooler
To each transmission
specified “a”
and the oil
is maintained
at the
pressure.
To transmission lubrication
From pump F23501308
1 O-26
TRANSMISSION
Function . There
SOLENOID
is one
directional
solenoid
and speed
VALVE
valve spool
installed
for
each
in the transmission
valve. When
the gear shift lever in the operator’s
partment
is
actuated,
operated,
the
and oil is drained
solenoid to actuate
com-
valve
is
the direc-
tional and speed spools.
Operation 1)
Solenoid
valve OFF
The oil of spool (1) enters port A. However, (2)
shuts
spool (I
off
the
oil, so directional
and
valve speed
) does not move.
423FO31
8
4 8 2)
Solenoid When
valve ON
the gear shift lever is operated,
the sole-
noid valve is pulled up. The enters
oil from
directional
port A and flows
circuit. Therefore, sure circuit, is moved
and from
speed
port A becomes
and directional
spool
(I)
port B to the drain the low pres-
and speed
to the right. As a result,
spool
(1)
the oil from
quick return valve flows to the piston. Fr reducing
valve 423 F032
1 O-27
Function l
If there is any failure in the electrical transmission valve
control
does
not
system,
work,
used. This spool
the
circuit of the
and the
is attached
valve
the machine *
mechanically. attention
is
the trans-
(It is used to drive
to a place where
Particular
spool
to each directional
and speed spool and is used to operate mission
solenoid
emergency
it can be repaired.)
must
be paid for when
using this spool. Operation 1.
When
solenoid
(Emergency When
valve
the solenoid
position)
valve is working
spool is maintained Oil from
is normal:
spool is at normal
normally,
the
in this position.
directional
and speed
spool
(I)
enters
port A, but it is shut off by solenoid valve (2).
From. ~ reducing valve
2.
When
a.
solenoid
Clutch
valve
is abnormal:
in disengaged
(Emergency
manual
left (at normal Emergency
position spool is pushed
(3) is pushed
to the left,
and the oil at port A is shut off regardless
of
the
oil
action
cannot
of
flow
From quick return valve
to the
position))
spool
423 F044
solenoid
valve
(2).
The
to port B, so the clutch
is not
actuated.
reducing valve 423 F045
b.
Clutch
in engaged
(Emergency
spool
actual
position))
When
emergency
right,
position is pulled spool
to the right
From quick return valve
(3) is pulled to the
the oil at port A is drained
regardless
(at
of the operation
to port B
of solenoid
valve
(2). As a result, the clutch is actuated.
From reducing valve
1 O-28
423 F046
INCHING
l
VALVE (INCHING
An inching reduce
valve
with
the shock
VALVE WITH MODULATING
modulation
when
is employed
the inching
pedal
VALVE)
to
is oper-
From
ated. OPERATION 1.
When The
inching
valve
oil from
the
is not depressed; pump
and B, goes through
passes
through
the F-R spool
ports
A
and is sent to
the F-R clutch. The
return
valve
spring
spool
of the
(2) and collar
to the right.
The oil passing
ters chamber prevents
valve
shut
orifice
To quick return
(1) Modulating valve
D en-
to push valve
the tension
of the return
moving.
E of the
off by spool
pushes
force
(1) from
The oil in chamber
pedal
push valve
through
C, and produces
(I) to the left. However, spring
inching (3). These
modulating
(2), so it does
valve
not flow
is
From pump
To oil cooler bypass valve
to drain
port F. 2.
When
inching
When
the
valve
spool
valve
it
words, clutch
of
the
between
modulating
to port
tension
drain
valve
and the
is reduced, F and
(7) is opened
is drained. hole
B is throttled In addition,
port
E passes Modulating
G, and the
of
in chamIn other
engaged.
the oil in chamber drain
the
pressure.
F-R clutch
is partially
4 F
so
When
inching
Valve
spool
valve
is fully
(2) moves
E of (2), so
u
Modulating valve
the throttle (7) moves
pressure
is kept
to re-
To oil cooler bypass valve
completely
to the
(5) is further
result,
hydraulic
pressure
the
the clutch
49 kPa (0:4 -
is completely
so
As a
2
F
‘zin
5 From pump
F-R clutch
0.5 kg/cm2),
and
disengaged.
The oil at port
E of modulating
nected
circuit
to drain
left,
reduced.
of the
From pump 235FO2007
depressed;
of spring
to 39 kPa -
1
pas-
chamber
through
the tension drops
1 n_:_ 4
Inch
duced. 3.
5A,
the
the
by spool
valve
main
6
(I) to the left to a
with
the F-R clutch
the passage
pressure
and
valve
balances
From pump
Drain
depressed,
(5) and (6), and the oil pressure
ber C becomes
sage
depressed;
is slightly
to the left, so the oil press-
C pushes
where
springs
pedal
(2) moves
ure in chamber position
is slightly
inching
valve
F, so the main
(7) is conpressure
is
kept reduced. 4.
Inching
valve
If spool port
(closed
(2) closes
E continues
-r open)
drain
the end of its stroke,
rises and returns
When
this happens, is engaged
F, the oil entering
modulating
and the pressure
circuit
F-R clutch
circuit
to push
valve
(7) to
Modulating valve
in the main
to the set pressure.
modulation smoothly.
is applied,
so the
To oil cooler bypass valve
From pump 235FO2008
1 O-29
TRANSMISSION
STRUCTURE AND FUNCTION
Serial No.: 12013 - 12015,
CONTROL VALVE
12019 and up
SWG00338
1. 2. 3. 4. 5. 6. 7. 8. 9. 10.
2nd connector 4th connector 1st connector L connector H connector 3rd connector F connector R connector Lower valve Upper valve
10-29-l 0
A. B. C. D. E.
Inching pressure pick-up Main pressure pick-up Priority pressure pick-up Lubricating pressure pick-up Oil cooler bypass pressure pick-up
STRUCTURE
AND
FUNCTION
TRANSMISSION
CONTROL
VALVE
LOWER VALVE
z-z 7. 8. 9. 10. 11. 12. 13. 14. 15.
High clutch spool 2nd spool Low clutch spool 4th spool 1st spool Pilot reducing valve F-R spool Lubrication valve 3rd spool
1O-29-3
SWG00339
STRUCTURE AND FUNCTION
SOLENOID
II
TRANSMISSION
CONTROL VALVE
VALVE
12
13
I4
15
Ifi
17
18
A-A
STRUCTURE . The transmission
solenoid valve is installed to the transmission together with the transmission control valve. When the gear shift lever is operated, the solenoid valve is actuated and moves the spool inside transmission valve.
1. 2. 3. 4. 5. 6. 7. 8. 9. 10. II. 12. 13. 14. 15. 16. 17. 18.
Valve body 2nd solenoid valve 4th solenoid valve 1st solenoid valve L solenoid valve H solenoid valve 3rd solenoid valve F solenoid valve R solenoid valve Emergency manual 2nd connector 4th connector 1st connector L connector H connector 3rd connector F connector R connector
SWG00340
spool
10-29-4 0
STRUCTURE AND
TRANSMISSION
FUNCTION
CONTROL
VALVE
PRIORITY VALVE
Function . Priority
valve
ure required oil to pilot any other
(1) ensures
the minimum
for pilot reducing reducing
valve
valve
oil press-
(2) and sends
(2) with
priority
over
circuit.
Operation l
When
the oil pressure
cm’),
the
oil from
is below
pump
flows
priority
valve
and also into port
ducing
valve.
Since
lower,
the priority
the flow
to ports
sult, the oil from pilot reducing
1.47 MPa (15 kg/ to port
valve
moves
To each transmission spool
A on the
B on the pilot
the oil pressure
To modulating valve
on port
reA is
to the left, causing
A and C to be shut off. As a rethe pump
valve
is delivered
only to the
circuit.
oil filter
423FO33
.
When
the oil pressure
kg/cm’), pet
the hydraulic
spring
priority
valve
(3) push
is more
than
pressure back
spring
(1) to the right.
port C to the clutch
(4) and
When
port A and port C are connected, from
1.47 MPa (15
and force
To modulating valve
To each transmission spool
of popmove
this happens,
and the oil flows
spool.
Pilot
oil filter
423FO34
1 O-29-5 0
STRUCTURE AND FUNCTION
PILOT REDUCING
TRANSMISSION
CONTROL VALVE
VALVE
Function . The pilot reducing pressure spools.
valve acts to control the needed to actuate the transmission
Operation . The oil from the pump
passes through the pilot filter and enters port A of pilot reducing valve (I). The oil passes through port B and enters through the orifice of transmission spool (2) to fill the inside of port C.
*
To Priority
valve
SWG00421
.
When the pressure inside port C rises, pressurized oil flows from orifice “a” of pilot reducing valve (I) and goes to port D. As a result, pilot reducing valve (I) moves to the right, and ports A and B are shut off, so the pressurized oil at port C is maintained at the same pressure. The pressure at this point is 1.06 MPa (IO.8 kg/cm2).
To Priority
valve
SWG00422
10-29-6 0
STRUCTURE
AND
FUNCTION
Function of pilot circuit drain This pilot valve functions as a reducing valve primary pressure: 1.47 MPa {I5 kg/cm*}; secondary pressure: 1.06 MPa I10.8 kg/cm*}. If the reducing valve does not have drain port a at the secondary side, it is impossible to obtain the specified reducing pressure. For example, at the Neutral position, if there is no secondary pressure at drain port a, theoretically the pressure generated at the secondary side is the same pressure as the primary pressure. (Actually, it is not as high as the primary side because of leakage from the valve spool.)
1 O-29-7 0
TRANSMISSION
CONTROL
VALVE
STRUCTURE
AND
MODULATING
VALVE
Function . The modulating together
result, same
AND
valve
In this
shifting
eration
TRANSMISSION
QUICK
and quick
speed
of peak operator time,
way,
range,
torque
valve
clutch reduce
the
power
is reduced,
comfort
and
act
and
As a at the
durability
F 5 Z k
.= 0
train are increased.
Shlftlng
40 -
the gen-
the
VALVE
(kg/cm*)
shock
train.
CONTROL
VALVE
pressure
and prevent
in the
fatigue
operator
of the power
they
RETURN
return
to raise the transmission
smoothly. when
FUNCTION
gear
30 -
20-
Trne
1)
Immediately
after
shifting
(Set) 423FO35
gear (Point A on Fig. 423FO35)
F23501303
Operation l
The
oil sent
from
valve
(1)
through
modulating return “a”
valve
valve of quick
clutch er when
pistion,
the
flows A,
(21, and enters
(3). The return which
it passes
pump port
oil passes valve
from
passes port
flows
has been actuated.
through
orifice
“a”
difference the oil flows
orifice
return
to the
is opened,
Howev-
it creates
in pressure
C. The quick
B of quick
through
(3) and
priority through
piston
valve
return to clutch
(3) moves and the
(4) flows
between
valve
port
moves
(5). In addition, to the right,
pressurized
B and
to the right when drain
port and quick
port
D
oil at the rear of
to the drain circuit.
a
10-29-8 0
STRUCTURE
2)
AND
FUNCTION
TRANSMISSION
CONTROL
VALVE
Clutch pressure rising (Point Bon Fig. 423FO35)
Dir&m
and speed spool
i
pilot reducing lve
F23501304
Operation l As the pressure pressure
at the
at port
(3) is pushed
back
closed.
The oil from
to
clutch
the
flows
from
The
oil at port
(4). It pushes (4) to the right.
1 O-29-9 0
piston
rises,
return
to the left and drain the pump
piston,
orifice
(3) and enters
clutch
C also rises. Quick
“b”
and
flows
at the
through
quick
port
from same return
the valve
D is
port C time
E acts on the modulating back
spring
(61 and moves
it
valve
port E. piston piston
At
the
same
time,
the
orifice
through modulating
valve
pressurized and
(2). It moves
(2) to the left and some to port G.
enters
oil also poppet modulating
passes (7)
of
valve
of the oil at port A flows
STRUCTURE
3) Completion
AND
FUNCTION
of rise in clutch pressure
TRANSMISSION
CONTROL
VALVE
(Point C on Fig. 423FO35)
irection
and speed
spool
It reducing
To inching
valve 235FO2005
Operation The oil entering port E continues to push piston (4). When the piston reaches the end of its stroke, the rise in pressure stops. When this happens, the pressure reaches 3.04 MPa I31 kg/cm’) as a set pressure of the modulating valve. In addition, port F and port G are closed by piston (4), so the oil at port A passes through port G and flows to the oil cooler. The oil at port E is connected to the inching valve through the throttle (the modulating valve is interconnected with the inching valve).
10-29-10 0
STRUCTURE
OIL
AND
FUNCTION
BYPASS
COOLER
TRANSMISSION
CONTROL
VALVE
VALVE
FUNCTION l
The oil cooler pressure stant
bypass
valve
of the oil entering
pressure.
the specified
It drains
acts to maintain the oil cooler
the
To each transmission
the
L
at a con-
oil if it goes
spool
above
pressure.
OPERATION l
The valve
oil from
the
(1) and
then enters
pump
passes
actuates
through
modulating
port A and flows
priority
valve
(2). It
to the oil cooler.
To transmission lubrication
From pump
2 F23501307
l
If the
oil
at
pressure,
it
port passes
cooler
bypass
moves
oil cooler
result,
the oil from
flowing specified
to
the
valve
A goes above through
(3) and enters
bypass oil
pressure
port
the
orifice
valve
port
of
spool
oil
B. It then
(3) to the left. As a
A is drained,
cooler
To each transmission
specified “a”
and the oil
is maintained
at the
of 0.49 MPa I5 kg/cm21.
To transmission lubrication
From pump F23501308
10-29-11 0
% z
TRANSMISSION
SOLENOID
VALVE
Function l
From quick return valve
There is one solenoid valve installed for each directional and speed spool in the transmission valve. When the gear shift lever in the operator’s compartment is operated, the solenoid valve is actuated, and oil is drained to actuate the directional and speed spools.
Operation I) Solenoid valve OFF The oil of spool (I) enters port A. However, valve (2) shuts off the oil, so directional and speed spool (I) does not move.
2)
Solenoid valve ON When the gear shift lever is operated, the solenoid valve is pulled up. The oil from directional and speed spool (I) enters port A and flows from port B to the drain circuit. Therefore, port A becomes the low pressure circuit, and directional and speed spool (I) is moved to the right. As a result, the oil from quick return valve flows to the piston.
From pilot reducing valve
SWG00423
From quick return valve -8
2?
From oilot reducing valve
10-29-12 0
EMERGENCY
SPOOL
Function . If there is any failure in the electrical circuit of the transmission control system, and the solenoid valve does not work, the emergency spool is used. This spool is attached to each directional and speed spool and is used to operate the transmission valve mechanically. (It is used to drive the machine to a place where it can be repaired.) * Particular attention must be paid for when using this spool.
Operation 1. When solenoid valve is normal: (Emergency spool is at normal position) When the solenoid valve is working normally, the spool is maintained in this position. Oil from directional and speed spool (1) enters port A, but it is shut off by solenoid valve (2).
From quick return valve
5/t, Kh
: :
A
3
% From Pilot reducing valve
2.
When solenoid valve is abnormal: a. Clutch in disengaged position (Emergency manual spool is pushed to the left (at normal position)) Emergency spool (3) is pushed to the left, and the oil at port A is shut off regardless of the action of solenoid valve (2). The oil cannot flow to port B, so the clutch is not actuated.
From quick return valve
, :,,, KL
: :
From Pilot reducing valve
Clutch in engaged position (Emergency spool is pulled to the right (at actual position)) When emergency spool (3) is pulled to the right, the oil at port A is drained to port B regardless of the operation of solenoid valve (2). As a result, the clutch is actuated.
b\
B
SWG00426
From quick return valve
From oilot reducina valve
10-29-13 0
: A
3
%
b.
SWG00425
SWG00427
INCHING
l
VALVE (INCHING
An inching reduce
valve
with
the shock
VALVE WITH MODULATING
modulation
when
is employed
the inching
pedal
VALVE)
to
is oper-
From
Drain
ated. OPERATION 1.
When
inching
The
valve
oil from
the
is not depressed; pump
and B, goes through
passes
through
the F-R spool
ports
A
and is sent to
the F-R clutch. The
return
valve
spring
spool
of the
(2) and collar
to the right.
The oil passing
ters chamber prevents
valve
The
oil in chamber
shut
off by spool
pedal
pushes
push valve
through
C, and produces
(1) to the left. However, spring
inching (3). These
orifice
(1)
D en-
force
to push valve
the tension
of the return
(I) from
Modulating valve
moving.
E of the
modulating
(2), so it does
valve
not flow
is
From pump
To oil cooler bypass valve
to drain
port F. 2.
When
235FO2006
inching
When
the
valve
spool
valve
the
clutch
of
the
between
modulating
to port
the
tension
drain
In other and the
is reduced, In addition,
port
F and
(7) is opened
the oil in chamber is drained. hole
pressure.
engaged.
valve
E passes Modulating
G, and
the
of
in cham-
B is throttled
F-R clutch
is partially
drain
(1) to the left to a
with
F-R clutch
the passage
pressure
and
valve
it balances
ber C becomes
the pas-
chamber by spool
through valve
main
so the
E of (2), so
the throttle (7) moves
pressure
is kept
to re-
c
duced. 3.
When
inching
Valve
spool
valve
is fully
(2) moves
’
From pump
To oil cooler bypass valve
235FO200:
depressed;
completely
to the
the tension
of spring
(5) is further
result,
hydraulic
pressure
the
From pump
Drain
depressed,
(5) and (6), and the oil pressure
words,
sage
depressed;
is slightly
to the left, so the oil press-
C pushes
where
springs
pedal
(2) moves
ure in chamber position
is slightly
inching
reduced.
of the
left,
so
As a
2
F
D:i”
5 From pump
F-R clutch
drops to 39 - 49 kPa (0.4 - 0.5 kg/cm2}, and the clutch is completely The
disengaged.
oil at port
nected
to drain
E of modulating circuit
valve
F, so the main
(7) is conpressure
is
kept reduced. 4.
Inching
valve
If spool port
(closed
(2) closes
E continues
-+ open)
drain to push
the end of its stroke, circuit
rises and returns this happens, is engaged
F, the oil entering
modulating
and the pressure
When
F-R clutch
circuit
valve
(7) to
Modulating valve
in the main
to the set pressure.
modulation smoothly.
is applied,
so the
To oil cooler bypass valve
From pump 235FO2008
10-29-14 0
STRUCTURE
AND
FUNCTION
TRANSMISSION Serial
TRANSMISSION
CONTROL
No.: 11001 - 11030
lIn
rd
II I..l
235COO2002
1.
Bolt
7. Rotary
3. Reverse
8. Connector
4. Forward 5. Button
1O-30 0
6. Gear shift lever
2. Shift lock lever switch switch switch
switch
9. Interlock 10. Interlock
lever
CONTROL
STRUCTURE
AND
TRANSMISSION
FUNCTION
CONTROL
6
l-l
A-A
6-B
lJ 235CD02003
Outline l
l
The
control
system
of this
machine
electrical
type.
So, the operation
operating
force
and stroke
When
operating
switching
gear
range
is used
rotary
is sent
to each
transmission
control
shift switch
lever
(6),
(7), and the valve
.
Press button when
moving
switch
the
F-R
current
so that
the
If gear
shift
and shift tion,
bolt
(5) on the gear shift lever only
the gear shift
(for both forward
(3), (4) and the speed
solenoid
valve
the
and the
are small.
is used F-R switch
signal
is used
is easy
lever
5 .+ 6 or 6 + 7
and reverse).
lever
lock lever (1) holds
(6) is placed
at the
(2) is placed gear
shift
N position
at the LOCK posi-
lever
(6) and keeps
the gear shift lever in the N position.
operates.
10-31 0
TRANSMISSION
STRUCTURE AND FUNCTION
Serial No.: 11031 - 12012, 12016 - 12018
1. Bolt
6. Gear shift lever
2. Shift lock lever
7. Rotary
3. Reverse 4. Forward 5. Button
10-31-l 0
switch switch switch
switch
8. Connector 9. Interlock 10. Interlock
lever
CONTROL
STRUCTURE
AND
TRANSMISSION
FUNCTION
c-c
A-A
Outline The transmission control is an electrical type. When the shift lever is operated, an electrical signal is sent to the transmission solenoid valve from F and R switches (4) and (3) when switching direction, and from rotary switch (7) for the gear ranges, and the control valve is actuated. . To prevent mistaken operation, when the shift lever is operated 5 + 6 or 6 + 7 (both forward and reverse) and when it is operated N tf P, button (5) installed to shift lever (6) must be pressed to move the shift lever. l
l
CONTROL
SDGOOOO 1
When shift lever (6) is at the N or P position, and shift lock lever (2) is set to the LOCK position, bolt (I) holds shift lever (6) and prevents it from moving back from the N position (1st and other drive positions).
10-31-2 0
STRUCTURE
AND
FUNCTION
TRANSMISSION
CONTROL
SWG00350
Outline . The transmission control is an electrical type. When shift lever (1) is operated, an electrical signal is sent to the transmission controller from F and R switches (3) and (2) when switching direction, and from potentiometer (5) for the gear ranges. The drive for the transmission solenoid valve is carried out by the transmission controller to protect the transmission from mistaken operation or failure in the control system. To prevent mistaken operation, when shift lever (1) is operated N ++ P, button (4) installed to the shift lever must be pressed to move the shift lever. l
10-31-4 0
INCHING
CONTROL
_--_I@
2-
A-A
T D
l-
“F’ ---
235CDO2004
1.
Inching
2.
Brake pedal
pedal
3.
Brake valve
4.
Transmission
1 O-32
control
valve
!!
e
!
:I
^
:
DRIVE
SHAFT
-I6 -
-
p
::: d----.
“\
_ h :P
F23501019
-
1.
Drive shaft
1o-33
STRUCTURE
AND
FUNCTION
FINAL DRIVE, DIFFERENTIAL
FINAL DRIVE, DIFFERENTIAL
LOCK AND
UNLOCK
PIPING
LOCK AND UNLOCK PIPING t
II A=========3
ii
I
SWG00351 +
1o-34 0
c
STRUCTURE
AND
FUNCTION
FINAL DRIVE,
DIFFERENTIAL
LOCK AND
UNLOCK
PIPING
SWG00352
[A SWG00353
1. 2. A-A
3. 4. 5.
Differential lock pump (LAL 12) Relief valve Set pressure: 2.5 MPa (25 kg/cm*} Solenoid valve Differential lock piston Bearing lubrication
1o-35 0
FINAL DRIVE
i 16
15
14
12
13 A-A
1. Shaft 2. Sprocket
(21 teeth)
3. Side case
235COO2006
7. Case
13. Gear (20 teeth)
8. Bevel gear (59 teeth)
14. Ring gear (78 teeth)
9. Coupling
15. Gear (28 teeth)
4. Flange
IO. Bevel pinion
5. Shaft
11. Disc
6. Gear (21 teeth)
12. Plate
1O-36 0
11
(16 teeth)
16. Pin
235CD02007
17. 18. 19. 20.
Filler tube Oil level gauge Breather support
Outline When motor graders carry out operations with the blade angled to the front or the chassis at an angle, there is a reaction to this. It applies a force in a sideways direction from the front, and the machine tries to turn to the left or right. It is necessary to give the machine the ability to resist this and travel in a straight line, so generally speaking, motor graders are not designed to be equipped with a differential. However, the GD825A is an articulated type, so when the machine is articulated, the rear wheels tend to slip to the side. For this reason, the machine is equipped with a differential to improve the wear resistance of the rear tires. Control of the differential can be carried out simply by pressing a switch in the operator’s compartment. Operation The power transmitted from the engine to the transmission is then transmitted by the meshing of bevel pinion (IO) and bevel gear (7), and is sent from shaft (6) -+ (I) + sprocket (2). The differential and differential lock are switched hydraulically by the contact between disc (11) and plate (12).
whee To
front
wheel \
1o-37 0
023502
Serial No.: 11001 – 12021
1. 2. 3. 4. 5. 6. 7.
Chain Breather Shaft Sprocket Cage Piston Spring
8. 9. 10. 11. 12. 13. 14.
Gear (105 teeth) Plate (138 teeth) Disc Tandem case Sprocket Oil level gauge Drain plug
10-39 (6)
023502
Serial No.: 12022 and up
1. 2. 3. 4. 5. 6. 7.
10-40 (6)
Chain Breather Shaft Sprocket Cage Piston Spring
8. 9. 10. 11. 12. 13. 14.
Gear (105 teeth) Plate (138 teeth) Disc Tandem case Sprocket Oil level gauge Drain plug
STEERING
PIPING
STEERING
1. 2. 3. 4. 5. 6.
SWING
CIRCLE
PIPING
Steering cylinder (R.H.) Steering cylinder (L.H.) Double relief valve Steering valve Check valve Check valve
10-41 0
STEERING CIRCUIT SYSTEM
L
,
I 235FO2011
7. Check valve
1.
Pump
2.
Servo
piston
3.
Servo
valve
4.
Check valve
5.
Steering
valve
6.
Steering
cylinder
1 O-42
flow devider
8. Priority
valve
9. Hydraulic
control
valve
(R.H.)
10. Hydraulic
control
valve
(L.H.)
11. Surge
pressure
absorbing
valve
STEERING CIRCUIT DIAGRAM
From hydraulic control valve
-c--
To hydraulic control valve t
235FO2012
1. Hydraulic
8. Steering
tank
2. Strainer 3. Hydraulic 4. Priority
pump flow
devider
7. Check valve
relief valve
IO. Steering
cylinder
11. Breather 12. Surge
5. Check valve 6. Last chance
valve
filter
valve
9. Double
pressure
13. Pressure 14. Emergency
absorbing
valve
switch pump
1o-43
STRUCTURE
AND
STEERING
FUNCTION
VALVE
STEERING VALVE ORBIT-ROLL
A-A
10
11 SEW01234
1. 2. 3. 4.
Needle bearing Center spring Drive shaft Valve body
1o-44 0
5. 6. 7. 8.
Rotor Cover Center pin Sleeve
9. 10. 11. 12.
Spool Stator Lower cover Check valve
STEERING VALVE
STRUCTURE AND FUNCTION
Outline l
.
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-roil valve, broadly speaking, consists of the following components: rotary type spool (9) and sleeve (81, which have the function of selecting the direction, and the Girotor set (a combination of rotor (5) and stator (IO)), 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. SLWO1980
Structure l
l
l
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 the 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 (81, 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 (41, and they are connected to the pump circuit, tank circuit, and the circuits at the head end and bottom end of the steering cylinders. The pump port and tank port are connected by the check valve inside the body. If the pump or engine fail, the oil can be sucked in directly from the tank by this check valve.
Connected steerlnu wheel shaft
Groove with
for center
to
meshins Pin
1o-45 0
STRUCTURE
AND
CONNECTION
FUNCTION
BETWEEN
STEERING
HAND
VALVE
PUMP AND SLEEVE
SBWOO725 SBWW726
.
.
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 I are connected to the head end of the left steering cylinder in the same way. In the condition in diagram above left, ports 1, 2, and 3 are the discharge ports of the Girotor set. They are connected to ports I, b, and d, so the 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”, the condition changes to the condition shown in diagram above right. 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.
1O-46 0
Suction / diTrge port
SBWGO727
SBWCQ728
STRUCTURE
.
.
AND
FUNCTION
STEERING
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 steering wheel: For every Ii7 turn of the steering wheel, the inner teeth of the Girotor gear advance 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.
Angle variation
sow0230 I
1o-47 0
DOUBLE
RELIEF VALVE
(For Steering) 1. 2. 3. 4. 5. 6. 7.
Relief valve Body Poppet(B) Sleeve Relief valve Poppet (A) Sleeve
FL?3501389 ll4-n
F238098
The check valve with safety valve protects the cylinder from abnormal pressure inside the cylinder caused by external force. OPERATION In the hydraulic circuit diagram above, oil from chamber A, enters. When there is abnormal pressure of over 210 kg/cm2, it pushes poppet (A) and flows to chamber A,. In the same way, when there is abnormal pressure of over 210 kg/cm2, oil from chamber Bz pushes poppet (B) and flows to chamber B 1.
F23BOSS
1 O-48
CHECK VALVE
1
1.
Nipple
2.
Joint
3.
Spring
4.
Valve
235FO2013 235FO2014
-8 FJJ __-
1.
I
*I
Spring
3.
Valve
4.
Nipple
ZJ I I
I
I
I
@ +-
Joint
2.
I
1
I
+---~\,L-__-------f
1
x
rX-
A
---------
1
LI
1
‘,
_‘Jk ,
* 235FO2015 F23501391
1o-49
EMERGENCY STEERING SYSTEM
235FO2017
235FO2016
OUTLINE .
If the oil pressure
in the hydraulic
0.7 MPa (7 kg/cm2)
because
gine or the pump,
pressure
ON, and emergency
pump
it possible *
of a failure switch
drops
to
in the en-
(3) is switched
(1) is actuated
to make
to steer the machine.
If the travel chine
circuit
speed
is stopped,
is below
1 km/h
the emergency
or the ma-
steering
sys-
tem is not actuated. *
The emergency
pump
do not continue
to operate
seconds.
1O-50
is an electric
pump,
so
it for more than 30
1.
Emergency
2.
Speed
pump
sensor
3.
Pressure
4.
Relay
5.
E.S.C controller
6.
Buzzer
7.
Select
8.
Starting
switch
switch motor
STRUCTURE
AND
FUNCTION
FRONT AXLE
FRONT AXLE Serial No,: 11001 - 12050
A-A
B-B
c-c
D-D 235CDO2009
1. Steering
cylinder
2. Tie rod
6. Housing 7. Bracket
3. Front axle
8. Leaning
4. Leaning
9. King pin
5. Hub shaft
cylinder
rod
10. Hub nut
1o-51 0
STRUCTURE AND FUNCTION
FRONT AXLE
023502
Serial No.: 12099 – 12502
10-51-2 (6)
STRUCTURE AND FUNCTION
FRONT AXLE
023502
Serial No.: 12503 and up
10-51-3 (6)
WHEEL Serial No.: 11001 - 12000
(OPT)
FRONT WHEEL
*\
1’
3A
1. 2. 3.
Side Rim Tire
ring
F23501039
F23501040
Tire size
18.00-25-I 2PR
Tire size
Rim size
13.00 x 25TB
Rim size
Air pressure
0.25 MPa (2.60 kg/cm*}
REAR WHEEL
I
23.5-25-12PR 19.5 x 25WTB
Air pressure
0.24 MPa 12.46 kg/cm*}
(OPT)
042
=23501041
Tire size Rim size Air pressure
1o-52 0
I
18.00-25-l 2PR
Tire size
I
23.5-25-l 2PR
13.00 x 25TB
Rim size
I
19.5 x 25WlB
0.25 MPa i2.60 kg/cm21
Air pressure
0.24 MPa 12.46 kg/cm21
2 FJ g
Serial No.: 12001 and up FRONT WHEEL
(OPT)
*\
l----1. 2. 3.
Side ring Rim
8H
Tire :23501039
F23501040
Tire size Rim size Air pressure
I
23.5-25-12PR
Tire size
18.00-25-12PR
19.5 x 25WTB
Rim size
13.00 x 25TB
0.24 MPa f2.46
kg/cm*}
0.25 MPa t2.60
Air pressure
kg/cm3
(OPT)
REAR WHEEL
F2350
F23501042
1041
Tire size
23.5-25-12PR
Tire size
I
18.00-25-I
Rim size
19.5 x 25WTB
Rim size
I
13.00 x 25TB
Air pressure
1 0.25 MPa I2.60 kg/cm?
Air pressure
1 0.24 MPa 12.46 kg/cm?
2PR
10-52-l 0
DISC BRAKE STRUCTURE
OF DISC BRAKE
1234
5
I II
Final drive
F23501056
Disc brakes are fitted actuated The shaft
motive (I),
on the four rear wheels
and are
by air pressure. force
from
1. Hub shaft 2. Gear
the final
drive
rotates
gear (2) and disc (4). This rotation
hub
is trans-
3. support 4. Disc
mitted to the tires which are fixed to the hub.
5. Plate
Each brake
6. Spring
consists
of discs (4) which
are meshed
with gear (2). plates (5) which
are meshed
with cage
7. Cage
(7) and piston
are cooled
by the oil
8. Piston
(8). The
inside the tandem
case.
discs
9. Nut IO. Bolt
1o-53
OPERATION 1.
Brake applied When
the brake pedal is depressed,
is connected When force
the air pressure of spring
and pushes generated
between
(2)) and the plates slows
down
is greater than the pushing
(6), piston
discs
the air circuit
A of the disc brake.
to chamber
(8) moves
(41 and plates
the discs (meshed (meshed
the rotation
stops it. In other words,
with
to the left,
(5). Friction
is
with gear
cage (7)). This
of the discs and finally the brake is applied.
From air tank
*
8 F23501057
2
Brake released When
the
brake
pedal
is released,
chamber
A is released.
Spring
(8)
to the
so the
back
reduced. discs
This
(4)
rotate
and
freely.
right, removes
plates In
(5),
other
the
the
(6) moves pushing friction
and words,
air in
4
piston force
5
8
is
between
allows
them
to
the
brake
is
released.
To air tank
F23501058
1o-54
PARKING BRAKE
Section A -A F23501061
Outline l
The
1. parking
brake is a disc type and is installed
on the transmission l
The force
output shaft.
of the spring inside the spring cylinder
(7) is used to apply the brake mechanically; released l
it is
by air pressure.
When
spring cylinder
juster
(6)
and
shaft
(7) yoke is moved out, ad(5)
turn
(3) and plate
and
piston
moves.
So discs
contact
and the parking brake is applied.
(2) are forced
Disc
2.
Plate
3.
Disc
4.
Piston
5.
Shaft
6.
Adjuster
7.
Spring cylinder
(4) in
1o-55
STRUCTURE
AND
BRAKE AIR PIPING
FUNCTION
BRAKE AIR PIPING
II
1. 2. 3. 4. 5. 6.
Brake valve Disc brake housing Safety valve Air governor Check valve Parking brake
7. 8. 9. 10. 11.
Parking brake valve Air tank Air drier Air compressor Automatic drain valve
1o-57 0
BRAKE AIR CIRCUIT SYSTEM
235FO2018
11. Stop lamp switch
1. Air compressor 2. Air drier
12. Disc brake
3. Air governor
13. Tire charger
4. Check valve
14. Horn valve
5. Air tank
15. Horn
6. Safety
8. Pressure
switch
gauge
9. Automatic 10. Brake valve
1 O-58
16. Parking
valve
7. Low pressure
drain valve
socket
brake valve
17. Exhaust
valve
18. Parking
brake
19. Bank-lock
valve
20. Bank-lock
cylinder
BRAKE AIR CIRCUIT DIAGRAM
SllG00003
1. 2. 3. 4. 5. 6. 7. 8. 9. 10.
Air compressor Air drier Air governor Check valve Air tank Safety valve Low pressure switch Pressure gauge Automatic drain valve Brake valve
11. 12. 13. 14. 15. 16. 17. 18. 19. 20.
Stop lamp switch Disc brake Tire charger socket Horn valve Horn Parking brake valve Exhaust valve Parking brake Bank-lock valve Bank-lock cylinder
1o-59 0
AIR DRIER
F23501047
The function from
protects vents
of the air drier is to remove
the compressed
air in the circuit.
the components
problems
with
the moisture In this way
of the equipment
operation
1. it
and pre-
in cold areas.
To Brakevalve
235FO2019
lo-60
Purge tank
2.
Check
3.
Spring
4.
Drier cylinder
5.
Drying
6.
Body
7.
Valve
8.
Valve
valve
agent body
9.
Oil filter
A.
Air compressor
8.
Air drier
C.
Air governor
D.
Air tank
OPERATION 1.
Drying When
the compressor
compressor
enters
then cooled and water (6).
The
which
is working,
by the outside and oil collect
air then
is fitted
passes
with
before
Any water
through
air enters
(5). When
drier cylinder then
the
oil filter
through
(9) Here
cylinder
(4).
in the air is removed the air reaches
check
To air tank
of dust are re-
drier
(4). it is completely
passes
(4).
of body
an oil mist separator.
still included
drying agent
the It is
of drier cylinder
in the bottom
the fine drops of oil and particles moved
air from
port A of the air drier.
by
the top of
dry. This dry air
valve
(2) and purge
From air compressor
tank (1) to the air tank.
F23501048
2.
Restoring When
drying
agent
the air pressure
the set pressure, compressor received Valve
inside the circuit
the air governor
to unloading.
by the
(8) opens
(4) is released
control
reaches
switches
The
governor
ports
of the
the
is also air drier.
and the air inside drier cylinder
to the atmosphere.
This drops the
air pressure
in purge tank (I 1, and the dried air in
purge
(I)
tank
passes
through
cause of the drop in pressure, and
becomes
through drying
dry more.
drier cylinder agent
closes,
the and
loading the
Be-
As the air flows
back from
is carried
This completely
agent (5) and prepares When
‘a’.
(41, it picks up water
(5) and the water
the atmosphere.
orifice
the dry air expands
it for further
cycle
air drier
starts returns
out to
dries out drying use.
again,
valve
to the
(8)
drying
action.
From air 9overnor
F23501049
10-61
AIR TANK
Section
The
air tank
duced
238FO66
A-A
acts
to store
the
compressed
air
pro-
by the air compressor.
Maximum
pressure:
0.93 MPa (9.5 kg/cm*) (Capacity
17.5 P x 2)
SAFETY VALVE
238FO67
The safety maintain inside kg/cm’)
valve safety
the air tank exceeds the safety
the atmosphere.
1 O-64
is installed
in the air tank and acts to
in the air circuit. valve
When
the
pressure
0.93 f 0.04 MPa (9.5 + 0.4 releases
compressed
air to
1.
Valve
2.
Ball
seat
3.
Release
4.
Spring
pin
5.
Spring
6.
Lock nut
cage
7.
Adjusting
screw
1.
Plate
2.
Plate
3.
Plate
4.
Boss
AUTOMATIC
!
DRAIN 2
VALVE 3
I. 2. 3. 4. 5. 6. 7.
Retainer Filter Body Plug Valve guide Inlet-Exhaust Cover
valve
238FO72
The automatic drain valve is installed at the bottom of the air tank. It acts to automatically drain any water which forms when the compressed air is cooled. OPERATION 1. When there is no air pressure inside the air tank, inlet-exhaust valve (6) is closed.
238FO73
1O-65
2.
When
air
exhaust
pressure
valve
enters
16) opens
is low. Air and water inlet-exhaust inside
valve
then stops
the air tank reaches
(until the governor
the
air
even when enter open
tank,
inlet-
the pressure
chamber
A. The
until the pressure
the maximum
pressure
is cut off).
238FO74
3.
When
the pressure
sure in chamber valve
guide
in the air tank
A are equal,
(5) closes
and the pres-
the spring
inlet-exhaust
action
valve
of
(6).
238FO75
4.
When
the pressure
pressure cm2), inlet
in chamber exhaust
in the air tank A is about valve
drops,
and the
0.03 MPa (0.3 kg/
(6) exhausts
the air and
water.
238FO78
1O-66
CHECK
VALVE 3
2
1
4
1. PI
PZ
Body
2.
Disc valve
3.
Spring
4.
Screw
cap
238FO64
The
check
valve
from flowing compressor
acts to prevent
air in the air tank
back to the air compressor
when the air
is stopped.
OPERATION When
air flows
into the check
valve
valve (2) leaks its seat and the air flows
from
the left,
freely to the
various ports. When valve
air flows
into the check
(2) is pushed
back
valve from
into its seat
the right,
by spring
(3)
and the air pressure. This shuts off the air flow.
238FO65
1 O-67
BRAKE VALVE
--. / 4L ix i’ /
1,
l’\ 0
\__,’
/ i
,I--‘,
I
: \ 0,
ii
‘._.’
(
l--r---___--_____r_~_
I
F23501050
2. 3. 4. 5. 6. 7.
Brake pedal Plunger Piston Inlet valve Piston Inlet valve Rubber spring
A. B. C. D.
From air tank From air tank To R.H. relay valve To L.H. relay valve
1.
t
I
235FO2020
1O-68
OPERATION 1.
Brake
operating
Upper
part
l
When
brake
operating rubber
spring
operating l
pedal
force
When
is depressed, plunger
(71, and
these
the
(2)
and
transmit
the
force to piston (3).
piston
haust outlet down
(1)
pushes
(3) moves
down,
it closes ex-
(9). At the same time, it pushes
inlet valve
(4) and air flows
from
air
air flows
to
tank A to right relay valve C. Lower l
part
When
inlet
chamber l
valve
(4)
The air pressure
pushes
this closes exhaust time,
it pushes
flows
from
actuate l
Only needed
opens,
‘a’ of piston (5). piston (5) down and
outlet
(I 0). At the same
down.inlet
valve
(6) and air
air tank B to left relay valve D to
the brake. a
small
amount
of
air
pressure
is
to move piston (51, so the movement
of the lower valve occurs at almost the same time as the movement
of the upper valve.
F23501051
2.
Brake
operation
when
lower
side
breakes
down If there is any leakage upper
side operates
does not actuate
of air at the lower side, the normally
but the lower
side
the brake.
F23501052
lo-69
3.
Brake operation when upper side breaks down . If there is any leakage of air at the upper side, piston (5) is pushed down mechanically when
the brake pedal is depressed.
Because
of this, the lower side operates
normally
the upper side does not actuate
the brake.
but
F23501053
4.
Balancing Upper
.
operation
part
If the air pressure
in relay valve
space below piston (3) becomes (3) will push rubber
spring
C and the high, piston
(7) and move up
to close inlet valve (4). l
When
this
happens,
mains closed,
exhaust
outlet
so the air pressure
valve is maintained.
(9) re-
in the relay
As a result, the brake re-
3
mains applied. Lower l
part
When
the air pressure
of piston
at the top and bottom
(5) becomes slightly
down
spring
under the force
at the top of the
piston
inlet valve (6). The exhaust the
air pressure
of the
and closes
valve is closed so
is maintained.
As a result,
the brake remains applied. l
The
pressure
balances
with
in the space the
4
the same, the piston
moves
in the upper
operating
pedal,
and the pressure
lower
part balances
force
in the space
9
5
part
of
the
in the
with the air pressure
in
t-i
the space in the upper part.
F23501054
1O-70
l
When
piston
stroke
inlet valves (4) and (6) are completely
opened.
(3) and
As a result,
spaces
(5) move
the air pressure
in the right and left relay valves Therefore, down,
in the
until
is the same
in the air reservoir. the
the braking
amount
5.
whole
in the upper part and lower part, and
as the air pressure l
their
piston
effect
its full
stroke
is controlled
by the
the brake pedal is depressed.
Pedal released Upper part l
If the pressure the operating
on the pedal pressure
top of the piston, cause
the piston
of the air pressure
the piston and the force spring.
As a result,
port (9) is opened
is reduced,
is removed
moves
the
up be-
at the bottom
of
of the piston return
the passage
to exhaust
and the compressed
the relay valve is released
and
from
air in
to the atmosphere.
Lower part l
If the pressure the compressed released,
the
on the pedal is reduced, air pressure
at the bottom
piston (5) pushes piston (5) up. Exhaust (10)
is opened
and
air at the top of piston (5) is
and the compressed
relay valve is released
of port
air in the
to the atmosphere.
F23501055
10-71
PARKING BRAKE SYSTEM
235CD02012
From air tank
235FO2022
235FO2021
1.
Parking
brake solenoid
RE-
2.
Exhaust
valve
and
3.
Spring
OUTLINE
.
If the LEASE
parking
brake
position,
solenoid
the air pressure cylinder l
switch
from
(3) to release
ING position,
solenoid
in spring valve by the brake.
1 O-72
cylinder
spring
brake. at the PARK-
(1) is closed
and the
the air tank is shut off, so the air (3) is discharged
(2), and the spring force
pushes
is placed
valve
at the
(1) is opened
the parking
brake switch from
valve
the air tank
If the parking air pressure
is placed
of the
cylinder
spring
from
exhaust
is pushed
to apply
the
back
parki_ng
cylinder
valve
PARKING BRAKE SOLENOID
VALVE
1.
Coil
2.
Body
3.
Inlet valve
4.
Outlet valve
A.
Inlet port
B.
Outlet port
C.
From air tank
423F119
Function l
The
parking
brake
solenoid
valve
is a valve
to
switch air to the parking brake spring cylinder.
l
Parking brake operated When
the shift
position, current
the solenoid flows),
spring
valve is switched
OFF (no
the tank enters
port C is sealed by valve (4). so
out. The
cylinder
air in the
is drained
around
port E. Therefore,
valve
parking
through
valve. The air from the exhaust A, passes
to the PARKING
and the air from
port C. However, no air flows
Spring
lever is moved
the
brake
exhaust
valve enters
(5) and is drained
port from
Exhaust Gz! From are tank
4
the spring force of the parking
235F239-1
brake spring cylinder applies the parking brake.
.
Parking brake released If the
shift
PARKING,
lever
is at any
solenoid
valve
position
other
is ON (current
and valve (5) moves down. Valve
then
flows),
(4) is connect-
ed to valve (5) by a rod, so valve (41 also moves down. The air from the tank enters port C, and valve (4) has moved (4).
down,
so the air passes around valve
It then flows from port A through
valve
to the
parking
release the brake.
brake
spring
the exhaust cylinder
From air tank
to 235F240-1
1o-73
EXHAUST VALVE
Section
A-A
z 4 2
F23501060
1.
l
When moved
Rubber valve
3.
Valve
4.
Cap
A.
To spring cylinder
B.
Exhaust
C.
From solenoid valve
the
through
Body
2.
the and
port
compressed solenoid opens
air valve,
the circuit
and A and then the air flows
l
When
this happens,
When
no air flows
spring cylinder moves haust
to
port
valve
between
C
(2) is
ports
C
to spring cylinder.
the parking brake is released. to port C, the
air from
the
is sent to port A so that valve (3)
to the right and the air is released port
B. When
brake is applied.
1o-74
flows rubber
this
happens,
the
to exparking
SPRING CYLINDER
423F
1. 2. 3. 4. 5.
Rod Boot Cylinder Spring Piston
I 24
OUTLINE The air pressure from the parking brake solenoid valve pushes spring (4) and compresses it to release the parking brake. Usually the parking brake is kept applied by spring (4), so the machine is prevented from moving. l
1o-75 0
HYDRAULIC CONTROL PIPING
STRUCTURE AND FUNCTION
HYDRAULIC
CONTROL PIPING
LOW AND HIGH PRESSURE PIPING
A-A
1O-76 0
STRUCTURE AND FUNCTION
HYDRAULIC CONTROL PIPING
1. 2. 3. 4. 5. 6.
L.H. hydraulic control valve R.H. hydraulic control valve Main relief valve Priority flow divider valve Hydraulic pump Hydraulic tank
1o-77 0
STRUCTURE
AND
HYDRAULIC
FUNCTION
CONTROL
HIGH PRESSURE PIPING Serial No.: 11001 - 12050
-___
4 7 i
y
Z
1. 2. 3. 4. 5.
--__-
/
Pilot check valve (for articulate) Articulate cylinder L.H. hydraulic control valve Pilot check valve (for blade lift) L.H. Pilot check valve (for power tilt)
1 O-78 0
: : I i
6. 7. 8. 9. 10.
R.H. hydraulic control valve Blade lift cylinder Pilot check valve (for leaning) Pilot check valve (For drawbar Leaning cylinder
shift)
PIPING
STRUCTURE
AND
FUNCTION
HYDRAULIC
Ii
11. 12. 13. 14. 15.
Pilot check valve (for blade lift) R.H. Shuttle valve Circle rotation motor Power tilt cylinder Circle rotation gear
CONTROL
PIPING
SWGOO 359
16. Swivel joint 17. Drawbar side shift cylinder 18. Blade side shift cylinder
1o-79 0
STRUCTURE
AND
HYDRAULIC
FUNCTION
CONTROL
PIPING
Serial No.: 12051 and up
II
1. 2. 3. 4. 5.
Pilot check valve (for articulate) Articulate cylinder L.H. hydraulic control valve Pilot check valve (for blade lift) L.H. Pilot check valve (for power tilt)
10-79-l 0
6. 7. 8. 9. 10.
R.H. hydraulic control valve Blade lift cylinder Pilot check valve (for leaning) Pilot check valve (for drambar Leaning cylinder
IO SWGOO
shift)
1360
STRUCTURE AND FUNCTION
HYDRAULIC CONTROL PIPING
18
11. 12. 13. 14. 15.
Relief valve (for leaning) Pilot check valve (for blade lift) R.H. Circle rotation motor Circle rotation gear Power tilt cylinder
SWG00361
16. Swivel joint 17. Drawbar side shift cylinder 18. Blade side shift cylinder
10-79-2 0
STRUCTURE AND FUNCTION
HYDRAULIC CONTROL PIPING
HYDRAULIC TANK PIPING
i
i
i
i
ii
ii 235COO2013
1.
Return
2.
Suction
3.
Hydraulic
1o-79-3 0
filter filter pump
STRUCTURE
AND
FUNCTION
HYDRAULIC
CONTROL
PIPING
RIPPER PIPING
I
:
__----
235COO2016
1.
Ripper
2.
Pilot check valve
cylinder
1o-79-4 0
STRUCTURE
AND FUNCTION
HYDRAULIC Engine running,
HYDRAULIC
CIRCUIT
SYSTEM
CIRCUIT SYSTEM
work
equipment
control
lever in HOLD
I
x3
1x1
1x4
I
L
235FO2023
1.
Servo
valve
5.
Steering
2.
Servo
piston
6.
Hydraulic
3.
Pump
7.
Surge
4.
Priority
8.
Hydraulic
1O-80 0
flow
divider
valve
valve control
pressure control
valve
(L.H.)
absorbing valve
valve
(R.H.)
STRUCTURE
AND
HYDRAULIC
FUNCTION
HYDRAULIC
CIRCUIT
DIAGRAM
CIRCUIT DIAGRAM
Serial No.: 11001 - 12022 27.4MPa ~280kdcm~l
IO _______
12
L.lI!ii I/
L___
27.4MPa (280wcm~t
27.4MPa (280Wcmzl
113
_-
----II--
I
II
-1 I t--
2: r
1 O-80-2 0
1---1p
2
STRUCTURE
AND
FUNCTION
II
3 -7+Q I I I
4 5I
I
HYDRAULIC
II
II
CIRCUIT
DIAGRAM
II
I
!I i
------------7
/
<
/
I
I I ; ---------------~~~_____-----__~_~--------_--------______---_________ I
i
,
I
24.5MPa i250ko/cm*i
I
SWG00363
10-80-3 0
STRUCTURE
HYDRAULIC
AND FUNCTION
1. Hydraulic
tank
2. Breather 3. Strainer 4. Hydraulic 5. Priority 6. Surge
pump flow
(VXD70-IF)
divider
pressure
7. L.H. hydraulic
valve
absorbing control
valve
7A. Blade lift (L.H.) control 7B. Ripper
control
(5-spool) spool
spool
7C. Blade side shift control 7D. Power
valve
tilt control
7E. Circle rotation
spool
spool
control
spool
7F. Relief valve 8. R.H. hydraulic
control
8A. Drawbar
valve
8B. Articulate
control
8C. Leaning
spool
8D. Service
spool
spool
8E. Blade lift (R.H.) control 8F. Relief valve 9. Blade lift cylinder
(L.H.)
10. Accumulator 11. Blade float 12. Ripper
solenoid
valve
cylinder
13. Blade side shift cylinder 14. Power
tilt cylinder
15. Swivel
joint
16. Circle rotation 17. Drawbar 19. Leaning
motor
shift cylinder
18. Articulate
cylinder cylinder
20. Blade lift cylinder 21. Pilot check valve 22. Check valve 23. Steering
valve
24. Double
relief valve
25. Steering
cylinder
26. Pressure
switch
27. Filter 28. Hydraulic 29. Emergency
1 O-80-4 0
(5-spool)
shift spool
filter pump
(R.H.)
spool
CIRCUIT
DIAGRAM
STRUCTURE
AND
FUNCTION
HYDRAULIC
CIRCUIT
DIAGRAM
Serial No.: 12023 - 12050
27.4MPa
27.4MPa ~280ks/cm~l
27.4MPa
14 rl
16
2
24.5MPa (250Wcm~l
--i-___ I
!
/
I
2
3
4
---i---.__.i..-.__.i.._..__i--__-_~j
a
ILS .*+-m-------
22
1 O-80-6 0
27
STRUCTURE AND FUNCTION
HYDRAULIC CIRCUIT DIAGRAM
24.5MPa
3-----4
5
Il
SWG00365
10-80-7 0
HYDRAULIC CIRCUIT DIAGRAM
STRUCTURE AND FUNCTION
1. Hydraulic
tank
2. Breather 3. Strainer 4. Hydraulic 5. Priority 6. Surge
pump flow
(VXD70-IF)
divider
pressure
7. L.H. hydraulic
valve
absorbing control
valve
7A. Blade lift (L.H.) control 78. Ripper
control
7D. Power tilt control 7E. Circle rotation
control valve
8B. Articulate
control spool
8D. Service
spool
9. Blade lift cylinder
(L.H.)
10. Accumulator solenoid
valve
cylinder
13. Blade side shift cylinder 14. Power
tilt cylinder
15. Swivel
joint
16. Circle rotation 17. Drawbar 19. Leaning
motor
shift cylinder
18. Articulate
cylinder cylinder
20. Blade lift cylinder 21. Pilot check valve 22. Check valve 23. Steering
valve
24. Double
relief valve
25. Steering
cylinder
26. Pressure
switch
27. Filter 28. Hydraulic
filter
29. Emergency 30.
Relief
valve
1O-80-8 0
(5-spool)
spool
8E. Blade lift (R.H.) control
12. Ripper
spool
shift spool
8C. Leaning
11. Blade float
spool
spool
control
8A. Drawbar
(5-spool) spool
spool
7C. Blade side shift control
8. R.H. hydraulic
valve
pump
(R.H.)
spool
STRUCTURE
AND
FUNCTION
HYDRAULIC
CIRCUIT
DIAGRAM
Serial No.: 12051 and up
27.4MPa
27.4MPa (28Ok/cm'l
27.4MPa (280kP/cmzl
x
7;
25
r i
_-
P
As
L
10-80-10 0
A4
!*-@L-------
_,
22 27
:--
A3 -_83 -.__-____
82 -._______ A2
Bl _ >
24.5MPa
I
STRUCTURE AND FUNCTION
HYDRAULIC CIRCUIT DIAGRAM
L_
24.5MPa
,-
; -----------
----yq+_____
____________________----_---------~
id27
27 i
IO
, , __-------_j@_
12
10-80-11 0
STRUCTURE
AND
1. Hydraulic
HYDRAULIC
FUNCTION
tank
2. Breather 3. Strainer 4. Hydraulic 5. Priority 6. Surge
pump flow
(VXD70-IF)
divider
pressure
7. L.H. hydraulic
valve
absorbing control
valve
7A. Blade lift (L.H.) control 7B. Ripper
control
tilt control
7E. Circle rotation 8. R.H. hydraulic
control valve
control
8C. Leaning
spool
8D. Service
spool
9. Blade lift cylinder
(L.H.)
10. Accumulator 11. Blade float solenoid
valve
cylinder
13. Blade side shift cylinder 14. Power tilt cylinder joint
16. Circle rotation 17. Drawbar
motor
shift cylinder
18. Articulate 19. Leaning
cylinder cylinder
20. Blade lift cylinder 21. Pilot check valve 22. Check valve 23. Steering
valve
24. Double
relief valve
25. Steering
cylinder
26. Pressure
switch
27. Filter 28. Hydraulic
filter
29. Emergency 30. Relief
valve
31. Relief
valve
10-80-12
(5-spool)
spool
8E. Blade lift (R.H.) control
15. Swivel
spool
shift spool
8B. Articulate
12. Ripper
spool
spool
control
8A. Drawbar
(5-spool) spool
spool
7C. Blade side shift control 7D. Power
valve
pump
(R.H.)
spool
CIRCUIT
DIAGRAM
CLOSED This
CENTER
machine
to supply
uses the CLSS
an oil flow
characteristics
actuator
the
system
to match
equipment
to the actuating
increases
SENSING
in the hydraulic
to each
of the work
corresponding This
LOAD
This system
the
l
at a pressure l
performance
and
(CLSS)
consists
Variable
of the following
displacement
components.
piston
pump
with
servo-valve
load.
working
SYSTEM
saves
Selector
valve
with
type
pressure
proportional
flow
control
function
the fuel consumption.
l
Reducing
compensating
valve
Advantages (I 1 Constant of work equipment speed not influenced by engine speed.
Increase of operating performance
(2)
Extension and retraction speeds of cylinder the same.
(3)
Excellent fine control performance
(4)
(6)
Saves
energy
I
I
-
Fine control
(I) Constant fluenced
of
work
by engine
(2) Extension
and
equipment
Relief loss saving
speed
not
in-
speed.
retraction
speeds
of cylinder
the
same. The flow tion
control
is decided
and the difference
of the throttle. difference
Even if the engine
in pressure
plate
angle
of the
pump
is constant,
mains the same.
1o-:‘-1
by the area of restric-
in pressure is equal
variable
on either speed and
side
rises, the the
displacement
so the delivery
loss saving
swash piston
of the pump
re-
type
pressure
Selector valve with proportional flow control function
Excellent control for compound operations
I
i
Reducing
Y/
’ /
(3)
Excellent The
fine control
oil flow
performance
to each actuator
area E of the gap between the selector fluenced
and
spool of the control valve. It is not in-
60
-
each
medium
to
body
by the load, so the fine control
a large move
is proportional the valve
70%. part
Therefore,
of the
speed
to
range is
it is possible
work
equipment more
enable
to
at
a
precise
operations.
F23501073
A
(4)
Excellent
control for compound
During
compound
servo detects trols the type
the
the larger actuating
pump
delivery
pressure
pressure)
difference
on
The
valve
reducing
on the
side controls
both
valve to a constant
hydraulic
force and con-
pressure.
compensating
load (actuating sure
operations.
operations,
sides
of
F23501074
selector is the
operations.
Reducing type pressure compensating valve
Variable displacement piston pump
_-_-__c----
(5)
I
I I
Actuating
-
Selector valve with proportional flow control function
++
Pump delivery pressure
_
control lever travel
the pres-
the
value, so the operation
same as for independent
Work equipment
IoW
-
To actuator
-
From actuator
t A pressure
f Return
Oil flow -w
F23501075
Control flow
Flow
control
to
match
each
part
of
work
x oil flow)
when
equipment The
power
operating cise
needed
movement,
which
needs
viously
(pressure
the blade lift cylinder, and
speed
different.
the gap explained
when
which needs pre-
rotating
and rotation
With
the CLSS,
(cylinder
speed)
12) Extension
circle, is ob-
if the ‘area of
in (3) Fine control
a large flow of oil can be supplied.
the
torque,
is increased,
Or, the oil flow
can be set in the same way for
and retraction
speed of cylinder.
(6)
Saves energy The CLSS is a system the necessary Compared
in which the pump delivers
oil flow at the necessary
to the hydraulic
pumps, the loss of hydraulic energy is extremely
pressure.
circuit used with gear power
and hydraulic
small.
c
Gear pump
CLSS
In neutral
CLSS
Gear pump
During fine control
Pump delivery amount Only an oil flow to replace the oil which leaks from the high pressure circuits of the valve and pump to the lower pressure circuit is needed. In addition, the delivery pressure is the standby pressure, so the power loss is small.
The pump is always delivering oil, and pressure is caused by the resistance in the piping circuit, so the power loss is large.
Both the pump delivery pressure and delivery amount are controlled, so the power loss is small.
The pressure corresponds to the load, but only part c the delivery amount is used, so the power loss is large.
The pump delivery pressure is kept low, so the power loss is small.
The pump delivery pressure depends on the load, so the power loss is small.
The hydraulic servo acts to All the oil delivered from the pump is wasted, so the prevent the pump delivery pressure from going above power loss is extremely large. the relief pressure, so the oil flow is reduced and the power loss is imall.
F (1 Uunderno load)
P: 0: m
Pressure Oil quantity Power loss
HYDRAULIC
PUMP
VXD70-1 F !
\
Suction port
Section A-A Detail of pump assembly
w Section B-B
21, I 17 ii /
t
1. Servo 2. Pump
valve
assembly
3. Cylinder 4. Piston 5. Shoe
1O-82 0
assembly
block
6. Swash
plate
\
18
\
Detail of servo valve
19
F23501077A
11. Coupling
16. Dummy
7. Front shaft
12. Housing
17. Yoke
8. Front cover
13. Swash
9. Housing
14. Rear shaft
19. Guide
15. Rear cover
20. Stopper
10. Center
section
plate
18. Servo
spool piston pin
PRINCIPLE
OF OPERATION
FUNCTION . It converts
the rotation
torque transmitted
pump shaft into hydraulic pressurized .
OF PISTON
energy,
oil corresponding
by the
and discharges
to the load.
It is possible to vary the amount by changing
PUMP
of oil discharged
the angle of the swash plate.
OPERATION Input shaft (2) is fitted with a spline and rotates
cylin-
der block
inside
(I ). The
the cylinder distance
block
move
by the angle
in a reciprocal
of swash
plate
parts that
pump.
lever is at the Neutral no movement
does
position,
when
by changing
When
control
plate is angled
rotates.
lever
continuous and
(8)
is is
speed
can be
angle
of the
the
is moved through
the piston
rotation,
the
is discharged
to the
port hole.
left,
B (71, and
through
motor
When
control
plate is angled
(I)
rotates.
sucked
(8) is moved
the
rotation, is discharged
motor in the opposite
the
through piston
to the port
hole.
oil passes to the
direction.
IS
is out
port A
to rotate
the
right,
to the right and cylinder
Oil passes
in through
continuous (71, and
lever
262F0
the
motor.
swash
I6
block
By carrying
oil passes to the
262F0
lever.
to the left and cylinder
Oil passes
in through
there
so no rotation
The transmission
swash sucked
the swash
the directional
and the sliding surface
of oil to the motor,
steplessly
only
and the cylinder
plate is flat and vertical,
to the motor.
This
(5). The
not contact
swash plate with the pump control
(6).
The
(3) of the pump.
Therefore,
of the pump swash
(I)
motion.
by trunnion
are the input shaft
input shaft
of the
controlled
plate
is supported
rotate
block. The
given
(4) contained
moved in and out by the pistons is controlled
swash
plate
nine pistons
motor
A
the
block
(61, and
By carrying through
Input Output
port
to rotate
is out B the
Output Input
262FO20
1 O-83
OPERATION
OF HYDRAULIC
PUMP
FUNCTION l
This is a variable piston
pump
amount flow
displacement
with
servo
discharged
needed
which
to match
for the work
swash
plate
type
can
control
the
the pressure
equipment
and oil
and steering
circuit. l
The
pump
servo
assembly
portion
consists
(servo valve
of the
and servo
pump
and
piston).
OPERATION 1.
When engine l
piston
pressure
of spring
Swash with
is generated,
(1) is pushed
force l
is stopped
No hydraulic
fully
swash
left
by the
(2).
plate (3) of the pump
servo
so servo
to the
piston
is interconnected
(I), so it is at the maximum
plate angle.
235FO2024
2.
Immediately control 1)
after engine starts (work equipment
lever, steering
The
pump
plate
angle,
charge sent
and
port
at the
main
oil discharged
control
but the valves
ure in the circuit This
circuit
chamber
valve
overcomes (4) moves
spool
valve
chamber
(4)
P is
steering
so the press-
with
servo
valve
pressure
the force
that is
of spring
(5),
to the right. moves
to
the
A and servo
are connected,
dis-
from
rises.
is connected
When
swash from
and
are closed,
A, and the hydraulic
generated so spool
maximum
oil is discharged
P. The
to the
valve,
not operated)
rotates
and servo
right,
piston
piston
servo
chamber
B
(1) is pushed
to the right. In addition,
discharge
with
piston
servo
chamber
B is larger
C, so servo spring
piston
plate
charge
amount
is a feedback improve
is 0. (Servo pressure servo
of
of chamber
This pushes where
piston
chamber.
back
the
chamber
disC
It is used to
and stabilize
piston,
in the circuit.)
the force
force
(3) to a position
the response
of the
pressure
1 O-84
(1) overcomes
to the right.
swash
C, but the area of
than the area of chamber
(2) and the pushing
C, and moves
ation
port P is also connected
chamber
regardless
the operof the
235FO2025
2) In the condition in the
in Section
circuit
valve
drops,
is pushed
(4) of the
servo
back to the left by spring
and the oil in servo through
I), if the pressure
spool piston
chamber
chamber
E and
(5),
B passes
is drained
to
the
and
the
case. The
pressure
force
removed, left
by
plate of
in chamber
pushing
servo
so servo spring
oil
from
ing force
the
angle
to increase
pump.
The
and piston
to a position
(1) is moved
(2), and
the
(1) to the right
piston
(3) is changed
rises again,
B drops,
piston
where
of swash
the discharge pump
(4) moves
it balances
of spring
is
to the
pressure
to the right
with
the push-
(5), and it then stays in this
position. When
this happens,
the difference
pressure
is determined
(5), and
is approx.
other
words,
the
2.0 MPa pump
swash
plate
started,
and provides
angle
immediately
after
in balance
by the force
of spring
(20 kg/cm2).
is at the
before
the
engine
the maximum
the
the swash
plate angle
to reduce
the discharge
engine
is
discharge
is started,
is immediately amount
In
maximum
but
returned
to nearly
the
235FO2026
minimum. 3.
Work equipment If the work ated,
the
through servo
pressure
(when
and steering valve
valve
In this
way,
down,
the
the
work
the high
at spool
the angle
As the amount creases,
of
the
the circuit
valve
control the
chamber
B goeS
(3)
becomes
increases. from
circuit
the pump rises.
the necessary spool
pressure
enters
pressure
pressure
(4) to the right. is balanced
at this
differential
point
by
In other is bal-
pressure
of apPz sent
prox.
2.0 MPa (20 kg/cm2)
+ load pressure
from
the actuator
the LS line.
through
in-
When
port A of
2.0 MPa (20 kg/cm2).
control
valve
to the left. As a
plate
pressure
and pushes
pump
by the
in
amount
differential
absorp-
side to cham-
(1) moves
with
(5) at approx.
pressure
(4) of the servo
in the
is filled
control
at the same time,
of oil discharge pressure
and oil flow, the servo
equipment
swash
the actuator
words,
passes D of the
to the left.
pressure piston
and the discharge
spring
are oper-
actuator
pressure
(4) moves
and servo
result,
anced
of the
(6) inside the surge
sends
is lost and spool
The
operated
or steering
are operated
ber D). The balance
larger
levers
the LS line and goes to chamber
shuttle tion
load
valve
lever
lever, steering
equipment
235FO2027
1 O-85
4.
When work equipment When
the cylinder
the relief
pressure valve
through
D of the servo is balanced
pressure
approx.
2.0
pressure
P2 of the
pressure
is equal
are relieved
the end of its stroke,
transmitted
is sent to chamber The servo
and steering
reaches
by control
MPa
(20
differential
kg/cm2)
LS line. Therefore,
to the relief
the LS line
valve.
pressure
+
load
the
pump
+ approx.
2.0 MPa (20 kg/cm2). The cylinder the flow plate
has reached
is kept
ure will
at the same
rise further.
further,
the balance
and the pressure rise. This pushes reduces In other
words, while
(minimization
angle,
If the
in servo servo at
the pump
pump
valve
piston
press-
pressure
rises
will be lost
chamber
B will
piston
(I) to the right
discharged
by the pump.
relief,
relief
the
the
discharge
of power
and
so if the swash
of the servo
the amount
maintained duced
the end of its stroke
of the oil has stopped,
pressure
amount
is
and is re-
loss).
235FO2028
1O-86
8 4 8
PRIORITY FLOW DIVIDER VALVE
8
,
7
6
17.2MPa
235FO2029
1.
Relief valve
2.
Strainer
3.
Spool
4.
Body
5.
PLUG, damping
6.
PLUG, flow
7.
Orifice
8.
Spring
orifice
control
orifice
(for high response
actuation)
235FO2030
1 O-87
FUNCTION l
When
the
hydraulic
equipment pump,
and
if the
operated
work
time,
prevent
priority
and
the
one are
is danger
that
may be insufthe steer-
dangerous,
to the steering
is maintained
work
by
steering
to operate
is extremely
this, the oil flow
given
and circuit
it impossible
ing. This condition
both
covered
there
of oil to the steering making
for
are
equipment
at the same
the flow ficient,
systems
steering
so to
circuit
by this
is
priority
valve. l
This valve
is a load sensing
the necessary steering tral,
flow
is operated.
if a large
circuit, cuit
will
and
the
when
of oil to the steeering
l
equipment
cir-
efficiency
will
this and to ensure is operated,
circuit
the steering
when
min),
and all the rest of the oil flows
equipment
circuit. pressure
a different for
the
function
relief work
at neutral
(approx.
of the steering
pressure
from
equipment
of preventing
circuit It also
abnormal
1 Q/
to the work
the relief
circuit. any
quick
the flow
is kept to the mini-
mum
The relief
the
is at neu-
to the steering
operating
the steering
only
when
the steering
of oil flows
poor. To prevent
response
and ensures
of oil to the work
drop,
become
When
amount
the flow
type
of oil to the steering
is set as pressure has
pressure
the in
the circuits.
OPERATION 1.
When engine Spool
is stopped
(1) is pushed
In this condition,
to the right by spring port
CF is opened
(2).
to the
maxi-
mum and port EF is closed.
235FO2031
1O-88
2.
When
engine
is started
(steering
and main con-
trol valves at neutral) The oil from
the pump
but the steering steering
circuit
The oil from in spool
the pump
drained
to the’tank
orifice
“c”
this flow
cm*)
time,
is formed
to the
sides
C + 1.0 MPa (10 kg/cm2), (1).
the
becomes passing the
smaller, through
to
pushed oil
through
becomes larger, close.
the larger.
the
opening acting
at
When
the
at portion
This is repeated
The forces
until
.
PB [-
portion
in the drain
“d” circuit
smaller,
sides
SO
spool (1)
is
(2), and the flow
of
Spool
portion oil
“d”
flow
again
becomes
“d” again
tries
to
is reached.
B and chamber
(converted
235FO2032
of orifice
pushing
a balance
on chamber
are as follows: . Force in left direction force):
“d” of spool
weaker.
opening
“b”. The
(1) is pushed
and the force by spring
a dif-
(IO kg/
in chamber
at
on both
becomes
to the right
of orifice
“b” becomes
pressure left
‘lb”,
1.0 MPa
portion
the oil flow
smaller
the
orifice
opening
orifice
differential
“b” becomes (1)
of
is
(the
1 Urnin.)
so spool
to close
C,
and
valve
B is the pressure
to the left and tries area
chamber
the steering
through
on both
“a”
spool
the oil passing
of approx.
in chamber
If the
in
orifice
LS circuit,
is normally
passes
in pressure
pressure
through
(1) enters
through
in the LS circuit
ference
valve,
so the pressure
B, and pushes
“b” of spool
from
When
passes
chamber
left. At the same
orifice
passes flow
to the steering
is closed,
CF rises.
(I), enters
(1) to the through
flows
valve
C
to hydraulic
1.6 MPa (16 kg/cm2)]
Force in right direction: PC + 1 .O MPa (10 kg/cm’) [= 1.6 MPa (16 kg/cm2)] [I.0
MPa
converted
(10 kg/cm2) for spring
is the
hydraulic
force
(2)]
1 O-89 0
3.
Steering
operated
(main
control
valve
wheel
is turned,
at neu-
tral) When
the
valve
is switched,
steering
connected
to
happens, higher,
the
the and
spring
and
port
steering
pressure spool
the
CF and cylinder.
(1) becomes
pump
passes
wheel
is being
goes from
larger,
through
port
turned,
to the
right
“d”
so the oil from
the
CF when
valve
by
of portion
the steering
and the necessary
the steering
this
C becomes
(2). The area of the opening
of spool
LS are
When
in chamber
(1) is pushed
steering
port
oil flow
to the steering
cylin-
der. If the
steering
wheel
is turned
area of the variable becomes
larger,
throttle
the
difference
both sides of the variable ing valve the
becomes
LS circuit
in
throttle
smaller,
rises.
quickly,
and
in the steering pressure
inside
and the
(The pressure
the
valve on
the steer-
pressure
in
in chamber
6
in chamber
C
drops) At the same also
rises,
right,
time,
(1) is moved
further
and the area of the opening
also becomes the
the oil pressure
so.spool
steering
steering
larger.
This sends
cylinder.
On the
wheel
is turned
pressure
on both sides
side
steering
the
of portion
other
slowly,
hand,
the
becomes
pressure
in chamber
B becomes
pressure
in chamber
C, so spool
becomes
smaller
to match valve.
if the
differential throttle
larger,
in-
and the
larger
than
the
(1) is pushed
the left, and the area of the opening for the steering
“d”
a large oil flow to
of the variable
valve
to the
of portion
the flow
It becomes
to “d”
of oil needed
balanced
in this
position. In other
words,
spool
(1) moves
in accordance
with the flow
of oil needed
for port CF to maintain
the differential
pressure
chamber
chamber
between
C at 1.0 MPa
(10 kg/cm2),
the opening
of portion
not needed
for the steering
and
‘Id”. (In this way,
B and adjusts
all the oil
can be used
at port
EF.) When
the oil from
linder
and load is applied,
port
cuit rises. This signal fed
back to the
the swash
plate
the discharge
feeds
1O-90
the
forms
valve.
back this information
the press-
the EL circuit on
the
of
to increase
and to increase load
and is
The angle
changed
cy-
in the cir-
the PLS circuit
servo
In this way,
hydraulic
the steering
the pressure
in the pump
amount,
ure in the circuit. detect
pump
CF enters
steering
to the pump.
acts to and
235FO2033
4.
Steering When
cylinder
at end of stroke
the steering
stroke,
and
cylinder
the
reaches
operator
steering
wheel,
stopped
regardless
the end of its
continues
the flow
to
of oil to the
of the opening
turn
the
cylinder
is
of the steering
valve. There
is no flow
of oil, so the CF and
ures rise together P, and
at the
with
same
the pressure
time,
also rise, and spool If pressure
PC goes above
relief valve
(3), which
by spring
pressures
(I) is moved
(4), opens
LS press-
at pump
port
PB and
PC
to the right.
17.2 MPa (175 kg/cm2),
is being
pushed
and drains
to the right
the oil in chamber
C. Because ure
of this flow
on both
pressure
spool the
Spool of the
spool
than
pressure
and
PB. As
to the left to a position
inside
the
spool
at a position
where
is throttled,
loss when
in press-
“b” is created,
lower
(1) moves
oil flow
(1) remains
large
of oil, a difference of orifice
PC becomes
a result, where
sides
and
is 1 Q/min. portion
this
the oil is drained
“d”
prevents
the
if the circuit
235FO2034
is
relieved. If spool
(1) moves
closed through
orifice
pressure moved
again
portion
“d”.
to the
same,
right
Because
of oil
PC
and
and spool
by spring
of this
“d” is
The flow
so pressure
the
in the steering
maximum
flowing.
“b” stops,
PB become
pressure
5.
too far to the left, portion
and the oil stops
is
(2) to open
repeated
circuit
(I)
action,
the
is maintained
at a
of 17.2 MPa (175 kg/cm2).
Steering
valve at neutral,
work
equipment
con-
trol lever operated If the work pressure
equipment
24.5 MPa (20 ing
valve
same
is at neutral,
main control
the
valve
spool rises
flowing
A large difference
the
area
becomes tion,
the
smaller
the oil flow
only 1 Q/min flows
and
the
oper-
of pressure at port
amount
of
CF oil
“b” increases. right,
is created, and
“d” becomes opening and
is the (steering,
and the force
regardless
in pressure
to the
of portion of
condition
is started
at neutral),
orifice
to 2.0 the steer-
PA rises, the pressure
through
opening
so the
momentarily,
(1) is pushed
are operated,
changes
However,
engine
(1) is constant
PA. If pressure also
levers
port
250 kg/cm2).
as when
ating
control
PA of the pump
of
the
so spool
area
larger. portion
is balanced.
is automatically to the steering
of the
However, “d”
In this adjusted
again condiso that
valve. 235FO2035
10-91
6.
Steering,
work
equipment
operated
simulta-
neously 1)
When
load
on steering
circuit
is higher
load on work
equipment
The actuation
condition
is basically
3 “When
steering
as in Section (main control
valve
“e”
the same
of spool
(I)
pressure
until
as pump
it balances
as the pressure
equipment. pressure
63 A
1
is operated
A, and port EF is throttled
pressure
e
at neutral).
Port CF is at the same chamber
than
circuit.
In other
at the same
needed
words,
for the pump
port
by portion for the work
the
main
circuit
is sent to the steering
circuit.
To steering cylinder J
235FO2036
2)
When
load on steering
on work
equipment
circuit
is less than load
circuit
Circuit
CF
amount
of oil and oil pressure
circuit,
satisfies
but compared
pressure through
at port portion
the pressure area
becomes pressure port
(I)
the
and
needed
less of the
(1) increases
moves
to the at
oil flow
matches
the
words,
pressure
that
and
steering in the
circuit
by priority work
and “d” the
needs
the pressure
circuit
left,
portion so
the
the of oil
B rises.
balances
for
the
CF, when the flow
It
plied to the steering
for
for the steering
port
opening
smaller.
CF. In other
flow
with
“d” of spool
spool of
demand
EF is higher,
in chamber
As a result, the
the
of
and oil is supregard-
equipment
circuit. 235FO2037
1 O-92
SURGE PRESSURE ABSORBING
VALVE
B-B
A-A
235FO2038
1.
Cover
P.
From hydraulic
2.
Body
T.
To hydraulic
From hydraulic
3.
Spool
Xl.
4.
Valve
X3. From steering
5.
Shuttle
valve
6.
Shuttle
valve
plug
pump
tank control
valve
R.H.
valve
L.H.
valve
X4.
From hydraulic
YI.
From servo valve
control
1o-93
FUNCTION . If the control position and
the
swash
control plate
minimum pump there
lever
is moved
to neutral,
valve plate
continues is high
pressure).
pump to the
by the inertia, oil.
As
in the pump
valve
the
returning
discharge
pressure
This
the pump
but
from
angle
to
an operating
between
is closed,
is prevented
swash
from
the circuit
is installed
so the
a result,
circuit
(surge
to prevent
this
high pressure. .
In order
to obtain
charged ment
from
the necessary
the
or steering
detect
the
pump
highest
pressure
pendent
valves
(left,
valve),
and
of oil dis-
work
equip-
it is necessary
from
the three
right,
main
to send
this
to
inde-
control
valve,
information
to
of detecting
the
servo valve.
This valve highest
the
are operated,
steering the pump
amount
when
also
has the function
pressure.
OPERATION I.
Control
lever or steering
If we take of the
right
steering
control
valve
pressure
valve,
as PXI which
PXI,
sent to chamber
The following PXI
>
PX3
is the
>
highest
and
hydraulic
PX4,
shuttle
the pump
pressures valve,
pressure, valves
is
(3) and
discharge
press-
to port A.
forces
are acting
to right from
on spool
chamber
(1).
A:
+ 2.0 MPa (20 kg/cm*)
[2.0 MPa (20 kg/cm*) ure
size of the left control
B by two
(4). At the same time, ure is connected Pressure
operated
the comparative
of
the
pump
is the differential control
pressure
pressfor
the
valve.] Pressure
to left from
chamber
B:
PXI
i- 2.4 MPa (24 kg/cm2)
[2.4
MPa
draulic
(24
pressure
The pressure
kg/cm2)
is the
for spring
in chamber
converted
A.
hy-
1
(2)]
B is larger,
is at the left and closes the drain
so valve
(I)
port. TO
priority flow 6 divider valve
235FO2039
1o-94
2.
When
operation
of control
lever
or steering
is
stopped The moment steering
and the valve tia,
the
pump
mediately the
pump
a result,
momentarily, port
is closed. swash
continues
B, valve
swash
pressure
or
of iner-
return
im-
plate angle,
and
oil, so there
to the
is
circuit.
chamber
it exceeds
(1) is moved
prevents
not
discharge in
lever
the pump
because
does
to discharge
and when
leases the pressure cuit and
between
However, plate
in the pump the
of the control
the circuit
to the minimum
high pressure As
the operation
is stopped,
rises
A
the pressure right.
in
This
re-
in chamber
A to the drain
cir-
the generation
of surge
press-
ure.
divider valve
235FO2040
1o-95
STRUCTURE AND FUNCTION
HYDRAULIC
HYDRAULIC CONTROL VALVE
CONTROL VALVE
Serial No.: 11001 - 12022 L.H. VALVE (Left blade lift, Ripper, Blade side shift, Power tilt and Circle rotation) 12345
H - H, J - J
1-G
K-K,L-L F-F
A-A
C-C.D--D
B-B \
io 1. Blade lift spool 2. Ripper
(L.H.)
spool
3. Blade side shift spool 4. Power
tilt spool
5. Circle rotation
spool
6. Pilot relief valve 7. Shuttle
valve
8. Body 9. Pressure
compensating
10. Flow control
valve
P. From hydraulic T. To hydraulic E-E 235FO2041
1O-96 0
pump
tank
valve
STRUCTURE AND FUNCTION
R.H. VALVE (Right blade lift, Leaning, Articulate,
HYDRAULIC CONTROL VALVE
Drawbar and Service)
G-G
l--G
H-H,J-J,
K-K
F-F
9
8
A-A,B-B,C-C
D-D
E-E
J \
10 235FO2042
1. Drawbar 2. Articulate
shift spool spool
3. Leaning
spool
4. Service
spool
5. Blade lift spool
(R.H.)
6. Pilot relief valve 7. Shuttle
valve
8. Body 9. Pressure
compensating
10. Flow control
P. From hydraulic T. To hydraulic
valve
valve pump
tank
1o-97 0
STRUCTURE
AND FUNCTION
Serial No.: 12023 and up L.H. VALVE (Left blade lift, Ripper, Blade side shift, Power
A-A.
c-c.
B-B D-D
HYDRAULIC
CONTROL
VALVE
tilt and Circle rotation)
E-E
H-H
G-G
10-97-l 0
SWG00366
1. 2. 3. 4. 5. 6. 7.
Blade lift spool (L.H.) Ripper spool Blade side shift spool Power tilt spool Circle rotation spool Pressure compensating Shuttle valve
P: T:
From hydraulic pump To hydraulic tank
valve spool
STRUCTURE
AND
FUNCTION
R.H. VALVE (Right blade lift, Leaning,
I
HYDRAULIC
Articulate,
2
3
4
Drawbar
CONTROL
VALVE
shift and Service)
5
F-F A-A, c-c. E-E
E-0 D-D
7
H-H
G-G
SWG00369
1. 2. 3. 4. 5. 6. 7.
Drawbar shift spool Articulate spool Leaning spool Service spool Blade lift spool (R.H.) Pressure compensating Shuttle valve
P: T:
From hydraulic pump To hydraulic tank
valve spool
10-97-2 0
PRESSURE COMPENSATING MECHANISM HYDRAULIC CONTROL VALVE Serial
No.:
11001
The control
OF
- 12022
valve
acts to start,
accelerate,
decelerate,
and stop the actuators. A feature
which
metering
function
trol flow
of the valve
lector the
valve).
lever
disadvantage when
the
in
pressure
To overcome
this problem,
constant
gardless
of the load
sating
either
to obtain
mechanism
by the and
load
slow
side
press-
it is fast when
the
the
control
control
flow
The pressure
is used to perform
the
to keep the
of
a constant
pressure.
by
it has the
it is necessary
on
(throttle)
valve
is the same,
is low
is high.
difference
of the se-
by controlling
However,
stroke
load pressure pressure
stroke
selector
it is influenced
if the valve
load
the
is the the con-
is obtained
is controlled.
that
ure, so even
functions between
and the spool
feature
installed
the
of these
(the relationship
This
throttle
amount
is typical
re-
compen-
this function.
OPERATION 1.
Control
lever
at neutral
(immediately
after
en-
gine is started) The oil discharged ber B from spool
(2), and
than the force spool
When
pressure
right,
and
control
flow
the
equipment spool
.cham-
C through
(3), so pressure
C
b
B
A
2
orifice greater compen-
to the right. spool
A and chamber 0.6 MPa
the force
(2) moves
(6 kg/cm2),
of spring
to
B are closed, which
(3), is supplied
B.
hydraulic to
enters
compensation
C becomes
compensation
pressure
with
to chamber The
chamber
(2) moves
chamber
balances
pump
in chamber
of spring
sation
the
A of pressure
enters
“b”. The pressure
the
from
chamber
pressure
from
work
equipment
circuit
is closed
the
pump
because by work
does the
not work
equipment
(1).
235FO2043
1 O-98 0
2.
When 1)
control
If the
lever is operated.
control
equipment
lever
spool
from
the pump
ber
E of work
through
is
operated
(1) moves enters
chamber
equipment
chamber
and
work
to the left, the oil F from
spool
cham-
(I),
G, and is sent
passes
to the work
equipment. The
pressure
spring
in chamber
chamber
applied
to the right
sation
spool
moves
pressure to chamber
chamber
pressure
and is applied pensation
passes through
in
spool
overcomes
chamber
(2), so the pressure becomes the
back acting
of
the
pressure)
(3), pressure to the
in cham-
right.
in
and when pressure
+
the
compensation
on pressure
“b” com-
rises, the force greater,
sum
D (load
pushed
orifice
to the left end of pressure
the left direction
force
(2) A is
B, and the pressure
ber C rises. As the pressure
spring
spool
chamber
B rises.
The pump
it
compenin cham-
compensation circuit
to
“a”, and is
the pressure
to the left, pump
connected
orifice
end of pressure
(2). When
ber D rises,
G is transmitted
D through
spool
At this
in
force
235FO2044
(2) is
point,
compensation
of the
spool
(2) is as follows. = pump
Force in right direction Force In
in left
direction
force
of spring
this
condition,
spool
pressure
load
=
force
f
(3) pressure
(2) is balanced,,so
compensation
the pressure
on the
left and right sides is equal. Pump
pressure
spring
(3)
The differential
load
pressure
tion
H (chamber
trols
the flow
pressure
of spring
and
+
force
of
on both sides of por-
F, chamber
of oil for work
(1) is determined force
=
kept
(3) (approx.
G), which
con-
equipment
spool
constant
by the
0.6 MPa
(6 kg/
cm2)).
1o-99
2)
When
the
pressure
for
the
rises,
the
pressure
in
chamber
chamber
D through
ance
at pressure
lost.
Pressure
pushed “J”
at the
left and
bypass
ber B and flows
spool
end,
to chamber
(2)
control
so the
chamber
bal(2) is
spool
opens
to
and the
is
corner
oil from
the
A through
cham-
G of work
equip-
(1).
pressure
pump
“a”,
compensation
passes from
ment spool The
orifice
equipment G goes
compensation
to the
pump
work
in
pressure
chamber
G
rises,
and the pressure
so
the
in chamber
B also rise. The pressure
in chamber
ber C through pensation
spool
right,
and
pressure
again
becomes
ference force
the
goes
down,
sides
com-
back
compensation The
of flow
F, chamber
to
the
spool
(2)
pressure control
dif-
portion
G) is taken
as the
(3).
235FO2045
pressure
to chamber
to cham-
so pressure
balanced.
of spring
When
B passes
“b”,
(2) is pushed
on both
H (chamber
3)
orifice
in the
the pressure D through
ance
at pressure
lost.
Pressure
work
orifice
to
the
through
control
right
and
corner
“J”
G goes
“a”, and the bal-
compensation
spool
compensation
pushed
equipment
in chamber
spool the
flow
C \\\\
b
B
J Lv/”
(2) is (2)
is
of
oil
at the bypass
end
is reduced. Because
of this,
and chamber pensation and
becomes pressure trol
spool
pressure
in chamber
so pressure
(2) is pushed At
difference H
the force
In this way,
pressure
compensation
balanced.
portion
becomes
the
C goes down,
back to the left spool
the
point
the
on both sides of flow
con-
(chamber
F,
of spring
pressure
chamber
difference portion
AP
control
stant
[approx.
0.6 MPa (6 kg/cm2)],
S of the opening
of flow
constant,
Q which
constant
0 m (proportional)
10-100
S X JZF
on both
H is kept
control
regardless
G)
(3).
of flow
remains
(2) again where
sides
oil flow
B
com-
passes
con-
se if area portion through
of the load.
H is it
235FO2046
Serial No.: 12023 and up OPERATION 1. Control lever at neutral (immediately after engine is started) The oil discharged from the pump enters chamber B from chamber A. The pressure in chamber C becomes greater than the force of spring (3), so pressure compensation spool (2) moves to the right. When pressure compensation spool (2) moves to the right, chamber A and chamber B are closed, and control pressure, which balances with the force of spring (31, is supplied to chamber B. The hydraulic pressure form the pump does not flow to the work equipment because the work equipment circuit is closed by work equipment spool (I ).
The control valve acts to start, accelerate, decelerate, and stop actuators. A feature which is typical of these functions is the metering function (the relationship between the control flow of the valve and the spool stroke of the selector valve). This feature is obtained by controlling the throttle installed in the selector valve by the amount the lever is controlled. However, it has the disadvantage that it is the influenced by the load pressure, so even if the valve stroke is the same, it is fast when the load pressure is low and slow when the load pressure is high. To overcome this problem, it is necessary to keep the pressure difference on either side of the control (throttle) constant to obtain a constant control flow regardless of the load pressure. The pressure compensating mechanism is used to perform this function.
-
SWG00428
10-100-1 0
2.
When work equipment lever is operated 1) When work equipment spool (1) is moved up, the oil in chamber B passes through chamber C of work equipment spool (1) and is sent to the actuator. At the same time, the pressure in chamber C is transmitted from small hole a to spring chamber D and is applied to the right side of pressure compensation spool (2). When the pressure in chamber D rises, spool (2) moves to the left. Pump circuit chamber A is connected to chamber B, and the pressure in chamber B rises. The pressure in chamber B is applied to the left end of pressure compensation spool (2), so as the pressure in chamber B rises, and the force to the right increases. When it overcomes the combined force of the pressure in chamber D (load pressure) + force of spring (31, spool (2) moves to the right. When this happens, the force acting on pressure compensation spool (2) is as follows:
1o- 100-2 0
Pressure pushing to right = pump pressure The force pushing to the left = load pressure + force of spring (31, so pressure compensation spool (2) is kept in balance in this condition. The forces to the left and right are equal. Pump pressure = load pressure + force of spring (31, so the difference in pressure at the front and rear sides of the flow control portion of work equipment spool (I) (chamber B and chamber C) is determined by the force of spring (3) and is kept constant.
2)
When the pressure for the work equipment rises, the pressure in chamber C goes to chamber D through orifice “a”, and the balance at pressure compensation spool (2) is lost. Pressure compensation spool (2) is pushed to the left and opens control corner “E” at the bypass end, so the oil from the pump passes from chamber A through chamber B and flows to chamber C of work equipment spool (I). The pressure in chamber C rises, so the pump puressure and the pressure in chamber B also rise. The pressure in chamber B pushes back pressure compensation spool (2) to the right, and pressure compensation spool (2) again becomes balanced. The pressure difference on both sides of flow control portion (chamber B, chamber C) is taken as the force of spring (3).
3)
When the pressure in the work equipment goes down, the pressure in chamber C goes to chamber D through orifice ” a I’, and the balance at pressure compensation spool (2) is lost. Pressure compensation spool (2) is pushed to the right and flow of oil through control corner “E” at the bypass end is reduced. Because of this, pressure in chamber B and chamber C goes down, so pressure compensation spool (2) is pushed back to the left and pressure compensation spool (2) again becomes balanced. At the point where the pressure difference on both sides of flow control portion (chamber B, chamber C) becomes the force of spring (3). In this way, pressure differnce AP on both sides of flow control portion is kept constant, so if area S of the opening of flow control portion is constant, oil flow Q which passes through it remains constant regardless of the load. QOC (proprotional) S X liAP
SWG00429
1o- 100-3 0
BLADE LIFT SPEED ADJUSTMENT
MECHANISM
Serial No.: 11001 - 12022
OUTLINE . If there
is a great difference
on the left and right, the
left
adjust l
and
with
right
4.8 turns,
blade
speeds,
the adjustment
The adjustment
bolt
in the blade
or if it is desired
it is possible
speed
to
bolt.
has an adjustment
and if the adjustment
the cylinder
lift speed to reduce
will become
bolt
range
of
is loosened,
slower.
FUNCTION l
When
adjustment
spring
(3) is reduced,
bolt (1) is loosened, so the force
the force
of
in the left direc-
2
3
1
tion is also reduced. .
In this both
l
condition, sides
control
chamber
G) is reduced
trol spool
(2).
Therefore, trol On
oil flow
portion
der speed l
the differential
of flow
the
screwed the blade
Q passing
becomes
lift cylinder
Q CC (proportional) (S = Area of opening
through
pressure oil flow
and the blade
F, concon-
lift cylin-
slower.
hand,
in, oil flow
on
AP
H (chamber
to balance
H is reduced,
other
pressure
portion
if
adjustment
Q increases, becomes
(1)
is
and the speed
bolt
of
faster.
S X p at portion
H)
235FO2047
1o- 100-4 0
Serial
No.: 12023 and up
Outline . If there is a great difference in the blade lift speed on the left and right, or if it is desired to reduce the left and right blade speeds, it is possible to adjust with adjustment bolt .
(I). If adjustment bolt (I) is loosened, der speed will become slower.
the cylin-
Operation . When adjustment bolt (I) is loosened, the force of spring (3) is reduced, so the force in the left direction is also reduced. In this condition, the differential pressure AP on the front and rear sides of flow control portion F (chamber B and chamber C) is reduced to balance pressure compensation spool (2). Therefore, the oil flow passing through oil flow control portion F is reduced, and the blade lift cylinder speed becomes slower. On the other hand, if adjustment bolt (I) is screwed in, oil flow Q increases, and the speed of the blade lift cylinder becomes faster. QOC (proprotional) S X m (S = Area of opening at portion F)
SWG00431
PILOT CHECK (For
Blade
lift
VALVE
R.H.)
1.
Pilot valve
2.
Check
valve
F23501093
F23501092
OPERATION When
the
control
blade,
pressure
blade
lift
throttle
cylinder.
and
check
valve
(2),
head
pressure
This
pushes
valve
cylinder
and
When
the
on the
it pushes
in chamber
C suddenly at the bottom
this
valve,
the check
cording and
prevent
ends.
this,
a damper,
This
a throttle
so even
the check
The
escapes
blade
hold lift
(21, the oil
to chamber
A, and
drops. is no throttle
will always cause
is installed
if the pressure
at the pilot
open and close ac-
in the pressure will
valve
a pilot
C at the blade
end of the check
the
through opens
in chamber tank.
head
if there
valve
to the changes
head
drops,
happens,
lower
end of the
passes (1). This
oil the
open
the pressure When
valve
to
to
at the bottom
pressure
pilot
returns
is acting
cylinder.
is operated
is generated
blade
at the bottom chattering.
at E which
To
E
acts as
at the bottom
end
valve will not close immediately.
I 1o-1 02
F23501094
PILOT CHECK VALVE (For Articulate,
Leaning
and
Drawbar)
,5
1. 2. 3. 4. 5. 6.
Check valve Piston Body Plug Plug Check valve
Al _
A2 -
F23BH1115 F23BH1116
OPERATION When the control valve is operated, the oil from the pump enters port A,, opens check valve (61, and flows into port B,. When a pressure is generated, the oil from orifice E pushes up piston (2) and opens check valve (1). so the oil connecting port B, and port A, flows into the drain port. Hunting occurs because check valve (1) opens and closes in accordance with the fluctuations in pressure at the bottom side and head side, but because of orifice E, a damper effect is provided so that check valve (1) will not close immediately even if the pressure at port A, goes down.
F23BH1117
10-103
PILOT CHECK VALVE
(WITH
SAFETY
VALVE)
(For Blade lift L.H.)
1.
Check valve
2.
Plug
3.
Body
4.
Piston
5.
Relief valve
.-. ----.-. R '-1
F23501098
I-
A2
The check valve with safety drift
of the
cylinder
from abnormal When
pressure caused
hydraulic
the
by external
stopper
is shifted
valve
installed
(left) acts to prevent
F23501099
position
to the side, the drawbar
and lifter come into contact.
safety
cylinder
force.
the blade lift is raised to the maximum
and the drawbar with
valve prevents
and also protects
L
Al
The check valve
to the blade
damage
lift cylinder
to the work equipment
caused by this contact. OPERATION When
the lever is operated
to retract
from the pump enters chamber valve
(1).
flows
to the chamber
push
the
bottom
passes
cylinder
end
chamber When
It then
through
chamber
BI
back
oil and
at the head of the cylinder
piston.
flows
the cylinder,
AI and pushes check
The
oil at
through
the
chamber
to
cylinder Bz and
AZ and returns to the tank.
the
lever
the oil from through
is operated
the pump
chamber
the pressure
to extend
enters chamber
B2 to the cylinder
in chambers
the cylinder, A2 and flows
bottom
end. As
A2 and B2 rises, piston
(4)
is pushed. This pushes open check valve (I ), and the oil at
the
through
cylinder
the throttle
from chamber If there
head
an abnormal
from
chamber
BI
AI hack to the tank.
is any shock
operations,
flows
of check valve (1). It then flows to the work
and the pressure pressure
of 280
equipment
in chamber kg/cm2
during
BI rises to
or more,
relief
valve (5) is pushed open and the oil flows to chamber B2. This raises the work shock.
10-104
equipment
and relieves
the 235F247
(For Ripper and Power tilt)
1.
Check
2.
Piston
3.
Body
valve
4.
Check
5.
Relief valve
valve
-5
The check
valve
drift
of
the
from
abnormal
with
cylinder
safety and
pressure
valve also
prevents
protects
caused
hydraulic
the
by external
cylinder
force.
OPERATION When
the lever
from
the pump
(2) and check
is.operated enters
valve
ber B, and flows of
the
back
cylinder. through
returns When
the
the
pushes
to the cylinder shock
kg/cm2
passes
oil at the
chamber
the lever is operated pump
sure in chamber
If
(4). It then
to the chamber The
the cylinder,
A, and pushes through
cham-
at the bottom cylinder
head
B, and chamber
oil
piston end flows A,’ and
to the tank.
oil from This
to extend
chamber
A,
open
in chamber
and oil flows
check valve
A,.
valve (I),
chamber
abnormal
As the (I)
the pres-
is pushed.
and the oil flows B,.
pressure
B,, it pushes
to chamber
the cylinder,
chamber
rises, check
head from
causes
to retract
enters
open
B, to relieve
of
over
relief ,valve
280 (5)
the shock.
10-105 0
CIRCLE
ROTATION
MOTOR
Serial No.: 11001 - 12050 ME300-FTS
F23501104
1. Cover
2. Bearing 3. Thrust plate 4. Slipper
retaining
ring
5. Slipper 6. Spring 7. Piston 8. Bearing 9. Thrust 10. Timing 1 1. Cylinder 12. Shaft 13. Casing ircle rotation
/
Circle rotatiol;
lo-106 0
motor
gear
F23501071-1
retainer plate block
plate
4
When
high
passes
pressure
through
oil flows
timing
plate
(1 1). This high pressure movement slipper force
(5) to push is generated
rotating which
of the piston
force forms
in from (10)
oil acts on piston
thrust
retainer
in cylinder
is transmitted
plate block
to
R, it
cylinder
(7). and the
in the axial direction
one unit with cylinder
causes
(9). Rotating (1 11, and
output
shaft
the (I 2),
block (1 1). When
the output shaft rotates
of the arrow
0
interconnected
main port
and enters
this happens,
oil after
F23501105
in the direction
, and even at low speed, performs operation
actuating
passes
smoothly. through
The low pressure timing
plate
(IO)
and flows out from main port L. If the inlet and outlet ports are reversed, of rotation
the direction
is also reversed.
1o-1 07
Serial No.: 12051 and up ME150203AAAA
1. 2. 3. 4. 5. 6. 7. 8. 9. IO.
Housing Key Coupling shaft Drive shaft Wear plate Rotor set Manifold Commutator ring Commutator End cover
lo-108 0
BLADE ACCUMULATOR
SYSTEM
235FO2048
i ----
Iii
3
1.
Solenoid
valve
(for blade float)
2.
Solenoid
valve
(for accumulator)
3.
Pilot check valve
4.
Accumulator
5.
Blade lift cylinder
6.
Blade lift control
valve
235FO2049
10-109 0
ACCUMULATOR
1. 2. 3. 4. 5. 6.
Cap Shell Bladder Valve Plug Slow return valve
A: B: C:
Nitrogen gas Pressure oil (from blade cylinder) From solenoid valve
0
t
C
SWG00004
FUNCTION When oil pressure is applied to the blade cylinder, the pressure oil flows to the accumulator through the solenoid valve and pushes valve (6). This pushes valve (4), and the oil flows into shell (2). Thereby, bladder (3) is compressed. Consequently, the shock imposed on the blade cylinder is reduced by the compressible amount of the bladder. When the oil pressure in the blade cylinder drops, the bladder expands by the gas pressure in bladder (31, and the oil in
10-110 0
shell (2) sends to the blade cylinder until the oil pressure in the shell balances to that in blade cylinder circuit. At this time, valve (5) closes throttling the return oil. This prevents the oil in shell (2) from flowing out abruptly and prevents the bladder from striking against the inside of the shell. The flow of oil in the accumulator hydraulic circuit is repeated smoothly to reduce the shock imposed on the blade.
BLADE FLOAT SYSTEM
235FO2050
OUTLINE l
When
the blade
blade float
(1) is actuated, blade l
is at the N position,
(6) is turned
ON, solenoid
and the bottom
lift cylinder
to the
circuit.
This sets the blade in a floating blade
lift lever
float
switch
is operated
switch
condition.
2
to the RAISE or LOWER posi-
(5) turns
blade
returns
condition,
and this condition
float
to the normal
lift lever
switch
(6), and
RAISE or LOWER
is maintained.
is returned
the blade is placed
in a floating
If the
blade
switch
blade
raised,
float
of
drain
(6) is ON, and the blade
the blade
If the blade
and valve
and head ends
(3) are connected
When tions,
t
lift lever
switch
to the N position, condition.
is turned
the blade will suddenly
ON with
the
drop. 235FO2051
1.
Blade float solenoid
2.
Pilot check valve
3.
Blade lift cylinder
4.
Blade lift control
5.
Switch
6.
Blade float switch
valve
valve
10-111 0
STRUCTURE
AND
FUNCTION
DRAWBAR
AND
DRAWBAR AND LIFTER Serial No.: 11001 - 12050
==v
i
==- -==
-_==
__--
235CD02018
OUTLINE The
drawbar
is
an
important
which
supports
the circle
worn,
use shim
(5) to adjust
so that there clearance (II),
adjust
bolt (9).
10-112 0
and blade.
is no excessive
at the with
contact shims
piece
of
If ball joint
the clearance play. When
portions (7) and
equipment at the joint
adjusting
of guides (IO),
(6) is
and
the
(8) and
adjustment
1.
Circle
2.
Drawbar
3.
Blade lift cylinder
4.
Drawbar
5.
Shim
6.
Ball joint
side shift cylinder
LIFTER
DRAWBAR
FUNCTION
AND
STRUCTURE
LIFTER
D-D
i2 ii c-c
B-B
A-A
AND
114
G-G
F-F
235CD02019
There ing
the
the
by
frame.
They
insertion
from
revolution.
pin stopping
the blade to make
holes
the operator’s
altogether
times, These
(a) get used much
for the
ance blade.)
the guide shims force
the
welded
clearance
between
to the frame
(15). Pin (20) combined prevents
bracket
12. Bolt 14. Lifter
more than other
the
can be adjusted
with
up and down
bracket
(Upper)
bracket
(Lower)
15. Shim
holes and a
bracket
bolt
11. Guide 13. Yoke
be(18) is used in it to make the clearance (This clearthe pin and the hole at a minimum. of the the up and down movement amplifies Also,
9. Adjustment 10. Shim
At other
bushing tween
7. Shim 8. Guide
Holes (b) and (c) are used for
a bank cut to left or right.
holes (a) are used.
in-
main
the
the guide
by revolving
a pin (17) controlled are two
for mov-
(16) are to
is welded
can be revolved
by extracting seat. There
which
guide
in the lifter (14) and
Brackets
device.
blade
stalled
installed
cylinders
are two
and
16. Lifter 17. Pin
18. Bushing 19. Bolt 20. Pin
with
bolt (19) tightening slippage.
10-113 0
STRUCTURE
AND
DRAWBAR
FUNCTION
Serial No.: 12051 and up
OUTLINE is an The drawbar ment which supports joint (6) is worn, use ance at the joint so
piece of equipimportant the circle and blade. If ball shim (5) to adjust the clearthat there is no excessive
play. When adjusting the clearance at the contact portions of guides (20) and (17), adjust with shims bolt (15). (16) and (191, and adjustment
10-113-l 0
1. 2. 3. 4. 5. 6.
Circle Drawbar Blade lift cylinder Drawbar side shift cylinder Shim Ball joint
AND
LIFTER
STRUCTURE AND FUNCTION
DRAWBAR AND LIFTER
B-B
I8
5
17
There are two cylinders installed in the lifter for moving the blade device. Brackets (7) and (9) are installed by the guide which is welded to the main frame. They can be revolved by revolving the guide by extracting a pin (13) controlled from the operator’s seat. There are two insertion holes altogether for the pin stopping revolution. Holes b and c are used for the blade to make a bank cut to left or right. At other times, holes a are used. These a get use much more than other holes and bushing (14) is used in it to make the clearance between the pin and the hole at a minimum. (This clearance amplifies the up and down movement of the blade.) Also, the clearance between the bracket and the guide welded to the frame can be adjusted with shims (8). Pin (12) combined with bolt (11) tightening force prevents bracket up and down slippage.
G-G
F-F
” SWG00376
7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20.
Lifter bracket (Upper) Shim Lifter bracket (Lower) Yoke Bolt Pin Pin Bushing Adjustment bolt Shim Guide Bolt Shim Guide
10-113-Z 0
STRUCTURE
AND
BLADE
FUNCTION
BLADE Serial No.: 11001 - 12050
\
\
6
V
1 Y
235CO02020
FUNCTION
1. Bracket
Side edge (5) installed
to the blade
2. Blade shift cylinder
it can
by turning
be used
moving
it to the other
A power angle tween
tilt
device
is designed
so that
it upside-down
and
is installed
the
cutting
can be made freely
25” and 84” using a single acts as a bushing
to adjust
be-
parts when
the blade to the side. If the clearance
from
sliding
parts
accuracy
cannot
be obtained,
10-l 13-3 0
is too
large replace
and
the
finishing
the guide.
5. End bit 6. Bolt 7. Nut
lever.
for the sliding
3. Support 4. Blade
(left or right) side.
of the blade. Adjustment
The guide shifting
twice
the
8. Cutting 9. Adjuster 10. Shaft
edge
BLADE
STRUCTURE AND FUNCTION
Serial
No.: 12051 and up
FUNCTION Side edge (5) installed to the blade is designed so that it can used twice by turning it upsidedown and moving it to the other (left or right) side. A power tilt device is installed to adjust the cutting angle of the blade. Adjustment can be made freely between 25” and 84” using a single lever. The guide acts as a bushing for the sliding parts when shifting the blade to the side. If the clearance from the sliding parts is too large and the finishing accuracy cannot be obtained, replace the guide.
1. 2. 3. 4. 5. 6. 7. 8. 9. 10.
Bracket Blade shift cylinder support Blade Side edge Bolt Nut Cutting edge Adjuster Shaft
10-113-4 0
LIFTER BRACKET CONTROL PIPING
235CD02021
Detail A F23501114
The lifter bracket
is fixed
bank cutting
position,
compressed
air to
removed
10-114
by pin (3). When setting in the control lever. This uses
2.
Bank-lock
be
3.
Pin
operate push
and the bracket
piston
(4). The
pin
can then be rotated.
can
1.
Air tube
4.
Piston
5.
Spring
6.
Bushing
valve
CIRCLE ROTATION Serial
GEAR,
No.: 11001 - 12050
6
7
8
Circle rotation
motor
li
16
13
14
1‘3 F23501400
1. Cover
Outline The
circle
rotation
connected When
to worm
the
plate
force
control
is driven
gear shaft
control
(15) are
motive
gear valve
separated is not
to pinion
operated,
disc
by spring
a brake.
gear
has
from
Pinion an
the
abnormal blade,
disc
(9)
motor
disc
(14)
and
oil, and
the
5. Shaft
gear
(9). If the
6. Case
(14)
and
7. Worm
(13) and
a clutch
rotating
force
(3) slips
to
plate act as
mechanism, is
prevent
transmitted breakage
justed
clutch
4. Plate
wheel
8. Plug 9. Pinion
gear
10. Shim 11. Nut 12. Bolt
of the blade. The
2. Spring 3. Disc
is operated,
together
if
oil
(17).
(15) are pressed and
an
by pressurized
is transmitted
valve
by
pressure
by the thickness
of this
clutch
of shim (IO).
mechanism
is ad-
13. Spring 14. Disc 15. Plate 16. Drain plug 17. Worm
gear shaft
10-115 0
Serial No.: 12051 and up
Outline The circle rotation gear is driven by an oil motor connected to worm gear shaft (13). Pinion gear shaft (2) has a clutch mechanism, and if an abnormal rotating force is transmitted from the blade, disc (6) slips to prevent breakage of the blade. The clutch pressure of this clutch mechanism is adjusted by the thickness of shim (IO).
lo-116 0
1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14.
Flowting seal Shaft Case Worm wheel Plate Disc Plug Spring Cover Shim Pinion gear Drain plug Worm gear shaft Oil motor
REAR MOUNT
RIPPER I
III
-7
Section A-A
Section B-B
Section E-E
Section C-C
Ripper
lifting
trolled
with
height ripper
cut into the digging Two
work
kinds
and digging cylinder
ground
heavy weight,
Section D-D
under
depth
(1). Since the
can be conthe
load of the ripper’s
the ripper easily performs which
of points
point for heavy-duty
cannot
heavy-duty
be done by the scarifier.
are selectively work
point tips
used:
A short
Section G-G
Section F-F F23501118
1
Ripper cylinder
2.
Pin
3.
Bracket
4.
Shank pin
5.
Shank
6.
Point
and a long point for ordi-
nary work.
10-l 17 0
CONTROL LINKAGE
HYDRAULIC
1234
7
9
8
10
235FO2052
l
wheel
Steering
panel tilting
and instrument
mech-
anism: Rotate suitable
angle can be adjusted
Console
box tilting
Depress
pedal
the console In this way,
steplessly
wheel
position
lever
20”. pin, and
for the operator.
box
lever
tilt lever
8. Blade shift lever
in five stages.
and console
7. Power
can
9. Ripper
lever
10. Blade lift L.H. lever 11. Tilt lever 12. Pedal
lo-118 0
lever shift lever
5. Drawbar
6. Circle rotation the dowel
box can be adjusted
the steering
lever
3. Leaning 4. Articulate
mechanism:
(12) to remove
be set to the optimum
to a
the lever.
then tighten
position,
The tilting l
the lock, move
(11) to loosen
tilt lever
1. Blade lift R.H. lever 2. Service
A-A
B-B
F-F
E-E
G-G H-H
235FO2053
10-119 0
023502
Serial No.: 11001 – 12502
10-120 (6)
023502
Serial No.: 12503 and up
1. 2. 3. 4. 5.
Main frame Articulate cylinder Center pin Pin Grease fitting
10-120-1 (6)
STRUCTURE AND FUNCTION
AIR CONDITIONER
023502
Serial No.: 11001 – 11013
10-120-2 (6)
STRUCTURE AND FUNCTION
AIR CONDITIONER
023502
Serial No.: 11014 and up
10-120-3 (6)
STRUCTURE AND FUNCTION
AIR CONDITIONER
MOUNT-ON CONDENSER OPERATOR CAB SPECIFICATION
023502
AIR CONDITIONER PIPING Serial No.: 12503 and up
SYSTEM DIAGRAM 1. 2. 3. 4. 5. 6. 7.
10-120-4 (6)
Air conditioner unit Receiver tank Compressor Condenser Hot water heater Evaporator Blower unit
ELECTRICAL WIRING DIAGRAM
023502
(1/3)
1. 2. 3. 4. 5.
Head lamp Front combination lamp Front working lamp (front of blade) Front working lamp (rear of blade) Parking brake valve
6. 7. 8. 9. 10.
Air horn valve Battery Radiator coolant level sensor Battery relay Transmission solenoid valve pick-up
10-121 (6)
023502
(2/3)
1. 2. 3. 4. 5. 6. 7. 8. 9.
Heater relay Fuel gauge pick-up Ground connection of engine Final drive oil temperature sensor Rear combination lamp Rear working lamp Back-up lamp Back-up alarm Differential lock valve
10-122 (6)
10. 11. 12. 13. 14. 15. 16. 17. 18.
Air pressure sensor Hydraulic oil temperature sensor Hydraulic oil level sensor Air gauge sensor Engine oil level sensor Engine oil pressure sensor Speed sensor Water temperature gauge pick-up Coolant level sensor (if equipped)
(3/3)
023502
Serial No.: 11001 – 12502
10-123 (6)
(3/3)
023502
Serial No.: 12503 and up
1. 2. 3. 4. 5. 6. 7. 8.
Cluster gauge and pilot lamp Turn signal lamp switch Monitor panel Fuse box 1 Fuse box 2 Stop lamp switch Hazard relay Flasher relay
10-123-1 (6)
9. 10. 11. 12. 13. 14. 15.
Horn relay Emergency steering relay Engine stop motor relay Emergency steering controller Warning buzzer (for emergency steering) Engine oil pressure relay Warning buzzer
Serial No.: 12013 - 12015, 12019 and up
1. 2. 3. 4. 5. 6. 7. 8. 9. 10.
R switch F switch Caution lamp Potentiometer (for shift lever) Alarm buzzer Relay (for alarm buzzer) Transmission controller Engine speed sensor Potentiometer (for inching) Transmission oil temperature sensor (transmission outlet port) 11. Transmission solenoid 12. Speed sensor
lo-124 0
*
This shows components that have been added because of the installation of the transmission controller.
MONITOR
PANEL, CLUSTER GAUGE AND PILOT LAMP
Serial No.: 11001 - 11030
27
235CD0202B
23
1. Coolant
temperature
2. Caution
monitor
15. Front wiper
gauge
16. Service
group
17. Front wiper
3. Speedometer 4. Accumulator, 5. Service
blade float select switch control
switch
7. Differential
control
indicator
8. Accumulator 10. Parking 11. Warning
18. Rear wiper
indicator indicator
lamp lamp
blake indicator lamp
lamp
lamp
switch
(Lower)
gauge
20. Door wiper
switch
21. Emergency
steering
select switch
22. Lift arm lock indicator
lamp
23. Bank cut switch 24. Cab head lamp switch 25. Rear working
lamp switch
12. Head lamp switch
26. Front working
13. Fuel gauge
27. Starting
switch
14. Dimmer
28. Parking
brake switch
switch
(Upper)
switch
19. Air pressure
meter
6. Differential
9. Blade float
switch
meter
lamp switch
10-125 0
Serial No.: 11031 and up
,22
‘23 27
26
1. Coolant temperature gauge 2. Caution monitor group 3. Speedometer blade float select switch 4. Accumulator, 5. Service meter 6. Differential control switch 7. Differential control indicator lamp 8. Accumulator indicator lamp 9. Blade float indicator lamp 10. Parking brake indicator lamp 11. Warning lamp 12. Head lamp switch 13. Fuel gauge 14. Dimmer switch 15. Front wiper switch (Upper)
10-126 0
25
24
SDG00009
16. 17. 18. 19. 20. 21. 22. 23. 24. 25. 26. 27. 28. 29.
Service meter Front wiper switch (Lower) Rear wiper switch Air pressure gauge Door wiper switch Emergency steering select switch Lift arm lock indicator lamp Bank cut switch Cab head lamp switch Rear working lamp switch Front working lamp switch (rear of blade) Front working lamp switch (front of blade) Starting switch Hazard switch
(1/2)
023502
Serial No.: 12013 – 12015, 12019 – 12098
10-134 4
(2/2)
023502
Serial No.: 12013 – 12015, 12019 – 12098
10-135 4
(1/2)
023502
Serial No.: 12099 – 12502
10-136 (6)
(2/2)
023502
Serial No.: 12099 – 12502
10-136-1 (6)
STRUCTURE
TRANSMISSION
AND FUNCTION
ELECTRICAL
ELECTRICAL
CIRCUIT
DIAGRAM
CIRCUIT
Serial No.: 11001 - 11030
CN-TO1
Rotary
Diode
______
I Transmission
;
solenoid
valve
SWG00437
10-137 0
STRUCTURE
AND
FUNCTION
Serial No.: 11031 - 12012,
ELECTRICAL
CIRCUIT
DIAGRAM
12016 - 12018
CN-RPB Relay (parking brake1
iJJ
Diode
SWG00438
lo-138 0
STRUCTURE
AND
FUNCTION
ELECTRICAL
FR
detect
Caution
CIRCUIT
buzzer
DIAGRAM
Cautlan
buzzer
CN-RDI
I
yifferential ock relay
lamp used)
Shift
potentic
meter
I
Shift
Potentlo
meter
2
Inching CN_TM,,
#-
Potentio mete ,.___________
SWG00440
023502
Serial No.: 12099 – 12502
10-141-2 (6)
STRUCTURE AND FUNCTION
ELECTRICAL CIRCUIT DIAGRAM
023502
Serial No.: 12001 – 12502
10-142-1 (6)
STRUCTURE AND FUNCTION
ELECTRICAL CIRCUIT DIAGRAM
EELCTRICAL CIRCUIT DIAGRAM FOR AIR CONDITIONER (Refrigerant for R-12)
023502
Serial No.: 11001 – 11013
10-143 (6)
(Refrigerant for R134a)
023502
Serial No.: 11014 – 12502
10-144 (6)
STRUCTURE AND FUNCTION
ELECTRICAL CIRCUIT DIAGRAM
r-k CN-A6
CN-A3
If--!
I
~
Damper
Air conditioner unit
ComPressor
“4 I”
I
CN-27
r
Pressure
II
r
r
From Lisnt
Fuse
switch
box
CN-
SWG00443
10-145 0
ELECTRICAL CIRCUIT DIAGRAM (1/6)
023502
Serial No.: 12503 and up
10-146-1 (6)
ELECTRICAL CIRCUIT DIAGRAM (2/6)
023502
Serial No.: 12503 and up
10-146-3 (6)
ELECTRICAL CIRCUIT DIAGRAM (3/6)
023502
Serial No.: 12503 and up
10-146-5 (6)
ELECTRICAL CIRCUIT DIAGRAM (4/6)
023502
(Transmission) Serial No.: 12503 and up
10-146-7 (6)
ELECTRICAL CIRCUIT DIAGRAM (5/6)
023502
(Steel cab) Serial No.: 12503 and up
10-146-9 (6)
ELECTRICAL CIRCUIT DIAGRAM (6/6)
023502
(Air conditioner) Serial No.: 12503 and up
10-146-11 (6)
STRUCTURE AND FUNCTION
ELECTRONIC VEHICLE MONITORING
ELECTRONIC VEHICLE MONITORING
SYSTEM (EVMS)
SYSTEM (EVMS)
Serial No.: 11001 - 12000
-4A
2A
5A
ii
1.
2.
IA.
Coolant
IB.
Fuel level
2A. Hydraulic
starting
items)
235COO2032
3B. Engine
5F. Differential warning
items)
oil temperature
oil pressure
3C. Hydraulic 3D. Coolant
tank oil level temperature
4A. Coolant
level
4B. Battery
charge
4C. Hydraulic
6. Turn signal
lock
pilot lamp
7. Head lamp (High beam) 8. Speedometer 9. Service
meter
10. Service
meter
11. Warning
3E. Air pressure (Warning
steering
5C. Parking 5E. Accumulator
level
(Emergency
monitor
5D. Float
tank oil level
3A. Differential
Caution
5F
5B. Emergency
oil level
2C. Coolant
4.
5E
5A. Preheater
temperature
Check (Check before
Caution
5D
5. Pilot indicator
Gauge
2B. Engine 3.
5c
indicator
lamp
items)
tank oil temperature
10-147 0
ELECTRONIC VEHICLE MONITORING
STRUCTURE AND FUNCTION
SYSTEM (EVMS)
Serial No.: 12001 and up
3E 30 3C 38
3A
6
7
6
4A
2A
48 9 IO 4c
‘5B
1.
2.
3.
4.
Gauge IA. Coolant temperature IB. Fuel level Check (Check before starting items) 2A. Hydraulic tank oil level 2B. Engine oil level 2C. Coolant level Caution (Emergency warning items) 3A. Differential oil temperature 3B. Engine oil pressure 3C. Hydraulic tank oil level 3D. Coolant temperature 3E. Air pressure Caution (Warning items) 4A. Coolant level 4B. Battery charge 4C. Hydraulic tank oil temperature
10-148 0
5. Pilot indicator 5A. Preheater monitor 5B. Emergency steering 5C. Parking 5D. Float 5E. Accumulator 5F. Differential lock 6. Turn signal pilot lamp 7. Head lamp (High beam) 8. Speedometer 9. Service meter indicator 10. Service meter 11. Warning lamp
STRUCTURE AND FUNCTION
INDICATION
ELECTRONIC VEHICLE MONITORING
ON MONITOR
SYSTEM (EVMS)
PANEL
Serial No.: 11001 - 12000 Category
Symbol
Indication
Hydraulic
Engine
tank oil level
oil level
low mark
Below
low mark
level
Below
low mark
Coolant
level
Below
low mark
charge
When charging defective
Displays when starting switch is turned to ON with engine stopped. - Display goes out when normal + Display flashes when abnormal
is
Hydraulic tank oil temperature
At specified temperature or above
Differential temperature
At specified temperature or above
Engine
Coolant
oil
oil level
Below
low mark
temperature
Above
105°C
Air pressure
Below specified pressure
Speedometer
0-
High beam
When
operated
When
operated
Turn signals
Service
meter
Service
meter
(right,
Displays when engine is running . Display goes out when normal . Display flashes when abnormal lamps flash at same time
and
Below specified pressure
oil pressure
Hydraulic
0
Below
Description
range
Coolant
Battery
--0 4D
Indication
item
left)
indicator
100 km/h
Displays when engine is running . Display goes out when normal . Display flashes when abnormel; buzzer and lamp actuated
Digital
display
Displays when starting switch Lights up when operated
0 - 99999/h displayed
Actuated Advances
When
Flashes when
operated
is turned
ON;
when engine oil pressure is normal 1 for every hour of operation
service
meter
is operating
10-149 0
STRUCTURE
Category
AND
Symbol
FUNCTION
ELECTRONIC
Indication
item
PREHEAT
Emergency
steering
Indication
temperature
MONITORING
SYSTEM
preheating
Displays when starting switch lights up during preheating
When
operated
Lights up when operated
;reen
IEVMS)
Description
range
When
Red
Coolant
VEHICLE
emergency
is turned
steering
115OC 102.3-C 97OC 90°C One lamp lights up to indicate
is
level
80°C White
67’C
FULL
Fuel level
All lamps
Red
EMPTY L
10-150 0
light up below
indicated
level
ON;
STRUCTURE
Serial Category
AND
FUNCTION
ELECTRONIC
VEHICLE
MONITORING
SYSTEM
(EVMS)
No.: 12001 and up
Indication
Symbol
Hydraulic
Engine
al
tank
item
Indication
oil level
Below
oil level
low
Below
low
range
Description
mark Displays when starting switch is turned to ON with engine stopped. . Display goes out when normal Display flashes when abnormal
mark
Coolant
level
Below
low mark
1 Coolant
level
Below
low
s0c000!8
e,.,,
Battery SAP00522
mark
When charging defective
charge
is
/
Hydraulic tank temperature
Differential temperature
Engine
@I~
Coolant
and
At specified temperature or above
oil
A specified temperature or above
oil
Below specified pressure
oil pressure
Hydraulic
Displays when engine is running. Display goes out when normal Display flashes when abnormal lamps flash at same time.
oil level
temperature
Below
low
mark
Above
105°C
Displays when engine is running. . Display goes out when normal . Display flashes when abnormal; buzzer and lamp actuated.
SDP00957
Below specified pressure
Air pressure
0 - 100 km/h
---
High
When
beam
Digital
display
operated Displays when starting switch Lights up when operated.
4
D
Turn
signals
(right,
left)
When
is turned
ON;
operated
lDGOOOl4
Service
meter
Service
meter
0 - 99999/h displayed
Actuated when engine oil pressure is normal Advances 1 for every hour of operation
When
Flashes
SKD00631
indicator
operated
when
service
meter
is operating
0 SKD00632
10-151 0
STRUCTURE
Category
AND
Symbol
FUNCTION
Indication
ELECTRONIC
item
Indication
VEHICLE
MONITORING
range
SYSTEM
Description
PREHEAT
When
preheating
Displays when starting switch lights up during preheating.
Emergency steering
When
operated
Lights up when operated
Red
(EVMS)
emergency
is turned
steering
is
115’c
El lOZf3'C
al
97-c
Coolant temperature
Green
90"c
One lamp lights
up to indicate
level
80"c
SDP00957
White
67°C
SWG00461
FULL
Fuel level
;reer
SAD00712
led
All lamps
EMPTY SWG00462
10-152 0
light
up below
indicated
level
ON;
STRUCTURE
TRANSMISSION
AND
TRANSMISSION
FUNCTION
CONTROL
CONTROLLER
1. 2.
cN3
CN4
CNl
Display window Connector
cN6
cN2
SWCOO388
2 Outline The transmission controller controls the system, and has a built-in computer. When the operator operates the shift lever, this is transmitted to the controller, and the controller observes the condition of the machine and shifts to the specified speed range. In this way, it is possible to prevent excessive load on the transmission and engine caused by any failure or mistaken operation by the operator. Protective functions of transmission 1) Observing disconriections or short circuits It judges if there is any abnormality in the transmission switch signals and uses a double system to prevent damage to the transmission clutches. If there is any abnormality, it carries out control to prevent the clutch for that speed range from being meshed.
10-154 0
SYSTEM
2)
3)
Prevention of overrun of engine or transmission When the transmission is shifted down, it judges if there is overrun of the engine or transmission, and does not shift down until the travel speed will not cause any overrun. If the machine is accelerated with the clutch still partially engaged (acceleration caused by the weight of the machine when traveling down hill), it shifts up at above the travel speed that is dangerous for the speed range for the lever position. Observing excessive inching load It calculates the temperature of the clutch and plate from the length of time that the clutch is partially engaged, and warns of overheating of the clutch.
STRUCTURE
AND
FUNCTION
Shift lever position
TRANSMISSION
and transmission
controller
Parking
lamp
Parking
brake
Backup
buzzer
Starting
motor
Differential
R
1
2
SYSTEM
output
Controller F
CONTROL
3
output
(0: output)
/ 4 / L / H j ST 1 FB 1 DF 1 PB 1 PL 1
lock solenoid
Transmission
H clutch
solenoid
Transmission
L clutch
solenoid
Transmission
4 clutch
solenoid
Transmission
3 clutch
solenoid
Transmission
2 clutch
solenoid
Transmission
1 clutch
solenoid
Transmission
R clutch
solenoid
Transmission
F clutch
solenoid
10-155 0
STRUCTURE AND FUNCTION
SENSORS
SENSORS Display (use) category
Q Q Q Q Q Q Q Q Q Q Q Q Q Q Q Q Q
Q Q Q Q
10-156 (6)
Type of sensor
Sensor method
When normal
When abnormal
Coolant level (Sub-tank)
Contact
ON (Close)
OFF (OPEN)
Coolant level (Radiator upper tank) (if equipped)
Contact
OFF (OPEN)
ON (Close)
Engine oil pressure
Contact
OFF (OPEN)
ON (Close)
Engine water temperature
Resistance
—
—
Hydraulic oil temperature
Resistance
—
—
Final drive oil temperature
Resistance
—
—
Transmission oil temperature
Resistance
—
—
Speedometer
Pulse
—
—
Engine speed
Pulse
—
—
Resistance
—
—
Air pressure
Contact
ON (Close)
OFF (OPEN)
Engine oil level
Contact
ON (Close)
OFF (OPEN)
Hydraulic oil level
Contact
ON (Close)
OFF (OPEN)
Fuel level
Resistance
—
—
Shift potentiometer
Resistance
—
—
Inching potentiometer
Resistance
—
—
Air pressure (for air pressure gauge)
023502
Transmission controller
Gauge
Caution 2
Caution 1
Check before starting
Machine monitor
STRUCTURE AND FUNCTION
SENSORS
COOLANT LEVEL SENSOR
1. 2. 3. 4.
Sub-tank Float Sensor Connector
023502
Function • The coolant level sensor is installed to the radiator sub-tank. If the coolant goes below the specified level, the float goes down and the switch is turned OFF. The warning lamp then flashes.
COOLANT LEVEL SENSOR (IF EQUIPPED)
1. 2. 3. 4. 5.
Float Sensor Tube Wire Connector
Function • The coolant level sensor is installed to the radiator upper-tank. If the coolant goes below the specified level, the float goes down and the switch is turned OFF. The warning lamp then flashes.
10-156-1 (6)
STRUCTURE
ENGINE
AND
OIL PRESSURE 1
2
SENSORS
FUNCTION
3
SWITCH 4
5
6 1. 2. 3. 4. 5. 6.
Plug Contact ring Contact Diaphragm Spring Terminal
Function . The engine oil pressure switch is installed to the engine cylinder block. It uses a diaphragm to detect the oil pressure, and when it goes below the specified pressure, the switch is turned ON. The engine oil pressure indicator lamp lights up to warn of the abnormality.
ENGINE WATER TEMPERATURE SENSOR TRANSMISSION OIL TEMPERATURE SENSOR FINAL DRIVE OIL TEMPERATURE SENSOR HYDRAULIC OIL TEMPERATURE SENSOR 1
@&-
1. 2. 3.
Connector Plug Thermistor
@%!I
Composition
of circuit
SBPO0379
Function . The engine water temperature sensor is installed to the right side of the engine. Thermistor (3) detects the temperature and sends a signal to the monitor panel. The monitor panel displays the water temperature according to that signal. If the temperature goes above the specified temperature, the warning lamp flashes and the alarm buzzer sounds to warn of the abnormality. . The hydraulic oil temperature sensor is installed to the hydraulic tank and the final drive oil temperature sensor is installed to
the final drive case. They send a signal to the monitor panel. If the temperature goes above the specified temperature, the warning lamp flashes and the alarm buzzer sounds to warn of the abnormality. The transmission oil temperature sensor is installed to the transmission oil piping and sends a signal to the transmission controller. If the temperature goes above the specified temperature, the warning lamp flashes and the alarm buzzer sounds to warn of the abnormality.
STRUCTURE
AND
FUNCTION
SENSORS
SPEEDOMETER SENSOR ENGINE SPEED SENSOR
I
c1
20 a
1
1. 2. 3. 4. 5.
Magnet Terminal Case Boot Connector
AIR PRESSURE
1. 2.
lo-158 0
2
3
4
I ii ._. 0 b
--?
5
F9
0.85fG c
0.85fG
Structure
1 2 of circuit SEW00289
Function . The speedometer sensor is installed to the transmission output gear. A pulse voltage is generated by the rotation of the gear teeth, and the signal is sent to the machine monitor to display the travel speed. . 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 transmission controller.
SENSOR
Connector Frame
Function . The air pressure sensor is installed to the air tank. Any change in the air pressure inside the air tank is converted to a change in the resistance, and a signal is sent to the air pressure gauge to display the air pressure.
STRUCTURE
AND
AIR PRESSURE
FUNCTION
SENSORS
SWITCH
Construction
of
circuit
1. 2. 3. 4. 5.
Plug Diaphragm Switch Wire Connector
1. 2. 3.
Connector Bracket Sensor Switch
swcoo447
Function . The air pressure switch is installed to the air tank. The diaphragm detects the air pressure, and when it goes below the specified pressure, it shuts off the electric current from the machine monitor. The warning lamp then flashes, and the alarm buzzer sounds.
ENGINE
OIL LEVEL SENSOR
4.
Composition circuit
of SBPOO376
10-159 0
STRUCTURE
AND
HYDRAULIC
OIL LEVEL SWITCH
SENSORS
FUNCTION
1. 2. 3. 4.
m
Float Switch Plug Connector
1
2
Construction
of
SWG00448
circuit
Function The hydraulic oil level switch is installed to the hydraulic tank, and the float moves up and down according to the oil level. If the oil goes below the specified level, the switch is turned OFF, the warning lamp flashes, and the alarm buzzer sounds.
.
FUEL LEVEL SENSOR
1. 2. 3. 4. 5. 6. 7.
Structure of circuit A-A
Function . The fuel level sensor is installed to the center of the front face of the fuel tank. Float (2) moves up and down according to the fuel level. As the float moves up and down, arm (3) actuates a variable resistance, and this sends a signal to the sub monitor to display the fuel level.
10-160 0
SBD02295
Connector Float Arm Body Spring Contact Spacer
STRUCTURE
AND
SENSORS
FUNCTION
SHIFT POTENTIOMETER INCHING POTENTIOMETER
1. 2. 3.
Construction
of
circuit
!
Lever Sensor Connector
ua I
// i,,
SWG00449
Function . The shift potentiometer is installed to the shift lever, and sends a signal to the transmission controller according to the amount that the lever is operated. The transmission controller controls the speed range of the transmission according to this signal. The inching potentiometer is installed to the inching linkage at the transmission end, and sends a signal to the transmission controller according to the amount that the inching pedal is depressed. It is used to detect inching overload.
lo-161 0
STRUCTURE
AND
ENGINE
FUNCTION
ENGINE STARTING
STARTING
CIRCUIT
CIRCUIT
Serial No.: 11001 - 11030
Engine staD lnator relay
Monitor
module
E ”
@ \
Non-continui port ion (hatched Parking brake
DO, End
lamp
_ start Ina
Alternator
motor
Fuse
box
Transmission control box CN-RST
Rotary switch
Start motor
ins relay
SWG00450
10-162 0
STRUCTURE
AND
FUNCTION
ENGINE
STARTING
CIRCUIT
Function Starting motor terminal E is separated from the ground only when the shift lever is at the neutral position, the parking switch is ON, and the starting relay coil is energized. If it is not in this condition, it is impossible to start the engine. Operation 1. When the starting switch is turned to the ON position, electricity flows from battery + starting switch terminals B - BR + engine stop motor relay terminals 1 - 2 + ground, and the relay coil is energized. 2.
3.
4.
The electric current from the battery flows from engine stop motor terminals A - B + relay terminals 5 - 3 + motor, and rotates the motor. When the motor rotates, terminal D also rotates at the same time. When the non-continuous portion of terminal D reaches terminal B, the circuit from terminal A to B opens, and the current from the battery to the motor is shut off. The motor attempts to continue rotating under inertia, but when the continuous portion of terminal D contacts terminal B, both poles of the motor are connected to the ground, and the motor stops rotating. In this condition, the engine stop motor cable is completely extended, and the fuel injection pump lever is set to the FULL position to place it in the operating condition.
5.
In addition, the current flows from starting switch terminal BR + battery relay coil -+ ground, and the battery relay switch is closed.
6.
Furthermore, if the shift lever is at the neutral position, electric current flows from the battery relay + fuse + starting motor relay (CN RST) terminals 1 - 2 + rotary switch terminals 2 - 11 + ground, and the relay coil is energized.
7.
If the parking brake switch is turned to the ON position, electricity flows from battery relay + fuse + parking switch terminals 1 2 + starting motor relay (CN RST) terminals 1 - 2 + ground, and the relay coil is energized.
8.
In this condition, if the starting switch is turned to the START position, electric current flows from starting switch terminals B C + starting motor terminal S + terminal E + starting motor relay (CN RST) terminals 5 - 3 + starting motor relay (CN RST) terminals 3 - 5 + ground.
9.
A circuit is formed from the battery + battery relay + starting motor terminal B, so the engine starts. If the shift lever is not at the N position, electricity is not supplied to terminal 1 of the starting motor relay (CN RST). Terminals 3 and 5 of the relay remain open, so the circuit in Item 6 is not formed, and the engine does not start. In addition, if the parking switch is not ON, electricity is not supplied to terminal 1 of the starting motor relay (CN RPST). Terminals 3 and 5 of the relay remain open, so the circuit in Item 7 is not formed, and the engine does not start.
10-163 0
STRUCTURE
Serial
AND
FUNCTION
No.: 11031 - 12012,
ENGINE
STARTING
CIRCUIT
12016 - 12018
Engine stop motor relay
Monitor
II
module
-
4
CN-25
I I
I
CN-PL
Parkine brake
End
IamP
Service
meter
StartIn
Alternator
motor
Fuse
box
Transmission control box
Rotary switch
Startin motor
rel
Parklna brake
rel
SWG0045
lo-164 0
I
STRUCTURE
AND
FUNCTION
ENGINE
STARTING
CIRCUIT
Function Starting motor terminal E is separated from the ground only when the shift lever is at the parking position and the starting relay coil is energized. If it is not at the parking position, it is impossible to start the engine. Operation 1. When the starting switch is turned to the ON position, electricity flows from battery --f starting switch terminals B - BR + engine stop motor relay terminals 1 - 2 -+ ground, and the relay coil is energized. 2.
The electric current from the battery flows from engine stop motor terminals A - B + relay terminals 5 - 3 + motor, and rotates the motor.
3.
When the motor rotates, terminal D also rotates at the same time. When the non-continuous portion of terminal D reaches terminal B, the circuit from terminal A to B opens, and the current from the battery to the motor is shut off. The motor attempts to continue rotating under inertia, but when the continuous portion of terminal D contacts terminal B, both poles of the motor are connected to the ground, and the motor stops rotating.
4.
In this condition, the engine stop motor cable is completely extended, and the fuel injection pump lever is set to the FULL position to place it in the operating condition.
5.
In addition, the current flows from starting switch terminal BR -+ battery relay coil + ground, and the battery relay switch is closed.
6.
Furthermore, ing position, battery relay terminals 1 11 + ground,
7.
In this condition, if the starting switch is turned to the START position, electric current flows from starting switch terminals B C -+ starting motor terminal S + terminal E -+ starting motor relay terminals 3 - 5 + ground.
8.
A circuit is formed from the battery + battery relay + starting motor terminal B, so the engine starts. .
if the shift lever is at the parkelectric current flows from the + fuse -+ starting motor relay 2 + rotary switch terminals 1 and the relay coil is energized.
If the shift lever is not at the parking position, electricity is not supplied to terminal 1 of the starting motor relay. Terminals 3 and 5 of the relay remain open, so the circuit in Item 6 is not formed, and the engine does not start.
lo-165 0
STRUCTURE AND FUNCTION
ENGINE STARTING CIRCUIT
023502
Serial No.: 12099 – 12502
10-166-1 (6)
STRUCTURE AND FUNCTION
ENGINE STARTING CIRCUIT
023502
Serial No.: 12503 and up
10-166-2 (6)
STRUCTURE
AND
FUNCTION
ENGINE
STARTING
CIRCUIT
Function Starting motor terminal E is separated from the ground only when the transmission controller recognizes the parking command and the starting relay coil is energized. If the shift lever is not at the parking position, it is impossible to start the engine. Operation 1. When the starting switch is turned to the ON position, electricity flows from battery + starting switch terminals B - BR -+ engine stop motor relay terminals 1 - 2 -+ ground, and the relay coil is energized. 2.
The electric current from the battery flows from engine stop motor terminals A - B + relay terminals 5 - 3 + motor, and rotates the motor.
3.
When the motor rotates, terminal D also rotates at the same time. When the non-continuous portion of terminal D reaches terminal B, the circuit from terminal A to B opens, and the current from the battery to the motor is shut off. The motor attempts to continue rotating under inertia, but when the continuous portion of terminal D contacts terminal B, both poles of the motor are connected to the ground, and the motor stops rotating.
4.
In this condition, the engine stop motor cable is completely extended, and the fuel injection pump lever is set to the FULL position to place it in the operating condition.
5.
In addition, the current flows from starting switch terminal BR -+ battery relay coil + ground, and the battery relay switch is closed.
6.
Furthermore, if the shift lever is at the parking position, electric current flows from the transmission controller + starting motor reJay terminals 1 - 2 -+ ground, and the relay coil is energized.
7.
In this condition, if the starting switch is turned to the START position, electric current flows from starting switch terminals B C + starting motor terminal S + terminal E + starting motor relay terminals 3 - 5 + ground.
8.
A circuit is formed from the battery -+ battery relay + starting motor terminal B, so the engine starts.
.
If the shift lever is not at the P position, electricity is not supplied to terminal 1 of the starting motor relay. Terminals 3 and 5 of the relay remain open, so the circuit in Item 7 is not formed, and the engine does not start.
lo-167 0
STRUCTURE
AND
FUNCTION
ENGINE STOPPING
ENGINE
STOPPING
CIRCUIT
CIRCUIT
Serial No.: 11001 - 11030 CN-53
CN-15
Engine stop motor relay
Monitor
module
I/I/ Parking brake
(hatched
~
portion)
lamp
Service
meter CN-SH
w
StartIne
Alternator
motor c
______.._.__
~__._
t
-.-..-.-
-----Transmission control box
-~~
7
z
_.__.__ ~_ CN-RST
Rotary switch
Start motor
ine relay
SWG00453
lo-168 0
STRUCTURE
AND
ENGINE
FUNCTION
Serial No.: 11031 - 12012,
STOPPING
CIRCUIT
12016 - 12018 CN-15
CN-53 Engine stop motor relay
Monitor
module CN-25
II
ir
Engine stop motor
\
Non-continuity port ion (hatched portion) End
Parking brake
IamP
Startin snitch
Service
meter
Transmission control box
Rotary switch
Start motor
Parking brake
ino relay
relay
SWG00454
1O-l 69 0
STRUCTURE AND FUNCTION
ENGINE STOPPING CIRCUIT
023502
Serial No.: 12099 – 12502
10-171 (6)
STRUCTURE AND FUNCTION
ENGINE STARTING CIRCUIT
023502
Serial No.: 12503 and up
10-172 (6)
ENGINE STARTING CIRCUIT
023502
STRUCTURE AND FUNCTION
10-173 (6)
20
TESTING
AND ADJUSTING
............... ............... Standard .............. Tool list for testing and adjusting ......... Testing and adjusting valve clearance pressure .............. compression Measuring ..... Testing and adjusting fuel injection timing pressure .................. blow-by Measuring engine oil pressure ................. Measuring exhaust gas color .................. Measuring ........... exhaust gas temperature Measuring pressure
(boost
Inching
belt tension
20-16 20-17 20-18 20-19
stop 20-20
..................
control
accelerator
force
and operating locking
differential
20-21
.......
20-22
....................
transmission
HYDROSHIFT
20-15
..............................
pedal travel
Checking
20-I 2 20-14
.............
the engine
for adjusting
motor cable Adjusting
20-I 1
) ..........................
and adjusting
Procedure
20- 8 20-10
air pressure
intake
Measuring
20- 4
table for chassis
value
Testing
20- 3
value table for engine
Standard
20-23
device 20-24
...............................
oil pressure
Steering .............................. .......................... Checking tire runout Checking air pressure of tire ................... Checking toe-in ............................... of articulate center pins ............ Installation
20-25
system
Checking Checking
parking
Checking
work
Checking
work
Charging Adjusting Bleeding Adjusting Adjusting
................. ............
20-30 20-30
oil temperature
equipment
........................
pressure
20-31
equipment
........................ hydraulic ...................... with gas .......... blade accumulator ..................... blade lift speed pump ............. air from hydraulic slip load of circle rotation clutch .....
hydraulic Measuring
force
and operating
work
20-29 20-29
....................... control lever equipment
hydraulic
Adjusting
20-28
brake
Checking
hydraulic
20-26 20-27
of brake disc ...................
wear
travel
20-26
pressure
drift
module
speedometer
machine
monitor
TROUBLESHOOTING
20-32 20-33 20-34 20-35 20-36
of
.......................... .
20-31
30-38 .
_. 20-39
20-l
A
A A
When
carrying
out
testing
pins, block the wheels, When
carrying
thorized When spurt
out
person checking out
and
and
adjusting,
and apply
or troubleshooting,
the parking
operations
with
two
stop
the
machine
on level
ground,
fit safety
brake.
or more
workers,
always
use signals,
and
do not allow
any
unau-
near the machine. the may
water
level,
cause
burns,
if the
radiator
so always
cap wait
is removed
for
the
when
engine
the
to cool
engine down
is hot, before
boiling
checking
water the
will water
level.
A A A
Be extremely
careful
not to touch
Be extremely
careful
not to get caught
When
removing
release
the
the
internal
any hot parts. in the fan or any other
plugs
or caps
from
pressure
first.
Fit the
places
under
measuring
rotating
hydraulic tools
parts. pressure,
securely
before
water
pressure,
carrying
out
or air pressure,
any
testing,
adjust-
ing, or troubleshooting. *
When
using the standard
be careful 1.
The standard standards mating
2.
values
for new
wear
during
the results
of various
for judgement
in testing,
in the standard
and machines
operation standard
or as target values
tests and standard
with the repair
Do not use this standard
20-2
table
adjusting,
or troubleshooting,
it is necessary
to
points.
for the new machines
judgement
together
values
machines
The failure erence
3.
of the following
values
shipped values
from
when
in the standard values
and operation
values
carrying value
for machines history
table as a standard
table
the factory.
should
given
as reference
from
be used as values
the
for esti-
out repairs.
table
are values
shipped
of the machine for judging
are values They
claims.
from
using
estimated
the factory.
when judging
values
based
Use these values
failures.
on
for ref-
TESTING
AND ADJUSTING
STANDARD
STANDARD
VALUE
TABLE FOR ENGINE
VALUE TABLE FOR ENGINE
Serial No.: 11001 - 12000
I
Engine Classifi cation
Item
Unit
Condition
S6D140-1
Standard
value
Permissible
High idling speed
rpm
2,350 + 50
Low idling speed
rpm
665 + 15
-
value
2,350 + 50
Engine
Quick acceleration (Low idling + High idling)
Bosch scale
Max.
5.0
7.0
At high idling
Bosch scale
Max.
1.5
2.5
Intake pressure (Boost pressure)
See “Measuring intake air pressure (boost pressure)”
kPa ImmHgl
Exhaust
See “Measuring gas temperature”
Exhaust
gas color
temperature
exhaust
“C
Max. 54 (405)
Max.
400
43 13201
600
Valve clearance (When engine is hot or cold)
Intake valve
mm
0.43
-
Exhaust
mm
0.80
-
Compression pressure (SAE30 oil)
Oil temperature:
VlPa {kg/cm?
Max. 3.1 I321
2.2 (22)
(rpm)
(160 - 200)
(160 - 200)
:Pa {mmH,OI
Max. 0.98 11001
1.96 {200}
At high idling
WPa {kg/cm2)
0.3 - 0.5 13.0 - 5.01
0.2 (2.01
At low idling
WPa {kg/cm2)
Min. 0.1 il.01
0.07 IO.71
“C
80 - 110
120
(Engine
Blow-by pressure (SAE30 oil)
valve
40 - 60°C
speed)
(Water temperature operating range)
inside
At rated output
(Water temperature operating range) Oil pressure (SAEBO pil)
All speed
Oil temperature
Fuel injection
timing
Fan belt tension
+
inside
(Oil in oil pan)
Before top dead center (B.T.D.C.)
Deflects when pushed with a force of 58.8 N 16 kg}
values given in the TESTING AND ADJUSTING DATA are NOT for adjustment of the output. Do not use these values as a guide to change the setting of the fuel infection pump.
The
20-3 0
STANDARD VALUE TABLE FOR ENGINE
TESTING AND ADJUSTING
Serial No.: 12001 and
UD
S6D140E-2
Engine Classification
Condition
Unit
ga,
High idling speed
mm
2,350 f 50
tm
Low idling speed
mm
650 +;
0
PC
Item
Standard
value
Engine
a
Exhaust
I‘ermissible
value
2,350 + 50 -
Quick acceleration (Low idling + High idling)
Bosch scale
Max.
4.0
6.0
At high idling
Bosch scale
Max.
1.0
2.0
gas color
Intake pressure (Boost pressure)
See “Measuring pressure (boost
intake air pressure)”
Exhaust
See “Measuring gas temperature”
exhaust
temperature
Min. 78.7 1590)
66.7 1500)
“C
Max. 700
700
-
kPa {mmHg)
Valve clearance (When engine is hot or cold)
Intake valve
mm
0.43
Exhaust
mm
0.80
Compression pressure (SAE30 oil)
Oil temperature:
MPa {kg/cm?
Max. 3.8 139)
2.7 f27)
(rpm)
(160 - 200)
(160 - 200)
(Engine
valve
40 - 60°C
speed)
8 z zz
Blow-by pressure (SAEBO oil)
(Water temperature operating range)
inside tPa ImmH,O)
Max.
0.98 UOO)
1.96 1200)
At rated output
(Water temperature inside operating range) Oil pressure (SAE30 oil)
Alternator tension
MPa (kg/cm?
0.3 - 0.5 (3.0 - 5.0)
0.2 (2.0)
At high idling
MPa Ikg/cm*)
3.25 - 0.44 (2.5 - 4.5)t
0.18 (1.8)
timing
(SAE IOW)
At low idling
(SAE 30)
MPa Ikg/crr+)
0.12 (1.2)
0.07 (0.7)
At low idling
(SAE IOW)
MPa {kg/cm?
0.10 (1.0)
0.07 (0.7)
All speed
Oil temperature
Fuel injection
At high idling (SAE 30)
(Oil in oil pan)
Before top dead center (B.T.D.C.)
degree
belt
Fan belt tension
80-
110
16 + 0.5
13Deflects when pushed with a force of 58.8 N 16 kg)
*
“C
120
16 + 0.5
16
mm 17 - 19
The values given in the TESTING AND ADJUSTING DATA are NOT for adjustment of the output. Do not use these values as a guide to change the setting of the fuel infection pump.
20-3-l
TESTING
STANDARD ADJUSTING,
AND ADJUSTING
VALUE TABLE FOR TESTING AND FAILURE JUDGMENT OF CHASSIS
STANDARD VALUE TABLE FOR TESTING AND ADJUSTING, FAILURE JUDGMENT OF CHASSIS Compo nent
Accelerator pedal
. Engine stopped . Up-down movement at joint between pedal and pin . Stroke from center of knob
Fuel control lever
mmI
I
160 + 10
I
160 f 20
Height H from floor to center of pedal mounting bolt mmL
Operating
effort
TOGO0001
. Engine stopped . Max. value to just before end of travel . Up-down
Travel
Operating
-
movement
of pedal
. Engine stopped . Max. value to just before end of travel
effort
. Engine stopped . Travel at tip of lever for each speed range
Travel
. Engine at full throttle . Lock brake . Set transmission at highest speed
Slippage of transmission
range, then release inching pedal and measure time until engine stalls
Main oil pressure Lubrication
. Engine
127.5 5 19.6 {I3 rt 2) 60 f 5
mm
&I
Play of steering wheel
20-4 0
I
13.0 29.4 +f 0.51 4.9
mm
27f
set
Max. 65 13.0 29.4 *f 0.5) 4.9
10
27+
Max. 3.0
12
Max. 3.0
at full throttle 40 - 60°C
. Oil temperature: oil
I Oil pressure
127.5 f 49.0 {13 + 51
. Engine at full throttle . Transmission: Neutral . Differential: Locked . l$a14$$e oil temperature: . Raise front tires 50 - 100 mm from ground . Turn steering wheel and measure distance to point where wheels start to turn to side
I
-
2.5
MPa g/cm’)
mm
1.1 f 0.1 {II f I}
$01
~
25-45
+0.5
o
I25 +;
1
Max.45
1
TESTING
)Compc nent
STANDARD ADJUSTING,
AND ADJUSTING
Measurement
Item
conditions
I
Unit
I
VALUE TABLE FOR TESTING AND FAILURE JUDGMENT OF CHASSIS
Standard value for new machine
Service
limit
value
. Raise front tires 50 - 100 mm
from ground, check point where steering wheel starts to turn, then turn steering wheel fully and measure distance to point where steering wheel stops turning Check distance to both IefI and right
Turning angle (lock-to-lock)
Operating effort steering wheel Runout
. Serial No.12001 and up
1
mm
I
Front tire MPa Rear tire {kg/cm21
Front tire MPa . 18.00-25-12PR . Serial N0.11001 - 12000 Rear tire {kg/cm3
Camber
5.7 f 1.0 turns
Max. 49 {Max. 5)
. Put a dial gauge in contact with side wall of both front and rear tires and measure runout
of tires
Tire inflation pressure
Max.
Max. 59 {Max. 61
7
Max.
7
0.24 12.451
0.24 i2.451
0.25 12.61
0.25 12.61
I
-----I
. Flat, paved
Toe-in
Leaning
road surface
I I deg
angle
Priority flow divider relief valve
Engine . Engine
at low
idling
. Measure at center of pedal . Measure when wheels are
$ I] g SE “Z ot $
Stopping distance
. Stopping distance when brakes are
Parking brake holding performance
. Tire slip limit when
fully
applied at travel speed of 32 km/h (SAE J 1473) is locked
. Engine
Air pressure
I
I
locked
brake
19.5 + 1.5 17.2 k 0.5 1175 + 51
at full throttle
Operating effort of brake pedal
2 I=
5.7 + 0.5 turns
. Engine at low idling . When traveling in Fl
of
. 23.5-25-12PR
F
-
parking
m
deg MPa (kg/cm21
at full throttle
313.8 k 19.6 {32 * 21
Max. 16 (SAE J1473) Min.
20
0.41 - 0.93 I4.2 - 9.51
I
I I
19.5 rt 1.5 17.2 + 1.0 U75 f 101 Max. 490 {Max. 501
Max. 22.8 (SAE J 1473) Min.
15
Max. 0.36 {Min. 3.7)
Leaning
N H N H
Left Right
30 + 5
30 f
Articulating
N H N H
Left Right
35 + 5
35 + 10.0
Blade lift (left, right)
N ti N H
RAISE LOWER
30 + 5
30 f 10.0
N tf N tf
Left Right
30 + 5
30 * 10.0
30 f 5
30 + 10.0
Blade
side shift
Drawbar shift
side
. Engine:
Stopped
. . Measure
at tip of lever
N tf N ti
Left Right
10.0
mm
Circle
rotation
N ++ Left N tf Right
30 * 5
30 + 10.0
Power
tilt
N ti Tilt forward N H Tilt back
35 f 5
35 f
N t;, RAISE N tj LOWER
35 f 5
35 * 10.0
Ripper
10.0
20-5 0
STANDARD VALUE TABLE FOR TESTING AND ADJUSTING, FAILURE JUDGMENT OF CHASSIS
TESTING AND ADJUSTING
-
Compc nent
T
Item
Measurement
Leaning
Articulating Blade lift (left, right) Blade side shift
. Engine: Stopped . Max. value to end of travel
Standard value LJnit for new machine
conditions
I I
N t) N t)
Left Right
N
N tf
Left Right
N tj N t)
RAISE LOWER
N tf N H
Left Right
N tf N tf
Left Right
H
14.7 - 29.4 {I .5 - 3.0)
I I
limit value
Max. 39.2 {Max. 4.0)
Max. 39.2 {Max.
4.0)
-
~
19.6 - 34.3 {2 - 3.5)
Max. 39.2 {Max. 4.0)
Right
19.6 - 34.3 I2 - 3.51
Max. 39.2 {Max. 4.0)
Power tilt
N ++ Tilt forward N tf Tilt back
14.7 - 29.4 {I .5 - 3.0)
Max. 39.2 {Max. 4.0)
Ripper
N tf N tf
14.7 - 29.4 11.5 - 3.0)
Max. 39.2 {Max. 4.0)
130 + 15
130 + 15
Drawbar shift
side
N tj Left
Circle rotation
Blade lifting speed
Blade side shift speed with movement of circle
N t)
RAISE LOWER
. Enaine: Rated soeed . Hydraulic oil ’ temoerature: 40 & 5°C . Time taken to move bottom edge of blade between 50 and 100 mm from ground
RAISE
LOWEf
. Engine: Rated speed . Hydraulic oil temperature: 40 & 5°C Left . Set height of bottom edge of blade to 100 mm with blade at center as standard condition . Side shift speed to left and Right right when shifting 200 mm horizontally with circle
. Engine: Rated speed . Hydraulic oil temperature:
Blade side shift
speed compared to circle
40 + 5°C
. Set height of bottom
.
Left
Ripper lifting speed
Blade rotation speed
.
I
130 * 15
I
130 + 15
edge of blade to 100 mm with blade at center as standard condition Side shift speed to left and Right right when shifting 200 mm horizontally with circle
. Engine: Rated speed . Hydraulic oil
20-6 0
19.6 - 34.3 {2 - 3.5)
Service
RAISE temperature: 40 f 5°C Speed to raise tip of center ripper shank LOWEf between 50 and 150 mm
. Blade angle speed with engine at full throttle . Hydraulic oil temperature: 40 f 5°C
Serial
No.
11001 - 1205C Serial No. 12051 and up
::::: 100 * 15
100 * 15
TESTING
Compc nent
STANDARD ADJUSTING,
AND ADJUSTING
Measurement
Item
conditions
Unit
VALUE TABLE FOR TESTING AND FAILURE JUDGMENT OF CHASSIS
Standard value for new machine
iervice
limit value
. Engine: Rated speed
. Hydraulic Hydraulic of blade
drift
Hydraulic drift of chassis when gc;;d up with
.
oil temperature: 40 f 5°C Downward movement of cylinder when blade is suspended at right angle to chassis and equally extended to left and right
Max. 10
Max.
10
Max.
10
Max.
IO
Max.
20
Max. 20
. Engine: .Rated speed . i$p5uF 011 temperature: 0
. Downward
movement of cylinder when blade is lowered I to ground and used to raise front wheels from ground ,
. Engine: Rated speed
. Hydraulic Hydraulic of ripper
drift
Hydraulic drift of chassis when pushed up with ripper
Priority valve pressure
.
oil temperature: 40 * 5°C Downward movement of cylinder when ripper is suspended
. Engine: Rated speed . Hydraulic oil temperature: 40 I?z5°C
. Downward
movement of cylinder when ripper is lowerec 1 to ground and used to raise and rear wheels from ground
Main control valve relief pressure
Max.
20
24.5 f 1.0 1250 f 10)
24.5 + 1.5 1250 + 15)
Right valve
24.5 f 1.0 {250 + IO}
24.5 f 1.5 (250 I!C151
Left valve
24.5 + 1.0 {250 + 101
24.5 + 1.5 {250 I!I 151
relief . Engine at full throttle . Hydraulic oil temoerature: 40 F 5°C
Max. 20
20-7 0
TESTING
STANDARD ADJUSTING,
AND ADJUSTING
Item
Measurement
conditions
Unit
VALUE TABLE FOR TESTING AND FAILURE JUDGMENT OF CHASSIS
Standard value for new machine
Service
limit value
1st
4.0 f 5 %
4.0 f 10 %
2nd
5.4 f 5 %
5.4 f 10 %
3rd
8.0 + 5 %
8.0 f 10 %
4th
11.5 f 5 %
11.5 + 10 %
5th
15.8 + 5 %
15.8 + 10 %
6th
21.4 + 5 %
21.4 rt 10 %
31.3 * 5 %
31.3 * 10 %
44.9 * 5 %
44.9 f 10 %
4.3 + 5 %
4.3 f 10 %
2nd
5.8 f 5 %
5.8 f 10 %
3rd
8.5 + 5 %
8.5 f 10 %
4th
12.2 * 5 %
12.2 L!z10 %
5th
16.9 +z 5 %
16.9 f 10 %
6th
22.8 + 5 %
22.8 f 10 %
7th
33.4 XL5 %
33.4 f 10 %
8th
47.9 + 5 %
47.9 f 10 %
Forward
7th
. Flat and dry road surface . Oil temperature and pressure in operating range . Engine at rated speed . No load . ~;;irressure of tire in specified
8th 1st
km/h
Reverse
Engine water
8
E 2
I
cooling
Engine oil temperature Transmission
. Oil and water levels are normal . Air temperature 40°C . Continuous traction IF-21 . On a concrete road surface . Using thermistor Performed with thermostat open
oil
z z!
Tandem case oil temperature
20-7-l 0
I
“C
Max.102
I
Max.
102
799-205-1100
Tachometer kit
6 – 99999.9 rpm
2.5, 6, 40, 60 MPa { 790-261-1204
60 MPa {600 kg/cm2} {
(5)
799-201-9001
Bosch index : Level 0 – 9
799-401-2311
200 kPa {1,500 mmHg}
79A-264-0091
0 – 490 Nm {0 – 50 kg}
79A-264-0021
0 – 294 Nm {0 – 30 kg}
}
}
Tachometer kit
799-205-1100
6 – 99999.9 rpm
2.5, 6, 40, 60 MPa { 79A-264-0021
}
0 – 294 Nm {0 – 30 kg}
0 – 1 MPa {0 – 10 kg/cm2}
0 – 1,080 Nm {0 – 110 kg}
(5)
TESTING
Ir
Adjust
AND
clearance
crosshead Intake
Remove
2.
Rotate pulley. intake with
3.
head cover
with
When valve
rotating,
No.
center,
adjust
crankshaft
check
1 cylinder
marked
of
(at 20°C)
mm
direction
mark the
of
to align
crankshaft
movement
in the normal
Set
top dead center.
marked top
of the
and No. 6 cylinder.
is at compression
the valves
to compression
the valves
TOP
at compression
one turn
cylinder
1.6
of No. 1 cylinder
When
top
and
(1).
in the normal
the
No. 1 cylinder
valve 0.80
I
the crankshaft (2)
lever
Exhaust
mm
cylinder
pointer
rocker
CLEARANCE
value.
(at 20°C)
0.43
1.
between
to following
valve
VALVE
ADJUSTING
l
top
. Then
direction,
dead
center,
dead
rotate
Valve
the
set No. 6 and adjust
o.
I 4.
To adjust,
insert
tool
F between
crosshead
(4) and
turn
clearance
is a sliding
fit.
Tighten
locknut
(6) to
rocker
adjustment hold
adjustment
lever
screw
(3) and (5)
screw
sition. w
20-l 0 0
Locknut:
arrangement
58.8 i
5.9 Nm (6.0 + 0.6 kgm)
until
in po-
TDD00714
5.
Then
rotate
one
turn
maining *
the crankshaft
and
adjust
valves
After
marked
adjusting
top
dead
in the normal
the
valve
center,
1 cylinder
it is also
120”
clearance
of each
for
by
the
re-
o. No.
crankshaft
direction
clearance
each
time
cylinder
at compression
possible
to turn
and adjust according
the
the valve
to the firing
order. Firing order:
l
t
After
1 -
tightening
5 -
3 -
the locknut,
6 -
check
2 -
4
the clearance
F621201068
again.
MEASURING PRESSURE
A 1.
measuring
muffler,
or to get caught
valve
2.
Warm
3.
Remove Install
6.
see
up engine
nozzle holder tool
in rotation
pressure,
be
manifold
or
parts.
TESTING
AND
ADJUSTING
gauge
Disconnect
connector INJECTION
nozzle
(2) of position,
the compression the the
holder
mount,
then
con-
in position.
f
where
60°C).
DI.
and measure Measure
40 -
assembly.
02 to the
tachometer
NO
exhaust
(oil temperature
Set engine
the
the
CLEARANCE.
nect pressure 5.
touch
clearance.
details,
VALVE
4.
compression
not
For
to
the
careful
Adjust *
Z % 2
When
COMPRESSION
stop
motor
(I),
set
then
crank
the
engine
pressure.
compression pressure
to
pressure
gauge
at the
indicator
point
remains
steady. *
When
measuring
measure within
the
engine
the specified
the
compression
speed
to
confirm
pressure, that
it is
range.
235FO2057
20-l 1 0
FUEL INJECTION
TESTING AND ADJUSTING Serial
There
No.:
are
11001
the
- 12000
following
ing the fuel injection
. .
*
*
Aligning pump
match
Delivery
valve
When
when
method
using the
without
when
valve
with
the
delivery
copper
gasket
new
adjust-
the
injection
repair.
assembling
the
injec-
or replaced.
valve
method,
and
parts.
and
pump.
assembling
engine
that has been repaired
place starting
of testing
of the injection
mark
to the original
tion pump
O-ring
Prepare
always
of the
these
re-
delivery
parts
before
the operation.
Set the center, For
methods
timing
No. 1 cylinder
at the
compression
top
dead
then test and adjust.
details,
see
TESTING
AND
ADJUSTING
VALVE
CLEARANCE.
.
Testing
1.
Turn the crankshaft
and adjusting
by aligning
match
mark
back 30” to 45” from
No. 1 cylin-
der TOP. 2.
Turn
the
and
align
damper 3.
crankshaft pointer
engine
oil
(4), then
pump. t After
slowly
injection
(1) with
Remove flange
the
the
hose
level
4.
Check
that
line
the
engine fit
If the the
lines
getting
tube
oil
crankshaft
(3) and the
level
hose
injection
gauge
plug
tube
to prevent
in. injection
pump
and
line
are aligned.
are not aligned,
coupling
direction,
on
(5) from
a blind
“a” on the
“b” on the coupling *
gauge guard
flange,
mud or dirt from
normal
line
(2).
remove
removing
and
in the timing
to align
the
loosen lines,
nut
then
(6), move tighten
the
nut. D .
Nut:
Testing
fuel
58.8 f 4.9 Nm (6.0 I 0.5 kgm)
injection
timing
by
delivery
valve
method *
Prepare O-ring
new of the
parts
for
delivery
the
copper
gasket
and
valve
before
starting
the
.operation. 1.
Disconnect
fuel
injection
pipe
(7) of the
der. 2.
Remove
20-12 0
delivery
valve
holder
(8).
No.
1 cylin-
TIMING
3.
Remove
spring
delivery
valve
livery
4.
valve
Remove
(9) and
holder
oil
(4), then
pump. * After
the
hose
With
No.
6.
Place
the
rotate tion valve
7.
In
the
fit
rotate
control priming fuel
in FULL
stops
position,
normal
pump,
where
and
out
I
423F302
slowly
direction
observe
flowing
the
timing
injection
If the
while
the
of the
outflow stamp
timing
injection
inspection
with
posi-
delivery
timing
stops,
crankshaft (2).
passed
through
is late.
stamp
shows
fuel
on
pointer
line
timing
The injection
of
line
stamp
The injection
of adjustment,
After
line
timing
did
not
reach
is advanced.
that
the
injection
timing
is
the
fuel
injection
timing
in
adjust
manner.
the
checking
the spring
Always
replace
O-rings
with
1)
lever in the
(1) to see if it is aligned
semble
*
in.
piston
injection
the following
*
getting
plug
tube
position,
position
If the
If the out
gauge
direction.
the pointer:
*
level
a blind
hose
injection
at TOP
the pointer: *
oil
the
30” to 40” in the reverse
the
the
damper
8 z z
(3) and
holder.
check *
de-
prevent
the
when
tube (5) from
engine
crankshaft
operating
the
the
to
fuel
the
gauge
the
1 cylinder
the crankshaft
(10) from
reassemble
guard
flange,
mud or dirt from
5.
valve
and
level
remove
removing
and
(8),
(8).
engine
flange
delivery
holder
Rotate
and
adjusting,
and the delivery
the
delivery
be
sure
to
reas-
valve.
valve
copper
gasket
and
new parts. the
direction,
crankshaft starting
30” to
from
40”
in the
TOP position
reverse
in No. 1 cy-
linder. 2)
Align (I)
the
with
shaft 3)
Loosen side
nut slot, little
pump
until holder.
Tighten flange
the
line
on damper
rotating
the
crank-
direction. injection
and
the
rotate little
by
no
fuel
nut
on the
pump
flange
operating
flows
out
injection
mounting
on the of
pump
the
priming
the
delivery
pump
mounting
slot.
Recheck properly
5)
stamp
(11) on the by
valve
*
timing
(2) by slowly
in the normal
flange
4)
injection pointer
If match
the
injection
timing
to
see
if it
is
adjusted.
marks
a and
b are not aligned,
stamp
new one.
20-l 3
TESTING
AND ADJUSTING
TESTING
AND ADJUSTING
FUEL INJECTION
TIMING
Serial No.: 12001 and up 1.
Testing 1) Procedure for fixing crankshaft in position i) Pull out pin (I), and remove nut (2). ii) Rotate the crankshaft in the normal direction and align pointer (4) with the fuel injection line on top of damper (3). * When doing this, check that line (5) on the injection pump camshaft is near the line on the pump case. If it cannot be seen, rotate the crankshaft one more turn. iii) Push in lock pin (7) towards the engine and rotate the crankshaft to insert pin (7) into the hole in gear (8). 2) In this position, check the position of line (5) on the injection pump camshaft and line (6) on the pump case. Note: In this condition, do not start the engine or try to crank it by force.
2.
Adjusting If the line in Step l-2) is not aligned, adjust as follows. I) Loosen coupling bolts (9) and nuts (IO) at two places. 2) Rotate camshaft (11) to align line (5) on the camshaft completely with line (6) on the injection pump case. 3) Tighten bolts (9) and nuts (IO). w Nut : 61.25 + 2.45 Nm t6.25 f 0.25 kgm}
3.
Procedure for releasing crankshaft 1) Remove lock pin (7) from the hole in gear (8). It If pin (7) is stiff, tighten nut (2) before removing the pin. * Pull the pin out completely toward this side to a position where it does not move. 2) Tighten nut (2). w Nut, bolt : 31.4 +_3.5 Nm 6.2 + 0.36 kgm1 3) Install pin (I).
EEP01138
BEP01139
BEPOll
20-13-l 0
MEASURING
Measure
the
BLOW-BY PRESSURE
blowby
pressure
under
the
following
conditions.
.
Temperature
of
cooling
water:
Within
operating
range
.
Temperature
Set tool Use tool Run the blowby +
E4
of hydraulic
and El to blowby
E3
to connect
engine
varies engine.
considered
When
A:
if the
check
defective
blowby,
with
Before
measure
the
dirty
taking
to the
condition
blowby
value
for
problems
such
defective
gas
or deteriorated
measurements,
When
setting
position,
color,
oil. be careful
measurements,
to the following
is
con-
as excessive
exhaust
any hot parts or rotating
starting
A
and
according
abnormal,
consumption,
equipment
output
Therefore,
to touch 1)
rated
greatly
and prematurely A
hose (1).
as follows.
Blowby
nected
55°C
tool El and Ez.
at the
pressure
of the
oil
oil: 45 -
not
parts.
set
the
work
posture. the
work
be careful
equipment
not to let the
in blade
hit the tire. B:
For the
drawbar
shift,
tion as the standard c: D:
take
the
center
posi-
position.
Shift the blade fully to the right. Rotate
the
circle
to
give
a propulsion
angle
of 50”. E:
Raise
the
blade
fully
on
both
the
left
and
hold
it at
right sides. 2)
Pull right
blade
lift
lever
(1) back,
and
the end of its stroke. *
Raise the
right
end
of the
blade,
and
relieve
the circuit. 3)
In the shift the
condition
lever same
in
Step
(2) and
circle
time
the
to
2),
operate
left
rotation
front
to
blade lever
move
the
left (3) at work
equipment. *
Use
the
left
rotation
amount
blade
left lever
shift to
lever set
the
and oil
the
circle
Front Opeate at same time
discharge
to the maximum. ;),8
2
-4:%/
3 235FO2059
20-14
MEASURING
*
For tests tricity
in the
Measure
the
the exhaust
1)
Fit the filter Insert
the
haust
pipe, the
paper.
Remove
the
the engine
gas suction
handle
the
paper
to judge
careful
is warm
the
the exhaust
the
exhaust
compare
ex-
566FO6118
and
gas with
on the
the condition.
Gl
exhaust
color,
be
careful
pipe.
color
when
the engine
is warm
is 60°C).
the
probe
and secure
2) Connect
the
and
into
suddenly,
METER
the exhaust
(oil temperature
port
engine
to catch
filter
measuring
1) Insert
be
in tool GI.
WITH SMOKE
Measure
color,
when
accelerate
operate
not to touch *
CHECKER
exhaust
color
paper
the filter
When
tests
pipe.
exhaust
scale provided
A
for
is 60°C).
2)
MEASURING
checker;
meter.
SMOKE
the exhaust
(oil temperature
is no air or elec-
smoke
use smoke
measuring
not to touch
there
handy
WITH HANDY
When
3)
where
use
shop,
MEASURING
*
field
available,
in a repair
A
EXHAUST GAS COLOR
in
the
outlet
it to the exhaust
the
probe
of
exhaust
pipe with
hose,
pipe
a clip.
accelerator
switch
plug
and air hose to tool Gz. *
The
pressure
under 3)
of
the
air
supply
should
be
1.5 MPa (15 kg/cm*).
Connect
the
power
cord
to
a
power
source
socket. *
Check
that
the
connecting 4)
Loosen
the
cap
insert the filter *
Fit the
power
switch
is OFF before
the cord. nut
of
the
suction
pump
and
paper.
filter
paper
securely
so that
the
ex-
haust gas does not leak. 5)
Turn the powr
6)
Accelerate
7)
time,
depress
relief
valve
and
paper.
Lay
the
filter
gas
color or
on
ON.
engine the
the filter
sheets
switch
the
suddenly.
accelerator catch
paper top
more)
the used
exhaust to
of
unused
inside
the
and read the indicated
At
pedal,
catch filter filter
the
same
operate gas the
color
on
exhaust
papers paper
566FO6120
the G2
(IO
holder,
value.
Fl RM02216A-K
20-l 6
EXHAUST GAS
MEASURING
A
When
removing
*
Raise
be caretul the
water
before
Set tool
installing
not to touch
cooling
ting range 1.
or
_
ment,
temperature
carrying
6 to exhaust
measuring
equip-
any hot parts. to
the
opera-
out measurements.
temperature
pickup
connector
(1). A
When
taking
to touch 2.
Run the
measurements,
engine
at rated
haust temperature
1) Before
output
and
measure
measurements,
to the following
A
careful
not
parts. the ex-
as follows.
starting
equipment A:
be
any hot parts or rotating
Wh en
setting
position,
set
the
work
posture. the
work
be careful
equipment
not to let the
in blade
hit the tire. B:
For the
drawbar
shift,
tion as the standard C: D:
take
the
center
posi-
position.
Shift the blade fully to the right. Rotate
the
circle
to
give
a propulsion
angle
of 50”. E:
8
s 8
Raise
the
blade
fully
on
both
the
left
and
hold
it at
right sides.
2) Pull right
blade
lift lever
(I)
back,
and
the end of its stroke. *
Raise the
right
end
of the
blade,
and
relieve
the circuit. 3)
In the shift the
condition
lever same
in
Step
(2) and
circle
time
the
to
2),
operate
left
blade
rotation
front
to
shift
lever
lever
left (3) at
move
the
work
and
the
circle
equipment. *
Use the left
amount 4)
In the
blade
rotation
left lever
to
set
the
oil
discharge
to the maximum.
condition
in Step
3). measure
the
blowby
pressure. A
The
blade
moves
so be careful the
diagram,
lever before A:
AB
e
and there careful
equipment B:
AB
during
to avoid
e careful
the
measurement,
the contact
stop
shown
operation
of
in the
is any contact. not
to
let
the
to
let
the
OsF{@J
OoooJ
work
hit the main frame. not
Front Opeate at
blade
hit
2
3
235FO2059
the tire.
235FO2060
20-17
MEASURING
A
When
removing
be careful 1.
or
installing
not to touch
Install
tool
coupler
(1).
A
INTAKE AIR PRESSURE (BOOST PRESSURE)
When
H
to
taking
touch
measuring
equipment,
any hot parts. intake
pressure
measurements,
measurement
be
any hot parts or rotating
careful
not
to
parts.
Note: Run the engine use the from
*
at a mid-range
self-seal
portion
speed
of the
or above,
gauge
then
to remove
oil
inside the hose. Insert
the
gauge
movement
about
to open
half-way
the
and
self-seal
repeat
the
remove
the
the gauge
will
and
oil. *
If there
is any
not move, 2.
Run
the
boost 1)
engine
pressure
Before
at
the
rated
starting
output
and
measurements,
to the following
A
hose,
be sure to remove
the oil.
measure
the
as follows.
equipment A:
oil inside
so always
When
setting
position,
set
the
work
posture. the
work
be careful
equipment
not
to let the
in blade
hit the tire. B:
For the
drawbar
shift,
tion as the standard c: D:
take
the
center
posi-
position.
Shift the blade fully to the right. Rotate
the
circle
to
give
a propulsion
angle
of 50”. E:
Raise
the
blade
fully
on
both
the
left
and
hold
it at
right sides. 2)
Pull right
blade
lift
lever
(1) back,
and
the end of its stroke. *
Raise the
right
end
of the
blade,
and
relieve
the circuit. 3)
In the shift the
condition
lever same
in
Step
(2) and
circle
time
to
the
blade
left
2),
operate
left
rotation
front
to
shift
lever
blade lever
left (3) at
move
the
work
and
the
circle
Front
equipment. *
Use the left
rotation
amount
lever
to
set
the
oil
discharge
to the maximum.
235FO2059
20-l 8
4)
In the
condition
in Step
3),
measure
the
boost
pressure. A
I
The
blade
moves
so be careful the
to avoid
diagram,
lever before A:
A
Be
during
and there
AB
the
measurement,
contact
stop
shown
operation
of
in the
is any contact.
careful
not
equipment B:
the
to
let
the
work
hit the main frame.
e careful
not
to
let the
blade
hit
the tire.
AA
BA 235FO2060
TESTING AND ADJUSTING Serial 1.
No.:
11001
BELT TENSION
- 12000
Fan belt 1)
Testing Check the
that
tween
fan
pulley 58.8
deflection
range pulley
(1)
is
pressed
adjust
belt
is within
portion
belt tension
with
If it
the
central
is not
“a” be-
adjustment
a force
of
within
approx.
the
standard
the
belt
the belt tension.
Standard
*
of
when
(2) and
N (6 kg).
value, 2)
the
standard
belt tension:
5 -
9 mm
Adjusting Use
adjustment
bolt
(3) to
adjust
ten-
sion as follows.
2.
If deflection
is too LARGE, TIGHTEN
bolt
If deflection
is too SMALL,
bolt
Alternator 1)
LOOSEN
b
belt
Testing Check
that
standard tween is
deflection when
alternator
pressed it
the range
with
not
(4) and
a force
within
of the central
the
belt
is wihin
portion
accessory
of approx.
the
“b”
pulley
be-
(5) is
235FO2062
58.8 N (6 kg). If
standard
value,
adjust
the
belt tension. * 2)
Standard
belt tension:
8 -
12 mm
Adjusting i) ii)
Loosen
belt
tension
adjustment
mount
bolt (7) of alternator
Using
a bar,
the
pull
belt tension’,
(6) and mount
alternator then
bolt
(6) and
(4).
tighten
(4) up to adjust adjustment
bolt
bolt (7).
20-l 9 0
Serial No.: 12001 and up 1.
Fan belt 1) Testing Check that the deflection of the belt is within the standard range when central portion “a” between fan pulley (2) and belt tension adjustment pulley (I) is pressed with a force of approx. 98 N {IO kg}. If it is not within the standard value, adjust the belt tension. * Standard belt tension: 17 - 19 mm 2) Adjusting If the deflection of the belt is too loose, tighten adjustment bolt (3); if the tension is too tight, loosen adjustment bolt (3).
a
TEGOOOOZ
2.
Alternator belt 1) Testing Check that the deflection of the belt is within the standard range when central portion “a” between alternator pulley (I) and accessory pulley (2) is pressed with a force of approx. 98N {IO kg}. If it is not within the standard value, adjust the belt tension. Ir Standard belt tension: 13 - 16 mm 2) Adjusting i) Loosen mounting bolt (3) of the alternator assembly and locknut (4) of the belt tension adjustment bolt. ii) Turn adjustment nut (5) to move the alternator assembly and adjust the tension of belt (6). After adjusting, tighten locknut (41, adjustment nut (5), and alternator assembly mounting bolt (3). iii) After adjusting the belt tension, check again that deflection “a” of the belt is within the standard value.
TLD00026
20-19-l 0
PROCEDURE FOR ADJUSTING MOTOR CABLE 1.
Temporarily jection
2.
Pull
the
to cable
ball joint
(1).
stop
(3)
ENGINE
pump
non-injection) to the
to the in-
stop motor
(fuel
ball joint
connected
(2) of engine
injection
STOP the
attach
pump
THE ENGINE STOP
lever position,
stop
lever,
to
the
temporarily
then
attach
fix the
cable
to
the bracket. t t
The
engine
stop
pulled
condition.
When
the
lever
OPERATING 3.
Turn
engine
ated
to
confirm
there
is
stopper *
that
a
Be
the
The engine
the engine stop
stop
lever
ON and
engine
between
is housed
in the is in the
spring).
switch
especially
clearance
when
the
(built-in
starting
smoothly.
cable
is free,
position
the
times
motor
OFF a few
stop
motor
actu-
to
confirm
that
sure the
stop
lever
and
is stopped.
motor
has built-in
limit
switches
on both sides of the cable stroke. *
When
the
in the into
engine
engine
the
is running,
stop
injection
motor pump
there cable. actuates
is some A
spring to
hold
opening position. . Engine stop motor stroke: 35 mm . Injection pump stop lever stroke: 30 mm
20-20
slack built the
23
ADJUSTING
ACCELERATOR
CONTROL
A-A
235FO2064
for adiustinq _
Procedure 1.
Fix stopper
- accelerator
control
bolt (2) at the standard
height
from
the
l
6.
After
Standard
height
of stopper
bolt:
spring
56 mm
or 2.
Adjust
so that the installed
length
of cable (6) at the
Depress
pedal
(1) until it contacts
then adjust cable mounting ator’s
compartment
the engine 4.
Adjust
end so that throttle
hook plate (IO) so that the engine
If the regulator vibration,
lever
stops.
lever moves back because
tighten
double
(7) to
angle of
nut (11) further
of the to in-
power.
oper-
lever (5) at
end is at the end of its stroke.
damper
bolt (9) so that reguSTOP, idling, and full
positions.
Standard
Adjust
set regulator
and adjust the mounting
bolt (2),
B atthe
(8) and stopper
speed
5.
stopper
dimension
lator lever (7) gives the engine l
the engine,
crease the holding
engine end is dimension A. . Dimension A: 307 mm 3.
starting
the STOP position,
floor.
length
the height
the engine
idling
of damper:
346 mm
of the decelerator position
pedal so that at
the head of decelerator
pedal (3) is level with the top surface
of the floor mat
(if there is no floor mat, level with the top surface
of
the floor).
20-2 1
INCHING
INCHING
PEDAL TRAVEL AND OPERATING
PEDAL TRAVEL
FORCE
CHECK
Use convex rule 0 to measure the length movement from up to down from beginning end of depressing inching pedal (I).
of the to the
i
235FO2065
INCHING PEDAL OPERATING FORCE CHECK Use push-pull scale @ to measure the maximum value in the travel to just before the inching pedal travel end. CHECKING
HEIGHT
OF INCHING
PEDAL
Using a steel tape, measure height H of the center of pedal mounting bolt (I) from the floor. ADJUSTING
HEIGHT
OF INCHING
PEDAL
Adjust the installed length using rod (3) and yoke (2) at the pedal end so that installed height H of the center of pedal mounting bolt (I) from the floor is 98:: mm. When doing this, remove pin (5) connecting the yoke and lever (4), then turn the yoke to adjust the length. t Check that portion A of the pedal does not interfere with the floor. Depress the pedal to the end of its travel, and adjust stopper bolt (6) at this position. Then screw in the stopper bolt a further one turn and lock it in position. * Check that portion B of the pedal does not interfere with the floor. After the completion of adjustment, start the engine and run it at full throttle. Depress the pedal and check that the machine does not move when the gear shift lever is put into Fl. Depress the service brake pedal and inching pedal, and put the gear shift lever into F8. From this position, release the inching quickly, and check that the engine stalls within 3 seconds. (Check with the engine running at full throttle.)
20-22 0
a
6
k
4
I
5
I
235FO2066
2
3
2 TOG00004
CHECKING STEERING WHEEL PLAY When dard
the play of the steering value
or vibrates
wheel
abnormally
is outside
the stan-
or pulls, replace
the
steering valve assembly.
CHECKING STEERING WHEEL OPERATING Using push-pull
scale 0,
measure
FORCE
the operating
force of
the steering wheel. *
Measure
operating
force
of the steering
the engine idling and with the wheels
wheel
with
on the ground.
F23B01039
20-25
CHECKING
TIRE RUNOUT
FRONT WHEEL CHECK 1. 2.
Start the engine and raise the front wheels off the ground, using the blade or scarifier as a jack. Use dial gauge @ to measure the tire runout while rotating the tire (I 1 by hand.
REAR WHEEL CHECK 1. 2. 3.
4.
Put jacks under the left and right tandem cases, and raise the rear wheels off the ground. Put stand @ under the tandem case. Start the engine and lower the blade to the ground.
Use dial gauge @ to measure the tire runout while rotating tire (2) by hand.
A
Always stop the engine before measuring.
CHECKING TIRE
AIR PRESSURE
OF
Use tire gauge @ to measure the air pressure of front and rear wheels.
20-26
023502
20-27 (6)
INSTALLATION OF ARTICULATE CENTER PINS 1. Insert the front frame in the rear frame.
Serial No.: 11001 – 12502
2. Insert center pins (1) and (2), adjust with bottom nut (4) so that all clearance “A” are equal, then tighten the unit. a For serial No. 12503 and after, install O-rings (7) to center pins (1) and (2). 3. Tighten top nut (3). 3 Nut (3) (1st pass): 255 ± 9.8 Nm {26 ± 1 kgm} (2nd pass): Loosen temporarily and then tighten to 215 ± 9.8 Nm {22 ± 1 kgm}.
Serial No.: 12503 and up
20-28 (6)
023502
4. Set lock plates (5) to nuts (3) and (4) and secure them with the bolts. a For serial No. 12503 and after, install washer (6) between lock plate (5) and frame.
CHECKING
1.
Remove
WEAR
plug (1) of checking
from direction
2.
Depress
hole.
brake pedal to push piston
Confirm
confirm
be seen through
(2) against
plate
disc 14).
that length A in the diagram
In other words,
DISC
hole and peep through
above the checking
(3) and to compress 3.
OF BRAKE
at right is not 0.
that a portion of the disc can
the checking
hole.
Checking hole
CHECKING CHECKING 1.
PARKING
PARKING
BRAKE
F23EC030
BRAKE
Place the gear shift lever at the P position.
2.
Check that slack adjuster
3.
Check
that
the
brake chamber
angle
(I) works smoothly.
between
push
and slack adjuster
rod (2) of the
(1) is greater
than
90”.
ADJUSTING 1.
Rotate
PARKING worm
shaft
BRAKE (3) with
a wrench
to adjust
the
clearance. 2.
When
adjusting,
be careful
to turn exactly
one notch
at a time.
20-29
CHECKING WORK EQUIPMENT CONTROL LEVER TRAVEL AND OPERATING FORCE CHECK AND ADJUSTMENT CONTROL LEVER TRAVEL Use a convex
rule 0
OF WORK EQUIPMENT
and measure
the operating
length
from the center of the knob of lever (1). *
Measure
t
The stroke of work equipment
with engine stopped. control
lever is deter-
mined by the spool travel of the control valve, but the neutral position of each lever is adjusted
by each rod.
CHECK AND ADJUSTMENT OF EACH WORK EQUIPMENT CONTROL LEVER OPERATING FORCE Use push-pull
scale @ to measure
maximum
value from
the tip of lever (I) to just before the stroke end. +
Measure
*
The
with engine stopped.
operating
force
lever is determined the control outside
valve
standard
connecting
of the work
equipment
control
by the spring load of the spool on side. When
the operating
value,
the movement
check
rod. If it is normal disassemble
valve and check the movement
force
is
of the
the control
of the spool.
CHECKING HYDRAULIC OIL TEMPERATURE Special
tool
Part number A
1.
1
799-101-I
Remove
502
hydraulic
Part name
I Q’tY
1Thermistor
oil
tank
cap
I (1)
and
’ remove
strainer.
A
When
removing
slowly
to release
in the hydraulic
2.
Insert
sensor
the remaining’oil
pressure
tank.
into filling
perature with thermistor
20-30
cap, loosen the oil filler cap
port
and measure
gauge A.
oil tem-
235FO2075
MEASURING EXTENTION
HYDRAULIC
DRIFT
OF BLADE CYLINDER
Start engine and after the pressure test, bring hydraulic oil temperature Raise
the
to the 40
blade
right angles
300
& 5°C range.
mm
from
to the machine
the
ground
and equidistant
and at to right
and left. Stop the engine and leave for 10 minutes. Use a convex
rule @
to measure
the amount
the
cylinder piston rod has dropped.
RETRACTION Start
OF BLADE
engine
after
CYLINDER
the pressure
test,
oil temperature
to the 40 & 5°C range.
Lower
until
blade
ground,
its
bottom
push the cylinder
about 300
bring hydraulic
edge
touches
the
and float the front wheels
mm off the ground.
Stop the engine and leave for 10 minutes. Use a convex amount
EXTENTION 1:
rule @ to measure
at the cylinder
OF RIPPER CYLINDER
Start the engine and test the pressure, the hydraulic
oil to 40
f
(If equipped) then warm
Raise the ripper about 300
3.
Stop the engine and wait for 10 minutes. tape
0,
measure
up
5°C.
2.
steel
the
of sinkage.
mm from the ground. the
distance
Then using the
cylinder
piston rod has moved.
RETRACTION 1.
OF RIPPER CYLINDER
Start the engine and test the pressure, the hydraulic
oil to 40 f
(If equipped) then warm
up
5°C.
2.
Lower the ripper to the ground, then extend the cylin-
3.
Stop the engine and wait for 10 minutes.
der piston or raise the rear wheels about 300 steel
tape
0,
measure
piston rod has moved.
20-32
the
distance
mm.
Then using th,e cylinder
CHARGING
Special
BLADE ACCUMULATOR
tool Part name
Part number 792-61 O-l 700
A
A 1.
Always
Charging
use nitrogen
lator with
when
Remove
plug
charging
assembly
When fully
3.
(2) from
installing
installing
valve
(4) gradually
gauge
the
accumu-
then
install
charging
valve,
TV8 tighten
valve
(3)
(4) fully.
and
valve the
accumulator
assembly
charging
will
tighten
A,
pressure
be shown
on
of the pressure
pressure:
2.4 +z.’ MPa (24 ‘A kg/cm*)
If pressure
gauge
loosen from
reaches If the kg/cm*), valve
the
accumulator, accumulator:
charging
Charging
cm*), gas
charging
(4).
A SI z z
the
and open valve
in the
1
assemblv
A.
After gas
Q’ty
gas.
Size of joint for connecting 2.
WITH GAS
(5) does
valve the
(3)
not reach
gradually,
cylinder
until
2.4 MPa (24 kg/ and
pressure
charge
with
gauge
(5)
2.4 MPa (24 kg/cm*). pressure remove (3) to
the atmosphere
gauge
registers
hose
release
gas
and adjust
(6). from
above
Then the
2.4
MPa
gradually
,_______j”____,
(24
loosen
accumulator
I
into
I
‘\.
to 2.4 MPa (24 kg/cm*).
Ii. Accu;;;;iator A
234F114E
Accumulator joint Gasket \
r-i-
t-7
!
5/8-18UNi
/ TV8
234F1146
TESTING
AND ADJUSTING
ADJUSTING SPEED
ADJUSTING
BLADE LIFT SPEED
BLADE LIFT
Serial No.: 11001 - 12022 If there is a difference between the left and right blade lift speeds, or when reducing the lifting speed on the left and right, adjust as follows. 1.
Loosen the locknut and adjust with adjustment bolt (1). * If there is a difference between the left and right balde lift speeds, adjust by loosening the bolt on the fast side to reduce the speed. * The adjustment bolt has an adjustment range of 4.8 turns.
TWG002.49
Serial No.: 12023 and up 1.
Loosen locknut (3) of the main control valve. Adjust with adjustment screw (2). * If there is a difference between the left and right blade speeds, adjust by loosening the adjustment bolt on the fast side to make it slower. m Locknut : 88.3 + 9.8 Nm 19 * 1 kgml
20-34 0
TWG00250
BLEEDING AIR FROM HYDRAULIC
A
Lower
the
work
completely
to
the
ground.
1. Remove
hydraulic
tank side cover.
2. Loosen
air bleed
plug (I) of the front
3. Loosen
air bleed
plug (2) of the rear pump.
4. Disconnect
drain
5. Add hydraylic *
Add
until
7. Install
drain
the
air bleed drain
hose (3).
and rear air bleed oil:
plugs
oil
(4).
9. Run
low
at
10. Run the
blade
engine
11. Loosen 12. Run the right *
blade
air bleed
idling,
raise
2 and
and
lower
3 times. raise
2 -
and
lower
3 times.
1
plug (5).
engine the
tank.
and
lift cylinders
at low
blade lift cylinders Relieve
idling,
lift cylinders
at high
the left and right
from
(1) and (2).
of the hydraulic
engine
out
4.0 Q
8. Install the side cover the
comes
ports.
3.5 -
hose (3) to elbow
the left and right
pump.
elbow.
hydraulic
Hydraulic
Qz 6. Tighten
hose (3) from
oil from
oil
the front
z R 8
equipment
PUMP
idling,
and
raise
to the end of their
hydraulic
pressure
and
the
left
and
stroke. bleed
the
air
completely. 13. Tighten *
air bleed
Run the system.
plug (5).
engine Then
to
check
tank and add hydraulic
circulate the
the
oil level
oil through in the
the
hydraulic
oil.
I
\
ii
!\
._235CD0204E
20-35
TESTING
ADJUSTING
AND ADJUSTING
ADJUSTING
SLIP LOAD OF CIRCLE ROTATION
SLIP LOAD OF CIRCLE ROTATION
CLUTCH
CLUTCH
Serial No.: 11001 - 12050 INSPECTION 1. Remove 2.
plug (I).
Make a mark on holder from the plug hole.
(2) and
lock plate
(3)
F23501402
‘1
3.
Make a mark on cover (4) that is on the same line as the mark on lock plate (3). I
Mark
heck mark from lug hole
F23501401
4.
Push the blade against the ground surface so that the circle does not rotate, lift the front wheels off the ground or fix the end of the blade in position. Method of raising front wheels off ground 1) Lower the work equipment to the ground, extend the blade lift cylinder further, and raise the front wheels off the ground. 2) Apply the parking brake. Front
a
wheels
raised
off
around
When raising the front wheels off the ground, put blocks under the frame at the center of the front axle to ensure safety.
TWG00300
Edge
of
blade
held
in Position TWG00301
20-36 0
TESTING
AND ADJUSTING
ADJUSTING
Operate the circle rotation lever and check if the clutch slips. METHOD OF CHECKING FOR SLIPPAGE 1) If it slips, the sound of sliding can be heard, so return the circle rotation lever to the neutral position to stop the slippage. 2) Check if the slippage occurred because the mark on the cover and lock plate were out of alignment. * However, if the angle of misalignment is within 20”, consider that it is not slipping. ADJUSTING 1. When clutch does not slip. 1) Loosen bolts (I) and add 0.2 mm shim (2). 2) Tighten bolts (1) in the order of tightening. 3) Refer to the procedure for inspection, and repeat Steps 1) and 2) until there is slippage to align to the slippage limit point. 2. When clutch slips. 1) Loosen bolts (I) and remove 0.2 mm shim (2). 2) Tighten bolts (I) in the order of tightening. 3) Refer to the procedure for inspection, and repeat Steps I) and 2) until there is no more slippage. When the slippage stops, loosen bolt (I), add one 0.2 mm shim (21, and align with the slippage limit. * If a shim is added, the pushing force of the belleville spring becomes smaller, and it is easier for the clutch to slip. If a shim is removed, the pushing force of the belleville spring becomes larger, and it is difficult for the clutch to slip. BREAKING IN CLUTCH . When the clutch disc is replaced with a new part, break in the clutch as follows. Adjust in Steps 1 and 2 above to align to the slippage limit point. 2) Make the clutch slip for 3.5 - 4.0 seconds. . Run the engine at full throttle . The clutch disc will rotate one turn when it slips for 3.5 - 4.0 seconds. 3) Repeat Step 2) 20 - 25 times at three minutes intervals. * Precautions a) If the clutch housing temperature exceeds 5O”C, stop the breaking-in operation until it cools down to the normal temperature. b) If the clutch stops slipping during the operation, add one shim of 0.2 mm to make the clutch slip. 4) Adjust again to the slippage limit point. * Wait for the clutch housing to cool down to the normal temperature before adjusting.
SLIP LOAD OF CIRCLE ROTATION
CLUTCH
5.
I
Cover
F23501405
\I
F23501406
i)
[Order of tightening bolts]
c
Shim thickness (Slipoaae limit (Alien to this thickness)
Shim Shim does
thickness not slip
F23501407
that slips Point) shim
thickness
that TWG00243
20-37
TESTING
AND ADJUSTING
ADJUSTING
SLIP LOAD OF CIRCLE ROTATION
CLUTCH
Serial No.: 12051 and up Testing 1. Remove bolt (I), then remove cover (2). 2. To prevent the circle from rotating, push the blade against the ground and raise the front wheels or secure the ends of the blade. . Method of raising front wheels I) Lower the work equipment to the ground, then extend the blade lift cylinder further to jack up the front wheels. 2) Apply the parking brake. Put a block under the frame at the center of the front axle. 3. Operate the circle rotation lever and check that the clutch slips. . When it starts to slip, there will be a sliding noise and the holder at the tip of the shaft will rotate. After checking, return the circle rotation lever to the neutral position. However, if the slippage stops immediately, judge that it is not slipping.
A
Front
wheels
raised
off
eround
I
TWG00300
Adjusting t Adjust the pushing force of belleville spring (6) by adjusting the number of shims (5). INCREASE shims to DECREASE pushing force and make it EASY to slip DECREASE shims to INCREASE pushing force and make it DIFFICULT to slip 1.
When clutch does not slit, 1) Remove bolt (3), then’remove holder (4) and add shim (5) of 0.2 mm. 2) Install holder (4), then tighten bolt (3). w Mounting bolt : 110.5 f 12.5 Nm Ill.25 f 1.25 kgm) 3) Repeat the testing procedure to check if the clutch slips. 4) Repeat steps I) to 3) until the clutch slips to align to the slippage limit point. 5) When the clutch slips, remove shim (5) of 0.2 mm. Set to the shim thickness where the clutch does not slip.
Edae
of
blade
held
in
position TWG00301
I +
Shim thickness (Slivvaae Ilmlt
that Point)
slips
l
Chim
I
I
20-38 0
Shim
(Al
thickness ian to this
that shim
does not thickness)
thickness SIIP TWG00302
I
TESTING
2.
AND ADJUSTING
ADJUSTING
When clutch slips 1) Remove bolt (3), then remove holder (4) and take out shim (5) of 0.2 mm. 2) Install holder (4), then tighten bolt (3). w Mounting bolt : 110.5 + 12.5 Nm ill.25 k 1.25 kgm1 3) Repeat the testing procedure to check if the clutch slips. 4) Repeat steps I) to 3) until the clutch slips to align to the slippage limit point. 5) When the clutch slips, remove shim (5) of 0.2 mm. . Set to the shim thickness where the clutch does not slip.
SLIP LOAD OF CIRCLE ROTATION
Shim thickness (SliPPage limit
1
CLUTCH
that slips Paint)
0.2mm
b
0
Chim Shim thickness (Alien to this
that shim
does not thickness)
thickness
slip TWG00302
Breaking in clutch When the clutch disc is replaced with a new part, break in the clutch as follows. 1) Adjust in Steps 1 and 2 above to align to the slippage limit point. 2) Make the clutch slip for 3.5 - 4.0 seconds. . Run the engine at full throttle . The clutch disc will rotate one turn when it slips for 3.5 - 4.0 seconds. 3) Repeat Step 2) 20 - 25 times at three minutes intervals. * Precautions exceeds a) If the clutch housing temperature 5O”C, stop the breaking-in operation until it cools down to the normal temperature. b) If the clutch stops slipping during the operation, add one shim of 0.2 mm to make the clutch slip.
.
z z 2
4) 5)
Wait for clutch to cool down to normal temperature. Adjust again to the slippage limit point. . Set to shim thickness that does not slip
20-39 0
TESTING
ADJUSTING
AND ADJUSTING
ADJUSTING CLEARANCE F AND R SWITCHES Adjusting 1. Set the shift lever to the neutral operate to the REVERSE position.
CLEARANCE
OF F AND R SWITCHES
OF
position
and
2.
Change the tightening position of nut (I) to adjust the clearance between shift lever plate (2) and R switch (3). * Clearance : 2 mm
3.
Set the shift lever to the neutral position operate to the FORWARD position.
4.
Change the tightening position of nut (I) to adjust the clearance between shift lever plate (2) and R switch (4). * Clearance : 2 mm
and
Checking actuation . Check that the LEDs in the F switch and R switch light up when the switch is ON. Turn the starting switch on and check that the F switch (R switch) LED lights up when the shift lever is operated to the F (RI position.
4
3
I
I
l
20-40 0
2
II
TWG00255
TESTING AND ADJUSTING
ADJUSTING SHIFT POTENTIOMETER
ADJUSTING SHIFT POTENTIOMETER
023502
Serial No.: 12013 – 12015, 12019 – 12098
20-41 (6)
TESTING
AND ADJUSTING
ADJUSTING Serial
ADJUSTING
INCHING
No.: 12013 - 12015,
INCHING
POTENTIOMETER
POTENTIOMETER
12019 and up
Transmission control valve \
From inchina Pedal
.
1. 2. 3.
4.
5.
TWG00303
Adjust the output voltage of the inching potentiometer by adjusting the mounting angle of potentiometer (2). Remove cover (I). Insert a T-adapter into connector TM1 1. Turn the starting switch ON and adjust the voltage between terminals @ and @ of TMII. . Adjust with the inching pedal not pressed. Voltage: 0.53 f 0.08 V . The voltage can be changed by loosening screw (3) and changing the mounting angle of potentiometer (2). & Portion A of potentiometer (2): LM-G Turn the starting switch OFF and remove the Tadapter. . Connect connector TM1 1 to its original position. Reset the controller (0 drift). 1) Turn the starting switch ON. 2) Ground the OD terminal inside the right console box to the chassis.
20-42 0
TWG00260
ADJUSTING MONITOR The
SPEEDOMETER
speedometer
common model,
part the
on
for
the
input
signal
different,
so it is necessary
to match
the model.
Adjustment Remove
machine
all models,
but
for
monitor
depending
the
to adjust
MODULE
travel
is
OF MACHINE
a
on the speed
is
the speedometer
procedure the machine
monitor,
and adjust
at the back
of the speedometer.
1.
Remove
rubber
caps
II and Ill at the back
of the
speedometer. 2.
When
the
switch
be
of
the
number switch
rubber
can with
the table
caps seen
are
removed,
a rotary
inside.
Check
the
part
speedometer,
then
turn
this
a screwdriver
to adjust
as shown
in
below.
(Part No. 7831-85-6000)
1
3.
Switch11
1
Switch
121213131E
After
III
completing
securely
3
/
3
1
3
adjustment,
and install the machine
1
3
i
7 Screwdriver
fit the rubber
b
423F336
caps
monitor.
423F337
20-43 0
TROUBLESHOOTING Points to remember when troubleshooting ....................................................................................... 20- 46 Sequence of events in troubleshooting ............................................................................................. 20- 47 Handling of electric equipment and hydraulic component ............................................................. 20- 48 Checks before troubleshooting ........................................................................................................... 20- 56 Electrical circuit system diagram ........................................................................................................ 20- 57 Connector types and mounting locations ....................................................................................... 20-60-49 Electrical wiring diagram .................................................................................................................. 20-60-60 Connection table for connector pin numbers ................................................................................ 20-60-63 T-branch box and T-branch adapter table ........................................................................................ 20-60-99 Method of using troubleshooting charts ...................................................................................... 20-60-102 Details of troubleshooting and troubleshooting procedure ....................................................... 20-60-104 Troubleshooting of engine (S mode) ................................................................................................. 20- 61
023502
Troubleshooting chart for electronic vehicle monitoring system (M mode) ................................. 20- 81 Troubleshooting chart for electronic (engine, parking brake, transmission control) (E mode) ..................................................................................................... 20-101 Troubleshooting chart for transmission controller (ET mode) ......................................................... 20-151 Troubleshooting chart for hydraulic system (H mode) ..................................................................... 20-201
20-45 (5) 2
POINTS
TROUBLESHOOTING
POINTS TO REMEMBER a
Stop the machine
AL
When
carrying
allow a
in a level
If the radiator
a
Be extremely
a
When
disconnecting
a
When
removing
careful
the internal The aim prevent When
wiring,
first.
of troubleshooting reoccurrence
of possible
carrying
keep
the negative which
the
basic
and important troubleshooting
of the failure
have
cause
that
would
point
produce
no connection
with
the reported
to find
a waste
reason,
when
carrying to carry
the
5)
parts,
will
Check
the stroke maintenance
4.
*
or
5.
in
.
the machine
with
suddenly,
what
conditions
repairs
were
these
same
kind
of failure
*
ma-
Check the oil level Check
the piping
20-46 0
any
external
or hydraulic
Check the travel
investigation
of the
to reenact do
not
or measure-
investigation
2 - 4 to narrow
of failure,
flowchart
worse.
then
to
and
in-
down
the
use the troubleshoot-
locate
the
position
of the
exactly.
The basic
procedure
for troubleshooting
Start
from
the simple
Start
from
the most
3)
Investigate
the
occurred
6.
Measures
.
to remove
Even if the failure of the failure
be-
will
occur
cause. of oil from
equipment. levers.
other
points. likely
related
points. parts
or in-
formation.
occur?
problem
of the control
of op-
symptoms,
1)
out?
leakage
the machine
2)
troubleshooting
1)
yourself,
it as a real fail-
the method
there
out before
carried
failure
before
or were
condition
carried
repairs
2) 3)
ex-
is considered
may make the problem
in Items
To prevent
for
spool.
is as follows.
did the failure
been
out any
results
failure the
with
operating
Use the
ing
apart from
about
of the to handle
troubleshooting
spection
occurred?
occur
before
valve
Troubleshooting
reported?
strange
the failure
When
causes occurred
problems
Check
idea
etc.
the
procedure.
has been
anything
before
Has the
some
can be checked
any item that
whether
ment that
prior
fore? 3.
so check
carry
failure? 6)
and to
and function.
to form
items
ure or as a problem
out troubleshoot-
Did the failure
When
release
swiftly,
of the control
Confirming failure . Confirm the extent
also lose
out thorough
problems
that
there
Had any
repairs
the structure
Other
to ask user or operator
Have any other
Under
for
symptoms.
this? 4)
or air, always
questions
4)
cause
out troubleshooting
the fixed
the problem
3)
various
ternally,
be disas-
of manhours,
and to carry with
chine
so wait
it properly.
out
to understand
of the user or operator.
it is necessary
Was
oil, water,
to carry
eration,
and at the same time,
investigation
2)
from
5) any
the fail-
parts will
impossible
also cause
the confidence
1)
burns,
first.
be sure to connect
is of course
do not hurry immediately
unnecessary
become
oil or grease,
Points
pressure
is to ask the operator
of the failure.
2.
and do not
parts.
of the battery
and judge
accordance
signals,
fitted.
to be necessary.
ure or other
For this
are securely
out and cause
rotating
of the failure,
sembled.
ing,
in any
equipment,
the components.
failure occurs: . Parts that
It will
to the agreed
(-) terminal
is under
measuring
is to pinpoint
are disassembled
It will
strictly
brake
of the failure.
If components
.
and parking
may spurt
or to get caught
a location
out troubleshooting,
to disassemble
hot parts
installing
cut to effective
causes
workers,
is hot, hot water
disconnect
out troubleshooting,
a short
pin, blocks,
troubleshooting.
any
When
or more
the engine
always
TROUBLESHOOTING
near.
starting
the plug or cap from
carrying
When
when
before
not to touch
pressure
However,
1.
down
two
to come
cap is removed
to cool
with
person
WHEN
WHEN TROUBLESHOOTING
and check that the safety
out the operation
any unauthorized
the engine
place,
TO REMEMBER
root
cause
is repaired,
is not repaired,
of failure if the root cause the same failure
again. this, occurred.
always Then,
investigate remove
why the
the root
TROUBLESHOOTING
SEQUENCE OF EVENTS IN TROUBLESHOOTING
SEQUENCE
OF EVENTS IN TROUBLESHOOTING
Office, shop eP 1 IExamination, 1)
When
confirmation a request
21
repairs
&Q
TFWII”II(I
Jobsite
is received,
first
,,
II
points.
*
Name
of customer
-
Type,
serial
-
Details
R ins!
number
of jobsite,
Ask questions
RO
1
of symptoms
for
ask the following
TFWnOl
Ring!
of machine etc.
to gain an outline
of the prob-
Ien% -
Condition
-
Work
of failure
being
carried
out at the time
TEW00182
of the
failure . .
Operating
eP 2 Determining 1)
environment
Past history,
details
of maintenance,
etc.
TEP01348 probable
Look
at the
shop
manual
location
of cause
troubleshooting to
find
section
locations
of
of the possible
causes.
* 2)
Hydraulic
Look essary
pressure
in the parts replacement
book
gauge end
Decide
kit, etc.
prepare
1 Repair
at
action
to take
/ )
jobsite
the necBefore
parts.
repair -
*
2)
starting simple
troubleshooting,
Check
before
Other
check
and
starting
select
n
items
items
See the Troubleshooting manual,
locate
failures.
Section
of the shop
a troubleshooting
flowchart
Step 6 &-enacting
.
Drive the
failure] and
operate
condition
and
the judge
machine if there
to confirm is really
a
failure. TEP01351
Was there chine
anything
before
Did the failure TEWOOlB9
-
Had any repairs failure?
strange
the failure occur
about
the
ma-
out before
the
occurred?
suddenly?
been carried
TEWOOl91
20-47 0
HANDLING OF ELECTRIC EQUIPMENT AND HYDRAULIC COMPONENT
1
To maintain the performance of the machine over a long period, and to prevent failures or other troubles before they occur, correct “operation“, “maintenance and inspection“, “troubleshooting“, and “repairs” must be carried out. This section deals particularly with correct repair procedures for mechatronics and is aimed at improving the quality of repairs. For this purpose, it gives sections on “Handling electric equipment” and “Handling hydraulic equipment” (particularly gear oil and hydraulic oil).
2.
Main failures occurring in wiring harness 1) 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. The corroded or oxidized contact surfaces may become shiny again (and contact may become normal) by connecting and disconnecting the connector about 10 times. 2)
20-48 (5)
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.
023502
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.
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.
4)
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. Accordingly, take care not to splash water over the connector. 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, if 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.
5)
Oil or dirt stuck to connector If oil or grease are 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 it dry with compressed air and spray it with a contact restorer. a When wiping the mating portion of the connector, be careful not to use excessive force or deform the pins. a 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.
023502
3)
20-49 (5)
Removing, installing, and drying connectors and wiring harnesses 1) Disconnecting connectors 1] Hold the connectors when disconnecting. When disconnecting the connectors, hold the connectors. 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. a Never pull with one hand. 2] q
20-50 (5)
When removing from clips Both of the connector and clip have stoppers, which are engaged with each other when the connector is installed.
q
When removing a connector from a clip, pull the connector in a parallel direction to the clip for removing stoppers. a If the connector is twisted up and down or to the left or right, the housing may break.
3]
Action to take after removing connectors After removing any connector, cover it with a vinyl bag to prevent any dust, dirt, oil, or water from getting in the connector portion. a If the machine is left disassembled for a long time, it is particularly easy for improper contact to occur, so always cover the connector.
023502
3.
023502
2)
Connecting connectors 1] Check the connector visually. Check that there is no oil, dirt, or water stuck to the connector pins (mating portion). Check that there is no deformation, defective contact, corrosion, or damage to the connector pins. Check that there is no damage or breakage to the outside of the connector. a 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. a If there is any damage or breakage, replace the connector. 2] Fix the connector securely. Align the position of the connector correctly, and then insert it securely. For connectors with the lock stopper, push in the connector until the stopper clicks into position. 3] Correct any protrusion of the boot and any misalignment of the wiring harness. For connectors fitted with boots, correct any protrusion of the boot. In addition, if the wiring harness is misaligned, or the clamp is out of position, adjust it to its correct position. a If the connector cannot be corrected easily, remove the clamp and adjust the position. q If the connector clamp has been removed, be sure to return it to its original position. Check also that there are no loose clamps.
20-51 (5)
Heavy duty wire connector (DT 8-pole, 12pole) Disconnection (Left of figure) While pressing both sides of locks (a) and (b), pull out female connector (2). Connection (Right of figure) 1] Push in female connector (2) horizontally until the lock clicks. Arrow: 1) 2] Since locks (a) and (b) may not be set completely, push in female connector (2) while moving it up and down until the locks are set normally. Arrow: 1), 2), 3) a Right of figure: Lock (a) is pulled down (not set completely) and lock (b) is set completely. (1): Male connector (2): Female connector (a), (b): Locks
q
Disconnection
q
Connection (Example of incomplete setting of (a))
023502
3)
20-52 (5)
023502
4)
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. 1] Disconnect the connector and wipe off the water with a dry cloth. a 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 oi l a nd wa ter fr om t he c om pressed air before blowing with air. 2] Dry the inside of the connector with a dryer. If water gets inside the connector, use a dryer to dry the connector. a 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. 3] 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. a After completely drying the conn e c t o r, b l o w i t w i t h c o n ta c t restorer and reassemble.
20-53 (5)
Handling controller 1) The controller contains a microcomputer and electronic control circuits. These control all of the electronic circuits on the machine, so be extremely careful when handling the controller. 2) Do not place objects on top of the controller. 3) Cover the control connectors with tape or a vinyl bag. Never touch the connector contacts with your hand. 4) During rainy weather, do not leave the controller in a place where it is exposed to rain. 5) Do not place the controller on oil, water, or soil, or in any hot place, even for a short time. (Place it on a suitable dry stand). 6) Precautions when carrying out arc welding When carrying out arc welding on the body, disconnect all wiring harness connectors connected to the controller. Fit an arc welding ground close to the welding point.
5.
Points to remember when troubleshooting electric circuits 1) Always turn the power OFF before disconnecting or connecting connectors. 2) Before carrying out troubleshooting, check that all the related connectors are properly inserted. a Disconnect and connect the related connectors several times to check. 3) Always connect any disconnected connectors before going on to the next step. a If the power is turned ON with the connectors still disconnected, unnecessary abnormality displays will be generated. 4) When carrying out troubleshooting of circuits (measuring the voltage, resistance, continuity, or current), move the related wiring and connectors several times and check that there is no change in the reading of the tester. a If there is any change, there is probably defective contact in that circuit.
20-54 (5)
023502
4.
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. Be careful of the operating environment. Avoid adding hydraulic oil, replacing filters, or repairing the machine in rain or high winds, or places where there is a lot of dust.
2.
Disassembly and maintenance work in the field If disassembly or maintenance work is carried out on hydraulic equipment in the field, there is danger of dust entering the equipment. It is also difficult to check the performance after repairs, so it is desirable to use unit exchange. Disassembly and maintenance of hydraulic equipment should be carried out in a specially prepared dustproof workshop, and the performance should be checked 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 danger of dirt entering or of the surrounding area being made dirty by leaking oil so never do this. Do not simply drain oil out onto the ground, but 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 Be careful not to let any dirt or dust get in when refilling with hydraulic oil. Always keep the oil filler and the area around it clean, and also use clean pumps and oil containers. If an oil cleaning device is used, it is possible to filter out the dirt that has collected during storage, so this is an even more effective method.
023502
1.
20-55 (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 3 m) particles that the filter built in the hydraulic equipment cannot remove, so it is an extremely effective device.
023502
5.
20-55-1 (5)
Electrical
check
components
Other
023502
items
A A A
compo”e”tS
Hydraulic. mechamcal
Item Electrical equipment Lubricating
Checks
P 0 13 .‘
water
starting
oil, cooling
before
8
TROUBLESHOOTING
ELECTRICAL
ELECTRICAL CIRCUIT SYSTEM
CIRCUIT
SYSTEM
DIAGRAM
DIAGRAM
ELECTRONIC VEHICLE MONITORING SYSTEM Serial No.: 11001 - 12012, 12016 - 12018
Final drive oil wllperature sensor
Engine oil pressure switch
[r/i
iii/i1
IF Radiator water level sensor
II/l
Hydraulic oil level sensor
CN PL
DIFF
+-.--J&
(Right) e *ensor
Accumulator Fl0a1
(Left
Parking To flasher relay Warning
To turn signal lamp To head lamp
I
II
lllll
Startina
watertemperature
62
I ST
Electrical Intake
Head lamp Hi-Low
u
---
.
,-,
235FO2079
20-57 0
ELECTRICAL
TROUBLESHOOTING
CIRCUIT
SYSTEM
DIAGRAM
Y”’
PleSS”le
switch
Electrical air
Head Iaav snitch
Winker (2OW)
Starting motor
w/-
Winker
125W)
Parking
13W)
Winker
(25W)
Parking
(3Wl
intake heater
Alternator TWG00345
20-59 0
TROUBLESHOOTING
ELECTRICAL
TRANSMISSION CONTROL Serial No.: 11001 - 11030
(l)The Procedure connectors
SYSTEM
DIAGRAM
SYSTEM
Body
PROCEDURE GEARSHIFT
CIRCUIT
1Transmission
control
box
Proximity switch(F)
Proximity switch(R1
(XtYPe)
IXtYPe)
ass’y Relay (Starting
FOR TESTING SIGNALS is
for as
connecting in shown
below.
to
the
GND lWG00244
20-60 0
TROUBLESHOOTING
Relay (BAck-uD buzzer)
ELECTRICAL
Relay (Diffe-
rent lall
Relay
(RI
CIRCUIT
SYSTEM
DIAGRAM
Relav(F)
Print
board
circus
CN-TO
1
Rotary
switch
I
Diode
(3lThe in (2)Connect specifications load and
q q q q q
the
pi
siana
iBack-uo
:Startina
lot
lamp check
1 to
actuation the table
is as below.
shown
(24V each
buzzer
motor
iDifferential
lock
LTransmission
R
clutch
solenoid
:Transmisslon
F
clutch
solenoid
solenoid
on
4th
clutch
so
enoid
on
3th
clutch
so
enold
on
2th
clutch
so
enoid
on
lth
clutch
so
enoid
on
low
clutch
so
on
hIat
clutch
enoid s 0 lenoid
TWG00245
20-60- 1 0
TROUBLESHOOTING
ELECTRICAL
Serial No.: 11031 - 12012,
SYSTEM
DIAGRAM
12016 - 12018
Body
Transmission -.._._-__-__-.._-.-._-___
CIRCUIT
solenoid
1 Transmission I
control
box
ass’y
valve
2nd 4th 1st LO Hi
3rd F R
PROCEDURE GEARSHIFT
FOR TESTING SIGNALS
(lIThe Procedure connectors Power drivino switch
1
difierkniiai
source
rotary relay
is
for as
connecting shown in
below.
to
the
for
lock
1 +14v 1
TWG00246
20-60-2 0
TROUBLESHOOTING
Relay
Relay
(BAck-ue buzzer)
(Differential)
ELECTRICAL
CIRCUIT
DIAGRAM
Relay Relar(R)
(Parking brake)
Relay(F)
int
board
CN-TO I (SWP type1
circuit ! p
-
(2)
SYSTEM
q q q q r-Y
sxich ISIP type1 P
-m
Diode
Connec t specif ~oao
0. 68rR
Rotary
the
Pilot
icationsi and sianal.
: Parking
lamp
: Parking
brake
iBack
lamp
to
check
(3)The in
(24V
actuation the table
is as below.
shown
each
buzzer
;Startino
motor
:Different
al
lock
;Transmlss
on
R
clutch
solenoid
;Transmlss
on
F
clutch
solenoid
:Transmiss
on
4th
clutch
solenoid
:Transmiss
on
3th
clutch
solenoid
:Transmiss
on
2th
clutch
solenoid
:Transmiss
on
Ith
clutch
solenoid
clutch
solenoid
:Transmiss
on
low
:Transmlss
on
hioh
solenoid
clutch
solenoid
TWG00247
20-60-3
023502
a-n -a :a --m 3m :;I:
memo,~ drift
CN-SWR ------1
CN-SWF
0
reset
CN-FRError
TROUBLESHOOTING
ELECTRICAL
CIRCUIT
SYSTEM
DIAGRAM
(2/2) Procedure (l)The
for testing
Procedure connectors
is
gearshift for as
signals
connecting to in below. shown Power sollrce for rI”l”g relay
far clutch
+24v
Power back-up
SoUrce for buzzer
+24V
Power startlna
source for motor
+24V
Power source differential
Power source transmission solenoid
the
Transmission cant rol box ass’
I
for lock
1 CN-E2’ +24V
Y
Transmission controller
----v
Ground
(2)
nect the oi cificationsl d and signal. iParking
(24V eat
:3) h
The in
actuation the table
is below.
as
shown
brake buzzer
:Starting
20-60-6 0
lamp check
lamp
:Parkino :Back
IO t to
mot0
r
iDifferential
lock
solenoid
:Transmission
R clutch
sole
:Transmission
F
sole
;Transmission
4th
clutch
so lenoid
:Transmission
3th
clutch
so lenoid
:Transmission
2th
clutch
so lenoid
;Transmission
lth
clutch
so lenoid
:Transmission
low
clutch
so lenaid
iTransmission
hioh
clutch
clutch
noid naid
s olenoid
TWG00306
TROUBLESHOOTING
CONNECTOR TYPES AND MOUNTING
CONNECTOR Connector
No.
TYPES AND MOUNTING 1Connectortype 1No. of pins 1
LOCATIONS
LOCATIONS
Mounting
1 Address
location
CNl
SWP
8
Intermediate
connector
(articulate
section)
F9, A4
CN2
X
8
Intermediate
connector
(articulate
section)
F7, A3
CN3
X
4
Intermediate
connector
(below
left side of floor
frame)
12
CN4
SWP
12
Intermediate
connector
(below
left side of floor
frame)
I2
CN5
SWP
14
Intermediate
connector
(below
left side of floor
frame)
HI
1 CN6
1 KES2
1
8
1 Intermediate
connector
(inside
of R.H. console
1 CN7
I
I
12
I Intermediate
connector
(left side of radiator)
SWP
box)
CN8
SWP
16
Intermediate
connector
(inside
of R.H. console
box)
CN9
SWP
12
Intermediate
connector
(inside
of R.H. console
box)
CNIO
Relay
5
Engine
oil pressure
CNII
-
1
Buzzer
(inside
/ G3, J3
1
1 E2, J7
1
1
G2 G2
relay
H4
of R.H. console
-
box)
1 CN12
I
-
I
-
Intermediate
connector
1 CN13
I
swp
I
8
I Intermediate
connector
(below
left side of floor
1
SWP
1
8
1 I ntermediate
connector
(inside
of R.H. console
connector
(next
CN14
I
I2 frame) box)
Gl
1
D2
SWP
12
Intermediate
CN16
KESl
2
Monitor
module
-
CN17
DLI
8
Monitor
module
-
module
CN19
/
DLI
I
12
1 Monitor
I
MIC
I
5
I Speedometer
I
module
16
Speedometer
module
CN21
M
3
Intermediate
connector
(below
CN22
X
4
Intermediate
connector
(next
CN23
-
Intermediate
connector
14
I Intermediate
connector
/
1 CN26 CN27
1
I
SWP
1
12
I Intermediate
connector
(below
1
SWP
/
16
I Intermediate
connector
(below
KESI
3
Head
lamp
CN29
YPC
2
Cab mount
CN30
SWP
2
Speed
CN31
X
1
Final
1
I Engine
1
I Fuel gauge
CN32
I
-
CN33
I
x
I I
Hi-Lo
frame)
/
HI
left side of floor
frame)
I
HI
left side of floor
frame)
I
G2
left side of floor
I4
switch
switch
oil pressure
2
Engine
water
1
Engine
oil level
switch
temperature
CN36
X
2
Hydraulic
K7
sensor
sensor
X
I
J6
1
J7
sensor
J9
sensor
oil level
J5
switch
L6
x
I
2
/ Air pressure
switch
(L.H.)
1 H9, K6
switch
(R.H.)
/
19, K6
I
D2
CN38
I
x
I
2
I Air pressure
CN39
/
KESI
I
3
/ Ra d’la t or coolant
CN41
c2
82, G7, 01
X
CN40
J4
to L.H. battery)
-
oil temperature
CN34
I
panel)
sensor drive
CN35
CN37
monitor
(below
selector
lamp
KESI YPC
3 6
Turn
signal
Hazard
level
switch
switch
(OPT)
I
H4
SWP
CN28
-
DLI
/ CN25
to L.H. battery)
]~~~:I
CN20
-
I
1A4. G9. 14.M51
CN15
I CN18
1
sensor
I5 -
20-60-7 0
I
TROUBLESHOOTING
cN -14
CN-74
ELECTRICAL
CN-37
Y
CN-30
cN-‘30
WIRING
DIAGRAM
CN-34
CN’-33
CNkT
ch -7
CN-7
1
CN-3
1
CN-37 CN-38
CN-36 CN-63
CN-
CN-32
CN- 82
CN-28
/
RPST
I
RPB
\ cN!lo
d-63
X
CN-40
CN-36
Y
,PL
c\N-61
7.-----
.21
i
/
‘\
14
I::4 63 91
20-60-11 0
TROUBLESHOOTING
ELECTRICAL
WIRING
DIAGRAM
(3/3)
RIL
R,CB
TM5 RBB \
\
SWF
CN-14
TM13
TM14
FR
TiC CN-30
TWG00299
20-60-12 0
TROUBLESHOOTING
CONNECTION
CONNECTION *
TABLE FOR CONNECTOR
The terms male and female refer to the pins, while refer to the mating portion of the housing.
No. of pins
TABLE FOR CONNECTOR
PIN NUMBERS
PIN NUMBERS
the terms
male housing
and female
Female
housing)
housing
X type connector Male (female
housing)
(male
2
TEW00222
TEW00223
1
2
3
4 TEW00225
TEW00224
3
1
4
2 TEW00226
20-60- 13 0
CONNECTION
TROUBLESHOOTING
AMP040
No. of pins
Male
(female
n
type
TABLE
FOR CONNECTOR
connector Female
housing) 4
8
PIN NUMBERS
8
(male
housing)
4
\
8
BLPOOO53
12
6
5
1
BLWOO54
6
12
ELW0056
8
?8 16
8
16
BLPO0057
10
20
B
20-60-14 0
1'
TEW00232
20
ii
BLWOO56
TEW00234
CONNECTION
TROUBLESHOOTING
No. of pins
TABLE
FOR CONNECTOR
PIN NUMBERS
DLI connector Female
(female
Male
housing)
I
(male
housing)
4
5 8
TLG00099
TLGOOlOO
I
7
12
12
TLGOOlOl
TLG00102
16
TLG00103
TLG00104
TROUBLESHOOTING
No. of pins
CONNECTION
T
TABLE
FOR CONNECTOR
PIN NUMBERS
MIC connector Male
5
(female
Female
housing)
H
BLPWO45
(male
housing)
BLP00046
9
BLPOoO47
BLPM)O48
13
8 13
H
BLmoo49
BLPCOO50
9
17 17
I
1
BLPOoo51
BLPOO052
21
1
20-60-16 0
1
TEW00259
TEW00260
CONNECTION
TROUBLESHOOTING
No. of pins
SWP type Male
(female
TABLE
FOR CONNECTOR
PIN NUMBERS
connector Female
housing)
(male
housing)
6
3
TEW00235
s
4’
TEW00237
8
4
BLPOOO35
BLPOOO34
1
4
8
11
3
i
io
‘14 TEW00239
4
11
8
4
14
IO
7
1
TEW00240
1
ELF00036
20-60-17 0
TROUBLESHOOTING
No. of pins
CONNECTION
T
TABLE FOR CONNECTOR
PIN NUMBERS
M type connector Male (female
housing)
Female
(male
housing)
2
1
BLPcoO39
BLP00038
3
TEW00244
TEW00243
2
4
4
2
TEW00245
‘6
8
20-60-l 0
8
TEW00247
TEW00246
4
1
6
3
TEW00248
TROUBLESHOOTING
No. of pins
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
Econoseal Female
(female
connector
housing)
Male
(male
housing)
2
TEZOQZZO
3
‘I TKL00295
TKL00296
TKL00297
TKL00298
4
8
5’
2
‘1
3
TKLOOZSS
TKL00300
3
TKL00302
12
6
2
I
TKL00301
20-60-19 0
CONNECTION
TROUBLESHOOTING
No. of pins
T
Automobile Male
(female
housing)
TABLE
FOR CONNECTOR
connector Female
(male
housing)
FB
2
I
BLPOO063
3
PIN NUMBERS
BLPOO064
2 2
I
3’
‘4
BVLOll43
3
1
6
BLPoOO69
8
5 BLPOO071
20-60-20 0
8 BLPOoO72
CONNECTION
TROUBLESHOOTING
No. of pins
Automobile Female
(female
connector
TABLE FOR CONNECTOR
% without
lock
Male (male
housing)
PIN NUMBERS
housing)
2
4
: I
TLG00048
TLG00049
3
6 2
1
5
4 TLG00050
TLG00051
20-60-21 0
TROUBLESHOOTING
CONNECTION
No. of pins
TABLE FOR CONNECTOR
PIN NUMBERS
Relay connector Male (female
housing)
Female
(male
housing)
5
1
3
6
BLPOOO73
BLPO0074
6
5
6
BLFuOO75
20-60-22 0
BLFQ0076
TROUBLESHOOTING
No. of pins
CONNECTION
TABLE FOR CONNECTOR
PIN NUMBERS
Yazaki (YPC) connector Female
(male
Male (female
housing)
/I;K
2
I
I
H
housing)
2
TLG00034
m 2
3
TLC00035
2
‘1, 3
y
I TLG00036
1
TLG00037
3
lx 0 0
4
6 TLG0003.3
TLG00039
20-60-23 0
TROUBLESHOOTING
METHOD 1.
Category
METHOD
OF USING TROUBLESHOOTING of troubleshooting
CHARTS
CHARTS
Component
s-00
Troubleshooting
of engine
M-00
Troubleshooting
of electronic
vehicle
monitoring
E-00
Troubleshooting
of electronic
(engine,
parking
ET-00
Troubleshooting
of transmission
H-00
Troubleshooting
of hydraulic
Method
TROUBLESHOOTING
code number
TroubleshootingCode No.
2.
OF USING
related
parts
controller
system brake,
transmission
control)
system
system
of using troubleshooting table for each troubleshooting mode code number and problem I) Troubleshooting The title of the troubleshooting chart gives the troubleshooting code, service code, and failure mode (problem with the machine). (See Example (I)) conditions 2) Distinguishing Even with the same failure mode (problem), the method of troubleshooting may differ according to the model, component, or problem. In such cases, the failure mode (problem) is further divided into sections marked with small letters (for example, a), so go to the appropriate section to carry out troubleshooting. (See Example (2)) If the troubleshooting table is not divided into sections, start troubleshooting from the first check item in the failure mode. troubleshooting chart 3) Method of following YES Check or measure the item inside v, and according to the answer follow either the YES line or the NO line to go to the next /. (Note: The number written at the top right corner of the I is an index number; it does not indicate the order to follow.) . Following the YES or NO lines according to the results of the check or measurement will lead finally to the Cause column. Check the cause and take the action given in the Remedy column on the right. (See Example (3)) . Below the 0 there are the methods for inspection or measurement, and the judgement values. If the judgement values below the I are correct or the answer to the question inside the I 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 I is given the preparatory work needed for inspection and measurement, and the judgement values. If this preparatory work is neglected, or the method of operation or handling is mistaken, there is danger that it may cause mistaken judgement, or the equipment may be damaged. Therefore, before starting inspection or measurement, always read the instructions carefully, and start the work in order from Item 1). 4) General precautions When carrying out troubleshooting for the failure mode (problem), precautions that apply to all items are given at the top of the page and marked with Ir (See Example (4)) _ The precautions marked * are not given in the I, but must always be followed when carrying out the check inside the I. tools 5) Troubleshooting When carrying out the troubleshooting, prepare the necessary troubleshooting tools. For details, see TOOLS FOR TESTING, ADJUSTING, AND TROUBLESHOOTING. position, pin number 6) Installation A diagram or chart is given for the connector type, installation position, and connector pin number connection. When carrying out troubleshooting, see this chart for details of the connector pin number and location for inspection and measurement of the wiring connector number appearing in the troubleshooting flow chart for each failure mode (problem). l
20-60-24 0
METHOD
TROUBLESHOOTING
(I) E-l Engine does not start (starting (4) *
motor
OF USING
TROUBLESHOOTING
CHARTS
works).
Before carrying out troubleshooting, check that all the related connectors are properly inserted. Always connect any disconnected connectors before going on the next step. Check that the coolant is at the specified level before carrying out troubleshooting
j, Sr
(2) a) cc)-
(coolant
level)
flashes
SAP00519
Divided oil level)
(engine
into sections
a) and b)
flashes
SAP00523
YES 1 Is voltage between CO1 (7) (13) and CO2 (11) (21) normal? * Turn starting switch ON. *20-30V
I
2
YES
Is voltage between fuse 1 NO a,;;;;;l:5is * Turn starting switch ON. *20-30V
NO
Defective governor, pump controller
Replace
Defective contact, or disconnection in wiring harness between fuse 1 and CO1 (female) (7) (13)
Repair or replace
Defective contact, or disconnection in wiring harness between fuse l-H15 (2kM14 (2) (I j-battery relay M
Repair or replace
20-60-25 0
TROUBLESHOOTING
METHOD
METHOD
OF USING TROUBLESHOOTING
This troubleshooting chart is divided into three sections: questions, check items, and troubleshooting. The questions and check items are used to pinpoint high probability causes that can be located from the failure symptoms or simple inspeciton without using troubleshooting tools. Next, troubleshooting tools or direct inspection are used to check the high probability causes to make final confirmation. [Questions] Sections @ + @ in the chart on the right corresponds to the items where answers can be obtained from the user. The items in @ are items that can be obtained from the user, depending on the user’s level. [Check items1 The serviceman carries out simple inspection to narrow down the causes. The items under @ in the chart on the right correspond to this. The serviceman narrows down the causes from information @ that he has obtained from the user and the results of @ that he has obtained from his own inspection. [Troubleshooting] Troubleshooting is carried out in the order of probability, starting with the causes that have been marked as having the highest probability from information gained from [Questions] and [Check items].
20-60-26 0
OF USING
TROUBLESHOOTING
CHARTS
CHARTS
TROUBLESHOOTING
METHOD
OF USING
TROUBLESHOOTING
CHARTS
The basic method of using the troubleshooting chart is as follows. Items listed for [Questions] and [Check items] that have a relationship with the Cause items are marked with 0, and of these, causes that have a high probability are marked with @. Check each of the [Questions] and [Check items] in turn, and marked the 0 or 0 in the chart for items where the problem appeared. The vertical column (Causes) that has the highest number of points is the most probable cause, so start troubleshooting for that item to make final confirmation of the cause. ‘331. For [Confirm recent repair history] in the [Questions] Section, ask the user, and mark the Cause column with A to use as reference for locating the cause of the failure. How+ ever, do not use this when making calculations to narrow down the causes. ,%2. Use the n in the Cause column as reference for [Degree of use (Operated for long period)] in the [Questions] section as reference. As a rule, do not use it when calculating the points for locating the cause, but it can be included if necessary to determine the order for troubleshooting.
Xl
Confirm recent repair history
%2
Degree of use
Operatred for long period
nna
20-60-27
METHOD
TROUBLESHOOTING
.
OF USING
TROUBLESHOOTING
CHARTS
Example of troubleshooting when exhaust gas is black Let us assume that [Clogged air cleaner] is taken to be the cause of black exhaust gas. Three symptoms have causal relationship with this problem: [Exhaust gas slowly became black], [Power slowly became weaker], and [Dust indicator is red]. If we look from these three symptoms to find the causes, we find that there is a relationship with five causes. Let us explain here the method of using this causal relationship to pinpoint the most probable cause.
s-7 Exhaust gas is black (incomplete combustion) General causes why exhaust gas is black . Insufficient intake of air . Improper condition of fuel injection . Excessive injection of fuel
Non-spmfied
fuel has been used
When check is,made
20-60-28 0
“sing
delivery
method.
in,ec,v,”
tm,i”g
TROUBLESHOOTING
METHOD
OF USING
TROUBLESHOOTING
CHARTS
Five causes
+
Step 1
Clarify the relationship between the three symptoms in the [Questions] and [Check items] section and the five Cause items in the vertical column.
Three symptoms t
t
A
Step 2 I Add UP the total of 0 and 0 marks where the horizontal lines for the three symptoms and the vertical columns for the causes intersect. (I) Clogged air cleaner element: 000 (2) Air leakage between turbocharger and head: 00 0 1 (3) Clogged, seized injection nozzle: (4) Defective contact of valve, valve seat: o (5) Worn piston ring, cylinder: 0 Step 3 The calculation in Step 2 show that the closest relationship is with [Clogged air cleaner element]. Follow this column down to the troubleshooting area and carry out the troubleshooting item marked 0. The Remedy is given as [Clean], so carry out cleaning, and the exhaust gas color should return to normal.
20-60-29 0
TESTING AND ADJUSTING
CONNECTOR TYPES AND MOUNTING LOCATIONS
023502
Serial No.: 12019 – 12502
20-60-52 (6)
TESTING AND ADJUSTING
CONNECTOR TYPES AND MOUNTING LOCATIONS
Serial No.: 12503 and up
023502
Connector No.
Connector type No. of pins
Mounting location
Address
CN1
DT-T
8
Intermediate connector (articulate section)
F9, A4
CN2
DT-T
8
Intermediate connector (articulate section)
F7, A3
CN3
DT-T
12
Intermediate connector (below left side of floor frame)
H1
CN4
DT-T
4
Intermediate connector (below left side of floor frame)
H1
CN5
DT-T
12
Intermediate connector (below left side of floor frame)
H2
CN6
KES2
8
Intermediate connector (inside of R.H. console box)
G3, J3
CN7
DT-T
12
Intermediate connector (left side of radiator)
E2, J7
CN8
SWP
16
Intermediate connector (inside of R.H. console box)
G2
CN9
SWP
12
Intermediate connector (inside of R.H. console box)
G2
CN10
Relay
5
Engine oil pressure relay
H4
CN11
—
1
Buzzer (inside of R.H. console box)
—
CN12
—
—
Intermediate connector
—
CN13
DT-T
8
Intermediate connector (below left side of floor frame)
G2
CN14
DT-T
8
Intermediate connector (inside of R.H. console box)
CN15
SWP
12
Intermediate connector (next to L.H. battery)
D2
CN16
KES1
2
Monitor module
—
CN17
DLI
8
Monitor module
—
CN18
DLI
12
Monitor module
—
CN19
MIC
5
Speedometer module
—
CN20
DLI
16
Speedometer module
—
CN21
M
3
Intermediate connector (below monitor panel)
J4
CN22
DT-T
2
Intermediate connector (next to L.H. battery)
C2
CN23
—
—
Intermediate connector
H4
CN25
DT-T
12
Intermediate connector (below left side of floor frame)
H1
CN26
DT-T
12
Intermediate connector (below left side of floor frame)
I3
CN27
DT-T
8
Intermediate connector (below left side of floor frame)
J2
CN27A
DT-T
8
Intermediate connector (below left side of floor frame)
I1
CN28
KES1
3
Head lamp Hi-Lo selector switch
I4
CN29
YPC
2
Cab mount lamp switch
—
CN30
SWP
2
Speed sensor
CN31
X
1
Final drive oil temperature sensor
K7
CN32
—
1
Engine oil pressure switch
J6
CN33
X
1
Fuel gauge sensor
J7
CN34
X
2
Engine water temperature sensor
J9
CN35
X
1
Engine oil level sensor
J5
CN36
X
2
Hydraulic oil level switch
L6
CN37
X
2
Air pressure switch (L.H.)
H9, K6
CN38
X
2
Air pressure switch (R.H.)
I9, K6
CN39
KES1
3
Radiator coolant level sensor
D2
CN40
KES1
3
Turn signal switch
I5
A4, G9, I4, M5
B2, G7, O1
20-60-55 (6)
Connector No.
CONNECTOR TYPES AND MOUNTING LOCATIONS
Connector type No. of pins
Mounting location
Address
CN41
YPC
6
Hazard switch (OPT)
—
CN43
—
1
Intermediate connector (inside of R.H. console box)
—
CN46
—
1
Intermediate connector (inside of R.H. console box)
—
CN50
M
6
Intermediate connector (rear of operators seat)
K4
CN51
SWP
8
Engine stop motor
D5
CN52
DT-T
6
Intermediate connector (below left side of floor frame)
H2
CN53 (inside of R.H. console box)
Relay
5
Engine stop motor relay
CN53 (hydraulic oil tank)
X
1
Hydraulic oil temperature sensor
L6
CN55
DT-T
6
Intermediate connector (below left side of floor frame)
G1
CN56
—
1
Back-up alarm
—
CN57
KES0
4
Rear combination lamp (L.H.)
—
CN58
KES0
4
Rear combination lamp (R.H.)
—
CN59
—
1
Rear work lamp
—
CN61
Relay
5
Emergency steering relay
H4
CN63
X
1
Intermediate connector (below left side of floor frame)
H2
CN64
KES2
4
ESC (emergency steering) (inside of R.H. console box)
—
CN65
KES2
2
ESC (emergency steering) (inside of R.H. console box)
—
CN66
—
1
Intermediate connector (inside of R.H. console box)
H4
CN67
DT-T
2
Intermediate connector (below left side of floor frame)
—
CN67A
DT-T
2
Intermediate connector (below left side of floor frame)
I2, N2
CN67B
DT-T
2
Intermediate connector (below left side of floor frame)
I1, N2
CN68
M
2
Pressure switch (emergency steering)
H1
CN69
—
1
Rear work lamp
—
CN71
KES2
2
Differential lock solenoid
K7
CN73
KES2
2
Parking brake solenoid
B5
CN74
—
1
Air drier
CN77
—
1
Starting switch
—
CN79
SWP
16
Intermediate connector (rear of operator’s seat)
K4
CN82
KES0
2
Air pressure sensor
L5
CN86
X
3
R.H. sensor (blade float) (blade lift lever)
—
CN87
X
3
L.H. sensor (blade float) (blade lift lever)
—
CN88
—
1
Intermediate connector (blade float) (below left side of floor frame)
—
CN89
Relay
5
Blade float relay (R.H.)
—
CN90
Relay
5
Blade float relay (L.H.)
—
CN91
DT-T
2
Intermediate connector (below left side of floor frame)
J2
CN93
DT-T
4
Intermediate connector (below left side of floor frame)
J1
CNA7
X
2
Intermediate connector (below air tank)
—
CNA28
X
1
Intermediate connector (below air tank)
—
CNAC
X
1
Air conditioner compressor
—
CNAG
YPC
2
Air gauge
—
20-60-56 (6)
H4, K6
G9, K5
023502
TESTING AND ADJUSTING
TESTING AND ADJUSTING
023502
Connector No.
CONNECTOR TYPES AND MOUNTING LOCATIONS
Connector type No. of pins
Mounting location
Address
CNE1
MIC
13
Transmission controller
—
CNE2
MIC
21
Transmission controller
—
CNE3 (No.1 – 20)
AMP040
20
Transmission controller
—
CNE3 (No.21 – 36)
AMP040
16
Transmission controller
—
CNE4
AMP040
12
Transmission controller
—
CNE5
MIC
17
Transmission controller
—
CNFBW
YPC
2
Blade work lamp switch
—
CNFR
—
1
Error memory reset (inside of R.H. console box)
M3
CNFW
YPC
2
Front work lamp switch
—
CNOD
—
1
0 drift (inside of R.H. console box)
M2
CNPL
KES0
6
Pilot lamp
—
CNPL
—
1
Panel lamp
J4
CNRBB
Relay
5
Back-up buzzer relay
M8
CNRCB
Relay
5
Caution buzzer relay
P8
CNRDI
Relay
5
Differential lock relay
N8
CNRIL
Relay
5
Tail lamp (not used)
O9
CNRPB
Relay
5
Parking brake relay
G4
CNRPST
Relay
5
Starting motor relay
G4
CNRST
Relay
5
Starting motor relay
M7
CNRW
YPC
2
Rear work lamp switch
—
CNSM
—
1
Service meter
—
CNST
AMP
3
Starting motor
I7
CNSWF
X
3
F switch
M5
CNSWR
X
3
R switch
M6
CNT03
SWP
12
Transmission control switch
—
CNTM3
X
4
For flash memory write (transmission controller)
—
CNTM4
X
3
Shift potentiometer 1
M7
CNTM5
X
3
Shift potentiometer 2
N8
CNTM9
SWP
2
Engine speed sensor
R7
CNTM10
SWP
2
Transmission oil temperature senor
R3
CNTM11
X
3
Inching potentiometer
R6
CNTM13
DT-T
12
Intermediate connector (inside of R.H. console box)
M5
CNTM14
DT-T
12
Intermediate connector (inside of R.H. console box)
M4
CNTM15
DT-T
12
Intermediate connector (below left of air tank installation table)
R4
CNTM16
DT-T
12
Intermediate connector (below left of air tank installation table)
R4
CNTM95
DT-T
3
Intermediate connector (engine speed sensor)
R5
CNTMC
—
1
Intermediate connector (below left side of floor frame)
N2
E5
—
1
Intermediate connector (slow below fuse – fuse box)
G2
E6
—
1
Intermediate connector (slow below fuse – fuse box)
G2
20-60-57 (6)
TESTING AND ADJUSTING
ELECTRICAL WIRING DIAGRAM
023502
ELECTRICAL WIRING DIAGRAM (1/3)
20-60-59 (6)
TESTING AND ADJUSTING
ELECTRICAL WIRING DIAGRAM
(2/3)
023502
Serial No.: 11001 – 12502
20-60-60 (6)
TESTING AND ADJUSTING
ELECTRICAL WIRING DIAGRAM
(2/3)
023502
Serial No.: 12503 and up
20-60-61 (6)
TESTING AND ADJUSTING
ELECTRICAL WIRING DIAGRAM
023502
(3/3)
20-60-62 (6)
Connection table for connector pin numbers a
(Rev. 2009.04)
The terms of male and female refer to the pins, while the terms of male housing and female housing refer to the mating portion of the housing.
20-60 (7)
63
20-60 (7)
64
20-60 (7)
65
20-60 (7)
66
20-60 (7)
67
20-60 (7)
68
20-60 (7)
69
20-60 (7)
70
20-60 (7)
71
20-60 (7)
72
20-60 (7)
73
20-60 (7)
74
20-60 (7)
75
20-60 (7)
76
20-60 (7)
77
20-60 (7)
78
20-60 (7)
79
20-60 (7)
80
20-60 (7)
81
20-60 (7)
82
20-60 (7)
83
20-60 (7)
84
20-60 (7)
85
20-60 (7)
86
20-60 (7)
87
20-60 (7)
88
20-60 (7)
89
20-60 (7)
90
20-60 (7)
91
20-60 (7)
92
20-60 (7)
93
20-60 (7)
94
20-60 (7)
95
20-60 (7)
96
20-60 (7)
97
20-60 (7)
98
T- branch box and T- branch adapter table
The vertical column indicates a part number of T-branch box or T-branch adapter while the horizontal column indicates a part number of harness checker assembly.
q
q
q q
Out of kit
799-601-4201
799-601-4101
799-601-9300
799-601-9200
799-601-9100
799-601-9000
799-601-8000
799-601-7500
799-601-7400
799-601-7100
799-601-7000
799-601-2800
Identification symbol
799-601-2700
Part name
T-adapter kit 799-601-2500
Part No.
Number of pins
a
(Rev. 2009.03)1
799-601-2600 T-box (for ECONO)
21
799-601-3100 T-box (for MS)
37
q q
799-601-3200 T-box (for MS)
37
q
799-601-3380 Plate for MS (14-pin)
q
799-601-3410 Adapter for BENDIX (MS)
24
MS-24P
q
799-601-3420 Adapter for BENDIX (MS)
24
MS-24P
q
799-601-3430 Adapter for BENDIX (MS)
17
MS-17P
q
799-601-3440 Adapter for BENDIX (MS)
17
MS-17P
q
799-601-3450 Adapter for BENDIX (MS)
5
MS-5P
q
799-601-3460 Adapter for BENDIX (MS)
10
MS-10P
q
799-601-3510 Adapter for BENDIX (MS)
5
MS-5P
q
799-601-3520 Adapter for BENDIX (MS)
17
MS-17P
q
799-601-3530 Adapter for BENDIX (MS)
19
MS-19P
q
799-601-2910 Adapter for BENDIX (MS)
14
MS-14P
q
799-601-2710 Adapter for MIC
5
MIC-5P
q q
q
799-601-2720 Adapter for MIC
13
MIC-13P
q q
q
799-601-2730 Adapter for MIC
17
MIC-17P
q q q
q q
q
799-601-2740 Adapter for MIC
21
MIC-21P
q q q
q q
q
799-601-2950 Adapter for MIC
9
MIC-9P
q q q
q
799-601-2750 Adapter for ECONO
2
ECONO2P
q q
799-601-2760 Adapter for ECONO
3
ECONO3P
q q
799-601-2770 Adapter for ECONO
4
ECONO4P
q q
799-601-2780 Adapter for ECONO
8
ECONO8P
q q
799-601-2790 Adapter for ECONO
12 ECONO12P q q
799-601-3470 Case
q
799-601-2810 Adapter for DLI
8
DLI-8P
q q
799-601-2820 Adapter for DLI
12
DLI-12P
q q
799-601-2830 Adapter for DLI
16
DLI-16P
q q
799-601-2840 Extension cable (ECONO type)
12 ECONO12P q q
799-601-2850 Case 799-601-4350 T-box (for DRC 60, ECONO)
q
q 60
q
799-601-4360 Case
q
799-601-7010 Adapter for X (T-adapter)
1
q
q
799-601-7020 Adapter for X
2
X2P
q q q
q
799-601-7030 Adapter for X 799-601-7040 Adapter for X
3
X3P
q q q
q
4
X4P
q q q
799-601-7050 Adapter for SWP
q
6
SW6P
q q q q q q
799-601-7060 Adapter for SWP
8
SW8P
799-601-7310 Adapter for SWP
12
SW12P
799-601-7070 Adapter for SWP
14
SW14P
799-601-7320 Adapter for SWP
16
SW16P
799-601-7080 Adapter for M (T-adapter)
1
q
q
799-601-7090 Adapter for M
2
M2P
q q q
q
799-601-7110 Adapter for M
3
M3P
q q q
q
q q
q q
20-60 (7)
99
8
S8P
q q q
q
799-601-7150 Adapter for S (White)
10
S10P
q q q
q
799-601-7160 Adapter for S (Blue)
12
S12P
q q q q q q
16
S16P
799-601-7330 Adapter for S (White)
16
S16PW
799-601-7350 Adapter for S (White)
12
S12PW
Out of kit
799-601-4201
799-601-4101
799-601-9300
q q q
799-601-7180 Adapter for AMP040
8
A8P
799-601-7190 Adapter for AMP040
12
A12P
q
q
799-601-7210 Adapter for AMP040
16
A16P
q q q
q
799-601-7220 Adapter for AMP040
20
A20P
q q q
q
799-601-7230 Short connector for X
2
—
q q q
q
799-601-7240 Case
799-601-9200
q
799-601-7140 Adapter for S
799-601-7170 Adapter for S (Blue)
799-601-9100
M8P
799-601-9000
8
799-601-8000 q
799-601-7340 Adapter for M
799-601-7500
q
q q q
799-601-7400
q q q
M6P
799-601-7100
M4P
6
799-601-7000
4
799-601-7130 Adapter for M
799-601-2800
799-601-7120 Adapter for M
Part name
799-601-2700
Identification symbol
Part No.
799-601-2500
Number of pins
T-adapter kit
q
q q
799-601-7270 Case
q
799-601-7510 Adapter for 070
10
07-10
q
799-601-7520 Adapter for 070
12
07-12
q
799-601-7530 Adapter for 070
14
07-14
q
799-601-7540 Adapter for 070
18
07-18
q
799-601-7550 Adapter for 070
20
07-20
q
799-601-7360 Adapter for relay
5
REL-5P
q
799-601-7370 Adapter for relay
6
REL-6P
q
799-601-7380 Adapter for JFC
2
—
799-601-9010 Adapter for DTM
2
DTM2
q
q
799-601-9020 Adapter for DT
2
DT2
q
q
799-601-9030 Adapter for DT
3
DT3
q
q
799-601-9040 Adapter for DT
4
DT4
q
q
799-601-9050 Adapter for DT
6
DT6
q
q
799-601-9060 Adapter for DT (Gray)
8
DT8GR
q
q
q
799-601-9070 Adapter for DT (Black)
8
DT8B
q
q
799-601-9080 Adapter for DT (Green)
8
DT8G
q
q
799-601-9090 Adapter for DT (Brown)
8
DT8BR
q
q
799-601-9110 Adapter for DT (Gray)
12
DT12GR
q
q
799-601-9120 Adapter for DT (Black)
12
DT12B
q
q
799-601-9130 Adapter for DT (Green)
12
DT12G
q
q
799-601-9140 Adapter for DT (Brown)
12
DT12BR
q
q
799-601-9210 Adapter for HD30-18
8
D18-8
q q
799-601-9220 Adapter for HD30-18
14
D18-14
q q
799-601-9230 Adapter for HD30-18
20
D18-20
q q
799-601-9240 Adapter for HD30-18
21
D18-21
q q
799-601-9250 Adapter for HD30-24
9
D24-9
q q
799-601-9260 Adapter for HD30-24
16
D24-16
q q
799-601-9270 Adapter for HD30-24
21
D24-21
q q
799-601-9280 Adapter for HD30-24
23
D24-23
q q
799-601-9290 Adapter for HD30-24
31
D24-31
q q
799-601-9310 Plate for HD30 (24-pin) 799-601-9320 T-box (for ECONO)
20-60 (7)
100
24
q q q q
q q
q
q q
q
799-601-9330 Case
Out of kit
799-601-4201
799-601-4101
799-601-9300
799-601-9200
799-601-9100
799-601-9000
799-601-8000
799-601-7500
799-601-7400
799-601-7100
799-601-7000
799-601-2800
799-601-2700
Identification symbol
799-601-2500
Part name
Number of pins
Part No.
T-adapter kit
q
799-601-9340 Case
q
799-601-9350 Adapter for DRC
40
DRC-40
q q
799-601-9360 Adapter for DRC
24
DRC-24
799-601-9410* Socket for engine (CRI-T2)
2
G
Adapter for engine (CRI-T2) 799-601-9420 Adapter for engine (CRI-T3) PFUEL Oil pressure sensor
3
A3
q q
2
P
q q
799-601-9440* Socket for engine (CRI-T2)
3
1,2,3
q
795-799-5520* Socket for engine (HPI-T2)
2
S
q
Socket for engine (HPI-T2) 795-799-5530* Socket for engine (CRI-T3) Temperature sensor
2
C
q q
2
A
q q
795-799-5460 Cable for engine (HPI-T2)
3
—
q
795-799-5470 Cable for engine (HPI-T2)
3
—
q
795-799-5480 Cable for engine (HPI-T2)
3
—
799-601-4110 Adapter for engine (140-T3) PIM
4
ITT3N
q q
799-601-4130 Adapter for engine (CRI-T3) NE, CAM
3
FCIN
q q
Adapter for engine (CRI-T3) 799-601-4140 Atomosphere pressure
3
FCIG
q q
799-601-4150 Adapter for engine (CRI-T3) POIL
3
FCIB
q q
Adapter for engine (CRI-T3) 799-601-4160 Oil pressure switch
2
4160
q q
799-601-4180 Adapter for engine (CRI-T3) PEVA
3
4180
q q
799-601-9430*
795-799-5540*
Socket for engine (CRI-T2) Socket for engine (CRI-T3) PCV
Socket for engine (HPI-T2) Socket for engine (CRI-T3) TIM
q
q
799-601-4190*
Socket for engine (CRI-T3) Commonrail pressure
3
1,2,3L
q q
799-601-4230*
Socket for engine (CRI-T3) Air intake pressure/temperature
4
1,2,3,4C
q q
799-601-4240* Socket for engine (CRI-T3) PAMB
3
1,2,3A
q q
799-601-4250* Socket for engine (CRI-T3) PIM
3
1,2,3B
q q
799-601-4330* Socket for engine (CRI-T3) G
3
1,2,3,G
q q q q
799-601-4340*
Socket for engine (CRI-T3) Pump actuator
2
2,PA
799-601-4380*
Socket for engine (CRI-T3)(95) Air intake pressure/temperature
4
1,2,3,4T
q
799-601-4260 Adapter for controller (ENG)
4
DTP4
799-601-4211 Adapter for controller (ENG)
50
DRC50
q q q
799-601-4220 Adapter for controller (ENG)
60
DRC60
q
799-601-4390* Socket for controller (95 ENG)
60
—
q
799-601-4280* Box for controller (PUMP)
121
—
q
799-601-9720 Adapter for controller (HST)
16
HST16A
q
799-601-9710 Adapter for controller (HST)
16
HST16B
q
799-601-9730 Adapter for controller (HST)
26
HST26A
q
2, 3, 4,
—
q
799-601-9890
Multi-adapter for DT2 – 4 and DTM2
“*” Shows not T-adapter but socket.
20-60 - 101 (7)
TROUBLESHOOTING OF ENGINE (S MODE)
S-l s-2
Starting
performance
is poor (Starting
Engine
does not start
@
Engine
does not turn
@
Engine
turns
@
Exhaust
gas comes
out but engine
s-3
Engine
does not pick up smoothly
s-4
Engine
stops
s-5
Engine
does not rotate
S-6
Engine
lacks output
s-7
Exhaust
S-8
Oil consumption
s-9
Oil becomes
s-10
Fuel consumption
S-l 1
Oil is in cooling
s-12
Oil pressure
S-l 3
Oil level rises
s-14
Water
S-l 5
Abnormal
S-l 6
Vibration
during
operations
(hunting)
contaminated
is poor)
injected)
(or exhaust
20-64 20-65
....................................................................
quickly
is excessive or water
................................................................................
gas is blue)
.....................................................................
noise is made is excessive
20-67 20-68 20-69 20-70 20-71
......................................................................................................
20-73
spurts
20-74
back, or water
up (drop in oil pressure)
becomes
20-66
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-72
level goes down
............................................
...........................................................................
...............................................................................................................................
temperature
20-63
...................................
injected)
....................................................................................
combustion)
20-62
.....................................
.....................................................................................................
gas is black (incomplete is excessive
out (Fuel is not being
.....................................................................................................
(no power)
lamp lights
..............................................................
does not start (Fuel is being
(Follow-up
smoothly
water,
takes time)
..............................................................................................................
but no exhaust
gas comes
always
too high (overheating)
.......................................................................
...............................................................................................................
...................................................................................................................
20-75 20-76 20-77 20-78 20-79
20-61 0
TROUBLESHOOTING S-l
Starting
General
performance
TABLE
is poor (Starting always takes time)
causes why starting performance
is poor
- Defective electrical system - Insufficient supply of fuel - Insufficient intake of air f Improper ASTM
Legend
selection of fuel
(At ambient
temperature
of -10°C
D975 No. 1, and -10°C
or below,
use
or above, use ASTM
.
The
Battery charging
specific
gravity
of 70% in the above
. In cold
charging
weather
Possible
a
: :
causes
probable
Possible Items
(judging causes
causes
from
due to length
to confirm
Questions
(judging
from
and check
Questions
of use (used
exceed
the value
for the charging
for a long
the cause.
rate
table.
the specific
gravity
must
exceed
the value
for the
table.
measured.
it IS found to be
IoIo/
I
I
I
I
I
I
I
I
I
I
I
items)
and Check
rate.
rate of 75% in the above
I
20-62
should
:
Q : Most 0
D975 No. 2 diesel fuel.) t
0
I
items1
period)
S-2 Engine does not start 0 Engine does not turn General
causes why
. internal *
engine
parts of engine
If internal
does not turn seized
parts of the engine are seized, carry
out troubleshooting
for “Engine
stops during
operations”.
. Failure in power train . Defective electrical system
Legend
*
: : :
0
: Items
0 G
Possible Most
causes
probable
Possible
(judging causes
causes
to confirm
due to length
IS turned
turned
to START,
moves
out, but
from
and check
Questions
of use (used
items]
and Check
for a long
items)
period)
ON
the cord,
1) When
Questions
the cause.
switch
connect
from (judging
terminal
pinion
and carry
out troubleshooting
B and terminal
C of starting
at ON switch
are connected,
20-63
@ Engine turns but no exhaust
gas comes out
(Fuel is not being injected) General comes
causes why engine turns but no exhaust
. Supply of fuel impossible f Supply of fuel is extremely small . Improper selection of fuel (particularly Standards
of fuel
Diesel
-22
-4
-30
-20
in winter)
for use of fuel Ambient
Type
gas
out
,4 -10
temperature
32
50
68
86
104
122°F
0
10
20
30
40
50°C
fuel
Legend 0 6,:)
: Possible causes (judging from : Most probable causes (judging
A : Possible 0
: Items
causes
to confirm
1 Confirm
20-64
due to length
Questions from
and check
Questions
of use (used
items1
and Check
for a long
items)
period)
the cause.
recent
reoair
historv
I
I
I
I
I
I
I
I
I
I
I
0
Exhaust
gas comes
out
but engine
does
not
out
but
start (Fuel is being injected) General engine
causes
why
exhaust
gas
comes
does not start
. Lack of rotating
force
due
to defective
electri-
cal system
. Insufficient supply of fuel . Insufficient intake of air . Improper selection of fuel
Legend 0 0 A
: : :
Possible Most
causes
probable
Possible
causes
l : Items to confirm
When
(judging causes
from (judging
due to length
Ouestions from
and check
Questions
of use (used
and
for a long
the cause.
fuel filter
is drained,
no fuel comes
out
items) Check
items)
period)
S-3 Engine does not pick up smoothly
(Follow-up
is poor)
General causes why engine does not pick up smoothly
. . * .
Insufficient
intake of air
insufficient
supply of fuel
Improper
condition of fuel injection
Improper
fuel used
Legend 0
:
Possible
causes
(judging
from
Questions
length
I
Replacement
When
exhaust
temperature
20-66
of filters
manifold of some
of use (used
has not been
is toLched cvlinders
When
fuel cap is inspected
When
feed
pump
and check
is operated,
items)
for a long
carried
period)
out according
Immediately
after
to operation
starting
IllI
I
Ill
III
engine,
is low
directly,
it is found
operation
to be clogged
is too light
or too heavy
0 l
S-4 Engine stops during operations General
causes why
engine
. Seized parts inside engine - Insufficient supply of fuel . Overheating *
If
there
is
output,
stops
overheating
carry
out
during
operations
and
insufficient
troubleshooting
for
over-
heating.
. Failure in power train *
If the the
engine
power
stops train,
because
carry
of a failure
out
in
troubleshooting
for the chassis.
:gend 0 a A 0
: : : :
Possible Most
Possible Items
causes
probable
(judging causes
causes
from
Questions
(judging
from
due to length
to confirm
and check
Questions
of use (used
for a long
items)
period)
the cause.
Confirm
recent
Deoree
of use
repair
history
1 Operated -_I
Condition
items)
and Check
when
for long .._:__
period ..^^
.^___I
engine
stopped
Non-specified When
feed
Mud
is stuck
Engine
fuel pump
Remove
used there
is no response
or it is heavy
0
0
0
0
0
0 d
to fuel tank cap
turns.
Try to turn
is being is operated,
but stops
by hand
head cover
transmission
control
lever
is
using
and check
When
qear train
Turns
when
When
fuel filter,,strainer
pump
Q
when
is inspected, auxiliary
directly it does
not tL
equipment
is removed
I
are inspected
directly,
they
is inspected
directly,
it is found
I
I
I
t-1
I
are found
I
I
I
I
I
5
I
1 2
l
to be clogged When
feed
pump
strainer
to be clogged Check feed When
I
does
pump
control not return
directly
rack is pushed,
it is found
to be heavy
or /I
III
I
III
III
I
20-67
S-5 Engine does not rotate smoothly (hunting) General
causes why
. Air in fuel system . Defective governor . Defective electric governor *
does not rotate
smoothly
mechanism goyernor
machanism
(electric
type)
If there rod
engine
is no hunting
is disconnected,
for the electrical
when carry
the electric out
governor
troubleshooting
system.
Legend 0 : Possible causes (judging from Questions and check items) 0 : Most probable causes (judging from Questions and Check items) A : Possible causes due to length of use (used for a long period) l : Items to confirm the cause.
Condition of hunting
epacemen
20-68
0
S-6 Engine lacks output (no power) General
. . . .
causes why engine
Insufficient
lacks output
intake of air
Insufficient
supply
of fuel
Improper
condition
Improper
fuel used
(if non-specified
of fuel injection
fuel is used, output
drops)
. Lack of output due to overheating *
If
is
there
output,
overheating
carry
out
and
troubleshooting
insufficient for
over-
heating.
Legend 0
: : :
Possible Most
causes
probable
Possible
cau
Color
(judging causes
from (judging
e to length
of exhaust
Questions from
and check
Questions
of use (used
items)
and Check
for a long
items)
period)
gas
en va ve c earance
IS c
20-69
S-7 Exhaust gas is black (incomplete
combustion)
General causes why exhaust gas is black
. Insufficient intake of air . improper condition of fuel injection * Excessive injection of fuel
Legend 0
@ a 0
: Possible causes (judging from : Most probable causes (judging : Possible causes due to length : Items to confirm the cause.
Color
of exhaust
Power
was lost
Questions from
and check
Ouestions
of use (used
and
items) Check
items)
for a long period)
gas
; .g I Fi
Non-specified
V
Noise
Dust indicator Blow-by
is being
used
is heard
from
around
turbocharger \?
is red
gas is excessive
Engine
pickup
When
exhaust
standard
20-70
fuel
of interference
c
is poor and combustion manifold
is touched
is irregular immediately
0 after
starting
::
0
0
0
0
engine,
value
When
muffler
is removed,
When
control
rack is pushed,
exhaust
gas color
it is found
returns
to be heavy,
to normal or does
not return
0
l
S-8 Oil consumption is excessive (or exhaust gas is blue) * Do not run the engine at idling for more than 20
minutes
continuously.
(Both
low
and
high
idling) General
causes why oil consumption
is excessive
. Abnormal combustion of oil . External leakage of oil . Wear of lubrication system
Legend 0
:
Possible
causes
(judging
from
Questions
and check
gth of use (used
for a long
items) period)
20-7 1
S-9 Oil becomes contaminated General
causes
why
oil
quickly
becomes
contaminated
quickly
. . . . .
Intake
of exhaust
gas due to internal
Clogging
of lubrication
Improper Improper
combustion oil used
Operation
under
wear
passage
excessive
load
Legend 0 6
: :
Possible Most
A : Possible 0
:
Items
2 0
_
causes
probable
(judging causes
causes
Questions from
due to length
to confirm
When
oil filter
is inspected,
When
exhaust
pipe
When
compression
When
breather
items)
period)
particles inside
are found
is found
0
to be dirty
with
rises auicklv pressure
,,,
is measured,
is inspected
oil filter oil cooler
Turbocharger
is inspected
directly.
is inspected
drain
tube
It is found
directly,
to be low
it is found
to be clogged
valve
it is found
directly,
it is found
to be clogged
is directly
-0
shaft
l
n
l
I.1
a b
I 0
spring
is found
to be catching
; P ‘G 8 5
l
I
__
inspected,
l
l
to be clogged
is cloqqed
play of turbocharger
safety
UJ E : c
h
oil
oil, or hose is broken
When
Excessive
metal
is removed,
element
When
When
for a long
gas
oil temoerature
dirty
items)
and Check
the cause.
of exhaust
with
and check
Questions
of use (used
Color
Enoine
20-72
from (judging
% .
t &
S-l 0 Fuel consumption General
. Leakage of fuel . Improper condition . Excessive injection
:
probable
:
Items
ca
causes
of fuel injection
ging
d
is excessive
of fuel
om Questions Most
A : Possible
l
is excessive
causes why fuel consumption
from
and check
Questions
gth of use (used
items)
and Check
for a long
items)
period)
to confirm
Condition
Injection Speed
of same
of fuel consumption
pump
test shows
of some
cylinders
that does
injection
amount
not change
when
model
l
is excessive operatjng
on reduced
l
cyltnders When
control
When
check
rack is oushed. IS made
using
it is found delivery
to be heavv.
method,
injection
or does timng
l
not return is found
to be incorrect Remove
head cover
and check
directly
Remove
feed
and check
directlv
pump
I
I
I
I
1
1.1
I
I
j
/.I
20-73
S-l 1 Oil is in cooling water, or water spurts back, or water level goes down General
causes why oil is in cooling
water
* Internal leakage in lubrication system . Internal leakage in cooling system
LegC!“O
ssible
2
0
causes
from
Engine
is being
oil level
used as cooling
has risen.
air bubbles
$
Hvdraulic
oil, torque
When
hydraulic
wilt07
ic fn,,nrl
inside
radiator,
converter,
oil, torque
test of oil cooler test of cylinder
Remove
cylinder
Remove
011 pan and check
0
white spurts
head and check directly
Q
oil is cloudv
there
head shows directly
0
back
transmission
shows
0
G
transmission
converter,
Pressure-tightness
increased
water
oil is cloudy
Pressure-tightness
20-74
items)
_____. , _
Excessive
u
and check
Graduallv
li
.S .,
Questions
Oil level Hard water
,”
(judging
white
oil is drained,
is leakage there
1s leakage
I
I
0
Cz
I I
I CC? I I
1
I
6
S-12
Oil pressure lamp lights up (drop in oil pressure)
General
. * * . +
causes why oil pressure
lamp lights up
Leakage, clogging, wear of lubricating Defective Improper
Deterioration
Standards
Type
of oil
system
oil pressure control oil used (improper viscosity) of oil due to overheating
for engine oil selection
I
Selection
-22 -30
-4 -20
of oil SAE number according to ambient temperature
14 -10
32 0
50 10
68 20
86 30
104 40
I 122°F 5o’c
!gend
: Possible causes (judging from : Most probable causes (judging
Questions from
and check
Questions
gth of use (used
Condition
When m .s 8 f
oil filter
Remove
for a long
items)
period1
oil pressure
is inspected
oil pan and check
Oil pump There
when
items)
and Check
rotation
is catching
is heavy, of relief
directly,
it is found
to be clogged
a
there valve
l 0
directly
F ‘Z 8 f =m ‘= + .e
0 0
is play or regulator
l
valve,
spring
or
1_
eB
20-75
S-13 Oil level rises t If there is oil in the cooling troubleshooting General
water,
for “Oil is in cooling
causes why
carry
out
water”.
oil level rises
. Water in oil (cloudy white) . Fuel in oil (diluted, and smells of diesel fuel) . Entry of oil from other component
I
Legend
20-76
I
S-14 Water temperature General
causes
why
becomes too high (overheating)
water
temperature
becomes
too high
. Lack of cooling
water
(deformation,
damage
of
fan)
I
. Drop in heat dissipation efficiency . Defective cooling circulation system . Rise in oil temperature of power train *
Carry out troubleshooting
I
for chassis.
Legend 0 a
l
: : : :
Possible Most
causes
probable
Possible Items
causes
to confirm
Degree
water
from (judging
due to length
Questions from
and check.items)
Questions
of use (used
and
for a long
Check
items)
period)
the cause.
1 Operated for long period E .,A^_,.. ^..^_L_^._A
of use
temperature
Temperature
even
(judging causes
a 1a
0 0
/A IA
gauge
difference
at the cracking
:\-
between
top and bottom
radiator
tanks
is
temperature
20-77
S-l 5 Abnormal noise is made * Judge if the noise is an internal external General
noise
or an
noise.
causes why
abnormal
noise is made
. Abnormality due to defective parts . Abnormal combustion noise * Air sucked in from intake system
Legend 0
: Possible
Q : Most
A : Possible 0
:
causes
probable
Items
causes
z 5
recent
Degree
of use
Engine
of abnormal
noise
fuel
or exhaust
Metal
particles
Noise
When
items)
and Check
for a long
items)
period)
1 Gradual1 y occurred Suddenly use ‘d
more
0
0 0
1-1
1 Blue under
are found
0
__._....
gas
0
0
occurred
liaht
load
I,
0 I,
/
@
in oil
gas is excesswe of interference pickup
is heard
fl
is poor and coml
exhaust
temperature
manifold of some
Seal on iniection
20-78
is being
be added
Color
Engine
and check
Questions
of use (used
history
oil must
Blow-by
from
repair
Non-specified
2
Questions
the cause.
Confirm
Condition
from (judging
due to length
to confirm
.g
g C
(judging causes
is touched cylinders
immedjately
is low
our-no has come
off
after
starting
engrne.
62
0
I
I
I
I
I
I 1
S-l 6 Vibration is excessive * If there is abnormal noise together vibration,
carry out troubleshooting
with
the
for “Abnor-
mal noise is made”. General causes why vibration
is excessive
. Defective parts (abnormal wear, breakage) * Improper alignment * Abnormal combustion
Legend 0
: : :
:: _z 0
Possible Most
causes
probable
Possible
causes
Vibration Exhaust
(judging causes
due to length
follows
Injection
engine
Questions from
and check
Questions
of use (used
items)
and Check
for a long
items)
period)
speed
0
0
0
0
0
gas is black
Seal on injection
1 Remove
from (judging
pump
0 has come
oil pan and check
directly
pump
that
test shows
0
off
injection
Q
I.1
amount
I
I
I
I
I
I
I
I
is incorrect
20-79
TROUBLESHOOTING CHART FOR ELECTRONIC VEHICLE MONITORING SYSTEM (M MODE)
M-l.
When
starting
switch
is turned
ON, monitor
panel display
does not appear
M-2.
When
starting
switch
is turned
ON, monitor
panel display
does not go out
M-3.
When
starting
switch
is turned
ON (engine
M-4.
Preheating
M-5.
When
operation
starting
(but there
switch
is turned
is no abnormality
M-6.
Buzzer does not sound
M-7.
There
M-8.
Monitor
M-9.
is not being
is no abnormality panel
lighting
ON and engine
with
engine
displayed
when
does not move
. Service
meter
continues
starting
on monitor,
to move when
.
ON (engine
M-16.
.
20-83 20-85
.
_. _. .
. .
20-86 20-91
stopped)
.
.
engine
abnormally
is stopped
M-l 1.
M-15.
20-82
.
. 20-91
.
20-92
is started
............. Coolant temperature gauge does not give a display .......................... Fuel level gauge always displays FULL ........................... Fuel gauge does not give any display ................... Speedometer display does not work normally Turn signal indicator pilot lamp does not light up ................ High beam pilot lamp does not Ilight up .........................
M-14.
20-82
items flash
is turned
Coolant
M-13.
displays
.
up
) .
but buzzer sounds
.
after engine
switch
lights
caution
M-10. M-12.
gauge
is started,
or CHECK items
does not light up
meter
display
.. .
. . .. . .
. .
check items flash
used but preheating
for 1 minute
. Service
temperature
stopped),
.
.....
20-93 20-94
low temperature
20-95 20-96 20-96 20-97 20-98
.
.
20-99
20-81 0
M-l
WHEN STARTING SWITCH IS TURNED DISPLAY DOES NOT APPEAR.
*
When
disconnecting
*
When
connecting
*
After
a)
NONE OF MONITOR
checking,
connectors
to connect
the T-adapter, connect
connect
the disconnected
Is voltage between chassis ground and fuse 13 20 - 30 V? 1) Turn starting switch ON.
b)
connectors
adapter),
to the socket
always specified
PANEL
turn the starting in
(
switch
Cause
YES
1) Connect T-adapNO ter to CN18 (female). 2) Turn starting switch ON.
Remedy
Defective monitor module
Replace
Defective contact, or disconsection in wiring harness Jetween CN18 (female) (1) - CN25 (4) - CN13 (3) -fuse 13, or between CN18 (female) (2) - chassis ground
After inspection, repair (clean) or replace
3lown fuse
After finding case, check for short circuit in wiring harness
Defective monitor module.
Replace
defective monitor module.
Replace
PANEL DOES NOT WORK.
Tester T-adapter or socket adapter (for DLl)
a) Related
electrical
CNIE
circuit
drawing
CN25
CNl3
Fuse
13
Monitor module
Fl 2
235FO2088
M-2 WHEN STARTING SWITCH IS TURNED ON, MONITOR PANEL DISPLAY DOES NOT GO OUT.
20-82
OFF.
).
again immediately.
Is voltage behveen CN18 (female) (I) and (2) 20 - 30 V?
PART OF MONITOR
Troubleshooting tools
M-l
(or socket
PANEL WORKS.
2 YES , -
the T-adapter
the male and female
ON, MONITOR
M-3 WHEN STARTING SWITCH IS TURNED ON (ENGINE STOPPED), CHECK ITEMS FLASH. * When disconnecting connectors to connect the T-adapter (or socket adapter), always turn the starting switch *
When
connecting
*
After checking,
a)
sl 8
the T-adapter,
connect the male and female
connect the disconnected
connectors
to the socket specified
in
(COOLANT LEVEL) FLASHES.
Defective level
3
YES
radiator
Defective
monitor
harness, tact 2) Connect
-
disconnect
CN39
(female)
starting
(3)
in wiring
or defective
between
male) CN18
to CN39
(fe-
(3) - CN25 (7) (female) (7).
harness,
NO
con-
CN39
Disconnection adapter)
module
Replace
Replace
I
CN39
(or socket
coolant
sensor
Disconnection
2) Turn
Remedy
Cause
YESI
OFF.
1.
again immediately.
VFS
1) Connect
(
in wiring
or defective
con-
tact between CN39 (female) (2) - CN25 (3) -
(female).
chassis
Table
CN39 (3) -
ground.
After
inspec-
tion,
repair
(clean)-or
re-
place
After tion,
inspecrepair
(clean)
or re-
place
Continuity
(2)
Connect
1
Yes
Disconnect
1
No
(ENGINE OIL LEVEL) FLASHES.
YES
Defective
Does
q
go out?
-
NO
_ 1) Connect male) level
CN35 (engine
sensor)
chassis ground. 2) Turn starting switch
ON.
(feto
2 Is there
oil
_
male)
YES
CNI 8 (fe(6) -
(Z)?
(See table) 1) Connect
T-adapter
to CN18
NO
(female).
2) Connect
-
CN35
male)
monitor
module
Defective connection
contact, or disin wiring har-
Replace
Replace
and
discon-
between
CN35
(fee-
After tion,
male)
(1) -
CN15
(1) -
(clean)
CN26
(2) -
CN18
(female)
place
inspecrepair or re-
(6).
Table
(feCN35
chassis
chassis
Tester T-adapter ifor DLl)
Defective
ness
ground.
tools
oil level
continuity
between
nect
Troubleshooting
engine
sensor
1
adapter
ground
Continuity
Connect
Yes
Disconnect
No
Short or socket
-
socket
adapter
T-adapter or socket ffor Econoseal)
adapter
20-83
cl
El b
(hydraulic
oil level) flashes.
‘ES
-I
1 Does @j go out when short connector is connected?
r-l
Connect short connector to CN36 (female) (hydraulic oil level sensor). 2) Turn starting switch ON. 1)
M-3
a) Related
2 YES
rl0
,
electrical
circuit
Defective
hydraulic
oil sen-
SOT
Defective
Is continuity between CN18 (female) (5) and (2) as shown in table?
1) Connect T-adaoter to CN18 (femaie). 2) Connect * disconnect CN36 (female) and shortconnector.
Remedy
Cause
monitor
module
Defective contact, or disconnection in wiring harness between CN36 (female) (1) - CN25 (8) CN18 (female) (5). or between CN36 (female) (2) CN25 (3) - chassis ground
NO Table ^,. ,. anorr SOCKBT: adapter
Replace
Replace
After inspection, repair (clean) or replace
Continuity
drawing
CN18
CN25
CN39
Monitor module
Coolant
level sensor
235FO2089
M-3
b) Related
electrical
circuit
CNl8
drawing
CN15
CN26
CN35
Monitor module
Engine
oil level sensor
235FO2090
M-3
c) Related
electrical
CNl8 Monitor module
circuit
drawing
CN25
CN36
Hydraulic oil level sensor
235FO2091
20-84
M-9
Service Service
l
l
meter does not move after engine is started meter continues to move when engine is stopped
*
When
disconnecting
*
When
connecting
*
After
a)
Service
checking,
connectors
connect
meter
to connect
the T-adapter,
connect
the disconnected
the T-adapter
(or socket
the male and female connectors
does not move after engine
adapter),
to the socket
always
turn the starting
specified
).
(
in
is started
Remedy
Cause
YES
Go to M5 a)
oil press-
ure CAUTION lighted 1) Turn switch 2) Start
lamp
-
2
up? -
starting
Is voltage -
CN19
NO and
ON. engine.
YES
Defective
service
meter
Replace
between
(female) (4) 20 -
1) Connect
(1)
-
30 V?
Disconnection
T-adapter
NO
in wiring
ness between
CN19
(4) and
(male)
CN25
hap
(female) (5)
to CN19. 2) Turn starting switch 3) Start
b)
Service
meter
to move when engine
Does service
meter
service
YES
stop
1
connected
-
when
_
1) Connect chassis 2) Turn
) Remove CN13.) Turn starting ON.
YES
meter CN32
is
to chas-
-
sis ground?
stop?
inspec-
tion,
repair
(clean)
or re-
place
ON.
2
-
After
engine.
continues
Does
switch
OFF.
again immediately.
1 Is engine
switch
switch
CN32
to
NO
ground.
starting ON.
is stopped Defective engine ure sensor
Wiring harness between engtne oil pressure relay (3) - CN13 (51 - CN25 (5) - CN19 (female) (41 short circuiting with chassis ground, or defective relay, or defective contact, or disconnection in wiring harness between engine oil pressure relay (2) CN13 (8) - CN15 (4) - CN32 Wiring
NO
oil press-
harness
CN13 (female) - CN19 circuiting
After tion,
inspecrepair
(clean)
or re-
place
between (5) -
CN25 (5
(female) (4) short with chassis
ground
Troubleshooting tools
Tester T-adapter lfor DLI)
or socket
adapter
20-93
M-9
Related
electrical
circuit
drawing
Engine oil pressure relay Monitor module
Service meter (speedometer module)
CN32 A ”
0 *
Engine oil pressure sensor
235FO2101
8
M-IO COOLANT TEMPERATURE GAUGE DISPLAYS ABNORMALLY LOW TEMPERATURE * When disconnecting connectors to connect the T-adapter (or socket adapter), always turn the starting *
When
t
After
connecting checking,
the T-adapter, connect
connect
the disconnected
the male and female connectors
to the socket
specified
in
(
1) Connect short conswitch ON.
orspray go
c
(male) cted to und?
to CN17. 2) Connect CN17 (1) to chassis ground. 3) Turn starting switch ON.
20-94
switch
OFF.
).
again immediately.
Cause
YES
R s1
Remedy
Defective coolant temperature sensor
Replace
Defective contact, or disconnection in wiring harness between CN34 (female) (2) - CN15 (2) CN25 (3) - chassis ground, or between CN34 (female) (1) - CN15 (3) - CN25 (9) - CN17 (1)
After inspection, repair (clean) or replace
Defective monitor module
Replace
M-II
COOLANT TEMPERATURE
*
When disconnecting
*
When
*
After
connecting checking,
connectors
to connect
the T-adapter, connect
connect
the disconnected
GAUGE DOES NOT GIVE A DISPLAY
the T-adapter
(or socket
the male and female connectors
F 2. YES
Does temperature “- -‘ty appear CN17 is dis.,.+*rl +#/est
1) Disconnect CN34. 2) Turn starting switch ON.
1) Disconnect CN17. 2) Turn starting switch ON.
M-l 0, M-l 1 Related
CN 17 Monitor module
electrical
always specified
-
II
circuit
NO
in
(
switch
OFF.
1.
Cause
Remedy
Defective coolant temperature sensor
Replace
Wiring harness between CN34 (female) (1) - CN15 (3) - CN25 (9) - CN17 (1) short circuiting with chassis ground
After inspection, repair (clean) or replace
Defective monitor module
IReplace
drawing
CN25 @
turn the starting
again immediately.
YES
when CN34 is disconnected (lowest
adapter),
to the socket
CN15
CN34 Coolant temperature sensor
CNIE
235FO2094
20-95
M-12 FUEL LEVEL GAUGE ALWAYS DISPLAYS FULL * When disconnecting connectors to connect the T-adapter (or socket adapter), always *
When
*
After
connecting checking,
the T-adapter, connect
connect
the male and female
the disconnected
connectors
Defective
I
Wiring
2 1) Disconnect (fuel level
Does
CN33 sensor).
-
2) Turn starting switch ON. 3) Wait min.
for approx.
1
fuel
ga”ge out?
YES
switch
OFF.
(female)
(4) -
CN7
between (3) -
(9) -
short
chassis
Replace
sensor
After
CN26
CN33
inspec-
tion, repair (clean) or re-
(1)
circuiting
place
ground
-
1) Disconnect CN17. 2) Turn starting 3) Wait min.
switch
).
level
harness
CN17
with go
(
in
fuel
(female)
level
disp’av
turn the starting
specified
again immediately.
YES
1
to the socket
Defective
NO
monitor
module
Replace
ON. for approx.
1
M-13 FUEL GAUGE DOES NOT GIVE ANY DISPLAY
ES
Does
FULL
display
appear?
2
NO Is there
1) Disconnect (fuel
2) Connect
sensor). short
male)
con-
nector.
4) Wait
Troubleshooting tools
M-12,
chassis
1
M-13
CN17. short
CNI?
monitor
module
Defective
contact,
or dis-
ness
NO
con-
sensor
Replace
Fieolace
in wiring
between
male)
(3) -
(9) -
CN33
CN17 CN26 (I)
After
har-
tion,
(fe-
(4) -
(female)
CN7
Short or socket
adapter
socket
T-adapter
date
adapter
or socket
adapter
(for Econoseal)
electrical
circuit
CN26
drawing CN33
Monitor module
Fuel
level
sensor
235FO2102
20-96
inspecrepair
(clean)
T-adapter (female).
Tester
Related
Defective
connection
nector. 3) Connect to CN17
T-adapter (for DLI)
level
(fe-
ground?
2) Connect
for approx.
min.
CN17 (3) and
1) Disconnect
3) Turn starting switch ON.
fuel
continuity
between
CN33
level
YES
Defective
or re-
M-14 SPEEDOMETER DISPLAY DOES NOT WORK NORMALLY * When disconnecting connectors to connect the T-adapter (or socket adapter), always turn the starting *
When
*
After
connecting checking,
the T-adapter, connect
connect
the disconnected
the male and female connectors
to the socket
specified
(
in
switch
OFF.
).
again immediately.
Cause
4
YE!
Defective
Remedy
speedometer
Replace
module setting
of speed
sensor
0.5 -
1.5 Defective
speed
sensor
Replace
mount 0
It It contacts .,. _ turn.
tweclt
bIYLV
male)
(7) and
300 R -
Is resistance
be-
tween
(male)
(I) and
CN30
Connect
(6)
(male)
T-adapter to
Defective ness male)
CN20 (2). and CN26
contact,
between
CN26
(6), (7) and
har(fe-
CN30
(2) Defective
NO
speed
sensor
inspec-
tion,
repair
(clean)
or dis-
in wiring
After
or re-
olace
(61, (7)
connection
gggi$gj sor) (male).
contact, or disin wiring har-
ness between (10) (female)
NO
1 kR?
(socket adapter) CN26 (female).
(2) 300 R -
Defective connection
,Ic-
(I),
After
inspec-
tion,
repair
(clean)
or re-
place Replace
Troubleshooting tools
T-adapter (for
M-14
Related
electrical
CN20 Monitor
or socket
adapter
T-adapter (for
DLI)
circuit
or socket
adapter
Econoseal)
drawing
CN 26
CN30 3 Speedometer
module
sensor
3
235FO2103
20-97
M-15 TURN SIGNAL t
The turn signal indicator
a)
Right turn signal
INDICATOR
PILOT LAMP DOES NOT LIGHT UP
lamp itself lights up.
indicator
pilot lamp
Remedy
1 YES Is voltage between CN20 (female) (3) and chassis ground normal? 1) Connect T-adapter NO to CN20. 2) Turn starting switch ON. 3) Turn right turn signal indicator switch ON. 4) Switches between 20 -30 V and 0 V in turn.
b)
Left turn signal indicator
1
I
Troubleshooting tools
M-l 5 Related
Replace
Defective contact, or disconnection in wiring harness between CN20 (female) (3) and CN40 (female) (3)
After inspection, repair (clean) or replace
Defective speedometer module
Replace
pilot lamp
YES
Is voltage between CN20 (female) (11) and chassis ground normal? 1) Connect T-adapter to CN20. 2) Turn starting switch ON. 3) Turn left turn signal indicator switch ON. 4) Switches between 20 - 30 V and 0 V in turn.
Defective speedometer module
Defective contact, or disEonnection in wiring harness between CN20 (fenale) (11) and CN40 (female) (2)
NO
Tester T-adapter or socket adapter 1 (for Dil,
electrical
circuit
1
I I
drawing CN40
Turn signal switch
Speedometer module
To turn signal lamp (L.H.)
20-98
To turn signal lamp (R.H.)
235FO2104
After inspection, repair (clean) or re-
TROUBLESHOOTING CHART FOR ELECTRONIC (ENGINE, PARKING BRAKE, TRANSMISSION CONTROL) (E MODE)
does
Starting
motor
E- 3
Parking
brake
E- 4
Parking
E- 5
Transmission
Fl and F8, or RI and R8 ..................................................................
20-108
E- 6
Transmission
does
not shift to 1st (F and R) ..................................................................
20-I 14
E- 7
Transmission
does
not shift
to 2nd (F and R) ................................................................
.20-l
14
E- 8
Transmission
does
not shift
to 3rd (F and R) .................................................................
.20-l
14
.20-l
15
brake
* * * *
does
not turn
............................................................................................
20-I 02
not work .............................................................................................
20-I 06
cannot does
between
works).
20-102
E- 2
does
motor
.................................................................
Engine
a position
*
not start
(starting
E- 1
be released
not shift
when
................................................................................... transmission
lever
is moved
20-106
to
E- 9
Transmission
does
not shift to 4th (F and R) .................................................................
E-10
Transmission
does
not shift to 5th (F and R) ..................................................................
E-l 1
Transmission
does
not shift to 6th (F and R) .................................................................
.20-l
15
E-12
Transmission
does
not shift to 7th (F and R) .................................................................
.20-l
16
E-13
Transmission
does
not shift to 8th (F and RI ..................................................................
20-I 15
20-I 16
If the controller displays an error on machines mounting a transmission controller (Serial No.: 12013 - 12015, 12019 and up), carry out troubleshooting for the transmission system first. When disconnecting or connecting the T-adapter (or socket adapter) or short socket adapter, or when disconnecting the connector for checking, turn the starting switch OFF to prevent accidents. 1) When connecting T-adapter (or socket adapter), connect to the connector specified. (CNxx( When disconnecting connectors or connecting T-adapters, return them to the original condition immediately after checking, then go to the next check. If the diagnosis indicates a defect in the shift controller, replace the sensor assembly (a diode and relay are assembled on the print board, so use the input from the rotary switch to output the signal voltage to drive the solenoid valve inside the transmission), the F-R switch assembly and the rotary switch assembly, do not disassemble the assemblies, otherwise dust or other impurities may get inside and cause secondary failures.
20-101 0
TROUBLESHOOTING
E-l
E-l
Engine does not start (starting
motor works). Cause
2 YES
lefective notor.
engine stop
Remedy
qeplace
Sjg-jH* Turn starting
switch OFF. - Disconnect CN51.
ES
1
NO
3 YES
Is voltage of CN51 (4) 20 3OV? . Turn starting switch ON. * Disconnect CN51
- Starting switch at both ON and OFF.
NO
U
E-2 Starting Serial
Iefective relay, or lefective contact, or lisconnection in wiring rarness.
?epair or replace.
Iefective notor.
?eplace
engine stop
Iefective relay, or lefective contact, or lisconnection in wiring rarness.
Repair or replace.
Iefective contact, or jisconnection in wiring rarness between battery elay and CN51 (4).
Repair
, Disconnection of starting motor START circuit, or defective contact. t Defective starting motor.
Repair or replace.
Iefective contact, or lisconnection in wiring jarness between ground :onnection - CNTOl (11) otary switch - CNTOI (2) )rint board - CNT02 (2) itarter relay, CN RST 12) nside transmission box.
Reoair
- Defective
contact, or disconnection in wiring harness between start in motor (E)_ - CN14 (5). . Defective relay or RPST.
Repair or replace.
Iefective contact, or iisconnection in wiring larness between parking rwitch and tarting motor clay.
Repair
Defective fuse (No. 14), or fefective power circuit.
Repair
motor does not turn.
No. 11001 - 11030 3
YES
Y
YE s
1
starting switch ON. * Turn parking 1 switch ON. s Connect Tadapter (or socket) to CN 14 (female) (male).
- Turn
20-l 02 0
*
switch
ON.
Place shift lever at
N position. * Turn parking
- Turn
Is voltage between CN14
starting switch ON. . Turn parking switch ON. . Connect Tadapter (or socket) to CN14 (female).
between CN14 (5) and starting
i
NO
Turn starting switch ON. * Turn parking switch ON. -
NO
E-2
TROUBLESHOOTING
Serial
No. 11031 - 12012,
12016 - 12018 Cause
2 YES
CN14 (famale) (1) and chassis ground 1) Turn starting switch ON.
Serial
Disconnection in wiring harness between starting motor (E) and CN14 (5)
YES
Is there continuity between CN14 (5) _ and chassis ground? NO I) Turn starting switch ON. 2) Place shift lever at P. 3) Connect T-adapter to CN14 (male) (female) IO
No. 12013 - 12015,
Failure of starting motor relay or rotary switch or disconnection in wiring harness between CN14 (male) (5) -starting motor relay- rotary switch -chassis ground Defective wiring
warning
starting ON.
Repair
-
Remedy
Use error code display to inspect location of abnormality
r
lamp flash and is
switch
Replace
12019 and up
YES
1) Turn
Repair
power source
Cause
controller
Remedy
3
YES
Is there continuity
NL!Ft5&J gg%_.. ‘,p 3) Connect T-adapter seconds after starting switch is turned ON
NO
to CN14 (male) (female
Disconnection in wiring harness between starting motor(E) and CN14 (5) Failure of starting motor relay or disconnection in wiring harness between CN14 (male) (5) -starting motor relay -chassis ground Defective wiring
power source
-
Repair Replace
Repair
-
20-l 03 0
E-2
TROUBLESHOOTING
E-2 Related
electrical
circuit diagram
Serial No. 11001 - 11030 Cbj27
CN15
1
ctq55
3 Start
CN8
ine
73
CNST 0422
-3
Rotary switch
CN14
Start motor
ina
3
I
From
CN9
3 3 3
battery Battery relay
-
TWCOO307
20-104 0
E-5
TROUBLESHOOTING
4) Transmission
shifts to 1st to 4th (F and RI but not to 5th to 8th
Cause
Remedy
(F and R).
Serial No.:11001 - 12012,12016-
12018
2 YES Is voltage between YES CNT03 (4) - CNTOI - (11) -ground 1 connection 20 3OV?
-
Is voltage between CNTO3 (1 j - (4) 20 - 3OV?
No * Turn starting switch ON. * Place shift lever between 5th and 8th.
* Turn
starting switch ON. - Place shift lever between 5th and 8th. . Connect Tadapter (or socket) to CNT03 (male).
5)
NO
Transmission
Defective transmission high solenoid valve.
Replace
* Defective contact, or disconnection in wiring harness. - Defective print board circuit.
Repair or replace.
Iefective contact, or iisconnection in wiring >arness between CNT03 and transmission solenoid valve.
Repair
Iefective transmission ow solenoid valve.
Replace
shifts to 5th to 8th (F and R) but not to 1st to
4th (F and R).
SerialNo.:11001-12012,12016-
12018 2 YES
YES _ 1 Is voltage between CNT03 (I) and (3) 20 3OV? I
. Turn starting switch ON. - Place shift lever between 1st and 4th. * Connect Tadapter (or socket) to CNT03 (male).
Is voltage between CNT03 I3)-CNTOl (II)ground connection 20 3OV?
_
NO
Defective contact, or disconnection in wiring harness. Defective print board circuit. Iefective contact, or iisconnection in wiring iarness between CNT03 Ind transmission solenoid valve.
Repair or replace.
Reoair
20-113 0
E-6, E-7, E-8
TROUBLESHOOTING
E-6 Transmission
does not shift to 1st (F and R).
Serial No.: 11001 - 12012,
12016 - 12018 Cause
YES
2 YES 1 -
Is voltage between CNTOZ 14) and CNTOl 13). CNT02 (6) and CNTOI (3) 20 - 3OV?
Is voltage between CNTO~ (3) and (11) 203OV?
No
’ Turn Starti”g switch ON. * Place shift lever at 1st.
E-7 Transmission
does not shift to 2nd (F and R).
Serial No.: 11001 - 12012,
E-8 Transmission
2 YES
Is voltage between CNTOZ (4) and
CNTOI (~),CNTOP (8) and CNTOl (5)
20 - 3OV?
. Turn starting switch ON. - Place shift lever at 3rd.
20-114 0
-
between CNTOI (5) and (11) 20 3OV? - Turn
stafiiw
switch ON. * Place shift lever 3rd.
1 NO
Replace
* Defective print board circuit. - Defective contact, or disconnection in wiring harness between print board and connector.
Repair
Defective switch.
Repair or replace.
inside rotary
Defective contact, or disconnection in siring harness of rotary switch.
Repair
* Defective p;int board circuit. - Defective contact, or* disconnection in wiring harness between print board and connector.
Replace
IIefective switch.
Repair or replace.
Reoair
12016 - 12018
Is voltage
YES
Defective contact, or disconnection in siring harness of rotary switch.
does not shift to 3rd (F and R).
Serial No.: 11001 - 12012,
1 -
Repair or reolace.
12016 - 12018
1 NO
. Turn starting switch ON. * Place shift lever atr 2nd.
inside rotary
-
1 NO
* Turn starting switch ON. * Place shift lever at 1st.
Defective switch.
Remedy
inside rotary
-
No
Iefective contact, or zlisconnection in siring larness of rotary switch.
. Defective print board circuit. * Defective contact, or disconnection in wiring harness between print board and connector.
Replace Repair
E-S, E-10, El1
TROUBLESHOOTING
E-9 Transmission Serial
does not shift to 4th (F and R).
No.: 11001 - 12012,
12016 - 12018
2 YES Is voltage YES between CNTOI 1 - (6)and (11) ZO3OV?
Is voltage between CNTOZ (4) and CNTOI (6), _ CNT02 19) and CNTOl (6) 20 3OV?
1
. Turn starting switch ON. - Place shift lever at 4th.
~
NO
switch ON. Place shift levr at 4th.
-
does not shift to 5th (F and R).
Serial No.: 11001 - 12012,
YES
~
Is voltage between CNT02 (5) and CNTOI (7), CNTOZ 16) and CNT02 (7) 20 3OV? . Turn starting switch ON. * Place shift lever at 5th.
Is voltage between CNTOI (7) and (11) 20 3OV?
* Turn
1
starting switch ON. * Place shift lever at 5th.
Serial
1 boardandconnector’
Defective switch.
inside rotary
-
NO
Defective contact, or disconnection in wiring harness of rotary switch.
- Defective
print board circuit. . Defective contact, or disconnection in wiring harness between print board and connector.
NO
E-l 1 Transmission
print board circuit. Defective contact, or disconnection in wiring harness between print
12016 - 12018 2 YES
1 -
Defective contact, or disconnection in wiring harness of rotary switch.
- Defective
NO
E-lOTransmission
inside rotary
-
* Turn starting
-
Defective switch.
does not shift to 6th (F and R).
No.: 11001 - 12012,
12016 - 12018
20-115 0
TROUBLESHOOTING
E-12, E-13
E-12Transmission Serial
does not shift to 7th (F and R).
No.: 11001 - 12012,
12016 - 12018 Cause
,EiZ ES
CNTOl (9), CNTOS (8)and CNTOl (9)
between
i-------NO
swtich ON. * Place shift lever
* Turn starting switch ON. * Place shift lever at 7th.
does not shift to 8th (F and R).
19)and CNTOI 20-3OV?
(IO)
* Turn starting switch ON. - Place shift lever at 8th.
20-l16 0
-
Is voltage between CNTOI (IO) and (11) 203OV? ' Turn
starting
switch ON. * Place shift lever at 8th.
1 NO
Repair or replace.
or disconnection in wiring harness between print board and connector.
Replace Repair
12016 - 12018 YES
2
Is voltage between CNTOZ(5) and CNTOl(lO), CNTOP
print board
-Defectivecontact,
No.: 11001 - 12012,
mz 1
inside rotary
Defective contact, or disconnection in wiring harness of rotary switch.
*Defective circuit.
-
E-13Transmission Serial
Defective switch.
CNTOl
Iefective switch.
inside rotary
Repair or replace.
-
No
Iefective contact, or disconnection in wiring larnss of rotary switch.
Repair
* Defective print board circuit. * Defective contact, or disconnection in wiring harness between print board and connector.
Replace Repair
TROUBLESHOOTING
LED DISPLAY
LED DISPLAY FOR TRANSMISSION Serial No. 12013 - 12015, 1)
CONTROLLER
CONTROLLER
12019 and up
Self-diagnostic display The error code is displayed by LEDs using a 2-digit code. If an abnormality is detected, the warning lamp and alarm buzzer are actuated. Method of displaying error codes and abnormal operation codes again Turn the starting switch OFF + ON and the error code and abnormal operation code will be displayed in the following order: [CHECK.SUMl + [Past failures] + [Existing failures] + [Abnormal operation] When the [Abnormal operation] display finishes, the [Existing failure] display is repeated.
2)
I I Error code
Abnormal
system
1 Short
circuit
in 1st clutch
A2
Short
circuit
in 2nd clutch
solenoid
output
system
0
A3
Short
circuit
in 3rd clutch
solenoid
output
system
0
A4
1 Short
circuit
in 4th clutch
solenoid
output
system
A5
Short
circuit
in High/Low
A7
Short circuit in FORWARD/REVERSEclutch solenoid output system
0
bl
Disconnection
in 1st clutch
0
b2
Disconnection
in 2nd clutch
solenoid
output
system
0
0
ET-8
:
b3
Disconnection
in 3rd clutch
solenoid
output
system
0
0
ET-9
g
b4
Disconnection
in 4th clutch
solenoid
output
system
0
0
ET-l 0
b5
( Disconnection
b6
Disconnection
b7
Disconnection
in FORWARD clutch solenoid
output
system
b8
1 Disconnection
in REVERSE clutch solenoid
output
system
cl
Disconnection
c2
Abnormality
in voltage
of shift
potentiometer
(I) signal
c3
/ Abnormality
in voltage
of shift potentiometer
(2) signal
Al
(
1
(
and content solenoid
clutch
of abnormality output
solenoid
solenoid
in Low clutch
solenoid
in High clutch
solenoid
in inching
c4
Discrepancy
in shift
potentiometers
c5
Abnormality
in both
shift
(
ET-3
/ ET-4
0
ET-5
0
ET-6
0
ET-7
0
1
I ET-II
(
0
0
ET-1 2
0
0
ET-13
0
1 ET-14
0
(
o-
-
ET-l 5
0
-
ET-l 6
0
1
-
( ET-17
0
(ET-16.17)
speed
sensor
I Disconnection
in speed
sensor
system
20-152 0
(
(
0 0
0
in engine
when
1
ET-2
signal
systems
are ON
Shift lever is not at P position
0
1
(ET-16.17)
I Disconnection
d7
system
0
1 ET-l
-
potentiometer
oil temperature
(
0
0
d4
in transmission
0
j
(I), (2) signals
1
1 Failure
system
0
0
system
system
) Both F and R switches
d6
/
system
output
dl
rd5
output
output
potentiometer
/
system
output
)
)
FOR TRANSMISSION
system
sensor
starting
switch
is ON
(
(
/
0
)
0
) ET-18
)
1
0
/
-
1 ET-19
1
I
0
I
-
1
-
)
-
) ET-21
0
1
0
xoml -
)
TROUBLESHOOTING
LED DISPLAY
Abnormal
system
and content
FOR TRANSMISSION
CONTROLLER
of abnormality
2
z 2
16
Engine
17
Acceleration
18
Transmission lubricating continued for more than
19
With transmission at neutral, travel speed above 4 km/h and engine speed above 1400 rpm continued for more than 10 seconds
IA
With transmission in F or R and inching pedal depressed, travel speed above 4 km/h and engine speed above 1400 rpm continued for more than 10 seconds
Error code
speed
Gearshifting
above
2350 rpm
to dangerous speed with inching pedal depressed
pattern
oil temperature 30 seconds
when
there
above
is abnormal
120°C
0
0
-
0
0
-
0
0
-
-
-
-
-
-
operation
-
i F
Shifts
N +
F when
travel
speed
is above
-
i A F i A
Shifts
N +
R when
travel
speed
is above
9 km/h
Shifts
F +
R when
travel
speed
is above
9 km/h
A i F
Shifts
R +
F when
travel
speed
is above
9 km/h
F i -
Shifts to F4 or above
when
travel
speed is below
2 km/h
A : -
Shifts to R4 or above
when
travel
speed
2 km/h
F i 0
Inching
used for long time
in F (FORWARD)
A i 0
Inching
used for long time
in R (REVERSE)
9 km/h
is below
t
I-----0 1 2 3 4
: Clutch Clutch Clutch Clutch Clutch
: : : :
temperature temperature temperature temperature temoerature
below 200°C 200 - 230°C 230 - 260°C 260 - 290°C above 290°C
20-153 0
LED DISPLAY
TROUBLESHOOTING
Saving error codes, abnormal operation The transmission controller saves any ated, and keeps these in memory even As a result, when the starting switch is ON, it is possible to check the content
3)
Display
-
Z 5 Z 2 Y-J I?
Z L =I Z 2 .-P Z ‘X LLI
g
0 ‘E
B x 0
Z E Z 5 m .-? 2 ul
Z 5 Z 2 ? ‘E 2 i2
item
(order
Transmission
controller
power
2)
All segments
of LED light
3)
(No comment)
4)
CHECK.SUM
5)
Trouble
6)
Error codes d4: Abnormality
Display time (se4
LED display Starting
ON
up
switch
OFF +
I-! -.-. I-!
ON
5
.Y
0.5
.Y
0.5
display
data
in engine
speed
7)
If there are any other failures Steps 5) and 6) are repeated.
8)
Existing failures * If there are no existing failures, displayed for 3 seconds.
9)
CONTROLLER
codes error codes and abnormal operation codes that are generafter the starting switch is turned OFF. turned ON and the transmission controller power is turned of all the abnormalities that have occurred so far.
of display)
1)
FOR TRANSMISSION
sensor
$
t3.E
is
Error codes F4: Disconnection in backup buzzer system, short circuit in power source
IO) If there are any other 9) are repeated.
failures,
11) Abnormal
record
operations
12) Abnormal operation codes 14: Inching used continuously 10 seconds
Steps
f-u
F
3
0.5
1-i
3
8) and
u for more
13) Gearshift pattern code when there is abnormal operation FO: FORWARD, clutch temperature below 14) Number of times of operation abnormal operation 02: 2 times
c(
in memory,
than
200°C
0.5
P+
3
FE
3
r:-- ,I
3
of this
15) If there are any other abnormal operations in memory, Steps 11) to 14) are repeated. When the display of abnormal operations in memory is completed, display returns again to existing failures. * If there are no existing failures, fi.3 is displayed.
20-154 0
-
-
TROUBLESHOOTING
.
LED DISPLAY FOR TRANSMISSION
CONTROLLER
Method of deleting error codes from memory After carrying out troubleshooting and completing repairs of the failure, the self-diagnostic display returns to the normal display. Always do as follows to delete the transmission controller error codes from memory. + The abnormal operation items cannot be deleted from memory.
(1) Turn the starting
switch to the ON position, and after completing the display for all the past failures in memory, check that the display returns to 17 17 . to connector number [FRI inside the (2) Take the connector (color of wiring harness: green) cor%zed right console box, and ground it to the chassis. (When doing this, make sure that the starting switch is at the ON position.) . After grounding the connector, install the blind connector to the FR connector in the original way. (3) Turn the starting switch OFF, then turn it ON again and check that the past error codes have been deleted from memory. . If the past error codes have been deleted from memory, CHECK.SUM is displayed, then E.!l is displayed immediately. (If there are any abnormal operation items saved in memory, the display will start to show the abnormal items.)
20-155 0
ET-1
TROUBLESHOOTING
ET-1 *
* *
[Al]
(Short circuit 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 for [Existing failure] is no longer displayed on the LED 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.
Cause
3
1Is voltage
YES
GotoA
II
H 11[ZFn y$ijiij!;;;g. When
(female) (2) and chassis normal?
1st is
YES
betwee”,st Is resistance
(male) (1) and (2) normal? -5-20R -Turn starting switch OFF. * Disconnect 1st.
-
NO
switch OFF. * Disconnect 1st and E2. NO
4 YES
Aj$!jnL’JHP
electrical
Short circuit with power source in wiring harness between 1st (female) (2) and E2 (female) (17)
Repair or replace
Short circuit in wiring harness between E2 (7) and 1st (I) and wiring harness between E2 (17) and 1st (2)
Repair or replace
Defective
1st solenoid
Replace
Defective controller
transmission
Repair or replace
Short circuit with power source in wiring harness between 1st (female) (1) and E2 (female) (7)
* Max. 0.1 V NO * Turn starting switch OFF. * Disconnect 1st and E2. * Turn starting switch ON.
ET-1 Related
Remedy
Repair or
circuit diagram
Transmission
controller
I
1st
solenoid
(+I
1st
solenoid
(-1
E2
1st
1st
solenoid
TWG00317
20-156 0
ET-2
TROUBLESHOOTING
ET-2 Ir
* t
[A21 (Short circuit 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 for [Existing failure] is no longer displayed on the LED 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.
Remedy
Cause
3
YES 2 is disconnected, is resistance between E2 (female) (81 and (18) normal? * Min. 1 MR *Turn startina switch OFF.. Disconnect 2nd and E2.
1
(male) (1) and (2) -5-20Q -Turn starting switch OFF. - Disconnect 2nd.
GotoA
between 2nd (female) (2) and chassis normal?
When 2nd
YE
YES
Is voltage
* Max. 0.1 V NO -Turn starting switch OFF. * Disconnect 2nd and E2. - Turn starting switch ON.
-
hln ‘*”
0
4 YES
AjZHP I
I
NO Max. 0.1 V *Turn starting switch OFF. * Disconnect 2nd and E2. *Turn starting switch ON.
electrical
Transmission
I
Repair or replace
Short circuit in wiring harness between E2 (female) (8) and 2nd (female) (1) and wiring harness between E2 (female) (18) and 2nd (female) (2)
Repair or replace
Defective
2nd solenoid
Replace
Defective controller
transmission
Repair or replace
Short circuit with power source in wiring harness between 2nd (female) (1) and E2 (female) (8)
I
-
ET-2 Related
Short circuit with power source in wiring harness between 2nd (female) (2) and E2 (female) (18)
Repair or replace
circuit diagram
controller
I
E2
2nd
2nd
solenoid
20-157 0
ET-3
TROUBLESHOOTING
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 for [Existing failure] is no longer displayed on the LED 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.
Cause
3 Is voltage between 3rd (female) (2) and chassis normal?
YES 2 YE 1
(male) (1) and (2) *5-20R . Turn starting switch OFF. s Disconnect 3rd.
When 3rd is disconnected,
is
- resistance between E2 (female) (9) and 119) normal?
* Max.
-
* Min. 1 MC2 * Turn starting switch OFF. * Disconnect 3rd and E2.
0.1 V
YES
GotoA
NO
Turn starting switch OFF. * Disconnect 3rd and E2. *Turn starting switch ON. *
NO
,h IV”
4 YES
+ZJgJH--
* Max.
0.1 V
NO
Turn starting switch OFF. * Disconnect 3rd and E2. * Turn starting switch ON.
electrical Transmission
Short circuit with power source in wiring harness between 3rd (female) (2) and E2 (female) (19)
Repair or replace
Short circuit in wiring harness between E2 (female) (9) and 3rd (female) (1) and wiring harness between E2 (female) (19) and 3rd (female) (2)
Repair or replace
Defective
3rd solenoid
Replace
Defective controller
transmission
Repair or replace
Short circuit with power source in wiring harness between 3rd (female) (1) and E2 (female) (9)
*
ET-3 Related
Remedy
Repair or replace
circuit diagram controller I
E2
3rd
3rd
solenoid
(+I
3
3rd
solenoid
(-1
3
3rd
solenoid
TWG00319
20-l 58 0
ET-4
TROUBLESHOOTING
ET-4 +
* *
[A41 (Short circuit 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 for [Existing failure] is no longer displayed on the LED 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.
Remedy
Cause
3 YES 2 -
YES
GotoA
Is voltage between 4th (female) (2) and chassis normal?
I When 4th is YES disconnected, is * Max. 0.1 V - resistance between *Turn starting switch E2 (female) (101and 1 * Disconnect 4th and p (201normal? _ Is resistance *Turn starting switch * Min. 1 MCI between 4th - *Turn starting NO (male) (1) and (2) switch OFF. normal? * Disconnect 4th -5-20R and E2. * Turn starting NO switch OFF. * Disconnect 4th.
NO OFF. E2. ON.
4 YES
+GjjiJH-*
electrical
Transmission
Repair or replace
Short circuit in wiring harness between E2 (female) (IO) and 4th (female) (I) and wiring harness between E2 (female) (20) and 4th (female) (2)
Repair or replace
Defective
4th solenoid
Replace
Defective controller
transmission
Repair or replace
Short circuit with power source in wiring harness between 4th (female) (1) and E2 (female) (10)
Max. 0.1 V NO * Turn starting switch OFF. - Disconnect 4th and E2. - Turn starting switch ON.
ET-4 Related
Short circuit with power source in wiring harness between 4th (female) (2) and E2 (female) (20)
Repair or replace
circuit diagram
controller
I
4th
E2
4th
solenoid
3 4th
solenoid
(-1
3
TWC00320
20- 159 0
TROUBLESHOOTING
ET-5
ET-5
[A51 (Short circuit in High/Low
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 for [Existing failure] is no longer displayed on the LED 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.
Cause
Remedy
GotoA
When YES -
1
~ Is resistance between Lo (male) (1) and (2) normal? *5-20R *Turn starting switch OFF. * Disconnect Lo.
Lo
is
disconnected. is resistance between E2 (female1 (2) and
* Max.
-
NO
0.1 V
Turn starting switch OFF. * Disconnect Lo and E2. *Turn starting switch ON. .
normal? * Min. 1 MR *Turn starting switch OFF. * Disconnect Lo and E2. (13)
NO
6 When YES
A
~ Is voltage between Lo (female) (1) and chassis normal?
-
5 -
disconnected,
-
_
*5-20R -Turn starting switch OFF. * Disconnect Hi.
YES
Hi is is
resistance between E2 (female) 121and (14) normal?
-
*Min. 1 MR NO *Turn starting switch OFF. * Disconnect Hi and E2.
NO
. * Max. 0.1 V * Turn starting NO switch OFF. * Disconnect Lo and E2. -Turn starting switch ON.
a
YES
(female) (2) and chassis normal? B
between Hi (female) (2) and chassis normal? * Max. 0.1 V * Turn starting switch OFF. * Disconnect Hi and E2. . Turn starting switch ON.
20-160 0
Short circuit in wiring harness between E2 (female) (2) and Lo (female) (I) and wiring harness between E2 (female) (13) and Lo (female) (2) Defective
NO
Is resistance YES between Hi (male) (1) and (2) 4 normal?
Short circuit with power source in wiring harness between Lo (female) (2) and E2 (female) (13)
_
* Max. 0.1 V NO -Turn starting switch OFF. - Disconnect Hi and E2. * Turn starting switch ON.
NO
Low solenoid
Repair or replace
Repair or replace
Replace
GotoB Short circuit in wiring harness between E2 (female) (2) and Lo (female) (I) and wiring harness between E2 (female) (13) and Lo (female) (2)
Repair or replace
Defective
Replace
Hi solenoid
Short circuit with power source in wiring harness between Lo (female) (1) and E2 (female) (2)
Repair or replace
Defective controller
Repair or replace
transmission
Short circuit with power source in wiring harness between Hi (female) (1) and E2 (female) (3)
Repair or replace
Short circuit with power source in wiring harness between Hi (female) (2) and E2 (female) (14)
Repair or replace
ET-5
TROUBLESHOOTING
ET-5 Related
electrical
circuit diagram
Lo solenoid ransmission
I
controller
Lo solenoid
(+I
Hi
solenoid
(+I
Lo solenoid
(+I
id
I
TWG00321
20-161 0
ET-6
TROUBLESHOOTING
ET-6 -+
* *
[A71 (Short circuit in FORWARD/REVERSE
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 for [Existing failure] is no longer displayed on the LED 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.
Cause
3 YES YESI
1When
FW is
I (female) (2) and chassis normal?
2 s-l
l-l
* Turn starting switch OFF. . Disconnect FW and E2. NO -5-20R -Turn starting switch OFF. - Disconnect FW.
and E2.
6
YES
jZ+Z&CJH--
YES
A
Is voltage between FW (female) (1) and chassis normal?
4
Is resistance between RE (male) (1) and (2) normal?
* Min. 1 MD NO *Turn starting switch OFF. * Disconnect RE and E2.
*5-20R -
NO
* Turn starbng switch OFF. * Disconnect RE.
- Max. 0.1 V 1 * Turn starting NO switch OFF. * Disconnect FW and E2. -Turn starting switch ON.
a YE 7
B
Is voltage between RE (female) (2) and chassis normal?
L-t f Max. 0.1 V -Turn starting switch OFF. * Disconnect RE and E2. * Turn starting switch ON.
20- 162 0
GotoA Short circuit with power source in wiring harness 2etween FW (female) (2) snd E2 (female) (15) Short circuit in wiring harness between E2 (female) (2) and FW (female) (1) and wiring harness between E2 (female) (15) and FW (female) (2) defective solenoid
NO
* I
YES
Max. 0.1 V NO * Turn starting switch OFF. - Disconnect RE and E2. *Turn starting switch ON.
Remedy
FORWARD
Iepair or eplace
Iepair or eplace
3eplace
GotoB Short circuit in wiring narness between E2 :female) (5) and RE :female) (1) and wiring narness between E2 ifemale) (16) and RE :female) (2) 3efective solenoid
3epair or eplace
REVERSE
Short circuit with power source in wiring harness between FW (female) (1) and E2 (female) (4)
Repair or replace
Defective controller
Repair or replace
transmission
Short circuit with power source in wiring harness between RE (female) (I) and E2 (female) (5)
Repair or replace
Short circuit with power source in wiring harness between RE (female) (2) and E2 (female) (16)
Repair or replace
ET-6
TROUBLESHOOTING
ET-6 Related
electrical
circuit diagram
FORWARD solenoid Transmlsslon
controller
FORWARD
solenoldlt)
REVERSE
solenoid(t)
FORWARD
solenold(-1
REVERSE solenoid
TWG00322
20-163 0
ET-7
TROUBLESHOOTING
ET-7 * *
[bll
(Disconnection
in 1st solenoid)
is displayed
Before carrying out troubleshooting, check that all the related connectors are properly Always connect any disconnected connectors before going on to the next step.
4YES1
YES When
When 1st(female) (1) YI ; Is groundedto chassis, - ISresistancebetween -
(male) (I) and (2) *5-20R * Turn starting switch OFF. * Disconnect 1st.
ET-7 Related
3 1st (female)
(2)
YES isgroundedto chassis, - is resistance between E2 (female)(17)and 2
~
1
~
E2 (female1
chassis n~~m.g
* Max. 1 R - Turn starting
(71 and
switch
OFF.
Is resistance
between
E2 (female) (17).1st ifemale) 12)and chassis normal? ~ * Min. 1 MR * Turn starting switch
OFF.
. Disconnect NO
chassisnormal? - Disconnect 1st and E2. - Max. 1 R * Ground 1st (female) (2) to chassis. -Turn starting NO switch OFF. + Disconnect 1st and E2. * Ground 1st (female) (1) to chassis.
NO
Transmission
Defective controller
transmission
Short circuit with ground in wiring harness between 1st (female) (2) and E2 (female) (17)
Defective contact or disconnection in wiring 1st and E2. 1 harness between 1st (female) (1) and E2 (female) (17) Defective contact or disconnection in wiring harness between 1st (female) (I) and E2 (female) (7) Defective 1st solenoid (internal disconnection)
\I0
electrical
*
inserted.
Repair or replace
Repair or replace
Repair or replace
Repair or replace
Reolace
circuit diagram
controller
1
1st
E2
1st
solenoid
C-t)
3
1st
solenoid
(-1
-3
1st
solenoid
TWG00317
20- 164 0
ET-8
TROUBLESHOOTING
ET-8 Ir Sr
[b2] (Disconnection
in 2nd solenoid)
is displayed
Before carrying out troubleshooting, check that all the related connectors are properly Always connect any disconnected connectors before going on to the next step.
I 4YEA resistance between E2 (female) 118). 2nd (female) (2) and chassis normal? Is
YI 1
-5-20R * Turn starting switch OFF. - Disconnect 2nd.
ET-8 Related
YES 3 When 2nd (female) 12) YES is grounded tO chassis, ~* Min. 1 MR NO - is resistance between *Turn starting E2 (female1 (18) and 2 switch OFF. p chassis normal? When 2nd (female) (1) * Disconnect 2nd and E2. f Max. 1 - R is grounded to chassis, . is resistance between - . Turn starting NO E2(female) (8) and switch OFF. chassisnormal? - Disconnect 2nd and E2. * Max. 1 R - Ground 2nd (female) (2) to chassis. - Turn starting NO switch OFF. * Disconnect 2nd and E2. * Ground 2nd (female) (1) to chassis. IO
electrical
Transmission
inserted.
Remedy
Cause
Defective controller
transmission
Short circuit with ground in wiring harness between 2nd (female) (2) and E2 (female) (18) Defective contact or disconnection in wiring harness between 2nd (female) (2) and E2 (female) (18) Defective contact or disconnection in wiring harness between 2nd (female) (I) and E2 (female) (8) Defective 2nd solenoid (internal disconnection)
Repair or replace
Repair or replace
Repair or replace
Repair or replace
Replace
circuit diagram
controller I
2nd
E2
2nd
solenoid
g) 3
I
TWG00318
20- 165 0
ET-9
TROUBLESHOOTING
ET-9 * Ir
Before Always
[b31 (Disconnection carrying connect
out troubleshooting, any disconnected
in 3rd solenoid)
is displayed
check that all the related connectors are properly connectors before going on to the next step.
Cause
4YEI
(female)
startina
(male) (I) and (2) *5-20n . Turn starting switch OFF. * Disconnect 3rd.
ET-9 Related
3rd (female)
Repair or replace
Repair or replace
Repair or replace
Defective 3rd solenoid (internal disconnection)
JO
Transmission
Repair or replace
Defective contact or disconnection in wiring harness between 3rd (female) (1) and E2 (female) (9)
(2) to chassis.
NO switch OFF. * Disconnect 3rd and E2. * Ground 3rd (female) (1) to chassis.
electrical
transmission
Defective contact or disconnection in wiring harness between 3rd (female) (2) and E2 (female) (19)
YE
* Ground
Remedy
Short circuit with ground in wiring harness between 3rd (female) (2) and E2 (female) (19)
(2) and
chassis normal? *Turn
Defective controller
inserted.
Replace
circuit diagram
controller
I
E2
3rd
3rd
solenoid
(+)
3
3rd
solenoid
(-)
3
3rd
solenoid
TWG00319
20-166 0
ET-10
TROUBLESHOOTING
ET-10 + +
[b41 (Disconnection
in 4th solenoid)
is displayed
Before carrying out troubleshooting, check that all the related connectors are properly Always connect any disconnected connectors before going on to the next step.
Remedy
Cause
Defective controller
1 When
4th (female)
(2)
is resistance between E2 (female) (20) and
Is 1
1chassis - Min. -Turn
1 /_
normal?
1 MR starting
NI
1
resistance between 4th (male) (I) and (2) normal? 5-20R * Turn starting switch OFF. * Disconnect 4th.
ET-10 Related
chassis normal? * Disconnect 4th and E2. * Max. 1 R * Ground 4th (female) (2) to chassis. * Turn starting NO switch OFF. * Disconnect 4th and E2. . Ground 4th (female) (1) to chassis.
Transmission
Repair or replace
Short circuit with ground in wiring harness between 4th (female) (2) and E2 (female) (20)
Repair or replace
Repair or replace
Defective contact or disconnection in wiring harness between 4th (female) (I) and E2 (female) (IO)
Repair or replace
Defective 4th solenoid (internal disconnection)
0
electrical
transmission
Defective contact or disconnection in wiring harness between 4th (female) (2) and E2 (female) (20)
YE
inserted.
Replace
circuit diagram
controller
E2
I
4th
4th
solenoid
TWG00320
20-167 0
ET-l 1
TROUBLESHOOTING
ET-11 Ir *
[b51 (Disconnection
in Low solenoid)
is displayed
Before carrying out troubleshooting, check that ail the related connectors are properly Always connect any disconnected connectors before going on to the next step.
inserted.
Cause
4YES Is resistance between E2 (female) (131, Lo Ifemale) (2) and
YES 3 -
When Lo (female) YES
2
1
between Lo (male)
-5-20R * Turn starting switch OFF. - Disconnect Lo.
ET-11 Related
grounded to chassis, is resistance between E2 (female)113) and
chassis
normal?
1 *
-
Min. 1 MR NO * Turn starting switch OFF. * Disconnect Lo and E2.
chassisnormal? ~ When Lo (femaleI (1) * Max. 1 R is groundedto chassis, is resistance between * Turn starting NO E2 (female)(2) and switch OFF. chassisnormal? . * Disconnect Lo and E2. * Max. 1 R * Ground Lo (female) (2) to chassis. * Turn starting NO switch OFF. * Disconnect Lo and E2. * Ground Lo (female) (1)
~
YE
-
(21 is
Defective controller
transmission
Repair or replace
Defective contact or disconnection in wiring harness between Lo (female) (2) and E2 (female) (13)
Repair or replace
Defective Low solenoid (internal disconnection)
electrical
Repair or replace
Short circuit with ground in wiring harness between Lo (female) (2) and E2 (female) (13)
Defective contact or disconnection in wiring harness between Lo (female) (I) and E2 (female) (2)
NO
Remedy
Repair or replace
Replace
circuit diagram
Transmission
controller
I
Lo
E2
Lo
solenoid
(+I
3
Lo
solenoid
(-1
3
Lo
solenoid
TWG00323
20-168 0
TROUBLESHOOTING
ET-12 + *
ET-12
[b6] (Disconnection
in High solenoid)
is displayed
Before carrying out troubleshooting, check that all the related connectors are properly Always connect any disconnected connectors before going on to the next step.
I
YES
-
2
1When
Hi ifemalel12)
grounded
is 1
to chassis, is
resistancebetweenE2 -
(femalei 114) and
’- Min.
1 MR NO * Turn starting switch OFF. * Disconnect Hi and E2.
~ chassisnormal? When Hi (female)(1) + Max. 1 R YES is groundedto chassis, - is resistance between - * Turn starting NO E2 (female)13)and switch OFF. 1 ~ chassis normal? ~ * Disconnect Hi and E2. Is resistance * Max. 1 Cl * Ground Hi (female) (2) to chassis. between Hi (male) _ * Turn starting NO (1) and (2) switch OFF. normal? * Disconnect Hi and E2. * Ground Hi (female) (I) to .5-20R 1 chassis. * Turn starting switch OFF. * Disconnect Hi.
ET-12 Related
electrical
Transmission
transmission
Short circuit with ground in wiring harness between Hi (female) (2) and E2 (female) (14) Defective contact or disconnection in wiring harness between Hi (female) (2) and E2 (female) (14) Defective contact or disconnection in wiring harness between Hi (female) (1) and E2 (female) (3) Defective High solenoid (internal disconnection)
NO
Remedy
Cause
Defective controller (female) (2) and chassis normal’
inserted.
Repair or replace
Repair or replace
Repair or replace
Repair or replace
Replace
circuit diagram
controller
Hi
solenoid
(+I
Hi
solenoid
(-1
I
E2
Hi
Hi
solenoid
@
TWG00324
20-169 0
TROUBLESHOOTING
ET-13 * *
Before Always
ET-13
[b7] (Disconnection carrying connect
out troubleshooting, any disconnected
in FORWARD
solenoid)
is displayed
check that all the related connectors are properly connectors before going on to the next step.
Cause
4YES YES 3 -
Is resistance between E2 (female) (15). FW (female) (21and
When FW(femiii chassis normai? YES isgroundedtochassis. L * Min. 1 MS2 NO - is resistancebetween * Turn starting E2(female)115)and 2 switch OFF. ~ chassisnormal? When Hi (female)(1) * Disconnect FW and E2. - Max. 1 R YES Is grqundedto chassis, - ISreelstancebetween - * Turn starting NO E2(female)(4) and switch OFF. 1 ~ ~chassisnormal? * Disconnect FW and E2. Is resistance * Max. 1 f2 * Ground FW (female) (2) to chassis. between FW * Turn starting (male) (1) and (2) NO switch OFF. normal? * Disconnect FW and E2. * Ground FW (female) (I) -5-200 to chassis. *Turn starting switch OFF. NO - Disconnect FW.
ET-13 Related
electrical
Transmission
Defective controller
transmission
Short circuit with ground in wiring harness between FW (female) (2) and E2 (female) (15) Defective contact or disconnection in wiring harness between FW (female) (2) and E2 (female) (15) Defective contact or disconnection in wiring harness between FW (female) (1) and E2 (female) (4) Defective FORWARD solenoid (internal disconnection)
inserted.
Remedy
Repair or replace
Repair or replace
Repair or replace
Repair or reolace
Replace
circuit diagram
controller
FW
YE2
FORWARD solenoid
FORWARD solenoid(-)
I
20- 170 0
I
TWG00325
ET-14
TROUBLESHOOTING
ET-14 * -)r
Before Always
[b8] (Disconnection carrying connect
in REVERSE solenoid)
out troubleshooting, any disconnected
is displayed
check that all the related connectors are properly connectors before going on to the next step.
Cause
YES 3 YES JZ
grounded to chassis, is
normal?
Ground
RE (female)
* Disconnect RE and E2. . Ground RE (female) (1) 1 to chassis.
electrical
circuit diagram
Transmission
controller
E2
it
1 MR
Defective controller
transmission
Short circuit with ground in wiring harness between RE (female) (2) and E2 (female) (16)
(2) to chassis.
Defective contact or disconnection in wiring harness between RE (female) (1) and E2 (female) (5) Defective REVERSE solenoid (internal disconnection)
NO
ET-14 Related
E2 (female) (16), RE (female1 12) and chassis normal? * Min.
4YES .1
between
Defective contact or disconnection in wiring harness between RE (female) (2) and E2 1 (female) (16) -
*5-20R * Turn starting switch OFF. * Disconnect RE.
-
Is resistance
REVERSE
solenoid(t)
5
REVERSE
solenold(-)
16
I
inserted.
Remedy
Repair or replace
Repair or replace
Repair or replace
Repair or replace
Replace
REVERSE solenoid
TWG00326
20-171 0
TROUBLESHOOTING
ET-15 +
* * *
ET-15
[cl] (Disconnection
in inching potentiometer)
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 for [Existing failure] is no longer displayed on the LED 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. Check that the inching potentiometer mount is normal.
Remedy
Cause
3 YES [When TM11 (female) 12) 1 7
GotoA Defective contact or disconnection in wiring harness between TM11 (female) (2) and E3 (female) (4)
YES 1
r
Short circuit with ground in wiring harness between TM1 1 (female) (3) and E3 (female) (7)
f Ground TM1 1 (female) (2) to chassis.
is grounded f~ chassis, is resistance between E3 Ifemale) (7) and - Max. 1 Q -Turn starting switch OFF. * Disconnect TM1 1 and E3. * Ground TM11 (female) (3) to chassis.
* Disconnect
Disconnection in wiring harness between TM1 1 (female) (3) and E3 (female) (7)
NO
6 YES YES 5
Is voltage between TM I I (3) and (2) normal?
* Min. 1 MR * Turn starting switch OFF. * Disconnect TM1 1 and E3.
electrical
Transmission
Repair or replace
TM1 1
When E3 is YEIS disconnetied, is * 0.45 - 0.61 v NO resistance between + Insert T-adapter into TM1 1. TM11 (female) (1) * Turn starting switch ON. and (21 normal? * Do not depress inching pedal. * Min. 1 Ma * Turn starting NO switch OFF. * Disconnect TM1 1 and E3. L
ET-15 Related
Repair or replace
Repair or replace
Defective transmission controller
Repair or replace
Defective inching potentiometer (internal disconnection)
Replace
Defective contact in wiring harness between TM1 1 (female) (2) and E3 (female) (4) and wiring harness between TM11 (1) and E3 (16)
Repair or replace
Short circuit with ground in wiring harness between TM1 1 (female) (2) and E3 (female) (4)
Repair or replace
circuit diagram controller
I
I
Inching
PO
n
E3
i ome
en
er
Inching input Power
SUPP
I Y (+5V)
GND I
1
\
I
\
/
I TWG00327
ZO-172 0
TROUBLESHOOTING
STANDARDS TABLE
FOR MEASURING
OF FAILURE
HYDRAULIC H-l
MODES
PRESSURE
Abnormal
H-2
Relief
H-3
Hydraulic
noise
sound
HYDRAULIC
AND
is made
is heard
(from
(when
oil overheats
Work
equipment
does
Work
equipment
is slow,
There Steering
H-8
Turning
H-9
Feeling
(work (work
is excessive wheel
equipment speed when
when
lacks power
at neutral)
POSITIONS..
drift
20-204
............................................
20-206
.............................................................................................
20-208
..................................................................................................
20-208
.............................................................................................. control lever is operated (steering at neutral). ..........................
...........................................................................................................
of work
equipment
.................................................................................
.20-208 20-209 20-210 20-21 1
............................................................................................................................
20-21 1
lacks power
at neutral)
operating
pump)
MOUNTING
.20-202
not turn
is slow,
equipment
FILTER
not operating)
not move
hydraulic
does
AND
around
SYSTEM
PRESSURE, AND JUDGEMENT VALUES ................................. ............................................................................................................
not operating)
(when
H-4 H-6
CAUSES
MEASUREMENT
H-5 H-7
CHART FOR HYDRAULIC (H MODE)
............................................................................................................................ wheel is strange.. .....................................................................................
steering
20-212 20-212
20-201 0
STANDARDS FOR MEASURING HYDRAULIC PRESSURE, AND JUDGEMENT VALUES
TROUBLESHOOTING
STANDARDS JUDGEMENT
FOR MEASURING VALUES
HYDRAULIC
PRESSURE, AND Unit:
T Posture
No.
for
machine
Measurement
*a=
l
All work Work
values (any value indicates a failure)
Ps (steering pressure)
PM (main oressure)
outside PP (pilot pressure)
*
equipment
at standard l
Judgement this range
conditions
MPa (kg/cm*)
Min.
position.
equipment
1.0 (IO), and
not operated.
Min.
2.0 (201, and Max. 2.0 (20) + 2.5 + 251 Pp+ 1.0 ( + 101
235FO21025
:Hm
l
Steering
cylinder
relief.
16.2 - 18.1 (165 - 185)
Vlax. Ps + 2.5 (25)
%I PSI & 1.0 (IO)
23.0 - 26.0 (235 - 265)
%I PSI + 1.0 (IO)
23.0 - 26.0 (235 - 265)
235FO2107
l
Left blade
lift cylinder
relief. 235FO2108
n l
Right
blade
lift cylinder
relief. 235FO2109 l
Front
wheels
raised
off
ground. l
Steering
l
Operating 1 turn/2
235FO2110
1.
The oil temperature
2.
Measure within
3.
With
with
shall
Max.
5.9 (60)
Vlax. 6.4 (65)
PQ5
t-205
1
speed: sec.
be 45 - 55°C.
engine
speed
at both
low
idling
and
high
idling,
and check
that
both
measurements
are
the standard. the CLSS, the hydraulic
reason,
pressures
put the measurement
are within El
the
operated.
the specified
“PSI” is the measured
at different
data into a formula
points
are mutually
for calculating
related
the judgement
and change standard,
together.
For this
and check that they
range. data
marked*.
To hydraulic
control
valve
PS \
To steer
ir
valve
I
20-202 0
I
235COO2220
TROUBLESHOOTING
TABLE OF FAILURE MODES AND CAUSES
TABLE OF FAILURE MODES AND CAUSES
Parts causing
Failure
Does
z
20-204 0
Pump
Surge pressure absorb-
Priority divider
flow valve
mode
not move
Slow,
P ‘E 8
failure
Turning
lacks power
speed
is slow,
Feeling when operating steering wheel is strange
lacks power
Changes
-
between
There
is kickback
There
is a grating
00 being
feeling
heavy
and light
0
0
I io I do I 4 I Q
0 0
0 0
I in
0
0
I A
z
023502
2
z
equipment
control
link
Troubleshooting
code
Shuttle valve for circle rotation
Slip clutch
Wrk o
gear (%I)
HYDRAULIC PRESSURE MEASUREMENT AND FILTER MOUNTING POSITIONS
TROUBLESHOOTING
PRESSURE MEASUREMENT
HYDRAULIC POSITIONS. 0
Measuring
port for work
main
equipment
Fia 1
oil pressure
Priority divler
(PM). l
Measuring
port for steering
oil pressure
(Ps).
AND FILTER MOUNTING
flow valve \
PM
\
( _______~______t___i_-______
Ps
/
235CD02221
Fia 2 pressure
l
Pilot
l
LS line
filter
measuring
port
(PP).
Surge Dressure valve absorbing
(3).
1
235COO2222
b@-+@A
Fig 3 .
Pump
filters
0
Filters
(41, (5),
(I),
(2).
I
Fig 4 (6) on top of surge
pressure
absorbing
valve.
absorbing
20-206 0
valve
235CDO2044
HYDRAULIC PRESSURE MEASUREMENT AND FILTER MOUNTING POSITIONS
TROUBLESHOOTING
0
Control
valve
filters
Fig 5
(71, (8).
I
Control
Valve
R.H.
COntrOl
Valve
L.H
235C00204E
l
Steering
valve
LS line filter
Fia 6
(9).
Fig 7 Measuring (Serial
No.:
port for
brake
piston
(circle)
pressure.
11001 - 12050)
20-207 0
H-l,
TROUBLESHOOTING
H-l
Abnormal
noise is made (from around pump). Cause
YES
Is strainer clogged?
YES
3 -
I;“‘”
H-2, H-3
raulic tank el normal?
Is problem corrected when - piping between NO tank and pump is tightened? ~
Y
NO
4YE Are metal particles found w,hen hydraulic 011 IS drained? N(
Remedy
Zlogged strainer.
Clean
_ooseness of piping :lamp.
Tighten
Iefective
Replace
pump.
Natch for a short time to ;ee if there is any change n the condition.
Inspect again [according to change in condition).
_ack of oil.
Add hydraulic oil.
Zlogged orifice.
Clean
Zlogged steering LS line ‘ilter (9) (See Fig. 6).
Clean
H-2 Relief sound is heard (when not operating). 1)
From priority
Is LS port orifice clogged?
flow
divider
valve.
H NO
2)
From surge
pressure
absorbing
valve.
Clogged spool orifice of priority flow divider valve.
H-3 Hydraulic 1 YES Is pilot line oil pressure high? . Priority flow divider valve is being relieved. * Steering oil pressure is high. [I72 MPa (175kg/cm?l
20-208 0
NO
oil overheats
(when not operating). Clogged steering LS line filter (9) (See Fig. 6).
Clean
Defective operation servo valve.
Repair or replace.
of
H-A
TROUBLESHOOTING
H-4
Work equipment at neutral).
does not move when control lever is operated Cause
I)
No work
equipment
(steering
Remedy
moves.
YES
-
Go to Item 2).
1 Is hydraulic pump main preSsure normal?
-
_
YES 2
24.5 + 1.5 MPa (250+15 NO kg/cm’)
Is pilot oil pressure normal?
YES 3
p
-
$5, MPa
Is surge pressure absorbing valve LS line filter clogged?
(_$ kg/cm*)
-
Main oil pressure
NO
4 YE
Does condition Check filter (3). _ become normal NO when servo valve (See Fig 2) is replaced? - Check operation spool.
2)
Work
equipment
for control
Pump filter (1) or (2) is clogged. (See Fig. 3)
Clean
Clogged filter (3). (See Fig. 2)
Clean
Defective operation servo valve.
Repair or replace.
of
Repair or replace.
N( of
valve on one
side only does not move.
Is surge pressure absorbing valve filter clogged? * Check filter (4) N or (6). (See Fig 4)
2 YES
Work
equipment
NO
Clogged filter.
Iean
Defective operation control valve.
of
lepair or eplace.
Defective operation control valve.
of
Repair or replace.
for one line only does not move. 2 YES
NO Is work equipment control link normal? - Check operation linkage?
Xean
Is control valve filter clogged? * Check filter (7) or (8). (See Fig 5)
3)
Clogged filter
of Circle rotation ge assembly ‘ES
normal?
-
Engine low idling
become normal
Defective
cylinder.
Repair or replace.
Defective
motor.
Repair or, replace.
Defective clutch.
adjustment
of
4djust
Defective operation shuttle valve.
of
qeplace
Defective operation :ontrol valve.
of
qepair or replace.
lefective inkafge.
of
qepair or .eplace.
5.gMPat6’
kg/cm? - Engine high idling : 8.8MPa (90 kg/cm*) - Blade raised.
NC
operation
20-209 0
H-5
TROUBLESHOOTING
is slow, lacks power.
H-5 Work equipment
Remedy
Cause I)
All work
equipment.
io to H-4.
2)
Work
equipment
valve on one side only. jefective
Does condition become normal when relief valve of control valve is adjusted?
idjust
relief valve.
-
. Relief pressure :24.5 t 1.5 MPa (250 2 15 kg/cm’)
3)
for control
;o to H-4.
NO
Work
equipment
for one line only. hen slow 2 YES Doescondition 1 Ibecome normal when blade float valve is
Blade lift
3epair or eplace.
defective blade float alve.
GotoA
1
* Engine: Rated
Is work equipment control linkage normal? . Check operation linkage.
)
([i%$Thift
1
Whenthereisnopower~
of
sot0
From IA
Is there defect inside cylinder?
4 YES
i!ic$q1damage,
dirt.
sd? * Check for oil leakage. * Defective relief pressure setting (only for machines with relief valve).
20-210 0
11
NO
H-4.
of
3epair or .eplace.
Iefective inkage.
operation
Defective
cylinder.
Repair or replace.
Defective valve.
pilot check
Repair or replace.
Defective
control
Repair or replace.
valve.
TROUBLESHOOTING
H-6
H-6, H-7
There is excessive work equipment.
hydraulic
drift of Remedy
Cause
1 YES Are cylinder, piston, seal damaged?
-
Check for oil leakage, damage.
H-7
NO
Damaged cylinder, piston, seal.
Replace
Defective valve.
pilot check
Repair or reolace.
Defective
steering
?epair or .eplace.
Defective cvlinder.
steering
Steering wheel does not turn (work equipment at neutral). 2 YES YE
L Does
cylinder move normally? NO
- Is there any internal defect?
‘) - 17.2 + 1.0 MPa (175 + 10 kg/cm’).
valve.
YES
Clogged pump filters (2). (See Fig.3)
I
I
Is pilot pressure , normal?
YES
(I),
Ilean
Clean
Clogged filter
at top and bottom of surge pressure
- Steering oil pressure : ‘_$$ Nm
k.” r
- Check filters (3),(5). (See Fig.2.4)
YES 1 pees condition
valve.
Repair or reolace.
Defective
shuttle
Defective
servo valve.
Repair or replace.
Defective
pump.
Repair or replace.
5[ [
From A
shuttle
* Check
valve. for dirt.
replaced? - Check operation of spool. * Check for dirt.
20-211 0
TROUBLESHOOTING
H-8, H-9
H-8 Turning speed is slow, lacks power (work equipment at neutral). Cause
YES
Remedy
Go to H-7
4 YE:
Defective cylinder.
steering
Repair or replace.
move normally?
YI
Is relief pressure
Go to H-7
Is relief pressure of double relief valve normal?
- 20.6
MPa (210 kg/cm?
,
NO
Defective valve.
double
relief
Defective priority divider valve.
flow
Adjust or replace.
. 17.2 ? 1.0 MPa 1175 + 10 kg/cm2)
10
H-9 I)
2)
3)
Feeling when operating is strange.
Changes
There
There
20-212 0
between
being
Adjust or replace.
steering wheel
heavy and light.
Defective steering check valve.
CF line
?epair or .eplace.
Defective steering line check valve.
CF, LS
qepair or .eplace.
Defective
valve.
7epair or .eplace.
is kickback.
is a grating
feeling.
steering
023502
30 DISASSEMBLY AND ASSEMBLY HOW TO READ THIS MANUAL. . . . . . . . . . . . . . . .30-1-2 COATING MATERIAL LIST . . . . . . . . . . . . . . . . . . .30-1-4 SPECIAL TOOL LIST . . . . . . . . . . . . . . . . . . . . . . . 30- 2 STARTING MOTOR Removal and Installation . . . . . . . . . . . . . . . . . . 30- 4 ALTERNATOR Removal and Installation . . . . . . . . . . . . . . . . . . 30- 4 NOZZLE HOLDER Removal and Installation . . . . . . . . . . . . . . . . . . 30- 5 FUEL INJECTION PUMP Removal and Installation . . . . . . . . . . . . . . . . . . 30- 6 WATER PUMP Removal and Installation . . . . . . . . . . . . . . . . . . 30- 7 ENGINE OIL COOLER CORE Removal and Installation . . . . . . . . . . . . . . . . . . 30- 8 TURBOCHARGER Removal and Installation . . . . . . . . . . . . . . . . . . 30- 9 AIR COMPRESSOR Removal and Installation . . . . . . . . . . . . . . . . . . 30- 10 CYLINDER HEAD Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30- 11 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30- 15 ENGINE (INCL. TRANSMISSION) Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30- 18 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30- 23 RADIATOR Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30- 29 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30- 31 FUEL TANK Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30- 33 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30- 34 PTO Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 30- 36 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30- 41 TRANSMISSION Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30-45-1 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30-45-5 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 30- 46 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30- 54 TRANSFER Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 30- 69 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30- 72 TRANSMISSION CONTROL VALVE Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 30- 76 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30- 78 HYDROSHIFT TRANSMISSION PUMP Removal and Installation . . . . . . . . . . . . . . . . . . 30- 80 TANDEM AND FINAL DRIVE Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30- 81 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30- 83 FINAL DRIVE Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 30- 85 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30- 94 BEVEL GEAR Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-106 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-109
BEVEL PINION Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-112 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-113 FRONT AXLE Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-114 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-116 Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-118 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-121 STEERING VALVE Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-125 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-128 WHEEL BRAKE Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-132 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-134 AIR TANK Removal and Installation . . . . . . . . . . . . . . . . . . 30-137 HYDRAULIC TANK Removal and Installation . . . . . . . . . . . . . . . . . . 30-138 HYDRAULIC PUMP Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-139 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-140 Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-142 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-156 HYDRAULIC CONTROL VALVE Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-179 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-180 MAIN CONTROL VALVE Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-182 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-184 CIRCLE ROTATION MOTOR Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-168 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-189 DRAWBAR SHIFT CYLINDER, BLADE LIFT CYLINDER, LIFTER GUIDE Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-195 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-197 ARTICULATE CYLINDER Removal and Installation . . . . . . . . . . . . . . . . . . 30-199 REAR MOUNT RIPPER CYLINDER Removal and Installation . . . . . . . . . . . . . . . . . . 30-200 HYDRAULIC CYLINDER Serial No. 11001 – 12502 Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-201 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-203 Serial No. 12503 and up Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . 30-205-1 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-205-5 CIRCLE ROTATION GEAR AND HYDRAULIC OIL MOTOR Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-206 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-207 Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-208 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-211
30-1 (6)
30-1-1 (6)
30-215 30-216 30-217 30-219 30-224 30-225 30-226 30-228 30-229 30-223
30-238 30-241 30-243 30-246
023502
BLADE Removal and Installation . . . . . . . . . . . . . . . . . . CIRCLE AND DRAWBAR Removal and Installation . . . . . . . . . . . . . . . . . . Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . REAR MOUNT RIPPER Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . METHOD FOR LIFTING UP ROPS CAB . . . . . . . . INSTALLATION OF ROPS . . . . . . . . . . . . . . . . . . . ROPS cab Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DISCONNECTION AND CONNECTION OF ARTICULATE SECTION Serial No. 11001 – 12502 Disconnection . . . . . . . . . . . . . . . . . . . . . . . . . . Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . Serial No. 12503 and up Disconnection . . . . . . . . . . . . . . . . . . . . . . . . . . Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . .
How to read this manual 1.
(Rev. 2009.01)1
Removal and installation of assemblies Special tools q Special tools which are necessary for r e m o v a l o r in s ta l l a t i o n o f pa r ts a r e described as A1, ••• X1 etc. and their part numbers, part names and quantities are described in the special tool list. q Also the following information is described in the special tool list. 1) Necessity t : Special tools that cannot be substituted and should always be used q : Special tools that will be useful if available and are substitutable with tools available on the market 2) Distinction of new and existing special tools N: Tools newly developed for this model. They have a new part number respectively. R: Tools made available by redesigning the existing tools which were developed for other models. Each of them has a new part number assigned by setting forward the part number of the existing tool. Blank : Tools already available for other models. They can be used without any modification. 3) Circle mark Q in sketch column: q The sketch of the special tool is presented in the section of “Sketches of special tools”. q Part No. of special tools starting with 79 T: means that they are not available from Komatsu Ltd. (i.e. tools to be made locally).
* *** ****
Removal q In “Removal” section, the work procedures, precautions and know-how to do the work, and the amount of oil and coolant to be drained are described. q Common tools that are necessary for removal are described as [1], [2]••• etc. and their part numbers, part names and quantities are not described. q Various symbols used in “Removal” section are explained and listed below. k : Precautions related to work safety a : Guidance or precautions for the work [*1] : This mark shows that instructions or precautions for parts installation work are given in “Installation” section. 6 : Amount of oil or coolant to be drained 4:
Weight of part or component
Installation Unless otherwise instructed, installation of parts is to be done in the reverse order to removal. q Instructions and precautions for parts installation is shown with the mark ([*1], [*2]...) which corresponds to the mark in “Removal” section. q Common tools that are necessary for installation are described as [1], [2]••• etc. and their part numbers, part names and quantities are not described. q Marks shown in the “Installation” section stand for the following. q
k
: Precautions related to work safety : Guidance or precautions for the work 2 : Type of coating material 3 : Tightening torque
a
5
: Amount of oil or coolant to be replenished
Sketches of special tools Various special tools are illustrated for the local manufacture.
q
30-1 (6)
2
2.
Disassembly and assembly of assemblies Special tools q Special tools which are necessary for disassembly and assembly of parts are described as A1, ••• X1 etc. and their part numbers, part names and quantities are described in the special tool list. q Also the following information is described in the special tool list. 1) Necessity t : Special tools that cannot be substituted and should always be used. q : Special tools that will be useful if available and are substitutable with tools available on the market. 2) Distinction of new and existing special tools N: Tools newly developed for this model. They have a new part number respectively. R: Tools made available by redesigning the existing tools which were developed for other models. Each of them has a new part number assigned by setting forward the part number of the existing tool. Blank : Tools already available for other models. They can be used without any modification. 3) Circle mark Q in sketch column: q The sketch of the special tool is presented in the section of “Sketches of special tools”. q Part No. of special tools starting with 79 T: means that they are not available from Komatsu Ltd. (i.e. tools to be made locally).
* *** ****
Disassembly q In “Disassembly” section, the work procedures, precautions and know-how to do the work, and the amount of oil and coolant to be drained are described. q Common tools that are necessary for disassembly are described as [1], [2]••• etc. and their part numbers, part names and quantities are not described. q The meanings of the symbols used in “Disassembly” section are as follows. k
: Precautions related to work safety : Guidance or precautions for the work 6 : Amount of oil or coolant drained
a
Assembly q In “Assembly” section, the work procedures, precautions and know-how to do the work, and the amount of oil and coolant to be replenished are described. q Common tools that are necessary for assembly are described as [1], [2]••• etc. and their part numbers, part names and quantities are not described. q The meanings of the symbols used in “Assembly” section are as follows. k
: Precautions related to work safety : Guidance or precautions for the work 2 : Type of coating material 3 : Tightening torque
a
5
: Amount of oil or coolant to be replenished
Sketches of special tools q Various special tools are illustrated for the local manufacture.
30-1 (6)
3
Coating materials list
(Rev. 2009.02) 1
a The recommended coating materials such as adhesives, gasket sealants, and greases used for disassembly and assembly are listed below. a For coating materials not listed below, use the equivalent of products shown in this manual. Category
Komatsu code
Part number
Q'ty
Container
Main features and applications
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 (2 pcs.)
• Used for plastic (except polyethylene, polypropylene, tetrafluoroethylene and vinyl Polyethylene chloride), rubber, metal, and non-metal parts container which require immediate and strong adhesion.
LT-2
09940-00030
50 g
Polyethylene • Features: Resistance to heat and chemicals. container • Used to fix and seal bolts and plugs.
Adhesive
LT-3 LT-4
790-129-9040
250 g
Holtz MH 705
790-129-9120
75 g
ThreeBond 1735
023502
790-129-9140
Can
• Used to stick and seal metal, glass, and plastics.
Polyethylene • Used to seal plugs. container Tube
• Heat-resistant seal used to repair engines.
50 g
• Quick-setting adhesive. Polyethylene • Setting time: Within 5 sec. to 3 min. container • Used mainly to stick metals, rubbers, plastics, and woods. • Quick-setting adhesive. • Quick-setting type. Polyethylene (max. strength is obtained after 30 minutes) container • Used mainly to stick rubbers, plastics, and metals.
Aron-alpha 201
790-129-9130
2g
Loctite 648-50
79A-129-9110
50 cc
• Features: Resistance to heat and chemicals. Polyethylene • Used for fitted portions used at high temperacontainer tures.
1 kg
• Used to seal various threaded portions, pipe Polyethylene joints, and flanges. container • Used to seal tapered plugs, elbows, and nipples of hydraulic piping.
LG-5
Gasket sealant
790-129-9060 Adhesive: 1 kg (Set of adhesive Hardener: 500 g and hardener)
790-129-9080
LG-6
790-129-9160
200 g
Tube
• Features: Silicon-based heat and cold-resistant sealant. • Used to seal flange surfaces and threaded portions. • Used to seal oil pan, final drive case, etc.
LG-7
790-129-9170
1 kg
Tube
• Features: Silicon-based quick-setting sealant. • Used to seal flywheel housing, intake manifold, oil pan, thermostat housing, etc.
Tube
• Features: Silicon-based, heat and cold-resistant, vibration-resistant, impact-resistant sealant. • Used to seal transfer case, etc.
LG-8 ThreeBond 1207B
419-15-18131
100 g
30-1-4 (6)
Molybdenum disulfide lubricant Grease
Main features and applications
790-129-9310
200 g
Tube
LG-10 ThreeBond 1206E
790-129-9320
200 g
Tube
• Used as lubricant/sealant when the radiator hoses are inserted. • Can be coated with paint.
LG-11 ThreeBond 1121
790-129-9330
200 g
Tube
• Feature: Can be used together with gaskets. • Used for covers of the transmission case and steering case etc.
ThreeBond 1211
790-129-9090
100 g
Tube
• Gasket sealant used to repair engine.
Tube
• Used to prevent scuffing and seizure of press-fitted portions, shrink-fitted portions, and threaded portions. • Used to lubricate linkages, bearings, etc.
Can
• Spray type • Thin molybdenum disulphide films are made on metal surfaces to prevent the metals from scuffing each other. • Applicable for the propeller shaft splines, needle bearings, pins and bolts of various links, etc.
—
Can
• Feature: Seizure and scuffing prevention compound with metallic super-fine-grain, etc. • Used for the mounting bolt in the high temperature area of the exhaust manifold and the turbocharger, etc.
Various
Various
• Feature: Lithium grease with extreme pressure lubrication performance. • General purpose type.
LC-G NEVER-SEEZ
09940-00040
09995-00250
—
SYG2-400LI SYG2-350LI SYG2-400LI-A G2-LI SYG2-160LI G0-LI SYGA-160CNLI *: For cold district SYG0-400LI-A (*) SYG0-160CNLI (*)
Molybdenum SYG2-400M disulfide grease SYG2-400M-A LM-G (G2-M) SYGA-16CNM
SYG2-400T-A SYG2-16CNT SYG0-400T-A (*) *: For cold district SYG0-16CNT (*)
Hyper White Grease G2-T, G0-T (*)
SYG2-400B Biogrease G2-B, G2-BT (*) SYGA-16CNB *: For use at high SYG2-400BT (*) temperature and SYGA-16CNBT under high load (*)
(6)
Container
• Used for rough surfaces such as the circle gear top seal which does not need to be clamped, water resistance of the clearance at the welded area, etc. • Can be coated with paint.
—
30-1-5
Q'ty
LG-9 ThreeBond 1206D
LM-P
Seizure prevention compound
Part number
200 g
190 g
• Used for parts under heavy load. Caution: 400 g x 10 Bellows-type • Do not apply grease to rolling bearings like swing circle bearings, etc. and spline. 400 g x 20 container • The grease should be applied to work equipment 16 kg Can pins at their assembly only, not applied for greasing afterwards. 400 g 16 kg
400 g 16 kg
• Bellows-type container Can •
Seizure resistance, heat resistance and water resistance higher than molybdenum disulfide grease. Not conspicuous on machine since color is white.
Bellows-type • Since this grease is decomposed by natural baccontainer teria in short period, it has less effects on microCan organisms, animals, and plants.
023502
Gasket sealant
CateKomatsu code gory
G2-U-S ENS grease
—
427-12-11871
SUNSTAR PAINT PRIMER 580 SUPER
Caulking material
Adhesive
023502
Primer
SUNSTAR GLASS PRIMER 580 SUPER SUNSTAR PAINT PRIMER 435-95
Q'ty
Container
Main features and applications
Tube
• Feature: Silicone grease with wide using temperature range, high resistance to thermal-oxidative degradation and performance to prevent deterioration of rubber and plastic parts. • Used for oil seals of the transmission, etc.
2 kg
Can
• Feature: Urea (organic system) grease with heat resistance and long life. Enclosed type. • Used for rubber, bearing and oil seal in damper. Caution: Do not mix with lithium grease.
20 ml
Glass container
• Used as primer for cab side. (Using limit: 4 months after date of manufacture)
20 ml
Glass container
• Used as primer for glass side. (Using limit: 4 months after date of manufacture)
20 ml
Glass container
200 g
417-926-3910
22M-54-27230
Adhesive for cab glass
G2-S ThreeBond 1855
Part number
• Used as primer for painted surface on cab side. (Using limit: 4 months after date of manufacture) • Used as primer for black ceramic-coated surface on glass side and for hard polycarbonate-coated surface. (Using limit: 4 months after date of manufacture)
SUNSTAR GLASS PRIMER 435-41
22M-54-27240
150 ml
Can
SUNSTAR SASH PRIMER GP-402
22M-54-27250
20 ml
Glass container
• Used as primer for sash (Almite). (Using limit: 4 months after date of manufacture)
SUNSTAR PENGUINE SEAL 580 SUPER “S” or “W”
417-926-3910
320 ml
Polyethylene container
• “S” is used for high-temperature season and “W” for low-temperature season as adhesive for glass. (Using limit: 4 months after date of manufacture)
Sika Japan, Sikaflex 256HV
20Y-54-39850
310 ml
Polyethylene container
• Used as adhesive for glass. (Using limit: 6 months after date of manufacture)
SUNSTAR PENGUINE SUPER 560
22M-54-27210
320 ml
Ecocart (Special container)
SUNSTAR PENGUINE SEAL No. 2505
417-926-3920
320 ml
Polyethylene container
SEKISUI SILICONE SEALANT
20Y-54-55130
333 ml
Polyethylene container
• Used to seal front window. (Using limit: 6 months after date of manufacture)
Cartridge
• Used to seal joint of glasses. Translucent white seal. (Using limit: 12 months after date of manufacture)
GE TOSHIBA SILICONES TOSSEAL 381
22M-54-27220
333 ml
Adhesive for cab glass
Grease
CateKomatsu code gory
• Used as adhesive for glass. (Using limit: 6 months after date of manufacture) • Used to seal joints of glass parts. (Using limit: 4 months after date of manufacture)
30-1-6 (6)
SPECIAL TOOL LIST Symbol
Parts No.
B
790-331-1110
C D
Installation of cylinder head Disassembly, assembly of transmission assembly Disassembly, assembly of final drive assembly
1
2
3
Disassembly, assembly of hydraulic cylinder
A
4
(*1) Serial No.: 11001 – 12050 (*2) Serial No.: 12051 and up
30-2 (6)
Part Name
Q’ty
Remarks
Wrench
1
For tightening cylinder head angle
799-301-1500
Leak tester
1
For checking operation of piston
792-571-1600
Chain puller
1
For securing chain
790-502-1003
Repair stand
1
790-502-2000
Repair stand
1
790-101-1102
Pump
1
790-330-1100
Wrench
1
Removal, installation of round head
790-302-1270
Socket (50 mm)
1
Leaning (*1)
790-302-1290
Socket (60 mm)
1
Leaning (*2)
790-102-1320
Socket (70 mm)
1
790-102-1330
Socket (75 mm)
1
790-302-1340
Socket (80 mm)
1
790-201-1702
Push tool Kit
1
790-101-5021
• Grip
1
01010-50816
• Bolt
1
790-201-1741
• Push tool
1
Steering
790-201-1751
• Push tool
1
Leaning (*1)
790-201-1761
• Push tool
1
Leaning (*2)
790-201-1781
• Push tool
1
Drawbar shift
Stand for disassembling cylinder
Blade lift Drawbar shift Blade shift Power tilt Articulate
Removal, installation of nylon nut
Ripper
023502
Nature of work
790-201-1791
• Push tool
1
Blade lift Blade shift Power tilt Articulate
790-201-1811
• Push tool
1
Ripper
Press fitting coiled bushing
Nature of work
Symbol
5
Disassembly, assembly of hydraulic cylinder
6
A
Parts No.
Part Name
Q’ty
Remarks
790-201-1500
Push tool KIT
1
790-101-5021
• Grip
1
01010-50816
• Bolt
1
790-201-1550
• Plate
1
Steering
790-201-1560
• Plate
1
Leaning (*1)
790-201-1570
• Plate
1
Leaning (*2)
790-201-1590
• Plate
1
Drawbar shift
790-201-1610
• Plate
1
Blade lift Blade shift Power tilt Articulate
790-201-1620
• Plate
1
Ripper
790-702-1000
Expander
1
796-720-1630
Ring
1
07281-00709
Clamp
1
796-720-1650
Ring
1
07281-01019
Clamp
1
796-720-1650
Ring
1
07281-01159
Clamp
1
796-720-1670
Ring
1
07281-01279
Clamp
1
796-720-1680
Ring
1
07281-01589
Clamp
1
791-560-1520
Floating seal installer
1
Press fitting dust seal
023502
Steering
Leaning
7
Blade lift Blade shift Drawbar shift
Installation of piston ring
Power tilt Articulate
Ripper Disassembly, assembly of circle rotation gear and hydraulic motor assembly (Serial No.: 12051 and up)
B
Installation of floating seat
(*1) Serial No.: 11001 – 12050 (*2) Serial No.: 12051 and up
30-3 (6)
REMOVAL OF STARTING ASSEMBLY
A
Disconnect
the
cable
from
the
MOTOR
negative
(-)
ter-
minal of the battery.
1.
Disconnect
connector
2.
Disconnect
wiring
3.
Remove
starting
(1).
(2). motor
assembly
(3).
INSTALLATION OF STARTING MOTOR ASSEMBLY l
Carry
out
installation
in the
reverse
order
to
remo-
val.
REMOVAL OF ALTERNATOR ASSEMBLY Serial No.: 11001 - 12000
A
Disconnect
the
cable
from
the
negative
(-)
ter-
minal of the battery. Disconnect Remove mount Move then
3 alternator bolt
(2)
wires
of
(1).
adjustment
plate,
then
loosen
bolt and nut (3). alternator loosen
alternator Remove
assembly
belt
tension,
(4) towards and
cylinder
remove
belt
block, (5) from
assembly. mount
nator assembly.
bolt
and
nut
(3), then
remove
alter-
m
INSTALLATION OF ALTERNATOR ASSEMBLY Serial No.: 11001 - 12000 l
Carry
out
installation
in the
reverse
order
to
remo-
val.
l
Adjust
the fan belt tension.
For details, judgement
30-4 0
see TESTING standard
value.
AND
ADJUSTING,
table
of
DISASSEMBLY
ALTERNATOR
AND ASSEMBLY
REMOVAL OF ALTERNATOR ASSEMBLY Serial
No.: 12001 and up
g
Disconnect the cable from the negative minal of the battery.
1.
Open engine
2.
Disconnect
3.
Remove locknut (3), and turn (4), then remove V-belt (5).
4.
(-) ter-
side cover.
alternator
wiring
(1) and (2).
adjustment
nut m
Remove mounting bolts (6) and move alternator assembly (8).
(7), then
re-
INSTALLATION OF ALTERNATOR ASSEMBLY Serial
.
No.: 12001 and up
Carry out removal.
installation
in the
reverse
order
to
m t
After installing the V-belt, adjust the tension of the belt. For details, see TESTING AND ADJUSTING, “Testing and adjusting of belt tension”.
30-4- 1 0
REMOVAL OF NOZZLE HOLDER ASSEMBLY 1.
Remove (I),
air
engine
hood,
cleaner
then
remove
assembly
(2),
and
muffler
assembly
intake
connector
(3).
2.
Disconnect
3.
Remove
cover
4.
Loosen
locknut
5.
Remove
connector
6.
Remove
holder
7.
Use a slide 10 mm,
delivery
tube
m
(5). m (6). m (7).
(8).
=
m
a
hammer,
Pitch
(4).
or screw
1.5 mm),
in bolt
then
(Thread
remove
nozzle
dia. = holder
(9) using a bar.
INSTALLATION OF NOZZLE HOLDER ASSEMBLY l
Carry
out
installation
in the
reverse
order
to
remo-
val.
m
Sleeve
nut:
23.5 i
m
Mounting
bolt:
m
Locknut:
36.8 12.5
w
Connector:
m
Mounting
1.0 Nm (2.4 + 0.1 kgm)
12 4.9 + 1.0 Nm (0.5 i
0.1 kgm)
m Nm (3.75 k 0.25 kgm)
m 36.8 + 2.5 Nm (3.75 + 0.25 kgm)
bolt:
66.2 k 7.4 Nm (6.75 i
30-4-2 0
0.75 kgm)
!
n
REMOVAL OF FUEL INJECTION PUMP ASSEMBLY 1. 2.
Open engine Remove tation *
right side cover.
oil gauge
guard
When
pipe
removing
the
not to let the spacer 3.
Remove
coupling
and disconnect 4.
5.
Disconnect
flange
fuel
rotation
guard,
lock
bolt
(4), then
control
rod
Disconnect
hoses
(9), (IO), and
fuel
careful
bolt
(5),
(II),
motor
cable
and fuel
re-
(12) and (13).
lubrication
Remove jection
be
remove
(6) and stop
(8).
Remove
ro-
m
spring
hoses
(2), and
on the inside fall out.
coupling.
nect 6 fuel injection 7.
hose
(7), and remove
turn 6.
(I),
(3).
tubes
4 mounting pump
(14) and
pipes (16). bolts
assembly
(15), and
discon-
m
(17), then
remove
fuel
in-
(18). m
g
kc :
INSTALLATION OF FUEL INJECTION PUMP ASSEMBLY l
Carry
out
installation
in the
reverse
order
to
remo-
val.
w
Coupling
lock bolt:
78.5 f 4.9 Nm (8 i
0.5 kgm)
w
Lubrication
tube
(14):
29.4 i 4.9 Nm
m
Lubrication
tube
(15):
22.5 i
(3 _C0.5 kgm) 2.9 Nm
(2.3 + 0.3 kgm) m
Fuel injection
pipe sleeve
nut:
23.5 k 1.0 Nm (2.4 + 0.1 kgm)
Adjust For
fuel injection
details,
see
ing fuel injection
timing.
TESTING timing.
AND
ADJUSTING,
Adjust-
DISASSEMBLY
AND ASSEMBLY
WATER
REMOVAL OF WATER PUMP ASSEMBLY 1. Drain
engine
cooling
water.
2. Disconnect 2 hoses (2) and 2 connectors washer tank (I). 3. Disconnect hose (5) and connector voir tank (4). 4. Remove together
6. Disconnect 7. Remove
(6) of reser-
washer tank (I) and resevoir with mounting bracket (7).
5. Remove alternator assembly For details, see REMOVAL ASSEMBLY.
(3) of
tank
(4)
(8). OF ALTERNATOR
Serial No.: 11001 - 12000
m
hoses (9), (IO), and (II).
tube (12) and connectors
(13).
Serial
8. Pull out spring (14), then twist tube (15) with a bar and push up. 9. Remove
bolt (161, then remove
pulley (17).
10. Remove mounting bolts (181, then remove ter pump assembly (19).
30-6 0
wa-
No.: 12001 and UD
PUMP
DISASSEMBLY
WATER PUMP
AND ASSEMBLY
INSTALLATION OF WATER PUMP ASSEMBLY .
Carry out removal.
installation
in the
reverse
order
Adjust the tension of the alternator belt. For details, see TESTING AND ADJUSTING, justing belt tension.
.
Ir
to
Ad-
Refilling with water Add water through water filler to the specified level. Run the engine to circulate the water through the system. Then check the water level again.
30-7 0
REMOVAL OF ENGINE OIL COOLER CORE ASSEMBLY 1. 2.
Drain engine Disconnect washer
3.
cooling 2
water.
hoses
(2)
and
2
connectors
(3)
of
tank (1).
Disconnect
hose
(5) and
connector
(6) of
reservoir
tank (4). 4.
5.
Remove
washer
tank
together
with
Remove
turbocharger
exhaust
muffler
(1)
mounting
and
bracket lubrication
drain
tube
reservoir
tank
(4)
(7).
(9),
return then
tube
(8) and
remove
tube
(IO). 6.
Remove
engine
oil cooler
7.
Remove
4 nuts (12), then
assembly remove
(11). cooler
core (13).
INSTALLATION OF ENGINE OIL COOLER CORE ASSEMBLY l
Carry
out
installation
in the
reverse
order
to
remo-
val.
.
Refilling
with water
Add water *
Run
the
through engine
water to
filler to the specified
circulate
the
water
level.
through
the
system. Then check the water %
Engine
cooling
level again. water:
Approx.
58 Q
235FO2204
REMOVAL OF TURBOCHARGER ASSEMBLY 1.
Remove
hood assembly
For details,
see
and air cleaner.
REMOVAL
OF NOZZLE
HOLDER
AS-
remove
inlet
SEMBLY. 2.
Disconnect connector
3.
dust
Remove
muffler
(6) and connector 4.
indicator
hose
(3), then
(4).
Disconnect
assembly
(5),
then
remove
elbow
(7).
clamp
(8),
then
remove
inlet
connector
(8). 5.
Disconnect
6.
Remove (12).
8
4
z
supply
hose (IO), and drain tube
mounting
bolts
and
turbocharger
(‘i 1). assembly
m
INSTALLATION OF TURBOCHARGER ASSEMBLY l
Carry
out
installation
in the
reverse
order
to
remo-
val. m *
Fit the gasket m
with
Mounting
“UP”
mark facing
up.
bolt:
66.2 & 7.4 Nm (6.8 k 0.8 kgm)
3%9
REMOVAL OF AIR COMPRESSOR ASSEMBLY
A 1.
Loosen Remove
drain valve
engine
(2), then remove 2.
Disconnect tubes
3. 4.
oil
and drain air tank pressure.
gauge
rotation
air hoses
pipe
guard
(4) and
(1) and
hose
flange
remove
water
remove
water
(3). (5), and
(6) and (7).
Remove
corrosion
Remove
air
hose (8).
tubes
(9) and
(IO),
then
tube (11). 5.
Remove pressor
lubrication
INSTALLATION COMPRESSOR l
Carry val.
30-&o
tube
(12), then
remove
air com-
(13).
out
installation
OF AIR ASSEMBLY in the
reverse
order
to remo-
REMOVAL OF CYLINDER HEAD ASSEMBLY 1.
Draining
cooling
water
Loosen drain valve
2.
Side covers,
hood
1)
Remove
precleaner
2)
Open
R.H.
cover
hinge,
3)
3.
(1) and drain
Remove
Air cleaner
side
and exhaust cover
then remove
assembly,
2)
Remove
inlet connector
Remove
mounting
4)
Remove
water.
pipe (2).
disconnect
hood
L.H.
side
(4) as one unit.
(5).
inlet connector
Disconnect
assembly
(3),
L.H. and R.H. covers
1) 3)
cooling
KOMA-CLONE band,
pipe at flange mounting then
(6) end.
bolts (7).
remove
air cleaner
(8). inlet
as one unit.
connector
(9) together
with
bracket
5.
Inlet connector,
6.
clip (13).
2)
Remove
mounting
3)
(15). Disconnect
electric
take heater
(18).
Corrosion 1) 2) 3)
7.
air intake
Remove
1)
resistor
Remove
bolts
(14) and
wiring
assembly,
(16),
inlet (17)
connector and
air
in-
tube
hoses (19) and (20).
Remove
mounting
assembly
(21).
Disconnect
tubes
bolts,
and
corrosion
resistor
(22).
Fuel, oil filter assembly 1)
Disconnect
2)
Disconnect
3)
Remove
fuel hoses (23) and (24). oil tubes mounting
and oil, fuel filter
8.
heater
Intake
bracket
mounting
bolts
3022
bolts, assembly
then
remove-
bracket
(27) as one unit.
manifold
Remove (30). m
(25) and (26).
mounting (29)
and
bolts intake
(28),
then
manifold
remove assembly
9.
Turbocharger,
exhaust
Disconnect
and drain tube Remove ifold,
bolts
2 -
remove
(33)
of
and remove
turbocharger
hose
(31)
exhaust
man-
remaining
and
exhaust
bolts. manifold
(34) as one unit. Turbocharger,
& ks
m
supply
3 bolts in position.
Sling turbocharger assembly
assembly oil
(32).
mounting
leaning
Then
manifold
turbocharger
assembly:
Remove
tube
10. Fuel injection
exhaust
manifold
40 kg
(35).
tube, fuel spill tube
1)
Remove
6 fuel injection
2)
Remove
spill tubes
tube
m
(36).
(37).
z 4 2 11. Head cover Remove cover
m
mounting
12. Rocker arm assembly Remove
mounting
lever assembly *
bolts
(38)
then
remove
head
(39).
When
m bolts
(40)
then
remove
rocker
lever,
loosen
screw
(43)
rocker
(41).
installing
then
turn
adjustment
times
to prevent
strain
locknut back
on the push rod.
(42),
2 -
3
13. Holder
/
Remove
mounting
bolts
(44),
then
remove
holder
(45). 14. Connection Loosen
m
lock
nut
(46),
then
@ (Thread
dia.
remove
connection
(47)
and pull out.
15. Nozzle Using
holder bolt
ng
mm), remove *
Check
=
10
mm,
Pitch
=
1.5
nozzle holder (48).
that there
is a gasket
fitted
to the tip of
the nozzle holder. 16. Push rod Remove
push rod (49).
17. Rocker arm housing Remove
mounting
) bolts
(50)
then
remove
rocker
arm housing (51). 18. Crosshead Remove
19. Cylinder 1)
m
crosshead
(52).
head assembly
Remove
mounting
der head assembly 2)
Remove
306’4
gasket (55).
m bolts (54).
(53) then
remove
cylin-
INSTALLATION OF CYLINDER HEAD ASSEMBLY .
Carry
out
installation
in the
reverse
order
to
remo-
in the
order
(1 -
Intake
val.
*
Tighten
the
shown
intake
manifold
manifold
24)
in the diagram. Intake
manifold
mounting
bolt
1
21
17
13
9
5
1
4
8
12
16
20
24
235FO2205
*
Tighten
the
shown
in the
the order w
exhaust
manifold
diagram,
(4 -
then
Exhaust
manifold
mounting
(1 -
3)
remainder
in
Exhaust
manifold
the
bolt
29.4 * 4.9 (3.0 + 0.5)
1
2nd Install
order
the
24).
1st
*
in the tighten
66.2 + 7.4 (6.8 k 0.8)
gasket
with
the
OUT
mark
facing
7 17
20 2
1 13
16 6
3 21
2412
the
outside.
I m
Sleeve
nut:
m
Spill tube joint
566FO6352
4.9 f 1.0 Nm (0.5 + 0.1 kgm) bolt:
8.8 f 1 .O Nm (0.9 + 0.1 kgm)
m
Head cover
mounting
bolt:
4.9 k 1.0 Nm (0.5 + 0.1 kgm) m *
Clean the oil hole of the mounting
*
Check that the ball of the adjustment curely
in the socket
w
Rocker
bolt and install. screw
is fitted
se-
of the push rod.
arm mounting
bolt:
98.1 k 4.9 Nm (10 + 0.5 kgm) w
Adjustment
screw
locknut:
48.0 k 2.9 Nm (4.9 + 0.3 kgm) *
Adjust
the valve
For details, valve
*
AND ADJUSTING,
Adjusting
clearance.
Set one rocker
clearance.
see TESTING
side
of holder
arm housing
on head
of mounting
bolt
or
and tighten.
30-&w
* *
m
Connection:
m
Locknut:
Check
that
holder
sleeve.
37.2 + 2.9 Nm (3.8 + 0.3 kgm) 63.7 k 4.9 Nm (6.5 f 0.5 kgm)
there
Check that there
is no dirt
or dust
is a copper
gasket
inside fitted
the
nozzle
to the tip of
the nozzle holder.
m
Rocker
arm housing
mounting
bolt:
98.1 * 4.9 Nm (10 f 0.5 kgm)
pi?icJ *
Adjust i) ii) iii) iv)
the crosshead
Loosen Hold
locknut
down
as follows. and turn
top
tighten
adjustment
When
adjustment
tighten
a further
Tighten
locknut
w
302 6
Locknut:
back adjustment
surface
of crosshead
screw. lightly
and
screw. screw
contacts
valve
20”. to hold in position.
58.8 i
5.9 Nm (6.0 +_ 0.6 kgm)
stem,
m
*
Check der
there
is no dirt
mounting
or dust
surface
on the
cylin-
or
inside
the
cylin-
does
not
come
der.
* *
that
head
Check
that
when
installing
the gasket.
Coat
the
threads
*
the bolt
pletely
with
Screw
in the
3 turns
grommet and
molybdenum
by
cylinder
hand,
seat
surfaces
disulphide
(LM-P).
head
then
mounting
tighten
out com-
bolts
as shown
2 in the
diagram. &
Mounting
bolt:
Anti-friction
621 OF301
compound
(LM-P) w
Cylinder
head mounting
bolt:
.
The first time:
147.1 I 9.8 Nm
l
The second
215.7 + 4.9 Nm
l
The third
(15 I 1 kgm) time:
(22 + 0.5 kgm) 1)
time:
When
using tool B
Use an angle tightening
wrench
and tighten
go”+30
Whe”n not using tool B
2)
Make
marks
on the bolt and head with
pen, then tighten +
Tighten
566FO6353
a felt
the bolt 90”‘::
bolt 0 to 66.2 i
7.4 Nm
(6.75 + 0.75 kgm). *
After
tightening,
bolt
head
to
make indicate
one the
punch number
the bolt has been used. . If any bolt has 5 punch it. Replace
.
Charging
.
Refilling Refill engine
it with
air conditioner
marks,
mark
on
of times do not
the
Put mark on the bolt and cylinder head
that reuse
a new bolt. with
gas.
with water
with
water
to circulate
to the
specified
the water
Then check the water
through
level,
and
run
F621201067A
the
the system.
level again. Make mark with punch
F621201061
3027
1
DISASSEMBLY
AND ASSEMBLY
ENGINE
REMOVAL OF ENGINE ASSEMBLY (Incl. TRANSMISSION) 1.
Remove mission -
2.
3.
:
drain case.
plug
Transmission
(I) and drain
oil from
case: Approx.
Radiator assembly Remove radiator assembly. For details, see REMOVAL SEMBLY. Lift up cabin. For details, see METHOD CAB.
trans-
25 f?
OF RADIATOR
FOR LIFTING
AS-
UP ROPS
4.
Air tank assembly Remove air tank assembly. For details, see REMOVAL OF AIR TANK ASSEMBLY.
5.
Hydraulic tank assembly Remove hydraulic tank assembly. For details, see REMOVAL OF HYDRAULIC ASSEMBLY.
TANK
P Serial
6.
Wiring piping, control Serial No.: 11001 - 12012, 12016 - 12018 1) Disconnect speed control wire (2) from transmission. -+ Turn cap A and completely loosen the thread before disconnecting. * Ring B does not turn. If you attempt to turn it by force, you will damage the wiring harness. (31, (3A), (4), (4A), and 2) Disconnect connectors 3) 4)
(5) Remove Remove
clip (6). ground connection
Connector Connector Connector
30-18 0
(2A): FW, (39): (40): (41):
235FO2206
No.: 11001 - 12012,
Wiring harness end
0
(7).
RE, HI, LO, Ist, 2nd, 3rd, 4th TM1 1 TM10 TM95
Serial
12016 - 12018
Alignment grove I
I
A
I
Serial No.: 12013 - 12015, 12019 and up Disconnect connectors (2A), (391, (401, and (41). Connector
5
solenoid valve end TWG00248
No.: 12013 - 12015,
12019 and UD
DISASSEMBLY
5)
AND ASSEMBLY
ENGINE
Remove hose (9A) and wiring connectors (IO) and (11) of radiator sub-tank (8) and washer tank (9), then remove tank and mounting bracket (12).
30-18-l 0
6)
Remove
cables
(13)
(’14)
and
motor.
from
starting
I,
235FO2207
7)
Remove
inching
control
rod
(15)
frqm
trans-
mission.
235FO2208
8)
Remove
hoses
(’16), (17), and
(18) from
hydraulic
pump.
9)
Remove
block
(19) from
frame.
335FO72OC
30&l 9
10) Remove
hoses (19A) and (19B).
w 11) Remove
12) Remove
air hose (19C).
drain
hose
(20) of engine
oil pan
from
from
com-
rear frame.
13) Remove pressors
hoses
(23),
(21) and (22).
(24),
and
(25)
19A
235FO221C
14) Remove
15) Remove
accelerator
hoses
(27)
cable (26) from
and
(28)
engine.
from
final
drive
pump.
I 16) Remove
transmission
oil filler tube
(29).
235FO2212
8.
Mounting Sling
bolts
engine
assembly
(32)
and
remove
mounting
bolts. Engine
I?zlkg
1)
Remove *
transmission
Check shims
2)
Remove *
assembly:
the
Check
the
shims,(37) 3)
Remove *
engine
Check shims
9.
the
from
number
(36) which
engine
2707 kg
front
were
were
and
(38) which
were
3022
engine
the
32
bolts (34). positions
and
of
the
of
the
nuts (35). positions
removed.
J
235FO2213
Engine assembly Remove
of
removed.
rear mounting number
bolts (33).
positions
removed.
mounting
number which
mounting and
assembly
(32) from
main frame.
INSTALLATION OF ENGINE ASSEMBLY (Incl. TRANSMISSION) 1.
Engine assembly Sling
engine
assembly
(32)
assembly:
2707 kg
and
set
to
frame. Engine
& kg t
If the
engine
installed, ways
Sling
is raised
the
muffler
remove
engine
with
will
the
muffler
be damaged,
Install front *
assembly
ii)
shim
Install mounting *
iii)
Install
bolts
and
install
(37)
bolts
mounting
tighten
and
4.1 mm
tighten
engine
front
(34).
(38)
bolts
transmission
(33).
shim thickness:
shim
Standard
and
shim thickness:
shim
Standard
mounting *
(36)
mounting Standard
still so al-
it.
bolts.
i)
main
and
3.1 mm
tighten
engine
(35).
shim thickness:
4.1 mm
rear a
235FO2213
30623
3)
Adjust
shim
I .._.-.=-,,--/--~+=-
J
235COO2053 G
shaft coupling
!
!
Final drive input shah coupling
Y
P
i)
Insert
shims
that
the
allel
to
when
at
portions
center the
line
final
supported
When
doing
ness
at
drive by
this,
portions
BL,
of the
and
portions the
BL
BR,
and
crankshaft propeller BL, BR
shim
A.
thick-
shall
be
3.8
mm. ii)
Decide
the
shim
ance at portion iii)
Raise
the
engine
and
of shim
to
0.7
of
from
mm
0.5 mm
semble.
so that
the
clear-
C is 0 mm.
0.7 mm add
30624
thickness
shim
of shim
transmission,
portion
and
C. Next,
portions to
portion
iv)
add
remove
BL and
BR,
A, then
as-
Finally, the
m
check
transmission
within
shaft
BR, and
standard and
A so is par-
that
the and
misalignment the
propeller
between shaft
3 mm.
Tightening
torque:
D:
235.4 -
E:
245.2 -
411.9 Nm (24 - 42 kgm) 308.9 Nm (25.0 -
31.5 kgm)
F:
490.3 -
608.0 Nm (50.0 -
62.0 kgm)
G:
245.2 -
284.4 Nm (25 -
29 kgm)
H:
823.8 -
872.8 Nm (84 -
89 kgm)
is
2.
Drive shaft dial gauge,
Using face
runout
and
coupling
missible
of
face
value,
(31). * If they
check-again coupling
are
m
at
Wiring,
runout
and end
drive
end
are within
per-
install
drive
shaft
(30) with
bolts
not
within mount
Mounting
bolt:
the
permissible
value,
ad-
shims again. 98.1 (10.0 -
3.
radial
transmission
at final
then
just the engine
that
face
122.6 Nm 12.5 kgm)
piping control
1)
Install transmission
2)
Connect
hoses
oil filler tube
(29).
(27) and (28) to final drive
pump.
8
3)
Connect
accelerator
235FO2.212
cable (26) to engine.
30625
4)
Connect
hoses
(23),
(24),
and
(25) to compress-
1
ors (21) and (22).
25 23 24
5)
Install
drain
hose
(20) of engine
oil
pan
to
rear
frame.
6)
Install
7)
Connect
block
(19).
hoses (19A) and (19B).
235FO2210
8) Connect
9) Connect
air hose (19C).
hoses
(16),
(17),
and
(18)
to
hydraulic
pump.
10) Connect
inching
11) Connect
cables
control
rod (15) to transmission.
(13) and (14) to starting
motor.
235FO22Oi
12) Install tank and mounting bracket (12) to rear frame, then connect connectors (IO) and (II), and hose (9A) to sub-tank (8) and washer tank (9). 13) Install ground
connection
(7).
14) Install clip (6). 15) Connect
connectors
(31, (3A), (4), (4A), and
(5). Serial No.: 11001 - 12012, 12016 - 12018 16) Connect speed control wire (2) to transmission. Set the connector facing 45” down to prevent water from getting inside the connector. Use a tie wrap to secure the wiring harness to prevent the slack in the wiring from interfering with the frame. Portion A must not interfere with the frame. Secure portion B with a band. Serial No.: 12013 - 12015, 12019 and up 16) Connect connectors (2A), (39), (40), and (41). Connector (2A): FW, RE, HI, LO, Ist, 2nd, 3rd, 4th Connector (39): TM1 1 Connector (40): TM10 Connector (41): TM95 4.
5.
6.
7.
Hydraulic tank assembly Install hydraulic tank assembly. For details, see INSTALLATION TANK ASSEMBLY. Air tank assembly Install air tank assembly. For details, see INSTALLATION ASSEMBLY. Cab Lower cab. For details, see INSTALLATION Radiator assembly Install radiator assembly. For details, see INSTALLATION ASSEMBLY.
30-28 0
I Serial
235FO2206
No.: 11001 - 12012,
12016 - 12018
Serial No.: 12013 - 12015,
12019 and up
OF HYDRAULIC
OF AIR TANK L
OF ROPS CAB.
OF RADIATOR
8.
Refilling with oil 1) Tighten drain plug. 2) Add engine oil through specified level. Q *
Transmission
oil filler (29) to the
case: 35 e
Run the engine to circulate the water and oil through the system. Then check the water and oil levels again.
30-28-l 0
REMOVAL
1.
Loosen
*
OF RADIATOR,
drain valve
If the
coolant
(1) and drain contains
coolant.
antifreeze,
dispose
of
ii
correctly. u
:
Coolant:
58 P
235FO221
2.
Remove
hood
3.
Remove
piping
Remove
(2).
and electric radiator
and aeration Disconnect Remove
hose
hose (5) from hose (6) from
fan guard
Disconnect
wiring
inlet
heater
(3),
outlet
hose
(4)
engine. sub tank (6A).
(7). tubes
(8) and
(9) from
radia-
tor (10).
4.
Loosen
bolts (11) and remove
panel
(12).
30629
Sling
radiator
assembly
(13).
and
remove
mounting
bolts. 1)
Loosen
front
& kg
Radiator
mounting
bolts (14).
assembly:
183 kg
L
13
” 235COO2056
2)
Loosen
rear mounting
bolts
(15).
I
I
I
23x002057 6.
Raise main hoses
radiator frame
(16) and
assembly.
30630
assembly
(18), then
(13)
about
disconnect
(17) from
radiator
100
mm
transmission
from cooler
and lift off radiator
INSTALLATION
1.
Raise
radiator
OF RADIATOR
assembly
(13) and
set on main
frame
(18). Radiator
&?Ikg Connect
assembly:
transmission
183 kg
cooler
hoses
radiator.
2.
Install 1)
radiator
Tighten
(16)
and
(17) to
(13).
front
mounting
bolts
(14)
i,
13
14
Y
Y 235C00205t
2)
Tighten
rear mounting
bolts
(15).
I 3.
Install
panel
(12) with
mounting
bolts
I 235COO205i
(11).
235CDO205E
30531
4.
Install
piping
and electric
1)
Install fan guard
2)
Connect
3)
Install
4)
hose (6) to sub tank (6A). radiator
inlet
hose
aeration
hose (5) to engine.
Connect
heater
5.
Install
6.
Tighten
hood
tubes
Run
drain the
valve engine
the system. Q
(3), outlet
hose
(8) and (9) to radiator
(4) and (10).
(2).
and
ler (19) to the specified *
wiring
(7).
add water
through
to
circulate
the
Then check the water
Coolant:
water
fil-
level.
58
water
through
level again.
Q
235FO2215
30632
REMOVAL OF FUEL TANK ASSEMBLY
A
Disconnect
the
lead from
the
negative
(-)
termi-
nal of the battery.
1. Remove
rear mount
For details,
ripper
assembly.
see REMOVAL
OF REAR MOUNT
valve
drain
RIPPER
ASSEMBLY. 2. Open
drain
(1) and
fuel
from
fuel
tank
(2). 3. Remove
fuel filler
pipe (3) from
fuel tank. 235FO2216
4. Remove
fuel
hoses
(4) and
(5) from
injection
pump
(6).
235FO2217
-I
5. Remove
wiring
6. Remove
cover
clips (9) and (9A). (7) and disconnect
wiring
(8).
235F0221E
7. Set jack @ in position Fuel tank: 8. Remove
mount
9. Loosen
nut
10.
under
it.
298 kg
bolt (IO), plate
(13),
and
then pull out shaft
(16).
Lower
fuel tank to support
jack 0 to lower
(II),
remove
and cushion bolts
(14)
and
(12). (15),
fuel tank.
30633
INSTALLATION OF FUEL TANK ASSEMBLY 1.
2.
Raise fuel tank
(2) with
jack 0,
through
rear frame and fuel tank.
&I
Fuel tank:
then
pass shaft
(16)
298 kg
Secure shaft (16) with bolt (15).
235FO227C
3.
Fit nuts (13) up to head
of bolts (14), then
install to
frame. 4.
Adjust left
position
and
right
of fuel tank by adjusting bolts
(14)
are
amount
screwed
in
so
that that
mount bolt (10) is installed straight in rear frame. 5.
When
position
bolts (14) with
of
fuel
tank
is determined,
nuts (13) in position
where
secure bolts are
in contact with fuel tank.
6.
Install mount bolt (IO), plate (1 I), and cushion (12).
frame
ill 7.
Connect wiring (8) and install cover (7).
8.
Install wiring clips (9A) and (9).
l-1
235FO222'
235FO2221
30634
9. Connect
fuel hoses (4) and (5) to injection
pump
(6).
235FO2217
10. Install fuel filler 11. Close
drain
pipe (3) to fuel tank (2).
valve
(I),
then
add
fuel
through
fuel
fil-
ler.
12. Bleed air from
fuel system.
1)
Loosen
2)
Loosen
knob
up
down
and
air bleed
with fuel from
plug (17).
of feed until
pump no
air bleed
air bleed
more
(18).
and
bubbles
operate come
it out
plug (17).
3)
Tighten
plug (17).
4)
Push in knob of feed pump
(18) and tighten.
13. Install ripper.
For details, see INSTALLATION
14. Connect
cable to negative
(-)
OF RIPPER ASSEMBLY.
terminal
of battery.
30-35 0
DISASSEMBLY
1.
2.
OF PTO ASSEMBLY
Cover, tube 1)
Remove
2)
Disconnect
tube
(2).
tube
(3).
PTO assembly Using
plate,
sling
PTO assembly
(4), remove
mount-
ing bolts, then lift off PTO assembly. *
The
center
gravity
and .it will
fall
block
to. keep
when
lifting.
of the
over it
to the
parallel
PTO assembly front, to
the
is high,
so use a lever mounting
face
235COO2060
3.
O-ring,
gear
1)
Remove
O-ring
2)
Remove
gear (6) from
(5).
3)
Remove
bearing
transmission
(7) from
case.
gear.
P2350
4.
Tube Remove
5.
tube
(8).
Gear assembly I)
Screw
in forcing
bly (9).
30636
screw
and remove
gear assem-
D 205
2i
Remove
snap ring (IO),
then pull out gear from
cage.
3) 4)
Remove
bearing
Remove
snap
(1 1) from gear (12). ring
(13),
then
pull out
bearing
(14) from cage (15).
P23505207
5)
6.
Remove
bearing
(16)
Cover, holder 1)
Using
forcing
screw
0
Pitch = 1.75 mm), remove 2)
7.
Remove
(Thread
dia.
=
12 mm,
cover (17).
holder (18).
Gear assembly 1)
Screw
in forcing
screw
and remove
gear assem-
bly (1 9).
2)
Remove
snap rings (20)
and (21),
gear from cage. 3)
Pull out bearing
4)
Remove
bearing
(22) from cage (23). (24) from gear.
then pull out
P2350f208
5)
Remove
mounting
bolts then remove
shaft
from gear (26). 6)
8.
9.
Remove
bearing outer race (27) from case.
Lubrication tube
I)
Turn over PTO case.
2)
Remove
lubrication
tubes (28) and (29).
Idler gear assembly 1) Remove snap ring (30).
2)
Remove
shaft and bearing as one unit.
3)
Remove
bearing
(31) from shaft (32).
(25)
4) 5)
Remove spacer (33) and gear (34). Remove spacer (35) and bearing inner race (36).
10. Shaft assembly I) Remove snap ring (37).
2) 3) 4) 5)
Turn over case the put case on block. Remove mounting bolts then remove holder (38). Pull out bearing and shaft (39) as one unit. Remove bearing (40) from case.
6) 7)
Remove bearing (41) and spacer (42) from shaft Remove gear (43) and bearing.
11. Snap ring, bearing
1) Remove snap ring (44). 2)
Remove case (47).
3020
bearing
outer
races
(45)
and (46)
from
ASSEMBLY
OF PTO ASSEMBLY
Preparatory work l
Clean the lubrication
l
Apply
engine
oil circuit thoroughly.
oil to sliding portion of each part before
installing.
1.
Bearing, snap ring 1)
Press fit bearing
2)
Press
(46).
fit bearing
(451,
then
fix with
snap
ring
(44). t
If bearing
(45)
goes
from the opposite
2.
on too far,
tap
it out
side.
Shaft assembly I) Set bearing and gear (43) to case. 2) Press-fit bearing (41) to shaft then install spacer (42).
z kc 2 3)
Align
spline
of gear
shaft assembly
3.
4.
(43)
and shaft
(39).
4)
Fix with snap ring (37).
5)
Turn over case (47).
Bearing cover I)
Press fit bearing
2)
Temporarily
(40).
install cover (I 7).
Holder Fit dowel pin and install holder (38). w
Mounting
bolt:
112.8 f 9.8 Nm (11.5 + 1.0 kgm)
*
Turn over case (47).
then
install
5.
Idler gear assembly I) Set bearing inner race (36) and spacer (35). 2) Set gear (34).
3)
6.
4)
Press fit bearing (31) to shaft and install spacer (33). Install shaft (32).
5)
Install snap ring (30).
Lubrication tube Fit O-rings and install tubes (29) and (28).
30642
7.
Gear assembly I)
Press fit bearing
2)
Install
shaft
(27) to case.
(25) to gear (26).
3)
Press fit bearing
4)
Press fit bearing
(24) to gear. (22) to cage,
then
fix with
snap
ring (2 1). 5)
Press with
6)
gear
Fit O-ring *
8.
fit
(26)
to bearing
of cage,
then
fix
snap ring (20).
(48) and install
When
installing
ticularly
careful
bearing
properly.
gear assembly
gear
assembly
to mesh
(I 9).
(19).
be par-
the gear and fit the
Cover holder 1)
Screw
in
forcing
mm, Pitch 2)
Fit dowel w
screw
0
(Thread
1.75 mm) and remove
pin and install Mounting
bolt:
holder
cover
(18).
112.8 + 9.8 Nm (11.5 + 1.0 kgm)
dia.
=
(17).
12
3)
Fit O-ring and install cover (17).
9. Gear assembly 1) Press fit bearing (I 6) to case.
2) 3) 41 5)
6)
Press fit bearing (I 4) to cage, then fix with snap ring (I 3). Press fit bearing (I 1) to gear (12). Press fit gear (12) to bearing of cage (15). then fix with snap ring (10). Fit O-ring (49).
Install gear assembly (9) to case. * When installing gear assembly (9) be particularly careful to mesh the gear and fit the bearing properly.
10. Tube Install tube (8)
11. Gear, O-ring 1) Press fit bearing (7) to gear (6). 2) Install gear (6) to transmission case. 3) Fit O-ring (5).
12. PTO assembly Sling PTO assembly
(4) and install
*
The
center
of
gravity
high,
and
it will
fall
lever
block
face when
to
keep
of over
it.
the
PTO
to the
it parallel
assembly
front, to
the
so use
is a
mounting
lifting.
235COO2061
13. Tube 1)
Connect
2)
Install tube
tube
(3)
(2).
DISASSEMBLY
TRANSMISSION
AND ASSEMBLY
REMOVAL OF TRANSMISSION ASSEMBLY (AS INDIVIDUAL PART) 1.
2.
Remove ROPS cab. For details, see REMOVAL Loosen oil. -
3.
5.
plug (I) of hydraulic
Hydraulic
Remove drain drain oil. -
4.
:
drain
:
OF ROPS CAB. tank and drain
oil: 108 I?
plug (2) of transmission
Transmission
case : 25
Air tank assembly Remove air tank assembly. For details, see REMOVAL SEMBLY. Hydraulic tank assembly Remove hydraulic tank. For details, see REMOVAL ASSEMBLY.
case and
e
OF AIR TANK
OF HYDRAULIC
AS-
TANK DEG00006
Serial 6.
No.: 11001 - 12012,
12016 - 12018
Wiring Serial No.: 11001 - 12012, 12016 - 12018 1) Disconnect speed control wiring (3) from transmission. 2) Disconnect connector (4).
I k Serial Serial No.: 12013 - 12015, 12019 and up 1) Disconnect speed control wiring (3) from transmission. Connectors to disconnect: FW, RE, HI, LO, Ist, 2nd, 3rd, 4th 2) Disconnect connector TM1 1 (3A). . Inching potentiometer wiring 3) Disconnect connector CN30 (4). Speed sensor wiring 4) Disconnect connector TM10 (4A). Transmission oil temperature sensor wiring l
l
30-45-l 0
No.: 12013 - 12015,
DEG00007
12019 and up
DISASSEMBLY
7.
Remove
AND ASSEMBLY
engine
TRANSMISSION
stop motor (5).
-------_.--._-=-~
8.
Remove between
bolt (7), then remove drive final drive and transmission.
9.
Piping, control 1) Remove inching mission.
control
shaft
($_
DEG00008
(6)
rod (8) from trans-
OEGOOOIO
2)
Remove hoses draulic pump.
(9), (IO),
and (11) from
hy-
30-45-2 0
DISASSEMBLY
3)
Remove
block
4)
Remove
hoses
5)
Remove
air hose
6)
Remove
transmission
30-45-3 0
TRANSMISSION
AND ASSEMBLY
(12) from
frame.
(13) and (14).
(15).
oil filler
tube
(16).
DISASSEMBLY
AND ASSEMBLY
TRANSMISSION
assembly (171, then remove 10. Raise transmission bolts (181, (19), and (20). * Check the number and location of shims (22).
I
\
\
\
\,\
DEGOOOl6
DEG00017
11. Remove transmission assembly frame when removing.
el kg
Transmission
assembly
(17) from main
: 1200 kg
DEG00301
30-45-4 0
DISASSEMBLY
AND ASSEMBLY
TRANSMISSION
INSTALLATION OF TRANSMISSION ASSEMBLY (AS INDIVIDUAL PART) 1.
Raise transmission frame.
assembly
(17) and set main
Transmission assembly : 1200 kg & kkgReplace O-ring (23) with a new part.
DEGO0019
2. Raise transmission mount bolt.
1)
2)
assembly
(17)
and
install
Install bolt (18). m Bolt : 110.5 2 12.5 Nm Ill.25 t 1.25 kgm) Insert shims (22) and install bracket (21). * Standard shim thickness: 4.1 mm w Bolts (19), (20) : 549 + 59 Nm I56 2 6 kgm)
I 3.
18
DEG00017
Install drive shaft (6) with bolts (7).
DFG00009
30-45-5 0
DISASSEMBLY
4.
AND ASSEMBLY
TRANSMISSION
Piping, control I) Install air hose (15).
2)
Install hoses (13) and (14).
DEG00013
3)
Install block (12) to frame.
4)
Install hoses (91, (IO), and (II).
DDGOOOI
1
30-45-6 0
DISASSEMBLY
5)
Install sion.
AND ASSEMBLY
inching
control
TRANSMISSION
rod (8) to transmis-
DEGOOOIO
6)
Install oil filler tube (16) to transmission.
erial No.: 11001 - 12012.
12016 - 12018
Serial No.: 11001 - 12012, 12016 - 12018 7) Connect connector (4). 8) Connect speed control wiring (3) to transmission.
.P Serial No.: 12013 - 12015, Serial No.: 12013 - 12015, 12019 and up 7) Connect connector CN30 (4). * Speed sensor wiring 8) Connect speed control wiring (3) to transmission. Connectors to connect: FW, RE, HI, LO, Ist, 2nd, 3rd, 4th 9) Connect connector TM10 (4A). . Transmission oil temperature sensor wiring IO) Connect connector TM1 1 (3A). . Inching potentiometer wiring
30-45-7 0
OEG00007
12019 and up
DISASSEMBLY
5.
install
6.
Hydraulic tank assembly Install hydraulic tank assembly. For details, see INSTALLATION TANK ASSEMBLY.
7.
8.
engine
TRANSMISSION
AND ASSEMBLY
stop
motor
(5).
Air tank assembly Install air tank assembly. For details, see INSTALLATION ASSEMBLY. ROPS cab assembly Install ROPS cab. For details, see INSTALLATION
OF HYDRAULIC
OF AIR TANK
OF ROPS CAB.
30-45-8 0
DISASSEMBLY ASSEMBLY . *
Preparatory Sling
1.
work
transmission
@ (Height
OF TRANSMISSION
assembly
(I),
then
set it on block
= 470 mm).
PTO assembly Sling
PTO assembly
then
remove
(2), remove
PTO
assembly
mounting
from
bolts
transmission
(3), as-
sembly.
235CDO2061
2.
Transmission 1)
control
Remove
valve assembly
transmission
control
valve
19 mounting
bolts (4). *
Do
not
remove
seat
%), or body service *
The
length
of the mounting
so check the length
2)
Using =
eyebolts
1.5 mm),
sembly
(5).
service
when
@ (Thread sling
and
bolts
bolts (marked
(marked
A).
bolts
is different,
removing.
dia.
remove
=
10 mm,
control
valve
Pitch as-
3.
Cage Screw Pitch
4.
in forcing’screw = 1.75
(Thread
dia.
=
12 mm,
in place with
its trans-
cage (6).
Snap ring, seal ring Remove *
snap ring (7) and seal ring.
Set transmission fer assembly
5.
0
mm), and remove
assembly
down.
Sleeve Remove *
sleeve
Using
(8).
eyebolt
(Thread
2.0 mm), remove
dia.
=
16 mm,
Pitch
=
sleeve.
N
6.
Transmission 1)
Using = 1.75
2)
case
eyebolts
@ (Thread
dia.
mm), sling transmission
Remove
mounting
bolts,
then
=
12 mm,
Pitch
case. remove
transmis-
sion case (9).
7.
Tie bolt +
Using
tool
before
disassembling.
Remove
tie bolts
C check (10).
operating
condition
of piston
8. Cage and reverse carrier assembly Using 2.0
eyebolts
mm),
@
sling
(Thread
cage
(1 11, then remove
and
dia. =
16 mm, Pitch
reverse
carrier
=
assembly
it.
9. Spring Remove
P2350
spring (12).
10. Spring, disc, plate Remove +
spring (13). disc (14). and plate (15) in order.
Springs
(13) are inserted
between
each plate.
11. Reverse ring gear Remove
reverse ring gear (16).
12. No. 1 housing, reverse piston
Using eyebolts @ (Thread dia. = 16 mm, Pitch = 2.0 mm), sling No. 1 housing and reverse piston (1 7) and remove *
it.
Hold piston by hand to prevent
it from falling.
13. Snap ring, reverse ring gear Remove
snap
ring
(18).
then
remove
reverse
ring
gear (19).
14. Spring Remove
spring (20).
15. Spring, disc, plate Remove *
spring (21), disc (22).
Spring
18. Forward Remove
(2 1) are inserted
ring gear forward
plate (23).
between
ring gear (24).
each plate.
P23501244
I 242
17. Holder Remove
holder (25).
18, I Forward carrier assembly Using 2.0
remove
1)
eyebolts
mm),
sling
@
(Thread
forward
dia. =
carrier
16 mm, , Pitch
assembly
(26)
= and
it.
Remove
snap ring (271, raise cage (281, then pull (29).
out carrier assembly 2)
Remove
spacer (30).
P2350
19. Spring Remove 20.
spring (31).
Spring, disc, plate Remove *
spring (32). disc (33), plate (34). in order.
Springs
(32) are inserted
between
each plate.
I249
P23501250
21. Guide pin Remove guide pin (35). 22. 4th~speed ring gear Remove 4th~speed ring gear (36).
23. Snap ring Remove snap ring (37). 24. 3rd. 4th speed carrier assembly Using bar and remove 3rd. 4th speed carrier assembly (381.
25. No. 2 housing, 3rd. 4th speed Using eyebolts (Thread dia. = mm), sling No. 2 housing and (39) and pull them out. Hold piston by hand to prevent
piston 16 mm, Pitch = 2.0 3rd. 4th speed piston it from falling.
26. Spring Remove spring (40). 27. Spring, disc, plate Remove spring (411, disc (421, plate (43) in order. t Springs (41) are inserted between each piston. 28. 3rd speed ring gear Remove 3rd speed ring gear (44). 29. 3rd. 4th speed sun gear I) Remove spacer (45) and 4th speed sun gear (46). 2) Remove spacer (47) and 3rd speed sun gear (48). 3) Remove spacer (49).
45
46
47 48 49
30650
30.
No. 3 housing, Using 2.0
2nd speed
eyebolts
31.
Spring, *
=
them. it from falling.
spring (5 1).
disc, plate spring (52),
Springs
disc (531, plate (54) in order.
(52) are inserted
1 st, 2nd speed carrier
Using eyebolts 2.0
mm),
2.0
eyebolts
mm),
each plate.
assembly
(Thread
dia. =
2nd speed
1 st speed @
16 mm, Pitch
carrier
assembly
=
(55)
piston
(Thread
dia. =
sling No. 4 housing
(56) and remove *
between
them.
No. 4 housing, Using
@
sling lst,
and remove
34.
16 mm, Pitch
Spring
Remove
33.
dia. =
Hold piston by hand to prevent
Remove
32.
piston
(Thread
sling No. 3 housing and 2nd speed piston
mm),
(50) and remove
*
@
16 mm, Pitch
and 1 st speed
them.
Hold piston by hand to prevent
=
piston
it from falling.
36. Spring Remove spring (57). 36. Spring, disc, plate Remove wave spring (58), disc (591, plate (60) in order. t Wave springs (58) are inserted between each plate. 37. 1 st speed ring gear Remove 1 st speed ring gear (61).
38. Cage assembly Using eyebolts @ (Thread dia. = 16 mm, Pitch = 2.0 mm), sling cage ksembly (62) and remove it.
39. Spring Remove spring (63). 40. Spring, disc, plate Remove spring (641, disc (65). plate (66) in order. t Springs (64) are inserted between each plate. 41. Guide pin Remove guide pin (67). * Guide pin (67) is different in length from guide pin (35).
I’2350
%252
PZ350
B262
Ring gear
42.
Remove
43.
ring gear (68).
No. 5 housing, Using 2.0
low speed
eyebolts
mm),
@
Rotary
clutch
is a bearing
shaft,
so tap
Transfer
Pitch
=
piston
the
(70) and remove
assembled transfer
it.
at the tip of the
case
with
a plastic
to remove.
assembly
Disassemble
transfer
For
see
details,
SEMBLY.
16 mm,
and low speed
assembly
There hammer
45.
dia. =
them.
Sling rotary clutch assembly t
piston
sling No. 5 housing
(69) and remove
44.
(Thread
assembly.
DISASSEMBLY
OF TRANSFER
AS-
ASSEMBLY ASSEMBLY *
Assemble For
* *
transfer
details,
see
assembly. ASSEMBLY
OF TRANSFER
ASSEM-
BLY. Coat
sliding
portion
of each
part
with
engine
‘oil be-
fore installing. Be careful rection,
1.
OF TRANSMISSION
Rotary
to install
clutch
Assemble
*
the seal facing
and fit the spring
securely
in the correct
di-
in the seat.
assembly rotary
For details,
clutch
assembly.
see ASSEMBLY
OF ROTARY
CLUTCH
ASSEMBLY. Sling
rotary
clutch
assembly
(70) and install
it.
s1 4 _-_,\\\\s,
2.
No. 5 housing, 1)
low speed
Fit seal rings
(71)
piston
and (721, then
install
piston
to
No. 5 housing. *
Assemble the housing
*
2)
Install
Using
with
the
seal
seal ring without
eyebolts
ring
3024
facing
@
(Thread
twisting.
dia. =
= 2.0 mm), sling No. 5 housing piston
groove
side.
(69) and install them.
16 mm, Pitch and low
speed
,,,:,,,,i\,,,~&\
zf
3. Ring gear Install ring gear (68) 4. Guide
pin
Install guide pin (67). t
Guide
pin (67)
is different
in length
from
guide
pin (35).
5. Spring,
disc, plate
Instal,l spring (641, disc (651, plate (66) in order. *
Spring:
5 PCS, disc: 5pcs. plate: 4 PCS.
6. Spring Install spring (63).
7. Cage assembly Using
eyebolts
@
(Thread
dia. =
2.0 mm), sling cage assembly *
Confirm
that
spring
(63)
16 mm, Pitch
=
(62) and install it. is firmly
installed
groove of cage and piston.
8. 1 st speed
ring gear
Install 1 st speed ring gear (61). 9. Spring,
disc, plate
Install wave spring (58), disc (591, plate (60) in order. *
Wave
spring:
3 PCS.
Disc:
3 PCS.
Plate:
2 pcs.
10. Spring Install spring (57).
in
11. No. 4 housing, 1 st speed piston I) Fit seal ring and install 1 st piston to No. 4 housing. Sr When installing seal ring, refer to 2.-l 1. 2) Using eyebolts @ (Thread dia. = 16 mm, Pitch = 2.0 mm), sling No. 4 housing and 1 st speed piston (56) and install them. + Hold piston by hand to prevent it from falling. + Confirm that spring (57) is firmly installed in groove of piston and housing.
12. 1 st, 2nd speed carrier assembly Assemble 1 st, 2nd speed carrier assembly. For details, see ASSEMBLY OF IST, 2ND SPEED CARRIER ASSEMBLY. Using eyebolts @ (Thread dia. = 16 mm, Pitch = 2.0 mm), sling 1 st, 2nd carrier assembly (55) and install them. * Confirm that sun gear and ring gear are firmly installed to planetary carrier.
*
13. Spring, disc, plate Install spring (52), disc (531, plate (54) in order. Ir Spring: 2 PCS,disc: 2 PCS, plate: 1 pc.
14. Spring Install spring (5 I). 15. No. 3 housing, 2nd speed piston 1) Fit seal ring and install 2nd speed piston to No. 3 housing. * When installing seal ring, refer to 2.-l 1. 2) Using eyebolts @ (Thread dia. = 16 mm, Pitch = 2.0 mm), sling No. 3 housing and 2nd speed (50) and install them. +r Hold piston by hand to prevent it from falling. +r Confirm that spring (5 1) is firmly installed in groove of piston and housing.
16.3rd.
4th speed
sun gear
Install spacer (49). 3rd speed sun gear (48). spacer (471, 4th speed sun gear (46) and spacer (45) in order.
17. 3rd speed ring gear Install 3rd speed ring gear (44).
44
18. Spring, disc, plate Install spring (411, disc (421, plate (43) in order. +I Spring: 3pcs. disc: 3pcs, plate: 2pcs. lg.
Spring
Install spring (40). p*l
5: 5
20. No. 2 housing, 3rd. 4th speed piston 1) Fit seal ring and install 3rd, 4th piston to No. 2 housing. When installing seal ring, refer to 2-I). * 2)
Using eyebolts (Thread dia. = 16 mm, Pitch = 2.0 mm), sling No. 2 housing and 3rd. 4th piston (39) are install them. Hold piston by hand to prevent it from falling. t * Confirm that spring (40) is firmly installed in groove of piston and housing.
P2350
I254
I
‘j ,,
,,
‘j
21. Sleeve Install sleeve (73).
P2350E273
22. 3rd. 4th carrier assembly * Assemble 3rd, 4th carrier assembly. For details, see ASSEMBLY OF PLANETARY GEAR. Fit seal ring (74). and install 3rd. 4th carrier assembly (38). + Confirm that ring gear is firmly installed on planetary carrier.
23. Bearing, snap ring Using with
push tool
@ press
fit bearing
(76)
and fix
snap ring (37).
24. 4th speed ring gear Install 4th speed ring gear (36). 25.
Guide pin Install guide pin (35).
26.
Spring,
disc, plate
Install spring (32), disc (33), *
plate (34) in order.
Spring: 3 PCS, disc: 3 PCS, plate: 2pcs.
27. Spring Install spring (3 1).
28. Forward, reverse carrier assembly * Assemble forward, reverse carrier assembly. For
details,
see
ASSEMBLY
OF
PLANETARY
GEAR.
1) Install spacer (30) to carrier assembly. 2) 3)
Install seal ring to cage (28). Press fit carrier assembly
(29) to bearing
and fix it with snap ring (27).
3028
of cage
it
42. Seal ring Install 2 seal rings (78). 43. Spacer, bearing, snapring 1) Install spacer (79). 2)
Press fit bearing
(80) and fix it with snap ring (7).
44. Cage
1) Install ball to cage and install caller (81). 2)
Press
fit bearing
(82)
and fix it with
snap
ring
dia. =
10
(83). 3)
Fit O-ring and install cage (6).
45. Control valve assembly Fit O-ring
and using eyebolts
mm, Pitch assembly m &
=
@ (Thread
1 .5 mm), sling and install control valve
(5). Mounting
bolt:
49.0 + 4.9 Nm (5.0 & 0.5 kgm)
Mounting
bolt: Coat the bolt marked
@ with
gasket sealant (LG-5).
c3 @ @ 235COO206:
L
46. PTO assembly Fit O-ring, assembly
30$2
sling PTO assembly (1). then tighten
(2) install transmission
mounting
bolts (3).
235CDO2061
DISASSEMBLY OF CAGE AND REVERSE CARRIER ASSEMBLY 1.
2.
3.
Forward
Remove
snap ring (1) and remove
2)
Remove
spacer
sun gear
Remove
sun gear (4).
Shaft shaft
cage (6).
Cage assembly 1)
Remove
snap ring (7).
2)
Remove
cage assembly
ASSEMBLY ASSEMBLY *
(5).
Cage Remove
5.
sun gear (2).
(3).
Reverse
Remove 4.
sun gear
1)
Coat
(8).
OF CAGE AND REVERSE CARRIER
sliding
portion
of each
part
with
engine
oil be-
fore installing. 1.
235FO2224
Cage assembly 1)
Install
2)
(9). Press fit bearing
spacer
3)
Install
seal
(10)
2.
reverse
(12).
install
(8). assembly
(8)
engaged
in
Cage cage (6).
Shaft Install shaft
4.
cage
assembly
snap ring (7).
Install seal ring (13) and install 3.
carrier
(11) to cage assembly
ring
and fix it with
to
Reverse
(5).
sun gear
InstaN sun gear (4). *
5.
Confirm
that
planetary
gear.
Forward
sun
gear
is
firmly
sun gear
1)
Install
spacer
2)
Install
sun gear (2) and fix it with
(3). snap ring (1).
OF 1 ST SPEED AND 2ND DISASSEMBLY SPEED CARRIER ASSEMBLY 1.
Low sun gear 1)
low sun gear
snap ring (1) and remove
Remove
(2). 2) 2.
3.
Remove
spacer (3).
2nd speed carrier assembly 1)
Remove
2nd speed carrier assembly
2)
Remove
mounting
(4). cage (5).
2nd speed ring gear and 1st speed carrier assembly 1) Remove 2nd speed ring gear and 1 st speed carrier assembly 2)
4.
bolt and remove
Remove
(6) from shaft.
snap ring (7) and remove
ring gear (8).
Shaft assembly 1)
2)
snap
Remove
ring
(IO)
from
remove
1 st speed sun gear (11).
Remove
spacer (12).
shaft
(9)
and
F23EC019A
/
P23EC
30664
I 56
P23EC
I 55
ASSEMBLY
OF 1 ST SPEED
CARRIER *
Coat
sliding
before 1.
AND
2ND
SPEED
ASSEMBLY
Shaft
portion
of
each
part
with
engine
oil
installing. assembly
I)
Install spacer (12) to shaft (9).
2)
Install
1st
speed
sun gear
(1 1) and fix it with
snap ring (10). 3) 2.
Install seal ring (13) to spacer (12).
2nd
speed
ring
gear
and
1st
speed
carrier
assembly I)
Press fit bearing
(15) to 1 st speed caTrier assem-
F23ECO
IS
bly (14) and fix it with snap ring (I 6). 2)
Install
2nd
speed
ring gear
(8)
and fix
it with
snap ring (7). 3)
Install 2nd speed ring gear and 1 st carrier assembly (6) on shaft.
3.
2nd speed 1)
Press
carrier
assembly
fit bearing
(17)
to 2nd
speed
carrier
as-
sembly and fix it with snap ring (18). 2)
Install cage (5). F’Z&
s1 I.0
3)
i?
0
Mounting
Install
seal rings
(I 9).
Thread (20).
tightener
Using
(LT-2)
press fit tool
(1) install 2nd speed carrier assembly
(4).
*
installed
Confirm planetary
4.
bolt:
that ring gear is firmly
on
carrier.
Low sun gear 1)
Install spacer (3).
2)
Install low sun gear (2) and fix it with
snap ring
(1).
P23EC
P23EC
f 53
I 56
DISASSEMBLY ASSEMBLY 1.
OF HIGH
ROTATING
CLUTCH
Shaft assembly Remove
mounting
bolt and remove
shaft
assembly
(1).
2.
Spring, Disc, Plate Remove *
3.
4.
5.
wave spring (2), disc (31, plate (4) in order.
Spring: 4 PCS, Disc: 4 PCS, Plate: 3 PCS.
Sun gear 1)
Remove
snap ring (5).
2)
Remove
sun gear (6).
Cage assembly I)
Put punch mark on cage (7) and carrier (8).
2)
Remove
bearing (9) together
with cage.
Planetary gear Remove
planetary
*
details,
For
GEAR.
gear (10). see
DISASSEMBLY
OF PLANETARY
ASSEMBLY ASSEMBLY
*
Coat
OF HIGH
sliding
ROTATING
portion
of
each
CLUTCH
part
with
engine
oil
before installing. 1.
Planetary
gear
Install planetary *
For
gear (IO).
details,
see
ASSEMBLY
OF
PLANETARY
GEAR.
2.
Cage assembly
1)
Press fit bearing
2)
Align the punch mark stamped
(9) to cage (7).
bly and install cage assembly a>_
3.
Mounting
bolt:
during disassem-
(8).
Thread
tightener
(LT-2)
Sun gear
1) Install sun gear (6). 2)
Turn
carrier
assembly
over and fix it with
snap
ring (5).
4.
Spring,
Disc,
Plate
Install wave spring (2). disc (3) and plate (4) in order. *
z R 2
5.
Spring: 4 PCS, Disc: 4 PCS, Plate: 3 PCS.
Shaft
assembly
Install shat assembly
(1).
30667
DISASSEMBLY 1.
OF PLANETARY (2) from planetary
Pull out shaft and remove
ball (3). Then
gear (51, thrust washer 2.
carrier assembly
remove
thrust
washer
(1) (41,
(6) in order.
Pull out bearing (7) from gear (5).
ASSEMBLY *
GEAR
Coat
OF PLANETARY
sliding
portion
of
GEAR
each
part
23P322
with
engine
of
before installing. 1. 2.
Install bearing (7) in gear (5). Inserting washer
shaft
(2)
into
carrier
(61, gear (5). thrust
and
washer
install
thrust
(4) in order. Then
fix shaft with ball (3). *
When
shaft
comes
out, lightly caulk ball groove
of carrier. 3.
After
assembly,
measure
gear (5) with feeler internal clearance *
Side clearance:
side clearance
gauge
within standard. 0.35
to 0.80
mm
rl
of planetary
(1) and confirm
measured
23P323
4 z
DISASSEMBLY ASSEMBLY
OF TRANSFER
1.
Transmission assembly Remove transmission assembly from transfer case. For details, see DISASSEMBLY OF TRANSMISSION ASSEMBLY.
i.
Speedometer output shaft, cover 1) Remove mounting bolts, then remove speedometer output shaft (1). 2) Using forcing screw 8, (Thread dia. = 12 mm, Pitch = 1.75 mm), remove cover (2).
3.
Speedometer 1)
2)
4.
drive gear bolts (3). Remove speedometer drive gear (4).
Fjemove mounting
Input shaft cage, gear 1) Remove mounting bolts, then using forcing screw @ (Thread dia. = 12 mm, Pitch = 1.75 mm), remove input shaft cage (5) and gear (6). *
2)
Confirm
installation
direction
of gear (6).
Remove snap ring (7). then pull out bearing from cage (8).
(9)
3029
5.
Cover, brake assembly I) Remove mounting bolts, then remove cover (I 0). 2) Remove mounting bolts, then remove brake assembly (I I).
6.
Coupling assembly I) Remove mounting (I 3).
2) 3)
7.
bolts (I 2) then remove holder
Remove coupling assembly (I 4). Remove mounting bolts (I 5), then remove plate (I 7) from coupling (I 6).
Output shaft assembly I) Remove mounting bolts, then using eyebolts @ (Thread dia. = 12 mm, Pitch = 1.75 mm), sling output shaft assembly 2)
Remove
30670
mounting
(I 8) and remove
it.
bolts (I 9). then remove
cage.
3) 4)
5) 6)
Remove oil seal (21) from cage (20). Put tool (inside diameter: 90 mm; height: 150 mm) in contaot with bearing (221, push out shaft, and remove bearing (23). spacer (24). gear (251, and spacer (26) from shaft (27). Remove cover (28). bearing (22) from cage (29). Remove bearing (3 I) from case.
39
21
22 29 40 28 24
26 25 23 31
8.
Cover, idler gear assembly 1) Remove mounting bolts, then using forcing screw @ (Thread dia. = 12 mm, Pitch = 1.75 mm), remove cage. 2) Remove bearing (331, O-ring (34) from cage (32).
3) 4) 5)
Remove gear assembly (35) from case (30). Remove 2 bearings (36) from gear assembly. Remove bearing outer race from case (30).
P23508300
9.
Strainer Remove connector (38) and strainer.
DISASSEMBLY ASSEMBLY
OF TRANSMISSION
CONTROL VALVE
UPPER VALVE
235FO2225
LOWER VALVE
235FO2226
30-&76
UPPER VALVE 1.
Remove
2.
Disassembly
covers
Remove Check
shim
(4), then
the
remove
1. 2.
guide
(5), shim
(II),
thickness
of
the
3.
valve. guide
(IO), then
(12),
valve
(13),
number
and
remove
spring
thickness
1) Remove
valve
and spring
2) Remove
5. g z z 6.
valve
spring
(20), then
(22), valve
(17),
shim
Remove
stopper
2)
Remove
valve
remove
number
and
valve
thickness
(54). and
stopper
(55),
then
(56).
of valve for F, R clutch (57), then
remove
collar
(58)
(60), then
remove
collar
(61)
(59).
Remove
spring (62).
Disassembly
(26), then
of pilot reducing
pressure
Check
the
shims,
and keep in a safe place.
remove
spring
*
(65)
valve
and valve
of the
number
(67),
and and
valve
valve
shim (64).
thickness shim (68),
of the
(66),
then
spring
(69),
(70).
Check
the
shims,
and keep in a safe place.
number
and
thickness
of the
valve 5. remove
Remove
spacer
(71).
plug (27).
of inching valve cover
(30), then remove
3)
Remove
cover
(32).
4)
Remove
spool
(33).
5)
Remove
stopper
Remove
then
spring
Remove
2) Remove
(21),
(25).
1) 2) Remove
spring
(52),
1)
t
(18),
(23), and shim (24).
of quick return
1)
6)
locknut
(28) and yoke
(34), spring
(37), spring valve (42),
(45), and valve 7.
(16),
and keep in a safe place.
stopper
stopper
(53).
spring valve
clutch
and
Disassembly
(19).
shims,
Remove
(51)
1) Remove valve (63), then remove
the
Disassembly
Remove
and valve
the
valve.
Check
Disassembly
valve
and valve
4. of modulation
spring
Remove
and keep in a safe place.
Disassembly
*
of valve for L, H, 4,3,2,1
(14), of
(49).
spring
2)
the
body
Disassembly
remove
(9) and
(50) from
1) 2)
(15).
Check
cover
remove
and
of priority valve
shims, 4.
Remove
(8).
number
spring
and valve *
(1).
and keep in a safe place.
Disassembly Remove
body
of cooler bypass valve
(7), and piston
shims, 3.
(2) and (3) from
spring
(6), valve *
LOWER VAVE
seal (31).
(35), shim
(36),
(38), and shim (39).
(40), then valve
(29).
(43),
remove sleeve
valve (44),
(41), spring
(46).
Spacer Remove
plug (47), then
remove
spacer
(48).
30677
ASSEMBLY
OF TRANSMISSION
CONTROL VALVE ASSEMBLY
UPPER VALVE
LOWER VALVE
235FO2225
235FO2226
REMOVAL OF HYDROSHIFT TRANSMISSION PUMP ASSEMBLY
A 1.
Lower
the
ground
and stop the engine.
Remove
Remove
see REMOVAL
inlet
transmission 3.
Remove pump
equipment
the
and
OF AIR TANK ASSEMBLY.
outlet
tube
(1) and
hose
(2) from
pump.
mounting
bolts
Hydroshift
(3) and
transmission
INSTALLATION TRANSMISSION Install
transmission
remove
transmission
mounting
Install
and outlet
inlet
mission
pump
assembly:
12 kg
OF HYDROSHIFT PUMP ASSEMBLY
pump
and tighten
For
to
(4).
6?lkg
Install
completely
air tank assembly.
For details,
2.
work
bolts tube
assembly
(4) to
PTO
(5)
(3). (1) and
hose
(2) to trans-
pump. air tank assembly.
details,
see
INSTALLATION
OF AIR
TANK
AS-
the
sys-
SEMBLY. Run the
engine
to circulate
tem. Then check the oil level again.
30680
the
oil through
REMOVAL OF TANDEM AND FINAL DRIVE ASSEMBLY 1.
Cover Remove
2.
cover
Draining Loosen U
and (1 B) from
final drive.
oil of final drive case drain
:
(IA)
plug (1) and drain final drive
Final drive
case:
case oil.
57 II
235FO2227
3.
Piping of final drive case Remove
4.
tubes
(2), (2A) and hoses
bolts
(4),
(3), (3A).
Hanger Loosen
disconnect
hanger
(5)
and
main
frame.
3
235FO2228
5.
Brake hose Disconnect
6.
brake hoses (6) and (7) from
joint
(8).
Drive shaft Loosen tween
bolts
(IO),
transmission
then
remove
drive
shaft
(9) be-
and final drive.
30A8 1
7.
Cap Support
final
drive
(11) with jack 0, *
8.
Distinguish
Tandem,
between
out tandem After
main
frame
cap
L.H. and R.H. caps.
rear end, and turning
and final drive assembly pulling
out tandem
wheel,
pull
(12) to rear.
and final
bly, support body with block.
30$2
mounting
final drive assembly
Lift up main frame +
and
and remove.
drive
assem-
INSTALLATION OF TANDEM AND FINAL DRIVE ASSEMBLY 1.
Tandem 1)
and final drive assembly
Lift up main
frame
set
and
tandem
rear end, turn
final
drive
the wheel,
assembly
(12)
and under
the chassis. 2)
Slowly
lower
the
and final drive
chassis
assembly
and
while
connect
moving
tandem
them.
\\\ 2.
shims
ing cap (II), Adjusting
a 3)
of final
drive
then support
and
main
with jack 0,
frame
mount-
and install.
shims
1) Tighten
bolt (B).
Tighten
bolt (A) and measure
clearance.
Loosen
bolt
shim
= clearance
g z z
235FO2231
Cap Adjust
l
/
(A) and above)
insert
(13)
(thickness
in (A) end.
4)
Loosen
bolt (B).
5)
Tighten
bolt (A).
‘3)
Tighten
bolt (8).
a
Mounting
bolt:
Thread
w
Mounting
bolt:
2745.9 + 294.2 Nm
tightener
(LT-2)
235COO2065
(280 + 30 kgm)
6 3.
A
13
235FO223;
Drive shaft Using
dial
runout
of
gauge,
check
coupling
coupling
face
missible
value,
that
face
at
final
then
radial
at drive
install
runout
transmission end
drive
are
shaft
end
(9) with
bolts
of the
method
of measuring
values
for
radial
see
INSTALLATION
and per-
permissible runout,
face
within
(IO). * For details
the
and
runout
OF ENGINE
and
the
and face ASSEM-
BLY. *
If they
are
not within
just the engine w
mount
Mounting
bolt:
the
permissible
value,
ad-
shims. 110.3 + 12.3 Nm (11.25 i
1.25 kgm)
30683
Hanger Install
hanger
(5) on main frame
by bolts (4).
a
Hanger
mounting
bolt:
Thread
w
Hanger
mounting
bolt:
926.7 -
tightener
(LT-2)
103.0 Nm
(94.5 k 10.5 kgm) Final drive case piping Install
tubes
(2), (2A),
hoses
(3), (3A) and
drain
plug
(1).
235FO2227
6.
Install cover
(IA)
and (1 B) to final drive.
3A 235FO2228
7.
Brake hose Connect
brake hoses (6) and (7) to joint
Refilling Tighten
final drive case with oil final
oil through Q
(8).
drive
oil filler
Final drive
Run engine
case
drain
case:
then
add
level.
63 Q
to let oil circulate
Then check the oil level again.
30684
plug,
(13) to the specified
in hydraulic
system.
engine
DISASSEMBLY ASSEMBLY Special
D
1.
tool
I I
Part number
I
792-571-l
1 Chain puller-
Tandem 1)
OF FINAL DRIVE
For
600
I O’e
Part name
and final drive assembly details,
see
DISMOUNTING
TANDEM
DRIVE
AND FINAL DRIVE ASS’Y. 2)
3)
Sling
tandem
and
remove
wheel
& kg
Tandem
final
drive
assembly
(1) and
(2). and
out wheel):
Set
tandem
and
0,
remove
drain
final
drive
assembly
(with-
4290 kg
final
drive
plug
(3)
assembly and
on
drain
block
tandem
case oil. .(. 4)
Tandem
Remove
drain
case (each): plug
(4) and
Approx. drain
120 9.
final
drive
case
oil. u *
:
Set
Final drive block
R.H. tandem 2.
with
covers
three
Approx.
places
(5)
63 Q
under
case and final drive.
Cover Remove
case:
the
L.H.
and
Chain I) Turn the pinion and align chain to access position.
connection
2)
chain,
Using tool
0
squeeze
the
pin (6) and pull out connection
3)
lock
Remove chain (8).
& kg
Tandem case assembly
Drive shaft Remove bolts from coupling.
3026
remove
pin (7).
Tandem case assembly 1) Sling tandem case assembly (9). 2) Remove mounting bolts (IO), tandem case assembly.
5.
part of
(111, then
remove
then
(each):
drive
remove
1242 kg
shaft
(I 2)
6.
Coupling Pull out coupling
7.
(13) from pinion shaft.
Tube Remove
tube (I 4) together
with O-ring.
235FO2233
8.
Strainer Remove
9.
Cover,
spring (15) and strainer
(I 6) from pipe.
pipe
1)
Remove
pipe (17) together
2)
Remove
cover (18).
with O-ring.
10. Tube Remove
tubes
(19)
and
(20)
then
remove
flanges
(21) and (22).
11. Side case assembly Remove ers (24), (25) from kg ET?!
side case mounting then center
sling
bolts
and remove
(23) and 24 washside case
assembly
case.
Side case assembly
(each):
655
kg
P2350
I325
I’2350
1326
12. Plate Remove
bolt (26) then remove
plate
(27).
P2350
I327
ti 0
13. Carrier assembly Sling and remove carrier assembly (28).
63 kg
Carrier assembly: 1 10 kg
14. Gear, carrier, pin Remove bolts (29), lock plate (301, plate (31) and Pin (32). then remove gear (33).
15. Holder, shim Remove holder (34) and shim (35).
16. Sprocket Remove sprocket (36) from shaft.
17. Bearing Remove
bearing
18. Rear axle
(37) from shaft.
shaft
assembly
Pull out rear axle shaft assembly lg.
Plate Remove
20.
21.
(38) to lower side.
bolts (39). washer
Washer,
O-ring,
Remove
washer
(40) and plate (41).
shim (42). O-ring
Flange Sling and remove Flange: Remove
O-ring
flange 74 kg
(46)
(45).
(43) and shim (44).
22. Side case 1) Pull out 2 bushings (47). 2)
Remove
washer
(49) from side case (48).
23. Shaft, bearing
Pull out bearing (5 1) from shaft (50).
24. Ring gear Remove
ring gear (52) from center case.
25. Sun gear Remove
snap ring (53)
from axle shaft,
collar (54) and sun gear (55).
then remove
26. Shaft Remove axle shaft (56) from center case.
27. Bevel pinion assembly 1) Remove cover (57).
2)
Remove bevel pinion assembly with shim (59). & kg
*
together
Bevel pinion assembly: 74 kg
Check the number and positions of the shims which were removed.
28. Bevel gear assembly 1) Sling bevel gear assembly (60).
30692
(58)
2)
Remove
bolts
(65), then
remove
cages
(62) and
(63). 3)
Remove t
shim (64).
Check shims
the
number
on the
left
and and
thickness
right,
and
of keep
the in a
safe place.
4)
Raise
bevel
center
case (61).
& kg 5)
Remove
gear
assembly,
Bevel gear assembly: bolt (67), then remove
and
remove
from
188 kg gear (66).
30693
OF FINAL DRIVE
ASSEMBLY ASSEMBLY Special
tool Part number
D
1.
792-571-l
Center 1)
Part name Chain puller
600
gear
(66) to center
Set left and
right
then
temporarily
(with
bearing
*
Insert
shims
*
Types t -
(61) with
dowel
(64) on center cages
races already
(64) on the
during
(61),
and
(63)
press fitted).
left
as
case
(62) and
those
right
which
of the were
disassembly.
of shims
0.1 mm
t = 0.2 mm
t = 0.5 mm
Bevel gear assembly Sling
bevel
install
bearing
gear
assembly
outer
(60) and install
case, then
race of cage.
Bevel gear assembly:
A kg 3.
shims
thickness
removed
case
bolts (67).
assemble
outer
same
2.
1
case assembly
Position
pin, then install with 2)
O’ty
188 kg
Bevel pinion assembly 1)
Fix
O-ring
assembly *
insert
Backlash
i)
shim
(59),
insta’ll
(58) and it is engaged Insert
adjusting
during
shims
as those
(59)
which
of the
were
Standard
iii)
Type of shims
shim thickness:
same
removed
disassembly.
ii)
pinion
gear.
shims
adjusting
thickness
bevel
in bevel
2.0 mm
t = 0.1 mm, t y 0.2 mm, t = 0.5 mm
2)
Measuring
with
Put a fuse
wire
the
of
teeth
Rotate
the
thickness *
*
3)
fuse wire @ (approx.
the
bevel
gear
bevel
gear
and
of the wire with
Put the fuse
wire
41.5
mm)
and then
pinion.
measure
a micrometer
in the
between
bevel
center
the
0. (approx.
20
mm from small end) and measure at least three points around the gears. Standard value for backlash: 0.2’5 to 0.33 mm
Measuring Install
preload
@ and bolt @ (16 mm x 2 mm 120 mm) to bevel pinion assembly, then measure starting torque with torque wrench 0.
*
locknut
Adjust
so that the starting
torque
pinion
is 0.68
(0.07
greater alone
than 9.8 -
When
the
1.0 Nm torque
for
12.8 Nm (1 .O -
doing
at the outside
this,
measure
circumference
the
at the bevel -
0.10
kgm)
bevel
pinion
1.3 kgm). the starting
torque
of the bevel
gear
alone. Starting
force
(bevel
gear alone): 9.8 -
12.8 N (1.0 -
1.3 kg)
4.
Testing Adjust tooth
and adjusting preload
contact Adjust
to taper of bevel
bevel
of 9.8 to
roller
pinion
12.8
bearing,
gear and bevel assembly
Nm
(1.0 to
backlash
and
pinion. for
starting
1.3 kgm)
force
as a single
assembly. Install
bevel
same shims Perform tooth
pinion
before
adjustment
contact
Measure while
assembly
as those
of
on
starting
preload,
torque
adjusting
change
the
cages
with
the
backlash
and
in parallel. of bevel
bevel gear is in mesh with
When
case
removal.
the
preload
amount
at the
left
of
and
gear
bevel of
shims
right
assembly
pinion. the
bearing,
inserted
sides
in
of the
the
center a=20to33mm b = 13to26mm
case.
end side
Small 23F032
1)
Adjust
tooth
contact
Coat
the
tooth
with
red
lead
forward
and
face
of the
(minimum). backward
bevel
Rotate and
pinion the
inspect
lightly
bevel the
gear
pattern
left on the teeth. *
The
center
should small
of
be end
the
center
are
adjusted
the
located of the
If the correct adjust
result tooth
of the
contact 26
gear.
tooth
this
tact will be correct t
-
bevel
of the to
tooth 13
again as follows.
If the
the
the be in gears
tooth
con-
load is applied.
inspection
contact
pattern from
It should
height.
pattern,
when
mm
is not
shows being
that
the
obtained,
i)
If bevel bevel
pinion
Contact
is at the
center
end
of
gear
and
end of the concave
tooth
face.
Procedure
the
B by
the
has
contact
pattern
If bevel
big
shims the
bevel
gear.
at
both
cages
bevel
gear
amount
at pinion
the in
Adjust of
the
in direc-
that
the
bevel
Check
the
tooth
and backlash
again.
is too
to center
line
of the
concave
of the
Procedure Increase bevel
close
of
tooth
the
end gear
and the big end
face.
thickness
pinion the
small bevel
for adjustment
direction
tion
convex
at the
nearer.
is at the
face
of the convex
bevel
of
gear.
Contact
just
the
the
same
moved
pinion
the
move
to the
to move
pinion
tooth
to
thickness
gear
tion
of
mount
A, nearer
shim
bevel
small
thickness
pinion
direction
bevel
line
for adjustment the
bevel
*
from
bevel
face
Reduce
ii)
far
of the
tooth *
is too
gear.
A,
away
shim
gear B by
of
mount
to from
thickness
to move the
bevel
pinion
tooth
contact
pattern
the
shims the
bevel
amount
moved
at the
pinion
bevel
at both
the
same has
the
move
gear.
cages gear equal
away.
and backlash
in Ad-
of the
in directhat
the
Check
the
again.
v
23FO50
30697
6.
Shaft Install axle shaft (56) to center case.
6.
Sungear Install sun gear (55)
and collar (54) to axle shaft, and
fix them with snap ring (53).
7.
Ring-gear Install ring-gear
8.
Shaft,
(52) to center case.
bearing
Press fit bearing (51) to shaft (50). *
When from
doing this, position
bearing is distance
30698
it so that the distance
the end face of the shaft A (1 15 mm).
to the tip of the
9. Side case i) Assemble washer (49) to side case (48) (with bearing and oil seal) so that end of washer is as shown in diagram on right. #TIJ=
ii)
Washer (contact surface) : Anti-friction compound (LM-P)
Assemble compared Assemble at the top case. &
bushing (47) so that slit is at bottom to UP mark on side case. the second bushing so that the slit is compared to the UP mark on the side
Bushing: Anti-friction compound (LM-P)
10. Flange Fit O-ring to side case, then sling and install flange (45). ks C?J
Flange: 74 kg
a
O-ring: Grease (G2-LI)
11. Washer, O-ring, shim i) Assemble washer (42) so that end of washer is as shown in diagram on right. ii) Assemble O-ring (43). ECC&
Washer (contact surface): Anti-friction compound (LM-P) iii) Assemble shim (44) so that it is the same height as washer (42). * Standard shim thickness: 1 .O mm (t = 0.1 mm, 0.2 mm, 0.5 mm) .
12. Plate Install
(41)
plate
and tighen
bolts
(39)
with
washer
(40). Bolt:
m
549.2 * 58.8 Nm (56 YC6 kgm)
13. Axle shaft assembly Install axle shaft assembly
(38).
14. Bearing Install bearing
(37) to shaft.
15. Sprocket (36) to shaft.
Install sprocket *
Assemble
the sprockets
so that the long ribs are
alinged.
16. Adjusting i)
Install (34).
30-A00
preload shim
of axle (35)
and
shaft
bearing
temporarily
install
holder
ii)
Install
3 gears
(33) to carrier
with
pin
(32), plate
(31) lock plate (30), and bolts (29).
iii)
Sling and install Carrier
rE?kg
iv)
Install
plate
w *
carrier assembly:
P2350
B328
P2350
I327
bolts (26).
926.7 + 103.0 Nm (94.5 k 10.5 kgm)
Tighten
bolt
plate
(27)
shim
(35)
to 9.8 -
(26) and and
bring
shaft
the
(38)
installed
the
torque
starting
(t =
faces
contact. in
Step
of the
of
Add 16)
bearing
1.3 kgm).
shim thickness:
of shims:
end
in
(temporarily
12.8 Nm (1.0 -
Standard Type
(28).
110 kg
(27) and tighten
Bolt:
and adjust *
assembly
2.0 mm
0.1 mm,
t =
0.2 mm,
t
= 0.5 mm)
4
Rotate and
the
right
starting
shaft to
at least
settle
torque
again.
washer
(67) with
m
Bolt:
the
three bearing,
Install
times
to the
left
check
the
(34) and
lock
then
holder
bolt (68).
277.0 + 31.9 Nm (28.25 + 3.25 kgm)
17 . Side case assembly and
Sling
install
case and tighten
side case
&
Side case assembly
KI&
Bolt (26) and axle shaft contact Antifriction Side case mounting
m
bolt:
(24). kg
655
(each):
to center
(25)
assembly
24 bolts (23) with washer
surface:
compound
(LM-P)
549.2 f 58.8 Nm (56 k 6 kgm)
18. Tube Install flanges
(22)
and (2 I) then connect
tubes
(20)
and (1 9).
19. Cover,
pipe
i)
Install cover (I 8).
ii)
Fit O-ring lower side.
and
install
pipe
(17)
suction
port
at
20. Strainer Install strainer (16) and spring (15) to pipe.
21. Tube Fit O-ring and install tube (14).
235FO2233
22. Coupling Install coupling (13) to pinion shaft.
23. Drive shaft Install drive shaft (12) to coupling and tighten bolts (1 1).
26. Cover Attach gasket on covers (5) (Front and rear: 6
PCS).
Mounting bolt (tandem case side) : Liquid gasket (LG-1)
&
dII&
Gasket side: Liquid gasket (LG-1)
27. Tandem and final drive assembly I) Lift tandem and final drive assembly (1) and install wheel (2). 2) Tighten tandem case drain plug and refill engine oil through filler port to the specified level. Q 3)
Tandem case (each): Approx. 120 Q
Tighten final drive case drain plug and refill gear oil through filler port to the specified level.
lb
Final drive case: Approx. 63 Q
DISASSEMBLY ASSEMBLY 1.
Remove
bolts
gear (3) from
(I),
OF BEVEL GEAR
lock
differential
plates
(2) then
remove
bevel
case A (4).
2.
Remove
bolts,
3.
Remove
bearing
(6) and seal ring (7) from
cage (5).
4.
Remove
piston
(8) from
remove
ring (9) from
5.
Remove
lock plates them
piston
cage
remove
(5) then
cage (5).
seal
(8).
seal ring (10) and washer
(1
1) from cage (5).
6.
Remove *
mating
Mating
plates (121, discs (13) in order.
plate:
7 PCS, disc:
6 PCS.
7.
Remove
plate (I 4).
8.
Remove
gear (I 5) from differential
9.
Remove
differential
case A (4).
case
B
(16)
case.
from
differential
10. Remove
cross joint
11. Remove
pinion
and 19D) from 12. Remove nion
nut
(19) and
assembly
(18, 18A, 19, 19A, 19B, 19C,
assembly cross joint
(18A)
from
bearing
(17).
(17). sleeve
assembly
(18), then (19A,
remove
19B.
pi-
19C, and
19D).
13. Remove ferential
30208
gear
(20) and
case A (4).
thrust
washer
(21) from
dif-
ASSEMBLY ASSEMBLY 1.
2.
Install
OF BEVEL GEAR
thrust
washer
case A (with
bearing)
Press fit bearings to pinion
(20) to differential
(19A), (19B) and spacers
(19C), (19D)
(19).
2A. Insert sleeve
(18) and tighten
w
Nut:
*
This bearing and
(21) and gear (4).
490.3 -
small
nut (18A).
608.0 Nm (50 -
62 kgm)
is a set, so the combination bearings
and
of large
2 spacers
must
not
all have
the same
be
changed. *
The bearings
and spacers
sym-
bols on the end face.
8
*
4 s1
After
tightening
the nut to the specified
tate the bearing rotates
at least 5 times,
ro-
that
smoothly.
3.
Install
cross joint
assembly
4.
Install
differential
case B (16) to differential
5.
Install
gear
(17).
torque,
and check
(17).
(15) bite on pinion
case A (4).
of cross joint
assembly
it
6.
Install plate (14). *
Assemble are 15”
mating plate (121, disc (13) in order.
the discs so that lubricating -
22”
apart.
disc so that it is rotated
holes
@
To do this, insert the 2nd three teeth from the 1 st
disc. *
Plate:
7 PCS, disc:
6 PCS.
(1 1) to cage (5).
7.
Install seal ring (I 0) and washer
8.
Install seal ring (9) to piston (8) and install to cage (5).
30210
9. Install them
10. Stop
bearing
(6), seal ring
(7)
to cage (5) and install
by bolts and lock plate.
bevel
gear
(3) with
A (4),. then install with
dowel
pin of differential
case
lock plate (2) and bolt (1).
30211
DISASSEMBLY ASSEMBLY
1.
Set
bevel
pinion
OF BEVEL PINION
assembly
(I)
in vice
and
remove
nuts (21, (3) and lock plate (4).
2.
Use press fit tool @ in press. separate *
Press
(I.D. 4200
pinion
(6).
mm) and set cage (5)
pull it out from
cage
to
pinion and cage.
It is possible
to remove
bearing
(7) and pull out
pinion at the same time.
3.
Remove
bearing
PCS.) and O-ring
4.
outer races
Use a bearing separator,
30212
(8) (upper and lower:
(9) from cage (5).
pull out bearing
(IO).
2
ASSEMBLY ASSEMBLY 1.
OF BEVEL PINION
Use press fit tool to press fit bearing
(10).
P2350t366
2.
Using
press
and lower: 3. 4.
Fit O-ring Pass
fit tool,
press
fit
outer
races
(8) (upper
2 PCS.) in cage (5). (9) to cage (5) and install
bearing
(7) through
pinion
pinion
(6).
(6) and
press
fit
to
cage (5). 6 5.
Bearing
Set the
pinion
roller section:
Fill with
in a vice
install
and
grease nuts
G2-LI.
(3), (2) and
lock plate (4). 6.
Starting 1)
torque
Tighten *
adjustment
nuts (2) and measure
Starting
torque:
starting
torque.
49.0 to 58.8 Nm (5 to 6 kgm)
2) Turn the shaft at least 3 times left and right, then
loosen
nut
(2) so that
it can start
to rotate
at 4.9 to 7.9 Nm (0.5 to 0.8 kgm) * 3)
Do not fully
Tighten *
second
Tightening
loosen
the nut.
nut (3). torque
of second
nut:
392.3 & 98.1 Nm (40 k IO kgm) *
Starting
torque: 9.8 to 12.8 Nm (1.0 to 1.3 kgm)
A
Measure pinion
the shaft
rotating 3 times
force and
again
after
fits well. Then bend lock plate
the
after bearing
rotating roller
(4) securely.
P2350t363
Pirs50
I 367
REMOVAL OF FRONT ASSEMBLY
1.
Front wheel
AXLE
assembly
1)
Loosen
wheel
2)
Raise front support
nut (1) a little.
wheel
using
the lower
the
blade
part of frame
as a jack
center
and
firmly
with
wheel
nuts
a block. 3)
Temporarily
sling
(1) and remove
Front wheel
kg r6?l
2.
Front axle 1)
Sling
wheel
wheel
and
remove
assembly assembly:
(2). 530 kg
assembly front
axle
assembly
(3)
and
put
on the
block 0. 2)
Remove
leaning
cylinder
and
steering
cylinder
and remove
leaning
hoses (41, (5). (6) and (7).
3)
Remove
bolt
rod (8) from stopper
(91, pin (IO), bracket
bolt (12).
(11)
then
remove
leaning
3.
Center pin 1) Remove stopper bolt (13).
2)
Remove assembly &
center pin (141, then remove (3) from main frame. Front axle assembly:
1080
kg
front
axle
INSTALLATION ASSEMBLY 1.
AXLE
Sling front axle assembly (3). matching center hole @ and main frame hole 0. Always align the holes with left mount @ of the leaning rod and leaning stopper @ removed.
-- kg &?I
2.
OF FRONT
Front axle assembly: 1080 kg
Fit center pin (14).
Tighten stopper bolt (13).
3.
Fix stopper bolt (12) to leaning rod (8). Install leaning rod L.H. side to bracket (1 I) by pin (10) and bolt (9). &
Bolt (9): Thread tightener (LT-2)
w
Bolt (9): 147.1 - 308.9 Nm (15 - 31.5 kgm)
4.
hoses
(6), (7),
der and steering
Connect
cylinder.
(4) and
(5) to
leaning
cylin-
36
5.
Front wheel 1)
install 2)
assembly
Temporarily
sling
to
hub
front
shaft
tighten
wheel
nut (1).
Raise
front
wheels
remove
the
wheel
assembly
assembly
and
using
block,
and
blade lower
(2), then temporarily
as body
a to
jack, the
ground. 3)
Tighten
wheel
el
Front wheel
kg
nut (1). assembly:
&
Wheel
nut: Anti-friction
w
Wheel
nut:
530 kg compound
(LM-P)
2206.5 k 245.2 Nm (225 f 25 kgm)
P2350
E369
OF FRONT AXLE
‘DISASSEMBLY ASSEMBLY *
Drain the oil from I
1.
:
2)
cylinder bolt
steering
cylinder
(4). Loosen
(3) bottom (5) and
locknut
end
remove
remove
(2),
pin from
steering
front
axle
cylinder
(6).
15 kg
cylinder:
Tie rod assembly 1)
remove
(7) and
Loosen
locknut
(8) from
hub shaft assembly.
Leaning 1)
rod, leaning
Loosen
bolts
tie rod
assembly
54 kg
Tie rod assembly:
3.
out
hub shaft assembly
Steering
& ks
pull
and
(I)
Loosen
head end from
2.
1.8 11
Front axle housing:
Steering 1)
inside the housing.
cylinder
(9), (10) and
pull
(13)
and
out
washer
(II),
pin (12). rod
leaning
Remove
(14) head end from Leaning
30218
yoke
rod:
(15).
50 kg
leaning
cylinder
2)
Loosen
bolt
remove
leaning
(16)
and
pull
cylinder
out
bottom
(17).
then
end from
pin
front
axle. Leaning cylinder:
& kg
4.
5.
6.
26 kg
Kingpin Loosen
bolt
remove
hub shaft assembly.
(18)
and
pull out
&
Hub shaft assembly:
king
154
pin (191,
then
kg
Bracket Loosen
nut
bracket
(22) from front axle.
&
Bracket:
Hub shaft
I)
(201,
pull out
shaft
(211,
then
29 kg
assembly
Loosen bolt (23) and remove
cover (24).
remove
2)
Loosen bolt (25) and remove
3)
Sling housing (28).
washer
(27) and remove
(26).
it from
hub shaft
ASSEMBLY ASSEMBLY
1.
OF FRONT
AXLE
Hub shaft assembly 1)
Install
housing
2)
Adjust
rotating
.
Insert
(27) to hub shaft
(28).
torque
shims
(30) and tighten bolts (25) with (26) so that it starts to rotate at 294 to 343 N (30 to 35 kg), as measured by a spring
washers balance
0 hooked
Turn the shaft l
Loosen
bolt
to hub bolt (29).
at least 3 times (25) and
pull
that it can start to rotate
left and right.
out
shims
(30) so
at 147 to 196 N (15 to
20 kg). l
Measure
the rotating
ing hub shaft roller
fits
force
3 times
well.
Then
again
after
rotat-
and after the bearing bend
lock
plate
(31)
securely. l
Adjust perature
3)
the
preload
becomes
after
the
normal.
install cover (24) with bolts (23).
bearing
tem-
2. Bracket Serial No.: 11001 – 12502
Serial No.: 11001 –
023502
1) Assemble bracket (22) to front axle (4), and insert shaft (21). 2 Shaft and shaft insertion portion: Grease (G2-LI) 2) Insert lock (21A) into groove [A] of shaft (21), then assemble collar, bolt, and nut (21B), (21C), (21D), (21E), and (21F) temporarily. (Do not assemble shim (21G).) 3) Measure clearance [B]. Standard clearance: 1.5 mm 4) Insert shim of thickness [B] + 0.2 mm, then assemble. 3 Bolt (21D): 343 – 427 Nm {35 – 43.5 kgm} a Standard shim thickness: 1.7 mm a Types of shims: t = 0.1 mm, t = 0.5 mm, t = 1.0 mm 5) Insert nut (20) to shaft (21). 3 Nut: 490 – 608 Nm {50 – 62 kgm}
Serial No.: 12503 and up 1) Assemble bracket (22) to front axle (4), and insert shaft (21). 2 Shaft and shaft insertion portion: Grease (G2-LI) 2) Install nut (20) to shaft (21). 3 Nut: 490 – 608 Nm {50 – 62 kgm}
30-122 (6)
Serial No.: 11001 – 12502
023502
3. King pin 1) Assemble hub shaft assembly (6) and bearing (33) to bracket (22), then insert king pin (19). 2) Measure clearance (C). a Standard clearance: 6 mm 3) Select one thrust washer of a thickness closest to (C) – 0.2 mm. a Types of thrust washer: t = 4.5 mm, t = 5.5 mm, t = 6.5 mm 4) Pull out king pin (19), and assemble selected thrust washer (32) to bracket (22). 5) Insert king pin into hub shaft assembly and bracket, insert bolt into hole [1] and secure. 3 Stopper bolt: 59 – 74 Nm {6.0 – 7.5 kgm}
Serial No.: 12503 and up
30-123 (6)
023502
30-124 (6)
023502
30-124-1 (6)
DISASSEMBLY VALVE t
Cleanliness steering
is extremely control
disconnecting oughly.
unit. the
from
Although
around
procedures
port
exterior
that
disassembly. explained
the
Follow
throughout
thor-
material
of the unit.
the unit
keep
a
Before
of unit
foreign
joints
show you
repairing area.
area
to remove
not all drawings
during
when
in a clean
clean
brush
recommended
vise
important Work
lines,
Use a wire
and debris
we
OF STEERING
in a vise, unit
the
in the
clamping
the manual.
Rotor (Gerotor) End 1. Clamp edges
unit
in vise
0,
of mounting
vise jaws.
rotor
area.
end
Use
Do not overtighten
up. Clamp
protective
lightly
on
material
on
jaws.
23EFO
2.
Remove
cap screw
3.
Remove
end cap (2).
4.
Remove
seal (3) from
5.
Remove
rotor
6.
Remove
seal (5) from
7.
I lOi
(1).
end cap.
(4). Be careful
Remove
drive
cm3/rev.
displacement
not to drop star.
rotor.
spacer(s)
(6) (not
used
on 49 and
73
units).
I
23EFOI
302
109
25
(7).
8. Remove
drive
9. Remove
spacer
10. Remove
(8).
plate
(10).
housing
seal (9) from
End
Control
11. Remove
from
cloth
to protect
bladed
screwdriver
housing
(10).
pry
to
ring
retaining
a
Use a thin
finish.
surface
on
housing
Place
vise.
housing
soft
clean
(11)
from
I
23EFOI
I I I
12. Rotate spool and sleeve until pin is horizontal. spool
Push thumbs from
sleeve
far
enough
just
Remove
housing.
to
with
forward
assembly
and
gland
free
bushing
I
your (12)
bushing.
I 13. Remove
quad
ring
seal
(13) from
seal
gland
23EFOI
I I2
bush-
ing. 14. Use from
a thin
bladed
seal gland
screwdriver
bushing.
to
pry
Do not damage
dust
seal
(14)
bushing.
I
23EFOI
I13
15. Remove
2 bearing
bearing
(16) from
races spool
(15) and
the
and sleeve
needle
thrust
assembly.
23EFOI
16. Remove
spool
and
sleeve
assembly
from
14
II4
hole
end of housing. *
Do
not
bind
spool
and
from
housing.
spool
sleeve
17. Push pin (18) from
18. Push
spool
then
and
spool
partially
remove
(20) carefully
6
spool
back
slowly
when
21. Remove
set screw
pliers, 23. Remove 24. Tip
end
springs
-
(24).
and
removing
seal (22) from
a #IO
Rotate removing
assembly
control
through
20. Remove
seat
and sleeve
from
housing. when
(17).
of sleeve
(21)
from
(19), spool
by hand.
spool
ball
in
slowly
centering
19. Push
22. Screw
sleeve
assembly
of sleeve.
Rotate
sleeve.
housing.
(23) from
housing.
24 machine Then
out
from
by
screw pulling
into on
end
of check
screw,
with
a
lift seat out of housing. 2 seals (25) from
housing
ball retainer
to
remove
check valve check
ball
seat. (27)
and
check
(28). 23EFOI
II7
ASSEMBLY VALVE *
Check
all
have
mating
surfaces.
scratches
Clean air.
OF STEERING
or
all metal
Do not
parts
wipe
that
with
lint or other
matter
system
and cause
damage.
Lubricate
all seals
Do not
(with
exception jelly
clean
not
excessive
Blow
dry
paper into
that
leakage. with
towel
the
be-
hydraulic
use a coarse
grit
parts.
petroleum
seal) with use
or
can get
these
parts
cause
solvent.
cloth
cause
any
could
in clean
dry
or try to file or grind *
Replace
burrs
of new
such
lubricant
guad
ring
as Vaseline.
on
seals
for
Do
meter
section. A good
service
policy
is to replace
all old seals
with
new seals.
Control end 1.
Use a pincette check
valve
straight 2. 3.
Install
to
check
12.9
Lubricate fore
on edge)
diameter
ball seat
do not twist
Install ference, fore
6.
to
that
and
sets
have
Test
for
11.1
diameter
thoroughly
be-
installing
seat
When Install
check
of seat
first.
allen
wrench
ball seat
Push
check
kgm).
of set
screw
to torque
prevent
a
inter-
is slightly
be-
and
sleeve
carefully
so
(19)
line up at the same parts
together.
identification free
in sleeve
To
rotation. with
finger
Some marks,
Spool tip
end.
Rotate
spool
and
align should
force
these rotate
applied
at
end.
*
a . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Spring
*
b . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Identification
30228
is
surface.
(20)
sliding
(1.2
top
slots
marks.
seals
seals. end
Nm
sure
sleeve
splined
(28) into retainer
ball seat (24).
Use a l/4”
spool
while
smoothly
seat
mounting
the spring
spool
sure
of hole.
11.8
make
housing
Assemble
retainer
(25) and
in housing. open
set screw.
screw
seal
or damage insert
ball seat to bottom
set
ball Make
in housing.
seals on check
check
installing
in housing,
5.
housing.
ball (27) in housing.
seal (26). Install 4.
of
(not tilted
Lubricate
lower-check
hole
slot
marks.
I
23EFOI
I IS
7. Bring
spring
parts
slots
on end
tool
through
able
spring
as part
ing
springs
together.
In this
slots
spool
installation 9. Center
spring
evenly
spool
bench
one
so that section
end
of
is
entire
tool.
assembly
set in the
and
flush
(20) and sleeve
10. Install
is avail-
of center-
center
of centering
sleeve
stand
spring (17)
set and
withdrawing
19
\
tool at the same time.
the
down
insert
end
Tool
on
arched
installation
and
(21) installation
3 pairs
of 3 each) and
line
parts.
Position
position,
extended
into
in
spring
of both
is down
set into spring
8. Compress
parts
Insert
(or 2 sets edge
push
both
No. 600057.
extended spring
of
of bench.
pin
(18)
ZBEFO
parts
with
so that
the
they
upper
I I20
push
surface
of
(19).
through
(17) until pin becomes
spool
and
sleeve
assembly
flush at both sides of sleeve.
8
4
si 11. Position
the
the splined of housing *
spool
with
housing
the bore
or
14
hole
assembly
cross
pin
the
flush
12. Place
bearing
I I22
23EF0
I I23
end
parts
do not tilt out
parts
gently
keep
pin
assembly
the end
parts of
are
dropping
into
the
With check
the for
spool free
with
light
clean,
lint
not
to
the meter
pull
prevent
the the
discharge
groove
assembly
in
rotation
finger
horizon-
at the
Do
point
of
place
within
flush
housing.
into
nearly
entirely
this
by turning
within
tip
force
this
lO---
the at the
end. housing
diameter 13. Install
from
position,
splined
14 hole
the
the
beyond
housing.
housing
23EFO
(17) so that
assembly enters
Push
action,
spool until
spool of
that
inserting.
rotating
Bring
end
careful
while
slight
tal.
sleeve
121
(10) first.
Be extremely position
and
end on the spool
23EFOI
on
seal (22) in housing 2 bearing
races
(15)
free
cloth.
Install
54.0
(IO). and
the
needle
thrust
(16) in the order.
14. Install or
dust
seal
smooth
wards
(14) in seal
side
of
dust
gland
seal
bushing
must
(12), flat
face
down
to-
f==b
bushing.
15. Install
dry
(12). Smooth
quad
seal
ring
in
seal
place
with
any seal that falls freely 16. Install
seal gland
twisting
motion.
rubber
hammer.
against
bushing
tap
around
ring
entire
finger.
bushing
Do not
use
of buhisng.
the
spool
bushing
sure
gland
in
that
end with
place
a
with
bushing
is
a
flush
23EFO
race.
ring
on
over
the
Make
retaining
ring,
your
into pocket
Tap
the bearing
17. Install
(13) in seal
(11) end
in housing. or
pry
circumference
11
After
with
of ring
I I.24
installing
screwdriver to properly
A seat
ring in grove.
23EF ‘01
18. Clamp
housing
mounting *
Check
in vise.
to insure
that
the
or slightly
below
the
Clean
upper
surface
with
the the
surfaces when
Clamp
palm
of clean
of the
meter
ready
for
spool
14 hole
section
reassembly.
edges
of
jaws. and
sleeve
surface
of the hand.
on
lightly
area. Do not over tighten
125
housing
Clean
each
parts Do
are flush
of the
housing.
by
wiping
of the
in a similar not
use
cloth
flat way or
paper to clean surfaces.
23EF0
19. Install 76.2 diameter 20. Install
spacer
plate
plate with tapped
I I26
seal (9) in housing. (8). Align
bolts
holes
in spacer
holes in housing.
23EF0
I I27
21. Rotate
spool
parrallel sure
and
with
sleeve
port
face
you
engage
drive
alignment,
mark
drive.
slotted
end
of
drive
to
assembly “a”.
until
Install
with
pin.
Note
pin
drive To
assure
relationship
splined
(18)
(7),
end
of
is
make proper
between drive
when
marking.
22. Install
76.2 diameter
23. With
seal
side
star valleys Note
the
seal (5) in meter
of
meter
toward
(4).
spacer
plate,
I
23EFOI
I
23EF0
129
align
(X) (ref. A) on drive (Y) (ref. B). parallel
relationship
of reference
lines
A, B,
C and D. Align
bolt
holes
without
disengaging
meter
from
drive.
24. Install
drive
spacer(s)
25. Install
76.2 diameter
(6) when
screws
7
cap
screws
to 14.7 Nm
I
seal (3) in end cap (2).
26. Install end tap on gerotor, 27. Install
used, in meter.
I I30
align holes. (1)
in
(1.5 kgm),
end then
27.5 Nm (2.8 kgm) in the sequence
cap. torque
shown
Pretighten screws
to
in Fig.
23EFOI
I31
F23EH01212
30-G31
ASSEMBLY
1.
Remove bolt (1) holder (2) an collar @ in order.
2.
Remove spacer (3). sprocket order.
A
(4) and collar (5) in
There are two types of wheel brake. In the other type, collar (5) must be removed before the sprocket. (The photograph shows the rear left and front right.)
3.
Remove 4 bolts (6) then remove support (7).
4.
Remove plates (81, discs (9) in order. + Plate: 9 PCS,disc: 8 pcs
5.
Remove gear (I 0).
6.
Remove
spacer (1 1).
7.
Remove
guide bolts @
=
(Thread dia. = 10 mm, pitch = 95 mm), th*en sling cage assem-
1.5 mm, length
bly (12) and remove
&
kg
8.
it.
Cage assembly:
Remove
6 bolts
(13).
80 kg
6 springs
(14)
then
remove
piston (15). *
If air is blown in to raise the piston, it is easier to remove. Be careful not to damage the O-ring or the sliding surface
9.
Remove
10. Pull out
O-rings bearing
of the piston.
(16) and (17) from piston (15). (18)
and
spacer
(19)
from
shaft
assembly.
P2350
1,406
30-l 33 0
ASSEMBLY ASSEMBLY
1.
BRAKE
Fit O-ring to shaft and install spacer (I 9). AD+
O-ring groove
2.
Press-fit
3.
Fit O-rings a
4.
OF WHEEL
bearing
part:
(G2-LI)
(18).
(I 6) and (I 7) to piston.
O-ring groove part:
Press-fit
Grease
bearing
outer
Grease (G2-LI)
race (20)
and oil seal (21)
to
cage. a
5.
Oil seal:
Grease (G2-LI)
Insert piston (15) slowly to cage (22) a*,2
Inner
surface
portion)
:
of
cage
Rust prevention
AMITY=
Sliding surface
AC&
Machined
part
of piston: (except
inside cage in contact
(non-machined coating
Grease for
(PU-4)
(G2-LI)
sliding
surface
with piston: Rust preventive
*
Be careful surface
*
not to damage
and sliding
when pushing in.
Push the piston pull back 5 mm.
30234
the O-ring
(KP-I)
in to the end of its stroke,
then
6.
7.
Install 4 springs (14) and 4 bolts (I 3).
ATL
Mounting
bolt:
m
Mounting
bolt: 49.0 Nm (5.0 kgm)
Blow in compressed port
air through
@ and move
times
to check
Thread
piston
tightener
cage brake piping air
up and down
that piston
(LT-2)
is returned
two or three to stroke
end
by the force of the four springs.
8.
After two
checking springs
procedure
9.
To
bolts
(13)
remaining
according
to
(I 2) and install to shaft.
Cage assembly:
prevent
of pistion, tighten
and two
in step 6.
Sling cage assembly
& kg 10
operation (I 4)
misalignment
80 kg of cage
and shaft,
four guide bolts @ (I 0 mm x 1.5 mm -
11. Install spacer (1 1).
install
95 mm).
12. Install gear (I 0).
13. Install plates (81, discs (9) in order. * Plate: 9 PCS,disc: 8 PCS.
14. Fit 2 O-rings to support (7) then install them to cage with 4 bolts (6).
15. Install collar (51, sprocket (4). spacer (3) in order.
A There
are two types of wheel brake. In the other type, collar (5) must be installed after the sprocket. (The photograph shows the rear left and front right.)
16. Install collar @ (c$ 95 mm) then temporarily install holder (2) with bolts (1).
302 36
DISASSEMBLY
REMOVAL
a
AIR TANK
AND ASSEMBLY
OF AIR TANK
Lower the work equipment ground and stop the engine.
completely
1. Disconnect the cable from the negative minal of the battery.
to the
H
ter-
2.
Depress brake pedal several times to completely release compressed air in air tank.
3.
Remove
4.
Disconnect tank.
5.
Remove
6.
Disconnect
outer panels (IA)
and (IB).
5 air hoses (I) at bottom
right of air
clips (2) and (3). wiring
connectors
(4), (5), (6), and
(7).
zz z 8
7.
Remove wiring harness from (Serial No.: 11013 and up)
8.
Remove wiring connector No.: 11013 and up)
9.
Sling air tank assembly (11) and remove.
INSTALLATION ASSEMBLY .
Carry out removal.
installation
welding
(9) from
(IO), then
clip (8).
clip. (Serial
loosen
235CDO2068
bolt
OF AIR TANK
in the
reverse
order
to
Serial No.: 11013 and
To
transmission
UD
DWG00233
REMOVAL TANK 1.
Disconnect
2.
Remove w
:
OF HYDRAULIC
cable from
drain
negative
(-)
plug (1) and drain oil.
Hydraulic
terminal
of battery.
i
oil: 108 Q
3.
Remove
outer
panels
4.
Remove
clip (2).
5.
Disconnect
wiring
6.
Disconnect
hydraulic
hoses (5), (6), (7), (8), and (9).
7.
Disconnect
hydraulic
hoses
8.
Sling
hydraulic
(IA)
and (IB).
connectors
tank
(3) and (4). 1235FO2244
/
/I
(IO), (1 I), and (12).
(13), then
loosen
bolts
(14) and
remove.
INSTALLATION TANK l
m
Carry out installation Tighten
the
OF HYDRAULIC
in the reverse drain
plug
order
and
through
the oil filler to the specified
Q
Hydraulic
tank:
to removal.
add
engine
oil
level.
108 R
235COO2
REMOVAL OF HYDRAULIC PUMP ASSEMBLY
A
Lower
work
1. Disconnect
equipment
cable
from
completely
negative
(-)
to the ground. terminal
of bat-
tery. 2. Loosen
drain
hydraulic I
:
plug
Hydraulic
3. Remove
(1) and
drain
oil
from
tank:
108 Q
air tank.
For details,
see REMOVAL
4. Disconnect
hoses
draulic
(2).
pump
(3),
OF AIR TANK ASSEMBLY.
(4), (5),
(6), and
(7) from
clip (9) from
pump.
5. Remove
bolt (8), then remove
6. Remove
bolts (IO), and disconnect
7. Remove
bolts
transmission
(12),
pump
Remove
bolts
(13). * The
pump
the
remove
are few
(11).
tube
(14)
transmission
with
hose
not to damage pump,
bottom
to loosen,
disconnect
is removed
hydraulic
(19). * There
and
flange
hy-
from
(13).
(15), then
so be careful 9. Sling
hydraulic
tank.
and
spacers
for
pump,
so modify
the
installed,
the hose.
remove
of the
(16)
pump
the and
mounting mounting they
‘t’ portion
are
bolts bolts
at
difficult
of spanner
A
(make it 7.0 mm) to loosen. 10. Remove
hydraulic
pump
Hydraulic
pump
4
(2). assembly:
106 kg
Rear
235CD0207t
trame
235C002074
INSTALLATION OF HYDRAULIC PUMP ASSEMBLY 1. Set
hydraulic
tighten *
pump
(2)
in
mounting
position,
and
bolts (19).
There the
are few
bottom
spacers
of the
to tighten,
so
for
the
pump,
modify
mounting
and
the
they
‘t’
portion
in
mounting
bolts
are
at
difficult
of spanner
A (make it 7.0 mm) to tighten. 2. Set
transmission
and tighten 3. Install tube 4. Connect
pump
(13)
position,
bolts (15). (14), and tighten
hoses
bolts (12).
(3), (4), (5), (6), and
(7) to
hydraulic
w-w (2). 5. Install clip (9) to pump. 6. Install flange
(11) to pump.
7. Bleed air from hydraulic For
details,
pump.
see
BLEEDING
AIR
see
INSTALLATION
FROM
HYDRAULIC
PUMP. 8. Install air tank. For
details,
OF AIR
TANK
SEMBLY. 9. Add hydraulic Qz 10. Connect
oil to hydraulic
Hydraulic
tank:
AS-
!
F23501322
tank.
108 Q
cable to negative
(-)
terminal
of battery.
Reartram
30- 140 0
235CDO2074
BLEEDING
A
AIR FROM
When
the
HYDRAULIC
hydraulic
replaced
or
pump
removed,
or
PUMP
piping
always
have
bleed
been
the
air
as
engine
oil
follows. 1.
Bleeding
air from hydraulic
1)
Remove
plugs
2)
Disconnect
pump case
(2) and (3).
hose
(1); and fill hose
with
(EO SAEI OW). Oil: 3.5 - 4 Q
Q 3)
When
oil comes
plugs 2.
from
Bleeding
air from hydraulic
1) Start
engine,
blade
and
lift cylinders
2) Run engine
at
left and right 3)
Run comes
4)
Run
lift
1.
2. 3. 4.
Hose Plug Plug Plug
(for (for (for (for
at
circuit
to specified
E
idling,
low that
lower
left
raise
and
right
and
lower
3 times.
loosen oil
with
plug no
(4) foam
plug. idling,
to
tighten
3 times.
2 -
idling,
end
at hydraulic oil
2 -
and
clean
low
cylinders
engine
and
lift cylinders
out, then tighten
air from Add
at
port,
hose (1).
pump piping
raise
high
check
engine
blade 5)
air bleed
at low idling
blade
engine
slightly,
:
out
(2) and (3), then install
raise of
left
stroke,
and
right
and
bleed
hydraulic
tank
relief.
(EO SAEIOW)
level.
draining oil from pump Case) bleeding air from front pump) bleeding air from rear pump) bleeding air)
to
DISASSEMBLY
Special
OF HYDRAULIC
PUMP ASSEMBLY
tools
~
1.
Draining
oil, cleaning
Raise
pump,
put
then remove W
:
*
oil container
drain
Hydraulic The drained
pump:
Fit removed
plug
covers
livery *
blind
Approx.
oil cannot
and
fit The
plugs from
(I),
plug,
3 S?
be used again.
and
blind
plugs
(4) to suction
and
blind
entering
the
so they can be fitted Clean pump fitted
drain
(2) again,
port
and
de-
port.
dirt
After
under
plug (I), and drain oil.
with flushing
cleaning,
remove
covers
are
pump
during
to
prevent cleaning,
simply. oil. plugs
and
blind
covers
at Item 2).
235CDO2076
2.
Seal assembly 1)
Remove
snap
bly (6) from *
The
ring
front
(5), then
remove
seal
stationary
seal
and
O-ring
cannot
used again.
2)
Remove *
rotating
The rotating
assem-
cover.
seal (7) at front seal cannot
shaft end.
be used again.
be
3.
LS valve (common for F and R pumps) Loosen *
5 bolts
Loosen
(1 I), then remove
bolts
in the
order
LS valve shown
(IO).
in the
diagram
on the right.
235FO2246
4.
Servo 1)
valve assembly
Loosen raise
plug servo
for F and R pumps)
(common
(12), and valve
remove
assembly
6 bolts
(13), then
(14) straight
up and
remove. 2)
Remove *
5.
gasket
(15).
The gasket
cannot
be used again.
Front pump 1)
Loosen
8 bolts
bolts marked 2)
Loosen pump *
(16), then
2 bolts and center
The
marked
% in turn,
surface
scratched,
the pump
bolts
leaving
2
in position. and
separate
section.
mounting
easily
remove
% remaining
when
of the
so put carrying
servo
a rubber
valve
mat
is
under
out the operation.
P2350
3)
Pull
out
(18). If the *
front pump
pump does
of the
spring
it with
a plastic
and
(17)
from
not come cannot
hammer
center out
by the force
be pulled
to remove
section
it.
out,
tap
I 529
_
F2350133i
4)
Remove *
5)
gasket
Remove
6)
(19).
The gasket
*
be used again.
1lA
2 pins (19A).
Remove shown
cannot
valve
plate
(20) with
in the diagram
The
mating
center
surface
section
careful
is
of
7)
Remove
Pull out coupling
the
lapped
not to scratch
8)
screwdriver
0
as
on the right. valve
plate
precisely,
so
and be
it.
pin (20A). (21).
Ll
9)
Remove *
bearing
Make position
6.
marks
to indicate
of the bearing
the
assembly
cup and shim.
Rear pump Remove Front
7.
cup (22) and shim (23).
match
rear
pump
in
the
Disassembly
of front pump
1)
pump
Set front *
30244
way
as
Item
5.
(24) on stand 0.
Set the front
pump
ful not to let bearing 2)
same
pump.
Remove
O-ring
together
in position
and
be care-
plate (27) fall. with
backup
ring (26).
F23501333
3)
Remove
bearing
plate (27) with
*
mating
surface
The
bearing
plate
is lapped
ful not to scratch
4)
Remove
pilot (28).
*
mating
The pilot
scratch 5)
6)
tool
and
so be care-
of the cylinder
precisely,
block
so be careful
and
not to
it.
Pull out pin (29) with
install
precisely,
0. block
it.
surface
is lapped
screwdriver
of the cylinder
pliers.
A to bearing,
and
pull
out
using
pul-
ler 0. 7)
Remove *
bearing
Make position
8)
Remove
(30) and spacer
match
marks
of the bearing.
guide
(32).
(31).
to indicate
the
assembly
9) Remove
pump
from
stand
and
set so that
shaft
is horizontal. 10) Rotate
cylinder
*
out
Pull
9 piston
11) Loosen
8
block the
kit (33) and pull out.
cylinder
block
kit together
with
assemblies.
bolts
(34),
and
remove
front
cover
(35).
P23501541
12) Remove *
gasket
The gasket
13) Pull out front 14) Set front rection *
The
(36). cannot
shaft (37) from
shaft
of arrow, bearing
in press,
a
housing.
push
then remove is press
do not disassemble
30- 146
be used again.
down bearing
fitted
it unless
to
shaft
in di-
(38). the
necessary.
shaft,
so
8 k=G 8
15) Loosen with
3 bolts
hammer
(39), then X,
and
tap
bottom
remove
of trunnion
trunnion
assembly
(40).
*
Make
match
position
16) Remove
marks
to indicate
the
mounting
of the trunnion.
shim
(41) and
O-ring
(42) from
trunnion
assembly.
*
Check
the number and thickness and keep in a safe place.
shims, *
The O-ring
cannot
of
the
be used again.
P23508547
17) Pull
out
swash
plate
assembly
(43)
from
hous-
ing. *
Make
match
position
18) Insert swash
handle plate
marks
of hammer (43), then
(44) lightly,
and remove.
*
removing
When
to indicate
of the swash
‘;
into
push
edge
the
not to drop or scratch
the
mounting
center
hole
plate.
thrust it.
of thrust
plate,
of
plate
be careful
19) Remove
snap
then remove 8.
ring
(45)
Disassembly
of rear pump
Disassemble
rear
pump
in Item 7. Disassembly *
There
are
Disassembly 1)
2)
Remove
some
pump
retainer
cylinder
Pull
out
(47). * The
plate
(43),
block
3)
Remove
guide
Remove
6 springs
as shown
in the
shape
of the
and rear pump.
together
assemblies
and
4)
way
with
9
pistons
kit.
9 piston piston
same
block kit (47)
slipper
so do not disassemble
30-&48
swash
pump.
differences
of cylinder
from
in the
of front
parts for the front
9.
from
pin (46).
(49). (50).
(48) from are caulked
them.
retainer together,
5)
6)
Set bolt
0
in vice,
, then
insert
spacer
@
remove
snap ring (52).
Remove
retainer
tighten
(53),
cylinder nut
spring
0
(54),
block
and
in turn.
10. Disassembly 1)
Remove
(51) and
slightly,
seat
and
(55)
of servo valve assembly O-ring
(79) and back-up
ring (80).
235COO2078
2)
Remove
plug (69).
3)
Remove t
4 control
Remove
cover
only
the
mounting 4 bolts
bolts (81). marked
*
81
in the
diagram. 3’
:
8
dL
O\ -\
’
235CW2CBZ
4)
Loosen
remaining
bolts
(81) in turn
cover
(61).
A
Remove from
2
control
gradually,
the
flying
cover
cover and
carefully
off under
the
Remove
gasket
(62).
6)
Remove
O-ring
(72) and back-up
30250
control
to prevent pressure
spring.
5)
mounting
remove
ring (73)
it
of the
235FO2247
7) Remove
spring
(63).
8) Remove
piston
(65).
235CDO2084
9) Remove
spring
(84).
235CDO2086
10) Set
housing
(60) at an angle,
and
remove
spool
60
(83).
*
Be careful
not to damage
11) Hold link (76) in position, *
Bolt
(71)
cannot
the spool.
and loosen be
83
reused
bolt (71). more
than
5
times. *
Use a jig for holding
the link.
235CD02087
66
71
u 235FO2248
12) Remove
link (76)
13) Remove
servo
14) Remove
2 pins (67).
15) Remove
piston
taper
plug
(66).
(77),
remove
then
spring
(76). 16) Remove *
pin (74).
Use long-nosed
pliers to remove.
Long-nosed
pliers
235F0224E
17) Remove
sleeve
(64) from
cover
18) Remove
O-ring
(82) from
sleeve
(61).
I
-
(64).
6432
19) Remove
plug (68) from
cover
(61).
68 \
\l\ 20) Remove
plug (68A).
61 I
235COO2096
21) Remove
plug (77).
::!2 0
J
77
--
--A
-
235CD02097
11. Disassembly 1)
Remove
of LS valve assembly 3 O-rings
(94).
235CD02098
2)
Remove *
plug (90).
If it is necessary
to
the vice at the position
use
a vice,
shown
clamp
with
by the arrow.
Mating surface
1
T-4 3)
Remove
spring
(92), spool
235FO2251
(87), spring
seat
(89)
and (93).
235FO2252
302 54
4)
Remove t
plug (85). If it is necessary
to use a vice, clamp with the vice at the position shown by the arrow. Mating surface
235FO2251
5)
Remove
O-ring
(91) from
plug (90).
6)
Remove
O-ring
(86) from
plug (85).
7)
Remove
3 plugs
235CD0210(
(68).
235FO225L
ASSEMBLY
Special
I
Part No.
Part name
790-445-6520
Push tool
B
790-445-6530 790-445-6540
Bar Coupling
c I
790-445-6550
A A. A
A
When
assembling,
The
I
O-ring,
1 1 1
I
the
sliding
1
surfaces
of
oil (CLASS CD, SAEIOW). and
backup
ring
cannot
be
used again. When
using
vice,
do not grip
the
lapped
surface
of parts. When
tightening the parts;
When The
the
vice,
be careful
use the minimum
replacing
and outer
A
coat
engine
gasket,
Q’ty
1 Guide
all parts with
form
A
the
bearing,
not
to
force
needed.
replace
the
decone
race as a pair.
rotating
seal
and
stationary
seal
cannot
be
used again.
Assembly Using front
2.
PUMP ASSEMBLY
tools
I I
*
1.
OF HYDRAULIC
cover
Assembly Using
of front cover
push
8,
press
fit
bearing
outer
race
in
fit
bearing
outer
race
in
press.
of rear cover
push
rear cover
tool
(59) with
tool
@, press
(6.0) with
press.
P
6
3.
Assembly
of front and rear shafts
1)
fit
bearing
(61)
to
front
shaft
(64)
with
fit
bearing
(61)
to
rear
shaft
(65)
with
Press press.
2)
Press press. *
When
replacing
the outer
4.
Assembly
Assembly Press fit with
bearing,
replace
it with
of trunnion
Press fit bearing
5.
the
race as a pair.
(62) in trunnion
of swash bearing
press.
(40) with
press.
plate
outer
race
(63) in swash
plate
(43)
6.
of seal assembly
Assembly 1)
Install O-ring & *
(67) to rotating
O-ring: The
seal
Grease
seal (66).
(G2-LI)
is precision
finished,
so
handle
it
carefully. *
The seal cannot
*
The O-ring
be used again.
cannot
be used again.
‘66
_,?2350
2)
Install
1 pin
(69)
and
6 springs
(70) to
i 665
retainer
(68).
P2350
3)
Install O-ring
(71) to retainer
6
O-ring:
*
The O-ring
Grease
I566
(68).
(G2-LI)
cannot
be used again.
P.2350 I567
-,
.
..“.“..
*
_._..-..-.
,
Rotating
seal
_“._..
\,
is not assembled t
The
seal
-,
._
.“_
_..._.
(66) is installed
is precision
The seal cannot
pump;
it
handle
it
to the seal assembly. finished,
carefully. *
\--,.
to the
be used again.
so
7.
Assembly 1)
of cylinder
*,*
block kit
Set bolt @ in vice, and insert cylinder
block (51)
to bolt 0.
2)
Assemble *
seat (55).
Install
the
seat with
the tapered
side facing
down.
3)
Install spring (54) and retainer *
Install the retainer ing up.
(53).
with the stepped
side fac-
5)
Install 6 springs
6)
Install guide
*
When of
(50).
(49).
installing
cylinder
guide
b: No tooth
8)
Install 9 piston
Install semblies
30-A60
(49),
(51)
(49) in a straight
a: Undersize
7)
guide
block
retainer Cylinder
a
Piston
spline
spline
“b”
“a” of
line.
1 place 1 place
assemblies
(47)
to cylinder
&
align
and
(48) to retainer
together
with
9
block.
block bore: assembly:
EO SAEIOW
EO SAEIOW
(47).
piston
as-
8.
Assembly 1)
of pump (common
Install with
2)
pin
for F and R pumps)
swash
plate
(43),
and
secure
snap ring (45).
Set swash
plate assembly
*
the
Install
as when
3)
to
(46)
Install
swash
(43) in housing.
plate
in the
same
position
disassembling.
O-ring
(42) and
shim
(41) to trunnion
as-
sembly.
2 % 8
*
The O-ring
*
Install
cannot
the
same
be used again. thickness
of
shim
as was
disassembled. The
shim
thicknesses
are
distinguished
by
color. Colors
&
Unit:
and shim thicknesses Color
Thickness
Amber
0.025
Green
0.075
Blue
0.127
Brown
0.254
Yellow
0.508
O-ring:
Grease
(G2-LI)
mm
ADJUSTING BEARING
A
PRELOAD
If any (40),
swash and
plate
bearing
just the preload
0
0
Install
OF TRUNNION
housing
have
(56),
been
trunnion
replaced,
ad-
d
43
56
of the bearing.
trunnion
clearance
(43), (57)
without
shims,
and
measure
“d”.
Standard
shim
shickness
=
Clearance
shims
between
“d”
+
0.075 + 0.025 mm.
0
Remove right, *
trunnion,
The
difference
thickness
5)
Tighten *
divide
left
and
and install. between
should
3 trunnion
Tighten
m
mounting
together
sition shown
left
be within
with
and
right
shim
0.13 mm.
bolts
40
=33501337
(39).
bracket
in the diagram
5i
(58) in the
po-
on the right.
Bolt: 49.0 Nm (5.0 kgm)
F23501338
6) Install thrust plate (44) to swash plate. *
Install
the
portion
of
the swash *
Coat
with
prevent
7)
Coat slipper engine
thrust the
plate outside
with
the
chamfered
circumference
facing
plate. grease
the thrust
portion
(G2-LI)
when
plate from
of piston
oil (EO SAEI OW).
installing
falling
assembly
to
out.
(48) with
8)
9.
Install
Assembly 1)
cylinder
kit (33) to housing
Align of the portion
shaft assembly
missing
tooth
cylinder “f”
portion
block
of the
(37)
“e”
kit with
spline
Set gasket *
(36) to housing.
The gasket
cannot
of the spline missing
of the
assembling.
2)
(56).
of front pump
Install front
*
block
be used again.
shaft
tooth when
3)
install
front
cover
assembly
(35)
and
tighten
8
bolts (34). m
*
Bolt: 98.1 + 9.8 Nm (IO f 1 kgm)
Tighten the
the
order
front
cover
shown
in
mounting
the
diagram
bolts on
in the
right.
F23501338
4)
Set front
pump
5)
Install spacer
(31).
6)
Using
tool
push
on stand,
A,
and install guide
press
fit
bearing
(32).
(30)
with
press. *
When
press
fitting,
be careful
not to damage
the part.
*
After
press
particles.
3op
fitting,
clean
off
all dirt
and
iron
7)
Install pilot (28).
8)
Install pin (29).
9)
Install bearing *
Align
plate (27).
pin (29)
and the
installing the bearing *
Coat
10. Assembly 1)
with
grease
(G2-LI)
hole when
when
installing
to
of rear pump
Install rear shaft assembly
*
mounting
plate.
Align
missing
of the portion
tooth
cylinder “f”
(73).
portion
block
of the
“e” of the spline
kit with
spline
missing
of the
tooth
shaft
when
assembling.
2)
”‘,\:: i,,, ,:
Stand rear pump upright.
*
Lay
rubber
mat
0
under
the
shaft
to
pre-
,,
vent damage.
P2350
L 585
30265
3)
Install guide
(32).
4)
Install spacer
(31).
5)
Using
tool
push
A,
press
fit. bearing
(30)
with
press. *
When
press
fitting,
be careful
not tc3 damage
the parts. *
After
press
fitting,
clean
off
all dirt
and
iron
when
in-
particles.
6)
Set gasket
(36) to housing.
*
The gasket
+
Make
sure
stalling
cannot that
be used again. the
gasket
is dry
it.
P23501588
7)
Install
rear
mounting w
cover
bolts
assembly
(74),
and
(75).
Bolt: 98.1 + 9.8 Nm (10 k 1 kgm)
tighten
8
*
Tighten order
the
rear
shown
cover
mounting
in the diagram
bolts
in the
on the right.
F23501340
8) Install
pilot
9) Install
pin (29).
IO) Install *
(28).
bearing
Align
plate (27).
pin
installing *
Coat
(29)
and
the
the bearing
with
prevent
grease
the bearing
mounting
hole
when
plate. (G2-LI)
when
plate from
installing
falling
to
out.
11. Rear pump 1)
Install taper w
2)
plug (76) to center
Plug:
14.7 Nm (1.5 kgm)
Install shim (23) to rear pump *
Install
section.
the
same
side.
thickness
of
shim
as
was
disassembled. 3)
Install *
bearing
Install
as when *
Coat
cup (22) to rear pump
the
cup
in the
side. same
position
disassembling.
with
prevent
bearing grease
the bearing
(G2-LI)
when
cup from
falling
installing out.
to
4)
Align
valve
plate
(20) with
stall to rear pump *
The
shape
shown *
the
grease from
of
the
rear
in the diagram
Coat
hole
“g”,
and
in-
valve
is
as
plate
on the right.
rear
surface
(G2-LI)
when
falling
pin
side.
of the valve
plate
installing
prevent
to
with it
out.
F23501342
5)
Install pump *
O-rings
and
backup
rings
(26)
to
rear
at 2 places.
The
O-ring
and
backup
ring
cannot
be used
again. 6)
Install gasket +
7)
(19).
The gasket
Coat
bearing
cannot
plate
be used again.
(27)
of
rear
pump
with
en-
gine oil (EO SAEl OW).
8)
Stand section t
rear
When center
302
68
pump
(77) upright,
(18) to rear pump installing, section
valve
be
from
and
install
center
top.
careful
not
plate fall out.
to
let
the
Method @
of tightening
Tighten right
@
in
bolts
turn
2 bolts
marked
%
in
diagram
until center
section
(18) is in close contact.
If bolt
becomes
difficult
to tighten
is still
not in close
contact,
but center
loosen
bolts
on
section
and tighten
again. @
Install
remaining
6 bolts and screw
them
in.
F2350134:
@
Set
pump
order m *
on
shown
its
side,
in diagram
and
tighten
8 bolts
(16)
in
on right.
Bolt: 62.8 f 5.9 Nm (6.4 + 0.6 kgm) Lay
rubber
damage
mat
0
under
to the ports when
the
pump
to
prevent
tightening.
F23501344
9)
Measure i)
Set
shaft end play of rear pump tool
B to
rear
shaft,
play with dial gauge. Standard end play: 0.15 ii)
If
measurement
adjust
is
and
measure
end
0.41 mm
outside
standard shim (23) again in Item 11.2).
End play too large:
Add shims
End play too small:
Remove
shims
range,
F23601345
12. Front pump 1)
Install shim (23) to center *
Install
the
same
section.
thickness
of
shim
as was
disassembled. 2)
Install *
bearing
Install
as when *
Coat
Align
bearing
with
grease
valve The
plate
*
with
prevent
when
cup from
(20) with of
the
pin
front
in the diagram
Coat
same
position
installing
falling
hole
to
out.
“g”,
and
in-
is
as
section.
shape
shown
section.
in the
(G2-LI)
the bearing
stall to center *
cup
disassembling.
prevent
3)
cup (22) to center
the
grease
the valve
valve
plate
on the right.
(G2-LI)
when
plate from
installing
falling
to
out.
F23501346
4)
Install coupling
5)
Install pump *
(21) to center
O-rings
and
backup
section.
rings
(26)
The
O-ring
and
backup
ring
cannot
again. 6)
Install gasket *
to
front
at 2 places.
(19).
The gasket
3oi!70
cannot
be used again.
be used
7)
Coat
bearing
plate
(27)
with
engine
oil
(EO
SAEI OW).
8)
Install front *
valve
Method @
0
pump
Be careful
to
let the
section
(18).
bearing
plate
and
diagram
on
plate fall out.
of tightening in turn
Tighten
(17) to center
not
bolts 2 bolts
marked
%
in
right until center
section
(18) is in close contact.
If bolt
becomes
difficult
to tighten
is still
not
in close
contact,
but center
loosen
bolts
and
, section tighten
again. 0
Install
remaining
6 bolts and screw
them
in.
F23501343
@
Tighten
8 bolts
(16)
in order
shown
in diagram
on
right. m *
Bolt: 62.8 k 5.9 Nm (6.4 + 0.6 kgm) Lay
a rubber
damage
mat
under
to the ports when
the
pump
to
prevent
tightening.
F23501345
9)
Measure i)
Set
shaft end play of front tool
C to front
pump
shaft,
and
measure
end
play with dial gauge. Standard ii)
If
end play:
measurement
0.15 is
0.41 mm
outside
standard
range,
adjust shim (23) again in Item 12.1). End play too large: Add shims End play too small:
13. Assembly 1)
Remove
shims
of servo valve assembly
Install w
plug (68) to cover
(61).
Plug: 14.7 Nm (1.5 kgm)
235CD02096
2)
Install *
To
O-ring
thread
3)
with
Install sleeve m
302 72
(82) to sleeve
prevent
damage
seal tape before
(64) to cover
Sleeve:
(64). to the
O-ring,
wrap
the
inserting.
(61).
86.3 Nm (8.8 kgm)
61
64
4)
Install
plug (68A) to housing.
m
5)
Plug:
Install
14.7 Nm (1.5 kgm)
pin (74) and spring
(78) to housing
with
plug
(77). m
6)
24.5 Nm (2.5 kgm)
Install
plug (77) to housing.
m
7)
Set
24.5 Nm (2.5 kgm)
pin
(67) to servo
piston
(66), then
insert
in
housing. Q *
Servo Insert places) piston
so of
piston:
Engine
oil (SAE IOW)
that
the
chamfered
the
large
diameter
are at the top (spring
portions of
chamber).
the
(2 servo
8)
Install link (76) to servo piston (66). m *
Bolt( 71): 111.8 Nm (11.4 kgm) Use a jig for holding the link.
66
71
LJ 235FO2248
9)
Insert spool (83) in housing (60). Q
Spool: Engine oil (SAEIOW)
235COO2087
10) Assemble
spring (84) in housing.
8?
235CDO2OBe
11) Assemble
spring (63) in housing.
I 30274
235CDO2084
12) Install
O-ring
(72) and back-up
ring (73).
2?5COO2083
13) Insert
piston
(65) in sleeve
Piston:
Q
Engine
(64).
oil (SAEI OW)
235COO210;
14) Install
gasket
(62) to housing.
235COO2103
15) Install
cover
(61)
to
housing,
and
tighten
with
bolt (81). *
Be careful
f
When bolts tighten m
not to let the piston
tightening on
the
bolts,
diametrically
all the other
drop out. first
opposite
tighten
two
sides,
then
bolts.
Bolt: 32.4 + 2.9 Nm (3.3 + 0.3 kgm)
235CDO21OL
16) Fit O-ring to plug (69) and install to housing.
17) Install *
O-ring
(79) and back-up
ring (80).
a small amount
of grease.
Coat with
235COO2078
14. Servo valve assembly 1)
Install
2)
Move
swash
(front
cover
* 3)
*
plate
(43) fully
or rear cover cannot
in direction
of arrow
side).
be used again.
link “h” of servo
swash
for F and R pump)
(common
(15).
The gasket
Align *
gasket
valve
(14) and
pin “i” of
plate, then install.
Check
that
backup
rings fitted
The
O-ring
there and
are
the
O-rings
and
the
to the servo valve.
back-up
ring
cannot
bolts
in
be used
again. *
Tighten shown w
the
mounting
in the diagram
the
order
below.
Bolt: 62.8 + 5.9 Nm (6.4 + 0.6 kgm)
--
F23501349
F23501348
15. LS valve (common 1)
Install 3 plugs Plug:
w
2)
Insert spool *
3)
14.7 Nm (1.5 kgm)
(87) in housing.
Be careful correct
for F and R pump) (68).
to
insert
If it is necessary
to
the vice at the position Insert
spring
holder
(89).
Fit O-ring w
facing
in the
to housing.
Plug: 23.5 i 7.9 Nm (2.4 + 0.8 kgm)
m
5)
spool
Fit O-ring to plug (85) and tighten *
4)
the
direction.
holder
use
a vice,
shown
clamp
with
by the arrow.
(93), spring
(92), and
to plug (90) and tighten
to housing.
spring
235FO2252
Plug: 122.6 i 9.8 Nm (12.5 f 1.0 kgm)
235FO2251
6)
Install 3 O-rings
(94).
16. Installation
of LS valve
Install LS valve (10) to servo valve with bolt (11). *
When
installing,
check
that
3 O-rings
are fitted
to the mating surface. *
See
the
diagram
tightening m
for
details
of
the
order
for
the bolts.
Bolt: 29.4 -
35.3 Nm (3.0 -
5
3.6 kgm)
3
‘w
235FO2256
17. Plugs Install 3 plugs (8). w
plug: 117.7 + 9.8 Nm (12 &- 1
18. Seal assembly 1)
kgm)
(front side only)
Install rotating seal (7). *
Do not use dirty
hands
or wear
gloves
for
side with
the
this operation.
2)
Install seal assembly &
3)
(6).
O-ring: Grease (G2-LI)
Install snap ring (5). *
Install
the
snap
ring with
curve facing the outside.
the
REMOVAL OF HYDRAULIC CONTROL VALVE ASSEMBLY
A 1.
Lower
work
equipment
completely
to
the
ground. Disconnect
cable
from
negative
(-)
terminal
of bat-
tery. 2.
Loosen w
:
drain
plug and drain
Hydraulic
tank:
hydraulic
oil.
108 Q
j235FO2244
3.
Remove
control
levers
(2)
from
hydraulic
control
valve.
4. 5.
Remove Remove
covers
11 hoses
(7), then remove *
There
(3), (4), and (5) from
are
and
tubes
platform.
(6) from
bolts (IO), and control 13 hoses
and
tubes
control valve
when
valve
(7). the
ripper
control
valve
is installed. 6.
Remove
11 hoses
(9), then remove
and
tubes
(8) from
bolts (IO), and control
valve
(9).
/
/I
INSTALLATION OF HYDRAULIC CONTROL VALVE ASSEMBLY 1.
Install
control
valve
hoses and tubes 2.
Install
control
valve
hoses and tubes
3.
Install
4.
Install control
5.
6.
Close
covers
drain
(9) with
(8) to control (7) with
bolts
(IO),
valve
(7).
and
connect
and
connect
(3), (4), and (5) to platform. levers
plug
(2) to hydraulic
(1) and
(11) to specified
Q
Hydraulic
tank:
cable to negative the
to
hydraulic
valve.
oil
through
108 II
*
engine
add
control
level.
Connect
system.
(lo),
(6) to control
oil filler
Run
bolts
valve.(g).
(-)
terminal
circulate
the
of battery. oil through
the
Then check the oil level again.
35FO2257
DISASSEMBLY
* * *
Be
careful
to
scratches Be
check
or
that
there
is
CONTROL VALVE
no
dirt
or
careful
not
to
damage
the
sliding
surface
other
the
parts,
spools,
mark
shuttle
valves,
with
tags
to
same valve
9. Pull out spool
to
assemble
10. Remove
be sure
in the
1)
case.
*
(1) and
(2) with
a box
wrench,
and
nuts
(1)
and
(2)
fitted
to
the
stud
out
2)
Remove
each
valve
Make
match
of each valve
Remove
O-rings
body
assembly
from
stud
5. Loosen
marks
on
the
mating
surface
valve
spring
(22).
fly. off.
plug (23), then pull out spool
(24).
(7) and (8) from valve
cap (25).
Remove
locknut
(27) from
cap (25).
Remove
collar
valve
assembly
(12),
and
(9).
remove
removing
let the spring spool
seal (17) with
bolt
collars
a screwdriver.
lever,
be careful
and
backup
plug (32), then pull out spool
not
to
remove
oil
of pilot
relief
ring
(33).
valve
2)
Loosen
cap
*
(13),
fly off.
(16) towards
(29),
screw
(31).
pilot relief valve
3) (12),
(with
adjustment
(28), o-ring
Remove move
(14), and plate (15).
When
(26) and
1)
cap (11). 2
valve
body.
washers bolt
compensation
screw)
(30), and spring
body.
2 bolts (IO), and remove
6. Loosen
7. Push
compensation
not to let the spring
Remove
13. Disassembly 4. Pull out shuttle
*
a screwdriver.
screw)
of pressure
Remove 3. Remove
spring
(19).
cap.
cap (21), then remove
Be careful
12. Removal
(5) and (6).
*
spring
pressure
adjustment
adjustment
bolts.
bolts
plate
nuts (3) and (4).
Leave
2. Pull
of
(without *
nuts
(16) from
oil seal (20) with
11. Removal
assembling,
loosen
(18), and remove
distin-
guish the location.
1. Hold
2 bolts
surface.
disassembling
any
When
8. Loosen
on any part.
and the mating When
OF MAIN
nut
adjustment
assembly
and
nut
screw
(34).
(36), then
(37)
and
2
reseal
(38).
Be careful
Remove
(35)
spring
and backup
not to let the spring (40),
valve
ring (43) from
(41),
valve
fly off. o-ring
body
(39).
(42),
1
235F501
30;
83
ASSEMBLY
Be
careful
scratches Be
OF MAIN
to
check
careful
any
not
to
no
dirt
or
damage
the
the
spools,
match
location
the same valve Replace
sliding
surface
shuttle
with
and
tags
be sure
valves,
used
the
1)
to
assemble
in
case.
O-rings,
sliding
of
backup
rings,
and
surface
with
engine
before
Insert
spool
(47) to plug
of pilot relief valve
Insert
valve
body
(39),
(41) and
and
spring
screw
in
(40)
in
valve
adjustment
screw
(24)
spring
There
in
valve
body,
then
install
to valve
(23) and
fit
(22) in cap (21).
are two
springs
in the
circle
rota-
tion only. 3)
Fit
O-ring
valve
4. Install
(48)
to
cap
(21)
and
install
to
case.
m
1)
valve
Plug: 78.5 k 9.8 Nm (8 + 1 kgm)
Insert *
assembling. Assembly
compensation
screw)
O-ring w 2)
oil seals oil
pressure
adjustment
case.
or
to distin-
new parts.
Coat
3. Assembly (without
the
parts,
the
with
is
surface.
assembling other
guish
there
on any part.
and the mating When
that
CONTROL VALVE
Cap: 78.5 + 9.8 Nm (8 F 1 kgm) oil seal (20) to valve
&
body.
Lip of oil seal: Grease
(G2-LI)
(37) lightly. 2)
Tighten nut
2 washers
(35)
to
(38),
nut
adjustment
(36),
screw
and
(37)
cap
tempo-
5. Insert spool *
(16) in valve
Be careful
body.
not to damage
the oil seal.
rarily. 3)
Install valve
4)
backup body
ring
(43)
and
Fit O-ring
(44) to pilot
relief
(34), and install to valve
case.
m
O-ring
(42)
to
(39).
Pilot relief valve:
valve
@El
assembly
After
adjusting
pilot
relief
the
valve,
set
pressure
tighten
nut
of the and
cap nut (35) fully.
2.
m
Nut: 44.1 + 4.9 Nm (4.5 i
m
Cap nut: 44.1 14.9
Assembly
of
pressure
(with adjustment
screw)
1)
(33)
Insert
spool
O-ring
(45) to
plug
0.5 kgm)
Nm (4.5 + 0.5 kgm)
compensation in
valve
(32) and
valve
body,
then
install
to valve
fit
case. m 2)
Plug: 78.5 & 9.8 Nm (8 k 1 kgm)
Install collar
3)
backup
ring
Tighten
adjustment
to
(25)
cap
Fit valve m *
O-ring
screw
temporarily,
(46)
O-ring
(29)
to
(27) and
and
locknut
insert
collar
to
cap
(25)
and
install
to
case. Cap: 78.5 f 9.8 Nm (8 k 1 kgm) Tighten
the
locknut
fully
after
adjusting
body.
Lip of oil seal: Grease
8. Assemble
plate
(14) to valve
(15),
body,
Bolt: Thread
m
Bolt:
9. Insert m
(G2-LI)
2 collars
(13),
then tighten
&?YZ
tightener
O-rings
12. Insert
valve
2 bolts
valve
0.1 kgm) body.
(7) and (8) to each valve body
in
stud
bolts
as for disassembly.
*
not
let the O-ring 13. Tighten
(10).
(9) to each valve
the same order Be careful
spring
(LT-2)
Bolt: 7.8 + 1.0 Nm (0.8 i
11. Install
and
bolt (12).
11.28 + 1.47 Nm (1.15 k 0.15 kgm)
cap (1 I), and tighten
10. Insert shuttle
(31) in cap.
the set pressure.
3Oi.84
and
(28).
(28) and spring 4)
(30)
oil seal (17) to valve
&
(36)
2 bolts (18).
Bolt: 7.9 k 1.0 Nm (0.8 & 0.1 kgm)
7. Install
68.6 f 9.8 Nm (7 * 1 kgm)
*
6. Fit plate (19) and tighten
to bend
the
protrude.
nuts (2) and (3).
m
Nut (2): 58.8 Nm (6 kgm)
w
Nut (3): 98.1 Nm (10 kgm)
body.
(5) and shuttle
(6)
valve
in or
LO
27/
34
235F501
302
85
DISASSEMBLY
OF CIRCLE ROTATION
MOTOR
Serial No.: 11001 - 12050 Special tools No.
1
A
1
A,
1 790-445-6210
1 * Stand
A,
1
790-445-6220
/ . Stud bolt
A,
1
790-445-6230
/ * Stud bolt
I
1
A., /
790-445-6240
I * Handle
2
/
790-445-6250
) . Nut
I
A, A,
1
01010-31045
1 - Bolt
A,
1
01643-31032
1 * Washer
I 2 I 4 I 4
A,
1
04025-00332
I . Spring pin
I
2
B
I
790-445-6260
I Plate
1
B,
/
790-445-6270
I . Plate
I
B,
1
01010-31030
1 - Bolt
790-445-6200
4 * *
I
Part No.
1 Stand
to check
that
Be
careful
I 1 I 1
F23501351
I 1 I 5
there
5
is no dirt
or scratches
not
to
damage
Remove
drain
2.
Remove
plug (2) from
3.
Set
shaft
secure *
plug (1) and drain
facing
with
Install
Insert
bolt
sliding
surface
and
put
stud
oil from
plate (3).
motor
(As) in the
motor,
hole
F23501352
on stand
(A,), then
(A,). for
the
piping
flange
bolt. bolt
retainer
secure
up,
retainer
bolt (AJ and washer
mounting
from
the
surface.
1.
5.
[MY
on any part. the mating
4.
assembly
* Washer
01643-31032
Be careful
Part NekF\c
(A,)
plate
with
nut
spring
pin (A&.
Loosen
bolt
(5),
in
hole
of
(3), screw (A&
and
and
plug
(2)
into
cylinder
install
handle
remove
cover
(6),
6,
‘P-l
5
removed block
(4),
(AJ
and
O-ring
(7),
and shim (8). *
Make
match
marks to cover
(6) and case (9).
F23501353
30-186 0
*
Be careful
not
shaft when
removing
6. Loosen
bolts
(9) from 7. Fit
(ll),
damge
oil
seal
(IO)
with
the
and
pull
out
case
secure
with
(14)
while
the cover.
(12),
and
(13),
top.
plate
(B,)
to swash
bolt (B,) and washer 8. Using
gear
pulling *
to
puller,
out inner
Be careful
9. Remove
plate
(14),
and
(BJ remove
swash
race of bearing
not to let pistons
plate (B,) from
swash
plate
(15). (16) fall. plate (14). I
I
10. Remove
piston
11. Remove
stud
(16) and springs bolt
(4), then remove
(A,)
screwed
cylinder
block
*
Be careful
not to remaining
*
Be careful
not to let timing
12. Remove
pistons
13. Remove
timing
14. Using from
gear retainer
15. Loosen plate plates
bolts
(16) inside
puller,
into
block
pistons
(16) fall.
plate (18) fall out.
cylinder
remove
cylinder
F23501354
(4).
plate (18), spring inner
block
(4).
(19), and pin (20). race
of bearing
plate
(3) and
(21)
plate (3). (22) from
(14), then
remove
(24), and slippers
16. Remove
(17) at shaft end.
retainer retaining (25).
O-ring (26) from retainer
swash
rings (23), retaining L
F23501355
plate (3).
F23501356
17. Remove sleeve *
O-ring (27) fitted
Do not
(28)
and
to retainer
remove
backup
ring
(29)
from
plate (3).
sleeve
(27) except
when
replac-
ing it. 18. Remove block
19. Remove *
outer
race
of
bearing
(21)
from
cylinder
(4).
Insert
oil seal (10) from pins
in two
cover holes
(6). of the
cover,
and
pull
out the oil seal.
F23501356
F23501357
ASSEMBLY Serial
OF CIRCLE ROTATION
MOTOR
No.: 11001 - 12050
Special tools No.
CL3
01643-01232
* Washer
1
C,
04205-00835
. Pin
1
C 10
04205-01038
* Pin
1
C,,
04052-00833
. Snap pin
1
C 12
04052-01038
. Snap pin
1
Be careful
to check
that
there
is no dirt
Part No.
Part Name Inserting
Q’ty
D
790-445-6400
D,
790-445-6410
. Push tool
D*
790-445-6420
. Inserting
E
790-445-6430
Top hat ass’y
1
B,
790-445-6440
. Top hat
1
E2
01010-31035
. Bolt
1
B,
01643-31232
. Washer
1
F
790-445-6450
F,
790-445-6460
Adjusting
tool ass’y
1 1
tool
1
tool ass’y
1
* Shim adjusting
,
tool
F,
1 01010-31055
1 . Bolt
I
4
F,
1 01643-31032
1 * Washer
I 4
F,
1 01050-31030
1 . Bolt
I
3
or scratches
on any part. Be
careful
the mating Coat
the
before Replace
not
to
damage
the
sliding
surface
and
surface. sliding
surface
with
engine
oil
(EOlO-CD)
assembling. the O-rings
and oil seals with
new parts.
30-189 0
1.
Fit O-ring 6
(26) to retainer O-ring:
2.
Knock sleeve
3.
Install
Grease
plate (3). (G2-LI)
(27) into retainer
backup
ring
(29)
plate (3).
and
O-ring
(28)
to
sleeve
(27) in order. & 4.
ring, O-ring:
Install
stoppers
taining
ring (23) to retainer
B 5.
-
Backup
(25),
Grease
retaining
(G2-LI)
plate
plate (3) with
(24),
and
16.n
A---‘
re-
bolts (22).
25.
Bolt: 5.9 Nm (0.6 kgm)
Shrink
fit inner
race
of bearing
(21) to retainer
plate
(3) to install. * 6. 7.
Shrink-fitting
Insert spring Install
Pin: Grease
Put retainer bolt (4)
9.
plate
plate
plate (18)
(AJ, and spring
13o’C
plate (18).
(G2-LI) (A,),
and
secure
with
(27), and secure
tim-
(A,).
(18) on sleeve with
Max.
(27).
(3) on stand
and washer
Put timing ing
(19) in sleeve
pin (20) to timing
& 8.
temperature:
stud
bolt
(AJ,
nut
(A,),
F23501356
handle
pin (A,).
F23501358
*
When
assembling
metrically the
to the
high
side
of retainer 10. Knock
timing
plate
left and
and low
(18),
right
side
set
of the
it sym-
line joining
of the angled
surface
plate (3).
outer
race
of bearing
block
(4) to retainer
(21) into
cylinder
block
(4). 11. Set cylinder
plate
(3) secured
to
stand. 12. Remove
stud bolt (As) holding
13. Fit stud retainer *
bolt
(A*), and
slipper
(25) with
of the cylinder 14. Fit piston
s! z 8
t
cylinder
(18).
block
(4) and
the
position
of the
bore
block.
rings (30) to pistons
pistons
der block 16. Insert
secure
plate
plate (3).
Align
15. Insert
timing
(16).
(16) at retainer
plate
(3) end
in cylin-
(4).
springs
Set the
(17) in cylinder piston
at the
block retainer
(4).
F23501356
plate
end
in posi-
tion securely. 17. Install *
retention
Align
tools (C, - C,,) to cylinder
stopper
(C,) with
the
position
block
(4).
of the
piston
hole. 18. Using
inserting
at swash
plate
tools
(D,) and
(14) end,
then
(D,),
insert
piston
stop
piston
with
(16) stop-
per (C,).
F23501359
F23501360
19. Install
slippers
(25),
retaining
ing ring (23) to swash w
Bolt:
20. Set
swash
(4). * Align
(24),
and
retain-
bolts (22).
5.9 Nm (0.6 kgm) plate
(14)
the thick
tainer
plate
plate (14) with
plate
in
sides
(3) so
position
on
of swash that
cylinder
plate
they
are
block
(14) and on
the
re-
same
side. 21. Set top
hat (E,) over
washer
(EJ
tighten
24. Set
shaft,
bolt
then
hole
in
retention
positioning case
(9)
tools
pin to swash over
cylinder
&
Bolt: Thread
tightener
w
Bolt: 78.5 Nm (8 kgm) seal
washers
(31)
to
case (9) and swash
(14).
block
(4),
to
then
secure
bolt (13).
(l-T-2)
bolts
Q&z
Bolt: 46.1 Nm (4.7 kgm)
(11)
and
tightener
(12),
then
(LT-2)
top hats (E, - EJ and stud bolt (A,). fit inner
race
of bearing
(15) to shaft,
stall. *
(E2) and shaft
plate (14).
Bolt: Thread
27. Shrink
plate
(3) with
&
26. Remove
of
(C, - C,,).
plate
tighten
bolt
face
F23501361
case (9) and retainer
25. Fit
screw
end
top hat (E,).
22. Remove 23. Install
into
Shrink-fitting
temperature:
Max.
130°C
then
inF23501362
F23501363
28. Knock outer 29. Adjusting 1)
2)
race of bearing
(15) into case (9).
shim
Put
shim
adjusting
tighten
to
washer
(F3).
Tighten
swash
3 bolts
tool plate
(F,) on (14)
case
with
(F,), and press
(9),
bolt
fit
and
(F2) and
bearing
outer
race (15). *
Make sure that it goes down w
* 3)
uniformly.
Bolt: 9.8 Nm (1 kgm)
Rotate the shaft at the same time.
Using
each
measure
hole
of
clearance
race
and
take
the
end
face
average
shim
adjusting
between of of
end
shim
each
face
adjusting dimension
tool of
(F,), outer
tool,
and
as dimen-
sion X.
X=A-B * The each
F23501364
difference place
of
between
the
dimensions
measurement
shall
at
be within
0.05 mm.
4)
Measure
dimension
and dimension
.
When
adjusting
(6) when
Calculate 0.1
Y, - Y, = 2 from
mm
(X + Z) and to
decide
the
add shim
(F,)
installed.
dimension
X.
Remove
shim adjusting
X.
a preload thickness,
of 0.05
-
then
in-
I
15 F23501365
stall the shim.
6)
FI
WhenY,
5)
tool
F4
Y, > Y,
Subtract
.
Y, of shim
Y, of cover
F3
F2
tool.
F23501366
30. Knock oil seal (10) into cover Lip of oil seal: Grease
& 31. Fit O-ring
32. Install
cover
(G2-LI)
(6).
(7) to cover O-ring:
&
Grease
(G2-LI)
(6) to case (9) with
bolt (5).
Bolt: 62.8 Nm (6.4 kgm)
w 33. Rotate *
(6).
34. Install
rotating
shaft, and measure
Rotating
torque:
torque.
6 kgm
plug (2) to retainer
plate (3). F23501367
F23501368
F23501352
30294
DISASSEMBLY
AND ASSEMBLY
DISASSEMBLY Serial
CIRCLE ROTATION
OF CIRCLE ROTATION
MOTOR
MOTOR ASSEMBLY
No.: 12051 and up
I
\
J
1.
2. 3. 4. 5. 6. 7.
Bolt (5 or 7) IA. Bolt (7) IB. Bolt (7) IC. Bolt (7) End cover Seal ring Seal ring Commutator Commutator ring Manifold
8. Rotor set 8A. Rotor 8B. Stator half 8C. Vane 8D. Stator half 8E. Vane 9. Wear plate IO. Drive link 11. Thrust bearing 12. Coupling shaft 12A. Key 12B. Nut 12C. Washer 12D. Bolt 12E. Lock washer 12F. Retaining ring
DWG00277
13. 14. 15. 16. 17. 18. 19. 20. 21.
Bearing (inside) Thrust washer Thrust bearing Seal Backup washer Housing Bearing (outside) Seal Backup washer
30-194-l 0
DISASSEMBLY
1.
AND ASSEMBLY
CIRCLE ROTATION
MOTOR
Remove shaft key (12A), bolt (12D), washers (12E) and (12C), and retaining ring (12F). Ir Polish the area around the key groove on the shaft and remove all burrs and flashes.
DWG00278
2.
Fix motor in vice and make mark to prevent it from moving out of position. * Grip the flange portion of the motor in the vice.
3.
Remove
7 bolts
4.
Remove
end cover
30-194-2 0
(I) from
end cover
(2).
(2) and seal ring (4).
Mark
/
DISASSEMBLY
AND ASSEMBLY
5.
Remove
commutator
ring (6).
6.
Remove
commutator
(5) and seal ring (3).
7.
Remove
manifold
CIRCLE ROTATION
MOTOR
(7).
DWGO
8.
Remove rotor set (8) together with wear plate (9), then remove drive link (IO) and thrust bearing (II). Lift rotor set (8) up together with the wear * plate to prevent the rotor set from coming apart. Make a mark to indicate the top surface of * the rotor set.
30-194-3 0
DISASSEMBLY
AND ASSEMBLY
9. Pull out coupling
CIRCLE ROTATION
shaft (12) from housing
MOTOR
(18).
10. Pull out inside bearing (13) from housing (18). Ir Measure the mounting depth (position) of bearing (13) and note the measurement.
=,
11. Remove
thrust
bearing
(15) and thrust
washer
(14).
12. Remove (17).
30-194-4 0
seal (16) and backup washers
(21) and
DWG00287
DISASSEMBLY
AND ASSEMBLY
13. Remove seal (20) and pull out outside (19) from housing (18).
CIRCLE ROTATION
MOTOR
bearing
30-194-5 0
DISASSEMBLY
CIRCLE ROTATION
AND ASSEMBLY
ASSEMBLY
OF CIRCLE ROTATION
MOTOR
MOTOR ASSEMBLY
Serial No.: 12051 and up
DWG00277
1.
2. 3. 4. 5. 6. 7.
Bolt (5 or 7) IA. Bolt (7) IB. Bolt (7) IC. Bolt (7) End cover Seal ring Seal ring Commutator ring Commutator Manifold
30- 194-6 0
8. Rotor set 8A. Rotor 8B. Stator half 8C. Vane 8D. Stator half 8E. Vane 9. Wear plate 10. Drive link 11. Thrust bearing 12. Coupling shaft 12A. Key 128. Nut 12C. Washer 12D. Bolt 12E. Lock washer 12F. Retaining ring
13. 14. 15. 16. 17. 18. 19. 20. 21.
Bearing (inside) Thrust washer Thrust bearing Seal Backup washer Housing Bearing (outside) Seal Backup washer
DISASSEMBLY
AND ASSEMBLY
CIRCLE ROTATION
* *
Replace all seals and bearings with new parts. Wash all parts with a petroleum-based solvent, then blow with air to dry.
1.
Press fit outside bearing (19) to housing (18). * Press-fitting depth (from flange surface): 7.37 - 7.87 mm & Bearing : Grease (G2-LI)
2.
Press fit seal (20) to housing (18). * Press-fitting depth (from end face of flange): 0.5 mm
3.
Install
backup
washers
MOTOR
(17) and (211, and seal
(16). * Install seal (16) with the lip at the top (the inside of the motor).
Inset-t thrust
washers
(14)
(15). * Install so that washers both sides.
5.
and thrust
bearing
hold the bearing
on
Press fit inside bearing (13) to housing (18). + Press-fitting depth (from flange surface) : 2.67 - 3.18 mm
=,
DWG00287
DISASSEMBLY
CIRCLE ROTATION
AND ASSEMBLY
6.
Install coupling shaft (12). * To prevent damage to the seal, wind masking tape around the key groove before installing. . Grip housing (18) in a vice. . If the assembly is made correctly, the coupling shaft will be approx. 2.5 mm lower than the mounting surface of the housing wear plate.
7.
Insert thrust bearing (II), (4) to housing (18). 6 Seal ring : Grease
8.
and install
seal ring
(G2-LI)
Install drive link (IO), then put wear it.
plate (9) on
9. Install seal ring (4) to rotor set (8), then put wear plate (9) on it. * Install with the seal ring side at the bottom. * Replace seal ring (4) between stators (8B) and (8D) of the rotor set with a new part. & Bearing : Grease (G2-LI)
30-194-8 0
MOTOR
DISASSEMBLY
10. Install (7). &
CIRCLE ROTATION
AND ASSEMBLY
seal ring (4) in seal groove Seal ring : Grease
MOTOR
of manifold
(G2-LI)
11. Put manifold (7) on rotor set (8). Ir Be careful to install the manifold the right way up. (Set it so that the oil passage hole with the large diameter pitch is at the bottom (rotor set side).)
/
12. After installing seal ring (4) in seal groove manifold (71, install commutator ring (6).
I II
---lJ---
I\
DWG00296
of
_=;i=;_
1 DWG00297
13. Install seal ring (3) to commutator (5), then install so that head of drive link enters hole in center of commutator.
3
DWG00298
30-194-9 0
DISASSEMBLY
AND ASSEMBLY
14. Install seal ring (4) in seal groove (2). &
Bearing
CIRCLE ROTATION
of end cover
4
/
MOTOR
\
I
: Grease (G2-LI)
15. Put end cover (2) on commutator ring (6), and install bolts (I). m Bolt : 67.7 + 6.9 Nm IS.90 + 0.70 kgm1
Bolt tightening order
DWG00300
16. Install shaft key (12A), bolt (12D), washers (12E) and (12C), and retaining ring (12F). * Check the direction of rotation of the motor. Direction of rotation of motor (seen from output shaft side) When pressure oil is applied to port A: Counterclockwise When pressure oil is applied to port B: Clockwise (Thread size of ports A and B: 518 - 14UNF)
B port /
I
30-194-10 0
DWG00278
REMOVAL OF DRAWBAR SHIFT CYLINDER, BLADE LIFT CYLINDER, LIFTER GUIDE
A A
Lower work equipment Stop
the
times
the remaining
engine.
completely
Operate
to the ground.
control
pressure
lever
from
several
the hydraulic
piping.
1.
Drawbar
shift cylinder
Disconnect
2.
hoses
(2)
cylinder
(1) and remove
kg C?YI
Drawbar
Blade
lift cylinder
I)
Temporarily connect and
and
(3)
from
drawbar
shift cylinder:
72 kg
sling blade lift cylinder
(41, then dis-
hoses (5) and (6) from blade lift cylinder
remove
cylinder
head
end
from
joint (7).
2)
shift
it.
Loosen bolt (81, and remove
holder (9).
drawbar
3) Remove blade lift cylinder assemblv (1 1) from lifter guide (10). kg tT?z
3.
Upper 1)
lifter
B
Blade lift cylinder assembly: 158 kg
guide
Sling upper lifter guide (101, then remove nut (12) and bolt (13). Upper lifter guide: 96 kg
2)
4.
P2350
F424
P2350
i 425
P2350
I427
Sling and remove upper lifter guide (10).
Lower
lifter
guide
1) Sling lower lifter guide (14). Loosen bolt (15) and pull out bank control pin assembly (16). A m 2)
Lower lifter guide: 550 kg
Sling lower lifter guide (14) and lower.
INSTALLATION OF DRAWBAR SHIFT CYLINDER, BLADE LIFT CYLINDER, LIFTER GUIDE
1.
Lower lifter guide 1)
Sling
lower
lifter
guide
(14)
guide hole 1s and main frame
& kg
2)
2.
Lower lifter guide:
and
lift
up align
hole 8.
550
install bank control pin assembly
kg
(16).
Upper lifter guide Sling
upper
tighten
kg C!z! * w
lifter
guide
(lo),
insert
shim
(17)
and
bolt (13) and nut (12). Upper
Standard
lift guide:
96 kg
shim thickness:
Mounting
2.0 mm
bolts: 539.4 & 49.0 Nm (55 k 5 kgm)
P2350
I425
P2350
I430
3.
Blade lift cylinder 1) Temporarily sling blade lift cylinder (4) and insert in upper lifter guide hole. kg &?I
4.
Blade lift cylinder: 158 kg
2)
Fix with holder (9) and bolt (8).
3)
Install blade lift cylinder head side to drawbar ball joint (7) and connect hoses (5) and (6).
Drawbar shift cylinder Install drawbar shift cylinder (1) head side to lifter guide ball joint (18). Install bottom side to drawbar ball joint (191, and connect hoses (2) and (3). & kg
Drawbar shift cylinder: 72 kg
REMOVAL OF ARTICULATE ASSEMBLY 1.
Disconnect remove
A
head
greasing
tube
(1) from
CYLINDER
pin
(2), then
bolt (3) and pin (2).
If it is difficult sidual nut
to remove
pressure
of hoses
the
pin
in the cylinder, (4) and
because
loosen
of re-
the sleeve
(5) to discharge
the
resid-
ual pressure. 2.
Disconnect
hoses (4) and (5) from
3.
Sling articulate
4.
Remove
5.
Sling and remove
cylinder
cylinder.
assembly
(6).
bolt (9) and pin (8).
Articulate
articulate
cylinder
assembly
cylinder
assembly:
72 kg
(6).
INSTALLATION OF ARTICULATE CYLINDER ASSEMBLY 1.
Sling
articulate
to mounting it with 2.
3.
Start
(6) and set bottom
then
insert
pin
(8) and
fix
hoses (4) and (5) to cylinder.
Install
hoses without
engine
rod
assembly
(IO),
lock plate (11) and bolt (9).
Connect *
cylinder bracket
and
connecting
insert
pin
twisting
extend
pin
cylinder
holes
(2) and fix
and interference.
with
it with
rod,
holes lock
align
piston
in bracket
plate
(12),
(13) and
bolt
(3). 4.
Connect *
grease
tube (1) to pin (2).
Operate
the
control
cylinder
then
add
tank to the specified
lever engine
to oil
circulate into
the
oil
in the
hydraulic
level.
30?A99
REMOVAL OF REAR MOUNT RIPPER CYLINDER ASSEMBLY
‘A
Lower work equipment
completely
1.
Sling cylinder assembly
(I 1.
2.
Remove
A
to the ground.
lock plate (2) at head end and remove
If it is difficult residual sleeve
to remove
pressure
in
the
the
pin (3).
pin because
cylinder,
nut of the hose to discharge
loosen
of the
the residual
pressure. 3.
Disconnect
cylinder
bottom
hose
(4)
assembly
(1).
and
cylinder
head hose (5) from cylinder. 4.
Remove
5.
Sling and remove &
support
Rear
(6). cylinder
mount
ripper
cylinder
assembly:
130
kg
INSTALLATION OF REAR MOUNT RIPPER CYLINDER ASSEMBLY 1.
Sling
cylinder
mounting
assembly
(11, and set bottom
hole to
bracket.
2.
Install support
3.
Connect
(6).
cylinder
head hose (5) and cylinder
bottom
hose (4). * 4.
Start
Install hoses without engine
and fully
rod hole and bracket 5. 6.
twisting. extend
cylinder.
Align
piston
hole.
Install head pin (13) and fix with lock plate (2). Operate through
the
control
lever
to
circulate
engine
oil
in cylinder. Then add engine oil into hydraulic
tank to be specified
30200
level.
DISASSEMBLY OF HYDRAULIC CYLINDER ASSEMBLY
023502
Serial No.: 11001 – 12502
30-201 (6)
3. Piston and head assembly 1) Set piston rod assembly (6) to tool A1. 2) Using tool A3, remove nut (7). Cylinder Steering Leaning
Width across flats of nut 46 mm 50 mm (*1) 60 mm (*2)
Blade shift
70 mm
Blade lift
70 mm
Drawbar shift
70 mm
Articulate
75 mm
Power tilt
75 mm
Ripper
80 mm
(*1) Serial No.: 11001 – 12050 (*2) Serial No.: 12051 and up
4. Disassembly of piston assembly Remove piston ring (11) and water ring (12) from piston (8). 5. Disassembly of head assembly 1) Remove O-ring and backup ring (13). 2) Remove snap ring (14), then remove dust seal (15). 3) Remove rod packing (16). 4) Remove bushing (17).
30-202 (6)
023502
3) Remove piston (8) and slider (9). a Slider (9) is installed to the steering cylinder only. 4) Remove cylinder head assembly (10).
ASSEMBLY OF HYDRAULIC CYLINDER ASSEMBLY
023502
Serial No.: 11001 – 12502
30-203 (6)
Cylinder Steering
Width across flats of nut 46 mm 50 mm (*1)
Leaning 60 mm (*2) Blade shift Blade lift
70 mm
Drawbar shift Articulate 75 mm Power tilt Ripper
80 mm
(*1) Serial No.: 11001 – 12050 (*2) Serial No.: 12051 and up
30-204 (6)
Nm {kgm} 785 ± 78.5 {80 ± 8} 1,080 ± 110 {110 ± 11} 1,770 ± 177 {180 ± 18} 2,600 ± 260 {265 ± 26.5} 3,330 ± 333 {340 ± 34} 2,600 ± 260 {265 ± 26.5} 3,140 ± 314 {320 ± 32} 2,840 ± 284 {290 ± 29} 3970 ± 397 {405 ± 40.5}
023502
3. Piston, head assembly 1) Set piston rod to tool A1. 2) Assemble cylinder head (10) to piston rod. 3) Fit slider (9) and install piston assembly (8), then using tool A3, tighten nut (7). a Slider (9) is installed to the steering cylinder only. a Wash and remove all grease and oil from the thread of the piston rod where the nylon nut is fitted. 2 Rod thread: Thread tightener (Loctite #262) 3 Piston nut
023502
30-205 (6)
DISASSEMBLY OF HYDRAULIC CYLINDER ASSEMBLY Serial No.: 12503 and up a The symbols used in the special tools and illustrations indicate the following cylinders. Cylinder
1. Set cylinder assemble (1) to tool A1.
Cylinder symbol ST LE BS BL DS AR PT RP
Steering Leaning Blade shift Blade lift Drawbar shift Articulate Power tilt Ripper
Special tools Parts No.
790-502-1003 1 790-502-2000 790-101-1102 2 790-330-1100 790-302-1290 790-102-1320 3 790-102-1330 790-302-1340 790-201-1702 790-101-5021 01010-50816 790-201-1741 4 790-201-1761 790-201-1781 790-201-1791 790-201-1811 790-201-1500 A 790-101-5021 01010-50816 790-201-1550 5 790-201-1570 790-201-1590 790-201-1610 790-201-1620 6 790-702-1000 796-720-1630 07281-00709 796-720-1650 07281-01019 796-720-1650 7 07281-01159 796-720-1670 07281-01279 796-720-1680 07281-01589
30-205-1 (6)
Part Name
Q’ty
Repair stand Repair stand Pump Wrench Socket (60 mm) Socket (70 mm) Socket (75 mm) Socket (80 mm) Push tool KIT • Grip • Bolt • Push tool • Push tool • Push tool • Push tool • Push tool Push tool KIT • Grip • Bolt • Plate • Plate • Plate • Plate • Plate Expander Ring Clamp Ring Clamp Ring Clamp Ring Clamp Ring Clamp
1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1
Remarks
LE BL, BS, DS PT, AR RP
ST LE DS BL, BS, PT, AR RP
ST LE DS BL, BS, PT, AR RP ST LE BL, BS, DS PT, AR RP
023502
Symbol
2. Cylinder head assembly • Power tilt, Blade lift, Drawbar shift, Articulate, Ripper cylinder 1) Remove cylinder head bolt. 2) Disconnect cylinder head assembly (2) from the cylinder. Cylinder
Blade shift cylinder Using tool A2, loosen cylinder head assembly (4) and disconnect from the cylinder. a Do not loosen bolt (18) but disconnect plate (19), collar (20) and cylinder head (4) as an assembly.
Width across flats of mounting bolt 22 mm 24 mm 27 mm
023502
Blade lift, Drawbar shift Power tilt, Articulate Ripper
•
•
Steering, leaning cylinder 1) Raise rotation stopper. 2) Using tool A2, disconnect cylinder head assembly (4) from the cylinder.
30-205-2 (6)
4. Piston and head assembly 1) Set piston rod assembly (5) to tool A1. 2) Using tool A3, remove nut (7). Cylinder Steering Leaning Blade shift Blade lift Drawbar shift Articulate Power tilt Ripper
Width across flats of mounting bolt 46 mm 60 mm 70 mm 70 mm 70 mm 75 mm 75 mm 80 mm
3) Remove piston (8) and slider (9). a Slider (9) is installed to the steering cylinder only. 4) Remove cylinder head assembly (10).
30-205-3 (6)
023502
3. Piston rod assembly Pull out piston rod assembly (5). a Put a container under the cylinder to catch the oil.
5. Disassembly of piston assembly Remove piston ring (11) and wear ring (12) from piston (8).
•
Blade shift cylinder 1) Remove bolts (18) (width across flats: 13 mm) to remove plate (19) and collar (20). 2) Remove ring (21) and dust seal (22) from collar (20). 3) Remove O-ring, backup ring (13) and O-ring (23). 4) Remove dust seal (15) and rod packing (16). 5) Remove bushing (17).
023502
6. Disassembly of head assembly • Steering, Leaning, Blade lift, Drawbar shift, Articulate, Power tilt, Ripper cylinder 1) Remove O-ring and backup ring (13). 2) Remove snap ring (14), then remove dust seat (15). 3) Remove rod packing (16). 4) Remove bushing (17).
30-205-4 (6)
ASSEMBLY OF HYDRAULIC CYLINDER ASSEMBLY
2) Using tool A5, assemble dust seal (15).
Serial No.: 12503 and up a The symbols used in the illustrations indicate the following cylinders. Cylinder Steering Leaning Blade shift Blade lift Drawbar shift Articulate Power tilt Ripper
Cylinder symbol ST LE BS BL DS AR PT RP
a Be careful not to damage the packings, dust seals, and O-rings when assembling.
3) Install snap ring (14) to dust seal (15). 4) Install rod packing (16), then install O-ring and backup ring (13). a Do not try to force the backup ring into position. Warm it in warm water (50 – 60°C) before fitting it.
30-205-5 (6)
023502
1. Assembly of head assembly • Cylinders other than blade shift cylinder 1) Using tool A4, press fit bushing (17) to head (10).
•
Blade shift cylinder 1) Using tool A4, press fit bushing (17) to head (10). 2) Using tool A5, assemble dust seal (15). a Take care of the installed direction of the dust seal.
4) Install wear ring (12).
023502
3) Install rod packing (16), O-ring (23), O-ring and backup ring (13). a Take care of the installed direction of the rod packing. a Do not try to force the backup ring into position. Warm it in warm water (50 – 60°C) before fitting it.
2. Assembly of piston assembly 1) Using tool A6, expand piston ring (11). a Set the piston ring on the expander and turn the handle 8 – 10 times to expand the ring. 2) Remove piston ring (11) from tool A6, and install to piston (8). 3) Using tool A7, retract piston ring (11).
4) Set dust seal (22) and ring (21) to collar (20) and install them to head (10). a Take care of the installed direction of the dust seal. 5) Install plate (19) and tighten bolts (18).
30-205-6 (6)
3. Piston, head assembly 1) Set piston rod (5) to tool A1. 2) Assemble cylinder head (10) to piston rod. 3) Fit slider (9) and install piston assembly (8), then using tool A3, tighten nut (7). a Slider (9) is installed to the steering cylinder only. a Wash and remove all grease and oil from the thread of the piston rod where the nylon nut is fitted. 2 Rod thread: Thread tightener (Loctite #262) 3 Piston nut Cylinder
Width across flats of nut
Steering
46 mm
Leaning
60 mm
Blade shift Blade lift
70 mm
Drawbar shift Articulate 75 mm Power tilt 80 mm
4. Piston rod assembly • Steering, blade shift, leaning cylinder. 1) Set cylinder to tool A1. 2) Assemble piston rod assembly (5) to cylinder.
023502
Ripper
Nm {kgm) 785 ± 78.5 {80 ± 8} 1,770 ± 177 {180 ± 18} 2,600 ± 260 {265 ± 26.5} 3,330 ± 333 {340 ± 34} 2,600 ± 260 {265 ± 26.5} 3,140 ± 314 {320 ± 32} 2,840 ± 284 {290 ± 29} 3,970 ± 397 {405 ± 40.5}
3) Using tool A2, install cylinder head (4). 3 Cylinder head Cylinder Steering Blade shift Leaning
Nm {kgm} 441 ± 44.1 {45 ± 4.5} 785 ± 78.5 {80 ± 8} 677 ± 67.6 {69 ± 6.9}
4) Caulk rotation stopper to cylinder. a Steering and leaning cylinder only.
30-205-7 (6)
•
Power tilt, ripper, blade lift, drawbar shift, articulate cylinder. 1) Set cylinder to tool A1. 2) Assemble piston rod assembly (5) to cylinder.
023502
5. Remove cylinder assembly (1) from tool A.
3) Assemble cylinder head (2) to cylinder, then tighten with a torque wrench. 3 Cylinder head mounting bolt Cylinder
Width across flats
Blade lift 22 mm
177 ± 19.6 {18 ± 2}
24 mm
278 ± 32.3 {28.3 ± 3.3}
27 mm
385 ± 42.1 {39.3 ± 4.3}
Drawbar shift Power tilt Articulate Ripper
Nm {kgm}
30-205-8 (6)
REMOVAL OF CIRCLE ROTATION GEAR AND HYDRAULIC OIL MOTOR ASSEMBLY Serial No.: 11001 - 12050
A
Lower
the work
Disconnect
cable
equipment from
to the grond.
negative
(-)
terminal
of bat-
tery. Loosen I
drain
:
plug (1) and drain
Hydraulic
tank:
hydraulic
oil.
108 P
235FO2244
Remove
4.
hoses
Remove
mount
bottom + 5.
bolt
(8), and
tap
dowel
pin
(9) from
to remove.
Dowel
pin: 2 places
Using
eyebolts
mm),
sling
assembly *
(2), (3), (41, (5), (6), and (7).
(Thread
circle
dia.
rotation
(IO), and remove
For details gear
ROTATION
12 mm, and
Pitch
hydraulic
gear assembly
of disassembling
assembly
CIRCLE
=
gear
(II),
see GEAR,
=
1.75
motor
(11).
the clutch
portion
of
DISASSEMBLY HYDRAULIC
OF MOTOR
ASSEMBLY. 6 kg
Circle rotation
gear, hydraulic
motor
assembly:
m
17
235CDO2107
262 kg 1
6.
Remove semf$y
circle
rotation
gear
and
hydraulic
motor
as-
(IO).
235FO227t
30-206 0
INSTALLATION OF CIRCLE ROTATION HYDRAULIC OIL MOTOR ASSEMBLY
GEAR AND
Serial No.: 11001 - 12050 1.
Using
eyebolts,
draulic
motor
and install f
For
gear assembly
(11).
details
of assembly (II),
TATION
Align
circle (IO),
assembly
2.
raise assembly
see
rotation then and
dowel
pin (9) with
on
and
hy-
drawbar,
adjustment
ASSEMBLY
GEAR, HYDRAULIC
gear set
of gear
OF CIRCLE
RO-
MOTOR ASSEMBLY.
pin hole,
and tighten
mount
bolt (8). 3.
Connect
/
7
hoses (2), (3), (4), (5), (6), and (7).
235COO2106
4.
5.
Tighten
drain
plug
(1) and
oil filler
(12) to specified
Q
Hydraulic
tank:
cable to negative
*
the
Run
engine
to
hydraulic
oil through
108 li
Connect
system.
add
level.
(-)
terminal
circulate
the
of battery. oil through
the
Then check the oil level again.
235CDO2107
235FO2244
30-207 0
DISASSEMBLY
CIRCLE ROTATION
AND ASSEMBLY
GEAR, HYDRAULIC
MOTOR
REMOVAL OF CIRCLE ROTATION GEAR, HYDRAULIC MOTOR ASSEMBLY Serial No.: 12051 and up a
Lower the work ground.
equipment
1.
Remove tery.
2.
Loosen drain plug (I) and drain hydraulic A & Hydraulic tank : 108 e
3.
Remove
hoses (2) and (3).
4.
Remove
mount
cable from negative
completely
to the
4-J terminal
of bat-
oil.
bolts (4).
I
I
5.
k
DWG00248
Using eyebolts (Thread = 20 mm, Pitch = 2.5 mm), lift off circle rotation gear and hydraulic motor assembly (5). & kg
Circle rotation gear, hydraulic sembly : 345 kg
motor as-
DWG00249
30-207-l 0
DISASSEMBLY
AND ASSEMBLY
CIRCLE ROTATION
GEAR, HYDRAULIC
MOTOR
INSTALLATION OF CIRCLE ROTATION GEAR, HYDRAULIC MOTOR ASSEMBLY Serial No.: 12051 and up 1. Using eyebolts, motor hydraulic bar.
gear and raise circle rotation assembly (5) and install to draw-
DWG00249
w
Mount
bolts
(4) : 549 + 59 Nm I56 t 6 kgm}
4
4
4
2.
Connect
hoses
DWG00248
(2) and (3).
L
drain plug Tighten filler (6) to specified Hydraulic
(I) and level.
tank
add
oil through
DWG00247
oil
: 108 e
of battery. (-1 terminal Connect negative the oil through Run the engine to circulate * the system. Then check the oil level again.
30-207-2 0
DISASSEMBLY OF CIRCLE ROTATION HYDRAULIC OIL MOTOR ASSEMBLY Serial 1.
No.:
11001
Draining
1)
- 12050
oil
Remove plug (I) and drain oil _ :
2)
Circle rotation gear: Approx.
Circle
Clutch:
rotation
Remove
gear
Approx.
180 mQ
- hydraulic
bolt (3) and dismount
sembly (5) from circle rotation
3.
16 II
Remove plug (2) and drain oil _ :
2.
GEAR AND
oil motor
assembly
hydraulic oil motor asgear assembly (4).
I
9A
2
1
235FO2277
Key
Remove key (6) from hydraulic oil motor assembly
P2350
4.
Clutch
1) 2) 3)
Remove cover (9A). Loosen locknut (7) and remove bolt (8). Remove cover (9).
4)
Remove washer order.
30-208 0
(1 O), spring (1 I), piston (12) in
1483
z z
4)
Remove *
5.
Reverse 1)
Disc:
discs
(13) and plates
6 PCS, plate:
(14) in order.
5 PCS.
gear (with dry clutch)
Loosen shim
bolt
(18A).
(18E), springs
then
remove
(18F), end
plate
cover
(18C),
(18G),
plates
(18H), and discs (18J). 2)
Loosen remove
lock holder
plate
(18L)
(18M),
(18P), gear (18R), and collar
and shims
bolt
(18K),
(18N),
then
coupling
(18T).
Ej -
+ziiib
18H
18J
F235014OI
6.
Cover Remove collar (2 1)
7.
Housing Remove housing (22) and shim (23).
$2350
8.
Worm wheel shaft assembly 1) Remove lock plate, then remove
gear (25)
I466
from
shaft (24). 2)
9.
Remove shaft (24) and washer
(26) from case.
Worm gear . Bearing assembly 1)
Remove
worm
gear
- bearing
assembly
from
case. 2)
Remove
bearing (28) from shaft (27).
P23503468
DISASSEMBLY
AND ASSEMBLY
CIRCLE ROTATION
GEAR AND
HYDRAULIC
OIL MOTOR
ASSEMBLY OF CIRCLE ROTATION GEAR AND HYDRAULIC OIL MOTOR ASSEMBLY Serial 1.
No.: 11001 - 12050
Worm gear . bearing assembly 1) Using press-fit tool ($1751, press fit bearing (28) on shaft (27).
P2350
2)
Inset-t worm into case.
gear
. bearing
assembly
I468
(29)
P2350 9 469
2.
Worm wheel shaft assembly 1) Using push tool kit (o98), press fit bearing (31) to case (30). 2) Using push tool kit (o115), press fit oil seal (32). & & 3)
3.
Oil seal lip: Grease (G2-LI) Outside circumference of oil seal: Gasket sealant (LG-I) Install gear (18) to shaft (17) and fix it with a lock plate. Sr Bend lock plate securely. Ir Insert washer (26) at the upper and lower ends of the shaft securely.
DEG00023
Housing 1) Attach shim (23) to housing (22) and install it in case. Sr Fix O-ring in housing. * Adjust rotating torque with shim. Ir Rotating torque: 4.9 to 15.7 Nm {0.5 to 1.6 kgm) & O-ring groove: Grease (G2-LI)
P23501470
30-211 0
DISASSEMBLY
4.
AND ASSEMBLY
CIRCLE ROTATION
Reverse gear (with drv clutch) 1) Fit O-ring (18% to dollar (18T) and gear (18R), then install to shaft (24). & Rotating portion: Lubricant (LC-G) 6 O-ring groove: Grease (G2-LI) 2) Fit O-ring (180) to coupling (18P), then install to shaft (24). 6 Spline portion of shaft and coupling (18P): Lubricant (LM-PI 3) Insert plates (18H) and discs (18L) between gear (18R) and coupling (18P). & Spline portion of gear (18R): Lubricant (LM-P) 4) Install shims (18N), holder (18M), and lock plate (18L) to shaft with bolt (18K). * Adjust so that clearance A of the shim is 1 mm. 5) Assemble end plate (18G) and springs (18F), then install shims (18E) and collar (18C) with bolt (18A).
GEAR AND
HYDRAULIC
OIL MOTOR
DEG00024
.lUJ
F23501409
F235014
30-212 0
DISASSEMBLY
5.
6.
AND ASSEMBLY
CIRCLE ROTATION
Cover Using push tool kit (o95), press fit bushing to cover (21), then install to case. Ir Install an O-ring to the cover. 6 O-ring groove: Grease (G2-LI)
i (33)
Clutch 1) Press fit oil seal (34).
2)
Insert plate (17) and snap ring (16) to housing (15). t Install an O-ring to the housing.
3)
Install discs (13) and plates (14) in turn. + Discs: 6 PCS. * Plates: 5 pcs.
$ i: Q $ 8 $
i
GEAR AND
HYDRAULIC
OIL MOTOR
DISASSEMBLY
4) 5)
6) 7)
AND ASSEMBLY
CIRCLE ROTATION
GEAR AND
HYDRAULIC
OIL MOTOR
Install piston (12). Ir Install an O-ring to the piston. Install spring (II) and washer (IO).
Install cover (9). Install bolt (8) and locknut (7), loosen l-1/4 turns after tightening, then lock with locknut. * Adjust the load on the clutch as follows. (with a) Loosen bolt (8) completely spring (11) not compressed). b) Tighten bolt (8) to compress spring (II). w
c)
Bolt: 56.9 2 4.9 Nm t5.8 + 0.5 kgml Turn bolt (8) back l/6 turns, then tighten locknut (7). F23501326
8)
7.
Remove every second mounting bolt (remove 3 bolts, one from each pair) of cover (9), then install cover (9A), and tighten with bolts that were removed.
Key Install
key (6) to hydraulic
oil motor
assembly
(5).
P2350
30-214 0
1483
z % g
DISASSEMBLY AND ASSEMBLY
CIRCLE ROTATION GEAR AND HYDRAULIC OIL MOTOR
8. Circle rotation gear, hydraulic oil motor assembly Align circle rotation gear assembly (4) and hydraulic oil motor assembly, then tighten with bolts (3). 9. Refilling with oil 1) Tighten drain plug (1), then add gear oil to the specified level. 5
Circle rotation gear case: Approx. 16 ¬ (GO90)
2) Tighten drain plug (2), then add engine oil to the specified level. Clutch: Approx. 180 m¬ (EO30)
023502
5
30-214-1 (6)
DISASSEMBLY
AND ASSEMBLY
CIRCLE ROTATION
GEAR, HYDRAULIC
MOTOR
DISASSEMBLY OF CIRCLE ROTATION GEAR, HYDRAULIC MOTOR ASSEMBLY Serial No.: 12051 and up 1.
Draining oil I) Remove drain plug (I) and drain oil. 2)
:
Remove -
:
Upper case: Approx.
9.8 Q
drain plug (2) and drain oil. Lower case: Approx.
0.2 k?
2.
Hydraulic motor assembly Remove 4 bolts (31, then remove motor 14). Ir Be careful not to drop key (41) fitted to the shaft of the motor.
3.
Clutch 1) Remove 8 bolts (61, then remove cover (7). 2) Remove 3 bolts (8), then remove holder (9) and shims (IO). * Check the number and thickness of the shims, and keep in a safe place. spring (12), and plate 3) Remove collar (II), 4)
(13). Remove clutch discs (14) and plates (15) in order, then remove washer (16). Clutch disc (14) : 11 Clutch plate (15) : 10
30-214-2 0
2’
DWG00250
DISASSEMBLY
AND ASSEMBLY
4.
Housing Remove nut (171, then remove housing (18). Ir Check the number and thickness of shims (191, and keep in a safe place.
5.
Worm wheel Install eyebolts (Thread = 6 mm, Pitch = 1 mm) to worm wheel (20), then remove worm wheel. Ir The % mark in the diagram shows the eyebolt hole.
CIRCLE ROTATION
GEAR, HYDRAULIC
MOTOR
-
OWC
Worm gear, bearing assembly I) Remove worm gear and bearing assembly from case (5). 2) Remove bearing (22) from worm shaft (21).
7.
Pinion gear 1) Remove 8 bolts (231, then remove cover (24).
23 24
1
DWG00256
30-214-3
DISASSEMBLY
2)
3)
CIRCLE ROTATION GEAR, HYDRAULIC MOTOR
AND ASSEMBLY
Extend lock plate (251, remove bolt (26), then remove holder (27). * Check the number and thickness of the shims under the lock plate, and keep in a safe place. Remove 4 bolts (291, then remove housing (30).
DWG00257
4)
Pull out bushing
(31) from
housing
(30).
I 5)
Remove collar (321, then remove pinion (33) and washer (34). Ir Be careful not to damage floating
DWG00258
gear seal
(35). 8.
Worm wheel shaft 1) 2)
Remove worm wheel shaft (36), then remove washer (37). Pull out bushing (38) from case (5).
32
30-214-4 0
33 DWGO
DISASSEMBLY
CIRCLE ROTATION
AND ASSEMBLY
GEAR, HYDRAULIC
MOTOR
ASSEMBLY OF CIRCLE ROTATION GEAR, HYDRAULIC MOTOR ASSEMBLY Serial 1.
No.: 12051 and up
Worm gear, bearing assembly I) Press fit bearing (22) to worm gear (211, and insert worm gear (21) to case (5).
2)
3)
Install housing (18) to case (5). . Install an O-ring to the housing. O-ring : Grease (G2-LI) & . Insert the same thickness of shim (19) that was removed during disassembly. To apply preload to bearing, add suitable thickness of shim (19) so that rotating torque of worm gear (21) is 4.9 - 9.8 Nm iO.5 - 1.0 kgm1
2.
Worm wheel shaft assembly Press fit bushing (38) in case (5). I) 2) Pass washer (37) over shaft (36), and insert in case (5). . P portion Install so that the chamfered of washer (37) is at the top.
3.
Pinion gear I) Press fit bushing
(31) to housing
(30).
30-214-5 0
DISASSEMBLY
2)
AND ASSEMBLY
Adjust shim at pinion gear portion. * With floating seal (35) removed, assemble pinion gear portion completely, and adjust clearance between washer (34) and pinion gear (33). i) Install washer (34) and pinion gear (33). Sr Insert three 0.2 mm clearance gauges between washer (34) and pinion gear (33) from 3 directions, and install in this condition. (In order to maintain 0.2 mm clearance) ii) Install collar (321, insert shims (28), then install holder (26). . Standard shim thickness: 2.5 mm Types (thickness) of shim (28): 235-70-15860: 1 .O mm 235-70-I 5870: 0.5 mm 235-70-15880: 0.2 mm iii) Install housing (30). iv) Adjust clearance between washer (34) and pinion gear (33) with shim. Clearance: 0.2 mm VI After adjusting, remove all parts installed in Steps i) - iii).
CIRCLE ROTATION
GEAR, HYDRAULIC
is
‘25
MOTOR
DWG00261
l
3)
Using tool B, install floating seal (35) to case (5), pinion gear (331, and housing (30). * Remove all oil and grease from the Oring and the O-ring contact surface. Ir There must be no dirt stuck to the mating surface (sliding surface) of the floating seal.
I
DWG00262
30-214-6 0
DISASSEMBLY
4) 5)
6) 7)
AND ASSEMBLY
CIRCLE ROTATION
GEAR, HYDRAULIC
Install washer (34) and pinion gear (33) to shaft (36). Install collar (321, insert shim (281, then install holder (26). Ir Insert the thickness of shim adjusted in Step 2) iv). + After tightening bolt (261, secure the bolt with lock plate (25). Install housing (30). Install cover (24) to housing (30). * Fit the O-ring in the O-ring groove of the housing. & O-ring : Grease (G2-LI)
I
MOTOR
DWG00256
33 32 28
30 29
4.
is
‘25
DWG00261
Worm wheel Fit eyebolt to worm wheel (201, and install to shaft (36). * Remove the housing of the worm gear. Mesh it with the worm gear, then install the worm gear housing again.
DWG00254
5.
Clutch 1) Insert washer (16) in worm wheel, then insert discs (14) and plates (15) in order. Discs (14): 11 Plates (15): 10 2) Install plate (II), spring (12), and collar (13). 3) Insert shim (IO) on top end of shaft (36), then install holder (9) with bolt (8).
6.
Cover Install cover (7) to case (5). * Install the O-ring to the cover. a O-ring : Grease (G2-LI)
30-214-7 0
DISASSEMBLY
AND ASSEMBLY
7.
Hydraulic motor assembly install hydraulic motor (4). Ir Install the key to the shaft of the hydraulic motor.
8.
Refilling with oil I) Install drain plug (I). 2) Remove oil filler plug (39), add a small amount of gear oil, and check that oil comes out from drain plug (2). 3) Install drain plug (2). 4) Remove level plug (40), then add gear oil until oil comes out from plug. Case : Approx.
CIRCLE ROTATION
MOTOR
10 e
2’
30-214-8 0
GEAR, HYDRAULIC
DWG00250
1
REMOVAL
OF BLADE
ASSEMBLY
Serial No.: 11001 - 12050
A
Start
engine,
operate
work equipment
the control
(approx. 200
Set a block (approx.
780
lever to raise the
mm).
mm) under the circle to sup-
port it securely.
1. Operate
the control
lever and extend
blade side shift
cylinder piston rod (1) to pull out blade (2). 2.
3.
Loosen
bolts (3) and (4), pull out pin (5) and remove
bracket
(6).
Fully retract
piston rod (1) and sling blade (2).
Raise blade
(2) with
a crane,
slide the sling position
of the wire to the center of the blade, and dismount
kg C!?J
Blade assembly:
INSTALLATION ASSEMBLY z
%
approx.
1540
it.
kg
OF BLADE
Serial No.: 11001 - 12050 1. Sling center of blade (2) and set to adjuster.
2
2.
While extend
sliding
it reaches a=d
the wire,
the cylinder
operate
B43,
P2350
I437
lever to
piston rod (1) and push it in until
a position where Blade
the control
P2350
guide
rail
it can be connected. (upper,
lower):
Grease
(G2-LI) 3.
Raise
blade
side shift
engine and operate
cylinder
the control
with
a crane,
lever to extend
start piston
rod (1). 4.
Set cylinder tighten
5.
rod to bracket
(6) fix with
pin (5) and
bolts (3) and (4).
Raise blade and pull out block from under the circle.
30-2 15 0
REMOVAL OF BLADE ASSEMBLY Serial No: 12051 and up A
Start the engine, operate the blade lift lever to raise the blade approx. 200 mm from the ground, then put a stand under the circle to support it securely.
1. Operate blade side shift lever to extend blade side shift cylinder piston rod (I) fully and push out blade (2). 2.
Remove 2 bolts (3), remove out pin (5).
3.
After retracting blade side shift cylinder rod (I) fully, raise blade (21, and move position of wire towards center while pushing blade out to remove. +j kg
Serial 1. 2.
: 1600 kg
Blade assembly
INSTALLATION ASSEMBLY
plate (4), then pull
OF BLADE
No.: 12051 and up
Raise center of blade (2), and set in position on adjuster. Move position of wire while extending blade side shift cylinder rod (I) and push in to position where it is possible to connect. & Blade guide rail (top, bottom): Grease
3. Lift blade side shift cylinder engine and extend fully.
rod (I),
(G2-LI)
then
start
4.
Position cylinder rod to bracket (61, secure with pin (5), then tighten plate (4) and bolt (3).
5.
Raise blade and remove cle.
30-215-l 0
support from under cir-
REMOVAL DRAWBAR 1.
2.
Lower work equipment Remove
drawbar
and remove
3.
Remove
completely
shift
shift
(I)
bottom
cap
(2)
(3).
cylinder
from drawbar
to the ground.
cylinder
from drawbar
blade
remove
4.
OF CIRCLE AND ASSEMBLY
(4)
head
cap
(5) and
(3).
Sling circle and drawbar
assembly
(6). loosen nut (7)
and pull out cover (8) from bolt (9). Remove
circle
and
drawbar
assembly
from
main
frame. +
Check the number
and thickness
of shims
(II),
and keep in a safe place. Circle and drawbar 3,050 3,600
assembly:
kg (Serial kg (Serial
No.: 11001 - 12050) No.: 12051 and up)
INSTALLATION OF CIRCLE AND DRAWBAR ASSEMBLY 1.
Sling
circle
and
top ball joint
drawbar
and cover (81, and tighten *
Install
the
same
disassembled. . Standard It
assembly,
(I 0) to main frame, number
of shims
shim thickness:
(11)
drawbar,
one shim
If too many
shims
&‘&
Ball joint:
as was
play in the
(11) each to adjust.
are removed,
will not move properly, nut to come
(1 I)
2 mm (0.2t x IO)
if there is excessive
remove
drawbar shim
nut (7).
After assembling,
Note:
2.
install
fix with
the ball joint
and this will cause the
loose. Anti-friction
Install blade lift cylinder
compound
(LM-P)
(4) head cap (5) to drawbar
(3) with shim (I 2). 3.
Install drawbar
30-216 0
drawbar
shift
cylinder
(3) with shim (I 3).
(1) bottom
cap
(2) to
-
235FO2279
DISASSEMBLY OF CIRCLE AND DRAWBAR ASSEMBLY Serial No.: 11001 - 12050 1.
Ball joint Loosen
nut
(3) from
drawbar
(1) and
remove
ball
joint
(2) and
cover
top end.
/, Circle
rotation
gear
and
hydraulic
oil
P2350
I445
motor
assembly Remove
circle
rotation
gear
and
hydraulic
OF
CIRCLE
oil motor
assembly. For
details,
see
REMOVAL
GEAR AND HYDRAULIC
ROTATION
OIL MOTOR ASSEMBLY.
Circle guide 1)
Loosen
nut
(6)
then separate
and
drawbar
remove
circle
guides
(5),
and circle assembly.
5
4.
5
5
235FO2281
Blade side shift cylinder Remove
snap
ring
(7), washer
remove
blade
side
shift
juster
cylinder
(8) and
pin
(9), then
(11) from
R.H. ad-
(IO). Blade side shift cylinder:
106 kg
P2350
t 448
30-217 0
5.
Power I)
tilt cylinder
Remove
power
tilt cylinder
(12)
head
bolt (131,
lock plate (I 4) and pin (151, then remove center bracket 2)
Remove
power
tilt cylinder
and cap (181, then remove
6.
(12) bottom
bolt (I 7)
it.
Power tilt cylinder:
r+
it from
(16).
83 kg
L.H. adjuster Loosen
nuts
(20),
(21)
and
(221,
and
remove
L.H.
adjuster. &
7.
L.H. adjuster:
60 kg
Shaft Loosen nut (23) and pull out shaft (24).
& kg 8.
Power
Shaft:
20 kg
tilt center
Loosen bolt (25)
bracket and remove
power tilt center
brack-
et (26).
kg CII?T?? 9.
Power tilt center bracket:
82 kg
R.H. adjuster Loosen
nuts (27)
and (28),
and remove
(29).
& kg
R.H. adjuster:
69 kg
R.H. adjuster
ASSEMBLY DRAWBAR Serial 1.
OF CIRCLE AND ASSEMBLY
No.: 11001 - 12050
R.H. adjuster Install
R.H. adjuster
(29)
to
circle
(30)
and
tighten
nuts (27) and (28).
2.
Power
power
bracket
Install
2)
Insert shim (32) to cap (31) and tighten
*
3.
tilt center
I)
Standard
tilt center
bracket
(26) to circle.
shim thickness:
2.0 mm
to R.H. adjuster
and center
bolt (25).
$
,, .b
‘I: ‘,{
Shaft Insert
shaft
and fix with
(24)
bracket
nut (23).
30-219 0
4.
L.H. adjuster Install adjuster (19) to circle and shaft and fix with nuts (201, (21) and (22).
5.
Power
tilt cylinder
Install power tilt cylinder (12) bottom end with cap (18) and tighten bolt (17). Install power tilt cylinder head end to center bracket (161, fix with pin (151, then tighten bolt (13) with lock plate (14).
6.
Blade side shift cylinder
,, ,,‘, _,, I
,,
I’
Install blade side shift cylinder (1 1) to R.H. adjuster and fix with pin (91, washer (8) and snap ring (7).
P2350
7.
Circle rotation gear and hydraulic oil motor assembly Install circle rotation gear and hydraulic oil motor assembly. For details, see INSTALLATION OF CIRCLE ROTATION GEAR AND HYDRAULIC OIL MOTOR ASSEMBLY.
t 448
8.
Circle guide I) Insert shim in circle guides (5), then temporarily assemble drawbar assembly and circle assembly with bolts (34A), (34B) and (340. * Standard shim thickness: 5.5 mm * Length of bolts: . 34A: 195 mm (x 4) . 34B: 170 mm (x 12) . 34C: 150 mm (x 2) '35FO2282
2)
Inspection clearance of circle guide. Ir If there is no clearance between the circle and root and tip of the teeth of the pinion gear of the circle rotation gear assembly, replace the guide to adjust. a i) ii)
Front
Center
Rear
When raising the blade off the ground, do not raise it higher than necessary. Set with the blade raised off the ground. Measure clearance of portion P with feeler gauge. . Standard clearance of portion P: 1.5 f 0.5 mm
iii) Measure clearances of portion P, C and R with feeler gauge. . Standard clearance F: 0 mm C: 0.7 mm R: 1.5 mm orF=C=R=l mm F is the clearance of the guide at the front. C is the clearance of the guide at the center. R is the clearance of the guide at the rear. * If the clearance at portion P and portion F, C and R is not the standard clearance, carry out adjustment.
235FO2283
0-B
A-A
DDG00026
J
DDG00027
30-221 0
3)
Adjusting clearance of circle guide. i) Raise blade so that drawbar and ground are parallel, and so that dimension E at tip of blade edge and ground surface is approx. 90 mm.
E
235FO2287
ii)
Loosen bolt (I), put circle guides (21, (31, and (4) and portion F, C and R of circle (5) in contact, and adjust shim (6) so that clearance P between top surface of circle and bottom surface of drawbar is 1.5 r 0.5 mm. (7), tighten pusher bolt ii) Loosen locknut (8) of rear circle guide (41, and move whole of circle to rear. * When not using circle guide pusher bolt (8) to move the circle, use a lever block to move it. L iv) Move circle to rear, and set clearance between tip of teeth of pinion gear (9) and root of teeth of circle (IO) to 0 mm. When doing this, measure clearance H between pinion gear (9) and circle (IO) (take the measurement as a). Adjust so that clearance H = a + 3.9 mm. v) Loosen locknut (121, tighten pusher bolt (13) of front circle guide (2), maintain clearance H between pinion gear (9) and circle (IO), and set clearance F between circle guide (2) and circle (5) to 0 mm, then tighten locknut (12).
‘4 DEG00028
L
9
3 Ifii-
A-A
30-222 0
I
‘2
I
DOG000 30
4
H
10
!-
235FO229
vi)
Check that clearance L between tip of teeth of pinion gear (9) and root of teeth of circle (IO) is 3.86 mm. vii) Check clearance H between pinion gear (9) and circle (IO) again, loosen locknut (14), then tighten pusher bolt (15) of center circle guide (3), and set clearance C between center circle guide (3) and circle (5) to 0.7 mm, then tighten locknut (14). viii)Adiust with pusher bolt (8) so that clearante R between rear circle guide (4) and circle (5) is 1.5 mm, then tighten locknuts (7). ix) Tighten
I B-B
3 DDG00031
bolt (I) and locknuts (71, (12) and
(14). &
x)
9.
Lubricated portion of circle guide: Anti-friction compound (LM-PI Check that rotation is possible at 90” high-bank position to both left and right. * If thickness Tl of wear plate (15) has reached 2 mm, replace it with a new part. * If either thickness T2 or T3 of wear plate (16) has reached 2 mm, replace with a new part.
DDG00032
Ball joint I) Install ball joint (2) and cover (3) to drawbar top end.
2)
Tighten
nut (I).
P2350t445
30-223
DISASSEMBLY
CIRCLE, DRAWBAR
AND ASSEMBLY
DISASSEMBLY OF CIRCLE, DRAWBAR ASSEMBLY Serial
No.: 12051 and up
1. Ball joint Loosen bolt (I), cover (3). 2.
3.
and remove
ball joint
(2) and
Circle rotation gear, hydraulic motor assembly Remove circle rotation gear and hydraulic motor assembly. For details, see REMOVAL OF CIRCLE ROTATION GEAR, HYDRAULIC MOTOR ASSEMBLY.
DWG00265
Circle guide Remove 16 bolts (8) and 2 bolts (8A), then remove circle guides (51, (61, (7) and (7A), and disconnect drawbar and circle assembly.
5’ 4.
s
‘7
DWGOO266
Blade side shift cylinder Remove bolt (9), lock plate (IO), and pin (II), then remove blade side shift cylinder (13) from adjuster (12). &I kg
Blade side shift cylinder
: 105 kg
DWG00267
5.
Power tilt cylinder 1) Remove bolt (151, lock plate (16), and pin (17) at head end of power tilt cylinder (14), and disconnect from adjuster (12). 2) Remove bolt (18) at bottom end of cylinder, remove cap (19), then remove cylinder.
el kg
Power tilt cylinder
: 83 kg
I 30-223-l I?\
DWC00266
DISASSEMBLY
6.
Adjuster Remove I) (22).
CIRCLE, DRAWBAR
AND ASSEMBLY
cotter
pin (20) and nuts (21) and
26
15
23
DWG00169
2)
Pull out shaft (241, then remove adjuster (12). Adjuster
//
: 300 kg
30-223-2 0
DISASSEMBLY
CIRCLE, DRAWBAR
AND ASSEMBLY
ASSEMBLY OF CIRCLE, DRAWBAR ASSEMBLY Serial No.: 12051 and up 1.
Adjuster 1) Insert
adjuster Adjuster
&I kg
(12) in circle.
: 300 kg
I 2)
3)
2.
Insert washer (25) and shims (26) in clearance between circle and adjuster, and adjust clearance. Clearance.(left, right): 0.5 - 1.0 mm each * Insert washer (25) and shims (26) uniformly on left and right. * Coat the contact surface of the shim and the circle with LM-P. Thickness of Washer: 3 mm Thickness of Shim (2 types): 0.5 mm, 1.0 mm Pass shaft (24) through, then install washer (231, nuts (21) and (221, and cotter pin (20).
Power tilt cylinder 1) Secure bottom end of power with cap (19) and bolt (18).
2)
tilt cylinder
DWGOO270
DWG00269
(14)
Power tilt cylinder : 83 kg & lni:all head end to adjuster with pin (17), and secure with lock plate (16) and bolt (15).
I
DWG00266
Blade side shift cylinder Install bottom end of blade side shift cylinder (13) to right side of adjuster (12) with pin (II), then secure with lock plate (IO) and bolt (9). & kg
Blade
side shift
cylinder
: 105 kg
Circle rotation gear, hydraulic motor assembly Install circle rotation gear and hydraulic motor assembly to drawbar. For details, see INSTALLATION OF CIRCLE ROTATION GEAR, HYDRAULIC MOTOR ASSEMBLY.
30-223-3 0
OWG00267
DISASSEMBLY AND ASSEMBLY
CIRCLE, DRAWBAR
023502
5. Circle guide 1) Set wear plate (28), put circle assembly on drawbar, lay out shims (29), then temporarily tighten guides (5), (6), (7) and (7A) with bolts. fl Lay out 2 wear plates (28) each. fl Install wear plate (27) to each circle guide. • Standard shim thickness : 5.5 mm • Bolt length • (8) : 175 mm (16 bolts) • (8A) for circle guide (7A): 155 mm (2 bolts)
6. Adjusting clearance of circle guide 1) Adjusting top and bottom clearances between circle and wear plate i) Loosen all mounting bolts, expand each circle guide towards outside, then make sideways clearance between wear plate and circle 0 mm. ii) Adjust thickness of shims (29) to adjust clearance P in vertical direction of wear plate (27) and circle. fl Adjust for all circle guides. fl Measure the clearance with the wear plate pushed tightly against the circle guide. • Clearance P: 1.5 ± 0.5 mm 2) Adjusting clearance from circle rotation gear case i) Loosen locknut (30) and pull in pushing bolt (31). (For front, center, and rear circle guides) ii) Loosen all mounting bolts, and move circle towards rear. iii) Push front circle guide (5) to front with pushing bolt (31) so that clearance H between circle (33) and circle rotation gear case (32) is specified value. • Clearance H: 20 – 21 mm iv) Tighten bolt to hold front circle guide (5) in position. • Clearance F: 0 mm
30-223-4 (6)
DISASSEMBLY
3)
CIRCLE, DRAWBAR
AND ASSEMBLY
Adjust clearance between circle and guide (center, rear) i) Set clearance F to 0 mm, then clearance C between circle and circle guide (6), and tighten bolt hold in position. Clearance C: 0.7 mm
circle adjust center (8) to
3d
3i
29
27
28 B-B
ii)
Set clearance F to 0 mm, then adjust clearance R between circle and rear circle guides (7) and (7A), and tighten bolts (8) and (8A) to hold in position. Clearance R: 1.5 mm
8 (8A)
DWG00275
7(7A)
31
30
2i c-c
7.
DWG002:‘6
I
bWG00265
1
Ball joint Install ball joint (2) and cover (3) to drawbar, and tighten bolt (I). w Bolt : 534.5 + 73.5 Nm I54.50 2 7.50 kgml
I
30-223-5 0
REMOVAL OF REAR MOUNT ASSEMBLY
A
Lower the work equipment
1.
Set stand
@ (height:
completely
approx.
800
RIPPER
to the ground. mm) under body
(I). 2.
Raise shank remove
(2) with
a crane,
pull out pin (3). then
shank (2).
3.
Disconnect
hoses (5) and (6) from cylinder
4.
Raise body
(lj,
(4).
pull out pin (71, then disconnect
rod
(8). 5.
Hold rod (9) with jack, pull out pin (IO),
then discon-
nect link (1 I). 6.
Lift off body. Sr
Rod (81, link (I I),
and cylinder
to the body.
kg CE?l 7.
Lift off bracket
& kg 8.
Body:
Bracket:
1390 kg
(12) with a crane. 241 kg
Pull out pin (131, and remove
30-224 0
rod (9).
(4) are attached
INSTALLATION OF REAR MOUNT RIPPER ASSEMBLY 1.
Hold rod (9) with jack, and knock in pin (I 3).
2.
Raise bracket
3.
(I 2) and install.
Raise body (1). align pin hole of bracket,
link (1 1) and
rod (9). then knock in pin (I 0). 4.
Align pin holes of rod (8) and bracket,
then knock
in
pin (7). 5.
Set stand
@ under body
(11, raise shank
(2) with
a
down,
it
crane, align pin holes, then knock in pin (3). *
If the will
center
hit the
shank work
is installed
equipment
upside cylinder
and
may
break, so be sure never to install it upside down. 6.
Connect *
hoses (5) and (6) to cylinder
Run the engine system.
Then
to circulate
(4).
the oil through
the
check the oil level in the hydraulic
tank again.
P2350
I475
30225
METHOD
FOR LIFTING UP ROPS
g
When lifting the cab, the lock pin which supports the cab must be securely locked. In addition, be extremely careful not to let the cab tilt at an angle during the lifting operation.
1.
Remove
mounting
bolts (I) of ceiling
of ROPS.
I 2.
Remove floor mat, and loosen (21, then remove plate (3).
mounting
235CD02108
bolts
’ 3.
Loosen bolt (4), then remove locks (5).
4.
Loosen bolt (61, and remove cover (7). (Both left and right) Serial No.: 11009 and up Cover (7) on the left side of machines equipped with an air conditioner is fresh air filter (37), but remove this also.
235COO210<
left and right door
DWG00224
5.
Remove
cab mounting
bolts (8), (9), and (IO).
235CD02111
30-226 0
235COO2112
*
When
lifting
up the
air conditioner so
remove
stand only
cab mount
shown
the
cab,
the
operator’s
are lifted 15
at the
mounting
seat same
bolts
and
I
time, of
the
in the diagram.
1235FO2293
6.
Disconnect
connecting
wiring
CN79
(11)
between
cab and floor. *
Push
the
wiring
harness
on
the
right
side
into
the box.
1235FO2294 7.
Tilt steering
post back one stage.
235FO2295
8.
Install f
chain
When supplied
block (14) to ROPS and cab. using
a chain
block,
always
use the
tools
with the machine.
30-227 0
9.
Remove
10. Wind
lock pin (13) installed
up chain
block
and
to cab.
raise
cab
until
ROPS
and
hole of cab lock pin are aligned.
A * *
Never lifting Before
go
under
the
ROPS
cab
during
the
operation.
lifting
the
wiring
and piping
Check
that
no
cab,
always
check
that
all the
have been disconnected. parts
hit
or
interfere
with
other
parts. 11. Secure
ROPS and cab with
INSTALLATION l
A
Carry out installation When ports tion,
lifting the
During
cab,
must
be extremely
at an angle during
A
OF ROPS in the reverse
the
cab
the
lock pin (13).
the
lock
be securely careful
the lifting
operation,
do
to removal.
pin
which
locked.
not to
let the
sup-
In addicab
tilt
operation. not
until the cab has been lowered
30-228 0
order
Floor
go
under
the
fully to the floor.
cab -
surface
for removing cab
DISASSEMBLY
REMOVAL
AND ASSEMBLY
ROPS CAB
OF ROPS CAB
This shows the procedure for lifting up the operator’s seat and air conditioner mount at the same time in the same way as when lifting up the cab. When lifting up the cab only, see the section for “Lifting up cab only”. Cab vibration stopper 1) Loosen bolts (4), and disconnect brackets (I), (2), and (3) from stopper (5). (Both left and right)
2.
Remove
*
bolts (6),
Eyebolts
then remove ROPS roof (7).
@ (Ml2
u
x 1.75) : 04530-l
1222
ROPS roof : 160 kg
30-229 0
DISASSEMBLY
3.
AND ASSEMBLY
Remove bolts (81, then remove left and right)
ROPS CAB
bracket (9). (Both m
4.
Remove bolts (IO), then remove (Both left and right)
5.
Remove bolts (12), then remove cover (13). (Both left and right) Serial No.: 11009 and up Cover (13) on the left side of machines equipped with an air conditioner is fresh air filter (371, but remove this also.
door lock (II).
DWG00225
6.
Remove floor mat, then remove remove plate (15).
bolts (14), and
7.
Remove
plate (17).
bolts (161, then remove
I
DWG00224
DECO0037
8.
Disconnect coupler water piping.
9.
Remove cab mounting (221, and bolts (23).
30-230 0
(18) of air conditioner
warm
bolts (19), (201, (211, and a
DISASSEMBLY
AND ASSEMBLY
ROPS CAB
-XT+--s-i-4 -
DEG00039
*
Remove the bolts with the white paint the head. Serial No.: 11001 - 11013: 16 bolts 11014 and up: 18 bolts (part marked % added)
on
FWD+
DWG00234
10. Disconnect connecting wiring CN79 (24) between cab and floor. * Push the wiring harness on the right side into the box.
DEG00042
11. Move steering
post 1 stage back.
DEG00043
30-231
DISASSEMBLY
ROPS CAB
AND ASSEMBLY
12. Disconnect connector (25) from move hose from clamp (26).
hose, then
re-
DWG00235
13. Disconnect couplers (27) and (28) of freon ing of air conditioner.
14. Lift off cab. + Lifting positions: Cab assembly
4 places marked
pip-
by arrows
: 600 kg
DECO0046
OEG00047
30-232 0
DISASSEMBLY
15. After lifting ROPS column, then remove ROPS column ROPS column
& kg
ROPS CAB
AND ASSEMBLY
remove (29).
bolts
(30), 1151
: 450 kg
DEG00046
INSTALLATION .
OF ROPS CAB
Carry out installation removal.
in the
reverse
order
to
m Adjusting cab vibration stopper 1) Front-to-rear direction Mounting dimensions of stopper Unit: mm
Ll
Free
After setting
Amount to push in
45
40
5 ROPS/FOPS roof Plate
i)
Set mounting dimension Ll of stopper (5) to 45 mm. ii) Put brackets (1) and (3) in light contact with stopper (51, then tighten bolts (4) temporarily. iii) Tighten adjustment bolt @ six turns, then tighten bolts (4). Adjustment bolt 0: 235-950-5440 bolt 0. iv) Remove adjustment 2)
Left-to-right direction Mounting dimensions
3 ‘5
DWG00236
of stopper Unit: mm
L2
Free
After setting
Amount to push in
47
42
5
ROFQ'FOPS roof plate
i)
Set mounting dimension L2 of stopper (5) to 47 mm. ii) Put bracket (2) in light contact with stopper (5), then tighten bolts (4) temporarily. bolt @ three turns, iii) Tighten adjustment then tighten bolts (4). Adjustment bolt 0: 01010-51075 bolt 0. iv) Remove adjustment
Outside +
I
DWG00237
30-233 0
DISASSEMBLY
AND ASSEMBLY
ROPS CAB
m Installation of ROPS roof m ROPS roof mounting bolt (6) : 277 f 32 Nm (28.25 f 3.25 kgm}
v, 2)
Rail guide ‘Adjust rail guide to front or rear so that rail at rear of cab is at center of rail guide. Roller Adjust roller bracket to front or rear so that clearance between roller and ROPS column is 4 + 1 mm.
DWG00238
Cab mounting bolt : 110.5 = 12.5 Nm (11.25 2 1.25 kgm} Unit: mm Bolt No.
Bolt length
Length of tube to use
19
30
-
20
60
Roller
21
m
I
465
I
bra
400
22
365
300
23
25
-
ROPS column mounting bolt (30) : 1715 + 195 Nm (175 + 20 kgm}
0 EL
Tube
i o cabin
30-234 0
DWG00240
DISASSEMBLY
ROPS CAB
AND ASSEMBLY
When lifting up cab only Serial No.: 11001 - 11008 When not lifting up the operator’s seat and air conditioner mount, the procedure for the following items is different. 1.
Removal 1) It is unnecessary to remove plates (15) and (17) and mounting bolts (14) and (16) in Items 6 and 7. 2) It is unnecessary to disconnect coupler (18) in Item 8. 3) Remove front defroster duct. a) Remove bolts (33) and (341, then remove duct (35) and gasket (36). b) Remove cap (37) and bolt (19) (white), then remove duct (38). Duct (38) is tightened together with * the cab mounting bolts. 4) Remove cover (32) at rear of operator’s seat 5)
8
k? g
6)
2. .
mount. There is a partial change in the bolts to be m removed in Item 9. See diagram on right. (Remove bolts with red paint also.) No. of bolts to remove: 18 seat down to Push backrest of operator’s front, then raise cab.
Installation Carry out installation removal.
in the
reverse
order
I
DEG00055
21 (White)
to
22IWhite)
116 w
DWG00226
Cab mounting bolt : 110.5 2 12.5 Nm (11.25 = 1.25 kgm} Unit : mm Bolt No.
Bolt length
Length of tube to use
19
30
-
20
60
-
21
465
400
22
365
300
31
270
200
I
(Wh
31 (Red)
22 (White)
Ig(White)
j[(White)
DWG00241
0 b
Tube
1 To
cabin
DWG00303
30-235 0
DISASSEMBLY
AND ASSEMBLY
When lifting up cab only Serial No.: 11009 and up When not lifting up the operator’s seat and air conditioner mount, the procedure for the following items is different. 1.
ROPS CAB
Damper
assembly
Removal 1) It is unnecessary to remove plates (15) and (17) and mounting bolts (14) and (16) in Items 6 and 7. 2) It is unnecessary to disconnect coupler,(l8) in Item 8. 3) 4) 5) 6)
Remove bolt (33) from left console box, then remove cover (34). Disconnect connector A6 (35). Remove bolt (36), then remove fresh air filter (37). Remove bolt (38), then remove damper assembly (40) together with bracket (39).
7)
Remove front defroster duct. a) Remove cap (41) and bolts (42) and (43), then remove duct (44) and gasket (45). b) Remove cap (46) and bolt (19) (white), then remove duct (47). Ir Duct (47) is tightened together with the cab mounting bolts. c) Remove bolt (48), then remove duct (49).
8)
Remove cover (32) at rear of operator’s seat mount. (Serial No. 11001 - 11013, only machines equipped with air conditioner)
DEG00055
30-236 0
DISASSEMBLY
ROPS CAB
AND ASSEMBLY
9)
There is a partial change in the bolts to be m removed in Item 9. See diagram on right. (Remove bolts with red paint also.) . No. of bolts to remove: 18 IO) Push backrest of operator’s seat down to front, then raise cab.
21 (White) 22IWhitel
22fWhite) jQ(Whlte)
2.
.
Installation Carry out installation removal.
in the
reverse
order
20CWhite)
DWG00241
to
a w
Cab mounting bolt : 110.5 + 12.5 Nm Ill.25
19
Length of tube to use
Bolt length
Bolt No.
I
30
I
f 1.25 kgml Unit: mm
I -
20
60
21
465
400
22
365
300
31
I
270
I
I To cabin
DWC00303
200
30-237 0
DISCONNECTION AND CONNECTION OF ARTICULATE SECTION Serial No.: 11001 – 12502
k Lower the work equipment to the ground.
k Stop the engine and move the each work
equipment control lever to release the residual pressure in the piping. k Disconnect the cable from the negative (–) terminal of the battery.
4. Remove right and left articulate cylinder assemblies (4). For details, see “Removal and installation of articulate cylinder assembly”.
Disconnection 1. Remove the ROPS cab. For details, see “Removal and installation of ROPS cab”. 2. Lift off floor assembly (1).
023502
5. Disconnect 9 left-hand hoses (5).
3. Remove engine mount brackets (2) and (3).
6. Disconnect grease hose (7) from lower center pin (6).
30-238 (6)
7. Disconnect grease hose (9) from upper center pin (8).
023502
8. Disconnect 9 right-hand hoses (10). 9. Disconnect wiring harness (11).
11. Remove bolts (14) and remove lock washers (15) from the upper and lower center pin nuts. fl Secure plates (16) with bolts (14) temporarily. (Serial No. 12051 and up)
10. Remove O-rings (12) and (13) from the upper and lower center pins.
12. Remove upper center pin nut (17).
1
30-239 (5)
13. Remove upper center pin (8). fl Loosen the lower center pin nut.
2
17. When replacing bushings (21) and (22) fitted to the rear frame, cut them with gas. 4
023502
14. Remove nut (18) of lower center pin (6) and remove lower center pin (6). 3 When removing the nut, take care that the center pin will not fall.
16. Remove upper and lower plates (16) from the rear frame. fl Serial No. 12051 and up
15. Sling front frame (19) and slowly pull out and disconnect it from rear frame (20). fl Check that all the connections are disconnected. When disconnecting, take care of the balance of the front frame.
30-240 (5)
18. When replacing bushing (23) fitted to the front frame, cut it with gas. 5
Connection • Carry out connection in the reverse order to disconnection.
3. Install lock washers (15) to the upper and lower center pins and tighten the nuts. a Install plates (16) before tightening the nuts. (Serial No. 12051 and up)
•
Install the upper and lower center pins according to the following procedure. 1. Insert upper and lower center pins (8) and (6) in front frame (19) and rear frame (20) and then tighten lower center pin nut (18) so that upper and lower clearances "A" will be even. 2. After adjusting the clearance, tighten nut (17) of upper center pin (8) to torque of 255 ± 9.8 Nm {26 ± 1 kgm} and then loosen it and tighten again to torque of 215 ± 9.8 Nm {22 ± 1 kgm}.
Install bushings (21) and (22) by expansion fit.
•
Install bushing (23) by expansion fit.
023502
•
30-241 (6)
Bleeding air Bleed air from the hydraulic cylinders. For details, see “Precautions when carrying out operation, 2. Precautions when carrying out installation work”.
•
Refilling with oil (Hydraulic tank) Add oil through the oil filler to the specified level. Run the engine to circulate the oil through the system. Then, check the oil level again.
023502
•
30-242 (6)
DISCONNECTION AND CONNECTION OF ARTICULATE SECTION Serial No.: 12503 and up
k Lower the work equipment to the ground.
k Stop the engine and move the each work
5. Disconnect left-hand hoses (5).
equipment control lever to release the residual pressure in the piping. k Disconnect the cable from the negative (–) terminal of the battery. Disconnection 1. Remove the ROPS cab. For details, see “Removal and installation of ROPS cab”. 2. Lift off floor assembly (1).
023502
6. Disconnect grease hose (7) from lower center pin (6).
3. Remove engine mount brackets (2) and (3).
7. Disconnect grease hose (9) from upper center pin (8).
4. Remove right and left articulate cylinder assemblies (4). For details, see “Removal and installation of articulate cylinder assembly”.
30-243 (6)
8. Disconnect right-hand hoses (10).
11. Remove bolts and washer (14) and remove lock washers (15) from the upper and lower center pin nuts. a When removing, take care not to lose washers (16) between lock washers (15) and frame.
023502
9. Disconnect wiring harness (11).
10. Remove O-rings (12) and (13) from the upper and lower center pins.
30-244 (6)
12. Remove upper center pin nut (17).
15. Sling front frame (19) and slowly pull out and disconnect it from rear frame (20). a Check that all the connections are disconnected. k When disconnecting, take care of the balance of the front frame.
13. Remove upper center pin (8). a Loosen the lower center pin nut.
023502
16. When replacing bushings (21) fitted to the rear frame, cut them with gas.
14. Remove nut (18) of lower center pin (6) and remove lower center pin (6). k When removing the nut, take care that the center pin will not fall. 17. When replacing bushing (22) fitted to the front frame, cut it with gas.
30-245 (6)
Connection • Carry out connection in the reverse order to disconnection. Install the upper and lower center pins according to the following procedure. 1. Insert upper and lower center pins (8) and (6) in front frame (19) and rear frame (20) and then tighten lower center pin nut (18) so that upper and lower clearances "A" will be even. a Install O-rings (23) to upper and lower center pins (8) and (6). 2. After adjusting the clearance, tighten nut (17) of upper center pin (8) to torque of 255 ± 9.8 Nm {26 ± 1 kgm} and then loosen it and tighten again to torque of 215 ± 9.8 Nm {22 ± 1 kgm}.
023502
•
3. Install lock washers (15) to the nuts of the upper and lower center pins and tighten bolts and washers (14). a Be sure to install washers (16) between lock washers (15) and frame.
•
30-246 (6)
Install bushings (21) by expansion fit.
023502
•
Install bushing (22) by expansion fit.
•
Bleeding air Bleed air from the hydraulic cylinders. For details, see “Precautions when carrying out operation, 2. Precautions when carrying out installation work”.
•
Refilling with oil (Hydraulic tank) Add oil through the oil filler to the specified level. Run the engine to circulate the oil through the system. Then, check the oil level again.
30-247 (6)
40
MAINTENANCE
STANDARD
HYDROSHIFT transmission and transfer.. .... .40- 2 Transmission pump ........................................ 40- 4 Transmission control valve ............................ 40- 6 Transmission solenoid valve ......................... 40-10 Final drive ........................................................ 40-I 1 Differential lock-up pump ............................... 40-12 Tandem drive .................................................. 40-13 Front axle ......................................................... 40-14 Steering cylinder ............................................. 40-16 Disc brake ........................................................ 40-17 Parking brake ................................................... 40-18 Spring cylinder ................................................ 40-19 Hydraulic control valve.. ................................. 40-20 Hydraulic cylinder ........................................... 40-22 Hydraulic pump.. ............................................. 40-24 Drawbar and lifter ........................................... 40-26 Blade.. ............................................................... 40-28 Circle rotation gear ....................................... 40-29-I Ripper ............................................................... 40-30 Frame ............................................................... 40-31
40- 1 0
023502
40-3-2 (6)
MAINTENANCE STANDARD
TRANSMISSION PUMP
Serial No. 12099 and up
023502
SAR (3)-080
Unit: mm
No.
Check item
1
Clearance between gear case and side plate gear
2
Clearance between plain bearing I.D. and gear shaft O.D.
3
Pin insertion depth
4
Spline shaft rotating torque
—
Deliver Engine oil CLASS-CD 45 – 55°C
Criteria
Remedy
Standard clearance
Clearance limit
0.10 – 0.15
0.19
0.06 – 0.149
0.20
Replace
0 14 –0.5
6.9 – 11.8 Nm (0.7 – 1.2 kgm) Pump speed (rpm)
Delivery pressure (MPa {kg/cm2})
Standard delivery (¬/min)
Repair limit of delivery (¬/min)
2,500
20.6 {210}
184
169
—
40-5 (6) 2
LOWER VALVE Serial No.: 11001 - 12012.12016-12018
40-8 0
Unit: mm Remedy
Criteria
Checkitem
No.
Tolerance
Clearance
1
between
F-R
I
spooland
body I
I 22
2
Clearance
betweenlstspooland
3
Clearance
between
2ndspooland
4
Clearance
between
3rd
5
Clearancebetween4th
6
Clearance
between
Lspooland
7
Clearance
between
H
body
22
body
22
spooland
body
22
spooland
body
22
I 0
-0.035
+0.013
-0.045
0
-0.035
+0.013
-0.045
0
0.035 0.058 0.035 0.058 0.035 0.058
I 0.08
0.08
0.08 Replace
body
22
spool and body
22
-0.035
+0.013
-0.045
0
-0.035
+0.013
-0.045
0
-0.035
+0.013
-0.045
0
-0.035
+0.013
-0.045
Standard
Ist,2nd,3rd,4th
I +0.013
-0.035 -0.045
0
0.035 0.058 0.035 0.058 0.035 0.058 0.035 0.058
0.08
0.08
0.08
0.08
size
speed
40-9
Serial No.: 12013 - 12015,
12019 and up
9
/ /
5 9
4
9
9
2 IO
I IO
11
13 12 8 SWG00398
40-9-l 0
Unit: Criteria
Check item
No.
Stasn$rd Clearance between
1 ;‘,“,:b;
Cle,;ar&xe
1st spool and body
22
-0.035 -0.045 -0.045 -0.035
22
+0.013 0
0.035 0.058 -
0.08
I
0 +0.013
0.058 0.035
0.08
I
0.08 0.08
3
Clearance between
2nd spool and body
22
-0.035 -0.045
f0.013 0
0.035 0.058
4
Clearance between
3rd spool and body
22
-0.035 -0.045
+0.013 0
0.035 0.058
between 4th spool and body
22
-0.045 -0.035
0 +0.013
0.058 0.035
0.08
I
0 f0.013
0.058 0.035
0.08
I
0.08
I
0.08
5 6 -
Clearance Clearance
between
Clearance between
-
Clearance between
,ha~‘er~Hole
Remedy
F-R spool and body
I 2
~
a
L spool and body
-0.045 -0.035
22
H spool and body
Clearance between pilot reducing valve spool and body
22
-0.045 -0.035
0 +0.013
0.058 0.035
25
-0.035 -0.045
+0.013 0
0.035 0.058
Standard 9
10
Free length
Spring for L., H., 1st. 2nd. 3rd. 4th speed
Spring for F-R spool
-
Installation load
75.7
98.1 N (1 o kg)
60.6
39
104 N (10.6 kg)
43.7
163.6 N (I 6.7 kg)
62
12
Pilot reducing
valve spring (inner)
I
26
13
Thickness
I
Free length
103 N (10.5 kg)
I
valve
Installation load
47
valve spring (outer)
of pilot reducing
Installation length
/
19
Replace
Repair limit
size
78
Pilot reducing
11
mm
5.7 N (0.58 kg)
99 N (10.1 kg) 60.1
25.2
Replace
155.9 N (15.9 kg) 5.4 N (0.55 kg)
3 mm [Pressure per each shim: 0.03 MPa (0.26 kg/cm?)]
Adjust
40-9-2 0
MAINTENANCE
TRANSMISSION
STANDARD
TRANSMISSION Serial No.: 11001 - 12012,
SOLENOID
SOLENOID
VALVE
VALVE
12016 - 12018
i-l
l-h
rl
n
l-l
l-l/’
I 4th
1st
LOW Hioh 3rd F R
40-10 0
MAINTENANCE
STANDARD
Serial No.: 12013 - 12015,
TRANSMISSION
SOLENOID
VALVE
12019 and up
4th
1st
LOW
A-A
SwG00400
40-10-l 0
FINAL DRIVE
235CDO2033
Unit: No.
Criteria
Check item
Remedy
1
Preload of bevel pinion bearing
Starting torque:
9.8 - 12.7 Nm (I .O - 1.3 kgm)
2
Preload of shaft bearing
Starting torque:
9.8 -
3
Preload of bevel gear bearing
4
Backlash between
Starting torque:
mm
12.7 Nm (1.0 - 1.3 kgm)
(Starting torque of bevel pinion bearing) + 0.69 - 0.98 Nm (0.07 - 0.10 kam)(Measured of pinion shaft)
Tolerance
Repair limit Adjust
ring gear and gear 0.20 - 0.63
1.6
0.25 - 0.33
1.3
5
Backlash between bevel gear
bevel pinion and
6
Backlash between
gear and gear
0.25 - 0.33
1.3
7
Backlash between
gear and gear
0.17 - 0.44
1.4
40-l 1
MAINTENANCE
STANDARD
DIFFERENTIAL
DIFFERENTIAL LOCK-UP PUMP
LOCK-UP PUMP
LAL12
-
I
I Check
No -
item
Standard
Clearance between gear case and side plate, gear
Spline torque Delivery (Engine
shaft
limit
0.20
I
I
-
I
rotating
oil CLASS-CD
Clearance
Remedy
0.15
0.06 - 0.119
I
2.0 - 4.9 Nm (0.2 - 0.5 kgm} Pump speed
45 - 55°C)
40-12 0
depth
clearance
0.05 - 0.10
Clearance between plain bearing I.D. and qear shaft O.D. Pin insertion
I
Criteria
I
Unit:
(rpm) 3500
Delivery pressure
(MPa {kg/cm% 17.2 I1751
Standard delivery
(Urnin) 26
Repair limit of delivery
(Urnin) 23
-
mm
023502
TANDEM DRIVE
40-13 (6)
023502
Serial No.: 12099 and up
40-15-1 (6)
023502
40-15-2 (6)
STEERING
CYLINDER
F23501044
Check item
No.
Criteria
I
Remedy
I
I
I
I
Clearance between piston rod and bushing 40
2 3 -
Clearance between piston rod support shaft and bushing Clearance between cylinder bottom support shaft and bushing
40-16
60
I
35
-0.060 -0.142
+0.132 +0.006
0.036 0.274
- 0.060 - 0.090
+0.010 -0.010
0.050 0.100
-
+0.039 0
0.025 a 103
0.025 - 0.064
Replace bushing
0.6
0.6
0.6
-1
DISC BRAKE
F23501062
Unit:
Check item
No.
Criteria Standard size
Thickness
Remedy Repair limit
of disc
2
Thickness
3
Total thickness
of plate
I
of discs and plates
3.8 i
0.1
2.3 i
0.1
51.1
f
3.3 2 0.1
-
I
1.7
47.1 i
Standard size 4
mm
Return spring
Free length
Installation length
71
52
I 1.7
Replace
Repair limit Installation load 247.1 N (25.2 kg)
Free length 67
Installation load -
40-17
PARKING
BRAKE
Section A -A F23501063A
Criteria
Check item
No.
Remedy
Standard size
Repair limit
16
8
Wear of brake pad
2
Tightening
40-18
torque of mounting
Replace pad
bolt
441.3 - 539.4 Nm (45 - 55 kgm)
Retighten
MAINTENANCE
SPRING
STANDARD
CYLINDER
SPRING CYLINDER
277*31_9Nm {28.25*3.25bml
SWG00413
Unit:
Standard 1
Piston
3
5001.4
Play of rod in axial direction
2.1
Installed
132
dimension
of rod
size Installation
Free length
spring
260 2
Remedy
Criteria
Check item
No.
mm
load
Replace
N {510 kg}
Adjust
40-19 0
MAINTENANCE
STANDARD
HYDRAULIC
HYDRAULIC
CONTROL VALVE
Serial No.: 11001 - 12022 L.H. VALVE (Left blade lift, Ripper,
Blade side shift, Power
tilt and Circle rotation)
1.5Nm 0.15!+3 A-A \
40-20 0
CONTROL
VALVE
MAINTENANCE
HYDRAULIC CONTROL VALVE
STANDARD
R.H. VALVE (Right blade lift, Leaning,
Articulate,
Drawbar
side shift and Service)
SWG00403
40-21
MAINTENANCE
HYDRAULIC
STANDARD
CONTROL
VALVE
Serial No.: 12023 and up L.H. VALVE (Left blade lift, Ripper,
Blade side shift, Power
tilt and Circle rotation)
F-F \
00.3*9.8Nm 'S*llaml
A-A. c-c.
/
B-0 D-D
68.3*9.8Nm S*lkPml
I
E-E
SWG00404
40-21-l 0
MAINTENANCE
HYDRAULIC CONTROL VALVE
STANDARD
R.H. VALVE (Right blade lift, Leaning,
Articulate,
Drawbar side shift and Service)
88.3i9.8Nm (9*lkpml
SWG00405
40-2 1-2 0
HYDRAULIC
CYLINDER
Serial No.: 11001 - 12050
F23501109
T
No
Unit: mm Check
l-
item
Criteria
Remedy
Clearance limit
0.6
Blade lift
3learance between liston rod and bushing
Blade side shift
65
-0.100 -0.174
+0.262 +0.067
0.167 0.436
0.6
Drawbar shift
60
-0.100 +0.174
+0.163 + 0.006
0.106 0.337
0.6
-0.080 -0.142
+0.152 + 0.007
0.067 0.294
-0.100 -0.174
+ 0.262 +0.067
0.167 0.436
45
Leaning Articulate Power
-
40-22 0
Ripper
65
c
0.6 0.6
L
0.6
tilt
i
0.6
Replace
Unit:
Check item
Criteria
Blade lift Blade shift
Clearance
between piston rod support shaft (ball joint) and bushing (rod end)
side
55 100
Learning
55
Standard clearance
, ,ole
100
Drawbar shift
Remedy
Tolerance
Standard size -0.05 -0.15
+O.l 0
-0.030 -0.076
+0.174 +O.lOO
-0.05 -0.15
+O.l 0
-0.030 -0.076
+0.174 +O.lOO
mm
0.05 0.25
Clearance limit
-
1.0
0.130 0.250
1.0
0.05 0.25
1.0
0.130 0.250
-
1.0
Replace
Clearance between cylinder bottom yoke (Support, support shaft, support ball joint) and bushing (rod end)
lift
Blade shift
side
-
75
-0.100 -0.174
+0.074 0
0.100 0.248
55
-0.030 -0.076
+0.174 +O.lOO
0.130 0.250
Learning
55
-0.030 -0.076
+0.046 0
0.030 0.122
Articulate
65
-0.030 -0.076
+0.174 +O.lOO
0.130 0.250
Power
85
-0.120 -0.207
+0.087 0
0.120 0.294
-0.120 -0.207
+0.207 +0.120
0.240 0.414
I
Tightening torque of piston nut
Blade
tilt
Rippar (if equipped) Blade
lift
Blade shift
side
go
1.0 1.0
-
1.0
-
1.0
-
1.0 1.0
3.3 5 0.3 kNm
1340 e 34 kgm1 (Width
across
flats:
70 mm)
2.3 2 0.2 kNm
1230 2 23 kgm}
across
flats:
70 mm)
(Width
Drawbar shift
2.6 + 0.3 kNm
(265 + 26.5 kgm1 (Width
across
flats:
70 mm)
Learning
912 2 91.2 Nm {93.0 + 9.3 kgm1 (Width
across
flats:
50 mm)
Articulate
3.1 2 0.3 kNm
{320 2 32 kgm}
(Width
across
flats:
75 mm)
Power
2.8 2 0.3 kNm
(290 2 29 kgm1 (Width
across
flats:
75 mm)
tilt
Ripper (if equipped)
4.0 + 0.4 kNm
1405.0 2 40.5 kgm)
(Width
across
flats:
80 mm)
Retighten
I 40-23 0
HYDRAULIC
CYLINDER
Serial No.: 12051 and up
F23501109
Check
NC
1
Clearance between 3iston rod and bushing
T
item
Remedy
Criteria
Blade lift
65
-0.100 -0.174
+0.262 +0.067
0.167 0.436
0.6
Blade side shift
65
-0.100 -0.174
+0.262 +0.06?
0.167 0.436
0.6
Drawbar shift
60
-0.100 +0.174
+0.163 +0.006
0.106 0.337
0.6
Leaning
50
-0.025 -0.087
+0.152 -l-o.007
0.032 0.239
0.6
Articulate
65
-0.100 -0.174
l +0.067
+0.262
0.167 0.436
0.6
65
-0.100 -0.174
+0.262 +0.067
0.167 0.436
0.6
70
-0.100 -0.174
+0.271 +0.075
0.175 0.445
Power Ripper
40-23- 1 0
Unit: mm
tilt
-
0.6
Replace
Unit:
-
T
Nc3. -
i
Check
Clearance between piston rod support shaft (ball joint) and bushing (rod end)
item
Criteria
1 Blade
lift
Blade shift
side
110
55
Remedy
Tolerance
Standard size
Shaft
mm
Standard clearance
Hole
-0.05 -0.15
+O.l 0
-0.030 -0.076
+0.174 +O.lOO
-0.05 -0.15
+O.l 0
0.05 0.25
Clearance limit
-
1.0
0.130 0.250
1.0
0.05 0.25
1.0
Drawbar shift
110
Learning
55
-0.030 -0.076
+0.174 +O.lOO
0.130 0.250
Articulate
65
-0.030 -0.076
+0.174 +O.lOO
0.130 0.250
-
1.0
-
1.0
hl 0
Fi 0 -
~~
Clearance between cylinder bottom yoke
Blade shift
Replace
side
Drawbar shift
55 110
-0.030 -0.076
+0.174 +O.lOO
-0.05 -0.15
+O.l 0
-0.120 -0.207
+0.207 +0.120
0.130 0.250
1.0
0.05 0.25
1.0
0.240 0.414
1.0
(Support,
3
support shaft, support ball joint) and bushing (rod end) Ripper (if equipped) Blade
4
Tightening torque of piston nut
lift
)l
go
3.3 + 0.3 kNm
(340 + 34 kgm1 (Width
across
flats:
70 mm)
2.3 2 0.2 kNm
(230 2 23 kgm}
across
flats:
70 mm)
2.6 + 0.3 kNm
(265 2 26.5 kgm)
(Width (Width
across
flats:
70 mm)
1.8 2 0.2 kNm
I180 2 18 kgm}
(Width
across
flats:
60 mm)
Articulate
3.1 k 0.3 kNm
{320 2 32 kgm}
(Width
across
flats:
75 mm)
Power
2.8 2 0.3 kNm
(290 2 29 kgm}
(Width
across
flats:
75 mm)
tilt
Ripper (if equipped)
4.0 2 0.4 kNm
1405.0 + 40.5 kgm}
(Width
across
flats:
Ret,ghten .
80 mm)
40-23-2 0
MAINTENANCE
PUMP
PUMP
HYDRAULIC FOR WORK VXD70-1 F
HYDRAULIC
STANDARD
EQUIPMENT
-
98* 9.8Nm (lO*lbml
I
amI
I
SWG00406
40-24 0
MAINTENANCE
DRAWBAR
STANDARD
DRAWBAR
AND
LIFTER
AND LIFTER
Serial No.: 11001 - 12050
\
m
981+49Nm
~100~5koml
SDG00029
Unit: Check
No.
,
item
Wear of ball joint drawbar tip
Criteria
at
2
Clearance between and bushing
3
Clearance between and bushing yoke at blade lift cylinder bottom
40-26 0
yoke
Standard size
Tolerance Shaft
Hole
180
-0.05 -0.15
+O.l 0
110
4.035
+0.207 +0.120
75
-0.100 -0.146
+0.074 0
mm
Remedy Standard clearance 0.5 - 0.9 0.120 0.242 0.100 0.220
-
Clearance limit 0.6 0.5
If it is impossible to adjust with shims, reolace ioint or’ball joint Replace bushing
MAINTENANCE
DRAWBAR AND LIFTER
STANDARD
A-A
0-B
\
\
m
981*49Nm (100*5bml
m
G-G
F-F
\
981*49Nm ~100*5kPml
SOG00030
Unit: Check
No.
Standard 4
Clearance between and drawbar
Clearance direction
of yoke
in axial
6
Thickness
of wear
plate
7
Thickness
of wear
plate
of lifter
9
End play
limit
1.5
1.0 - 2.0
0.3 - 0.8
1.7
Standard
Wear
Clearance
clearance
circle
5
8
Remedy
Criteria
item
bracket
of ball joint
Repair
size
2
8
2
shim
thickness:
0.7 -c 0.2
2
f it is imposjible to adjust with shims, replace circle guide Replace bushing
limit
6
Standard
mm
Replace plate
wear
If it is impossible to adjust with shims, replace lifter bracket Replace
40-27 0
MAINTENANCE
STANDARD
DRAWBAR
AND
LIFTER
Serial No.: 12051 and up
No.
,
2
3
Check item
Criteria
Wear of ball joint at drawbar tip Clearance between and bushing
yoke
Clearancebetween bushingand yoke at bladelift cylinder bottom
40-27-l 0
Standard size 180 110 75
Tolerance Shaft
Hole
Remedy Standard clearance
Cl~;~i;ce
0.5-0.9
-
-0.05 -0.15
+O.l 0
4.035
+0.207 +0.120
0.120 0.242
0.6
-0.100 -0.146
+0.074 0
0.100 0.220
0.5
If it is impossible to adjust with shims, replace joint or ball joint Replace bushing
MAINTENANCE
STANDARD
DRAWBAR
7
981*49Nm ~100~5koml
G-G F-F
f
SWG00408
Unit:
Check
Nt3. 4
Clearance between and drawbar
5
Clearance direction
of yoke
in axial
6
Thickness
of wear
plate
7
Thickness
8
Wear
9
End play
of wear
of lifter
limit
circle
I
-
Clearance
clearance 1.5
1.0 - 2.0
0.3 - 0.8
1.7
Standard
of ball joint
I
shim
If it is impossible to adjust with shims, replace circle guide Replace bushing
limit Replace plate
wear
2
I Standard
bracket
2
I
8
plate
Repair
size
7
mm
Remedy
Criteria
item Standard
-
AND LIFTER
thickness:
0.7 + 0.2
2
If it is impossible to adjust with shims, replace lifter bracket Replace
40-27-2 0
MAINTENANCE
STANDARD
BLADE
BLADE Serial No.: 11001 - 12050
SDG00031
Unit: mm Check
No.
Criteria
item
Wear of cutting edge Wear of side edge
I
Less than 10 mm from blade holder Repair limit:
Standard
40-28 0
Side face 25 Within 10 mm from blade holder
Repair limit:
Wear of blade rail
Wear of blade rail guide
Remedy
size
Height Thickness
I
Replace
85 35 Repair limit
9
6
9
5
Replace as soon as one value reaches limit
MAINTENANCE
Serial
BLADE
STANDARD
No. 12051 and up Xl
------;~5------.
V X
!it
SWG00409
Unit:
Check
item
1
Wear
of cutting
2
Wear
of side edge
3
Wear
of blade
rail
Wear
of
rail
4
blade
Remedy
Criteria
edge
Less than
I Repair
limit:
11
blade
Side face 25
Within
Repair
guide
10 mm from
limit:
mm
IO mm from Height Thickness
holder
blade
holder
I Replace
85 35
!gii :it 40-29 0
CIRCLE ROTATION
GEAR
Serial No.: 11001 - 12050
\ ‘.
\7
“-
L.3
F235014’12 Unit:
Check item
No.
1
Criteria
Remedy
Clearance between worm wheel shaft and bushing
2
Clearance between worm wheel shaft and bushing
3
Backlash between worm and worm wheel
90
-0.036 -0.071
+0.144 +0.052
0.088 - 0.215
0.4
90
-0.036 -0.071
+0.223 +0.065
0.101 - 0.294
0.4
Standard
4
Clearance between worm wheel shaft and wear plate
5
Wear of pinion gear
6
Thickness of disc
I
7
Thickness of plate
I
8
Thickness
of disc
9
Thickness
of plate
10
Total thickness
11
Preload of worm shaft bearing
0.3 - 0.5
2.0
1.o
_
Standard
40-29- 1 0
of disc and plate
I I I
Replace
Clearance
clearance
2.8 ‘O0.1
I
2.0 f 0.07
I
3.6 k 0.1
I
2.6
1.7 f 0.05
I
1.5
97.1
limit
Adjust
Repair limit
size
I
mm
2.4
I
_
Replace
I
95.4
Starting torque: 4.9 - 9.8 Nm (0.5 - 1.0 kgm) (when worm wheel is not meshed)
Adjust
MAINTENANCE
STANDARD
CIRCLE ROTATION
GEAR
Serial No. 12051 and up
swcoo4
Unit: Check
No
1
2
item
Criteria
Clearance between worm wheel shaft and bushing
90
Clearance between pinion gear bottom collar and bushing Backlash between and worm wheel Clearance and worm
Tolerance
Standard size
100
-0.036 -0.090
+0.207 +0.120
0.156 0.297
-0.036 -0.090
+0.207 +0.120
0.156 0.297
-
5
Wear
6
Thickness
of disc
7
Thickness
of plate
8
Preload ing
of worm
gear
shaft
I bear-
0.4 Replace
0.4 limit
Repair
size
34 3.2 +
Clearance limit
2.0
0.2 Standard
of pinion
Clearance
0.3 - 0.5
between blade wheel shaft
Standard clearance
Hole
clearance
mm
Remedy
Shaft
Standard
worm
I I
Adjust limit
28 0.08
2.0 2 0.05
Replace
1.8
I
-
Starting torque: 4.9 - 9.8 Nm {0.5 - 1.0 kgm} (when worm wheel is not meshed)
I Adjust
40-29-2 0
RIPPER
Section A-A
Section E-E
sectionc-c
Section F-F
Section D-D
F23501124
Unit: mm No.
Check item
Criteria
Remedy
Tolerance 1
Clearance between pin and bushing
Standard size Shaft
60
2
Standard clearance
- 0.025 -0.055
Hole +0.174 +0.100
Replace
0.125
- 0.229
Standard size
Repair limit
320
170
Wear of point
40-30 0
Clearance limit
0.5
Replace
023502
FRAME
Unit: mm No.
Check item
Criteria Standard size
1
Outside diameter of center pin
–0.036
118 –0.090
2
Tightening torque of nut
Remedy Repair limit Replace 116.910
1. Adjust nut at bottom pin end when tightening so that clearance A and B are uniform. 2. After tightening nut at top pin end to 255 ± 10 Nm {26 ± 1 kgm}, loosen once, then tighten again to 235 ± 30 Nm {22 ± 1 kgm}.
Tighten
40-31 (6)
Komatsu America international Company 440 North Fairwav Drive I Vernon Hills, IL 66061-8112 U.S.A. Attn: Technical Publications Fax No. (847) 970-4186
PROPOSAL
1
FOR MANUAL
REVlslON
FOR INTERNAL USE ONLY -- No. PMR 2
NAME OF COMPANY:
:
PHONE NO:
: S
DEPARTMENT:
E R
NAME:
MANUAL NAME: MANUAL NO: MACHINE MODEL: S/N IF APPLICABLE: PAGE NO: PROBLEM:
Attach photo or sketch. If more space is needed, use another sheet.
1 FOR INTERNAL USE ONLY CORRECTIVE ACTION:
PFMRl 081696
LOCATION:
DATE:
