SEBM04230107
KOMATSU
WA3504 MACHINE
MODEL
SERIAL
WA350-
1
10001
l
This shop manual available items
Please
and up
attachments consult
and optional
equipment
your local Komatsu
distributor
that are not for those
you may require.
Materials
l
may contain
in your area.
No.
and specifications
WA350-1
mount
For details
of the engine,
05-90(03)03561
the S6Dll
are subject
O-l
to change
without
notice.
engine.
see the 110
Series
Engine
Shop Manual.
oo-1 a
CONTENTS No. of page
10
20
40
ENGINE 11
STRUCTURE
12
TESTING
13
DISASSEMBLY
POWER
60
80
90
00-2 0
AND ADJUSTING
.. . . .. . . .
AND ASSEMBLY..
........
...
. .. .
.
.
.....
. . .. .
.
.
1 l-l 12-1 13-1
TRAIN
STRUCTURE
22
TESTING
23
DISASSEMBLY
AND ASSEMBLY
24
MAINTENANCE
STANDARD
AND FUNCTION
AND ADJUSTING
STEERING
............................................... ................................................. .............................................
.................................................
21-1 22-l 23-l 24-l
SYSTEM
41
STRUCTURE
42
TESTING
43
DISASSEMBLY
AND FUNCTION
BRAKE AND
............................................... .................................................
AND ADJUSTING
MAINTENANCE
AND ASSEMBLY STANDARD
AND FUNCTION
...............................................
STRUCTURE TESTING
53
DISASSEMBLY
AND ASSEMBLY
54
MAINTENANCE
STANDARD
.................................................
AND ADJUSTING
EQUIPMENT
STRUCTURE
62
TESTING
............................................... .................................................
63
DISASSEMBLY
AND ASSEMBLY
64
MAINTENANCE
STANDARD
AND
STRUCTURE
82
TESTING
83
DISASSEMBLY
42-l 43-l 44-l
51-1 52-l 53-l 54-l
SYSTEM
AND ADJUSTING
ELECTRIC
.............................................
.................................................
AND FUNCTION
81
41-1
AIR SYSTEM
52
61
.............................................
.................................................
51
WORK
... .. . .
.................................................
21
44
50
AND FUNCTION
.............................................
.................................................
ELECTRONIC
AND FUNCTION
AND ADJUSTING
62-l 63-l 64-l
SYSTEM
............................................... .................................................
AND ASSEMBLY
61-1
.............................................
81-1 82-l 83-l
OTHERS AND FUNCTION
...............................................
91
STRUCTURE
93
DISASSEMBLY
97
GEAR PUMP ................................................................
AND ASSEMBLY
.............................................
91-1 93-l 97-l
WA350-1
must
pages
affected
The following
to these
be taken
are
use of the
by the
indicated
It is requested
marks.
necessary
that
actions
LIST OF REVISED Revision number
oo- 1 oo- 2
@
lark
Revision number
Page
l3-
6
dark
0
Page to be replaced
Replace
Page to be deleted
Discard
1
are not revised
no marks
at this time.
PAGES
Revision number
Page
Add
Page to be newly added
Pages having
Page
required
0
(
Mark
Action
Indication
Mark
to the list below.
pages according
Aark
Revision number
Page
dark
Revision number
Page
@
13-47
21-40
@
23-
8
@
1
21-41
@
23-
9
@
0
13-8
@
21-
@
21-
2
21-42
@
23-10
@
@
23-11
@
23-12
@ @
00-
2-l
@
13-g
oo-
2-2
@
13-10
@
2l-
3
21-43
00-
2-3
@
13-11
@
21-
4
21-44
00-
2-4
@
13-12
@
21-
5
21-45
@
23-13
21-46
@
23-14
@
@
23-15
@
13-13
@
21-
6
oo- 4
13-14
@
21-
7
21-47
00.
5
13-15
@
00-
6
13-16
@
2121-
8 9
21-48 21-49
oo- 7
13-17
0
21-10
22-
1
@
23-18
@
00-
8
13-18
@
21-11
22-
2
@
23-19
0
oo-
9
13-19
@
21-!2
22-
3
0
23-20
@
oo- 10
13-20
@
21-13
22-
4
@
23-21
@
00-11
0
13-21
@
21-14
22-
5
@
23-22
@
00-12
@
13-22
@
21-15
22-
6
@
23-23
0
13-23
@
21-16
22-
7
@
23-24
@
22-
8
@
23-25
@I
3
oo-
II-
1
23-16
@
23-17
@
II-
2
13-24
@
21-17
11-
3
13-25
@
21-18
22-
8-l
@
23-26
@
II-
4
13-26
@
21-19
22-
8-2
@
23-27
@
II-
5
13-27
@
21-20
22-
9
@
23-28
@
12-
1
13-28
@
21-21
22-11
@
23-29
0
13-29
0
21-22
22-12
0
23-30
@
13-30
0
21-23
22-13
@
23-31
@
21-24
22-14
@
23-32
@
0
12-2
@
12-3 12-4
@
13-31
0
12-5
@
13-32
@
21-25
22-15
@
23-33
@
12-6
@
13-33
0
21-26
22-16
@
23-34
@
12-7
@
13-34
@
21-27
22-17
@
23-35
@
8
23-36
@
12-8
@
13-35
0
21-28
22-18
12-9
0
13-36
@
21-29
22-19
@
23-37
@
12-10
0
13-37
0
21-30
22-20
@
23-38
@
12-11
0
13-38
@I
21-31
22-21
@
23-39
0
12-12
0
13-39
0
21-32
22-22
0
23-40
@
12-13
@
13-40
0
21-33
23-l
@
23-41
@
@
13-41
0
21-34
23-
2
@
23-42
@
0
13-42
@
21-35
23-
3
@
23-43
@
13-2
@
13-43
0
21-36
23-
4
@
23-44
@
13-3
0
13-44
0
21-37
23-
5
@
23-46
@
0
21-38
23-
6
@
23-47
@
23-
7
@
23-48
@
12-14 13-
13-4 13-5
WA350-1
1
0 0
13-45 13-46
@
00-2 -1 0
Mark
Page
Revision number
/lark
Revision
Page
number
Aark
Page
Revision number
Aark
Page
Revision number
lark
Page
Revision number
23- 49
@
23-105
@
41-21
44- 2
52-20
23- 50
@
23-106
@I
41-22
44- 3
53- I
23- 51
@
23-107
@I
41-23
44- 4
53- 2
23- 52
@
23-108
@
41-24
44- 6
53- 3
23- 53
@
23-109
0
41-25
44- 7
53- 4
23- 54
@
23-110
@
42- 1
44- 8
53- 5
23- 55
@
23-111
@
42- 2
44- 9
53- 6
23- 56
@
23-112
@
42- 3
44-10
53- 7
23- 57
@
23-113
@
42- 4
44-11
53- 8
23- 58
@
23-114
@
42- 5
44-12
53- 9
23- 59
@
23-Cl5
@
0
42- 6
44-13
53-10
23- 60
@
23-116
@
0
42- 7
44-14
53-11
23- 61
@--
23-117
@
42- 8
44-15
53-12
23- 62
@
23-118
@
42- 9
51- I
53-13
23- 63
@
23-119
0
42-10
51- 2
53-14
23- 64
@
24-
1
42-11
51- 3
53-15
23- 65
@
24-
2
42-12
51- 5
53-16
23- 66
-0
24-
3
43- I
51- 6
53-17
23- 67
@
24-
4
43- 2
51- 7
53-18
23- 68
@
24-
5
43- 3
51- 8
53-19
23- 69
@
24-
6
43- 4
51- 9
53-20
23- 70
@
24-
7
43- 5
51-10
53-21
23- 72
@
24-
8
43- 6
51-11
53-22
23- 73
@
24- 9
43- 7
51-12
23- 74
@
24- IO
43- 8
51-13
53-23 53-24
23- 75
@
24- 11
@
43- 9
51-14
53-25
23- 76
@
24- 12
@
43-10
51-15
53-26
23- 77
@
24- 14
43-11
51-16
53-27
23- 78
@
24- 15
43-12
51-17
53-28
23- 79
@
24- 16
@
43-13
51-19
53-29
23- 80
@
24- 17
@
43-14
51-20
53-30
23- 81
@
24- 18
@
43-15
51-21
53-31
23- 82
@
24- 19
43-16
51-22
53-32
23- 83
@I
24- 20
@
43-17
51-23
53-33
23- 84
@
24- 21
@I
43-18
51-24
53-34
23- 85
@
41-1
0
43-19
51-25
53-35
23- 86
@
41-2
@
43-20
52- I
53-36
23- 87
@
41- 3
0
43-22
52- 2
53-37
@
@ @
23- 88
@
41- 4
0
43-23
52- 3
53-38
23- 89
@
41-5
8
43-24
52- 4
53-39
23- 90
@
41- 6
@
43-25
52- 5
53-40
23- 91
@
41- 7
0
43-26
52- 6
53-41
23- 92
@
41-
8
@
43-27
52- 7
53-42
23- 93
@I
41-
9
0
43-28
52- 8
53-43
23- 94
@
41- 10
43-29
52- 9
53-44
23- 95
@
41- II
0
43-30
52-10
53-45
23- 96
@
41- 12
0
43-31
52-11
53-46
23- 97
@
41- 13
0
43-32
52-12
53-47
23- 98
@
41- 14
0
43-33
52-13
53-48
23- 99
@
41- 15
43-34
52-14
54- 1
23-100
@
41- 16
43-35
52-15
54- 2
23-101
@
41- 17
0
43-36
52-16
54- 3
23-102
@
41- 18
@
43-37
52-17
54- 4
23-103
@
41- 19
0
43-38
52-18
54- 5
23-104
@
41- 20
@
44- I
52-19
54- 6
00-2 -2 0
WA350-1
@
Mark
Page
Revision number
/lark
@
54- 7 54- 8
0
Revision
Page
number
Jlark
Page
Revision number
lark
Page
Revision number
lark
Page
Rewsion number
63- 5
81-10
82-27
82- 86
@
63- 6
81-11
82-28
82- 87
@I
54- 9
0
63- 7
81-12
82-29
82- 88
@I
61- I
@
63- 8
81-13
82-32
82- 89
0
61- 2
63- 9
81-14
82-33
82- 90
@
61- 3
63-10
81-15
82-34
82- 91
Cj)
61- 4
@
63-11
81-16
82-35
82- 92
0
61- 5
@
63-12
81-17
82-36
82- 93
@
6l- 5-l
0
63-13
81-18
82-37
82- 94
@
6l- 5-2
@
63-14
81-19
82-38
82- 95
@
6l- 6
@
63-15
81-20
82-39
82- 96
@
63-16
81-21
82-40
82- 97
@
63-17
81-22
82-41
82- 98
0
6l- 9
63-18
81-23
82-42
82- 99
@
61-10
63-19
81-24
82-43
82-100
@
61-11
63-20
81-25
82-44
82-102
@ @
6l- 7 6l- 8
-.
61-12
@
63-21
81-26
82-45
82-103
61-14
@
63-22
81-27
82-46
82-104
@
61-15
63-23
81-28
82-47
82-105
@
61-15-I @
63-24
81-29
82-48
82-106
@
61-15-2 @
63-25
81-30
82-49
82-107
@
61-16
63-26
81-31
82-50
82-108
@
61-17 61-18
63-27
82-51
82-109
@
63-28
81-32 81-33
82-52
82-110
@
61-19
63-29
81-34
82-54
82-111
@
61-20
63-30
81-35
82-55
82-112
@
63-31
81-36
82-56
82-113
@
61-22
63-32
81-37
82-57
82-114
@
61-23
63-33
81-38
82-59
82-115
@
61-24
63-34
81-39
82-60
83-
I
@
61-25
63-35
81-40
82-61
83-
2
@ @
61-21
@
@
61-26
@
63-36
81-41
82-62
9l-
I
62- 1
@
63-37
82- I
82-63
91-
2
62- 2
@
63-38
82- 2
82-64
9l-
3
@
62- 3
@
64- 1
82- 5
82-65
9l-
4
@
62- 4
@
64- 2
82- 6
82-66
9l-
5
62- 5
@
64- 3
82- 8
82-67
91-
6
62- 6
@
64- 3-l
82- 9
82-68
9l-
7
62- 7
@
64- 3-2
82-10
82-69
93-
I
@
62- 8
@
64- 4
82-11
82-70
93-
2
@
62- 9
@
64- 5
82-12
82-71
93-
3
@
62-10
@
64- 6
82-13
82-72
93-
4
@
62-11
@
64- 7
82-14
82-73
93-
5
@
62-13
@
64- 8
82-15
82-74
93-
6
@
62-14
@
64- 9
82-16
82-75
93-
7
@
62-15
@
64-10
82-17
82-76
93-
8
@
62-16
@I
8l- I
82-18
82-77
93-
9
0
62-17
@
8l- 2
82-19
82-78
93- IO
@
62-18
@
8l- 3
82-20
82-79
97-
1
@
62-19
@
8l- 5
82-21
82-80
97-001
@
62-20
@
8l- 5-2
82-22
82-81
97-002
@
63- I
@
8l- 6
82-23
82-82
97-003
@
63- 2
@
8l- 7
82-24
82-83
97-004
@
63- 3
@
8l- 8
82-25
97-005
@
63- 4
@
81-
82-26
82-84 82-85
97-006
@
WA350-1
l
9
00-2 -3 a
Mark
Page
Revisior number
Aark
Page
Revision number
dark
Page
Revision number
Aark
Page
Revfsion number
Mark
Page
Revision number
97407 97-008 97-101 97-102 97-103 97-104 97-105 97-106 97-107 97-108 97-109 97-110 97-111 97-112 97-113 97-114 97-115 97-116 97-117
00-2 -4 a
WA350-1
A Proper The
service
service
manual
and repair and
injury
to workers,
cautions
in this
followed
carefully.
safety,
designed
manual.
The cautions
If any dangerous
and take the necessary
by Komatsu
of operation.
by Komatsu
the symbols
A
actions
of your machine.
and
Some
described
of these
in this
operations
re-
used to mark safety
pre-
for the purpose.
and
*& are 4 these
accompanying situation
NOTICE
for the safe operation
recommended
and safe methods
specially
SAFETY
important
techniques
effective
quire the use of tools To prevent
is extremely
repair
are both
IMPORTANT
symbols
should
arises or may possibly
always
be
arise, first consider
to deal with the situation.
A SAFETY GENERAL
6. Decide
PRECAUTIONS
a place
keep tools Mistakes Read
in operation
the
are extremely
Operation
carefully
BEFORE
and
dangerous.
Maintenance
operating
Manual
the
tools
and
Always
carrying
read
all
decals
the
precautions
which
2.When
out any greasing are fixed
carrying
out
or repairs,
given
on
any
operation,
safety
shoes
and helmet.
loose
work
clothes,
or clothes
parts with .
safety
wear
grinding
always
with
3. If welding
repairs
trained,
experienced
work.
When
always
wear
and
glasses
buttons
when
hitting
glasses
a grinder,
are needed,
welding
other
carry
out
have a out
welding
gloves,
clothes
carrying
inform
suited
the
work,
apron, for
controls
any operation always
procedure your
step
work,
out
workers,
erating
5. Keep
7. Before
FOR
adding
block
the
of the
hang
8. Before ground.
provided
for
working.
safety to
welding
warning
op-
other
Before
starting on
the
condition
way to use them.
and
it
the
ripper, to the
levers
the
the work
In addition,
is
or
be sure and
hang
starting
oil from
to
get
use the
when
blocks,
impossible
the
on
or
on
steps
and
handrails,
getting
Never jump
sup-
jacks
work.
and
used
or steps,
assembling,
with
Always
steps
ladders
and
insert
to prevent
control
all mud
machine.
If learn
blade,
equipment
possible,
falling.
machine
places
machine.
compartment.
is not
the
before
10. Remove
repairs,
to prevent
lower work
disassembling the
starting
signs
all
any
signs on them.
stands
or
work,
from
lock
before
REPAIR
in good
on the
two
or tracks
pin or use blocks
glasses,
with
making
moving.
If this
equipment
port
or
wheels
starting
Always
operation.
in the operator’s
the correct
areas while
on hard, level ground,
or any other
starting.
workers
UNDER
all tools
agree
before
fellow
places.
and make
WORK
oil
from
9. When
or more
any
PREPARATIONS
bucket
always
welder
carrying
when
etc.
work. 4.When
the
Never smoke
machine
safety
parts with
correct
area clean
Do not wear
a hammer.
Always
cap
in
park the machine wear
in their
the
missing. Always
to keep
to the machine.
wear
.
workshop
parts. Always
is no dirt or oil on the floor.
only
smoking.
repair
the work
there
Smoke 1. Before
parts
keep
sure that
the machine.
in the
and removed
or
off
or the
ladders off
the
on or off the machine. to
use
use a stand
the
handrails,
to provide
safe
footing.
00-3
PRECAUTIONS 11. When or
DURING
removing
the oil filler
hydraulic
loosen
pressure
them
spurting
slowly
cap, drain
measuring
to prevent
plug plugs,
Replace l
sure
the oil from
of the
remove
oil,
the
or removing
water
compo-
or air circuits,
pressure
completely
the
20. When
the
engine
when
oil
in the
circuits
is stopped,
are
hot
so be careful
rying
out
any
work
to cool before
on
the
oil
or
carwater
starting
battery.
14. When
work,
Always
the negative
(-1
that
remove
the
parts
lead
from
components,
are free from
damage.
use
lifting
ample
capacity.
Install
the
places.
use
a
slowly
equipment
other
covers
ternal
pressure
or
spring,
always
under
loosen
bolts
components, the
removing
on the
in-
from
a on
the pressure,
piping,
be careful
not
Damaged
fires. stop
the fuel
or oil
out. If any fuel or oil drips on to
wipe
floor
any
in position
wiring.
may cause electrical
the floor,
with
the bolts to remove.
or damage
spilling
hit-
are under
release
it up immediately. can cause
you
Fuel or oil
to slip,
or can
even start fires. 18.As
a general
wash
parts.
mum
of
parts.
00-4
rule,
do
In particular,
gasoline
when
not
use gasoline
to
use ,only the miniwashing
the ma-
hoses,
twisted. for
that
make
Damaged
high
care-
pressure
connecting
or installing tightening
protective
parts
two
or hand.
fingers
caught
always When
violently
be particularly
aligning
parts, torques.
parts such as guards,
vibrate
speed,
or
rotate
careful
or at
to check
correctly. holes,
never
Be careful
insert
your
not to get your
in a hole.
electrical
measuring the
24. Take
hydraulic
measuring
bled before
from
pressure
leave two
sides. Slowly
removing
17. When from
which
when
so be extremely
check
fingers
that
by the hoist or crane.
removing
break
operate
Do not work
15. When
then slowly
correct
and
the component
by
has
at the
or crane
part.
part still raised
opposite
which
equipment
a hoist
to prevent any
and hooks
not
that they are installed
23. When
lifting
Use
chains
be
installed.
which
high
first.
rope,
wires,
be damaged
parts
tubes
assembling
22. When
the wire
Always
wiring
Also,
the leads from
hoist or crane. Check
to
installing
are correctly
remove
heavy
not
pressure
are
are dangerous,
when
installing
terminal
raising
16. When
high
they
use the specified
13. Before
ting
ful
21. When
circuits.
the
will other
installing
circuits.
not to get burned. Wait for the oil and water
with
that
tubes and
they
new parts.
and
first
from
sure
water
hoses
in their
chine is being operated.
circuit. 12. The
that
again
parts with
installing
contact
disconnecting
all parts
any damaged
When
out.
Before nents
19. Be sure to assemble original places.
WORK
care
taking when
tracks
of track-type removing
either
pressure,
check
is correctly
assem-
any measurements. removing
When
rates suddenly,
tool
or installing
the
machines. the
track,
so never
end of the track.
the
track
let anyone
sepa-
stand
at
FOREWORD
This
shop
serviceman repairs effect
has been
an accurate
at every
This shop
prepared
understanding
and make judgements.
a service For
manual
Make
as an aid to improve
of the product
the
quality
and by showing
sure you understand
of repairs
by giving
the
him the correct
way to perform
of this manual
and use it to full
the contents
opportunity.
manual
mainly
contains
the necessary
technical
information
for operations
performed
in
workshop. ease
components;
of
understanding,
these chapters
STRUCTURE
AND
This section
AND
This
section
explains
section
assembling MAINTENANCE This section
the structure
of the structure,
into
chapters
into the following
and function
for
each
main
group
of
sections.
of each component.
but also serves
explains
checks
to
be made
to be made at completion
Troubleshooting
This
is divided
divided
as reference
It serves
material
not only to give
for troubleshooting.
ADJUSTING
adjustments
DISASSEMBLY
manual
FUNCTION
an understanding TESTING
the
are further
charts AND
correlating
before
and
of the checks
after
performing
repairs,
as well
as
and repairs.
“Problems”
to “Causes”
to be followed
when
are also included
in this section.
ASSEMBLY
explains
the
order
each component,
as well as precautions
removing,
to be taken
installing,
for these
disassembling
or
operations.
STANDARD gives
the judgement
standards
when
inspecting
disassembled
parts.
NOTICE The
specifications
contained
in this
shop
time
and without
any advance
notice.
Contact
latest
manual your
are subject
to change
at any
KOMATSU
distributor
for the
information.
00-5
HOW
TO
READ
THE
SHOP
HOW
MANUAL
TO READ THE SHOP
VOLUMES
REVISED
Shop manuals are issued as a guide to carrying out repairs. They are divided as follows:
When recorded pages.
Chassis
volume:
Engine volume:
Each issued as one volume to cover all models
These various volumes are designed to avoid duplicating the same information. Therefore to deal with all repairs for any model, it is necessary that chassis, engine, electrical and attachment volumes are ready. AND
MARK
(@)a@
-.-- )
a manual is revised, an edition mark is on the bottom outside corner of the
REVISIONS Revised pages are shown at the LIST OF REVISED PAGES on the between the title page and SAFETY page.
SYMBOLS So that the shop manual can be of ample practical use, important places for safety and
UPDATING
Any additions, amendments or other changes will be sent to KOMATSU distributers. Get the most up-to-date information before you start any work.
quality
Symbol
FILING
EDITION
Issued for every machine model Issued for each engine series
Electrical volume Attachments volume
DISTRIBUTION
MANUAL
METHOD
1. See the page number on the bottom of the page. File the pages in correct order. 2. Following examples shows how to read the page number. Example 1 (Chassis volume):
are marked
with
the following
Item
symbols.
Remarks Special safety precautions are necessary when performing the work.
A Safety
Extra special safety precautions are necessary when performing the work because it is under internal pressure.
*& *
IO-3
%
Example
Item number (IO. Structure and Function) Consecutive page number for each item. 2 (Engine volume):
*
Caution
Weight
12-410
F
Unit number (I. Engine) Item number (2. Testing and Adjusting) Group No. (4. Fuel system) Consecutive page No. (Page 10 of Group 4)
3. Additional pages: Additional pages are indicated by a hyphen (-1 and number after the page number. File as in the example. Example: 1 o-4
12-203
1 o-5
12-204
00-6
Special technical precautions other precautions for preserving standards are necessary when performing work.
or
the
Weight of parts or systems. Caution necessary when selecting hoisting wire, or when working posture is important, etc. Places that require special for the tightening torque during assembly.
Tightenattention ig torque ?
Coat
Places to be coated with adhesives and lubricants
etc.
Xl, water
Places where oil, water or fuel must be added, and the capacity.
Drain
Places where oil or water must be drained, and quantity to be drained.
HOISTING
INSTRUCTIONS
HOISTING
lifted
INSTRUCTIONS
Heavy parts (25 kg or more) must be with a hoist etc. In the Disassembly
1. If a part cannot be smoothly the machine by hoisting, checks should be made: . Check for removal of all the part to the relative parts. . Check for existence of causing interference with rem-oved.
removed from the following bolts
fastening
another the part
to
part be
2. Wire ropes I) Use adequate ropes depending on the weight of parts to be hoisted, referring to the table below:
Wire ropes (Standard “Z” or “S” twist without galvanizing) Rope diameter
(mm)
Allowable
ropes
load (tons)
10
1 .o
11.2
1.4
12.5
1.6
14
2.2
16
2.8
ia
3.6
20
4.4
22.4
5.6 10.0
30 40
I a.0
50
28.0
60
40.0
The allowable load value is estimated be one-sixth or one-seventh of breaking strength of the rope used. 2) Sling wire ropes of the hook.
from
the
Slinging near the edge of the hook may cause the rope to slip off the hook during hoisting, and a serious accident can result. Hooks have maximum strength at the middle portion.
middle
100%
88%
79%
71%
41% FSO064
3) Do not sling a heavy load with one rope alone, but sling with two or more ropes symmetrically wound on to the load. Slinging with one rope may cause turning of the load during hoisting, untwisting of the rope, or slipping of the rope from its original winding position on the load, which can result in a dangerous accident.
A
4) Do not sling a heavy load with ropes forming a wide hanging angle from the hook. When hoisting a load with two or more ropes, the force subjected to each rope will increase with the hanging angles. The table below shows the variation of allowable load (kg) when hoisting is made with two ropes, each of which is allowed to sling up to 1000 kg vertically, at various hanging angles. When two ropes sling a load vertically, up to 2000 kg of total weight can be suspended. This weight becomes 1000 kg when two ropes make a 120” hanging angle. On the other hand, two ropes are subjected to an excessive force as large as 4000 kg if they sling a 2000 kg load at a lifting angle of 150”.
to the
portion 30”
go*
60” Lifting
angle
120’
150”
: 01 FSO065
00-7
STANDARD
TIGHTENING
m
TORQUE
STANDARD
1. STANDARD
TIGHTENING
TIGHTENING
TORQUE
OF BOLTS AND
The following charts give the standard tightening sections of “Disassembly and Assembly”.
torques
TORQUE NUTS of bolts and nuts. Exceptions
are given in
Width across flat (mm)
Thread diameter of bolt (mm)
I ..
I
km
Nm
10
1.35kO.15
8
13
3.2kO.3
31.4k2.9
10
17
6.7 f 0.7
65.7k6.8
12
19
11.5*1.0
112t9.8
22
18.0t2.0
177*19
24
28.5*3
279&29
6
14
-
16
13.2*
18
27
3924
383?39
20
30
56*6
549*58
22
32
76+8
24
36
94.5*
1.4
745278 10
927*98
27
41
135+15
1320+
140
30
46
175220
1720-r
190
33
50
225&25
221 Ok240
36
55
28Ok30
27502290
39
60
335t35
3280&340
This torque table does not apply to the bolts with which nylon packings or other nonto otherwise specified ferrous metal washers are to be used, or which require tightening torque. Sr Nm (newton
2.TlGHTENlNG
meter):
1 Nm + 0.1 kgm
TORQUE
OF SPLIT
FLANGE
BOLTS
Use these torques for split flange bolts.
Thread: gtl,eter (mm)
00-8
Width across flats (mm)
Tightening kgm
torque Nm
10
14
12
17
II.521
112t9.8
16
22
28.5t3
279t29
6.7kO.7
65.7 k6.8
STANDARD
TIGHTENING
TORQUE
Sealing surface
3.TlGHTENlNG Use these
TORQUE torques
Thread diameter of nut part (mm)
for
FOR
nut part
NUTS
OF FLARED
of flared.
Width across flats of nut part (mm)
r
Tightening
Nm
km
14
19
2.5kO.5
24.5 k4.9
18.
24
522
49*
19.6
22
27
822
78.5 f
19.6
24
32
1423
137.3k29.4
30
36
1823
176.5229.4
33
41
20*5
196.1
36
46
2525
245.2+49
42
55
30&5
294.2*49
COATING The recommended Nomenclature
Adhesives
Gasket
torque
coating
materials
&49
MATERIALS
prescribed
in Komatsu
Shop
Manuals
are listed
below.
Applications
Komatsu code LT-1 A
Used to apply
LT-18
Used to apply resin, rubber, metallic and non-metallic parts when a fast, strong seal is needed.
LT-2”
Preventing
LT-3
Provides an airtight, electrically Used for aluminum surfaces.
LG-1
Used with
LG-3
Heat-resistant and exhaust
LG-4
Used by itself on mounting mission cases. (Thickness
sealant
LG-5
rubber
bolts,
pads, rubber
gaskets,
nuts and plugs from
gaskets
gasket piping.
loosening
insulating
and packings
and cork plugs.
oil.
seal.
to increase
for precombustion
and leaking
sealing
effect.
chambers
surfaces on the final drive and transafter tightening: 0.07 - 0.08 mm)
Used by itself to seal grease fittings, tapered screw fittings and tapered screw fittings in hydraulic circuits of less than 50 mm in diameter.
Antif
riction
pound including
com-
(Lubricant molybde-
LM-P
Applied
to bearings
prevent
sticking,
and taper
burning
shafts
to facilitate
press-fitting
and to
or rusting.
num disulfide) Grease (Lithium Vaseline
grease)
G2-LI -
Applied to bearings, sliding parts and oil seals for lubrication, prevention and facilitation of assembling work. Used for protecting
lLT-2 is also called
LOCTITE
battery
in the shop
electrode
terminals
from
rust
corrosion.
manuals.
00-9
ELECTRIC WIRE
CODE
ELECTRIC In the wiring
diagrams,
various
colors
and symbols
This wire code table will help you understand Example:
5WB
indicates
CLASSIFICATION
a cable having
WIRE are employed
WIRING
a nominal
to indicate
the thickness
of wires.
DIAGRAMS.
number
5 and white
coating
with
black stripe.
BY THICKNESS
Copper wire
Nominal number
CODE
Number str_ands
_ Cable O.D.
Dia. TF;ands
Cross section (mm2)
Applicable
(mm)
circuit
0.85
1
11
1
0.32
1
0.88
1
2.4
1
12
1
2
1
26
1
0.32
/
2.09
I
3.1
I
20
1 Lighting, signal etc.
Starting,
lighting, signal etc.
5
65
0.32
5.23
4.6
37
Charging and signal
15
84
0.45
13.36
7.0
59
Starting
40
85
0.80
42.73
1 1.4
135
Starting
60
127
0.80
63.84
13.6
178
Starting
100
217
0.80
17.6
230
Starting
CLASSIFICATION
BY COLOR
109.1
AND
(Glow plug)
CODE
Circuits ity
\
ChTng
Class+ fication
/
GrTd
Signal
Other
G
I
L
Code
(GLI
1
-
Color
(Green & Blue)
1
-
1
White
Black
Code
WR
-
Color
White & Red
-
Code
WB
“‘Or
White & Black
2
3 &xi_
liary 4
t Code Color
-
WL White&Blue
-
Code 5
t- Color 6
00-l 0
/
WEIGHT
GENERAL
WEIGHT
A
TABLE
TABLE
This weight table is a guide for use when transporting or handling components.
(Unit: kg) 11118 and up
‘3Yl7 Engine assembly
700
700
Radiator assembly
105
105
Torque converter assembly
160
160 Lift cylinder (I piece)
Rear drive shaft
12
Front axle assembly
)
I
12
Dump cylinder
185
185
Engine hood
134
134
Front frame
1,129
1 1,129
Rear frame
1,109
1,109
Bucket link
Front differential assembly
191
191
Rear differential assembly
176
176
Rear axle assembly
P~;t&rr~carrier
assembly
II
68
1
68
!
Tilt lever
1,250 I
1,040
I
1,308 1,021
52
52
248
248
204
204
)
Planetary hub assembly (I piece)
I
Axle pivot
1 61183
( 61183
Fuel tank
1
1
100
Battery (1 piece)
44
44
210
210
Operator’s seat
37
37
Steering valve
32
32
Floor plate
75
75
Steering cylinder (1 piece)
27
27
CAB
310
310
111
111
Front/Rear
Wheel (1 piece) Tire (I piece)
Brake (1 piece)
73
100
(
73
l
l
WA350-1
: with teeth. * : with bolt on cutting edge.
00-l 1 0
TABLE
GENERAL
TABLE
0 : OIL AND
COOLANT
OF
OIL
AND
COOLANT
QUANTITIES
QUANTITIES
RESERVOIR
Engine oil pan
Brake
Transmission case
Hydraulic system Axle (Front and rear)
See NOTE (4) oiese, fue,
Fuel tank
Cooling system
each 45
each 45
52
-
LASTPAD975 No. 1
Add antifreeze
Water
NOTE: (1) When
fuel
change
sulphur
oil in the
content
oil pan
nance hours described Change
oil according
sulphur content
is less
every
than
periodic
(2) When
0.5%.
oil of
in this manual. to the following
starting
perature
mainte-
table
even
if fuel
SAEIOW, though
to 10°C
is above 0.5%. (3)
the engine
of lower
in an atmospherric
then 0°C.
tem-
be sure to use engine
SAEIOW-30
and
an atmospheric
SAEI
5W-40,
temperature
goes
up
more or less in the day time.
Use API classification classification
CD as engine
CC, reduce
the engine
oil and if API oil change
in-
terval to half. (4)
For axle oil, use only recommended SHELL:
Above 1.0%
l/4 of regular interval
I
*
RPM TRACTOR
CHEVRON:
TRACTOR
TEXACO:
TDH OIL
MOBIL:
MOBILAND
It is possible
American
SAE:
Society
Specified
capacity:
Refill capacity:
00-12 0
Society
of Testing
of Automotive
HYDRAULIC
HYDRAULIC SUPER
to substitute
FLUID
FLUID
UNIVERSAL
engine
oil CLASS-CD
for axle oil.
and Material
Engineers
Total amount
Amount
oil as follows.
TT or TD
CALTEX:
SAEBO
ASTM:
DONAX
of oil including
oil for components
of oil needed to refill system
and oil in piping.
during normal inspection
and maintenance.
WA350- 1
ENGINE
11 STRUCTURE
AND FUNCTION
Engine mount Radiator
..............................
..................................
Fueltankandpiping Engine control
WA350-1
11-2 11-3
........................
11-4
.............................
1 1-5
11-1
STRUCTURE
AND
FUNCTION
ENGINE
MOUNT
ENGINE MOUNT
423FOO5
.
The
engine,
transfer .
There transfer
torque
are
rubber
transmission,
mounts
at the
engine
end
mount
mount
View 2
11-2
and
together.
end.
1. Transmission 2. Engine
converter,
are each joined
WA350-1
and
STRUCTURE
AND
FUNCTION
RADIATOR
RADIATOR
Section X-X
423FOO6
I.
Radiator
2.
Coolant
3.
Fan guard
4.
Hydraulic
5.
Torque
Specifications level sensor oil cooler
converter
Coolant
inlet port
6.
Coolant
outlet port
1
G6 type
Cross-sectional
area:
52.57
area of water tubes:
m2 138
cm2
oil cooler
A.
WA350-
Core type:
Total heat dissipating
11-3
STRUCTURE AND FUNCTION
FUEL TANK AND The fuel level sensor is installed
FUEL TANK AND PIPING
PIPING in the fuel tank.
__
F4230001
1. Connector 2. Fuel level sensor 3. Injection
pump
4. Drain cock 5. Fuel filler port
11-4
WA350- 1
STRUCTURE
ENGINE
AND
ENGINE
FUNCTION
CONTROL
CONTROL
F4230002
1. Accelerator pedal 2. Injection pump
WA350-1
11-5
ENGINE
12 TESTING
AND ADJUSTING
Standard
value table
Tool list for testing Adjusting
valve
Measuring Testing
and adjusting engine
Testing
*
The
following
precautions
troubleshooting
or during
1. The values
in these
used as target 2. The standard standard
values
repairing
in these
tables
for the machine
values
tables
using
4
timing
..
..
5
12-
6
12-
8
. . 12-
9
.
12-l
0
....
12-l
1
.
fan belt tension
exhaust
Measuring
accelerator
gas color
..
..
pedal operating
.
angle
..
fuel cut solenoid
Value
. . . . 12. . . 12-
.
pressure
Measuring
the Standard
on the values or when
must
shipped
for new
estimating
for judgement
when
be used as reference value
when
3
. .
force
. ..
.. ..
..
Tables
to make
judgements
leaving
the plant,
so they
12-l
2
12-l
4
during
and adjusting.
are based
when
standard
use these
tables
values
values
they should 3. These
are necessary testing
.
pressure
.
blow-by
and operating
2
12-
oil pressure
and adjusting
Adjusting
. 12-
.
fuel injection
and temperature Measuring
. . _. .
.
clearance
compression
Measuring
..
.
and adjusting
when
from
in combination
with
after a period
troubleshooting
the plant,
values
when
should
be
of use. are estimated
and on the results
repair and operating
not be used for standard
alone to make simple
machines
wear
values
of various
records
when
judging
claims.
based
tests.
making
on the
Therefore, judgements.
In addition,
do not
judgements.
WA350-1 %’
TESTING
ADJUSTING
AND
STANDARD
TABLE
VALUE
STANDARD
r
Engine Cate
Unit
Condition
Item
gory
High idling speed Engine speed
TABLE
VALUE
rpm
Low idling speed
rpm
Komatsu Standard value
O-l
S6Dll
Permissible value
2,350
- 2,450
-
2,430
- 2,530:
-
650-750 -
(680-780)
0°C
starting .
Necessary speed
- 20°C
Intake resistance pressure
Exhaust
(using starting
aid)
(When
u”
moBlow-by
Oil pressure oil temperature: (SAE30 min. 8d’C)
Oil consumption
ration
pressure
Fuel injection timing Coolant
mm
6.5 (8.5)
Max. 1 .O
2.0
(Max. 2.5)
(3.5)
0.25
0.25 0.45
13002-43501
mmH,O
Max. 150
300
At high idling
kg/cm2
3.5-5.5
2.5
At low idlino
ko/cm2
Min. 1.5
1 .o
Oil temperature [engine speed1
40
60°C
min. 60°C
At continuous rated horsepowe (oroportion to fuel consumption)
“C
10
80-I
120
I
1 %
Max. 0.5
1 .o
Nozzle tester
kg/cm2
250
200
Before top dead center
degree
16
16+1
70-90
100
OC I
temperature when fully open
“C
74.5 - 78.5
74.5 - 78.5
“C
90
90
Lift when fully open
mm
9.5-10.5
Deflection when pushing with finger force approx. 6 kg
mm
7.5 4-7
force
Operating
angle cy
degree
Operating
travel L
mm
42
kg
cY,33
CYI45
height L,
mm
15-25
Stopper
height Lz
mm
15-25
mm
136-146
X
9.5 - 10.5 5-10 Max. 10.5
Stopper
(
12-2 0
Max. 5.0 (Max. 6.5)
Operating
Rod length
Max. 650
0.45
Temperature
Fan belt tension pulley) (Alternator-Fan
75
Max.
Min. 30 [300 - 3501
Valve cracking function
Max. 650
mm -
Whole speed range (at engine outlet)
temperature
Thermostat
Bosch index
Whole speed range (inside oil pan)
Oil temperature
Fuel injection
Bosch index
50
Max.
kg/cm2 [rpml
At high idling, oil temoerature
pressure
Max. 635
“C
Exhaust valve
pressure
Compression
Max. 300
mmHg
Intake valve
engine is cold)
Min. 100
All speed
At high idling
Valve clearance
Min. 150
Min. 100
mmH,O
At abrupt acceleration Exhaust gas color
Min. 150
rpm
All speed
All speed (intake air temp. 20°C)
Exhaust temperature
vm
-
1: Serial No. 1 1 1 18 and up WA350-1
TESTING
AND
TOOL
I 7~ No.
ADJUSTING
LIST
TOOL
FOR TESTING
Testing and measuring item
1
Engine speed
2
Battery specific gravity
3
Coolant freezing temperature
4
Water temperature, oil temperature, intake temperature
AND
Tool
LIST
FOR
TESTING
Remarks
Tachometer
799-203-8000
Battery coolant tester
795-500-1000
Digital display 60-I 9,999
790-500-I
300
1.100
-
-5
-
-50°C
0 -
200°C
0 -
1,ooo”c
or
temperature gauge
799-l
01-6000
Exhaust temperature
6
Lubricating oil pressure
0 -
10 kg/cm2
7
Fuel pressure
0 -
20 kg/cm2
0 -
1,500 mmHg
0 -
1,000 mmH,O
Intake pressure,
Engine presssure
exhaust pressure
measuring kit
rpm
1.300
5
8
ADJUSTING
ADJUSTING Part No.
Thermistor
AND
799-203-2002
Blow-by pressure
9
10 Intake resistance ~ I_
- 1,000
-
0 mmH,O
11
Compression pressure
Compression gauge
795-502-I
204
0 -
70 kg/cm2
12
Blow-by pressure
Blow-by checker
799-201-I
503
0 -
500 mmH,O
13
Valve clearance
Feeler gauge
795-l
14
Exhaust gas color
Smoke meter
15
Fuel on water mixed in oil
Engine oil checker
799-201-6000
16
Coolant quality
Water quality tester
799-202-7001
PH. nitrous acid ion concentration
17
Leakage from cooling system
Cap tester
799-202-9001
0 -
2 kg/cm2
18
Fuel injection pressure Nozzle injection condition
Nozzle tester
0 -
300 kg/cm2
19
Electrical circuit
Tester
20
Accelerator
Push-pull scale
-
m
When
pedal force
carrying
out testing,
adjusting
25-l 330
Commercially available
Commercially available Commercially available 7AO-262-0020
or troubleshooting,
0.25,0.45
mm
Discoloration 0 to 70% standard color (Discoloration %x l/l O=Bosch index) Water content 0.1%. 0.2% in standard sample
Current, voltage, resistance Commercially available 0 -
stop the machine
on level ground,
25 kg
insert the safety
pins and block the tracks.
A A
When
working
When
checking
while the water
A
in groups,
use agreed signals and do not allow unauthorized
the water
Be careful not to get caught
WA350
1
level in the radiator
is hot. Boiling water
wait for the water
to cool.
persons near the machine. Do not remove
the radiator
cap
may spurt out.
in rotating
parts.
12-3 al
AND
TESTING
ADJUSTING
ADJUSTING *
Condition:
*
Adjust
ADJUSTING
VALVE
VALVE
CLEARANCE
CLEARANCE
Engine is cold.
clearance
between
valve and rocker
lever
as follows. Unit: mm
Intake valve Cold
0.25
tool
Special
0.45
--
Part number
Part name
1 795-125-1330
A
Exhaust valve
I
1. Remove
air
connector,
2. Rotate
1 Feelergauge
cleaner
I 1
assembly
then remove
the
Q’ty
and
intake
cylinder head cover (I ).
crankshaft
in the normal
direction
to
align pointer
(2) with the 1.6 TOP mark on crank-
shaft
When
pulley.
of the valves. 1.6 TOP
rotating,
When
mark,
check the movement
the pointer
No.1
cylinder
is in line with the
should
be at com-
pression top dead center. No. 1 cylinder
3. When
is at compression
center, adjust the valve marked When
No.6
cylinder
is at compression
center, adjust the valves marked
4. To adjust,
insert tool A between
rocker
(4) and turn adjustment
until clearance
is a sliding
nut (6) to hold adjustment Lock nut:
3.2 *
and adjust
After
adjusting
top dead crankshaft clearance
120” of
one turn in the normal
(5) lock
clearance
di-
of the re-
o.
No.1
center,
tighten
(3)
screw in position.
the valve
maining valves marked t
Then
lever screw
0.3 kgm
5. Next, rotate crankshaft rection
fit.
top dead
0.
and valve stem
m
top dead
.
l
cylinder
at compression
it is also possible
to turn the
each time and adjust the valve
each
cylinder
according
to
the
firing order. l
Firing order:
Zr After
tightening
l-5-3-6-2-4 the lock nut, check
the clear-
ance again. r
I
423F301
12-4 a
WA350-1
TESTING
AND
ADJUSTING
MEASURING
MEASURING
COMPRESSION
*
Measurement
l
Coolant
l
Engine valve clearance:
l
Engine speed:
COMPRESSION
PRESSURE
PRESSURE
condition
temperature: 360
Inside operating Standard
to 380
range.
value.
rpm Unit: kg/cm2
Item Compression pressure
Standard value
Permissible value
Min. 28
Min. 19.5
Special tools
1
Al---
795
502-I
If
performance
worn, measure
m
When
IQ’ty
gauge
I ’
Tachometer
tests
that the piston,
Part name
1Compression
204
799-203-8000
B
*
1
Part number
1
or troubleshooting
shows
piston ring or cylinder liner may be the compression
measuring
pressure.
the compression
careful
not to touch
muffler,
or to get caught in rotating
pressure,
be
manifold
or
the exhaust
parts.
1. Adjust valve clearance. t
For details,
see ADJUSTING
VALVE
CLEAR-
ANCE. 2. Warm
up engine (oil temperature
3. Remove
40°C)
nozzle holder assembly.
4. Install
adapter
assembly,
A
in
mount
and connect
5. Set engine tachometer 6. Disconnect
of
nozzle
holder
pressure gauge.
B in position.
fuel
CUT-OFF
solenoid
valve
connector. Crank
engine
compression Zr Measure where
with
starting
motor
and
measure
pressure. the compression
the
pressure
pressure
gauge
at the point
indicator
remains
steady. *
When measure
measuring
within the specified *
the
the engine
compression
speed
to confirm
WA350-1
that it is
range.
Installing the nozzle holder assembly ing the compression
pressure,
after measur-
pressure.
12-5 @
TESTING
AND
TESTING * l
AND
Measurement Coolant
TESTING
ADJUSTING
ADJUSTING
FUEL
AND
ADJUSTING
INJECTION
FUEL INJECTION
TIMING
TIMING
condition
temperature:
Inside operating
range. Unit: degree
Standard value
Item
m-~
B.T.D.C.
TESTING
FUEL
1. Disconnect 2. Remove
Permissible value 16+
INJECTION
fuel injection delivery
(
16
1
TIMING
pipe (1) of No. 1 cylinder.
valve
holder
(2).
then
remove
delivery valve (3) and spring (4). and install delivery valve holder (2) again.
3. Place fuel control lever at FULL position. 4. Operate slowly
priming
stops flowing
5. Check and
pump
in normal direction.
that
and
rotate
Check
crankshaft
point where
fuel
from delivery valve holder (2). 16”
pointer
I.J. line on crankshaft
16) are
aligned
at point
pulley where
(5) fuel
stops flowing. *
BEYOND
injection
timing line: Timing
RETARDED
Sr BEFORE injection timing line: Timing ADVANCED
*
If the test shows incorrect,
that
the fuel injection
timing
is
adjust as follows.
/j&v
423F302
12-6 0
WA350-1
TESTING
AND
TESTING
ADJUSTING
ADJUSTING FUEL INJECTION BY DELIVERY CHECK 1. Turn
crankshaft
back
30
-
AND
ADJUSTING
FUEL INJECTION
TIMING
TIMING
40”
from
top dead
center. 2. Rotate
cankshaft
to align
16”
I.J. line on crank-
shaft pulley and pointer correctly. 3. Loosen flange little
nut
(7) on the
by little
by operating
until no fuel flows 4. Tighten
pump
mounting
stops
hole of mountijng
the bolt, check
flowing
from
holder at the point where
the
delivery
ery valve
(9)
flange
valve
holder
(3) and spring
again that the delivery
the pointer
with the line on the crankshaft 5. Remove
pump
pump.
After-tightening fuel
the priming
out of the delivery valve holder.
nut (7) in oblong
of fuel injection +
injection
bolt, and rotate the flange on the pump side
valve
is aligned
pulley.
(2). assemble
(41, then
install
delivdelivery
valve holder (2) again. w
Delivery
holder:
3.3
-C 0.2 kgm
6. Connect fuel injection pipe (I). m
Sleeve
WA350-1
nut:
2.4 + 0.1 kgm
12-7 0
TESTING
AND
ADJUSTING
MEASURING 1. Measuring
ENGINE
engine
t
Measurement
l
Coolant
MEASURING
OIL
ENGINE
PRESSURE
OIL
AND
PRESSURE
AND
TEMPERATURE
TEMPERATURE
oil pressure.
condition
temperature:
Inside operating
range. Unit: kg/cm*
~~
Special
tool
Part number
A
Part name
799-203-2002
A
When
measuring,
in rotating A
Install
Q’ty
Engine pressure measuring kit
be careful
1
not to get caught
parts.
and
remove
the
plug
and
oil pressure
gauge with the engine stopped. t
Measure
the engine
perature
is at the specified
1) Remove
oil pressure
when the oil tem-
temperature.
plug (I 1.
2) Install oil pressure gauge A (25 kg/cm? *
Install the oil pressure fected
as little
gauge
so that it is af-
as possible
by the
engine
vibration. 3) Start engine and measure 2. Measuring
oil temperature.
*
Measurement
l
Coolant
Oil temperature
0
condition
temperature:
Item
12-8
oil pressure.
Inside operating
Permissible value
Standard value 190-
110°C
range.
I
120°C
WA350-1
TESTING
AND
MEASURING
ADJUSTING
MEASURING
BLOW-BY
BLOW-BY
PRESSURE
PRESSURE
* Measurement condition . Coolant temperature: inside operating range. . Engine valve clearance: Standard valve Unit: mm H,O
Item
Standard value
Blow-by pressure
Max. 150
Permissible value
I
300
Special tool ~
r A
P&t
number
1 799-201-1503
1
Part name
1 Blow-by checker
1 1
2. Precautions when measuring blow-by It Blow-by may vary greatly according to the condition of the engine, so if there is any abnormality in the reading, to
defective
consumption,
defective
early deterioration
WA350-1
check for any problem
blow-by,
such
related
as excessive
exhaut
or contamination
gas
color,
oil or
of the oil.
12-9 0
TESTING
AND
TESTING
ADJUSTING
TESTING
AND
ADJUSTING
FAN
AND
ADJUSTING
FAN
BELT TENSION
BELT TENSION
Testing fan belt tension Check the amount with
a force
between
of
the fan belt deflects approx.
6
when
kg at a point
the fan pulley and the alternator
pushed
Fan pulley
midway
pulley. Unit:
mm
Alternator
pulley
423F303
Measuring procedure 1. Push the V-belt with midway 2. Use
between
a scale
a force
of 6 kg, at a point
the pulley and the alternator.
to measure
the
Adjustment procedure 1. Loosen mounting bolt
(1)
amount
the V-belt
deflects.
assembly,
and
the
stick
or
mounting
of
the
bolt
of adjustment
alternator
plate (2). 2. Insert
a
mounting
the alternator Qf
bar
bolt and the
between cylinder
the block,
alternator then
raise
to the outside.
If the alternator hands, there
is moved
is danger
to the inside with the
of catching
and insuring
the fingers. 3. Adjust
the belt (3) tension
mounting 4. Check
that the belt tension
all mounting
12-10 0
and temporarily
tighten
bolt. is correct
then tighten
bolts fully.
WA350-1
TESTING
AND
ADJUSTING
MEASURING t
Measurement
MEASURING
EXHAUST
GAS
condition
l
Coolant temperature:
l
Valve clearance:
Inside operating
Standard
range.
value. Unit:
Bosch index
~
Special tool Part number A
*
Part name
Commercially available
When
Smoke
measuring
the
1. Insert probe @
in outlet
secure to exhaust
2. Connect
probe
color;
be careful
pipe. of exhaust
pipe (I)
and
pipe with clip.
hose, connector
hose @of
accel-
and air hose to smoke meter A.
erator switch
*
1
meter
exhaust
not to touche the exhaust
Q’ty
The pressure
of the air supply should
be under
15 kg/cm2. 3. Connect
power cord to AC1 OOV socket.
Sr Check that the power
switch is OFF before con-
necting the cord. 4. Loosen
cap nut of suction
pump
and insert filter
paper. 5. Turn power switch
ON
6. Accelerate
suddenly.
depress
engine
accelerator
catch exhaust
At
pedal, operate
the
filter
papers
(10
gas color on
sheets
or more)
inside filter paper holder, and read indicated
WA3561
time,
gas color on filter paper.
7. Lay filter paper used to catch exhaust top of unused
same
relief valve and
value.
COLOR
EXHAUST
GAS COLOR
MEASURING ADJUSTING
AND
TESTING
PEDAL
ACCELERATOR MEASURING ANGLE AND OPERATING *
Measurement
l
Coolant
OPERATING
OPERATING PEDAL ANGLE OPERATING
FORCE
condition range.
Inside operating
temperature:
kg
Unit:
Operating force of accelerator oedal
a
Permissible value
Standard value
Item
4-7
Max. 10.5
_-
tool
Special
ACCELERATOR AND FORCE
423 F304
Part name
Part number
scale
Push-pull
7AO-262;0020
A
OPERATING
FORCE
1. Measuring
procedure
Q’ty 1
I) Put push-pull scale A in contact with the accelerator pedal at point 150 mm from pedal fulcrum “a”. *
of push-pull
center
The
be in
scale A must
mm from the pedal
with a point 150
contact fulcrum.
2) Start the engine, push the pedal in the direction and measure
of operation when
the maximum
value
end
of the
to the
idling
from
pushing
pedal travel (high idling).
2. Testing
and adjusting
I) Stop the engine. the cable
2) Disconnect celerator
of the ac-
at the bottom
and
pedal, and check that the linkage at
ball joint
bottom
the
of
the
move
pedal
smoothly. 3) Connect
the cable
then disconnect tion
pump,
at the bottom
at the connection
and
check
that
the
of the pedal, for the injeccable
moves
smoothly. *
When
carrying
replace operating
parts force
out this inspection, as
again
within the standard
12-12 0
necessary. and
adjust
or
Measure
the
that
it is
check
range.
WA350-1
MEASURING TESTING
AND
OPERATING PEDAL
ADJUSTING
ANGLE
OF
ACCELERATOR FORCE AND
PEDAL OPERATING OPERATING ANGLE
ACCELERATOR
Unit: mm
Operating travel
L
I
w
42
I
423 F305 Installed height of accelerator pedal stopper
Installed length X of rod
136-146
-
I
1. Measuring procedure 1) Stop the engine. 2) Measure
the
operating
angle
gauge
pedal
it is operated
angle
in contact
cyl, cxz, put the
with
from
the
accelerator
low-idling
and high
the
open
idling. 2. Adjusting 1) Remove
procedure the
cover
under
cab,
the
engine hood and fit the safety lock. 2) Loosen
nut (I)
and adjust
rod (2) until it is 160 3) Release
the
f
accelerator
and adjust the height
installed
length
X of
5 mm. pedal,
loosen
L, of the stopper
nut
(5)
bolt (6)
until it is 18 +- 5 mm. 4) Depress
the
accelerator
and adjust the height
pedal,
loosen
nut (3)
Lz of the stopper
bolt (4)
until it is 17 +- 5 mm. 5) Depress
the accelerator pedal, loosen lock nut (7) and adjust the length of cable so that the injection pump governor lever contacts the high idle stopper.
t
After
making
measurements
the above adjustments, again
are within the standard
WA350-1
and
check
take all that
they
value.
12-13
TESTING
AND
ADJUSTING 1. Confirm pump (I
that
stop
FUEL CUT lever
FUEL
CUT
SOLENOID
SOLENOID
(2) of the fuel
injection
1 is at the STOP position.
(Usually,
the return
the STOP
position.)
2. Adjust
ADJUSTING
ADJUSTING
rod so that
spring
holds the stop lever at
the solenoid
has a maximum
stroke. Adjust
rod
between stopper
so clearance
injection
on the engine
the solenoid 4. Tighten
is 0.4
0.1
mm
(2)
and
key and confirm
that
stopper
*
lever
(3). Stroke-“a”
3. Turn
“b”
pump
=
12 mm
starting
stroke “a” is the standard
dimension.
nuts (5) and (6) of rod (4).
423F338
12-14 0
WA350-1
ENGINE 13 DISASSEMBLY
AND ASSEMBLY
.. STARTING
MOTOR
Removal
ASSEMBLY
Removal
.
13-
2
Installation
. . . . . . . . .._........_....__
13-
3
Removal
13-
3
Installation
13-
4
Removal
13-
4
Installation
13-
5
Removal
13-
5
Installation
13-
6
13-
6
13-
8
.
ALTERNATOR
. ..
Installation INJECTION
Removal
PUMP
.
PUMP
Removal
.
.
.
.
.
FUEL
HOLDER
HEAD
.
.
Removal
. . , _, . . .
.
13-24
.
. . . . 13-27
ASSEMBLY ..__..__..._........._........ .
.
13-29
. .
..
. . . 13-29
ASSEMBLY
TANK
..............................
.
.
..
.
13-30
. . 13-37
ASSEMBLY
.
. .
. .
. .
13-44
..
.
13-46
.
13-14
.._........._.
.
. .
13-22
..
.
13-22
.
13-23
ASSEMBLY
.. ...
Removal Installation
.. .
the following
cylinders,
.
ASSEMBLY
.
COMPRESSOR
pumps engine,
2. Operate 3. Continued
WA350-1
.. .
..
.
Installation
,
ASSEMBLY
TURBOCHARGER
NOTE:
.
_....__...__..._...__.....
Installation
4. After
.
.. ,.
ASSEMBLY
.
Removal
1. Start
.
..........................
Installation CYLINDER
.
.
COOLER
ENGINE
ASSEMBLY
ASSEMBLY
.
Removal
Sr Take
.
. . . . . . _.........__..,_....
Installation NOZZLE
..
. . . ..__..._.........._....
Installation WATER
OIL
ASSEMBLY
Removal
ASSEMBLY
2
Installation
FUEL
RADIATOR 13-
..........................
. .
,
method
for
air bleeding
when
you
start
to operate
hydraulic
cylinders
after
reassembling
keep idling. cylinder
to operate After
13-23
and pipings.
hydraulic
finishing
.
above
4 -
cylinder steps,
long storage,
5 cycles, 3 -
but do not exceed
4 cycles
keep normal
until stroke
engine
same procedure
beyond
100
mm of stroke
end.
end.
speed.
is required.
13-I 0
DISASSEMBLY
AND
REMOVAL
A
Disconnect terminal
1. Remove
OF STARTING the
cable
from
the
negative
MOTOR
MOTOR
ASSEMBLY
(-1
of the battery.
catch, then open hood.
2. Disconnect 3. Remove
STARTING
ASSEMBLY
wire (I) and connector
ground connection
ing motor assembly
(2).
(3). then remove
start-
(4).
__
INSTALLATION OF STARTING MOTOR ASSEMBLY 1. Fit O-ring
and install starting
then tighten 2. Connect
together
connector
motor
assembly
with ground connection
(41, (3).
(2) and wire (1).
3. Close hood, then lock with catch. 4. Connect
13-2 0
cable to negative
(-1
terminal
of battery.
WA350-1
DISASSEMBLY
REMOVAL
n
AND
ALTERNATOR
ASSEMBLY
OF ALTERNATOR
ASSEMBLY
Disconnect the cable from the negative (-1 terminal of the battery.
1. Remove catch, then open hood. 2. Disconnect wires (I), (2) and (3). 3. Remove bolt (4) of adjustment plate, then loosen mounting bolt and nut (5). 4. Move alternator assembly towards cylinder block to loosen belt tension, then remove belt (6). 5. Remove mounting bolt and nut, then remove alternator assembly (7).
INSTALLATION ALTERNATOR
OF ASSEMBLY
1. Install alternator assembly (71, then partially tighten mounting bolt and nut (5). 2. Fit belt (6) in pulley groove and install. 3. Partially tighten bolt (4) of adjustment plate. 4. Insert a bar between alternator assembly and cylinder block, raise alternator assembly and adjust tension of belt. * The belt should deflect about IO mm when pushed with a finger pressure of 6 kg at a point midway between the alternator and the fan pulley. 5. Tighten bolt of adjustment plate, mounting bolt and nut (5). 6. Connect wires (31, (2) and (I ). 7. Close hood, then lock with catch. 8. Connect cable to negative (-1 terminal of battery.
WA350-1
13-3 0
DISASSEMBLY
AND
REMOVAL 1. Remove
ASSEMBLY
FUEL
OF FUEL INJECTION
PUMP
INJECTION
PUMP
ASSEMBLY
catch, then open hood.
1and (2).
2. Disconnect
control rods (I
3. Disconnect
boost compensator
4. Disconnect
fuel hoses (4) and (5).
5. Disconnect
fuel supply hose (6).
6. Remove
lubrication
7. Disconnect
hose (3).
tubes (7) and (8).
6 fuel injection tubes (9).
8. Remove
coupling
9. Remove
4 mounting
bolt (10). bolts, then pull out fuel injec-
tion pump assembly
(I 1) to rear to remove.
INSTALLATION OF FUEL INJECTION PUMP ASSEMBLY 1. Place
fuel
bracket, mounting 2. Rotate
injection
and
crankshaft
crankshaft timer
(1 I)
on
Partially
tighten
4
coupling bolt (IO).
and align pointer
(13)
with
line
line is not at the front,
rotate
the
one more turn.
line A on fuel injection side, then
uniformly
assembly
pulley (I 2).
If the timer
3. Align
pump
in position.
bolts, then tighten
on crankshaft t
set
tighten
pump with
mounting
line B on
bolts of pump
in turn.
4. Connect
6 fuel
injection
tubes
(9).
and
tighten
nuts. w
Sleevenut:
5. Fit gaskets
2.4kO.l
and install lubrication
6. Fit gasket and connect 7. Fit gaskets
kgm
and connect
fuel hoses (51 and (4).
8. Connect
boost compensator
9. Connect
control rods (2) and (I ).
IO.
tubes (8) and (7).
fuel supply hose (6). hose (3).
Close hood, then lock with catch.
13-4 0
WA350-1
DISASSEMBLY
REMOVAL
AND
ASSEMBLY
OF WATER
WATER
PUMP
1. Remove catch, then open hood. Loosen drain valve (I) and drain cooling water. * If the coolant contains antifreeze, dispose of it correctly. 2. Remove fan guard (2). then remove fan (3). 3. Loosen adjustment bolt (41, mounting bolt and nut (5), move alternator assembly (6) towards cylinder block, then remove belt (7). 4. Disconnect radiator outlet hose (8) and bypass hose (9). 5. Remove bracket (IO) and plate (I 1). then remove water pump assembly (I 2).
INSTALLATION OF WATER PUMP ASSEMBLY 1. 2. 3. 4. 5.
6. 7. 8.
9.
Fit gasket and install water pump assembly (I 2). Install plate (I I). Install bracket (10). Connect bypass hose (9) and radiator outlet hose (8). Fit belt (7). insert a bar between alternator assembly (6) and cylinder block, raise alternator assembly and adjust tension of belt. Tighten adjustment bolt (4). and mounting bolt and nut (5). * For details of adjusting tension of belt, see 12 TESTING AND ADJUSTING. Install fan (3). Install fan guard (2). Tighten drain valve (1) and add water through water filler to the specified level. It Run the engine to circulate the water through the system. Then check the water level again. Close hood, then lock with catch.
WA350- 1
AS SEMBLY
PUMP
DISASSEMBLY
AND
REMOVAL
ASSEMBLY
OF NOZZLE
1. Remove
catch, then open hood.
2. Loosen
hose
clamp
(I),
and band, then remove 3. Remove sembly 4. Remove
NOZZLE
drain tube
remove
HOLDER
bracket
remove
ASSEMBLY
bolt (2)
air cleaner assembly
(41, then
HOLDER
(3).
muffler
as-
(5). spill pipe (6).
5. Disconnect
fuel injection
tube (7) at nozzle
holder
end. 6. Remove *
nozzle holder assembly
When
removing
around
the
(8).
nozzle
holder,
clean
the no.zzle holder and fit a blind plug to
prevent dust or dirt from entering. Sr Mark
the nozzle
cylinder
holders
with tags showing
the
No. and keep in a safe place. If there
no abnormality
in the
nozzle
holder,
install
is in
the same position when assembling.
INSTALLATION OF NOZZLE HOLDER ASSEMBLY 1. Install nozzle holder assembly w *
Mounting Tighten
the
bolt:
(8).
1.7 +0.2
nozzle
holder
kgm mounting
bolts
uniformly. 2. Connect B
fuel injection tube (7). Sleeve
nut:
2.3kO.2
kgm
3. Fit gasket and install spill pipe (6). 4. Install muffler
assembly
(51, then install drain tube
(4). 5. install air cleaner assembly
(3). then tighten
brack-
et bolt (2). 6. Tighten
hose clamp
(I), then secure with band.
7. Close hood, then lock with catch.
13-6 0
WA350-1
DISASSEMBLY
AND
REMOVAL
CYLINDER
ASSEMBLY
OF CYLINDER
HEAD
HEAD
ASSEMBLY
2
Intake Co”“ector.
3 WA350-1 Wheel loader
-I
Hood
11 FIGI
iniertinn
12 intake heater
13-8 0
WA350-1
DISASSEMBLY
AND
ASSEMBLY
CYLINDER
1. Hood Remove
catch,
then open hood.
2. Draining water 1) Loosen
radiator
drain
plug
(I
) and drain cooling
water. 2) Loosen
drain
plug
and drain cooling *
(2) of engine water
If the coolant
from
contains
cylinder
cylinder
antifreeze,
block
block. dispose
of
it correctly. ..
3. Muffler,
fuel
1) Remove 2) Remove fuel filter 3) Disconnect perature
assembly
13-10 0
of
(5), then
move
(3).
muffler
(4) together
with
it to outside.
connector
(6)
of
coolant
tem-
(7) of turbocharger,
then
assembly
1) Disconnect
2) Remove
drain tube
bracket
sensor.
4. Air cleaner remove
filter
muffler
inlet
2 bracket
band
hose bolts
(9),
(8).
then
remove
air
cleaner
(IO).
WA350-1
HEAD
DISASSEMBLY
5. Bracket,
AND
ground
ASSEMBLY
connection
1) Remove
bracket
2) Remove
ground connection
6. Turbocharger
(I I).
turbocharger
remove
drain tube (14).
connector,
1) Disconnect remove
(I 2).
piping
Remove
7. Intake
CYLINDER
connector
electrical
tube
air intake
boost compensator
suction
2) Disconnect
oil supply
(I 3).
then
heater
hose (I 5). then
hose (I 6) of compressor.
wire
(171,
(18)
together
then
remove
with
intake
electrical
air
intake heater (I 9).
8. Turbocharger,
exhaust
Remove
turbocharger
manifold
(2 I).
9. Corrosion Remove
resistor bracket
resistor assembly
WA350-1
manifold (20)
assembly
together
with
exhaust
assembly (22)
together
with
corrosion
(231, and move it to outside.
HEAD
DISASSEMBLY
AND
ASSEMBLY
CYLINDER
HEAD
10. Oil filter
I) Disconnect
connector
(241, then remove
mount-
ing bolt (25) of tube. 2) Remove
oil filter
and bracket
11. Fuel injection Remove
together
with
tube
(27)
tube
6 fuel injection tubes (29).
12. Electrical Remove
(26)
(28).
air intake
heater
wiring clamps
electrical
air intake
switch
(30) and (31).
heater
switch
then remove
(32)
and move it
to outside.
13. Bracket,
hoses
1) Disconnect thermostat 2) Disconnect 3) Remove
aeration
hose (33).
then disconnect
outlet hose (34). bypass hose (35).
bracket
(36).
14. Spill pipe Remove
15. Nozzle
spill pipe (37).
holder
Remove *
assembly
nozzle holder assembly
When
removing
the
around
the nozzle
(38).
nozzle
holder,
clean
holder and fit a blind plug to
prevent dust or dirt from entering. k
Mark the nozzle cylinder
holders
with tags showing
the
No. and keep in a safe place. If there is
no abnormality
in the
nozzle
holder,
install
in
the same position when assembling.
13-12 0
WA350-1
DISASSEMBLY
16. Cylinder
ASSEMBLY
CYLINDER
head cover
Remove
17. Rocker
AND
cylinder
head cover
(39).
arm assembly
1) Loos& screw
lock (41)
2) Remove
nut
(40),
then
loosen
adjustment
2 to 3 turns.
rocker
arm assembly
(42).
18. Push rod
Remove push rod (43).
19. Cylinder
head assembly
1) Remove
mounting
2) Remove
cylinder
head assembly
Cylinder
head assembly:
WA350-1
bolts
of cylinder
head.
(44). 57 kg
HEAD
DISASSEMBLY
AND
INSTALLATION
ASSEMBLY
OF CYLINDER
CYLINDER
HEAD
HEAD
ASSEMBLY
WA350-1 Wheel loader
13-14 0
WA350-1
DISASSEMBLY
AND
CYLINDER
ASSEMBLY
HEAD
15
-L
11 Oil filter
1I9
I
Refilling water
witt
423F402
13-15 0
ASSEMBLY
AND
DISASSEMBLY
CYLINDER
tool
Special
Part number
Part name
I
I
A
*
1
face,
mounting
head
cylinder
material
on
or inside
the
is no dirt or foreign
that there
Check
I
Feeler gauge
head assembly
1. Cylinder the
330
25-l
795-l
IQ%
cylinder.
I) Set gasket (45) on cylinder block. use
(44),
4
and set on cylinder
as guides
bolts
mounting
assembly
head
cylinder
2) Raise block. 3) Tighten *
mounting
Tighten
the
shown
and
bolts with
of the mounting or engine oil.
compound
antifriction *
bolts (46).
Coat the threads
mounting to
the
in the
bolts
order
tightening
following
torques. Mounting
a
bolt:
Antifriction Cylinder
m
head mounting
compound
Antifriction Order
Target (kgm)
(LM-P)
compound bolt
Engine oil Target (kgm)
Range (kgm)
Range (kgm)
Center
Front
Rear
142F212
2. Push rod Assemble *
The
push rod (43). push
rods
for
the
intake
and
exhaust
valves are both the same part. *
Check
that
the
into the tappet.
13-16 0
push
rod is fitted
completely
HEAD
DISASSEMBLY
AND
ASSEMBLY
CYLINDER
3. Rocker arm assembly Install rocker arm assembly * *
Check
(42).
that the ball of the adjustment
screw
is
fitted properly
into the socket of the push rod.
If the tension
of the valve spring pushes against
the rocker arm, turn the adjustment to prevent
screw
back
strain on the push rod.
4. Adjusting valve clearance
*
Adjustclearance
between
valve and rocker arm
lever as follows.
Intake valve Valve clearance
0,25
Exhaust valve
mm
0.45
(cold)
Firing order:
1 -
5 -
3 -
I) Rotate the crankshaft align pointer crankshaft
(49) pulley
the movement
6 -
2 -
mm
4
in the normal direction
(50).
When
to
TOP” mark on
with the “1.6
rotating,
check
of the valves.
*
When
is at compression
top
*
dead center, adjust the valves marked l When No. 6 cylinder is at compression
top
No. 1 cylinder
dead center, adjust the valves marked
2) To adjust, insert feeler gauge A between arm (47)
and valve stem
ment screw 3) Then
tighten
(48)
(41) until clearance lock nut (40)
o
rocker
and turn adjustis a sliding fit.
to hold adjustment
screw in position. m
Lock nut:
4) Next, rotate direction remaining
* After
crankshaft
and adjust tightening again.
kgm
one turn in the normal
the valve clearance
valves marked
clearance
WA350- 1
3.2kO.3
the
of the
o lock
nut,
check
the
HEAD
DISASSEMBLY
5. Cylinder
CYLINDER
ASSEMBLY
HEAD
head cover
Fit O-ring t
AND
and install cylinder
Put adhesive
head cover (39).
on the O-ring
cover to prevent
of the cylinder
head
it from slipping out of position
when assembling. Mounting
m
6. Nozzle
holder
nut of cylinder head cover: 0.9 fO.l
assembly
Install nozzle holder assembly *
Check
that
there
(38).
is no dirt inside
the
sleeve or on the nozzle holder contact *
kgm
Coat the threads
of the mounting
holder
face.
bolts of the
nozzle holder with engine oil. *
Tighten
the
nozzle
holder
mounting
bolts
uniformly. w
Mounting
bolt:
1.720.2
kgm
7. Spill pipe Install breather 8. Bracket
hose (37).
and hose
I) Install bracket (36). 2) Connect
bypass hose (35).
3) Connect
thermostat
4) Connect
aeration
9. Electrical
air intake
1) Install electrical 2) Install (30), 10.
electrical
heater
switch
air intake heater switch air intake
heater
(32).
wiring
clamp
(31).
Fuel injection
pipe
Install fuel injection
13-18 0
outlet hose (34).
hose (33).
pipe (29).
WA350-1
DISASSEMBLY
AND
1 1. Oil filter 1) Fit O-ring together tighten
to with
ASSEMBLY
tube tube
and (27)
CYLINDER
install
oil filter
and bracket
(28).
(26) then
bolt (25).
2) Connect
connector
(24).
12. Corrosion resistor assembly Install
coirosion
with bracket
assembly
(23)
together
(20)
together
exhaust manifold
13. Turbocharger, Fit gasket
resistor
(22).
and install
with exhaust
manifold
turbocharger (21).
14. In1take connector, electrical air intake heater I) Fit gasket and install electrical air intake heater (19)
together
connect 2) Connect
boost
install suction
WA350-1
with
intake
connector
(181, then
wire (I 7). compensator
hose
(151,
hose (16) of compressor.
then
HEAD
DISASSEMBLY
AND
15. Turbocharger
CYLINDER
ASSEMBLY
HEAD
piping
1) Fit gasket
and install drain tube (I 4).
2) Fit O-ring
and istall turbocharger
oil supply tube
(13).
16. Bracket,
ground
connection
1) Install ground connection
(12)
2) Install air cleaner bracket
(I I).
17. Air cleaner
assembly
1) Fit air cleaner,
then
connect
inlet hose
(7) of
turbocharger. 2) Tighten
bracket
3) Secure
18.
Muffler,
bolts (8).
air cleaner assembly
(IO) with band (9).
filter
1) Connect
connector
(6)
of water
temperature
sensor. 2) Fit gasket bracket
and install muffler
3) Install muffler *
13-20 0
(4) together
with
and fuel filter (5). drain tube (3).
Fit the gasket with the TOP mark facing up.
WA350-1
DISASSEMBLY
AND
CYLINDER
ASSEMBLY
HEAD
19. Refilling with water I) Tighten
drain plug (2) of engine block.
2) Tighten
drain plug (I
spection
) of radiator, then install in-
cover.
3) Add water through
water filler (5 I) to the speci-
fied revel. *
Run
the
through
engine
to
Then check the water
WA350- 1
circulate
the
water
the system. level again.
13-21 0
DISASSEMBLY
AND
REMOVAL 1. Remove 2. Remove
TURBOCHARGER
ASSEMBLY
OF TURBOCHARGER
ASSEMBLY
catch, then open hood. bolts
(I).
then
disconnect
connector
(2)
and turbocharger. 3. Disconnect
hose
(3),
remove
then loosen air cleaner assembly
bracket
bolts
(4).
band and move air cleaner
(5) to side.
4. Disconnect
connector
5. Disconnect
oil supply tube (7).
6. Remove
drain tube (8).
7. Remove
turbocharger
hose (6).
assembly
(9).
INSTALLATION OF TURBOCHARGER ASSEMBLY 1. Fit gasket and install turbocharger +
assembly
(9).
Fit the gasket with the TOP mark facing up.
2. Fit gasket and install drain tube (8). 3. Fit O-ring and install oil supply tube (7). 4. Connect
connector
5. Fit air cleaner
(4). then connect assembly 6. Connect
hose (6).
assembly
(51, tighten
bracket
hose (31, and secure
bolts
air cleaner
with band. exhaust
connector
(21, then tighten
with
2 bolts (I 1. 7. Close hood, then lock with catch.
13-22 0
WA350-1
DISASSEMBLY
AND
REMOVAL
ASSEMBLY
COMPRESSOR
OF COMPRESSOR
ASSEMBLY
1. Remove catch, then open hood. 2. Remove fuel injection pump assembly. For details, see 13-4 REMOVAL OF FUEL INJECTION PUMP
3. 4. 5. 6. 7. 8.
ASSEMBLY.
Disconnect
suction
Disconnect
unloader
Disconnect
air outlet tube (4).
Disconnect
lubrication
hose (I) of compressor. tubes (2) and (3). tube (5).
Remove
air governor
(6).
Remove
mounting
bolts
pressor assembly
(7).
then
remove
com-
(8).
INSTALLATION OF COMPRESSQR ASSEMBLY 1. Fit gasket,
align
compressor *
Remove
“0”
assembly
mark
the cover of the meter
check the “0” match 2. Coat
4
of spline
mounting
and
install
(8). pick-up
port to
mark.
bolts
(7) with
gasket
sealant,
then tighten. 3. Install air governor 4. Install lubrication
16). tube (5).
5. Connect
air outlet tube (4).
6. Connect
unloader
tubes (3) and (2).
7. Connect
suction hose (I ). 8. Install fuel injection pump assembly. For details, see 13-4 INSTALLATION JECTION
PUMP
OF FUEL IN-
ASSEMBLY.
9. Close hood, then lock with catch.
WA350-1
13-23 0
DISASSEMBLY
AND
REMOVAL
A
Stop
the
OF RADIATOR machine
the safety parking
wheels
Q!
the
pressure remaining
Loosen filter,
and
put
oil filler levers
pressure
plug (I)
times
terminal Draining
to release
cable
the the the
piping.
at the top of the hydraulic
the
apply
under
to release
in the hydraulic
and plug (2) of the pump
Disconnect
Then
tank. Then operate
tank
piping to prevent
the oil inside the tank from flowing +
install
from moving.
cap slowly
several
ASSEMBLY
the bucket
blocks
the machine
inside the hydraulic
the control
and
Lower
and stop the engine. brake
to prevent
Loosen
on level ground
bar on the frame.
to the ground the
RADIATOR
ASSEMBLY
from
out.
the
negative
(-1
of the battery.
water
Loosen drain valve (3) and drain cooling water. Sr If the coolant
contains
antifreeze,
dispose
of it
correctly. - :
Cooling water:
2. Radiator
52 II
grille
1) Remove
radiator
grille (5) from engine hood (4).
2) Open engine hood and fit lock.
3. Wiring I) Disconnect
connector
(6) of wiring
of coolant
level sensor. 2) Disconnect wiring.
13-24 0
connector
(7)
of
working
lamp
DISASSEMBLY
AND
RADIATOR
ASSEMBLY
4. Engine hood 1) Close
engine
hood
(41, and install safety
bolts
(8).
2) Remove
mounting
bolts
(9)
of
engine
hood,
and baffle seat.
3) Raise engine mounting
hood
bolts
(4) about
(IO)
of
300
left
mm, remove
and
right
safety
wires (I I). then lift off engine hood (4). Engine hood:
5. Radiator
134
kg
hoses
1) Disconnect
radiator
upper
hoses
(I 2) and (I 3)
lower
hoses (14)
at engine end. 2) Disconnect
radiator
at engine
end. Sr Loosen
the hose clamps
at the connections
with the radiator. 3) Remove
clamp
of radiator
cooling
water
drain
hose.
WA350-1
13-25
DISASSEMBLY
AND
RADIATOR
ASSEMBLY
6. Hydraulic piping Disconnect
oil cooler
hoses
(18) from tube connector *
Cover to prevent
(I 51, (161,
at bottom
(I 7) and
of radiator.
dirt or water from entering.
36 mm
Hose nut:
7. Support Sling
radiator,
radiator
then
remove
side of radiator
mounting
bolts
at
support
(I 9).
(20).
then
remove
fan
the
radiator
fins
8. Fan guard, engine fan I) Remove
hose
clamp
guard (2 I). 2) Remove t
engine fan (22).
Be careful
not to damage
when removing.
9. Radiator Remove
mounting
bolts, then lift off radiator
&
Radiator:
105 kg
13-26 0
(23).
WA350-1
DISASSEMBLY
AND
ASSEMBLY
INSTALLATION
RADIATOR
OF RADIATOR
1. Radiator Raise radiator (23). set in mc )unt ing position install mounting + Tighten
ASSEMBLY
and
bolts.
the mounting
partially,
bolts
then tight-
en them fully after installing the engine hood.
2. Fan guard, engine fan
1) Install-engine t
fan (22).
Be careful
not to damage
the
radiator
fins
when installing. w
Mounting
6.5 kgm
bolt of engine fan:
2) Install fan guard
(21)
to radiator,
then
install
hose clamp (20). t
Install
so that
the
fan and fan guard top and bottom
clearances
between
the
at the left and right, and
are the same.
3. Support Install radiator Sr Tighten
support
(19) to radiator.
the mounting
bolts partially,
then tight-
en them fully after installing the engine hood.
4. Hydraulic piping Connect
oil cooler
to tube at bottom Sr Fit the make
hoses
O-rings sure
(I 5), (I 61, (17)
and (18)
of radiator. securely
that
they
in the are
not
grooves, caught
and when
installing. Hose nut:
WA350-1
36 mm
13-27 0
DISASSEMBLY
5. Radiator
AND
RADIATOR
ASSEMBLY
hoses
1) Connect
radiator
Tighten
the
lower hose (I 4) at engine end.
hose
clamps
at the
connections
with the radiator. 2) Connect
radiator
upper
hoses
(12)
and (I 3) at
engine end. 3) Install
clamp
of
radiator
cooling
water
drain
hose. *
Install the hose without
6. Engine
twisting
or interference.
hood
I) Raise engine wires
(1 I),
hood,
install left and right safety
and set in mounting
tighten the mounting 2) Install
mounting
position,
then
bolt (IO).
bolts
(9) of engine
hood,
and
baffle seat. Sr Tighten
the
mounting
so that
the
clearances
fan and shroud and bottom *
Tighten
3) Remove
safety
of the
between
radiator
the engine
at the left and right, and top
are the same.
the
and support
bolts
mounting
bolts
of the
radiator
fully. bolts, open hood and fit lock.
7. Wiring 1) Connect
connector
(6)
of
wiring
of
coolant
level sensor. 2) Connect
8. Radiator Close
connector
(7) of working
lamp wiring.
grille
hood,
lock with
catch,
then
install radiator
grille.
9. Refilling
with
1) Tighten
oil,_water
plug and add engine oil through
(24) to the specified 2) Tighten
drain
valve
and
add
water
water filler (25) to the specified
/ tiz
Coolant:
Sr Run the engine through
through
level.
52 Q to circulate
the oil and water
the system.
Then, check the oil and water
13-28 0
oil filler
level.
levels again.
WA350-1
DISASSEMBLY
AND
REMOVAL 1. Remove
drain
OIL COOLER
OF OIL COOLER
catch,
2. Loosen
ASSEMBLY
ASSEMBLY
then open hood. valves
(I)
and (21, and drain
cooling
water. *
If the coolant
contains
antifreeze,
dispose
of it
correctly.
3. Remove
fuel injection
For details, TION
pump
see 13-4
PUMP
assembly.
REMOVAL
OF FUEL INJEC-
ASSEMBLY.
4. Disconnect corrosion resistor hose (3). 5. Remove oil tubes (4) and (5). 6. Remove oil cooler assembly (6).
INSTALLATION OF OIL COOLER ASSEMBLY 1. Fit gasket
and install
2. Fit O-rings 3. Connect 4. Install
corrosion
For details, 5. Tighten lock with
pump
see 13-4 PUMP
drain
assembly
oil tubes
resistor
fuel injection
JECTION
6. Add
oil cooler
and install
(6).
(4) and (5).
hose (3). assembly.
INSTALLATION
OF FUEL IN-
ASSEMBLY.
valves
(2) and (I),
close
water
to the
hood,
then
catch.
water
through
filler
specified
level. *
Run the
engine
the system.
WA350-1
Then
to circulate check
the water
the coolant
through
level again.
13-29 0
DISASSEMBLY
A
Stop
AND
the
ASSEMBLY
machine
the safety
ENGINE
on level ground
bar on the frame.
and install
Lower
bucket to and stop the engine. Then apply the parking brake and put blocks under the wheels to prevent the machine from moving.
the ground
! z3i
Loosen
the oil filler
pressure
inside
operate
the
release
cap slowly
the
control
the remaining
to release
hydraulic levers
tank.
several
pressure
the Then
times
to
in the hydraulic
piping. l
Loosen filter,
plug (3) at the top of the hydraulic tank the plug (2) of the pump piping to
and
prevent the oil inside the tank from flowing out. Disconnect the cable from the negative (-1 terminal of the battery.
+
1. Draining
water
Loosen drain valve (3) and drain cooling water. +r If the coolant contains antifreeze, dispose of it correctly.
*
A
Coolant:
2. Radiator
52 !=?
grille
1) Remove
radiator grille (5) from engine hood (4). 2) Open engine hood and fit lock.
3. Wiring 1) Disconnect
connector
(6) of wiring
of coolant
level sensor. 2) Disconnect wiring.
WA350-1
connector
(7)
of
working
lamp
DISASSEMBLY
AND
ASSEMBLY
ENGINE
4. Engine hood 1) Close
engine
hood
(4).
then
bolts
(9)
remove
safety
bolts (8)
2) Remove
mounting
of
engine
hood,
and baffleseat.
3) Raise engine mounting
hood
bolts
(4) about
(IO)
of
300
left
mm, remove
and
right
safety
wires (1 I), then lift off engine hood (4). Engine hood:
134
kg
5. Radiator hoses 1) Disconnect
radiator
upper
hoses
(12)
and (I 3)
lower
hoses (14)
at engine
at engine end. 2) Disconnect
radiator
end. Sr Loosen
the hose clamps
at the connections
with the radiator. 3) Remove
clamp
of radiator
cooling
water
drain
hose.
13-32 0
WA350-1
DISASSEMBLY
AND
ASSEMBLY
ENGINE
6. Hydraulic piping Disconnect
oil cooler hoses (15). (161, (17) and (18) from tube connector at bottom of radiator. * Cover to prevent dirt or water from entering. 36 mm
Hose nut:
7. Support Sling
radiator,
radiator
then
remove
side of radiator
mounting
bolts
at
support
(I 9).
(ZO),
then
remove
fan
the
radiator
fins
6. Fan guard, engine fan 1) Remove guard (2 2) Remove *
hose
clamp
I). engine fan (22).
Be careful
not to damage
when removing.
9. Radiator Remove
mounting
bolts, then lift off radiator
Radiator:
105
WA350- 1
kg
(23).
DISASSEMBLY
AND
ASSEMBLY
ENGINE
10. Electric wiring 1) Disconnect starting
wiring
(24)
between
motor at starting
2) Disconnect
cable
(25)
battery
and
motor end. between
starting
motor
and ground at frame end. 3) Remove
switch
4) Disconnect 5) Remove Sr After
(27) from switch
connectors
box (26).
(28) and (29).
clamps. removing
the connectors,
tag to distinguish
mark with
a
when installing.
11. Fuel hoses 1) Disconnect
hose
(30)
between
fuel
tank
and
fuel filter at fuel tank end. 2) Disconnect
fuel
return
hose
(31)
at fuel tank
and
(33)
at governor
end.
12. Air tubes Disconnect
air tubes
and compressor
(32)
end.
13. Hydraulic piping I) Remove converter
bracket
(34)
charging
of tube pump
between
and
torque
transmission,
transfer.
13-34 0
WA350-1
DISASSEMBLY
AND
2) Disconnect
tube
torque converter 3) Disconnect transmission 4) Remove
filter
(35)
between
oil cooler
at torque converter
tube
(36)
between
at transmission
and
end.
oil cooler
and
end.
tube clamp (37).
5) Disconnect verter
ENGINE
ASSEMBLY
tube
charging from
(38)
torque
(39). then remove
14. Fuel control cable I) Disconnect fuel
between
pump
and
converter U-clamp
control
torque
torque
con-
converter
charging
pump
(40).
cable
(41)
from
ball
joint (42). 2) Remove
fuel
control
cable
(41)
from
bracket
(43).
15. Brake
hose
Disconnect
hose (44)
brake chamber
WA350-1
between
slack adjuster
from slack adjuster.
and
DISASSEMBLY
AND
ASSEMBLY
16. Transmission
stand
Put stand under transmission
ENGINE
(45).
Sr Use a stand with adjustable
height, and fix it so
that it cannot slip out of position.
17. Engine assembly I) Remove *
muffler
When
(46).
removing
to damage
be careful
not
23 kg
Muffler:
2) Remove
the muffler,
the gasket.
bracket
(47)
for engine
oil drain valve
from fuel tank (48). 3) Sling engine
(49).
then remove
mounting
bolts
(50) of engine and torque converter.
4) Remove
engine
mounting
bolts
(511,
then
lift
off engine assembly. *
Note
how
installed,
cushions
and
and
the
use
reference
g-ear
of
for
spacers
are when
installing. Sr The
ring
meshed verter
and
engine,
the
engine
flywheel
is
with the ring gear of the torque conthe
keep
shaft,
so when
the assembly
raising
the
horizontal
when
be careful
not to
removing. *
When
removing
damage
the engine,
the suction tube of the fuel tank.
Engine assembly: Mounting
13-36 0
bolt:
700
kg
36 mm
WA350-1
DISASSEMBLY
AND
ASSEMBLY
INSTALLATION
ENGINE
OF ENGINE
Wheel loader
ASSEMBLY
8 Electric wiring
\ToB
I7 B--t
Refilling wth oil, water 423F405
WA350-1
13-37 0
DISASSEMBLY
AND
ASSEMBLY
1. Engine assembly I) Raise engine tighten converter *
(49).
set in mounting
mounting
bolts
and
and torque
uniformly.
Install the engine
horizontally.
mesh the flywheel verter
position,
of engine
Be careful
ring gear and torque
ring gear, and to fit the torque
to
con-
conver-
ter shaft correctly. a
O-ring
at contact
torque
converter:
2) install engine mounting *
face
the cushions
10.5 kgm
bolt:
94.5f
Mounting
bolt:
36 mm
(47)
and spa-
direction.
Mounting
3) Install bracket
and
bolts (5 1).
Be careful to assemble
cers facing in the correct B
of engine
Grease (G2-LI)
for engine
oil drain valve to
fuel tank (48).
4) Set muffler
(46)
stall mounting
13-38 0
in mounting
position,
then in-
bolts.
WA350-1
DISASSEMBLY
AND
2. Transmission
stand
Remove
ASSEMBLY
ENGINE
stand from under transmission
(49)
3. Brake hose Connect
hose
brake chamber
(44)
between
slack
adjuster
and
to slack adjuster.
4. Fuel control cable I) Install fuel control cable (41) to bracket 2) Connect
(43).
fuel control cable (41) to ball joint (42).
5. Hydraulic piping I) Connect charging torque
tube
and
converter
stall U-clamp
WA350-1
(38)
pump
(40).
between
torque
torque
converter
charging
pump
(39).
converter filter
to
then in-
DISASSEMBLY
2) Connect
AND
ASSEMBLY
tube (36) between
ENGINE
oil cooler and trans-
mission to transmission. 3) Connect
tube
(35)
torque converter 4) Install tube clamp
5) Install bracket verter charging
between
oil
cooler
and
to torque converter. (37).
(34) of tube between
torque con-
pump and transmission
transfer.
6. Air tubes Connect
tubes (32) and (33) at governor
and com-
pressor end.
7. Fuel hoses 1) Connect 2) Connect
fuel return hose (31) at fuel tank end. hose (30)
between
fuel tank and fuel
filter at fuel tank end.
13-40 0
WA350-1
DISASSEMBLY
AND
ASSEMBLY
ENGINE
8. Electric wiring 1) Install clamps.
2) Connect
connectors
3) Install switch 4) Connect
(28) and (29).
(27) to switch
cable (25)
box (26).
between
starting
motor and
ground at frame end. 5) Connect
wiring
(24)
between
ing motor at starting
battery
and start-
motor end.
9. Radiator Raise radiator
(23).
install mounting *
Tighten
set in mounting
position
and
bolts.
the mounting
bolts partially,
then tight-
en them fully after installing the engine hood.
10. Fan guard, engine fan
1) Install engine fan (22). *
Be careful
not to damage
the
radiator
fins
when installing. Mounting
B 2) Install
fan
guard
bolt of engine fan: (2 1) to radiator,
6.5 kgm then
install
hose clamp (20). *
Install
so that
the
fan and fan guard top and bottom
clearances
between
the
at the left and right, and
are the same.
11. Support Install radiator *
Tighten
support
(I 9) to radiator.
the mounting
bolts partially,
then tight-
en them fully after installing the engine hood.
DISASSEMBLY
AND
ENGINE
ASSEMBLY
12. Hydraulic piping Connect
oil cooler
to tube at bottom t
Fit the
hoses (I 51, (16).
O-rings
make
sure
(I 7) and (18)
of radiator. securely
that
they
in the are
grooves,
not
caught
and when
installing. 36 mm
Hose nut:
13. Radiator hoses 1) Connect
radiator
Tighten
the
lower hose (I 4) at engine end.
hose
clamps
at the
connections
with the radiator. 2) Connect
radiator
upper
hoses
(121 and (13)
at
engine end. 3) Install
clamp
of
radiator
cooling
water
drain
hose. Sr Install the hose without
twisting
or interference.
14. Engine hood 1) Raise engine wires
(I I),
hood,
install left and right safety
and set in mounting
tighten the mounting 2) Install
mounting
bolts
position,
then
bolt (I 0) (9) of engine
hood,
and
baffle seat. t
Tighten
the
so that
the clearances
mounting
fan and shroud and bottom *
Tighten
the
and support 3) Remove
13-42 0
safety
bolts
of the
between
radiator
the engine
at the left and right, and top
are the same. mounting
bolts
of the
radiator
fully. bolts, open hood and fit lock.
WA350-1
DISASSEMBLY
AND
ASSEMBLY
ENGINE
16. Radiator grille Close hood, lock with catch, then install radiator grille (5).
17. Refilling with oil, water 1) Tighten plug and add engine oil through oil filler (52) to the specified level. 2) Tighten drain valve and add water through water filler (53) to the specified level.
a *
Coolant: 52 II
Run the engine to circulate the oil and water through the system. Then check the oil and water levels again.
WA350-1
13-43 0
DISASSEMBLY
AND
REMOVAL
a
Stop
OF FUEL TANK
the
machine
the safety the
on level ground
bar on the frame.
to the ground
r
parking
Remove Q
V
Lower
and
and
put
blocks
TANK
ASSEMBLY install
the bucket
and stop the engine. Then brake
wheels to prevent the machine
1. Radiator
FUEL
ASSEMBLY
apply
under
the
from moving.
grille radiator
grille (I ).
Open hood (2) and fit lock (3).
2. Draining
fuel
Loosen drain valve (4) and drain fuel.
3. Drain valve Remove
engine oil drain valve (5) from fuel tank.
4. Fuel tubes,
wiring,
I) Disconnect 2) Disconnect
clamp
fuel tubes (6) and (7) from fuel tank. wiring
(8)
for
fuel
unit
from
connector. 3) Remove
13-44 0
clamp (9) of cooling water
drain hose.
WA350-1
DISASSEMBLY
AND
FUEL TANK
ASSEMBLY
5. Fuel tank 1) Sling
fuel
tank
(IO),
remove
mounting
bolts,
then lift off fuel tank. *
Lay a pallet
below
tank balanced Fuel tank:
the fuel
tank,
keep
the
and lower slowly.
198 kg
2) Pull fuel tank (10) out from under machine. * Be careful not to let the breather tube hit the machine body.
WA350-1
13-45 0
DISASSEMBLY
AND
FUEL TANK
ASSEMBLY
INSTALLATION
OF FUEL TANK
ASSEMBLY
1. Fuel tank I) Set
fuel
tank
(I 0)
below mounting *
Be careful machine
*
Tighten
not to let the breather
in to
tube hit the
position,
bolts.
the mounting
Mounting
Sr When
pus1
(101, set in mounting
mounting
order: Left w
i
then
body.
2) Raise fuel tank then tighten
on pallet,
position.
bolts in the following
rear +
right.
bolt:
94.52
10.5
kgm
raising the tank, keep it horizontal
set in the mounting
and
position.
2. Fuel tubes, wiring, clamp 1) Connect
wiring (8) for fuel unit to connector.
2) Connect
fuel tubes (6) and (7) to fuel tank.
3) Install clamp
(9) of cooling water drain hose.
3. Drain valve Install engine oil drain valve (5) to fuel tank.
13-46 0
WA350-1
DISASSEMBLY
AND
ASSEMBLY
FUEL
TANK
4. Hood Release
lock (3) and close
radiator
grille
with
fuel
drain
valve
6. Refilling Tighten
(2)
grille
5. Radiator Install
hood
(1)
(4) and add fuel
through
fuel
filler (1 1).
WA350-1
13-47 0
POWER TRAIN
21 STRUCTURE
AND FUNCTION
.
General .
.
.
.
..
Hydraulic
circuit for power train Hydraulic circuit diagram for power train yorque converter and transmission piping Torque converter charging pump . Torque
converter
.
..
Torque
converter
oil filter
Torque
converter
oil cooler
Torque
converter
relief valve
Transmission
.
Upper valve
.
Lower valve
. .
. .
.
Transmission
.
Emergency
.
Priority valve
.
Modulating
solenoid valve
.
21-
7 8 1
21-I
2
.
21-I
3
. . .. ...
21-l
4
.
21-22 21-24
. .
.
.
21-25 21-26 2 I-30
.
valve and quick return valve Accumulator valve .
21-31 2 1-34
.
Pilot reducing
21-36
manual spool
.
valve.
pilot filter
Transfer Drive shaft
. .
Torque
2 1-37 21-38
.
. .
_.
proportioning
.
Tire and wheel
. . 2 I-39
. ..
Axle and differential. ;inal drive
21-27
.
Axle mount
5 6
2 I21-I
.. .
Transmission
WA350-1
.
.
control valve
.
2 4
..
.
Transmission
21-
. 21. 21. 21-
21-40 21-42
differential
.
21-47 21-48
.
.
.
21-49
21-1
STRUCTURE
AND
GENERAL
FUNCTION
GENERAL
423FOO3
OUTLINE The motive flywheel to
force from
through
torque
converter
uses oil to convert spond
force
addition,
(2).
The
in the
load.
converter
tuated valve
torque to corre-
transfer
output
shaft
input
In
passes
and steering
charging
move
the
spool of the control speed
selection
REVERSE
speeds.
of
by
operating
directional valve.
which the
spool
solenoid and
The transmission
four
FORWARD
The
speeds
are
and
(5)
transmits
motive
force
to the
from
The power
for the front axle passe through
drive shaft
(15)
transmitted
to front
and front
drive shaft
axle !I 0);
center
(I 3) and is
the power
rear drive shaft
for the (I 6) and
The
motive
force
and rear axle and
ring
(21)
gear
of
transmitted
axle
(IO)
is reduced
by the pinion
gear
differential
(1 1),(20).
the differential
to front
range
passes from
has a
(axle shaft) of final drive (8),(18).
It then
to the sun gear shaft
four
selected
manually.
21-2 @
the
is then sent to the front and
is sent to rear axle (21).
(3) to are ac-
The
rear axle passes through
pump
pump
transmission
the gear of the tranfer
rear axle.
the
shaft.
.
hydraulically to
of
shaft.
It transmits
(5) has six clutches
shaft
force through output
drive these pumps. Transmission
output
motive
the pump drive gear of the torque conver-
and torque
The
transfer
force from the engine
ter and is sent to the hydraulic (4).
.
converter
torque
to the transmission
the motive
through
(1) passes from the
the transmitted
to changes
motive
engine
the ring gear and is transmitted
WA350- 1
STRUCTURE
AND
FUNCTION
1. Engine (S6DllO-I) 2. Torque
converter
3. Torque
converter
charging pump pump and steering pump 5. Transmission
4
Hydraulic
6. Transfer 7. Front wheel
WA350-1
GENERAL
8. Final drive (Front) 9. Brake (Front) 10. Front axle 1 1 Differential
(Front)
12. Parking brake 13. Front drive shaft 14. Flanged bearing
15. Center drive shaft 16. Rear drive shaft
423 FOO4A
17. Rear wheel 18. Final drive (Rear) 19. Brake (Rear) 20. Differential (Rear) 2 1. Rear axle
21-3 @
STRUCTURE
HYDRAULIC
AND
GENERAL
FUNCTION
CIRCUIT
FOR POWER
TRAIN
21
r.,
\
w
17
18
19
m E
7-r
16
15
j j; .j .j ;; ;:: : :: ,: : ; ,, .: PI WI Ej ::
!
2
j
:
:
:: : ;:
:
23
8 423 F050A
21-4 @
WA350-1
STRUCTURE
HYDRAULIC
AND
FUNCTION
CIRCUIT
GENERAL
DIAGRAM
FOR
POWER
TRAIN -15
14k& Cl-f 8
I I
I I I ,
3 kg/cm’
19 r_~-_“--,
r----i
I I I
20 r---7
2A
150 Mesh
I I
1
1 1. Transmission
case 2. Strainer 3. Torque converter charging 4. Oil filter
pump
5. Priority valve 6. Modulating valve 7. Quick return valve 8. Pilot oil filter 9. Pilot reduction valve 10. Torque converter relief valve II. Torque converter 12. Oil cooler WA350-1
13. Transmission lubrication 14. Transmission lubrication 15. Reverse clutch
relief valve
16. Forward clutch 17. 4th clutch 18. 3rd clutch 19. 2nd clutch 20. Accumulator 2 1. 1 st clutch 22.
Reduction
23.
Emergency
24.
Solenoid
valve spool, F-R spool spool
valve
21-5 0
STRUCTURE
TORQUE
AND
FUNCTION
CONVERTER
TORQUE
AND
CONVERTER
TRANSMISSION
AND
TRANSMISSION
PIPING
PIPING
6
423F007A
1. Transmission 2. Transmission
pilot filter
3. Transmission
control
4. Torque
21-6 0
5. Torque
converter
charging
pump
6. Radiator
converter
valve
7. Torque
converter
oil cooler
8. Torque
converter
oil filter
WA350-1
STRUCTURE
TORQUE
AND
TORQUE
FUNCTION
CONVERTER
CHARGING
. The torque converter charging pump is installed to
CONVERTER
CHARGING
PUMP
PUMP .
the torque converter case. It is driven by the motive force from the engine and supplies oil to the torque converter and transmission system.
The torque converter charging pump sucks in oil from the bottom of the transfer case through a strainer and sends oil to the oil filter.
423FOO8 Sect-on
A-A
5
Specifications: 1. 2. 3. 4. 5.
Front cover Drive gear (Teeth 12) Gear case Rear cover Driven gear (Teeth 12)
WA350-1
SAL(3)-056
Model: Theoretical
discharge:
56 cclrev
Max. pressure:
2 10 kg/cm2
Max. pump speed:
2,500
rpm
21-7
STRUCTURE
TORQUE
AND
FUNCTION
TORQUE
CONVERTER
CONVERTER
423FO12
3 /
Specifications Model: Type:
TCA34-2A 3-element.
Stall torque
ratio:
I. Mount
of torque
single stage,
single
phase
3.10
converter
charging
pump
2. Housing 3. Mount
for hydraulic
and steering
pump
Section A-A
21-8 @
WA350-1
STRUCTURE
AND
TORQUE
FUNCTION
Section B-B
4, Pilot 5. Drive case 6. Turbine 7. Pump
1 1. Transmission
WA350-1
423F013A
8. Idler gear (PTO gear driven) 9. PTO gear (drive) 10. Stator
CONVERTER
A.
Inlet port
B.
Output
port
input shaft
21-9 %
STRUCTURE
Flow
AND
of motive
The the
converter
and
passes
case
(5).
gear (drive)
from
Drive
force
This
sion input
between
the
force
from
motive flywheel
and
(51, pump
with
bolts.
enters
(8) and PTO
They
are rotat-
of the engine.
of pump
transmits
shaft
The motive
(8) uses oil to rotate motive
force
tur-
to transmis-
(10).
force
of drive
PTO gear (driverIg) force
the
case
by the rotation
The motive
installed The
(9) are fixed
ed directly bine (6).
is
transmission.
engine
drive
CONVERTER
force
torque
engine
TORQUE
FUNCTION
case (5) passes
through
and is also used as the motive
to drive the gear pump.
10
4A
Flow l
of oil
The oil pressure
is adjusted
ter relief
valve.and
through
the
to
pump
applied.
In
oil enters
(IO),
(6) so the
transmission The
oil from
again passes
is fixed motive input
(2) and flows
centrifugal
turbine
force
is
(6) and the energy
to the turbine. to
transmission
force
shaft
turbine
(8)
conver-
inlet port A, passes
in housing
pump
of the oil is transmitted Turbine
by the torque
enters
oil passage
(8). The
then
the
pump.
from
the
stator
shaft to the
(I 0).
(6) is sent
enters
input
is transmitted
However, through
to stator part outlet
(9) and of the
port
oil
B and
is sent to the cooler.
u
21-10 0
423FO15
WA350-1
STRUCTURE
AND
TORQUE
FUNCTION
TORQUE
CONVERTER
OIL
CONVERTER
OIL FILTER
FILTER
1. Relief valve 2. Element 3. Center
bolt
4. Drain plug Filtration area: Relief pressure:
8,900 3.25
cm2 kg/cm’
,
LLlJ
423FOO9
To transmission control valve
OPERATION .
The oil from (5) enters
the torque
the filter
the outside
converter
charging
pump
inlet port A and passes
of element
(2) to the inside.
from
It then
flows to the outlet port B.
423FOlO
To transmission control valve
. If the element temperature rises.
When
port A opens the
outlet
(2) is clogged
with
is low, the pressure this happens, relief valve (I)
port
the oil from and flows
B. This prevents
pump or filter element
(2).
dirt, or the oil
at the inlet port A the inlet directly
damage
to
to the
2
423FOll
WA350-1
21-11
STRUCTURE
AND
TORQUE OUTLINE . The oil because
CONVERTER
which
converter
comes
outlet of
port
the
force.
This
through
oil cooler
Here it is cooled flows
the transmission
out is at
energy
motive
oil then
TORQUE
FUNCTION
from
used
oil
port
the passes
the oil cooler.
cooling
oil outlet
and returns
torque
in transmitting
port A and enters
out from
the
temperature
converter
by the engine
OIL COOLER
OIL COOLER
a high
torque
CONVERTER
water.
The
B, lubricates
to the transfer
case.
423FO49
21-12
1.
Radiator
2.
Hydraulic
3.
Torque
oil cooler converter
oil cooler
A.
Torque
converter
oil inlet port
B.
Torque
converter
oil outlet
C.
Hydraulic
oil inlet port
D.
Hydraulic
oil outlet
port
port
WA350-1
STRUCTURE
AND
TORQUE
FUNCTION
CONVERTER
FUNCTION . The torque converter the pressure
(1)
the
and
then
enters -. converter.
pressure.
VALVE
A
the torque It drains
conver-
the
oil if it
pressure.
pump
actuates port
RELIEF VALVE
To each transmission spool
goes above the specified
OPERATION . The oil from
RELIEF
CONVERTER
relief valve acts to maintain
of the oil entering
ter at a constant
valve
TORQUE
passes
through
modulating and
flows
priority
valve to
the
(2).
It
torque
To tranimission lubrication
From pump 423FO42
.
If the
oil
at
port
A goes above
the
through
“a” of torque
it passes
converter
relief valve (3) and enters port B. It then
moves torque converter
orifice
relief valve (3) to the left.
As a result, the oil from
port A is drained,
oil flowing
converter
to the torque
the specified
To each transmission spool
specified
pressure,
and the
is maintained
.>:.:.: _...........,.,............. ;;;; .,.,. i:.:.:.:.: ........::::: _.. .. .:.: ii;; j:j: :;:: _... ..:.: j:j; :j:: //
at
pressure.
To tranimission lubrication
From pump 423FO43
WA350-1
21-13
STRUCTURE
AND
FUNCTION
TRANSMISSION
TRANSMISSION
/
Section B-B
423FO16
1
Oil filler
2. Transmission
input
shaft
3. Transmission 4. Transfer 5. Transfer
output
6. Transmission View Z
21-14
coupling control
valve
7. Pilot filter 8. Strainer
WA350-1
9. No. 1 sun gear (Teeth 25) 10. No. 1 planetary gear (Teeth 23) 1 1. No. 1 ring gear (Teeth 76) 12. No. 1 clutch
13. No. 1 idler ring gear (Teeth 7 1)
14. No.
2 sun gear (Teeth 3 7)
15. No. 2 planetary gear (Teeth 19) 16. No. 2 clutch 17. No. 2 ring gear (Teeth 75) 18. No. 3 sun gear (Teeth
17)
19. No. 3 planetary gear (Teeth 30) 20. No. 3 clutch 2 1. No. 3 ring gear (Teeth 76) 22. No. 4 planetary gear (Teeth 19) 23. No. 4 clutch 24. No. 4 ring gear (Teeth 76) 25. No. 4 sun gear (Teeth 38) 26. No. 5 ring gear (Teeth 76) 27. No. 5 clutch 28. No. 5 planetary
gear (Teeth 18)
29. No. 6 clutch No. 5 sun gear (Teeth 42) 3 1. No. 6 gear (Teeth 75) 30.
REVERSE
FORWARD
4th
3rd
2nd
1 st
423FO17A
Section
WA350-1
32.
Output shaft
33.
No.
34.
No. 2, 3,4
35.
No. 5 carrier
1 carrier carrier
A-A
21-15 0
STRUCTURE
AND
TRANSMISSION
FUNCTION
Clutch combination
Speed range OUTLINE The transmission REVERSE transfer,
consists
speed
and transmission
In the transmission, shaft
of a 4-FORWARD,
planetary
is changed
gear
4-
Fl
transmission,
I
control valve.
the motive force of the input
by the combination
of No. 1 or
F3
NO. 2 clutch with No. 3, 4, 5 or 6 clutch to give FORWARD
1 -
is transmitted
4 or REVERSE
1 -
4 speed, and
R3 R4
OF
through
transmission.
No. 2, No. 5 No. 2, No. 4 No. 2, No. 3
I
I I I
No. 1, No. 6 No. 1, No. 5 No. 1, No. 4 No. 1, No. 3
CLUTCH
Engaged The oil sent from the transmission passes
No. 2, No. 6
I
R2
.
I
F4
to the output shaft. RI
OPERATION
I
the
When
oil
control
passage
it reaches
inside
valve the
the rear of piston
(2). it moves the piston (2). .
When
the piston (2) moves, disc (4) and plate (5)
are pressed
together.
Ring gear
(6)
is meshed
with disc (4). so the rotation is stopped.
423FO 118
.
Disengaged When
the supply of oil from the transmission
con-
trol valve is shut off, the pressure of the oil acting on the rear of piston (2) is reduced.
The piston is
then pushed back to the right by return spring (3). and disc (4) and plate (5) are separated. (6) then
rotates
freely,
and no motive
Ring gear force
is
transmitted.
423FO19
21-16
WA350-1
STRUCTURE
AND
FORWARD
1 ST
FUNCTION
TRANSMISSION
E423F020
.
In 1 st FORWARD,
No. 2 clutch
and No. 6 clutch
are engaged.
motive
transmitted
the torque
The
converter
force
.
from
No. 2 clutch applied
by input shaft (2) is transmit-
(17)
is actuated
to the clutch
shaft
in position.
draulic
pressure
by the hydraulic
No. 6 clutch is actuated applied
(2)
through pressure
piston, and it locks ring gear to the clutch
holds gear (3 I) in position.
by the hypiston,
and
force the torque
.
is transmitted
to planetary
Ring gear (17)
is held in position
so the rotation
of planetary
rier (341, which This
carrier
through
is transmitof the input gear
(15)
sun gear (I 4). by No. 2 clutch,
gear (15)
rotates
car-
is on the inside of ring gear (I 7).
is connected
to
No.
5 carrier
No. 4 ring gear (241, so when
is actuated,
the rotation
(35)
No. 6 clutch
of carrier (35) is transmit-
ted to gear (31) and rotates
WA350-1
converter
ted to the input shaft (2). The rotation
ted to output shaft (32). .
The motive
output shaft (321.
21-17 @
STRUCTURE
AND
FORWARD
2ND
TRANSMISSION
FUNCTION
E423F021
. In 2nd FORWARD, are engaged. the torque
No. 2 clutch
The
converter
motive
force
and No. 5 clutch transmitted
from
hydraulic
The rotation
and No. 5 clutch
pressure
applied
are actuated
to the
clutch
motive
transmitted the
input
from
the
to the input shaft shaft
(15) through
21-18 Go
force
is transmitted
torque
of carrier
(34)
ring gear (24) to carrier (35).
piston,
Ring gear (26) so the
converter
is
(2). The rotation
of
to planetary
of planetary
by the
and they hold ring gears (I 7) and (26) in position. The
Ring gear (1 7) is held in position so the rotation
by No. 2 clutch,
gear (I 6) rotates
car-
rier (34), which is on the inside of ring gear (I 7).
by input shaft (2) is transmit-
ted to output shaft (32). No. 2 clutch
.
gear
rotation
gear (28).
is transmitted
is held in position of carrier
The planetary
(35)
by No. 5 clutch, rotates
gear rotates
of ring gear (261, and rotates sun gear rotates
through
planetary
on the inside
sun gear (30).
output shaft (32).
sun gear (I 4).
WA350-1
The
STRUCTURE
AND
FORWARD
3RD
FUNCTION
TRANSMISSION
/J
i
il
I I
I
E423F022
l
In 3rd FORWARD,
No. 2 clutch
and No. 4 clutch
are engaged.
motive
transmitted
the torque
The
converter
force
by input shaft (2) is transmit-
ted to output shaft (32). l
No. 2 clutch hydraulic
.
and No. 4 clutch are actuated
pressure
applied
to the
clutch
The
motive
transmitted the
input
from
the
to the input shaft shaft
(I 5) through
WA350-1
force
is transmitted
torque
is held in position
so the rotation
of planetary
rier (341,which
is on the inside of ring gear (I 7).
Ring gear (24)
is held in position
so the
piston,
planetary
rotation
of carrier
gear (I 5).
is
(2). The rotation
of
(25).
by No. 2 clutch,
gear (I 5) rotates
(34)
The sun gear rotates
car-
by No. 4 clutch, is transmitted
The planetary
the inside of ring gear (24),
converter
to planetary
Ring gear (17)
by the
and they hold ring gears (1 7) and (24) in position. l
.
from
gear rotates
and rotates
to on
sun gear
output shaft (32).
gear
sun gear (I 4).
21-19 0
STRUCTURE
FORWARD
AND
FUNCTION
TRANSMISSION
4TH
2
15
14
16
19
21
18
E423F023
.
In 4th
FORWARD,
are engaged. the torque
The
converter
No. 2 clutch
and No. 3 clutch
motive
transmitted
force
by input shaft (2) is transmit.
ted to output shaft (32). l
No. 2 clutch hydraulic
and No. 3 clutch are actuated
pressure
applied
to the
and they hold ring gears (I 6) and (2 .
The
motive
transmitted the
input
from
the
to the input shaft shaft
(15) through
21-20 Go
force
.
from
is transmitted
clutch
is on the inside of ring gear (I 5).
planetary
rotation
of carrier
gear (19).
of
(34)
car-
by No. 3 clutch, is transmitted
The planetary
the inside of ring gear (21).
(2). The rotation
gear (I 5) rotates
Ring gear (1 6) is held in position
piston, is
to planetary
rier (34). which so the
converter
by No. 2 clutch,
of planetary
by the
I) in position.
torque
Ring gear (I 6) is held in position so the rotation
gear rotates
and rotates
to on
sun gear
(18). which forms one unit with output shaft (32).
gear
sun gear (I 4).
WA350-1
STRUCTURE
REVERSE
AND
FUNCTION
TRANSMISSION
1 ST
r_ CL
E423F024
.
In 1 st REVERSE, engaged. torque
The
No. 1 clutch and No. 6 clutch are motive
converter
force
transmitted
by input shaft
from
the
(2) is transmitted
No. 1 clutch applied
(33) in position. draulic
clutch
.
The
pressure
motive
transmitted the
input
applied
force
shaft
pressure
and it locks
to the clutch
carrier
by the hypiston
and
1) in position. from
the
to the input shaft
(I 2) through
WA350-1
by the hydraulic piston,
No. 6 clutch is actuated
holds ring gear (3
(33)
rotation
is transmitted
gear
Carrier
converter
is
(2). The rotation
of
to planetary
planetary
clutch
rotates
which
rotates
is actuated,
the
in the opposite
so ring
direc-
(I 3) rotates
of carrier (34) rotates rotates
6 clutch.
the rotation
to gear (31)
rotates
Ring gear
then No.
by No. 1 clutch,
gear
and the rotation (231,
(35)
transmitted torque
of
the input shaft.
carrier (34). ring
is held in position
Ring gear (13)
tion from
is actuated
to the
Carrier the gear.
to output shaft (32). .
l
carrier When
of carrier
and rotates
(3.5). No. 6 (35)
output
is
shaft
(32).
gear
sun gear (9).
21-21 0
STRUCTURE
CONTROL
TRANSMISSION
ii 1
-
CONTROL
VALVE
VALVE
\ 3
2
Serial No. 10001
Serial No. 11118
TRANSMISSION
FUNCTION
AND
\ 8
11117
and up 423F025B
1. Lower 3. Upper
27-22 0
lubricating
converter
pressure
7. Modulating
pick-up
valve
4. Transmission 5. Torque
6. Priority
valve
2. Pilot reducing
pressure
relief pressure
pick-up pick-up
pick-up
pressure
pick-up
8. Accumulator
pressure
pick-up
9. Transmission
solenoid
valve
10. Connector
WA350-1
STRUCTURE
AND
TRANSMISSION
FUNCTION
CONTROL
VALVE
Reverse Forward 4th 3rd 2nd
i
i Section A-A 423FO26
8
I \ \
7
6
5
4
1.
Connector
2.
1 st solenoid
valve
3.
2nd solenoid 3rd solenoid
valve
8. Body
4.
valve
9. Emergency
5.
4th solenoid
valve
3
6. FORWARD 7. REVERSE
solenoid solenoid manual
Actuation table for solenoid valve
and clutch
valve valve spool
STRUCUTRE .
The transmission transmission valve. lever
solenoid together
When
the directional
are operated,
and moves
WA350-1
the spool
valve with
is installed the
to the transmission
lever or speed
the solenoid
valve
control
is actuated
inside the transmission
valve.
21-23 @
STURUCTURE
UPPER
AND
TRANSMISSION
FUNCTION
CONTROL
VALVE
VALVE
OUTLINE The oil from enters
port
the torque A,
and
converter
passes
valve.
It is then divided
clutch
pistons,
valve.
The
charging
through
the
pump priority
into two lines: one to the
and the other to the pilot reducing
priority
valve
acts to control
lines so that the pilot reducing
the two
valve is the priority
other
oil line flows
and quick return valve. ing valve pressure actuating
The oil flowing
to the pilot reducing
the pilot pressure and speed
spools.
used to actuate The
valve passes
valve controls the directional
oil regulated through
by the pilot
the orifice
in each
to the modulating
valve raises the clutch
This reduces
the FORWARD,
the shock
REVERSE
3rd, and 4th speed clutches
the oil flow at the
the filling time when shift-
ing from 2nd to 1 st or 3rd gear. The
lubrication
valve
controls
the
lubrication
inside the transmission.
spool and fills the spool.
21-24
when
and 1 st, 2nd,
to change gear.
valve controls
2nd clutch and reduces
valve
The action of the modulat-
and quick return smoothly.
The accumulator
circuit.
reducing
The
WA350-1
oil
STRUCTURE
AND
FUNCTION
TRANSMISSION
CONTROL
VALVE
LOWER VALUE
10 Section B-B
I, Torque
WA350- 1
converter
relief Vak?
8. 4th spool
2. Quick return valve 3. Modulating valve 4. Priority valve
10. FORWARD
spool
1 1 Lubrication
valve
5. Housing
12. Reverse
9. Pilot reducing
valve
spool
6. 1 st spool
13. 3rd spool
7. 2nd spool
14. Accumulator
21-25
FUNCTION
AND
STRUCTURE
Function There is one
VALVE
each
for
transmission
in the
spool
speed
and
installed
valve
solenoid
l
CONTROL
VALVE
SOLENOID
TRANSMISSION
directional
TRANSMISSION
valve. When
the
levers
in
valve
the solenoid
operated,
to
drained
are
and oil is
is actuated,
and
directional
the
actuate
spools.
control
compartment
operator’s
the
speed
and
lever
directional
speed
..
Operation 1) Solenoid
valve
OFF (I
The oil of spool (2) shuts
1 enters
port A. However, and speed
off the oil, so directional
valve spool
(I) does not move.
2) Solenoid
valve
operated, The
oil
enters circuit.
ON
the solenoid from
port
port
is pulled and
directional
from
A and flows
Therefore,
sure circuit,
valve
shift
gear
and
directional
the
When
speed port
A becomes
and directional
lever
are
spool
(I)
From quick return val
up. B to the drain the low
and speed
spool
pres(I) is
actuated.
423FO32
21-26
WA350- 1
STRUCTURE
AND
EMERGENCY
FUNCTION
MANUAL
TRANSMISSION
CONTROL
VALVE
SPOOL
Function .
If there
is any failure
transmission
in the electrical
control
valve does not work, is used.
system,
the emergency
This spool is attached
and speed machine
circuit of the the
to a place where
Particular
attention
solenoid
manual
spool
to each directional
spool and is used to operate
mission valve mechanically. *
and
the trans-
(It is used to drive the it can be repaired.)
must
be
paid
for
when
using this spool.
_ . Normal position
Operation When
the solenoid
valve is working
spool is maintained Oil from
normally,
the
in this position.
directional
and
speed
spool
(1)
enters
port A, but it is shut off by solenoid valve (2).
reducing valve
.
423FO44
Clutch OFF Emergency
manual
spool (3) is pushed to the left,
and the oil at port A is shut off regardless action of solenoid
of the
valve (2). The oil cannot flow to
port B, so the clutch is not actuated.
reducing valve 423FO45
.
From quick
Clutch ON When
emergency
manual
spool (3) is pulled to the
right, the oil at port A is drained less of the operation
of solenoid
to port B regardvalve
(2).
As a
result, the clutch is actuated.
reducing valve
WA350-1
423 F046
21-27
STRUCTURE
AND
FORWARD
1 ST
TRANSMISSION
FUNCTION
1st
CONTROL
2nd
F
T/C:
VALVE
R
Torque converter
I. Solenoid
valve
2. Solenoid
valve
3. Oil filter 4. Priority valve 423 FO47A
5. 1 st spool 6. FORWARD
spool
7. Spring 8. Spring 9. Piston 10. Quick return valve 1 I. Pilot reducing
21-28 0
valve
WA350- 1
STRUCTURE
AND
FUNCTION
TRANSMISSION
CONTROL
oil line flows
priority
VALVE
Operation When
the directional
moved
and speed control
to FORWARD
1 st, solenoid
levers are
valves
(I)
and
(2) are opened. The
oil from
the
pump
passes
through
filter
(3)
oil from
one
goes
other
the pump
to
goes
pilot
is divided
reducing
valve
to the clutches.
gear is shifted,
priority
The
other
into 2 circuits:
It then flows
fice “a”, and directional
and speed
(6).
and flows
it starts
passes through
the
valve
rear of modulating
E. When
the
port D disappears.
valve.
However,
solenoid
to the drain circuit.
in pressure
is created
and this overcomes
spool valves
1st spool
spool (6) and
(5) are gpen, so the oil passing through flows
the orifice
As a result, a difference
between the force
D. Quick
to the right, and the oil at
ing valve through solenoid
it
a difference
return valve (I 0) moves drain circuit
difference
The
the left by the difference
piston
(9) flows
to
between
valve
port
is pushed
C and back to
in area of the valves, and
drain circuit E is closed. At this point, each clutch oil has not reached at port D flows
of springs
the
(7) and
port
each clutch is filled with oil,
in pressure
port A and port B,
(8). The port to the clutch is then connected.
C and
1st
in pressure
of each speed
port
and clutch,
the to
between
ori-
(5) and
the
is given to the oil flowing
(1) and 12) of FORWARD
clutch to the
orifice “a” and creates
One of the two oil lines flows from the pilot reducto the
to flow
(4) to
and
the clutches. the orifice
spools
to the FORWARD
When
valve
through
when
(I I),
However,
from
quick return valve (IO).
clutch.
and enters priority valve (4). The
l
back
moves
of
is filled with oil, but the
the specified
pressure.
through
orifice
modulating
piston
(9).
to the right and the clutch
slowly.
When
the -modulating
end of its stroke, specified
level,
the clutch and
the
The oil
“b” and reaches The
piston
pressure
rises
piston
reaches
the
pressure
reaches
the
clutch
is
completely
engaged.
WA350-1
21-29 0
Function . The priority
controls
valve
valve.
reducing
of the pilot
the priority
In addition,
reducing
valve
circuit.
over the other
To modulating
Operation .
The oil from
the pump
(I) and port-B
valve
to port
flows
of.pilot
reducing
valve
To each transmission
Ci).
423FO33
To modulating
The
priority
valve
and force
from
A flows spring valve
priority
happens,
and the oil flows
port
To each transmission
spool
of
back
spring When
(3) push
valve
pressure
(1) to the right.
A and port
from
“a”
orifice
(1) to port D. The hydraulic
of poppet
(4) and move this
port
oil entering
spool
A of priority valve
&
.
VALVE
pressure
the minimum
to the pilot
the oil flow
gives
priority
CONTROL
VALVE
PRIORITY
valve
TRANSMISSION
FUNCTION
AND
STRUCTURE
C are connected,
port Cto the clutch
spool.
Pilot oillfilter
423FO34
21-30
WA350-1
STRUCTURE
AND
MODULATING
VALVE
Function . The modulating together
TRANSMISSION
FUNCTION
valve
AND
and
QUICK
quick
return
to raise the transmission
slowly.
In this
way,
shifting
gear,
torque
in the
fatigue
is reduced,
comfort
and the
increased.
they
power
valve
clutch
reduce
and prevent
RETURN
the generation
train.
As
act
(kg/cm’
Shifting gear
when of peak
operator
E
and at the same time,
operator
2 P h
of the power
)
40 -
a result,
durability
VALVE
VALVE
pressure
the shock
CONTROL
train
are
__
30 -
20-
= 0
Time
1) Immediately
(Secl
after shifting gear (Point A on Fig. 423FO35)
423 F035A
valve
@j&q 423FO36 To torque converter
Operation .
The oil sent valve
(I)
modulating return “a”
from
the pump
through
port
priority through
and
port
the
right
(2). and enters
port B of quick
addition,
(3).
The oil passes
through
orifice
the
to the
pressurized
valve
return
piston,
valve
which
ever
when
ates
a difference
WA350- 1
from
passes
valve
of quick
clutch
flows
A,
it passes
(3) and flows
has been actuated. through
in pressure
orifice
“a”
between
How-
right,
C.
The
and when drain
quick
the
return
oil flows
quick port
return
valve to
moves
clutch
valve
In
(3) moves
to
D is opened,
oil at the rear of piston
to
(5). and
(4) flows
the to
the drain circuit.
it creport
B
21-31 0
STRUCTURE
AND
FUNCTION
TRANSMISSION
CONTROL
VALVE
2) Clutch pressure rising (Point B on Fig.423FO35)
pIlot luclng ralve I
To torque converter 423FO37
ODeration
. As the pressure at the clutch piston rises, the pressure
at port C also rises. Quick return valve
(3) is pushed closed.
back to the left and drain port D is
The oil from the pump flows
C to the clutch flows
from
piston,
orifice
from
port
and at the same time it
“b”
through
quick
At the same
time,
through
orifice
the
modulating
valve
pressurized and (2).
oil also passes
enters It
poppet
moves
valve (2) to the left and some
It pushes
back spring
(6) and moves
return piston.
piston
(4)
to the right.
21-32
of
of the oil at port
A flows to port G.
valve (3) and enters port E. The oil at port E acts on the modulating
(7)
modulating
WA350-1
STRUCTURE
AND
3) Completion
of rise in clutch
TRANSMISSION
FUNCTION
pressure
(Point
CONTROL
VALVE
C on Fig. 423FO35)
pllot reducing Ive
423FO38
To toraue converter
Operation .
The oil entering
port E continues
to push
(4).
the
piston
the
rise
in pressure
When
stroke,
the
happens,
the pressure
of the modulating port G are closed A
passes
torque
WA350-1
through
reaches
stops.
reaches
valve. port
of
When
its this
the set pressure
In addition,
by piston
piston
end
port
F and
(4). so the oil at port G and
flows
to
the
converter.
21-33
FUNCTION
AND
STRUCTURE
ACCUMULATOR
VALVE
Function . The accumulator
valve
shifting
2nd clutch
piston to escape
2nd to 1 st. This allows
gaged smoothly
CONTROL
VALVE
the filling
acts to reduce
gear by allowing
time when from
TRANSMISSION
the oil at the
slowly when
shifting
the clutch
to be en-
when shifting from 2nd to 1 st.
.
1. Shifting to 2nd . When shifting to 2nd pump
passes
through
gear, the
the
the 2nd transmission
A and port B are connected
valve
return
and enters port A of the transmission When
the
oil from
quick
spool (2).
spool moves, and the oil flows
port to
port C. The oil at port C flows from check orifice
valve
(2) and
“a” to port D.
From quick return valve
423 F039
21-34
WA350-1
STRUCTURE
AND
FUNCTION
. As the pressure
TRANSMISSION
of the oil entering
the oil continues
to push
piston
port
CONTROL
VALVE
D rises,
(3) to the left
until it stops. At the same time, and actuates
oil is sent to the clutch
2nd clutch
piston
(4). From quick return valve
From pilot reducing valve
423 FO40
2. Shifting from 2nd to 1 st . The oil from the clutch piston enters valve
port (2).
orifice way
“a” the
reduced.
of 2nd clutch (4) D and acts on the rear of the check
The
oil from
and flows shock
port
D passes
to the drain
when
shifting
circuit. gears
through In this can
be
From quick return valve
From pilot reducing valve 423FO41
WA350-1
21-35
STRUCTURE
PILOT
AND
FUNCTION
REDUCING
TRANSMISSION
CONTROL
VALVE
VALVE
Function . The pilot reducing
valve acts to control
sure needed to actuate
the pres-
the transmission
spools.
Operation l
The
oil from
the pump
passes
through
filter and enters port A of pilot reducing orifice
of transmission
inside of port C.
pilot
port B and enters through
The oil passes through the
the
valve (I ).
spool
(2)
to fill the
__
e
To priority valve
423FO30
. When the pressure inside port C rises, pressurized oil flows
from
orifice
“a” of pilot reducing
valve
(1) and goes to port D. As a result,
pilot reducing
valve (I)
moves
to the
right, and port A and B are shut off, so the pressurized
oil at
port
C
is maintained
at the
same
pressure.
valve
423FO29
21-36
WA350-1
STRUCTURE
FUNCTION
AND
TRANSMISSION
PILOT
TRANSMISSION
PILOT
FILTER
FILTER
II-
0 ----_-_ -----_-_
1
I
I 423 F048
1. Oil filter head 2. Element 3. Case
Specification: Filtration
area:
370
cm2
21-37
STRUCTURE
AND
TRANSFER
FUNCTION
TRANSFER Outline . The transfer
is installed
of the transmission
at the power
output
end
and is secured to the transmis-
sion case by bolts.
Transmission l
Output transfer force
path
shaft
(I)
input
of the transmission
gear
is transmitted
(2)
is coupled
by a spline.
to output
gear
The
to
motive
(6) through
idler gear (4) and output shaft (7). Part of the power-transmitted is transmitted drive shaft power
to the output
to the front axle through and front
is transmitted
drive shaft.
The
shaft
the center rest of the
to the rear axle through
rear drive shaft.
the
1. Transmission
output shaft
2. Transfer
input gear (teeth 50)
3. Rotating
pick-up
4. Transfer
idler gear (teeth 64)
sensor
5. Housing 6. Output gear (teeth 7 1) 7. Output shaft 8. Front coupling 9. Rear coupling
423F052A
423FO53
WA350-1
STRUCTURE
DRIVE
AND
FUNCTION
DRIVE
SHAFT
SHAFT
Outline The motive
force
the torque
converter,
from
the engine transmission
passes through and transfer.
Part of this motive
When
the
shock
from
body
is articulated,
the road surface
or when during
there
traveling,
is or
force passes through rear drive (4) and goes to the rear axle; the rest of the motive force passes through center drive shaft
when there is shock during operations, the axles in front and behind the engine and transmission change position.
(3). flanged bearing (2) and front drive shaft (1) and is sent to the front axle. In addition to transmitting the motive force, the drive shafts have the following purposes.
To allow the motive
shaft
force to be transmitted withto parts of the machine when there is or when the components move position,
out damage shock
the drive shafts
have a universal joint and a sliding This allows them to handle changes in angle and length.
joint.
\
1. Front drive shaft 2. Flanged bearing 3. Center drive shaft
.‘\ E423F054
4. Rear drive shaft
WA350-1
21-39 @
STRUCTURE
AXLE
AND
FUNCTION
AXLE
MOUNT
MOUNT
Serial No. 11118anduD
?rial No. boo1 - 11117
*_
ai ’
L
0
_
,-
1 c Y
t
=JaJ 0
4 \
U42301001
423FO68 Section A-A
21-40 0
Section B-B
WA350-1
STRUCTURE
AND
FUNCTION
AXLE
MOUNT
View i! Serial No. 10001 - 11117
View Y 423FO69
6
Serial No. 11118andup
View Y
1. Front
axle
Front axle . The front
2. Rear axle 3. Front frame mounting
6. Pivot
axle
during operations,
4. Rear frame 5. Axle
U42301002
frame
(I)
receives
so it is fixed
(3) by axle mounting
bolts
the
force
directly
directly
to the front
(5).
bolt
Rear axle l
The rear axle
(2) has a structure which allows the of the rear axle to float, so that all tires can be in contact with the ground when traveling over soft ground.
center
WA350-1
21-41 0
STRUCTURE
AXLE .
AND
FUNCTION
AND
The motive
force
converter,
drive
shafts,
AND
DIFFERENTIAL
DIFFERENTIAL
the
torque
AXLE
from
the engine transmission,
and is then
passes
through
transfer,
sent to the front
.
and
Inside
the axles,
bevel
pinion
angles.
and rear
axles.
At
the motive
to the bevel the
same
and passes
through
axle
The
shaft.
further drive
reduced
force
time,
the front
motive by
force a
passes
from
gear and is sent the
speed
is reduced
differential of the
the
at right
(I) to the axle
shaft
planetary-gear-type
is
final
(5) and is sent to the wheels.
Front
E423F055
1. Front differential ’
View 2
2. Parking
brake
3. Housing 4. Brake (See page 5 l-l 5. Final drive
9)
(See page 21-48)
6. Drain plug
21-42 @
WA350-1
STRUCTURE
AND
AXLE
FUNCTION
AND
DIFFERENTIAL
Section A-A
E423F056A
Section B-B
7. Side gear (Differentialjtteeth 8. Bevel pinion (teeth 9) 9. Pinion (Differentialjtteeth 9) 10. Shaft 1I ‘n’A350-1
Bevel gear (teeth 40)
12)
STRUCTURE
AND
AXLE
FUNCTION
AND
DIFFERENTIAL
Rear
,’
4
423FO57
I. Rear differential 2. Housing 3. Brake
(See page 5 l-l
4. Final drive
9)
(See page 2 I-48)
5. Drain plug
21-44
WA350-1
STRUCTURE
AND
AXLE
FUNCTION
AND
DIFFERENTIAL
Section A-A
Section B-B
E423F058
6. Bevel gear (teeth 40) 7. Side gear (DifferentiaDkeeth 8. Pinion (Differentialjkeeth 9) 9. Shaft
12)
10. Bevel pinion (teeth 9)
21-45 0
AXLE AND
FUNCTION
AND
STRUCTURE
DIFFERENTIAL
Outline l
bevel gear (5).
passes to the
drive
by 90”,
force
the
reduces
shaft
and is transmitted
The bevel gear changes
tion of the motive time
(I)
bevel pinion
through
the
from
force
motive
The
motive force through
and at the same the
transmits
It then
speed.
the direc-
(4) to the sun
the differential
gear shaft (2).
423 F059A
When l
driving
straight
the machine
When
speed
rotating
forward forward,
is driven straight
of the left and right wheels
the is the
same, so the pinion gear (4) inside the differential does not rotate. The motive force of the
assembly carrier
the pinion gear (4) and
(6) is sent through
the side gear (3) and is transmitted left and right sun gear shafts (2).
equally
to the
423 F060A
When l
turning
When
turning,
right wheels side rotate
gear
the rotating
(3)
inside
in accordance speed
speed
of the left and
so the pinion gear (4) and
is different,
the
differential
with the difference
assembly between
of the left and right wheels.
the rotating The motive force of the carrier (6) is then transmitted to the sun gear shafts
(21.
423F061A
21-46 0
WA350-1
STRUCTURE
TORQUE
AND
AXLE
FUNCTION
PROPORTIONING
AND
DIFFERENTIAL
DIFFERENTIAL
Function Because
of the nature of their work, 4-wheel-drive
loaders have to work face is bad.
in places where
ity to work
as a loader is reduced,
of the tire is reduced. differential
The
is installed
In structure
of teeth. from
tion
of the
of meshing (3A).
(38)
proportioning this problem.
differential
of
of the difference
the road surface,
the posi-
pinion
gear
(4) and side
and
this
changes
changes,
the
of the left and right tires.
Operation When traveling straight (equal resistance road surface to left and right tires) If the resistance and
an
pinion gear (4) has
Because
in the resistance gear
the
but the differential
an odd number
and also the life
torque
to overcome
it resembles
automobile,
traction
the road sur-
In such places, if the tires slip, the abil-
right
tween
from
wheels
the road surface
is the
same,
the
from
be-
point “a”
of the left side gear is the same as the distance tween
the pinion
gear
and meshing
30
to the left
distance
the pinion gear and the meshing
3A
point
be-
“b” of
423FO63
right side gear (3B). Therefore
the
side traction
left
side traction
TL and the right
TR are balanced.
Direction
of spider rotation
When traveling on soft ground (resistance from road surface to left and right tires is different) On soft
ground,
if the tire on one side slips, the
side gear of the tire on the side which
has least
resistance
to rotate
from
forward.
the
Because
road
surface
of this rotation,
tries
the meshing
of -
the pinion gear and side gear changes. If left side gear (3A) distance point
between
“a”
slightly
forward,
left
side gear
between
becomes
longer
the pinion gear and the
port “b” of the right side gear.
tion is balanced
the
the pinion gear and the meshing
of the
than the distance meshing
rotates
The posi-
as follows. Direction
axTL=bxTR The
ratio
between
can change Therefore
the distances
of spider rotation
to “a” and “b”
to 1: 1.38. when
the ratio of the distances
to “a”
and “b” is less than 1 :1.38 (that is, the difference between
the resistance
from
the road surface
the left and right tires is less than 38%). gear will not rotate
freely,
to
the pinion
so drive force
will be
given to both side gears, and the tires will not slip. Because by 20
-
of this effect, 30%.
the tire life can be increased
and at the same the operating
effi-
ciency is also increased.
WA350-1
21-47 0
STRUCTURE
AND
FINAL
FUNCTION
a large
drive
force,
planetary
gear
system
to
send drive force The motive through
force
around
in this way then
transmitted
sent
(I)
drive
the
uses a
speed
and
gear
transmits
from
the differential
to sun gear (6) is transmit(2).
the inside
planetary
the final reduce
to the tires.
axle shaft
ted to planetary
to the
DRIVE
DRIVE
To gain
tates
FINAL
The
planetary
of a fixed rotation
carrier
to the wheels
(4).
at a reduced This
(5) which
gear
ro-
ring gear (3) and motive
speed force
are installed
is to
the carriers.
i 6
5
423FO66
1. Axle shaft 2. Planetary
gear (Teeth
3. Ring gear (Teeth 4. Planetary
27)
72)
carrier
5. Wheel 6. Sun gear (Teeth
21-48
18) WA350-1
STRUCTURE
TIRE
AND
AND
must .
to the machine,
rotate
power Various
drives
types
purpose. the
in contact
which
correct
of
WHEEL
the shock
from
the ground
and at the same time they with
the ground
to gain the
the machine. tires
Therefore tires
AND
WHEEL
. The tire acts to absorb surface
TIRE
FUNCTION
are
it is very
for the type
available important of work
to
suit
the
to select and bucket
capacity.
E423F070
I. Tire 2. Side ring 3. Lock ring 4. Rim 5. Air valve
WA350-1
21-49
POWER TRAIN 22 TESTING
AND
ADJUSTING
Standard
.
value table
..
Tool list for testing and adjusting Measuring
engine stall speed
Measuring
oil pressure
converter Measuring Method
*
The following
precautions
troubleshooting 1. The values
are necessary
. . .. . ..
Troubleshooting
...
in these
2. The standard
tables
are based on the values for new machines or when estimating
values in these tables for judgement
values for the machine
they should be used as reference 3. These
Value
4
.. . ..
. .
.
22-
6
. 22-
8
of emergency
Tire and wheel
using the Standard
3
22-
.
.
2
22-
Tables
. . .. . _. .
. .
. . 22-8-l . 22- 9
..
22-l
to make judgements
1
during
or during testing and adjusting.
used as target values when repairing standard
when
.
shift lever
manual spool
22-
of torque
and transmission
for operation
... .
standard
when
leaving the plant, so they should
troubleshooting
are estimated
values based on the
when shipped from the plant, and on the results of various tests. in combination
be
wear after a period of use.
with repair and, operating
value tables must not be used for standard
Therefore,
records when making judgements.
values when judging
claims.
In addition,
do not
use these values alone to make simple judgements. WA350-1
22-1 0
TESTING
AND
ADJUSTING
STANDARD
Testing
STANDARD
VALUE
and measuring
Shift lever operating
Measurement l
and stroke l
Torque
condition
converter
temperature:
Directional
lever operating
force
l
Unit
lever operating
kg
kg
3rd-4th
mm
N-F
Speed
mm
Coolant
Engine stall speed
l
l
High idling
Hydraulic
Torque
converter
Hydraulic
range
temperature: -
55°C
stall
rpm
stall Engine speed: High idling.
l
Full stall
Oil pressure of torque converter and transmission l
Pilot reducing
l
Modulating
Max. 1.4
0.3 -0.9
Max. 1.4
0.3 -0.9
Max. 1.4
32-42
27 -47
32-42
27 -47
32-42
27 -47
Torque
pressure
l
Torque
l
Lubrication
converter
range.
converter
temperature:
- 2,450
-
2,430
- 2.5301
2,070
2,170-2,370 - 2.3901
(2,090
- 2,490)
2,100
- 2,300
2,000
- 2,400
2,050
-2,250I
(I ,950
- 2,350)
1,580
- 1,780
1,480
- 1,880
1,575
- I,7751
(I ,475
- 1,875)
60
*
1 .O
IO.821.0
-
kg/cm2
80°C
1.5
32.5+-
1.5
34.5 + 1.5
34.5?
1.5
6.0+
1 .O
32.52
1 .O
1 .I to.4
lock ring (A)
- 2,470
2,190
6.0*
Tire inflation
1.1*0.4
pressure:
Specified
pressure mm
(B) of wheel
-
2,350
10.8
relief pressurt
Tire and wheel
Clearance
-
oil
oil pressure
Fitting of wheel
650-750 (680-780)
temperature:
Inside operating
High idling
l
0.3 -0.9
Engine speed: High idling Coolant
pressure
Low idling
l
Max. 1.4
temperature:
Inside operating
Low idling
45 l
Max. 1.4
0.3 -0.9
lever lst-2nd-3rd-4th
l
0.3 -0.9
lever travel N-R
l
value
force
1 st--2nd
Directional
Permissible
80°C
~_ 2nd-3rd
l
value
Engine speed: Low idling
N-F Speed
Standard
oil
60 -
N-R l
TABLE
TABLE
item
force
VALUE
lockr ing (Cl
Max. 2.5 Max. 4.0 2-10
-
423F309
(
22-2 0
1: SerialNo.11118andup WA350-1
TESTING
TOOL
No. besting
AND
TOOL
ADJUSTING
LIST
FOR TESTING
and measuring
item1
AND
Tool
Part number
01-6000
1 o-1,ooo”c
01-5000
3
Oil pressure
Hydraulic
tester
799-l
4
Pedal and lever operatino force
Push-pull
gauge
7AO-262-0020
5
Measuring
carrying
Then apply
A
cut testing, lower
the parking
Do not allow
kit
or troubleshooting, to the ground,
brake and block
unauthorized
measuring
adjusting
the bucket
persons
the engine
operator’s
seat to operate
Be careful
not to get caught
WA350- 1
ADJUSTING
60 - 20,000
rpm
O-25 kg/cm2 0 - 50 kg/cm2 O-25
kg
clearance
bar on the frame,
When
display
799-l
Thermistor
A A
Digital
I
1 Oil temperature
When
AND
Remark
I
799-203-8000
2
A
FOR TESTING
ADJUSTING
I
Tachometer
1 1 Enginespeed
LIST
stop
the machine
on level ground,
install
the safety
and stop the engine.
the tires.
near the machine.
speed,
one worker
the controls. in rotating
Always
should check
measure
the engine
that the operation
speed
while
the other
is safe, and use agreed
sits in the
signals.
parts.
22-3 0
TESTING
AND
MEASURING *
Measurement
l
Coolant
l
Hydraulic
l
Torque
MEASURING
ADJUSTING
ENGINE
STALL
Inside operating
range
temperature: converter
45
-
j;
60 -
650 - 750 (680 - 780)
1
High idling
2.350-2.450 (2,430 - 2,530)
-
converter
2.170-2,370 (2,190 - 2,390)
stall
P Hydraulic
2.070-2.470 (2,090 - 2,490) I
stall
Full stall
2,1002.300 (2.050-2.250)
2,000 - 2.400 (1.950-22.350)
1.580-1.780 (1,575-1,775)
1.480-1.880 (1.475-1.875)
(
Special
): Serial No. 11 1 18 and up
tools
I A
Part name
Part number
1 799-203-8000
Check
that
the
Before engine
A
idling the
stall
to engine
1
high
idling
speeds
speeds,
speed
pick
install
up (I)
ta-
on the
block.
Check
that
value.
If any
check
for any looseness
A
and
I ’ kit
value.
measuring
chometer
Thermistor
low
are the standard
IQ-v
Tachometer
1
799-l 01-6000
-
rpm
Permissible value
Standard value
I
u
SPEED
80°C
Low idling
Torque
.-z_
SPEED
55°C
oil temperature:
Item
I
STALL
condition
temperature:
Unit:
-0
ENGINE
Apply
the
the parking
1. Measuring
torque
1) Start
engine
2) Put
the
speeds
is outside
est speed
are
the
the
standard
permitted
range,
for play in the linkage.
brake and block the tires. converter
stall
and run at low idling.
directional
REVERSE, 3) Using
engine
item
lever
and speed
in
control
FORWARD
lever
or
in the high-
range.
the brake,
the engine
speed
stop the machine when
and measure
the engine
reaches
high
idling. t
Turn
the
transmission
to OFF, and
use the
cut-off left
valve
brake.
switch
(Check
that
the pilot lamp is OFF.)
*
Do not run at stall speed seconds,
oil temperature
22-4 0
for
more
and do not let the torque rise above
than
20
converter
120°C
WA350-1
TESTING
AND
2. Measuring
MEASURING
ADJUSTING
hydraulic
ENGINE
STALL
SPEED
stall
1) Start engine and run at high idling. 2) Operate
the dump or lift lever to move the cylin-
der to the
end
of its stroke
and
actuate
the
relief valve of the main control valve. 3) Measure *
the engine speed at this point.
Do not run the engine at stall speed for more than
20
seconds,
and
operate
the
control
lever quickly.
3. Measuring Measure
full stall the engine
stall and hydraulic
speed
when
torque
stall are reached
converter
at the same
time. *
Measure
full stall when
ter -and
hydraulic
either
stall speed
normality
WA350- 1
stall
both the torque speeds
isabnormal,
and measure
are
conver-
normal.
remove
If
the ab-
the stall speed again.
22-5 a
TESTING
AND
TORQUE
ADJUSTING
MEASURING OIL PRESSURE AND TRANSMISSION *
Measurement
l
Coolant
l
Torque
l
Engine speed:
converter
Inside operating
oil temperature:
Item
80°C
High idling
Standard value
I
10.8i 1.o ._
I
A
10.8il.O
I
tool
,, Block
The
1
Hydraulic
1 1
tester
the tires. procedure
following
before
Q’ty
Part name
799-101-5000
Measuring *
kg/cm”
Permissible value
I
Part number A_
CONVERTER
range
60 -
Unit:
Special
OF TORQUE
conditions
temperature:
Pilot radusing pressure
MEASURING OIL PRESSURE OF CONVERTER AND TRANSMISSION
preparatory
measuring
Remove Turn
the covers
the
OFF and
work
is
necessary
any oil pressure. on both sides under the cab.
transmission
cut-off
valve
switch
use
left
brake.
(Check
that
from
the
the
to the
pilot lamp is OFF.) Remove
the
plug
the transmission Install
hydraulic
pull port, compartment,
measuring
port
of erial No. 10001
valve. tester
the
A
gauge
then
start
to to
the
the the
-
l
measuring operator’s
engine
and
mea-
sure the pressure. t
Check
that
there
is no leakage
of
oil from
any
IF-J-W
joints. 1. Measuring I) Measuring 2) Put
the
pressure
pilot reducing port
in neutral, the
speed
and
1
P5+T1/8)
(P5).
F-R lever when
pressure measure
control
lever
Serial No.
the
l
-
is
operated.
;
22-6 0
-1
423F306A WA350-1
TESTING
AND
2. Measuring
ADJUSTING
modulating
I) Measuring 2) Put the
TORQUE
MEASURING OIL PRESSURE CONVERTER AND TRANSMISSION
OF
pressure
port (P I). F-R lever in neutral,
pressure
when
the
speed
and measure control
the
lever
is
the pressure
at
operated.
3. Torque
converter
1) Measuring 2) Start
inlet
port oil pressure
port (P8).
the engine
and measure
high idling. ._
4. Measuring
lubrication
I) Measuring
valve
pressure
port (P9).
2) Start _the engine
and measure
the pressure
at
high idling.
PS(PTl/S)
PS(PTl/S)
Serial No.
l
PI (PTl /8)
-
423F307A
P5 (PTl/S)
WA350- 1
22-7 al
TESTING
AND
MEASURING Measuring
SHIFT
SHIFT
LEVER
LEVER
conditions
Engine speed:
l
MEASURING
ADJUSTING
Stop Unit: Permissible value
Standard value
item
kg
Neutral-Forward
0.3-0.9
Max. 1.4
Neutral-Reverse
0.3-0.9
Max. 1.4
Ist-2nd
0.3-0.9
Max. 1.4
2nd-3rd
0.3-0.9
Max. 1.4
3rd -4th
0.3 -0.9
Max. 1.4
Directional lever
c
Neutral-Foward
32-42
mm
27-47
mm
Neutral-Reverse
32-42
mm
27-47
mm
In each range from 1 st three 4th speeds
32-42
mm
27-47
mm
Directional lever
x 5 C
Speed lever
Special
tools
Part number A
1 7AO-262-0020 799-l
A
Part name
1
Q’ty 1 1
Push-pullscale
01-6000
Thermistor
1
kit
Be sure to set chocks firmly against the tires.
1. Measuring
1) Attach
the lever push-pull
the lever
knob
operating
effort
operating
effort
scale A or a spring balancer at the center required
and measure
to the
to pull it in the operat-
ing direction. t
The
measurement
should
be made
in each
speed range. 2. Measuring
the lever
travel
I) Put mark “1” on the center on the control knob and measure
the travel when
moved in the operating
lever
the lever is
direction.
WA350-1
**g8
TESTING
AND
METHOD FOR OPERATION OF EMERGENCY MANUAL SPOOL
ADJUSTING
METHOD SPOOL
OF EMERGENCY
FOR OPERATION
MANUAL
OUTLINE The
l
transmission
Therefore, to enable failure
valve
is controlled
the emergency the machine
to be moved
in the electrical
electrically.
manual spool is installed
system,
if there is any
or in the solenoid
valve and spool.
A
The
emergency
failure
manual
machine
from
being
chine to-be moved place where The
spool is for use when
in the transmission
emergency
prevents
It allows
from a dangerous
repairs
used except
control
moved.
place to a
can be carried
manual
when
spool
the
the ma-
out safely.
must
the transmission
never
control
be has
broken down.
A
When
operating
follow
the correct
the emergency order
and pay full attention
manual
of operation
to safety
spool, exactly,
when
moving
the machine.
A
To
prevent
the
bucket
brake,
the
and
pressure
machine
to the
from
ground,
block
the
moving,
apply
wheels.
the
Check
lower parking
that
inside the air tank is above
the
the speci-
fied pressure.
1. Remove
R.H. machine
Always
LY
panel.
stop the engine
before
operating
the
1
spool.
2. Remove
lock plate
(I)
of the emergency
spool of the transmission t
Simply
loosen
the
manual
valve.
mounting
bolts
to remove
the lock plate. 3. Decide
the
(forward
direction
to
or in reverse),
move
manual spool to the operating FORWARD:
Rotate 1 st
machine
/ii\ REVERSi spool
position.
FORWARD
spool
the
then move the emergency clutch 10
\\ 4th spool
3rd spool
2nd spool
spool and
counterclockwise,
pull out approx.
FORtiARD kpool
and
‘I St spool
423 F339
mm to the ON
position. REVERSE:
Rotate 1 st
REVERSE
spool
clutch
spool
counterclockwise,
pull out approx.
10
and and
mm to the ON
position. 4. Check
that
then remove
the area around
the machine is safe, the blocks from under the wheeis. 423F340
‘J\IA35C-1
22-z- 1 w
TESTING
AND
METHOD FOR OPERATION OF EMERGENCY MANUAL SPOOL
ADJUSTING
5. Sit in the operator’s
seat,
and
depress
the
left
brake pedal fully.
6. Start the engine, release
the
release
brake
the parking
pedal
gradually
brake, to
then
start
the
machine. When
A
is
the engine
engaged
Therefore, always safe,
is started,
and
check
the
the transmission
machine
before
starting
that
the direction
and -always
keep
the
will the
start. engine,
of travel brake
is
pedal
depressed. +
If the machine spool, and
3rd
screw
does
spool,
not start,
and 4th
turn the 2nd
spool clockwise,
10 mm to the OFF
in approx.
position.
7. After
moving
the machine,
stop the engine,
apply
the parking brake, and block the wheels. 8. Return the emergency
manual
spool to the neutral
position, and install the lock plate.
22-8-2 0
WA350-1
TESTING
TIRE
AND
TIRE
ADJUSTING
AND
AND
WHEEL
WHEEL Unit:
kg/cm2 Tire
Item
Standard value
No.
Permissible value
Fitting of wheel lock ring
Clearance of wheel lock ring
C
I
I
2-10
-
L
v‘
__
Measuring 1. Fitting
procedure of wheel
Measuie
2. Clearance Measure
O-ring
lock ring
dimentions
of wheel dimension
Wheel
i-
F42301008
A and B with a feeler gauge
lock ring C.
\ 423F309
WA350-1
22-9 0
TROUBLESHOOTING Precautions Method
when
troubleshooting.
of reading
troubleshooting
Preventing Method
recurrence of locating
troubleshooting Troubleshooting 1. Machone
or shifting
WA350-1
transmission table
lacks power
3. Excessive
toohigh
of trouble
main problem
points
.
or speed
time lag when
starting
gear..
converter
22-l
6
22-l
7
22-l
8
22-l
8
when
system .
2
22-14
does not move
2. Machine
4. Torque
22-l table
22-20 machine 22-22
oil temperature 22-23
22-11 a
TROUBLESHOOTING
PRECAUTIONS
PRECAUTIONS
WHEN
WHEN
TROUBLESHOOTING
TROUBLESHOOTING
1. SAFETY l
/I
Stop
the machine
on level ground,
and check
that the safety
pins and parking
brake
are correctly
applied,
and that the tires are blocked. l
When
l
Be careful
working
l
Always
in groups,
use agreed
not to get burned disconnect
the
signals
and do not allow
by hot parts or to get caught
cable
from
the
negative
(-)
unauthorized
in rotating terminal
persons
near the machine.
parts.
of the
battery
before
disconnecting
any
wiring. l
Always
release
pressure,
the
pressure
and connect
before
all measuring
removing tools
2. METHODS FOP TROUBLESHOOTING * Just because a failure occurs, do not immediately If the machine l
is disassembled
The machine problem
may be disassembled
The customer
l
Time will be wasted,
and operator
these
problems,
and operator
b. Was there
anything
occur
was the machine
e. Had the machine
before
doing
when
been repaired
place
under
hydraulic
or air
the machine.
that the problem
the following
cannot
be located,
so the cause
of the
items
which
b. Check
for leakage
c. Check
travel
of control
levers.
stroke
of spool
in control
d. Check 3. Reenact
the failure the
user
comparison, b. Compare
of oil from
and check
or operator
parts and greasing.
about
the breakdown.
the one reported? broke
or had there
been signs of trouble
the breakdown
down? before?
occurred?
the breakdown?
If so, who
carried
out the repair,
and when?
before?
can be checked
piping
for excess
troubleshooting.
the machine
before
oil level.
when
questions
apart from
occurred
a. Check
or hydraulic
simply
by visual
checks
etc.
equipment.
valves.
the condition
if the
decision
of the machine about
the failure
(particular
conditions
was
based
made
at the time
on measured
of failure)
values,
or by
or by feeling. extent
of failure
safety
before
with
l
Check
l
Did not make any check
4. Try to locate electric
In particular,
carrying
the possible
The transmission
system
standard
values.
out any check.
or measurement
causes
that will make the condition
worse.
for the failure
consists
of the transmission
itself,
the transmission
in the
system,
control
valve,
and the trans-
control.
when
trouble
occurs
transmission
the probable
location
of the failure
can be
as follows.
l
Transmission
itself,
l
Transmission
electric
To decide
22-12 0
any
in you.
the following
suddenly,
Had the same kind of failure
divided
of
checks,
will be incurred
procedure
problems
unusual
c. Did the breakdown d. What
costs
use the following
been any other
mission
start to disassemble
the proper
will lose confidence
a. Have there
a. Ask
making
in such a way
and unnecessary
1. Ask the customer
2. Check
or caps
-
l
f.
plugs
will be unknown.
As a result,
To avoid
before
the
correctly.
which
or transmission
of these
control
valve
control two
is the location
of the failure,
go to page 22-l
7.
WA350-1
TROUBLESHOOTING
PRECAUTIONS
Carry out troubleshooting
two types
1. TROUBLESHOOTING
TABLE..
2. TROUBLESHOOTING The troubleshooting
of troubleshooting
FLOW charts
CHART..
consist
can be checked
are likely to be the cause
these
charts
At the same time, related
l
Check
that there
TRAIN,
52
BRAKE
AND
62
WORK
EQUIPMENT
82
ELECTRIC
SYSTEM, AIR
AND
SYSTEM, SYSTEM
ELECTRONIC
SYSTEM
of such failures.
the following
points.
items. are no other
of troubleshooting
failures
tables,
or breakdowns.
see page 22-l
4.
causes of breakdown
Even if the breakdown will occur
again.
occurring
again.”
is repaired,
To,investigate
3. PRECAUTIONS
PARTS
POWER STEERING
easily
do not forget
Check
6. Investigate
22 42
to carry out troubleshooting.
l
For details
charts.
of:
1) Items which which
TROUBLESHOOTING
charts.
_.
2) Items Follow
.
using the troubleshooting
There are the following
WHEN
if the original
and remove
WHEN REMOVING, TROUBLESHOOTING
DURING
If it is necessary
to remove,
install,
cause
of the problem
the original
cause,
INSTALLING,
disassemble
is not removed,
see “Actions
DISASSEMBLING
or assemble
the same breakdown
to take to prevent
OR
parts for troubleshooting,
failures
from
ASSEMBLING
remember
the follow-
ing points. Carry
out the various
testing
and adjusting
while
observing
the items
on quality
control
given
in “Testing
and
Adjusting”. When right,
removing
parts,
check
their
condition
of mounting,
and distinguish
between
front
and rear, left and
and top and bottom.
Check
the match
If a part cannot remove
it. Check
assemble When Remove
WA350-1
marks,
or make match
be removed
even when
the part to see if there
marks
to prevent
mistakes
the nuts and bolts is any problem
when
installing.
have been removed,
with
it, and remove
do not use excessive
the problem
before
trying
force
to
to dis-
the part.
installing
or assembling,
all grease
or oil before
clean off all dust and dirt and repair any scratches coating
with
gasket
or dents.
sealant.
22-13 0
METHOD
TROUBLESHOOTING
METHOD
OF READING
DESCRIPTION
OF SYMBOLS
The following column
symbols
to indicate
READING
TROUBLESHOOTING
USED
are used
OF
IN TROUBLESHOOTING
TROUBLESHOOTING
TABLE
TABLE TABLE
in the “Remedy”
the method
of eliminating
the
cause of a fault.
: Replace;
X A:
A: Repair C:
Adjusting;
Clean
METHOD OF READING ING TABLE The
symbol
causes
be diagnosed, If the result table “d”.
is inserted
only
for
the corresponding
box is left blank.
the cause
to lie between to make
it is necessary
to perform
“e”,
to the
possibility
of the
“a”
it is not possible
(owing
cannot
1 using the troubleshooting is abnormal,
be assumed
Because
problem
table
If a cause
at right
can
regarding
the
can be diagnosed.
of problem
shown
trouble
in
0
which
TROUBLESHOOT-
and
a problem the next
of a multiple
fault). If the result the
fault
such
of problem
does
a case,
however,
not
before
carry
1 is normal,
lie between diagnosing
out a check
the cause
“a”
and
the cause
by means
of
“d”.
In
as “e”,
of problem
2 or 5. If now the result result “a”,
of “b”
or “d”.
3 is abnormal, one of “b” “d”
2 normal, In addition,
the cause
or “d”.
is the actual
If the
result
next
narrow
the
cause
and the is one
if the result
perform
of problem
which problem
is abnormal,
of
of problem
will be narrowed
To determine
cause,
the corresponding the
1 is abnormal
of problem
problem
down
to
of “b”
or
4. blacken
out
o in the table and then perform
problem
on
these
causes
in order
to
the likely causes. Unnecessary problem
Example
1:
Problem
1 +
Abnormal
From the table of
Problem
2 +
Normal
example
Problem
3 -Abnormal
Problem
4 +
Normal
Problem
1 +
Normal
Problem
2 +
Abnormal
Example
i
In example “e”
From the table of example
tional
carrying
2, the
cause of the fault
2, it is evident
without
problem
22-14 0
is “b”.
2:
I *
1, the
cause of the fault
is “e”. that
out problem
2 is performed
by way
the cause
is
Unnecessary problem
2, however of an addi-
check.
WA350-1
TROUBLESHOOTING
Example
METHOD
OF READING
3:
Problem
1 +
Abnormal
From the table of
Problem
2 4
Abnormal
example
3, the cause
Problem
3 +
Normal
is one
of
I I I , I 1 I I I Continuk
I
“a”,
“c”
and “e”.
problems
I
I
Problkm Problem
Example
From the table of
4 1, Normal 5 -
example
Normal
3 - 1, the
cause is “c”.
Example 3-1
4:
Problem Problem
1 +
Abnormal
2 -+ Normal 1
Continue
1
I
From the table of example
4, the
cause is one of
problems
I
Problem
3 L
Abnormal
From the table of
Problem
4 +
Abnormal
example
Problem
5 +
Normal
cause is “a” or “d”.
As can be seen from necessary
to perform
Also,
looking
many
l
the above
4 - 1, the
examples,
Example 4-l
it is not
all of the problems.
at a particular cause, no matter how marks there are in the column corresponding
to that cause, it will cause to be an actual cause there is even one o mark in the same column.
WA350-1
if
TROUBLESHOOTING
TABLE
TROUBLESHOOTING
PREVENTING
PREVENTING
RECURRENCE
The troubleshooting equipment. Also,
table
this table
only describes
mention
what
In order
to remove
while
referring
Regarding ing”
action
should
the action
the root
cause
to the following
the method
in the Shop
HYDRAULIC
the direct
the root cause
be taken
cause
with
part or piece of equipment.
It does
not
of the root cause.
so as to prevent
a recurrence,
carefully
investigate
the real cause
items.
of checking
and adjusting
each part or piece of equipment,
3) Oil cleaning
air
cause
or
Accordingly,
of almost
equipment other
or
not
substances,
it
all faults
is the
foreign
it is necessary
whether
inclusion
matter
in
to check
contains
any
occur-
l
refer to “Testing
and adjust-
the
and then take appropriate
the
Check
Sr If the
the
means
of a diesel
oil
for
to remove
possible
water
ingress
oil checker
or other
or replace
oil is contaminated
When
washing
the strainer
engine
particles
in the oil, either
the
it.
by water, water
forwash
it is not
by means
of
an oil refresher.
action.
ingress
Check
of metal
is discovered
possible
above +
for water
matter
the oil using an oil refresher
oil.
the oil to see of
and replacement
If a large amount eign
of
I) Oil checks l
of a part or piece of
however.
EQUIPMENT
in hydraulic
water,
TROUBLE
Manual.
The fundamental ring
or breakdown
or failure,
the particular
a recurrence
1. Oil checks l
of damage
of the damage
to be taken
to prevent
of a fault
OF
OF TROUBLE
is used to establish
It is not able to establish
RECURRENCE
the oil, also wash
and replace
or replace
the filter.
by
or a hot
plate. l
Check
for ingress
Remove
the
the bottom if
any
the
Viscosity Check
foreign and
degree
matter
filter,
then
and also the filter
matter
has
collected
of contamination
of a contamination l
plug
of the tank
foreign
Check
of other
drain
check to see
by means
confirm
of ingress that
disassemble cylinders
and
whether
or not
the
fragments
oil is
such
fragments
and
wash
such
which
are
other
foreign
a recurrence
becoming or hydraulic
may
to wash liable
parts to
checks,
oil is contaminated
thus due to
in various
equipment.
other
foreign
matter,
where
the
contamination
it is discovby water
or
to find
out
it is necessary is occurring
the take steps to prevent
and also
it.
Water:
Oil storage
Sand:
Oil replenishing
tank,
breather,
etc.
or replacing
meth-
od, etc. Rubber:
Cylinder
Metal:
Wear
or damage
ment
such
well
as
converter,
22-16 a
packing,
etc. to hydraulic
as pump transmission
and
equip-
motor,
and
as
collect
matter,
of faults
lodged
pass
the oil.
point
of the above
the
and
to prevent
of the engine
If, as a result ered
In addition, valves helping
of the oil using a viscometer
satisfactory. 2) Check
.
metal
check to
into the oil line. It is thus necessary
there.
checker.
the viscosity
in order
of damaged parts 2. Cleaning fragments . If a part becomes damaged, fragments
as
torque
etc.
WA350-1
parts
METHOD TROUBLESHOOTING
OF LOCATING MAIN TROUBLESHOOTING
PROBLEM POINTS WHEN TRANSMISSION SYSTEM
METHOD OF LOCATING MAIN PROBLEM POINTS TROUBLESHOOTING TRANSMISSION SYSTEM The problem
points
in the transmission
1. Transmission
itself and transmission
2. Transmission
electric
Use the following
Problem:
can be broadly
control
valve.
divided
into the following
two
areas.
control.
method
to decide
which
Machine
will not start.
Machine
will only travel
2 YE
system
WHEN
Does machtne move If screw of emergency spool for ForRandlstis pushed in7
of the two areas has the problems.
in one direction
(FORWARD
YES
or REVERSE)
z
Replace transmission valve
control
Go to Troubleshooting transmission (See page 22-l
resistance of F or R solenoid correct?
8 -
for 22-23)
11 Voltage 20 - 3ov. 2) Resistance approx. 60fi.
GO to Troubleshooting electrical system of transm1ss10n fSee page 82-46
Problem:
Machine
will not move
in certain
speed
-
for
82-52)
ranges
Replace transmkon
control
valve Y
Is
voltage and
resstance of solenoid
for problem
GO to Troubleshooting transmission (See page 22-18
-
for 22.231
speed range correct? I) 2)
Voltage 20 - 3ov. Resistance approx. 600.
Go toTroubleshooting electrical system of transmission ISee page 82-46
WA350-1
-
for
82-52)
22-17 0
TROUBLESHOOTING
TROUBLESHOOTING
TROUBLESHOOTING 1. Machine
TABLE
TABLE
does not move
Ask the operator the following l
Did the machine
l
Was
suddenly
Yes = Component there
seized or damaged.
any abnormal
chine stopped
points.
stop moving? noise when
the ma-
moving?
Yes = Component
broken.
Checks before troubleshooting 0 Is oil level in transmission case correct? l
Is voltage
of solenoid
l
Is monitor
display normal?
valve correct?
l
Is drive shaft broken?
Transmission
8
Pilot reducing pressure defective
Note 1: If the solenoid
I
valve and hydraulic
I
I
I
I
I
pressure
are normal, the “I” in the Causes column
indi-
cates that the valve spool does not work. Note
2: If the
transmission
but the cause cannot table, a possible
clutch
pressure
be found
cause is cracks
is low,
in the above in the valve
or transmission.
22-18 0
WA350-1
TROUBLESHOOTING
The following symbols are used to to be taken when a cause of failure X: Replace A: Adjust
-
WA350-1
TROUBLESHOOTING
TABLE
indicate the action is located. A: Repair C: Clean
22-19 0
TROUBLESHOOTING
TROUBLESHOOTING
2. Machine
lacks power or speed
Checks
troubleshooting
before
l
Is oil,level in transmission
l
Is there any leakage
l
Is parking brake or brake locked?
l
Is operation
TABLE
case correct?
of oil from joints of piping
or valves?
Checking
of electric circuit correct?
for abnormalities
Engine high idlcng speed Toque
converter
Machine
Transmission Pressure
stall speed
travel speed clutch pressure
at outlet port of pump
Pilot reducing Tire inflation
pressure pressure
The following symbols are used to indicate the action to be taken when a cause of failure is located.
22-20 0
WA350-1
TROUBLESHOOTING
TROUBLESHOOTING
3. Excessive or shifting Checks
time gear
before
lag when
Is there
machine
troubleshooting
0 Is oil level in transmission .
starting
TABLE
any leakage
case correct?
of oil from
joints
of piping
or valves? 0 Is operation Checking l
Check
of control
valve
normal?
VALUE
TABLE
for abnormalities STANDARD
that time lag is actually
to confirm
excessive
3
Machine moves normally in certain speed ranges
4
Transmission modulating in every speed range
5
As in item 4; indicator
6
Torque converter range.
pressure too low
fluctuates
oil temperature
0 0
violently
0
0
0
0
0
is above operating
0
0
The following symbols are used to to be taken when a cause of failure X: Replace A: Adjust
WA350-1
0
indicate the action is located. Repair C: Clean
A:
22-21 0
TROUBLESHOOTING
TROUBLESHOOTING
4. Torque
converter
oil temperature
Ask the operator the following l
Does the torque during
torque
coverter
converter
the torque converter Yes
=
Normal
TABLE
too high
points.
oil temperature
go up
stall, and down
when
is not stalled?
(Incorrect
selection
of
gear
speed)
Checks before troubleshooting l Is oil level in transmission and steering correct? l
case
_-
Is filter clogged?
Checking for abnormalities l
Check
STANDARD
that torque
VALUE
converter
TABLE
to confirm
oil temperature
is actually
high. *
If the oil temperature temperature
gauge
is normal is outside
range, the oil temperature
4
Transmission
modulating
but the
the operat’
gauge is defecti
pressure too low
The following symbols are used to to be taken when a cause of failure X: Replace A: Adjust
22-22 0
indicate the action is located. A: Repair C: Clean
POWER TRAIN DISASSEMBLY
23
AND ASSEMBLY
.. TORQUE
CHARGING
CONVERTER
........... Installation ......... Removal
2
Removal
,..................
23-
3
Installation REAR
TRANS-
..............................
............................
Installation TORQUE
CONVERTER
Assembly TRANSMISSION
ASSEMBLY
Assembly TRANSFER
3
TRANSMISSION Removal
FRONT
23-46
REAR
LOWER
23-64
DRIVE
23-73
FINAL
UPPER
Assembly
23-74
...........................
23-
86
23-
89
23-
97
23-
99
23-101 23-l
05
............ ..............
.
23-l
09
23-l
11
23-l
13
23-l
16
DRIVE
Disassembly
VALVE
Assembly
85
SHAFT
Assembly
23-72
.
............... .............
Disassembly
VALVE
Disassembly
84
23-
AXLE
Installation
23-61
. .
............... .............
Removal
............................
Installation
23-
81
AXLE
Installation
23-32
. . .
............ ..............
Assembly
23-26
..............................
78
DIFFERENTIAL
Removal
CONTROL
.. .
............... .............
Disassembly
........................... .............................
Assembly
............ ..............
.
23-74
VALVE
Disassembly Assembly
*
For details
*
Take
........................ ...........................
of disassembly
the following
cylinders,
pumps engine,
2. Operate 3. Continue 4. After
23-l
. 23. 23-
DIFFERENTIAL
Installation
ASSEMBLY
Disassembly
1. Start
4
23-21
........................... .............................
Disassembly
23-
ASSEMBLY
........................... .............................
Disassembly
............... .............
Removal
ASSEMBLY
Removal
DIFFERENTIAL
23-
-CONVERTER, TRANSMISSION,
TORQUE FER
FRONT
PUMP
,..................
WA350-1
and assembly
method
for
of the gear pump,
air bleeding
when
you
see SECTION
start
to operate
97. hydraulic
cylinders
after
reassembling
keep idling. cylinder
to operate After
23-76
and pipings.
hydraulic
finishing
NOTE:
23-76
above
cylinder steps,
long storage,
4 -
5 cycles,
3 -
but do not exceed
4 cycles
keep normal
until stroke engine
same procedure
beyond
100
mm of stroke
end.
end.
speed.
is required.
23-l 0
DISASSEMBLY
AND
REMOVAL
a
Stop
the
OF TORQUE machine
the safety
A
and
Lower
brake
to prevent
and
put
Then
blocks
the machine
CONVERTER
CHARGING
CHARGING
PUMP
PUMP
install
the bucket
and stop the engine.
parking
wheels
CONVERTER
on level ground
bar on the frame.
to the ground the
TORQUE
ASSEMBLY
apply
under
the
from moving.
Open hood (1) and fit lock (2).
1. Engine oil filter Remove
oil filter (3).
2. Hydraulic
piping
1) Disconnect
tube
charging
pump
torque converter *
Remove
2) Disconnect
torque
charging
the U-clamp tube
charging
pump end.
mounting
verter charging There
converter filter
at
holding the tube.
(5) between
pump and transfer
Remove
torque converter
pump end.
charging
3. Torque converter
f
(4) between and
torque
converter
at torque
converter
charging pump bolts, then remove
torque
con-
pump (6).
is little space,
so be careful
not to injure
your hands or fingers.
23-2 0
WA350-1
DISASSEMBLY
AND
INSTALLATION 1. Torque
converter
Set torque *
OF TORQUE
charging
converter
ing position,
CHARGING
CHARGING
PUMP
PUMP
pump (6) in mount-
mounting
securely
CONVERTER
CONVERTER
pump
charging
then tighten
Fit the O-ring
TORQUE
ASSEMBLY
bolts.
in the groove,
and make
sure that it is not caught when installing.
2. Hydraulic
piping
1) Connect
tube
(5)
between
charging
pump and transfer
charging
pump.
2) Connect charging
tube
(4)
pump
torque converter Sr Fit the make
O-ring sure
between
and
torque
charging it
converter
torque
converter
converter
filter
to
pump.
securely that
torque
to torque converter
is
in the not
groove, caught
and when
installing. Sr Secure
3. Engine
the tube with a U-clamp.
oil filter
Install engine oil filter (3). *
Close the hood and fit the catch.
WA350-1
23-3 0
DISASSEMBLY
AND
REMOVAL TRANSFER
ASSEMBLY
TORQUE
OF TORQUE ASSEMBLY
CONVERTER,
CONVERTER,
TRANSMISSION,
TRANSFER
TRANSMISSION,
1
2 --Ladder
’A
4
Hydraulic tank piping
i
Wheel loader
\\\
Brakevalve
H
&asier
Drive shaft
423F406
23-4 0
WA35071
DISASSEMBLY
A
Stop
AND
the
machine
the safety the
parking
wheels
Q!
and
inside
operate
the
release
put
control
pressure
TRANSFER
install
Then
apply
under
the
to release
hydraulic levers
the remaining
TRANSMISSION,
from moving.
cap slowly
the
CONVERTER,
the bucket
blocks
the machine
the oil filler
pressure
and
Lower
and stop the engine. brake
to prevent
Loosen
on level ground
bar on the frame.
to the ground
TORQUE
ASSEMBLY
tank.
several
the Then
times
to
in the hydraulic
piping. t
.
Disconnect terminal
Loosen filter,
the cable from
the negative
plug (1) at the top of the hydraulic and the
plug
(2) of the pump
tank
piping
prevent the oil inside the tank from flowing
A
(-)
of the battery. to
out.
Open hood (3) and fit lock (4).
1. Draining
air
Loosen drain valve (5) and drain air from air tank.
2. Ladder Sling
ladder
remove *
(6).
remove
mounting
bolts,
then
ladder.
Remove
the ladders
on both the left and right
sides. Ladder:
WA350-1
65 kg
23-5 0
DISASSEMBLY
AND
TORQUE
ASSEMBLY
CONVERTER,
TRANSMISSION,
TRANSFER
3. Hood 1) Remove
clamps
window
washer,
of wiring then
and
remove
vinyl
tube
window
for
washer
tank (7) from hood. 2) Sling hood (81, remove
mounting
bolts, then lift
off hood. t
Be careful
not to hit the rear window
of the
cab when lifting off the hood. 62 kg
Hood:
4. Hydraulic tank piping 1) Disconnect and work
hose
(9)
equipment
between
hydraulic
circuit at work
tank
equipment
circuit block end.
2) Loosen clamp tank
and
of hose
steering
disconnect
and
(IO)
between
hydraulic
hose at hydraulic
hydraulic
pump,
then
tank end.
5. Brake oil tank 1) Disconnect
connector
(1 1) of wiring
for brake
oil tank. 2) Disconnect oil tank
hoses (I 2) and (I 3) between
and brake
chamber
at brake
brake
chamber
end.
23-6 0
WA350-1
DISASSEMBLY
AND
ASSEMBLY
TORQUE
CONVERTER,
TRANSMISSION,
TRANSFER
6. Main control valve piping 1) Disconnect
lift cylinder
2) Disconnect
dump cylinder hoses !I 4) and (I 5).
3) Disconnect
steering
4) Disconnect
hose
hoses (1 6) and (I 7).
valve hose (I 8). (19)
for
work
equipment
circuit.
5) Disconnect
bucket
control
linkage
(20)
at main
control valve end.
7. Support Sling
support
(21).
remove
mounting
bolts, then
lift off support. * *
Remove
the bracket
of the block for the work
equipment
circuit.
Be careful
not to hit the rear window
of the cab
when lifting off the support.
8, , Electric wiring I) Disconnect (271,
(281,
frame
(22).
*
After
connectors (29)
and
removing
to distinguish
(23). (30)
(241,
(25).
at bracket
the wiring,
(26),
of floor
mark with
a tag
when installing.
2) Disconnect
ground connection
3) Disconnect
connector
and connector.
of wiring for brake sole-
noid valve.
WA350- 1
23-7 0
DISASSEMBLY
9. Brake
AND
ASSEMBLY
hoses
(3
TORQUE
CONVERTER,
TRANSMISSION,
TRANSFER
valve
1) Disconnect valve
10. Fuel control
at brake vlave
brake end.
cable
1) Disconnect joint
I) and (32) between
and brake chamber
fuel
control
cable
(35)
from
ball
(36).
2) Remove
fuel
control
cable
(35)
from
bracket
(37). Sr Remove
11. Floor frame, I) Remove control
23-8 0
the strap
properly.
cab assembly lever lock plate
(38) of work
equipment
lever box inside cab.
WA350-1
DISASSEMBLY
AND
2) Remove
floor surface
ment control *
Remove
3) Sling
floor
remove t
TRANSMISSION,
TRANSFER
of work equip-
the plate with the boot attached.
frame
lifting
assembly,
plate (39)
CONVERTER,
lever box.
mounting
After
TORQUE
ASSEMBLY
and
cab
assembly
(40),
bolts, then lift off assembly. off
remove
the the
floor
frame
and
steering
shaft
check
numbers
cab from
the gear box. *
If
shims
are
inserted,
of
shims. 6 kg
WA350-1
Floor frame,
cab assembly:
250
kg
23-9 @
DISASSEMBLY
AND
3) Disconnect
ASSEMBLY
tube
(45)
TORQUE
between
brake
CONVERTER,
TRANSMISSION,
TRANSFER
chamber
and brake valve from brake chamber. 4) Remove 5) Sling
air tank tube (46).
brake
chamber
(47).
remove
mounting
bolts, then lift off.
14. Torque
converter
oil filter
I) Disconnecttube charging
pump
(48)
between
and
torque
from torque converter 2) Disconnect
torque
converter
converter
oil filter
oil filter.
hose (49) between
oil filter and transmission
torque converter
from torque converter
oil filter. 3) Disconnect mission
hoses (50) and (51) between
valve
oil filter
and transmission
transfrom
filter. 4) Remove remove
mounting torque
bolts
converter
of
bracket,
oil filter
then
(52) together
with bracket. 15. Hydraulic 1) Remove bracket
piping tube
clamp
and U-bolt,
then
remove
(53).
2) Disconnect
tube
(54)
between
transmission
and oil cooler from transmission. 3) Disconnect
tube
(55)
between
transfer
and oil
cooler from transmission.
16. Drive
shaft
Disconnect
center
drive shaft
(56)
and rear drive
shaft (57) from transfer.
23-10 0
WA350-1
DISASSEMBLY
17. Torque sembly
AND
ASSEMBLY
converter,
1) Disconnect for torque
clamp
TORQUE
transmission,
transfer
and connector
of wiring
converter
and transmission
CONVERTER,
TRANSMISSION,
TRANSFER
as(58)
solenoid
valve.
2) Put block
@between
engine to support t
When
inserting
damage
rear axle and bottom
of
engine. the block,
be careful
not to
of oil supply
tube,
the brake tube.
3) Rotate transfer move towards
mount
(59)
inside
of machine
body,
then
secure with 1 bolt. *
Be careful
not to let the mount
the transfer,
and tighten
ately after rotating *
Before frame,
moving remove
4) Sling torque fer
assembly
out of
immedi-
the mount.
to
the
inside
of
the
rear
the oil filler cap.
converter, (60).
bolts (61) of torque
WA350-1
come
the bolts
transmission then
remove
converter
and transconnecting
and engine.
23-11 0
DISASSEMBLY
AND
5) Remove
left
then remove Sr Measure
TORQUE
ASSEMBLY
and
right
spacer
mounting
bolts
(63) and cushion
all the clearances
CONVERTER,
TRANSMISSION,
TRANSFER
(621,
(64).
of the positioning
bolts. t
Make
match
mounting sure
the
marks
bracket protrusion
to give a guide
6) Raise torque fer assembly
when
converter, (60)
to disconnect,
on
the
mount
and rear frame, of the
of
positioning
bolts
installing.
transmission
and trans-
20 to 30 mm, move
then
the
and mea-
remove
to front
left and right
brack-
ets (65). *
When
raising
meshing
ring gear shaft,
7) Lift
off
transfer
the assembly,
of the engine
torque assembly
be careful
and torque
of the
converter
and lift off the assembly.
converter, (60).
transmission
Be careful
not
and hit rear
frame. E?Ikg
Torque
converter,
fer assembly:
23-12 0
710
transmission,
trans-
kg
WA350-1
DISASSEMBLY
AND
ASSEMBLY
TORQUE
INSTALLATION CIF TORQUE TRANSFER ASSE MBLY
CONVERTER,
CONVERTER,
TRANSMISSION,
TRANSFER
TRANSMISSION,
2 -
Drive shaft
ToA
3 -To
6
= ToC
Torque converte
WA350-1 Wheel loader
transfer assembl
Brake oil tank
A-
16 Ladder
17
18
I 423 F408
WA350-1
23-13 0
DISASSEMBLY
1. Torque sembly
AND
ASSEMBLY
converter,
I) Raise torque
transmission,
converter,
fer assembly
TORQUE
transmission
position. and par-
*
TRANSFER
and trans-
Align ring gear and shaft, then connect mounting
TRANSMISSION,
as-
and set in mounting
tially tighten
(60)
transfer
CONVERTER,
bolts.
Raise the assembly
horizontally
and be care-
ful of the ring gear and shaft when installing. *
Use a new
O-ring
and fit it securely
in the
groove. E??YE
O-ring-at
contact
2) Install
left
and
transmission, brackets, *
right
fit cushions
then tighten
Assemble
the
face
of engine
and
Soapy water
torque converter:
brackets
(65)
and spacers
mounting
cushions
to
behind
bolts (62).
so that
the
cham-
fered face is on the spacer side. *
Never
use oil or soap when
assembling
the
cushions. +
Partially
tighten
the mounting
bolts, then set
in position and tighten the bolts fully. m
Mounting
bolt of bracket: 18.Ok2.0
w
Mounting
3) Install
connecting
bolt:
94.5 + 10.5
bolts
(61)
of
kgm
kgm
torque
con-
verter and engine, then tighten fully.
4) To
position
justment
the transmission,
screw
the specified
(66)
value,
so that
adjust
with
clearance
then tighten
ad-
“a”
is
the mounting
bolts fully. Clearance w
“a”:
1 - 2 mm
Mounting
bolt:
28&3
kgm
Clearance a
23-14 8
424F114
WA3561
DISASSEMBLY
5) Rotate
AND
transfer
TORQUE
ASSEMBLY
mount
(59)
of oil supply
CONVERTER,
TRANSMISSION,
TRANSFER
tube,
then pull to outside of machine. Sr Be careful the
not to let the mount
transfer,
mediately Sr When
pulling
6) Remove
tighten
after rotating
first remove
bottom
and
block
come
the
out of
bolts
im-
the mount.
to outside
of the rear frame,
the oil filler cap, then tilt over.
@
from
between
rear axle and
of engine.
7) Connect
clamp
for torque
and
converter
connector
of wiring
and transmission
(58)
solenoid
valve.
2. Drive
shaft
Connect
rear
drive
shaft
(57)
and
center
drive
shaft (56) to transfer. m
Mounting
WA350- 1
bolt:
11.5*
1 .O kgm
23-15 0
DISASSEMBLY
3. Hydraulic
AND
TORQUE
ASSEMBLY
CONVERTER,
TRANSMISSION,
TRANSFER
piping
I) Connect
tube
cooler
(55)
between
transfer
and
oil
to transmission.
2) Connect
tube
oil cooler 3) Install
(54)
between
transmission
and
to transmission.
bracket
(531, then
converter
oil filter
install
tube
clamp
and
U-bolt.
4. Torque
I) Set torque position, 2) Connect mission
converter
oil filter
then tighten
mounting
bolts.
and
between
hoses valve
3) Connect oil filter
hose and
(50)
oil filter (49)
(51)
(52)
in mounting
and transmission between
transmission
transto filter.
torque
converter
to torque
converter
torque
converter
oil filter. 4) Connect charging
tube
(48)
pump
and filter
between
to torque
converter
oil
filter.
5. Brake
chamber
I) Raise
brake
position, 2) Install
air tank tube
3) Connect
tube
brake valve
4) Connect chamber 5) Connect
23-16 0
chamber
(47).
set
in
mounting
and install. (45)
(46). between
brake
chamber
and
to brake chamber.
hoses
(43)
and
and slack adjuster connector
(44)
between
brake
to brake chamber.
of brake chamber
wiring.
WA350-1
DISASSEMBLY
AND
TORQUE
ASSEMBLY
CONVERTER,
TRANSMISSION,
TRANSFER
6. Steering valve piping 1) Install
hose
(42)
between
steering
valve
and
between
steering
valve
and
securely
in the
main control valve. 2) Install
hose
steering t
(41)
pump.
Fit the
O-ring
make
sure
that
it
is
not
groove,
and
caught
when
installing.
7. Floor frame, cab assembly 1) Raise floor frame mounting *
and cab assembly
position,
Insert
the
spline
of
steering the
(40).
set in
then tighten mounting shaft
steering
correctly
column,
bolts.
into the
and
secure
with wire so that it does not come out.
2) Select number “a” and I( b”, 3) Loosen
of
mounting
shim (671, retighten *
423F485
423 F484
68
shims
matching
bolts,
and
mounting
Install shims. The
lower
should
after
not bulge
clearance
after
inserting
bolts.
rubber
mounts
tightening
(68)
mounting
bolts. *
There
should
not
stalled
portion
of shim. Move
be any
clearance
at in-
shim by hand
if there is clearance.
4) Install lever lock plate (38) of work equipment lever box. 5) Install
floor
surface
plate
(39)
of work
equip-
ment lever box inside cab. Sr Coat with
the outside
circumference
of the lever
soap,
assemble
boot
then
the
to the
plate first.
WA350-1
23-17
DISASSEMBLY
AND
8. Fuel control
TORQUE
ASSEMBLY
9. Brake
TRANSMISSION,
TRANSFER
cable
1) Install fuel control cable (35) to bracket 2) Connect
CONVERTER,
fuel control
(37).
cable (35) at ball joint (36).
valve
I) Connect
hoses
(33)
and
(34)
between
brake
valve and air tank at brake valve end. 2) Connect
hoses
(31)
and
valve and brake chamber
10. Electric
(32)
between
brake
at brake valve end.
wiring
I)
11. Support I) Raise
support
(211,
set
in mounting
position
and install. 2) Install
bracket
of
block
for
work
equipment
circuit. t
Be careful cab when
23-18 0
not to hit the rear window
of the
installing the support.
WA350-1
DISASSEMBLY
12. Main
AND
control
1) Connect
valve work
TORQUE
ASSEMBLY
CONVERTER,
TRANSMISSION,
TRANSFER
piping equipment
control
linkage
(20)
to main control valve.
2) Connect
hose (19) for work equipment
3) Connect
steering
4) Connect
dump cylinder
5) Connect
lift cylinder
13. Brake
circuit.
valve hose (I 8). hoses (I 4) and (I 5).
hoses (I 6) and (I 7).
oil tank
1) Connect
hoses (I 2) and (I 3) between
tank and brake chamber 2) Connect
connector
brake oil
at brake chamber
of wiring
for brake
end. oil tank
(I I).
14. Hydraulic I) Install steering tighten
WA350- 1
tank piping hose
(I 0)
between
and hydraulic
hydraulic
pump
tank
and
at tank end, then
clamp.
23-19 0
DISASSEMBLY
AND
2) Connect work
hose
(9) between
equipment
cuit block
TORQUE
ASSEMBLY
circuit
hydraulic
at work
tank
CONVERTER,
TRANSMISSION,
TRANSFER
and
equipment
cir-
end.
15. Hood 1) Raise
hood-(8).
tighten 2) Install
set in mounting
mounting window
stall vinyl
position,
then
bolts. washer
tube
tank
(7) to hood,
for window
washer
then
in-
and clamps
of wiring.
16.
Ladder Raise
ladder
tighten It
(6).
set
mounting
Install
in mounting
position,
then
on
left
right
bolts.
the
ladders
with
oil
both
the
and
sides. 17. Refilling 1) Tighten
plug
and plug oil through *
Run
(I)
at top
(2) of pump oil filler
the
of hydraulic
piping,
tank
(66) to the specified
engine
filter,
then add hydraulic
to circulate
the
level.
oil through
the system. Then check
the oil level again.
2) Add transmission
Transmission
@ *
oil to the specified
Run the engine oil through wait
for
oil:
53 Q
to circulate
the system.
15 minutes,
level.
the transmission
Stop
then
the engine
check
and
the oil level
again. 18 . Bleeding
air, checking
Bleed air from For details
brakes,
of bleeding
then check
operation.
air, see 52 TESTING
AND
ADJUSTING. /I
?
2 3-20 0
Close hood,
then
lock with
catch.
WA3561
DISASSEMBLY
AND
ASSEMBLY
DISASSEMBLY
TORQUE
OF TORQUE 1
CONVERTER
2
3
CONVERTER
ASSEMBLY
4
5 t
ToA
assembly
I\
Special
tools
A
790-501-5000
AI
790-901-21
A,
IQ’ty
Part Name
Part No.
Unit repair stand
1
Bracket
1
793-310-2140
Plate
1
B
790-I
01-2501
Push-puller
BI
790-I
01-2102
Puller
1
B2
790-101-1102
Pump
1
Preparatory Remove For
(kit)
1
work
torque
converter,
10
converter
transmission
detailes,
CONVERTOR,
see
23-4
assembly
(2) from
and transfer
assembly
REMOVAL
TRANSMISSION,
OF
torque (I 1.
TORQUE
TRANSFER
ASSEMBLY.
WA350- 1
23-21 0
DISASSEMBLY
AND
ASSEMBLY
1. Turbine, case assembly 1) Set torque converter assembly
2) Remove remove t
mounting
bolts
TORQUE
(2) in tool A
(3)
of
case,
turbine and case assembly
When
removing
mounting
the mounting
bolts on opposite
over the assembly remove
then
(4). bolts, leave 2
sides, then turn
(pilot side at the top) and
the remaining
3) Disassemble
CONVERTER
turbine
2 mounting
and
case
bolts.
assembly
as
follows. i)
Remove
pilot (5).
ii)
Remove
snap ring (6), then remove
iii)
(7). Using 2 forcing IO mm,
pitch
screws =
spacer
@
(Thread
dia. =
1.5 mm),
remove
turbine
(8) from case (9). *
Pull out from bearing inner race side.
423F410
23-22 Q
WA350-1
DISASSEMBLY
AND
ASSEMBLY
TORQUE
CONVERTER
2. Stator Remove
snap ring (13). then remove
stator (I 4).
3. Pump Remove
pump (I 5).
4. Case Remove
WA350-1
12 bolts, then remove
case (16).
23-23 0
DISASSEMBLY
2) Using
AND
tool
TORQUE
ASSEMBLY
B, remove
gear
(19)
and
CONVERTER
bearing
(20).
.
6. Stator
shaft
Remove shaft t
8
mounting
bolts,
then
remove
stator
(23).
Tap the end of the shaft
with
a copper
hammer
to remove.
7. Pump drive Screw
gear assembly
in forcing
gear assembly
screw
and
remove
pump
drive
(25).
8. Idler gear shaft Using
2 forcing
mm, pitch t
Check
= the
screws
@
1.5 mm), remove number
(Thread shaft
and thickness
dia.
=
10
(38). of the shims,
and keep in a safe place.
23-24 0
WA350-1
DISASSEMBLY
9. Idler gear, Remove
AND
ASSEMBLY
TORQUE
CONVERTER
bearing
gear (39) and bearing (40).
WA350-1
23-25 0
DISASSEMBLY
AND
ASSEMBLY
ASSEMBLY
TORQUE
OF TORQUE
CONVERTER
2
1
4
CONVERTER
ASSEMBLY
5 t
7
9
A
Special
423F411
tools
-
793-310-2140
A2
1. Idler gear, 2) Install (39).
23-26 0
1 Plate
I ’
bearing
1) Set torque outer
converter race
9
(41)
case in tool A. (O.D.:
1 10 mm)
on gear
ToA
DISASSEMBLY
3) Assemble
AND
ASSEMBLY
bearings
(40)
TORQUE
CONVERTER
on both sides of gear
(391, then set in case.
..
2. Idler gear shaft 1) Fit-o-ring,
align with
inner race of bearing
and
install shaft (38).
2) Press
fit
between 0. 3) Select
shaft
fully,
then
case and shaft
measure
shims so that measured
0.005
mm (+I.
4) Insert
selected
shims,
clearance
(38) with feeler gauge
then
clearance tighten
is 0 to
mounting
bolts.
3. Pump drive
I) Assemble i)
gear assembly gear assembly
Install bearing
(35)
as follows. (O.D.: 100
mm) in cage
(36). ii)
Install snap ring (42).
WA350-1
23-27
DISASSEMBLY
iii)
Push Install
race
inner
and install
bearing, iv)
ASSEMBLY
AND
(I.D.:
TORQUE
55
mm)
side
cage (36) on shaft
CONVERTER
of
(34).
snap ring (33).
.
v) Install inner race (31) (I.D.: 50 mm) on gear (32). vi)
Install
snap ring (30).
vii)
Install
gear (29)‘on Mounting
m
(27)
bolt:
7kO.5
kgm
(O.D.: 90 mm) in case (28).
2) Install
bearing
31 Install
snap ring (26).
23-28 0
shaft.
WA350-1
DISASSEMBLY
AND
4) Fit O-ring
TORQUE
ASSEMBLY
CONVERTER
and install pump drive gear assembly
(25).
4. Stator
shaft
1) Using
guide
pitch =
bolt
@
(Thread
dia.
=
10 mm,
1.5 mm), install stator shaft (23).
2) Install seal ring (24) on shaft (23). *
Coat the seal ring with grease and make the protrusion
5. Gear,
from the shaft uniform.
bearing
1) Install
bearing
(21)
(O.D.:
180
mm)
on gear
(I 9). 2) Push inner race end and install bearing shaft together
WA350-1
(21)
on
with gear.
23-29 0
DISASSEMBLY
AND
TORQUE
ASSEMBLY
CONVERTER
6. Case Install case (I 6) m
Mounting
bolt:
3.220.2
kgm
.
7. Pump Align bolt holes and install pump (I 5).
8. Stator 1) Install stator (I 4). 2) Install snap ring (I 3)
9. Turbine,
case assembly
I) Assemble
turbine
and
case
assembly
as
follows. i)
Assemble
ii)
Install bearing
snap ring to bearing
(I 0).
(I 0) (O.D.: 1 10 mm) in case
(9).
23-30 0
WA350-1
DISASSEMBLY
iii)
AND
Support
turbine
(8),
push
70 mm) of bearing, turbine
TORQUE
ASSEMBLY
inner
race
CONVERTER
(I.D.:
and install case (9) on
(8).
iv) Assemble
spacer
(7) and install
snap
ring
(6). VI Install pilot (5). m
Mounting
bolt:
720.5
kgm
423F412
i
2) Align
bolt holes,
assembly
3) Install 24 mounting w
Mounting
. Torque converter Fit O-ring, with
WA350-1
install turbine
and case
bolts (3) of case. bolt:
3.2kO.3
kgm
assembly
align spline of transmission
boss of turbine,
assembly
then
(4).
then install torque
(2) on transmission
assembly
input shaft converter (I 1.
23-31 0
DISASSEMBLY
AND
DISASSEMBLY
TRANSMISSION
ASSEMBLY
OF TRANSMISSION
ASSEMBLY
7 Transmission assembly
Transmission
Checking operation of piston
Special tools
23-32 0
WA350-1
DISASSEMBLY
AND
TRANSMISSION
ASSEMBLY
14
15 t
ToA
-
ToB
25
24 No. 5 sun gear
423F413
WA350-1
23-33 0
DISASSEMBLY
AND
TRANSMISSION
ASSEMBLY
1. Torque converter assembly Raise torque
converter
from transmission
(2) and remove
assembly
assembly
(I ).
2. Filter assembly Remove
filter assembly
(3).
3. Control valve assembly Remove
control valve assemblies
(4) and (5)
4. Sleeve Using eye bolts
@
= 2 mm), remove
5. Transfer
dia. =
16 mm, pitch
assembly
1) Set transfer 2) Remove *
(Thread
5 sleeves (6).
assembly
at bottom.
2 tie bolts (8).
Remove where
the there
surface
two
bolts
are bulging
on
opposite
sides
oil holes on the top
of the plate.
These are holes for eye bolts. 3) Remove
mounting
bolts
of transmission
case
and transfer. 4) Screw assembly assembly
23-34 0
in
forcing (9)
and
screw,
raise
disconnect
transmission from
transfer
(7).
WA350-1
DISASSEMBLY
AND
6. Transmission
case
TRANSMISSION
ASSEMBLY
1) Remove mounting
bolts (IO)
of case, and lower
to ground. 2) Remove
2 housing
lock bolts (I I) each on left
and right.
3) Using pitch
2 eye bolts
@
G 2 mm), remove
(Thread
dia. =
transmission
16 mm, assembly
(12) from case.
7. Checking
operation
I) Set transmission
of piston assembly
2) Using tool B, check
(12) on tool A.
operation
of piston
before
disassembling.
8. Input shaft, 1) Remove
No. 1 carrier
assembly
tie bolt (8).
2) Lift off input shaft
and No. 1 carrier
assembly
(14).
WA350-1
23-35 0
DISASSEMBLY
AND
9. No. 1 clutch
ring gear,
Remove 10.
t
spring
ring gear (I 5) and spring (I 6).
No. 1 clutch Remove
TRANSMISSION
ASSEMBLY
disc, plate
discs (17) and plates (I 8).
There are 4 discs and 3 plates.
11. No. 1 housing Remove
No. T housing
*
with
Tap
a
(20).
copper
hammer
to disconnect
dowel pin, then remove.
12. Guide
pin, spring
Remove
guide
pin (I 9) and No. 2 clutch
spring
(21).
13. No. 2 clutch Remove *
disc, plate
discs (22) and plates (23).
There are 4 discs and 3 plates.
23-36 0
WA350-1
DISASSEMBLY
AND
TRANSMISSION
ASSEMBLY
14. No. 1 idler ring gear 1) Remove
snap ring (251, then remove
ring gear
(26). 2) Remove
plate (27).
15. Ring gear of No. 2 clutch Remove
ring gear (28).
16. No. 2 housing Remove
No. 2 housing
+I Tap
with
a
(30).
copper
hammer
to
disconnect
dowel Pin, then remove.
17. No. 3 clutch Remove *
disc, plate,
springs (33).
spring
discs (34) and plates (35).
There are 3 discs and 2 plates.
WA350-1
18. Bearing, Remove
TRANSMISSION
ASSEMBLY
AND
DISASSEMBLY
cover snap ring (37). then remove
19. No. 2,3,4
cover (38).
assembly
carrier
I) Remove snap ring (40) at shaft end. @,
2) Using puller assembly *
remove
No. 2, 3 and 4 carrier
(41).
No. 3 clutch
ring gear will come
off at the
same time.
20.
No. 3 housing Remove *
Tap
housing with
a
(42). copper
hammer
to
disconnect
dowel pin, then remove.
21.
No. 4 clutch Remove t
disc, plate,
spring
springs (441, discs (45) and plates (46).
There are 2 discs and 1 plate.
23-38 0
WA350-1
DISASSEMBLY
22.
AND
ASSEMBLY
TRANSMISSION
Ring gear for No. 4 clutch 1) Remove
snap ring (471, then remove
ring gear
(48). 2) Remove
plate (49).
.
23.
No. 4,5
housing
Remoie
No. 4 and 5 housing assembly
24. Spacer,
assembly (50).
No. 4 sun gear
1) Remove
snap
ring
(51),
then
remove
spacer
(52) and No. 4 sun gear (53). 2) Remove
25.
snap ring (54).
No. 5 sun gear Remove
snap
ring (55).
then
remove
No. 5 sun
gear (56).
WA350-1
23-39 0
26.
assembly
No. 5 carrier I) Remove 2) Tap
mounting
bolts.
copper
hammer
with
OF
DISASSEMBLY CARRIER
27.
28.
the
disassembling
When
dowel
to disconnect assembly
No. 5 carrier
pin, remove *
TRANSMISSION
ASSEMBLY
AND
DISASSEMBLY
(57).
planet
INPUT
see
gear,
SHAFT,
NO.
1
Step 7 for details.
ASSEMBLY,
Hub, spring I) Remove
hub (58).
2) Remove
spring
disc, plate,
No. 6 clutch Remove
29. Output
(59).
discs
spring
(60) and plates
(61).
shaft
I) Remove
output
shaft
2) Support
collar
end,
assembly and
push
from
tool A.
shaft
(63)
with
press to remove.
23-40 0
WA350-1
DISASSEMBLY
AND
ASSEMBLY
TRANSMISSION
30. Cage
I) Remove
snap ring (64).
2) Support
No.
(65) with
6 housing
(631,
and
push
cage
press to remove.
DISASSEMBLY OF INPUT CARRIER ASSEMBLY
SHAFT,
NO. 1
remove
No. 2 sun
1. No. 2 sun gear Remove
snap
ring
(75).
then
gear (76). 2. No. 1 sun gear I) Remove
snap rings
2) Remove
No. 1 sun gear (79).
(77) and (78)
3. Spacer Remove 4. Input
spacer
(80)
shaft
Support
housing
(811,
and
push
shaft
(82)
with
press to remove.
5. No. 1 carrier 1) Remove
assembly snap ring (85).
Sr On inner race side. 2) Support assembly
WA350-1
housing (87) with
(86).
and
push
carrier
press to remove.
23-41 0
DISASSEMBLY
AND
ASSEMBLY
TRANSMISSION
6. Spacer Remove spacer (88). 7. Planet gear 1) Remove shaft (89). Sr Be careful not to lose ball (90).
2) Remove planet gear thrust washer (93).
DISASSEMBLY ASSEMBLY
(91).
OF NO. 2,3,4
bearing
(92)
and
CARRIER
1. No. 3 ring gear Remove No. 3 ring gear (I 00)
423P
f 390
2. No. 4 carrier assembly Remove No. 4 carrier assembly (102) from No. 2 and 3 carrier assembly (103). t Remove the mounting bolts, tap with a copper hammer to disconnect dowel pin, then remove assembly.
423P139f
23-42 0
WA350-1
DISASSEMBLY
AND
ASSEMBLY
TRANSMISSION
3. No. 4 carrier, planet gear t When disassembling the planet gear, see DISASSEMBLY
OF INPUT
RIER ASSEMBLY,
SHAFT
AND NO. 1 CAR-
step 7 for detailes.
carrier, planet gear 1) Using tool C, remove shaft (I 04).
4. No. 2,3 t
Be careful
2) Remove washer
gear
not to lose ball (I 05)
(106).
bearing
(I 07)
and thrust
!I 08).
DISASSEMBLY
OF
NO.
4,5
HOUSING
ASSEMBLY
1. No. 4 housing Remove *
Lever careful
No. 4 housing up where
(I IO).
the
not to damage
2. Discs, plates, springs Remove springs (1 131,
dowel
pin is located.
Be
the housing.
discs
(I 14)
and
plates
(1 15). *
There are 3 discs and 2 plates.
WA350-1
23-43 0
DISASSEMBLY
AND
ASSEMBLY
TRANSMISSION
3. No. 5 clutch ring gear Remove ring gear (I 16)
23-44 0
WA350-1
AND
DISASSEMBLY
ASSEMBLY
TRANSMISSION
OF TRANSMISSION
ASSEMBLY
ASSEMBLY
No. 6 clutch housmg
6 No. 5 sun gear
20 No. 1.2 carrier ring gear
tools
Special
Part name
Part number
Q’ty
A
790-501-5000
Unit repair stand
1
A,
790-901-2110
Bracket
1
A,
793-31
Plate
1
( Plate
I I
1 Leak tester
I I
A, B
o-21 40
1 793-310-2150 ( 799-301-I
23-46 0
500
WA350-1
DISASSEMBLY
AND
.
TRANSMISSION
ASSEMBLY
8
To B
1
\,
ToC
30 B
423F419
WA350-1
23-47 0
DISASSEMBLY
ASSEMBLY ASSEMBLY
AND
TRANSMISSION
ASSEMBLY
OF NO. 4,5
HOUSING
1. No. 5 clutch ring gear Set ring gear (I 16) on No. 5 housing.
2. Discs, plates, springs Install discs (I 14), plates (I 15) and springs
(1
13).
* There are 3 discs and 2 plates.
3. No. 4 housing I) Assemble
seal ring (I 12) on piston (1 1 1).
2) Assemble
seal ring on.housing
*
The seal ring must
(I 10).
be installed
correct
direction.
Install
receiving
the pressure
facing
with
in the
the
side
facing the groove.
3) Install piston (I 1 I) in housing (I 10). Housing /
423F420
4) Align dowel pin and install No. 4 housing (I IO). +r Tap
the
position
of the
dowel
pin with
a
copper or plastic hammer. 42!3Pl3$4
23-48 0
WA350-1
DISASSEMBLY
AND
ASSEMBLY ASSEMBLY 1. No. 2,3
OF NO. 2,3
carrier,
I) Assemble
planet
bearing
then fit thrust
TRANSMISSION
ASSEMBLY
CARRIER
gear (I 07)
washers
on planet (108)
gear
(1061,
on both sides and
set in carrier. t
Align the center of all parts with the shaft hole.
2) Tap shaft
(I 04) with a plastic hammer
to install.
Assemble
ball (I 05) and knock in completely.
t
that
Check
the
gear
and
thrust
washer
the
NO. 2. 3
rotate smoothly. 3) Caulk tip of shaft at one point. No. 4 carrier, Sr Install
planet
in the
gear
same
way
as for
carrier, planet gear.
3. No. 4 carrier Align (102).
dowel
assembly pin and install No. 4 carrier assembly
then tighten
bolts (I 02A).
6~
Mounting
bolt:
Adhesive
(LT-2)
m
Mounting
bolt:
10 - 12.5
kgm
+
Tap the position
of the dowel
pin with a copper
or plastic hammer.
4. Seal ring Install seal ring (I 01). 5. No. 3 ring gear Install No. 3 ring gear (100). *
Install with carrier.
WA350-1
the internal
teeth
facing
the No. 4
ASSEMBLY
AND
DISASSEMBLY
OF INPUT ASSEMBLY CARRIER ASSEMBLY
TRANSMISSION
SHAFT,
NO. 1
1. Planet gear *
see
details,
For
CARRIER
2,
OF NO.
ASSEMBLY
3, 4
ASSEMBLY.
2. Bearing I) Install carrier 2) Install
bearing
90
(O.D.:
mm)
to
No.
1
snap ring_(97).
3. No. 1 carrier I) Install
(98)
(99).
assembly
bearing
(95)
(O.D.:
mm)
to housing
assembly
(87).
125
(96). 2) Install
snap ring (94).
4) Install
housing
*
(86) on carrier
Press fit the inner carrier.
5) Install
23-50 0
snap ring (85).
race of the housing
to the
DISASSEMBLY
AND
ASSEMBLY
TRANSMISSION
4. Input shaft I) Install
snap ring (84) on shaft
2) Install
shaft
(82) in carrier
(82).
(83).
5. Spacer lnstalf spacer
(80)
6. No. 1 sun gear 1) Install
No. 1 sun gear (7%.
2) Install
snap rings
(78) and (77).
7. No. 2 sun gear Install
sun gear (761, then install
(ASSEMBLY
OF
snap ring (75)
TRANSMISSION)
1. Cage
1) Install bushing 2) Install
WA350-1
bearing
(73)
(O.D.:
(72) to No. 6 housing
1 f55
mm)
and
(63).
snap ring (7 I).
23-51 0
DISASSEMBLY
AND
ASSEMBLY
TRANSMISSION
3) Install bearing (69) (O.D.: 95 mm) in cage (65). 4) Install snap ring (68). 5) Install seal ring (67).
6) Install cage (65) in housing (63). +
Press ftt the housing inner race.
7) Install snap ring (64).
8) Install piston (65)
and guide pin (66)
in housing
(63). *
For details see
of installing
ASSEMBLY
OF
the piston NO.
4,
5
seal ring, HOUSING
ASSEMBLY.
2. Output shaft Fit seal ring, then install output housing assembly *
shaft
(62)
in No. 6
(63).
Press fit the inner race of housing to the shaft.
23-52 Q
WA350-1
DISASSEMBLY
AND
ASSEMBLY
TRANSMISSION
3. Hub 1) Set No. 6 housing assembly
(62) in tool A.
2) Install hub (58).
4. No. 6 clutch
discs,
plates,
springs
Install dis‘cs (60). plates (61) and springs (59).
5. No. 5 carrier
assembly 1) Align with dowel pin, and install No. 5 carrier assembly (57).
2) Tighten w *
When
mounting
bolts.
Mounting
bolt:
assembling
SEMBLY
11 .O+ 1 kgm
the planet
OF NO. 2,3,4
gear,
CARRIER
see AS-
for details.
6. No. 5 sun gear 1) Install sun gear (56). 2) Install snap ring (55).
WA350-1
23-53 0
DISASSEMBLY
7. No. 4,5 Align
AND
housing
TRANSMISSION
ASSEMBLY
assembly
No. 5 clutch
ring gear with
planet
install No. 4 and 5 housing assembly
gear and
(501.
8. No. 4 sun gear 1) Install snap ring (54). 2) Install No. 4 sun gear (53).
9. No. 4 clutch
ring gear
1) Install plate (49). 2) Install ring gear (48). 3) Install snap ring (47). *
Pull the ring gear to check that the snap ring is correctly
10. No. 4 clutch
fitted.
discs,
Plates.
Springs
Install discs (451, plates (46) and springs (44). *
There
23-54 0
are 3 discs and 2 plates.
WA3561
DISASSEMBLY
AND
ASSEMBLY
TRANSMISSION
11. No. 3 housing I) Install piston (43) in housing. *
For details of assembling SEMBLY
OF NO. 4,5
2) Install housing *
Tap with
the piston, see AS-
HOUSING.
(42).
a copper
stall the dowel
or plastic
hammer
to in-
pin.
12. Spacer I) Install spacer (52) 2) Install snap ring (5 I).
13. No. 2,3,4 Align
carrier
assembly
planet gear with sun gear, then install No. 2,
3 and 4 carrier assembly
14. Bearing, I) Install
(41).
cover bearing
(39)
to carrier
and shaft
at the
same time. 2) Install snap ring (40).
WA350-1
23-55 0
DISASSEMBLY
AND
TRANSMISSION
ASSEMBLY
3) Install cover (38). then install snap ring (37)
15. No. 3 clutch discs, plates, springs Install discs (34), plates (35) and springs (33). * There are 3 discs and 2 plates.
16. No. 2 housing 1) Install piston (3 1) in housing. *
For details of assembling SEMBLY
2) Assemble
OF NO. 4,5
the piston, see AS-
HOUSING.
sleeve inside housing.
3) Install housing (30). +
Tap with
a copper
stall the dowel
or plastic
hammer
to in-
internal
teeth
pin.
17. No. 2 clutch ring gear Install ring gear (28). t
Install
with
the
side
with
no
facing up.
23-56 0
WA350-1
DISASSEMBLY
18.
No. 2 clutch
AND
TRANSMISSION
ASSEMBLY
discs, plates, springs
Install discs (221, plates (23) and springs (2 I). k
There are 4 discs and 3 plates.
19. No. 1 housing
1) Install piston (24) in housing. *
For details of assembling SEMBLY
OF NO. 4,5
the piston, see AS-
HOUSING.
2) Install housing (20). t
Tap
with
a copper
stall the dowel
20.
No. I,2
carrier
or plastic
hammer
to in-
pin.
ring gear
I) Install plate (27). 2) Install ring gear (26). 3) Install snap ring (25). *
Pull the ring gear to check that it is correctly installed.
21
No. 1 clutch
ring gear
Install ring gear (I 5). *
Install
with
the side with
internal
teeth
facing
up.
WA350-1
23-57 0
DISASSEMBLY
AND
22. No. 1 clutch
discs,
TRANSMISSION
ASSEMBLY
plates
Install discs (I 7) and plates (I 8). t 23.
There are 4 discs and 3 plates.
Guide
pin, spring
Install guide pin (19) and spring (I 6).
24. Input shaft, No. 1 carrier assembly 1) Align meshing of sun gear and teeth,
then
assembly 2) Tighten *
planet
gear
and No. 1 carrier
(14). tie bolts (8).
Do not install in the holes for eye bolts.
m
25.
install input shaft
Tie bolt:
Checking
11 .O+l
operation
kgm
of piston
Using tool B, check operation *
Air pressure:
3 -
+
Piston stroke:
and stroke of piston.
5 kg/cm2
Clutch No.
Stroke
(mm)
No. 1 No. 2 No. 3 No. 4 No. 5 No. 6
26. Clutch
case
1) Using pitch
eye =
bolts
2 mm),
@
(Thread
raise
dia.
transmission
=
16
mm,
assembly
and install to case (12). Sr Align the dowel
pin of the collar with the pin
hole in the case.
23-58 0
WA350-1
DISASSEMBLY
2) Install
AND
housing
ing bolts
(IO)
ASSEMBLY
mounting
bolts
(I I) and mount-
of case.
Both faces
k??k
TRANSMISSION
of housing
mounting
Gasket
27. Transfer
gear, transfer
3) Install m
28.
bolt: (LG-I)
assembly
I) Fit b-ring 2) Align
sealant
on case side.
output then
shaft raise
assembly
2 tie bolts
with
spline
transmission
of transfer
input
(9) and install
to
(7).
(8).
Tie bolt:
1 1 .0&l
kgm
Sleeve Fit O-rings
WA350-1
and install
5 sleeves
(6).
23-59 0
DISASSEMBLY
29. Control
AND
valve
Fit gaskets
ASSEMBLY
TRANSMISSION
assembly
and install
control
valve
assemblies
(5)
and (4). w
Mounting
30. Filter
bolt:
1 kgm
assembly
Fit O-ring
31. Torque
on tube, then
converter align
with
of turbine,
spline
assembly
install filter
assembly
(3).
assembly
Fit O-ring,
23-60 0
6.5+
spline
of transmission then
(2) to transmission
install
torque
assembly
input
shaft
converter (1).
WA350-1
DISASSEMBLY
AND
DISASSEMBLY
ASSEMBLY
OF TRANSFER
TRANSFER
ASSEMBLY
Transfer assembly
423F414
1. Speedometer Remove
gear assembly
speedometer
gear assembly.
2. Cover Remove
WA350-1
cover (2)
23-61 0
DISASSEMBLY
3. Cage
(transfer
Screw *
AND
input)
in forcing
Check
the
TRANSFER
ASSEMBLY
screw
number
and remove and thickness
cage (3). of the shims,
and keep in a safe place. 4. Gear assembly Remove
(transfer
gear assembly
input) (5).
5. Idler gear cage Screw t
in forcing
Check
the
screw
number
and remove and thickness
cage (I 6). of the shims,
and keep in a safe place. 6. Idler gear assembly Remove
idler gear assembly
7. Coupling Remove 8. Cage Screw
(I 8).
(rear) coupling
(21).
(rear) in forcing
9. Coupling
screw
and remove
(front)
1) Remove
bolt (221, then remove
2) Remove
coupling
10. Cage Screw *
cage (26).
holder
(23).
(24).
(front) in forcing
Check
screw
the number
and remove and thickness
cage (27). of the shims,
and keep in a safe place.
23-62 0
WA350-1
DISASSEMBLY
AND
ASSEMBLY
TRANSFER
11. Output shaft Using tool D, remove output shaft (33).
12. Gear, cpllar Remove collar (3 1) and gear (32).
WA350-1
23-63 0
DISASSEMBLY
ASSEMBLY
AND
ASSEMBLY
TRANSFER
OF TRANSFER
ASSEMBLY
14
10
11
t
ToA
*
ToB
t
ToC
12
B
C 423F415
23-64 0
WA350-1
DISASSEMBLY
AND
1. Gear assembly
ASSEMBLY
(transfer
TRANSFER
side)
1) install outer race (13)
(O.D.: 140 mm) on case.
9
2) Install worm gear (9) and pin (8) to gear (I 0).
/
3) Install cover (71, then install snap ring (6).
16
4) Install bearing
(I I) (I.D.: 80 mm) on gear (I 0).
5) Install gear assembly
2. Cage
(transfer
(5).
side)
1) Install outer race (4) (O.D.: 140 2) Install
shims
which
were
mm) to cage (3).
removed,
fit O-ring
and install cage (3).
3) Rotate
shaft
measure t
with
torque
Preload of bearing i) ii)
wrench
Alone:
0.01
Combined
(rotating -
Adjust
with
rotating
torque.
WA350-1
and
0.18
kgm
torque).
0.1 kgm
with idler gear: 0.04
*
@
preload of bearing.
shims
to
obtain
-
the
above
23-65 0
AND
DISASSEMBLY
ASSEMBLY
TRANSFER
3. Idler gear assembly 1) Install outer race (20) (O.D.: 150 mm) on case. (19) (I.D.: 85 mm) on idler gear
2) Install bearing assembly
(18).
3) Install idler gear assembly
(I 8).
4. Idler gear cage
1) Install outer race (17) (I 6). 2) Install
shims
which
(O.D.: were
150
mm) to cage
removed,
fit O-ring
and install cage (16).
3) Rotate
shaft
measure *
(IO)
preload
with
Preload of bearing i)
Combined
torque
wrench
*
23-66 0
Alone:
0.01
Adjust
with
rotating
torque.
and
,.
(rotating torque)
,,, ,.
,,
:
with input shaft: 0.04
ii)
0
of bearing.
-
0.18 kgm
- 0.1 kgm
shims
to
obtain
the
above
WA350-1
DISASSEMBLY
AND
TRANSFER
ASSEMBLY
5. Gear 1) Install outer race (40)
(O.D.: 125
mm) to case.
2) Set gear (32) in position.
.
6. Output
shaft
1) Install
inner
race
(38)
(I.D.: 65
spline
with
gear
(321,
mm)
to shaft
(33). 2) Align
then
install
shaft
(33).
7. Cage
(rear)
1) Install
bearing
(36)
(O.D.:
120
mm)
to cage
(26). 2) Install snap ring (37).
3) Install oil seal (35) *
Be careful
#?I&
(O.D.: 1 10 mm).
not to damage
Lip of oil seal:
or deform
Grease
the seal.
(G2-LI)
4) Install cover (34). &
Mounting
bolt:
Thread
tightener (LT-2)
WA350-1
23-67 0
DISASSEMBLY
AND
ASSEMBLY
TRANSFER
5) Fit O-ring and install cage (26).
8. Collar, bearing 1) Turn over tiansfer 2) Using
hydraulic
mounting
case. jack
0,
hold output
shaft
in
position.
3) Install collar (31).
4) Install bearing (29) (I.D.: 70 mm) 5) Install spacer (30).
6) Install bearing
(29) (I.D.: 70 mm).
7) Install outer race (28) (O.D.: 125 mm).
23-68 Q
WA350-1
DISASSEMBLY
AND
TRANSFER
ASSEMBLY
9. Cage (front) 1) Install oil seal (42) (O.D.: 1 10 mm) to cage (27). It
Be careful
a
not to damage
or deform
the seal.
Grease (GZ-LI)
Lip of oil seal:
2) Fit O-ring and temporarily
install cage (27)
10. Coupling 1) Installcoupling 2) Install
(24). then assemble
holder
(23),
then
install
O-ring
(25).
mounting
bolts
(221. m
Mounting
11. Adjustment, Adjust
bolt:
kgm
3923
cage
the preload of the bearing as follows.
1) Tap cage (27) with a plastic hammer 2) Hold
cage
between t
down
to install.
and measure
clearance
cage and case.
If using careful
It
(27) bolts
to
hold
down
the
cage,
be
and
take
the
not to screw in the cage.
Measure
at
2
or
3
places
3) Select shims of following
value:
average. Measured 4) Fit shim and tighten
value -
(0 -
0.05)
cage (27).
12. Coupling (rear) Install coupling
(21).
t
coupling
Install
the
between
the
couplings
is within 8”.
WA350-1
positions
so of
that the
the front
difference and
rear
23-69
DISASSEMBLY
AND
ASSEMBLY
TRANSFER
13. Cover Fit O-ring
and install
14. Speedometer Install
23-70 0
cover
(2).
gear assembly
speedoineter
gear assembly.
WA350-1
DISASSEMBLY
AND
REMOVAL
A
Stop
OF TRANSMISSION
the machine
the safety parking
wheels
and stop the engine. brake
and
the oil filler
pressure
put
the remaining
Hydraulic
levers
Then apply under
the
from moving.
cap slowly
pressure
and install the bucket
blocks
inside the hydraulic
ate the control
For
Lower
to prevent the machine
Loosen
Remove
on level ground
bar on the frame.
to the ground the
TRANSMISSION
ASSEMBLY
to release
tank.
several
Then
times
the
oper-
to release
in the hydraulic
piping.
tank hydraulic
details,
see
tank. 63
REMOVAL
OF HYDRAULIC
TANK. Transmission I) Remove
control tube
(2)
valve between
hydraulic
tank
and
pump (I 1.
2) Disconnect
connector
of wiring
valve, then disconnect
3) Remove
mounting
(3) for solenoid
wiring at top of valve.
bolts
(5)
of
transmission
control valve (4). then lift off valve. *
When
removing,
or deform
Transmission
23-72 0
the careful
the thread
not to damage
of the connector control valve:
case.
53 kg
CONTROL
VALVE
CONTROL
VALVE
DISASSEMBLY
AND
INSTALLATION 1. Transmission 1) Raise
OF TRANSMISSION
control
CONTROL
CONTROL
VALVE
VALVE
valve
transmission
mounting
TRANSMISSION
ASSEMBLY
control
position,
valve
then tighten
(4).
set
mounting
in
bolts
(5). t
To prevent
the valve from
the mounting
twisting,
bolts in diametrically
tighten opposite
positions. *
Repeat this procedure
two or three times.
Fit the O-ring
in the groove.
2) Connect valve,
securely
connector
then
secure
of wiring wiring
(3) for solenoid
at top of valve with
clamp. *
Be careful
not to mistake
the direction
of the
connector.
3) Install
tube
(2)
between
hydraulic
tank
and
pump (I 1.
2. Hydraulic
tank
Install hydraulic For details,
tank.
see 63
INSTALLATION
OF HYDRAU-
LIC TANK.
WA350-1
23-73 0
OF LOWER
DISASSEMBLY
TRANSMISSION
ASSEMBLY
AND
DISASSEMBLY
CONTROL
VALVE
VALVE (1).
1. Remove
solenoid valve assembly
2. Remove
stopper
3. Remove
valves (5) and (6). and shim (7).
4. Remove
spring
(2), spring (3) and valve (41. (81, then
(91, valves
shim
remove
(1 I), (12) and (I 31, and spring (I 4) as a set. 5. Remove
covers (I 5) and (I 6).
6. Remove
stopper
7. Remove
valve (I 7).
8. Remove
spring (I 8) and valve (19).
9. Remove
plug
(2). spring (3) and valve (4).
(201,
then
remove
collar
and
(21)
spring (22).
ASSEMBLY 1. Assemble
OF LOWER spring
(22)
VALVE
to collar
(21).
install
body
(231, then fit O-ring and install plug (20). 2. Assemble
spring (I 8) in valve (I 91, then install.
3. Install valve (17). 4. Install valve (4). spring (3) and stopper
(2).
5. Fit gasket and install covers (I 6) and (I 5). 6. Assemble
valve (I I), spring (I 31, valve (121, shim
(9) and spring (8) in valve (I 0). then install in body. 7. Assemble
shim (7) in valve (61, then install in body.
8. Install valve (5). 9. Install valve (41, spring (3) and stepper(2). 10.
Fit gasket and install solenoid valve assembly
23-74 0
(1).
WA350-1
DISASSEMBLY
AND
TRANSMISSION
ASSEMBLY
CONTROL
VALVE
__
7
0
21 P
20 423F421
WA350-1
23-75 0
TRANSMISSION
ASSEMBLY
AND
DISASSEMBLY
CONTROL
VALVE
OF UPPER VALVE
DISASSEMBLY 1. Remove
covers (I
2. Remove
guide
) and (2). spring
remove
(3). then
(4). shim
(51, valves (6), (7) and (91, and spring (8) as a set. (IO),
valves
3. Remove
and
spring
quick
return
(131,
and
(I 2)
(I I). (14).
stopper
4. Remove
then
remove
valve (I 5). 5. Remove
spacer (I 6).
6. Remove
snap ring (17). then remove
(22) and (24). 8. Remove
ring
snap
7. Remove
(I 91, shim
guide (I 8).
(201,
valves
(21).
and spring (23) as a set.
cover (25).
valve (261, shim (271, and spr-
ings (28) and (29) as a set. 9. Remove
cover (30).
10. Remove plug (3 I), then remove spacer (32).
ASSEMBLY 1. Assemble
OF UPPER (32)
spacer
VALVE
in body (331, fit O-ring
and
install plug (3 I). 2. Install cover (30). 3. Assemble valve
shim (27).
(28)
and springs
(261, then assemble
and (29)
in body, fit O-ring
in
and
install cover (25). 4. Assemble (20)
(22)
valves
and spring
(19)
and (24).
spring
in valve (21).
(23).
shim
then assemble
in body (33). 5. install guide (I 81, then install snap ring (I 7). 6. Install spacer (I 6). 7. Assemble
valve (I 5). fit O-ring
and install stopper
(I 4). 8. Assemble
valves
(I 2) and (1 O), and spring (1 1) in
valve (I 3). then install in body (33). valves (9) and (71, spring (8). shim (5) and spring (4) in valve (61, then install guide (3).
9. Assemble
10. Fit gaskets and install covers (2) and (1).
23-76 0
WA350-1
DISASSEMBLY
AND
ASSEMBLY
TRANSMISSION
CONTROL
VALVE
14
% 16
423F422
WA350-1
23-77 0
DISASSEMBLY
AND
REMOVAL
Special
OF FRONT
DIFFERENTIAL
DIFFERENTIAL
tools
Part name
Part number A
793-520-2420
B
793-520-25
Q?
FRONT
ASSEMBLY
Stop
the
10
machine
the safety the
parking
wheels 1. Draining
Bracket
1
Bracket
1
on level ground
bar on the frame.
to the ground
Lower
and stop the engine. brake
to-prevent
Q’ty
and
put
the machine
blocks
and
install
the bucket Then
apply
under
the
from moving.
oil
Remove
drain
plug
(I)
and
drain
oil from
axle
assembly. - :
Axle assembly:
2. Tire,
Approx.
45 L
wheel
I) Using under
lift arm, left
raise front
housing
and
axle, then put
block
put stand @
under
front frame. 2) Sling left tire and wheel
(2). remove
mounting
bolts, then lift off.
4kg
Tire, wheel:
310
kg
,,, ,,,,\,,,,, ,,
,,,,,,,,,,
3. Covers Remove
23-78 0
left and right covers (3).
WA350-1
DISASSEMBLY
AND
FRONT
ASSEMBLY
DIFFERENTIAL
4. Axle shaft Using
forcing
screw,
pull out axle shaft
sun gear (5) about 200
5. Drive
(4) and
mm.
shaft
1) Disconnect
grease tube (6).
2) Disconnect
front
drive
shaft
(7) at differential
and at center. 3) Remove
flange
bearing
drive shaft towards
6. Parking
(81, then
move
front
rear frame.
brake
1) Release
parking
brake,
then
disconnect
lever
(9) of linkage. 2) Remove
parking brake caliper (I 0).
7. Hydraulic piping Remove
lift cylinder
tube (1 1) from
on left and right of front inside
front
frame,
then
frame, move
brackets
(I 2)
and bracket
(13)
it towards
rear
frame.
WA350- 1
23-79 0
FRONT
ASSEMBLY
AND
DISASSEMBLY
DIFFERENTIAL
8. Differential 1) Remove
bolts of differential
2 mounting
Screw
t
After
the thread of the guide bolts in fully. in the guide bolts, remove screwing
(14)
forcing
bolts.
mounting
the remaining
to differential
2) Fit lifting tool @
3) Install
(14),
14 mm,
= 50 mm).
pitch = 2 mm, length *
dia =
bolts (Thread
then install guide
and
screw,
case (I 5).
pull out differential 20 mm from
along guide bolts about
axle
housing (I 6). *
not
Be careful
differential
the
to damage
O-ring. 4) Install tools A and B to garage jack, then insert and and axle housing, differential between install tool A to differential.
5) Adjust
el kg
6) Operate
of lifting
height
and remove
Differential:
garage
jack
from under machine 7) Remove
t
O-ring
To remove the
axle
differential
23-80 0
tool
and
garage
jack,
(I 4) carefully.
differential
191 kg
and
pull differential
out
body.
(17).
the rear differential, assembly,
then
first remove remove
the
from the axle.
WA350-1
DISASSEMBLY
AND
ASSEMBLY
INSTALLATION
FRONT
OF FRONT
DIFFERENTIAL
DIFFEF SENTIAL
1. Differential I) Install tools A and B to garage jack, then ins tall differential (14) in tool A. 2) Operate
garage
under machine
jack
and
pull
in
differential
body.
3) Install guide bolts (Thread
14 mm, pi tch
dia. =
= 2 mm, length = 50 mm) in axle housing. 4) Fit lifting tool to differential
5) Fit O-ring lifting
to differential,
tool and garage
ferential *
(17)
adjust
jack,
height
and assemble
of dif-
along guide bolts.
Fit the make
case (I 5).
O-ring sure
securely
that
it
is
in the not
groove
caught
and when
installing.
6) When
clearance
between
and differential
(14)
tool A and tighten 7) Remove
guide
mounting
bolts
axle
is about
20
housing mm,
(16)
remove
bolts uniformly.
(I 8) and install mounting
bolts. D
WA350-1
Mounting
bolt:
18.Ok2.0
kgm
23-81 0
DISASSEMBLY
AND
FRONT
ASSEMBLY
DIFFERENTIAL
2. Hydraulic piping Install left
lift cylinder
and
right
tube
of front
(1 I) to brackets frame,
and
(12)
bracket
on (13)
inside front frame.
3. Parking
brake
1) Install parkiing brake caliper (IO). 2) Connect
parking
brake linkage to lever (9), then
apply parking brake.
4. Drive shaft 1) Temporarily 2) Connect
install flange
front
bearing (8).
drive shaft
(7) at differential
and
at center. 3) Connect 4) Tighten
grease tube (6). flange
Sr When
bearing fully.
connecting
contact
surfaces
the drive shaft,
and mesh the pilot correctly m
Mounting
clean the
of the spider and coupling,
bolt:
28.5*3
to install. kgm
5. Axle shaft Push in axle shaft (4) together
23-82 0
with sun gear (5)
WA350-1
DISASSEMBLY
AND
ASSEMBLY
FRONT
DIFFERENTIAL
6. Cover Fit O-rings
(18)
in grooves
of covers
(3) and install
on left and right sides. t
Fit the O-ring
securely
in the groove
make
sure that it is not caught when installir
.
7. Tire,
wheel
1) Raise
tire
and
wheel
(2).
position, then install mounting m
Mounting
2) Remove
8. Refilling Tighten
nut:
48*6
in
mounting
nuts. kgm
stand.
with
oil
level
plug and add oil through
(I 8) and (I 9) to the specified *
set
Set the machine final drive
oil fillers
level.
so that the drain plug of the
is at the bottom
when
refilling
with
oil.
G
Axle assembly:
WA350-1
45 II
23-83 @
AND
DISASSEMBLY
to prevent
wheels
put
and
brake
parking
the engine.
and stop
to the ground the
Lower
bar on the frame.
the safety
the machine
DIFFERENTIAL
DIFFERENTIAL
ground
on level
machine
the
Stop
REAR
OF REAR
REMOVAL
a
ASSEMBLY
install
and
the bucket apply
Then
blocks
under
from
moving.
the
1. Rear axle Remove
rear axle. OF REAR AXLE.
see 23. REMOVAL
For details,
oil
2. Draining
plug
drain
Remove
(1)
drain
and
oil
from
axle
assemblv. -
:
45Q
Axleassembly:
3. Axle
shaft
I) Remove
(2).
cover
forcing
2) Using
screw,
sun gear (4) about
4. Differential Using forcing
pull out axle shaft
(3) and
mm.
assembly screw,
Differential:
23-84 0
200
remove 176
differential
(5).
kg
WA3501
DISASSEMBLY
AND
REAR DIFFERENTIAL
ASSEMBLY
INSTALLATION
OF REAR
DIFFERENTIAL
1 Differential Raise
differential
then tighten *
Check
that
mounting w
(51,
mounting
set
in mounting
position,
bolts.
there
is an
O-ring
fitted
to
the
face of the differential.
Mounting
bolt:
kgm
18*2
.
2. Axle shaft 1) Pushin *
axle shaft (3) together
If the
axle shaft
the differential
cannot
coupling
with sun gear (4). be inserted,
rotate
lightly. Never
try to
force the shaft in.
2) Fit O-ring Sr Check
(6) on cover (2) and install cover. that
mounting t
Make
there
is an O-ring
surface
of the cover.
sure
that
the
O-ring
fitted is not
to the caught
when installing. 3. Rear axle Install rear axle. For
details,
see
23
INSTALLATION
OF
REAR
AXLE.
4. Refilling with oil Tighten
drain plug and add oil through
and (8) to the specified *
Set the machine
oil fillers (7)
level.
so that
the level plug of the
final drive is at the bottom
when
refilling
with
oil. %
/
WA350-1
Axle assembly:
45 Q
23-85 0
DISASSEMBLY
AND
DISASSEMBLY 1. Differential
OF DIFFERENTIAL
gear
1) Remove 2) Loosen
DIFFERENTIAL
ASSEMBLY
ring gear stopper adjustment
bolt.
ring lock bolt, then remove
lock plate (I 1. +
Rotate
the
adjustment
the differential
ring and disconnect
gear from the pinion gear.
3) Remove bearing cap (2). Zr Make
match
marks
on the
left
and
right
bearing caps.
4) Remove
adjustment
ring
(3)
and
bearing
cup
(4).
5) Remove *
differential
The pilot bearing
gear (5) from carrier. will hit the carrier,
SO tilt it
slightly to the right when raising. Differential
23-86 0
gear assembly:
75 kg
WA350-1
DISASSEMBLY
DIFFERENTIAL
ASSEMBLY
AND
2. Case
I) Remove
bearing
2) Remove
case (7).
*
Make
3) Rempve
(6). marks
match
side gear
washer
remove
ring gear
(12).
bearing
2) Remove
mounting
(I 3) and flange
bolts,
then
half (I 4).
over differential
Turn over differential
WA350-1
(91, thrust
half
I) Remove
4. Turning
(81, spider
removing.
gear (I I).
(IO) and pinion
3. Ring gear, flange
before
gear
gear.
23-87 0
AND
DISASSEMBLY
DIFFERENTIAL
ASSEMBLY
5. Pinion gear 1) Loosen mounting *
bolts of yoke (I 5). fitted.
Leave the yoke temporarily
2) Remove
pinion gear (I 7) from
differential
case
(16). *
are
There number
so
installed,
shims
thickness
and
of
the
check
the
shims,
and
keep in safe place.
shaft
6. Pinion
1) Using press, remove 2) Remove
pinion shaft (I 8).
cups (20)
bearing
and (2 I) from
cage
bearing
(23)
(19).
3) Remove
pilot
bearing
(22)
and
from pinion shaft (I 8). *
Do not remove
pilot bearing
(22) and bearing
(23) if not necessary.
423 F424
22
23-88 0
29
20 423F426
19 423 F425
WA3561
DISASSEMBLY
AND
ASSEMBLY
Special
ASSEMBLY
OF DIFFERENTIAL
tool
Part number A
*
DIFFERENTIAL
Part name
1 793-520-2620
If the
pinion
replace
Q’ty
( Plate
or ring
gear
them both together
I 1 are
replaced,
always
as a set. Never mix old
and new parts. Replace the flange
half and the case also as a set.
1. Pinion shaft 1) Press fit pilot bearing (22) on pinion shaft (I 8). 2) Press fit bearing t
Press-fitting
(23) on pinion shaft (I 8). force
for bearing
(23)
and pilot
bearing (22): 5 ton
423F427
3) Press
fit bearing
cups
(20)
and
(21)
on cage
(I 9). t
Press-fitting
force for bearing cap: 5ton
Inside circumference a
outside circumference
of cage, of cup:
Axle oil (See page 01-l 4) Assemble
0)
cage (19) to pinion shaft (I 8) and in-
stall spacer (25).
423F425
2. Adjusting
preload
1) Press fit bearing
WA3561
(24) on pinion shaft (I 8)
23-89 0
DISASSEMBLY
AND
3) If the measurement range,
replace
DIFFERENTIAL
ASSEMBLY
is not within
bearings
(23)
the standard
and
(24).
spacer (25) with new parts and measure 4) Check
the
standard
end
play
range
within the standard *
must
when
measurement
the is
range.
Max. 0.152
End play:
and
again.
also be within
if the
25
mm
23
423F428
3. Pinion gear I) Press
fit
oil
temporarily *
seal
(27)
install coupling
on
cage
(261,
and
(15).
Use a new oil seal.
e
Lip of oil seal:
w
Mounting
Grease (G2-LI)
bolt of coupling: 28.5*3
kgm
423F429
2) Assemble
pinion
(I 6) without
gear
(I 7) in differential
case
fitting shims.
423F430A
23-90 @
WA3561
DISASSEMBLY
AND
ASSEMBLY
3) To adjust the backlash
between
and pinion gear, calculate to
insert
between
DIFFERENTIAL
the bevel gear
the thickness
the
differential
of shim
case
and
cage, then adjust the shim. *
This
calculation
thickness
is to
calculate
the
initial
of the shim. The thickness
shim is adjusted
finally
tion of the tooth
according
contact
of the
to inspec-
between
the bevel
gear and pinion gear. *
If the bearing, replaced,
pinion gear, or bevel gear are
follow
this procedure
to adjust the
shim. i) Install
tool A to differential
measure
distance
case
(I 6), then
“L” from tool A to the end
face of the pinion gear, and calculate sion “c”
from
the center
dimen-
line of the
bevel
gear to the end face of the pinion gear. Calculate as follows. C = L ii) Using
Thickness
dimension
of tool A
A and dimension
6 shown
on the end face of the pinion gear, calculate standard
value “D”. Calculate
D = MDA -
as follows.
MDB F423C1060
= (204 *
Be
+s,
-
careful
to
values correctly t
(101
+c)
calculate
the
+
for the displayed
and
-
values.
The displayed
values for dimension
A and
dimension
are
actual
B
100
times
the
Dimension
value for the dimension. iii) Next,
calculate
above Steps
shim
thickness
i) and ii). Calculate
“T”
from
as follows.
-.
T=D-C *
Select the minimum
number of shims.
MoA Thickness
3 \
of shim (T)
Pinion gear
B
F42301001
F42301002 4)
Assemble
shim
differential
case (I 6).
and install
pinion gear
6
Mounting
bolt:
Adhesive
m
Mounting
bolt:
18&2
WA350-1
(17)
to
(LT-2)
kgm
23-91 8
DISASSEMBLY
AND
ASSEMBLY
DIFFERENTIAL
4. Bevel gear 1) Press fit bearing (I 2) in flange half (14).
.
2) Knock pin (27) into bevel gear (13). 3) Install flange half (14) on bevel gear (13).
4) Tighten mounting bolts. &
Mounting bolt: Adhesive (LT-2)
w
Mounting bolt: 1822
kgm
5. Side gear Install washer (28). then install side gear (8) 6. Pinion gear Assemble pinion gear (1 1) and thrust washer (10) on spider (9).
23-92 @
WA350-1
DISASSEMBLY
AND
ASSEMBLY
DIFFERENTIAL
7. Side gear 1) Assemble side gear (8) and washer (28).
2) Press fit bearing (6) on case (7). 3) Install case (7). * Align the match marks and install. m
Mounting bolt: 18t2
kgm
8. Differential gear 1) Raise gear (51, assemble bearing cup (4) on bearing, then install in case.
2) Align with thread of differential case (I 6) and install adjustment ring (3). 3) Align match marks and install bearing cap (2). Sr Be careful not to damage thread of the cap. w
WA350- 1
Mounting bolt: g4.5? 10.5 kgm (Width across flats: 36 mm)
ASSEMBLY
AND
DISASSEMBLY
9. Adjusting preload of bearing ring with a bar until bevel gear
Turn adjustment
pinion gear, and adjust until there is no
contacts backlash.
the bearing
Rotate
well so that it is properly and tap the
parts,
all other
with
in contact
hammer.
bevel gear with a copper
Coat the bearing well with oil. If
ring
adjustment
the
on
by one turn, tighten
loosened
is
side
one
the ring on the
other side bK one turn.
Install spring balance
to bevel gear and measure
the rolling resistance
torque.
B
Target:
*
torque:
Rolling resistance
1.4 -
2 kg
2 kg
10. Adjusting tooth contact, backlash as follows.
Adjust the backlash
ring to adjust bevel gear.
1) Use adjustment Always
t
adjustment
the
turn
2) Put dial gauge in contact
at both
rings
in the same direction.
ends the same amount
with tooth face at out-
side tip of bevel gear, and turn adjustment
ring
to adjust. Measure
t
at
3
or 4
places,
and
keep
the
pinion gear fixed when measuring. *
Backlash:
0.25
-
0.33
Adjust the tooth contact 1) Mix red lead with teeth
of
pinion
mm
as follows.
oil and coat gear
lightly
face
of 7 or 8
with
red
lead
(miniurn). 2) Rotate
the pinion
gear forward
and inspect the pattern
23-94 @
and backward
left of the teeth.
WA350-1
DISASSEMBLY
11. Adjusting
AND
tooth
ASSEMBLY
DIFFERENTIAL
contact
Coat face of 7 or teeth of bevel pinion lightly with red lead (miniurn). brake, rotate the pinion gear forward
Tooth
contact
and backward
left on the teeth.
Procedure
Cause The tooth contact
Hold the bevel gear by hand to act as a
and inspect the pattern
pattern
Adjust
for adjustment
the pinion gear by adjusting
the shims at
should start from about
the cage. Adjust the bevel gear in the same way as
5 mm from the toe of
when adjusting
backlash.
the bevel gear and cover about 50% of the length of the tooth. It should be in the center of 2OBF514
the tooth height. Bevel pinion gear is too
1. Reduce shims at pinion gear to bring closer
far from bevel gear.
to bevel gear. 2. Move bevel gear further
away from pinion
gear and adjust backlash
2
correctly.
*
? a’ 2OBF519
2OBF515
Bevel pinion gear is too
1. Increase
shims at pinion gear to move away
from bevel gear.
close to bevel gear.
2. Move bevel gear closer to pinion gear and adjust backlash
2
correctly.
c
? J 20BF520
20BF516
Bevel gear is too close to
1. Reduce shims at pinion gear to bring closer
pinion gear.
to bevel gear. 2. Move bevel gear further
away from pinion
gear and adjust backlash
correctly.
1
;a 2OBF519
2OBF517
Bevel gear is too far from
I. Increase
pinion gear.
shims at pinion gear to move away
from bevel gear. 2. Move bevel gear closer to pinion gear and adjust backlash
correctly.
2 c
? d 20BF520
20BF518
*
When
adjusting
the bevel gear, do not change
left and right. Always
WA350-1
the preload
keep the same total thickness
of the bearing. Adjust
by moving shims between
the
of shims.
23-95 0
DISASSEMBLY
12.
AND
DIFFERENTIAL
ASSEMBLY
Lock plate After
adjusting
tooth
contact,
wipe
off
red lead
and install lock plate (I 1.
.
13. Adjustment After
rear face tighten &
bolt
adjusting,
tighten
bolt (29)
l/2
turns and
lock nut (30). Adjustment
bolt: Thread
m
until it contacts
of ring gear, then loosen
Adjustment
bolt:
22.552.5
tightener
(LG-51
kgm
423F431
23-96 Go
WA350-1
DISASSEMBLY
REMOVAL
AND
ASSEMBLY
OF FRONT
FRONT
AXLE
AXLE
Stop the machine on level ground and install the safety bar on the frame. Lower the bucket to the ground and stop the engine. Then apply the parking brake and put blocks under the wheels to prevent the machine from moving.
Put blocks under the rear wheels to prevent the machine from moving, and apply the parking brake securely. Insert block @between frame (2) and the top surface of rear axle housing (I).
Jack up the machine, and put blocks @under front frame on the left and right sides.
the
Tire, wheel Sling left and right wheels (3). remove mounting nuts, then lift off. Tire, wheel: 310 kg
2. Drive shaft Disconnect drive shaft (4) at differential end.
WA350- 1
23-97 0
DISASSEMBLY
AND
FRONT
ASSEMBLY
3. Brake tube Disconnect *
After
brake tube
(5) from
disconnecting
slack adjuster
the piping,
dust or dirt from
cover
(6).
to prevent
entering.
4. Parking brake Release
parkiing
brake,
then
disconnect
from
lever
(7) of linkage.
axle 1) Sling front
5. Front
garage 2) Fit
axle
housing
jack under
garage
other
jack
(8) on one side, and fit side.
under
bottom
of
differential
case. *
Be careful
not
the parking
brake disc.
Sr When
installing
not to crush
3) Remove
under
jack
to
the
lifting
the
side
tool,
face
of
be careful
the brake tube.
mounting
4) Put block garage
to damage
bolts front
(9) of front
axle, then
maintain
axle.
using
balance,
hoist
lower
and front
axle. Front axle: 5) Pull out front
23-98 0
1130
axle assembly
kg from
machine.
WA3561
AXLE
DISASSEMBLY
AND
FRONT
ASSEMBLY
INSTALLATION
OF FRONT
AXLE
AXLE
1. Front axle 1) Pull front axle under machine body. 2) Fit lifting tool to front axle (10). set garage jack under parking brake disc and maintain balance while setting in mounting 3) Install
mounting
position.
bolts
(9)
1052
of front
axle
with
engine oil. m
Mounting
bolt:
6
Founting
bolt: Engine
2. Parking
10 kgm
oil and washer
brake
Release
parking
brake,
then
connect
lever
(7) Of
linkage. A
Apply the parking brake.
3. Brake
tube
Connect t
brake tube (5) to slack adjuster
Wipe the connection
4. Drive
(6).
with a clean cloth.
shaft
Connect
front drive shaft (4) at differential
m
Mounting
WA350-1
bolt:
end.
11.5 f: 1 .O kgm
23-99 0
DISASSEMBLY
AND
FRONT
ASSEMBLY
AXLE
5. Til re, wheel I) Set
left
and
right
wheels
position, then install mounting w
2) Jack
Mounting
up machine,
nut:
(3)
in
mounting
nuts.
48*5
kgm
then remove
block
@
from
under front frame. 3) Remove surface
6. Bleeding
block
0
from
between
frame
and top
of rear axle housing.
air from
brakes
Bleed air from brakes, then check operation. It
For details
of
bleeding
air, see
52
TESTING
AND ADJUSTING.
23-100 Gc
WA350-1
AND
DISASSEMBLY
machine
the
Stop
parking
brake
to prevent
wheels
from
machine
Then
the machine
moving,
the
from moving.
wheels apply
and
apply
under
blocks
put
and
under the front
Put blocks
the bucket
Lower
and stop the engine.
to the ground
install
and
on level ground
bar on the frame.
the safety the
AXLE
OF REAR AXLE
REMOVAL
a
REAR
ASSEMBLY
to prevent the
the
parking
brake securely. Jack frame, Tire, Sling
up the machine,
put block
@under
the rear
and put a stand under the counterweight. wheel left and right wheels
(I),
remove
mounting
nuts, then lift off. Tire, wheel:
6 kg
2. Drive
kg
shaft
Disconnect
3. Brake
310
rear drive shaft (2) from rear axle.
hose
Disconnect
hose (3) between
brake chamber
and
slack adjuster.
WA350-1
23-101 0
DISASSEMBLY
AND
ASSEMBLY
REAR AXLE
4. Grease tubes Disconnect
grease
tubes (4) and (5) from rear axle
support.
5. Engine oil drain valve Remove
bracket
(6) of engine
oil drain valve from
fuel tank (7).
6. Rear axle, 1) Secure
support
assembly
axle support
(8) and rear axle (9) with
chains. *
Fit the chains on the right side where
there is
no grease tube.
2) Sling
rear axle and support
assembly
(IO)
on
one side, and fit garage jack under axle housing. t
When
installing
the
lifting
tool,
be careful
not to crush the brake tube.
23-102 0
WA350-1
DISASSEMBLY
3) Remove then
AND
mounting
using
hoist
ASSEMBLY
bolts and
(1 I)
garage
balance,
lower rear axle.
&
Rear axle, support
REAR AXLE
of axle support, jack
to maintain
assembly:
4) Pull out rear axle and support
1260
assembly
kg
from
machine.
7. Rear axle 1) Remove front support (I 2) from rear axle (9). *
Be careful not to damage Front support:
the O-ring.
61 kg
2) Remove retainer (I 3) from front support. 3) Remove 4) Remove
O-ring O-rings
(14) from retainer. (15)
and
(161,
and
bushing
(17) from front support.
423F432
WA350-1
23-103 0
DISASSEMBLY
AND
ASSEMBLY
REAR AXLE
5) Raise rear support (I 8) and remove cover (19) Rear support:
83 kg
6) Remove thrust washer (20), thrust plate (21) and thrust‘ washer (22) from rear axle. 7) Remove rear support (18). 8) Remove O-ring (23) and bushing (24) from rear support.
423F433
23-104 0
WA350-1
DISASSEMBLY
AND
REAR
ASSEMBLY
INSTALLATION
AXLE
OF REAR AXLE
1. Rear axle 1) Install bushing
(24) and O-ring
(23) on rear sup-
port (18). Zr Assemble
the
bushing
with
the
chamfered
edge on the axle housing side. Zr Fit the make
O-ring sure
securely that
it
in the
is
not
groove,
caught
and when
installing. t
Check
that the O-ring
is on the axle housing
side_.
2) Raise rear support,
and set in position
on rear
axle mount. 3) Install thrust
washer
thrust washer
(22).
thrust
plate (21)
and
and
O-ring
(I 6) on front
(20).
4) Install cover (I 9).
5) Install
bushing
support
(17)
(I 2).
Sr Assemble
the
bushing
with
the chamfered
edge on the axle housing side. 6) Assemble
O-rings
(14)
and
(15)
on
retainer
(I 3). 7) Install retainer on front support. t
Fit the make
O-ring sure
securely that
it
is
in the not
groove,
caught
and when
installing.
423F432
8) Raise front
support
13
17
12
16
(I 2) and insert on rear axle
mount. *
Be careful
not to damage
the seal with
the
coupling.
WA350-1
23- 105 Q
DISASSEMBLY
AND
REAR AXLE
ASSEMBLY
2. Rear axle, support assembly 1) Secure rear axle (9) and axle support
(8) with
chains. Sr Fit the chains on the right side where
there is
no grease tube.
2) Raise rear axle and support
assembly
(IO)
on
one side, ahd fit garage jack under axle housing. Sr When
installing
the
lifting
tool,
be careful
not to crush the brake tube.
3) Pull rear axle and support
assembly
(IO)
under
machine. 4) Using
hoist
balance,
set
mounting *
and
garage
in mounting
Tighten Coat
to
maintain and
install
bolts of axle support. the mounting
port on opposite *
jack position,
engine
washers,
bolts of the front sup-
sides in turn.
oil on the
mounting
bolts
and
then tighten.
&
Bolt and washer:
m
Mounting
bolt:
Engine oil 105*
10 kgm
3. Engine oil drain valve Install bracket
(6) of engine
oil drain valve to fuel
tank (7).
23-106 @
WA35071
DISASSEMBLY
4. Grease
AND
ASSEMBLY
REAR
AXLE
tubes
Connect
grease
tubes
(4)
and
(5)
to
rear
axle
support.
5. Brake
hose
Install hose (3) between
brake chamber
and slack
adjuster.
6. Drive
shaft
Connect Sr When tact
rear drive shaft (2) at rear axle end. connecting the drive shaft, wipe the consurface of the spider and coupling, and
mesh the pilot correctly w
Mounting
7. Tire,
bolt:
when installing.
11.5f
1 .O kgm
wheel
1) Set left and right position, then tighten w
Mounting
2) Remove stand
machine
WA350-1
block
from
@
under
wheels mounting
nut: from
4825 under
(I)
in
mounting
nuts. kgm rear frame,
counterweight,
then
and lower
to ground.
23-107 @
DISASSEMBLY
8. Bleeding
AND
air from
ASSEMBLY
REAR
AXLE
brakes
Bleed air from brakes, then check operation. * For details of bleeding air, see 52 TESTING AND ADJUSTING.
23-108 0
WA350- 1
DISASSEMBLY
AND
DISASSEMBLY
ASSEMBLY
OF DRIVE
DRIVE
SHAFT
SHAFT
1. Front drive shaft 1) Remove coupling and tube (I). * Make match marks “a” before removing so that the direction of the coupling does not change.
2) Loosen bolt (21, then remove coupling (3) and retain&-. * Make match marks before removing so that direction of the coupling does not change.
3) Using a press, remove flange bearing (4).
2. Center drive shaft, rear drive shaft * Follow the procedure in 1. Front drive shaft Step I).
WA350-1
23-109 0
DISASSEMBLY
AND
DRIVE
ASSEMBLY
SHAFT
3. Spider, bearing I) Remove seal and bearing caps (5).
.
2) Remove ring (7) of spider (6) and bearing, then tap with plastic hammer to remove spider and bearing. *
Repeat
the
same
procedure
for
the
front,
center and rear drive shafts.
423 F434
23-110 0
WA350-1
DISASSEMBLY
AND
ASSEMBLY
ASSEMBLY
DRIVE
OF DRIVE
SHAFT
1. Spider, bearing 1) Set spider (6) and bearing in mounting assemble *
SHAFT
position,
ring (7). then install.
Assemble
so that the grease
nipples face in
the same direction. *
Repeat
the
same
procedure
for
the
front,
center and rear drive shafts.
423F434
2) Install seal and bearing cap (5). *
Check
that
washer
inside the bearing cap.
6 *
there
is a bearing
Derling
Grease (G2-LI)
Bearing cap: If the spider
and
and bearing
cap are worn,
re-
place the spider and bearing. *
Heat will damage
the bearing,
so do not weld
strap (8) of the cap.
2. Front drive
shaft
I) Press fit flange bearing
(4).
Zr Do not hit the flange
bearing
directly
with a
hammer.
2) Align
match
marks,
install coupling
tainer (9). then tighten *
Tighten
mounting
(3) and re-
bolt (2).
the bolts to the specified
tightening
torque after installing on the machine. e::
Spline:
B
Mounting
WA350- 1
Grease bolt:
(G2-LI) 94.5&l
0.5 kgm
23-l 11 @
DISASSEMBLY
3) Align
AND
match
DRIVE
ASSEMBLY
marks
and
install
the
couplings
coupling
SHAFT
and
tube (1). *
Check
that
are facing
in the
same direction. *
If the spline is worn,
replace
the whole
drive
shaft assembly. /ic1,
Spline:
Grease (G2-LI)
3. Center drive shaft, rear drive shaft
*
Follow Step
23-112 0
the- procedure
in 2. Front drive
shaft
I) to 3).
WA350-1
DISASSEMBLY
AND
DISASSEMBLY
a
ASSEMBLY
OF FINAL
FINAL
DRIVE
DRIVE
Stop the machine on level ground and install the safety bar on the frame. Lower the bucket to the ground and stop the engine. Then apply the parking brake and put blocks under the wheels to prevent the machine from moving.
Special tool Part number A
793-520-2320
Part name Fixture
IQ’V 1
1. Tire, wheel Jack up axle, insert stand under axle, then lift off tire and wheel (I I. * After removing the tire and wheel, put a stand under the axle. Tire, wheel:
310 kg
2. Draining oil Remove drain plug (2) and drain oil from axle assembly. * Set the drain plug at the bottom. , Axle assembly: 45 II &
3. Cover Remove cover (3). then remove O-ring (4)
WA350-1
23-113 0
DISASSEMBLY
AND
ASSEMBLY
4. Axle shaft assembly Remove axle shaft assembly
FINAL
(5) from
DRIVE
axle.
5. Planet carrier assembly Remove carrier
3 mounting assembly
Sr Make
bolts
(61, then
lift off
planet
as a guide
when
(7).
match
marks
to
act
installing. Zr Be careful
of the
center
of gravity,
and lower
slowly. Planet
carrier
68 kg
assembly:
6. Ring gear assembly 1) Using
tool
sembly Sr Install
A, hold
remove t
There
as-
mounting are
bolts
shims
of retainer
ness
of
shims,
installing.
the
(IO).
then
retainer
and
(I I).
between
when
sides, and
clearance.
ring gear assembly so check
23-114 0
on opposite
to adjust
axle housing,
kg tIYz?z
hub (8) and brake
tool A to points
use washers
2) Remove
wheel
(9) in position.
the
the number and
Ring gear assembly:
use
for
and thickreference
29 kg
WA350-1
DISASSEMBLY
AND
7. Disassembly I) Using
FINAL
ASSEMBLY
DRIVE
of planet carrier
a press,
pull out shaft
(12)
and remove
pinion gear (I 3). *
There
is a lock ball (14)
careful Sr Write
a number
removed
2) Remove spacer
on the shaft,
so be
not to lose the ball. on the case and keep all the
parts separately
bearing
in sets.
cups (I 5) and (I 6). cone (I 71,
(18) and snap ring (19) from pinion gear
(I 3). Sr The bearings together,
and other
parts have settled
in
so mark the parts and keep them in
sets.
8. Disassembly I) Remove
of ring gear lock
plates
(201, then remove
2) Screw mm,
in forcing pitch
=
(21)
screws
1.75, length
gear hub (20). and remove
WA350-1
from
ring gear
hub
ring gear (22).
(Thread 70
mm)
dia.
=
from
12 ring
bearing (23).
23-115 0
DISASSEMBLY
AND
ASSEMBLY
FINAL
ASSEMBLY
OF FINAL
DRIVE
DRIVE
Special tool Part name
Part number A
793-520-2320
Q’ty
Fixture
2
1. Assembly of ring gear 1) Press fit bearing (23) on ring gear hub (20). t
After
press
there
is no clearance
fitting
the
bearing,
check
between
the
that
rib and
bearing. 2) Set ring gear hub (20)
on ring gear
(22),
then
install lock plates (2 1). t
Install the lock plates with the wider ones on the inside.
Sr Remove fil,
all grease and oil from the bolt.
Hub mounting
bolt:
Thread tightener (LT-2)
2. Assembly
of planet carrier
I) Install snap ring (19)
and spacer
(18)
gear (I 3), then press fit bearing
on pinion
cups (I 5) and
(16). *
Do not raise the bearing
cups
too
press-fitting
force
for the
high as this will damage
the snap ring. *
Press fit bearing cup (I 5) first.
6
Inside
circumference
portion of bearing cup:
of
press-fitting
Oil (SAESO) 15/
2) Assemble (I 31, then
bearing
cone
using lifting
(17)
bar 0,
on
pinion
423F436
gear
set in position
on carrier mount. +
insert all three pinion gears in the carrier.
/
23-116 0
423F437
WA350-1
DISASSEMBLY
3) Align
AND
holes
ASSEMBLY
of carrier
FINAL
and gear,
then
DRIVE
press fit
cooled shaft (12). Q
?
Do not touch the cooled shaft directly t
by hand. Press fit so that the hole for the lock ball is
t
on the outside circumference, then stop with the hole at the front and align the holes. Cool the shaft at - 30°C for 20 minutes.
4) Assemble
lock ball (I 4) on shaft, then press fit
shaft again. *
After
press fitting
gear rotates
the shaft,
check
that the
smoothly.
423F438
3. Ring gear assembly
1) Raise ring gear assembly
(I I),
set in mounting
position, and insert in axle housing. *
Align
the
assembly
2) Tighten
retainer
then remove
*
spline
Remove
(IO)
Do
*
not
Rotate
temporarily
all grease
shims
the wheel
3) Insert a depth of
retainer
“a” between
with
3 bolts,
in the
retainer
when
temporarily.
Mounting
hole
the
and oil from the bolt hole
hub to settle
then tighten to a uniform m
insert
mount.
insert
tightening
and
tool A.
of the retainer *
groove
slowly.
the bearing,
torque. 3.0 kgm
bolt of retainer:
micrometer (I 0).
and
through
measuring
measure
clearance
end face of housing
and end face
of retainer. *
Measure
WA350-1
at 2 places and take the average.
23-117
DISASSEMBLY
AND
FINAL
ASSEMBLY
DRIVE
4) Shim thickness is clearance “a” + 0.2 mm. * Use the smallest number of shims which gives the required thickness. Be careful that the total shim thickness is no less than “a” + 0.2 mm. 1 .O mm, 0.3 mm, 0.2 mm * Shim thickness:
5) Install tool A to brake assemblv and wheel hub, (IO). Install required retainer and remove thickness of shims, then install retainer (IO) again. * Always install tool A before assembling the shims. the hub and tighten * Rotate the wheel bolts uniformly to the specified mounting tightening torque. a
Mounting
bolt: Thread tightener
m
Mounting
bolt:
11.5+
(LT-2)
1 .O kgm
4. Planet carrier Fit O-ring (24) to wheel hub (81, raise planet carrier (71, set in mounting position, then install. * Align mounting holes and install carefully so that the O-ring does not slip out of place.
5. Axle shaft Install axle shaft (5). * If the position of the sun gear does not match, rotate the wheel hub to align.
23-118 0
WA350-1
DISASSEMBLY
AND
FINAL
ASSEMBLY
DRIVE
6. Cover Fit O-ring
(4) in groove
in cover, then install cover
(3). @El
Mounting
bolt:
7.OkO.5
kgm
7. Refilling with oil Tighten
drain
plug and add oil through
(25) to the specified
level.
*
so that
Set the machine
level plug
the level plug of the
final drive is at the bottom
when
refilling
with
Oil. Q
8. Tire,
Axle assembly:
45 Q
wheel
Install tire and wheel m
WA350-1
Mounting
(I 1, then remove
nut:
48k5
stand.
kgm
23-119 @
POWER TRAIN ti
MAINTENANCE
STANDARD
Transmission
and engine
Torque
converter
Torque
converter
TORQFLOW
mount
charging
transmission
.
I. Transmission 2. Transmission 3. Solenoid Transfer
control
. .
Differential Final drive Axle
WA350-1
mount
. .
2 3
24-
4
24-
6
.
24-
6
24-
8
24-l
2
. .. ... .
.
2424-
. valve
valve
Drive shaft
pump
. .
24-14 24-16 24-l
8
24-19
.,.
.
24-20
24- 1
MAINTENANCE
TRANSMISSION
STANDARD
TRANSMISSION
AND
ENGINE
AND
ENGINE
MOUNT
MOUNT
h
h
/
423F205
View Z
Unit: Criteria
Check item
No.
1
Clearance between transmission bracket and adjustment bolt
2
Tightening torque of mounting bolt
3
Tightening torque of bracket mounting bolt
11.5?1.0kgm
4
Tightening torque of bracket mounting bolt
18.02
5
Tightening torque of mounting bolt
6
Tightening bolt
2i2
torque of clearance adjustment
Adjust
l-2
94.5&
94.52
Remedy
10.5 kgm
2.0 kgm
Retighten
10.5 kgm
28.0 ‘_ 3.0 kgm
WA350-1
mm
MAINTENANCE
TORQUE .
Model
STANDARD
CONVERTER
TORQUE
CHARGING
CONVERTER
CHARGING
PUMP
PUMP
SAL (3) -56
Section
A-A \
2/ 423F206
Unit:
Standard clearance
mm
Clearance limit
Clearance between gear case and side plate,
0.06 - 0.15
0.9510.25
Oil: EOl O-CD Temperature: 45 -
WA350-1
kgm
55°C
24-3
MAINTENANCE
TORQUE
STANDARD
TORQUE
CONVERTER
CONVERTER
5
10
12 \
24-4
WA350-1
MAINTENANCE
TORQUE
STANDARD
CONVERTER
Unit:
mm
Standard size
Width and thickness
of seal ring
0.192
-
0.485
6.8 ir 0.7 kgm
7
Tightening
torque of bolt
8
Tightening
torque of bolt
3.2t
9
Tightening
torque of bolt
3.220.3
kgm
10
Tightening
torque of bolt
6.8i0.7
kgm
11
Tightening
torque of bolt
6.8t0.7
kgm
12
Tightening
torque of bolt
13
Tightening
torque of bolt
WA350-1
I
I
0.3 kgm
Retighten
11.3?1.2kgm
6.820.7
kgm
24-5
MAINTENANCE
STANDARD
TORQFLOW 1.
TORQFLOW
TRANSMISSION
TRANSMISSION
TRANSMISSION
423F208
Unit: Check item
No.
Criteria
1
Backlash between No.1 sun gear and planet gear
0.13 -
2
Backlash between No.1 planet gear and ring gear
0.12 - 0.33
3
Backlash between No.2 sun gear and planet gear
0.1 1 -
0.28
4
Backlash between No.2 planet gear and ring gear
0.12 -
0.32
5
Backlash between No.3 sun gear and planet gear
0.1 1 -
0.28
24-6
Remedy
0.33
Replace
WA350-1
mm
MAINTENANCE
TORQFLOW
STANDARD
TRANSMISSION
Unit: No.
6
Backlash between No.3 planet gear and ring gear
0.12 - 0.33
7
Backlash between No.4 sun gear and planet gear
0.11 -
0.28
8
Backlash between No.4 planet gear and ring gear
0.12 -
0.32
9
Backlash between No.5 sun gear and planet gear
0.16 - 0.25
Backlash between No.5 planet gear and ring gear
0.12 -
10
0.32
Repair limit
Standard size
11
Remedy
Criteria
Check item
mm
Installation load
Installation load
Free length
Installation length
Free length
59
46.8
12.2 kg
57
10.2 kg
59
48.8
10.2 kg
57.5
8.3 kg
41.5
31.8
15.5 kg
40
13.1 kg
No.1 clutch springs
12
No.2 clutch springs
13
No.6 clutch springs
14
No.3 and No.4 clutch spring
51.8
40.8
11.7 kg
50
9.8 kg
15
No.5 clutch spring
38.4
31.3
IOkg
37.5
8.7 kg
I
Reolace Repair limit
Standard size
35 +0.26
16
Thickness of assembled for No.1 clutch
4 discs and 3 plates
I?
Thickness of assembled 4 discs and 3 plates for No.2 clutch
+0.26 35 -0.26
31.1
18
Thickness of assembled 3 discs and 2 plates for No.3 and No.4 clutches
25+o.22
22.2
19
Thickness of assembled for No.5 clutch
2 discs and 1 plate
,5+o.17 -0.17
13.3
20
Thickness of assembled for No.6 clutch
3 discs and 2 plates
26 f0.22 -0.22
22.2
21
Thickness
of 1 disc
5+0.1 -0.1
4.4
22
Thickness
of 1 plate
6+0.1 -0.1
4.5
23
Outside diameter of input shaft bearing
24
Outside diameter of output shaft bearing
72+o.ol 3 -0.006
72.018
25
Outside diameter of output shaft bearing
g5+0.016 - 0.006
95.022
26
Wear of seal ring for input shaft
I
-0.26
-0.22
75+o.013 - 0.006
I
Width Thickness
27
Wear of seal ring for output shaft
Width Thickness
WA350-1
I
I
31.1
75.018
3$8$
2.6
2.1 r$:
1.8
3-o.01 -0.03 2.1 $:I
2.6 1.8
24-7 0
MAINTENANCE
2.
TRANSMISSION .
UPPER
TORQFLOW
STANDARD
CONTROL
TRANSMISSION
VALVE
VALVE
_------lo
-5
\
i2
24-8
2
423F210
WA350-1
MAINTENANCE
STANDARD
TORQFLOW
TRANSMISSION
Unit: No.
1
Check item
Criteria
mm
Remedy
Clearance between torque converter valve spool and body
I
25
- 0.045 -0.035
+0.013 0
0.035 0.058-
0.08
2
Clearance between priority valve spool and body
25
-0.035 -0.045
+0.013 0
0.035 0.058
0.08
3
Clearance between quick return valve spool and body
12
- 0.035 -0.045
+0.011 0
0.035 0.056
0.08
4
Clearance between modulating and body
25
- 0.035 -0.045
+0.013 0
0.035 0.058
0.08
-
valve spool
Replace Repair limit
Standard size
5
Priority valve spring
Free length
Installation length
Installation load
Free length
Installation load
62
37.7
22.1 kg
59.6
19.9 kg
6
Torque converter
relief valve spring
62
48
12.8 kg
60.6
11.5 kg
7
To;zx
relief valve spring
26
19
0.58 kg
25.3
0.52 kg
118
106.5
22.5 kg
117
20.5 kg
145.7
141.5
4.14 kg
145.3
3.7 kg
converter
W&lating
valve spring
9
Mc&$ting
valve spring
10
Thickness
of shim for accumulator
11
Thickness
of shim for modulation
12
Thickness
13
8
1 mm (pressure per 1 piece:
0.19 kg/cm21
4 mm (pressure per 1 piece:
0.55 kg/cm2)
of shim for priority valve
2 mm (pressure per 1 piece:
0.26 kg/cm?
Thickness
of shim for torque converter valve
2 mm (pressure per 1 piece:
0.26 kg/cm*)
Tightening
torque of modulation
valve
Adjust
-
WA350- 1
locknut
4.3 * 0.7 kgm
Retig hten
24-9 0
MAINTENANCE
.
LOWER
STANDARD
TORQFLOW
TRANSMISSION
VALVE
8
9
4
5
8
8
8
8
1
13
7
24-10
423F211
WA350-1
MAINTENANCE
STANDARD
TORQFLOW
TRANSMISSION
Unit:
mm
C
No.
Check item
Criteria
Remedy
Tolerance Clearance between FORWARD-REVERSE spool and body
Standard size Shaft
Standard clearance
Clearance limit
Hole
22
-0.035 - 0.045
+0.013 0
0.035 0.058
0.08
1st speed spool and body
22
-0.035 -0.045
+0.013 0
0.035 0.058
0.08
3
Clearance between 2nd speed spool and body
22
-0.035 -0.045
+0.013 0
0.035 0.058
0.08
4
Clearance between 3rd speed spool and body
22
- 0.035 - 0.045
+0.013 0
0.035 0.058
0.08
5
Clearance between 4th speed spool and body
22
-0.035 -0.045
+0.013 0
0.035 0.058
0.08
6
Clearance between and body
22
-0.035 -0.045
+0.013 0
0.035 0.058
0.08
7
Clearance between lubrication and body
Clearance between
-
pilot reducing valve
valve plunger
22
-0.035 -0.045 /
I
I
Standard size
8
FORWARD-REVERSE, No.1, No.2, No.3 and No.4 speed spring
0.035 0.058
+0.013 0
Replace
0.08 I
Repair limit
Free length
Installation length
78
48
10.5 kg
75
9.5 kg
162
125.6
40 kg
158
36 kg
Installation load
Free length
Installation load
Reolace 9
Accumulator
10
F”o;;;ducing ”
valve spring
62
43.7
16.7 kg
60.1
15kg
11
F?l$educing
valve spring
26
19
0.58 kg
25.3
0.52 kg
12
Lubrication
39.4
37
6.2 kg
39.2
5.6 kg
13
Thickness
spring
-
WA350-1
valve spring
of shim for pilot reducing valve
3 mm (pressure per 1 piece:
0.26 kg/cm’)
Adjust
24-11 @
MAINTENANCE
STANDARD
3.
VALVE
SOLENOID
TORQFLOW
TRANSMISSION
Section A-A
423F212A
No.
Remedy
Criteria
Check item Tightening
torque of solenoid valve mounting
0.17 f
0.01 kgm
2
Tightening screw
torque of solenoid valve terminal
0.17 t
0.01 kgm
6
Tightening screw
torque of solenoid valve terminal
0.075
f
0.005
kgm
4
Tightening torque of solenoid valve connector mounting screw
0.07 % 0.01 kgm
6
Tightening screw
0.07 2 0.01 kgm
6
Tightening torque of solenoid valve ass’y mounting bolt
torque of terminal mounting
6.7 t
Retighten
0.7 kgm
WA350-1
MAINTENANCE
STANDARD
TRANSFER
TRANSFER
i
24-14
423F209
WA350-1
MAINTENANCE
STANDARD
TRANSFER
Unit:
mm
No.
Check item
1
311seal sliding surface of output shaft coupling [Rear)
Criteria
Remedy
-
85
2
3
~;ss;l
sliding surface of output shaft coupling
Sta$wd
I
140
84.82
-:.087
a5
1
Repair limit
Tolerance
Standard size
-
I 1
g.087
shafolerrHo,e
I 1
S$ann;;;
84.82
I
1 Cle;;;ce
1
Clearance between Input shaft bearing and housing
I
4
Clearance between idler shaft, beanng and housina
5
Clearance between output shaft, bearing and housing (Rear)
6
I
-:.015
150
0
-00.035
-00.035
I
I
I
0
-:.018
-:.035
- g.035
125
-oO.oTa
-00.035
-EC35
Clearance between output shaft and bearing
70
+0.051 - 0.032
-:.015
0.032 0.066
7
Clearance between output shaft and bearing
65
+0.039 -0.020
Jo13
0.020 0.052
-0.02
8
;;Z;;,“nce
between
85
i-0.023 +0.045
-:.020
0.023 0.065 -
-0.02
;l;;wrvce
between idler shaft and beanng
a5
f0.045 +0.023
-:.020
0.023 0.065
-0.02
-
I
1 Replace
I
0
0
Idler shaft and bearing
9
Standard 10
Repalr limit
size
Clearance between input cover and case Preload 0.01 -
2
0.1 kgm Adjust
11
llearance
12
Clearance between Idler cover and case
13 -
3acklash of input gear
0.1 a
-
14
Backlash of output gear
0.21
- 0.52
between output cover and case
2
Less than 2.05
Preload 0.01 -
2
0.1 kgm
0.49 Replace
15
Tightening
WA350-1
torque of coupling mounting
bolt
38.5k3.5
kgm
Retighten
24-15
MAINTENANCE
DIFFERENTIAL
STANDARD
DIFFERENTIAL
15
423F214A Unit: Criteria
Check item
No.
Remedy
Tolerance Standard size
1
Clearance of side bearing of differential gear assembly
Standard clearance
Clearance limit
Shaft
Hole
Outer race 150
0 -0.018
+0.054 +0.014
0.014 0.072
-
Inner race 100
+0.073 +0.051
-:.020
-0.051 -0.093
-
Outer race 130
0 -0.018
-0.020 - 0.045
-0.002 -0.045
-
Inner race 60
i-o.033 +0.020
0 -0.015
-0.020 -0.048
-
Replace
Clearance of pinion shaft of bearing
2
24-16 0
WA350- 1
mm
MAINTENANCE
STANDARD
DIFFERENTIAL
Unit:
mm
No
Clearance of pilot bearing
Backlash of gear
0.25 -0.33
End play of pinion gear
13
Less than 0.152
Thickness
of side gear washer
19
Tightening
torque of mounting
bolt
18.0 & 2.0 kgm
20
Tightening
torque of mounting
bolt
11.5 ? 1 .O kgm
21
Tightening
torque of mounting
bolt
18.0 *
22
Tightening
torque of mounting
bolt
23
Tightening
torque of mounting
bolt
24
Tightening
torque of adjustment
14 15 16
17
18 -
WA350-1
lock nut
94.5 f
28.5 f
Retighten
2.0 kgm
10.5 kgm
3.0 kgm
22.5 * 2.5 kgm
24-17 0
MAINTENANCE
FINAL
STANDARD
FINAL
DRIVE
DRIVE
I C(
‘
10
9
423F215
Unit: No
1
Criteria
Check item
Remedy
I
Clearance between planetary shaft and bearing 40
+0.013 +0.002
JOI
165.1
+0.064 -IO.038
+0.025 0
-
2
2
Clearance between ring gear hub and bearing
3
Thickness
4
Backlash between planet gear and sun gear
5
Backlash between planet gear and ring gear
6
Thickness
7
Tightening
torque of mounting
bolt
11.5t-
l.Okgm
a
Tightening
torque of mounting
bolt
7.0 f
0.5 kgm
9
Tightening
torque of nut
1c
Tightening
torque of mounting
0.002 0.025
-
0.013 0.064
_
-
of retainer at ring gear hub mount
0.21
- 0.58
I
of standard shim for wheel hub
-
Retighten
24-18 @
48 f
bolt
3.2 f
5 kgm
0.3 kgm
WA350-1
mm
MAINTENANCE
DRIVE
STANDARD
DRIVE SHAFT
SHAFT
,,,,, \
423F213
-i\ “\
No.
Criteria
Check item
1
Tightening torque of mounting bolt
11.5+
1.0
2
Tightening torque of mounting bolt
28.5”
3.0
3
Tightening torque of mounting bolt
94.52
10.5
4
Tightening torque of mounting bolt
11.5*
1 .o
5
I
I
11.5-11.0
Tightening torque of mounting bolt I
6
Tightening torque of mounting bolt
11.5irl.O
7
Tightening torque of mounting bolt
11.55
WA350- 1
Unit:
kgm
Remedy
Retighten
I
1 .o
24-19
MAINTENANCE STANDARD
AXLE
AXLE MOUNT
MOUNT
Serial No. 10001 - 11117
Serial No. 11118andup
U42301003
Section A-A
u 2
E423F216
Section B-B
24-20 0
WA350-1
MAINTENANCE
AXLE
STANDARD
MOUNT
View 2 423FO69
Unit:
No.
Criteria
Check item
Repair limit
Thickness of thrust plate 20
2
Remedy
Tolerance
Standard size 1
mm
5
Thickness of wear plate
-
-:.I5
-
-00.1
Tolerance Standard clearance
Standard size 3
Shaft
Clearance of shaft and hole Front support side Dia. 260
-
- 0.056 -0.137
+0.439 +0.023
0.079 0.576
- 0.043 -0.106
+0.455 •f- 0.027
0.070 0.561
Clearance of shaft and hole Rear support side
5
Tightening torque of mounting bolt
28.5 & 3.0 kgm
6
Tightening torque of mounting bolt
26.5 *
-
Replace
Hole
4
Dia. 170
Clearance limit
3.0 kgm
Retighten
. (~$Y engine 7
Tightening torque of mounting bolt
105 ? 10 kgm (Coat engine oil)
8
Tightening torque of axle mounting bolt (F)
105 f
10 kgm (Coat engine oil)
-
WA350-1
24 -21 0
41 STRUCTURE
AND
FUNCTION
General .................................. Hydraulic circuit for steering ............... l Hydraulic circuit diagram for steering ..... l Operations of steering valve ............. Steering control system ................... l Steering valve ......................... l Steering relief valve .................... l Safety valve (Differential type) ........... l Operation of demand spool ............. l Two-way restrictor valve ............... Steering cylinder .......................... Steering column and gear box .............. Center hinge pin .......................... Steering linkage .......................... Emergency steering pump (if equipped) ..... Diverter valve (if equipped) ................. Security valve (if equipped) ................
WA350-1
41- 2 41- 4 41- 5 41- 6 41- 8 41- 8 41-I 0 41-I 1 41-l 2 41-I 4 41-I 5 4 1- 16 41-I 7 41-I 8 41-I 9 41-20 41-23
41-l 63
STRUCTURE
AND
FUNCTION
GENERAL
GENERAL OUTLINE l
l
The oil from hydraulic tank (I) is sent to steering valve (3) by hydraulic and steering pump (2). When steering wheel (7) is operated, the movement is transmitted by steering column (61, universal joint, gear box (5), drag link, and link, and actuates steering valve (3).
. When steering valve (3) is actuated, oil flows to steering cylinder (4) and the steering is actuated. . When steering wheel (7) is not being operated, all the oil which enters steering valve (3) flows to main control valve.
F4230003
41-2 @
WA350-1
STRUCTURE
AND
GENERAL
FUNCTION
F4230004
\
/
I. Hydraulic 2. Hydraulic
tank and steering
3. Steering
valve
4. Steering
cylinder
pump
(See
page 61-I
2)
c
Turn right
@
Turn left
5. Gear box 6. Steering
column
7, Steering
wheel
WA350-1
41-3 0
STRUCTURE
AND
HYDRAULIC
FUNCTION
CIRCUIT
HYDRAULIC
CIRCUIT
FOR STEERING
FOR STEERING
Engine running, steering wheel is not being operated.
-8 e
Main control L
Steering’ Hydraulic pump I v-v
. The steering steering .
wheel
is not being operated,
so the
spool (6) does not move.
The oil from the steering pump enters port A. At the same time, the circuit for the oil from the hydraulic pump is closed, so the pressure rises. It
.
423FO866
The
merged
flows
to
oil passes
steering
spool
throuoh (6).
orifice
However,
“b”
neutral,
so the oil does not flow to the cylinder.
pushes
open check
to the hydraulic
valve
It
(8) and all the oil flows
circuit.
pushes check valve (4) open, so the oil enters port A and merges with the oil from the steering pump.
41-4 0
and
it is at
WA350-1
STRUCTURE
HYDRAULIC
AND
FUNCTION
CIRCUIT
HYDRAULIC
DIAGRAM
To
main
control
FOR
valve
CIRCUIT
FOR STEERING
STEERING
-
1 -I
F423C1009A
I. Hydraulic
tank
2. Hydraulic
and steering
3. Steering 4. Check
valve valve
7. Steering pump
8. Check 9. Safety
relief valve valve valve
5. Demand
spool
10. Steering 1 1. Two-way
6. Steering
spool
12. Two-way
WA350-1
(with
suction)
cylinder restrictor restrictor
valve valve
41-5 8
STRUCTURE
STEERING
OF
OPERATIONS
CIRCUIT
HYDRAULIC
FUNCTION
AND
FOR STEERING
VALVE
Turning right
.A. ::j
‘, i:i
..i
.... ::::
::::
:::: jjjj
::::
.... :.: .,.,._.,._.,.,.,.,.
. . . . . . . . . . . . . . . . . . . . . . . . . . ..A..
................... ,\.................. j:j:
‘12
11’
,6
-5
e
Main control
valve
-----&. When the steering wheel is turned to the right, the
valve (I
“I1, and flows to the bottom end of the left
spool (6)
cylinder
and rod end of the right cylinder
control
is actuated
linkage
and steering
the machine
moves to the right. The
oil from
through spool spool,
41-6 0
(6).
The
pushes
pumps
the
demand
spool
oil passes the
enters
port
(5) and flows
poppet
through
A
passes
to steering
port B of the
of two-way
The
oil from
through
to turn
to the right. the
two-way
drained through
left
and right
restrictor
cylinders
valve
port C of the steering
(I 2).
passes and
spool.
restrictor WA350-1
is
STRUCTURE
Turning
AND
HYDRAULIC
FUNCTION
CIRCUIT
FOR
STEERING
left
6
control valve
423F088B
. When
the steering
control
linkage
wheel
is turned
is actuated
to the left, the
and steering
spool
(6)
The
moves to the left. The
oil from
through
the
pumps
the demand
spool (6).
The oil from
the poppet oil flows WA350-1
of two-way
to the
bottom
enters
port
spool and flows
A,
passes
to steering
end of the right cylinder
to turn the ma-
chine to the left. oil from
through
the
two-way
drained through
left and right restrictor
cylinders
valve
(1 I),
passes and
is
port B of the steering spool.
port C of the spool pushes restrictor
valve
(121, and
rod end of the left cylinder
and
41-7 0
STRUCTURE
AND
STEERING STEERING
41-8 0
FUNCTION
STEERING
CONTROL
CONTROL
SYSTEM
SYSTEM
VALVE
A.
To steering
B.
To hydraulic
cylinder circuit
C.
To steering
cylinder
D.
From hydraulic
E.
To steering
pump
pump
F.
To hydraulic
tank
WA350-1
STRUCTURE
AND
STEERING
FUNCTION
CONTROL
Section
SYSTEM
Y-Y
Section X-X
Section Z-Z E423F075B
1. Lever 2. Valve
6. Steering body
3. Check 4. Demand 5. Check
WA350- 1
valve
7. Steering 8. Safety
spool relief valve valve (with suction)
spool valve
41-9 0
STRUCTURE
AND
STEERING
STEERING
FUNCTION
CONTROL
SYSTEM
RELIEF VALVE
1. Main valve 2. Valve seat 3. Pilot poppet 4. Spring 5. Adjustment
5608
Function . The steeringvalve.
relief
When
valve
the steering
of its stroke
is inside
the
cylinder reaches
and abnormal
pressure
This
prevents
damage
to
F069
steering the end
is generated,
the oil sent from the pump is relieved valve.
screw
through
the
this
pump
or
pressure
of
circuit. (The
relief
valve
sets the
maximum
560BF070
the circuit.)
Operation Port A is connected to the pump circuit, and port l
C is connected through
to the drain circuit.
the orifice
The oil passes
in main valve (1) and fills port
B. Pilot poppet (3) is in contact with valve seat (2). 56OBFO71
1
When the
the
pressure
pressure
pressure), pressure
set
pilot poppet
the
at port B escapes
the pressure
main valve between opened
spring
(set
from port D to port C.
at port B.
at port B drops, the orifice
(1) generates
port
poppet
(3) opens and the hydraulic
This lowers the pressure When
port A and B reaches
inside by
a difference
of
in pressure
A and port B. Main valve (I) is at port A and the oil at
by the pressure
port A is relieved.
41-10
WA350-1
STRUCTURE
AND
SAFETY
FUNCTION
(with
VALVE
STEERING
suction
valve)
CONTROL
SYSTEM
Function l
The safety valve. sure
valve
If shock in the
neutral,
(with causes
when
the
safety
valve
(with
the
releases
the
abnormal
from
damage.
valve
2. Main valve 3. Main valve
valve)
pressure
main
high valve
suction and
presis at valve)
protects
the
4. Pilot piston 5. Suction
spring
is in the main
any abnormally
cylinder
cylinder
I. Suction
suction
6. Valve
valve
spring
body
421 F045
Operation As a safety valve Port A is the cylinder
circuit and port B is the drain
circuit. The pressure
oil in port A flows
a hole
pilot
in the
through
piston.
an orifice
consisting
and the pilot piston The pilot lock
piston
nut.
to port
of the main valve to the safety
diameter
(cross-sectional
D through C (2)
(4).
is secured
The
to port
It also flows
of
area) gives
the
valve
cross
by a
section
a relationship
of d2 >
dl > d3 > d4. If abnormally
high
the suction
valve
port
because
hydraulic
(2) is equivalent
poppet
spring
actuated,
force
are connected
with
pressure
Therefore, valve
valve
“a”
in port A drops, hydraulic
than oil pressure oil
pressure “a”
+
(1) opens, port
building
WA350-1
poppet
port
is
D
D and A
The tank
equivalent
pressure
smaller
from
the
into port B.
in port A, port
other.
pressure
When
B into
be-
up to the
pressure
421 F047
to the area dif-
“e” “a”
to the safety
in port E. acts to open the acts to close
the
(I 1.
pressure)
valve
goes
d2 and dl is applied
hydraulic
pressure
d4 in
on the main
because
of the tank pressure
If the pressure tive
each
and hydraulic
suction
421 F046
to port E.
between
because
is generated pressure,
in port B is applied
valve
pressure
(set pressure),
pressure
also has negative
ference
of
valve
If negative
Hydraulic
A,
d3 >
pressure
and the oil in port A flows
As a suction
in port because
to the area difference
ds and da. If this
tween
occurs
actuated
of the relationship
A and C, the
valve
is not
d2 > dl.
the relationship However,
oil pressure (I)
A.
valve
“a”
negabecomes
“e”.
“e”
becomes
spring
causing This
(approaching
pressure
the oil to flow
prevents
up in port A.
larger
(5) force, negative
than
oil
the suction from
port
pressure
421 F048
41-11 0
STRUCTURE
AND
OPERATION
STEERING
FUNCTION
OF
DEMAND
at low speed
.
oil from
The
the same draulic
pump
the
pushes
oil
port .
A to
demand oil flow
spool
valve
with
oil
spool
(I)
the
port A.
passes
through
hy-
(2), so
and the
enters steering
orifice
“a”
of
port B. However,
so the pressure
at port
8
At
the
spool
open
oil from
(2) and enters
is small,
Therefore,
by demand
check
merge
enters
for the oil from
is closed
rise and the spool .
pump
the circuit
pump. The merged
From steering cylinder
Q
the steering
time
SYSTEM
SPOOL To steering cylinder
Engine
CONTROL
the
B does not
does not move.
all the
oil
flows
(4) to the steering
from
steering
valve
cylinder.
423FO83B P,: Steering pump PI: Hydraulic pump
Engine .
at midrange
The oil from the same
.
time,
draulic
pump
pushes
back
the circuit the
the valve
merges
with
oil
spool
oil is larger fice
at
port
C.
of spring
passes
“a”
in
B. The flow
of
is at low speed, of the ori-
becomes
(5). and demand
greater spool
(2)
+
some through
of the oil from port
D and
alve
the hydraulic flows
to the
valve.
All the oil from
the steering
der of the oil from steering
pressure
It
and
port A and
B rises because
This
(I)
orifice
port
w
pump.
through
the engine
rises.
valve
the steering
From steering cylinder
+
At
to the right.
main control .
when at port
For this reason, pump
check
A.
the hy-
pressure
so the oil enters
passes
than
than the force moves
of
(2) and enters
so the pressure
port
for the oil from
spring open,
enters
so the
the oil from
merged
demand
pump
is closed,
pushes The
To steering cylinder
speed
the steering
pump
the hydraulic
and the remain-
pump
flows
to the
d
'/PI/
P2
/II@
cylinder.
P,: Steering pump P1: Hydraulic pump
41-12 0
423FO84B
WA350-1
STEERING
FUNCTION
AND
STRUCTURE
Engine at high speed
pump
is divided
which
enters
merges
of demand
“a”
even
sure becomes
than
(51, so the demand
hydraulic
the
port D and oil
valve
when
(I). ori-
through port
the engine
6. is at
B rises
at port
of port
From steering cylinder
A.
from
passes
steering cylinder
C. The pres-
higher
than the force
spool
is moved
of spring
further
to the e
right. reason,
For this pump merges
SYSTEM
is at
the engine
enters
pressure
of the orifice
because
port
enters
(2) and enters
spool
so the
speed,
midrange
check
at portA
of oil is larger
The flow higher
into oil which
port A from
The oil which fice
when oil
the
so
speed,
midrange
pump
(2) is opened
spool
Demand
steering
the
oil from
The
TO
CONTROL
and
part
at port
valve.
all of the of
the
oil
D and flows
the
from
steering
pump
main
control
to the
alve
hydraulic
oil from
a
i 423 FO85B P,: Steerrng pump P,: Hydraulic pump
WA350-1
41-13 0
STRUCTURE
AND
TWO-WAY
FUNCTION
STEERING
RESTRICTOR
CONTROL
SYSTEM
VALVE
1. Body 2. Spring 3. Poppet
423FO80
Function .
To reduce machine
the shock when
is installed
caused
the steering
by the inertia of the is operated,
an orifice in the oil line of the return circuit from
the cylinder.
This applies
oil, and regulates
the
pressure to the returning
movement
of the
cylinder
piston.
Operation
. When
the oil is flowing
spring
(2) and flows
tween
poppet
to arrow
through
, it pushes
&
the orifice,
and be-
(3) and the poppet seat.
From pump
423F081A
a
. When the oil is flowing to arrow only from
orifice
+,
the oil flows
“a” inside the poppet
(3). SO the
flow is controlled.
423F082A
41-14 0
WA350-1
STRUCTURE
AND
STEERING
FUNCTION
STEERING
CYLINDER
CYLINDER
423 F089
Specifications bore:
80 mm
1. Head
Cylinder
2. Rod
Rod diameter:
3. Cylinder
Stroke:
442
4. Piston
Cylinder
max. length:
5. Piston nut
Cylinder
min. length:
Width
WA350-1
45 mm mm 1,209 767
mm mm
across flats of piston nut:
50 mm
41-15
STRUCTURE
AND
STEERING
STEERING
FUNCTION
COLUMN
AND
GEAR
COLUMN
AND
GEAR BOX
BOX
Outline .
The steering
gear is a recirculating
In this
of gear
thread balls thread.
type
there
cut in the steering (6)
between Ball
accordance
nut
the (5)
.
ball type gear.
shaft. nuts
moves
with the rotation
There
which up
are several slide
and
in this
down
of the steering
Balls
(6)
together
is a round-bottomed
in
They
move with
pass from
passage
in the
nut
the rotating
groove
of the
of the steering
shaft wheel.
the end of the nut through
on the outside,
the
and return to the nut to be
recirculated
shaft,
and turns the center shaft.
9-
n I
I
Section D-D Section B-B
Section C-C 423FO72
1. Steering
wheel
6. Ball
2. Center shaft
7. Worm
3. Steering
8. Tilt lever
4. Gear box
column
9. Pitman arm
5. Ball nut
41-16
WA350-1
STRUCTURE
AND
CENTER Outline . The front connected
HINGE
frame
(3)
through
and
a bearing
pin (5), (6).
The
steering
and
right
when
the cylinders
at the middle
HINGE
PIN
PIN
to the
left
CENTER
FUNCTION
rear
frame
cylinders
front
(4)
by the center and
are operated,
to give the desired
are
I. Front axle
hinge
2. Rear axle
are connected rear
frames,
the frame
3. Front frame
so
4. Rear frame
bends
5. Upper hinge pin
angle, that is the
6. Lower hinge pin
desired turning radius.
Serial No. 10001 - 11117
Serial No. 11118andup
U42301004
Serial No. 10001
-
11117
Serial No. 11118
Section A-A
and UD
section A-A Section B-B
Section B-B
U42401008 E423FlS4
WA350-1
41-17 0
STRUCTURE
AND
STEERING
FUNCTION
LINKAGE
STEERING
LINKAGE
-
SerialNo. 10001
10186
Section A-A and up
Serial No. 10187
Section A-A
423FO73A
1. dear box 2. Pitman arm 3. Steering
column
4. Link 5. Steering
41-18 @
valve
WA350-1
STRUCTURE
AND
EMERGENCY
FUNCTION
EMERGENCY
STEERING
PUMP
STEERING
PUMP
(If equipped)
Section A-A
419F479
View Z
1. Drive gear (Teeth
12)
2. Front cover 3. Gear case 4. Rear cover 5. Driven
gear (Teeth
12)
Specifications l
Model:
l
Direction
.
Theoretical
l
Max. delivery
WA350-1
SAM(2)-040 of revolution: delivery: pressure:
Possible 50.8
to rotate
both direction
cc/rev.
210
kg/cm2
41-19 co
STRUCTURE
AND
DIVERTER
FUNCTION
DIVERTER VALVE
(If equipped)
\
1. Diverter
Section X-X
D
Section Y-Y
2. Valve
VALVE
419F480
A. From steering
valve
B. To steering
body
3. Check
valve
C. To hydraulic
4. Check
valve
D. Sensor
pump
valve tank
mounting
port
E. Emergency
pump
port
F. Emergency
pump
port
G. From hydraulic
pupm
FUNCTION l
If the engine
stops
chine
traveling,
steer,
the
turn
rotation
the emergency
or the pump
and
it
seizes
becomes
of the’ transmission steering
pump
during
ma-
impossible is used
to make
to to
steer-
ing possible.
41-20 @
WA350-1
STRUCTURE
AND
DIVERTER
FUNCTION
VALVE
OPERATION l Pump and engine are working normally.
To steering cylinder
From steering cylinder @ _....
:::: :: ::: :::: :: ::: ::: ::: ::: ...
it ::: :jj :!: :: :., ::: j:j ::: ::: ::: ::: ::: .:.
i$$ .:.. ii;; ..:.
....I
:;
11
:i: i;; : i:; :j:
.A. .A. .A. ::::
.A. .A. .A. .A. .A. .A. .A. .A. .A. .A.
:!: ::: :i:
_
Hydraulic
tank 423F501
. When
the steering
normally, switch
pump
the hydraulic
and engine
pump,
pump are rotated
are working
steering
pump,
and
To steering cylind,er
From steering cylinder
by the engine. Therefore,
oil is sent to the steering
valve,
and the machine
can be steered. In addition,
the emergency
ed by the transmission, diverter
valve
steering
pump is rotat-
so oil from
pushes
open
check
port A of the valve
(2) and
enters port 6. Pressure
oil from
the steering
port D, so it pushes
spool
is flowing
to
(3) in the direction
pump
of
is drained to the hydraulic
WA350-1
0
Steering pump
the arrow. As a result, the oil from
port B flows to port C and tank.
423F502
41-21 @
STRUCTURE
l
AND
DIVERTER
FUNCTION
VALVE
Failure in pump or engine when machine is traveling.
To steering cylinder
From steering cylinder $J
::: ::: :::
3
Q 0
Hydraulic Steering
T’ .C
main
pum
pump
Hydraulic
tank 423F503
l
If there is a failure in the pump or engine when the machine
is traveling,
transmitted emergency
the rotation
through steering
The steering oil is formed
pump
the
of the wheels
transfer
to
Emergency steering pump \P--
is not rotating,
so no pressure
at port D. As a result,
spool
(3) is
of the arrow by spring (4).
The oil from the emergency
steering
pump passes
port B and flows to the steer-
ing valve to make steering
* The emergency
is the
pump.
pushed in the direction from port A through
rotate
possible.
steering
pump
is designed
so
that it can rotate both directions. 426FO65
41-22 @
WA350-1
STRUCTURE
AND
SECURITY
SECURITY
FUNCTION
VALVE
VALVE
(If equipped)
Section A-A 419F4S4
FUNCTION 1. Valve body
l
If hoses
between
3. Spring
broken, security valve prevents lower
point, security
oil level
and
(including
each
work
cylinder
oil flowing
until float
valve actuates
to work equipment
WA350-1
valve)
valve
equipment When
control
security
2. Spool
valve
are
out. actuating
to return all oil flows
control valve to hydraulic
tank.
41-23 @
STRUCTURE
AND
FUNCTION
SECURITY
VALVE
OPERATION 1) When work equipment circuit is normal. (Hydraulic tank oil level is correct.)
To steering cylinder
From steering cylinder
To main
Hydraulic circuit l
Oil from pushes
steering spool
also it reaches l
Oil from
(I)
pump
enters
in the
direction
port
to float valve (2) chamber
steering
valve
control valve through
flows
“a”,
and
of arrow,
to work
it
To steering cylinder
From steering cylinder
and
A. equipment
port “b”.
423F505
41-24 @
WA350-1
STRUCTURE
AND
FUNCTION
SECURITY
VALVE
2) When work equipment circuit is abnormal. (Hydraulic tank oil level is to low.)
To steering cylinder
From steering cylinder @
iii
:i: .:. ::: ::jj I ::: ::: :::
1 iteering
pump
423F506 Hydraulic circuit l
When
oil in the hydraulic
tank is decreased,
float TO steering cylinder
From
steering
cylinder
(3) goes down and oil from the pump circuit flows to the
hydraulic
goes down
tank.
and spool
then oil from steering
The
pressure
(1) moves
of port
to +
“a”
direction,
I
valve flows to tank circuit to
prevent the leak from the damaged
part.
423F507
WA350-1
41-25 Go
STEERING SYSTEM 42 TESTING
AND
ADJUSTING
Standard Measuring
wheel
steering
steering
Testing
operating
Adjusting
precautions or during
1. The values
in these
used as target 2. The standard standard
tables when
are based repairing
in these
tables
for the machine
values
value
tables
when
using
the Standard
.
42-3
.
42-4
of wheel
lock to lock.
. ...
.
42-5 .
42-6
.. . . . .. ..
42-8
__.__.,.....................
Value
Tables
42-7
42-9
to make
judgements
the plant,
so they
during
and adjusting. on the values or when
must
shipped
for
estimating
for judgement
when
be used as reference
standard
use these
WA350-1
values
values
they should 3. These
values
are necessary testing
42-2
..
linkage
oil pressure
Troubshooting
42-2
linkage
steering
Steering
. .
.
time of steering steering
. .
play
force
.
wheel
Operating
troubleshooting
.
and adjusting
Measuring
Sr The following
...
value table
Tool list for testing
when
from
in combination
with
new
machines
wear
after a period
troubleshooting
the plant,
alone to make simple
values
when
should
be
of use. are estimated
and on the results
repair and operating
not be used for standard
leaving
values
of various
records
when
judging
claims.
based
tests.
making
on the
Therefore, judgements.
In addition,
do not
judgements.
42-l 0
TESTING
AND
ADJUSTING
STANDARD
Testing Steering
STANDARD
VALUE
and measuring
Measurement
item
horizontal,
play
wheel
Operating
operating
(Low
45 Machine
l
surface
-
Facing
Tire inflation
between
front
straight
Hydraulic
oil pressure
TOOL No.
LIST
Testing
FOR TESTING
1
Steering
wheel
2
Steering
oil pressure
Steering
wheel
3
time
Clearance
between
front
frame
A
When Then
A
carrying
out testing,
bar on the frame,
When
apply
the parking
installing
lic tank.
lower
Then
or removing operate
the
Max.
kg/cm2
210
5.0
-
30
tester
799-l
watch
2 lo+_‘;
Remark O-25
I
01-5000
0 -
7AO-262-0550 Commercially
scale
or troubleshooting, to the ground,
kg
400
l/IO
kg/cm2 second
I
I
Convex
“-2
Part number
Hydraulic
gauges, control
Max. 5.0
2.2-3.2
20 -
7AO-262-0020
brake and block
3.3
3.2 -4.2
mm
scale
adjusting
the bucket
Max.
Push-pull
Stop
and rear frame
1.5-2.2
ADJUSTING
I
I
4
55°C
Tool
force
operating
-
AND
item
operating
kg
pressure
45
and measuring
20-100
temperature:
Main relief oil pressure
l
20-70
Sec.
and rear frame Steering
value
pressure:
Specified
frame
Permissible
posture:
idling)
linkage
Clearance
l
value
mm
55°C
(High idling) Steering
standard
temperature:
force
time of steering
wheel
Unit
Flat,
dry, pavet
Hydraulic
l
Steering
condition
Road surface:
wheel
TABLE
TABLE
wheel
Steering
VALUE
stop
the machine
-
available
on level ground,
install
the safety
and stop the engine.
the tires.
loosen levers
the oil filler cap slowly several
times
to release
to release
the pressure
the remaining
pressure
inside the hydrauin the hydraulic
piping.
A
When
A
The oil in the circuit
42-2 CJ
taking
measurements,
do not allow
is hot, so be careful
unauthorized
persons
near the machine.
not to get burnt.
WA350-1
TESTING
HOW
AND
TO
1. Turn
the
ADJUSTING
the
STEERING
WHEEL
PLAY
MEASURE steering
wheel
counterclockwise neutral
Put mark
MEASURING
two
position “1”
lightly
or three
clockwise
times
of the steering
on the outer
frame
and
and confirm mechanism.
of the vehicle 419F302
monitor. 2. Turn the steering tion where
wheel
clockwise.
Align the posi-
the tires begin to move with mark “I”,
then put mark “2” on the steering wheel. 3. Turn the
the steering position
mark wheel. tween
wheel
where
” 1 “, then Measure
counterclockwise.
Align
the tires begin to move
put
mark
“3”
the distance
on the
of a straight
with
steering line be-
mark “3” and mark “2”.
TESTING AND ADJUSTING * Inspect the steering linkage for looseness
and free
play. If any, adjust the linkage.
1. Loosen lock nuts (4) on the steering gear box. 2. Then,
adjust by turning
adjustment
screw
(5) in or
out. t
To
decrease
screw
the
free
in, to increase
play,
turn
the
adjustment
the free play, turn the screw
out.
-~ -_ ____ 423F311
WA350-1
42-3 0
TESTING
AND
ADJUSTING
MEASURING
MEASURING
OPERATING
OPERATING
FORCE
FORCE OF STEERING
OF
STEERING
WHEEL
WHEEL
Condition Road surface:
Flat, horizontal,
dry, paved surface.
Coolant temp: Inside operating Hydraulic
oil temp: 45
Tire inflation
-
pressure:
range
55°C
Specified
Engine speed: Low idling (bucket
pressure unload) Unit:
Item
stZi::rd
Force of steering
Special
wheel
1.5-2.2
Max. 3.3
-
tool
-(Partnumber
1
~0-262-0020
1 Push-pull scale
Measuring
kg
Part name
IQ’ty
I 1
procedure
1. Hock push-pull
scale
A
to the knob of the steer-
ing wheel.
2. Start the engine. *
After
starting
about 400
3. Pull push-pull
the
scale
A
value when the steering Do not read
engine,
raise
the
mm and remove the safety
the
valve
at a tangent, wheel
bucket
bar.
and read the
is moving smoothly.
at the time,
the
steering
wheel starts to move.
42-4 0
WA350-1
TESTING
AND
ADJUSTING
OPERATING
OPERATING
TI ME
OF STEERING
Measurement
condition
Road surface:
Flat, horizmontal, dry, paved surface
Coolant
temp: Inside operating
Hydraulic
oil temp: 45
Tire inflation
pressure:
-
TIME
OF
STEERING
WHEEL
WHEEL
LOCK
TO
LOCK
TO
LOCK
LOCK
range
55°C
Specified
pressure.
Engine speed: Low idling and high idling set
Unit:
Standard value
Item
Special
Permissible value
tool
Part number 7AO-262-0550
Measuring
Part name
Q’ty
Stop watch
1
procedure
1. Start the engine. *
After
starting
about 400
2. Turn
the
the
engine,
mm and remvoe
steering
wheel
raise
the
the safety
so that
the
bucket
bar.
machine
is
turned fully to the left or fully to the right.
3. Measure
the time taken
for the steering
wheel
to
be turned to the right (left) to the full lock position. *
Turn
the
without t
Measure
steering
forcing
wheel
as fast
as possible
it.
at low idling and high idling, and when
turning to the right and to the left.
WA350-1
42-5 0
TESTING
AND
TESTING
STEERING
Measurement Hydraulic
TESTING
ADJUSTING
STEERING
LINKAGE
LINKAGE
condition
temperature:
Road surface: Tire inflation
45
-
55°C
Flat, horizontal, pressure:
Engine speed:
dry, paved surface
Specified
1200
pressure
rpm
square with the machine
Center lever: Pitman arm:
Prependicular
center line
to the machine
rear frame Unit: set
Serial No. 10001
Measuring
10186
Serial No. 10187
and up
procedure
1. Start the engine and operate
the steering
set the front and rear frames
2. Check
-
looseness
in a straight
of mounting
wheel
to
line.
bolts and nut (I)
of
linkage and play of ball joint (2). rod (3) and center lever bearing
(4). 423F3
3. Check that the center
I2
lever is at right angles to the
center line of the machine. *
The steering
spool should be at neutral.
4. Check that the pitman
arm is perpendicular.
5. Start the engine and turn the steering
wheel to the
left and right to the full lock position. clearance
“a”
frame stoppers *
When
between
is the standard
measuring
justment
the front
screw
Check
frame
that
and rear
value.
the clearance (5) should
to the right, ad-
be in contact
Clearance
with
423F313
the pitman arm. *
When
measuring
justment
screw
the clearance (7) should
to the left, ad-
be in contact
with
the pitman arm. *
Conform
that adjustment
not in contact
with
screws
the valve
(6) and (8) do
lever respectively.
I
42-6 0
423F314
WA350-1
TESTING
AND
ADJUSTING
ADJUSTING * . . .
Measurement Hydraulic
STEERING
Tire inflation
45
pressure:
LINKAGE
LINKAGE
50°C dry, paved surface.
Specified
pressure.
bar and stop the engine.
procedure
1. Set the machine stall the safety 2. Disconnect 3. Adjust
-
Flat, horizontal,
Install the safety
Adjustment
STEERING
condition
temperature:
Road surface:
A
ADJUSTING
facing
steering
steering
is at 90” steering
directly to the front and in-
bar. linkage (I ).
linkage
(2) so that center
to the center
lever (8)
line of the chassis
when
valve lever (9) is at neutral.
4. In the condition
in Step 3, move the steering
valve
lever to the end of its travel so that the valve lever contacts Then
stopper
turn
bolts (5) and (6).
it back
l/2
turn,
and lock in position
with the nut. 5. Set
pitman
frame,
arm
adjust
(7)
the
then connect
perpendicular
length
steering
to
of steering
linkage
the
front
linkage
(I),
(1) and pitman
arm
(7). 6. Remove 7. Start
the safety
the engine,
bar. turn the steering
the left and right, arm contacts
stopper
ance “a” between stopper
and adjust
is 20
-
wheel
so that
fully to
the pitman
bolts (3) and (4) when clear-
the front frame
and rear frame
30 mm, then lock in position
with
the nut. *
After
completing
spect
again
the
to check
are within the standard
above that
adjustments,
the
in-
measurements
value.
423F3
WA350-1
I3 A
42-7 a
TESTING
AND
STEERING * l l
STEERING
ADJUSTING
OIL
OIL PRESSURE
PRESSURE
Measurement condition Hydraulic temperature: 45 Engine speed: High idling
55°C
Unit: kg/cm2
Special tool Part number A
799-l
01-5000
Part name
Q’ty
Hydraulic tester
1
Procedure for measuring main relief pressure Loosen
a
the
pressure
oil filler
cap slowly
inside the hydraulic
ate the steering the remaining
wheel
pressure
to release
tank.
several
Then
times
in the hydraulic
the
oper-
to release piping.
1. Fit safety bar (1) on the frame, then remove cover (2). 2. Remove
plug
steering
(3)
3. Install hydraulic 4. Start
for
measuring
the
right
turn
circuit. tester A to the measuring
port.
and run at high idling.
Turn
the engine
steering
wheel
to
the
right
and
measure
the the
pressure when the relief valve is actuated. *
When
removing
steering
circuit,
the
plug
for
the
turn the steering
left
wheel
turn to the
left and measure.
Testing
n
and adjusting
Always
stop
hydraulic
the
engine
before
adjusting
the
pressure.
1. Stop the engine. 2. Remove
cap nut (4) of the relief valve.
3. Loosen
lock nut (5). then turn adjustment
screw
(6) to adjust. t
Amount
of adjustment
for 1 turn of adjustment
screw. 1 turn:
Approx.
24.8
Sr Adjust the set pressure To INCREASE To DECREASE *
If
the
relief
accurately,
42-8 0
kg/cm2 as follows.
pressure, pressure, pressure
TIGHTEN LOOSEN cannot
screw. screw. be
measured
do not try to adjust the pressure.
I
6 423F315
WA350-1
TROUBLESHOOTING Troubleshooting
table
does not turn
2. Steering
wheel
is sluggish
3. Steering
wheel
moves
is subjected particular
tends
carrying
page 22-l
out
RENCE OF TROUBLE”
WA350-1
the
2, “METHOD
troubleshooting OF READING
page 22-l
in this
section,
TROUBLESHOOTING
read
“PRECAUTIONS
TABLE”
page
.
22-l
.. .
42-10
.
42-11
or
.
to turn naturally
direction
42-10
.
unsteadily
to large shock
5. Left and right turning
Before
.
wheel
4. Machine
*
.
1. Steering
42-12 in one
traveling
42-12
radii are different
42-12
when
WHEN
TROUBLESHOOTING”
4 and “PREVENTING
RECUR-
6.
42-9 0
TROUBLESHOOTING
TROUBLESHOOTING
TROUBLESHOOTING 1. Steering
wheel
Ask the operator l
l
Damage
for some
Checks
wheel -
questions.
suddenly
cease
in steering
to turn?
circuit.
show
signs of being
Worn
parts
sluggish
in steering
circuit
seal.
before
Is oil
wheel
time?
or faulty
l
the following
to equipment
Did steering
TABLE
does not turn.
Did the steering -
TABLE
level
troubleshooting inhydraulic
tank
and
type
of
oil
satisfactory? l
Is there
any damage
the steering l
Has
the
*
safety
Is the steering
Because ment
the
circuit
check steering
gear box or
bar
been
removed
from
the
_
frame? l
to the steering
linkage?
linkage
steering
properly
circuit
are intimately
the operation behaves
adjusted?
and the related
of the work
work
to each equipment
equipother, if the
abnormally.
The following symbols are used to indicate the action to be taken when a cause of failure IS located.
42-10 0
WA350-1
TROUBLESHOOTING
TROUBLESHOOTING
2. Steering
wheel
TABLE
is sluggish.
Ask the operator the following questions. l
Did
the
steering
wheel
suddenly
become
sluggish? l
Damage
to equipment
Did
steering
wheel
show
for some
time?
--*Worn
or faulty
seal.
the
sluggish ing circuit
in steering
circuit. signs
of
being
parts
in steer-
type
oil sat-
Checks before troubleshooting Is oil level
in hydraulic
tank
and
isfactory? Is there
any
abnormality
in the
steering
box mounting
part, steering
column
Is the adjust
of the steering
valve
gear
or linkage? control
lever
correct? Is there
any
oil leakage
hose, valves, Is there
cylinders,
any seizure
and bushing ing cylinder Check
from
the
oil pressure
etc?
between
the pin, pin bearing
of the center
hinge
and the steer-
pin and bushing?
tire pressure.
Fault check .
Measure
the
ing wheel
and also the time required
operating
turn the machine operated, against
when
then check
there
of
the steering
the
steer-
to is
the results
the judgement
table to see whether
force
criterion or not
is any abnormality.
Problems 1
Steering wheel is sluggish in both left and right directlons.
2
Steering wheel IS sluggish in one of left and right directions.
3
Steering wheel is particularly
4
Boom lifting speed is insufficient throttle.
5
Steering wheel is sluggish
6
1 Hydraul’ IC oil
0
0
when engine is at full
Steering circuit pressure is low.
8
Oil pressure In return side piping of steertng cylinder rises.
0
0
and jerky.
7
0
I
lIIIllol 0
0
I 0
0 0
The followlng symbols are used to to be taken when a cause of failure X: Replace A: Adjust
WA350- 1
0
0
0
0
sluggish at low engine speed.
overheats.
0
0
0
indicate the action is located. D: Repair C: Clean
42-11 0
TROUBLESHOOTING
TROUBLESHOOTING
3. Steering wheel moves unsteadily subjected to large shock.
TABLE
or is
Checks before troubleshooting Is oil level
in hydraulic
tank
and also oil type
satisfactory? Is there
any damage
mounting
to the steering
part, steering
is there any play in the center or steering
cylinder
Does tire inflation Steering
wheel
gear
box
column or linkage? pin hinge bearing
pin bushing? pressure fluctuate?
play
Fault check Operate check
the the
wheel
wheel becomes
wheel
loader
conditions
in a safe
under
which
place
the
and
steering
unsteady.
is sluggish”.
No.
1
Machine body is unsteady when traveling on bumpy road surface.
2
Steering wheel becomes unsteady if suddenly turned when working or traveling.
3
Machine body becomes unsteady when traveling at high speed.
4
Machine body becomes unsteady during engine starting.
4. Machine tends to turn naturally titular direction when traveling.
in one par-
0 0
0
0
0
to be taken
when a cause of failure IS located.
Cause: Faulty steering valve 0 Incorrect
positioning
of Spool.
l
Faulty safety valve.
l
Oil leakage
l
Does tire pressure fluctuate?
in steering
5. Left and right turning
Cause: Incorrectly
radii are different.
adjusted
Left and right
cylinder.
steering
steering
linkage
balance,
lock posi-
tion of stopper. (Valve
relief noise can be heard upon com-
pletion of turning.)
42-12 0
WA350-1
STEERING SYSTEM AND ASSEMBLY
DISASSEMBLY
43
GEAR
STEERING
.
Removal
3
Disassembly
43-
4
43-
5
______ VALVE
STEERING Removal
.
Installation Disassembly .._
Assembly
.
. . . . . _.
Installation
.
. .. .. ..
Assembly
. . .. .. .. . .. .. Installation
*
Take
method
the following pumps
cylinders, 1. Start
engine,
2. Operate 3. Continue 4. After NOTE:
WA350-1
you
see SECTION
start
2
to operate
43-l
5
.
.
.. .
. . . 43-18
. . . . . . 43-22 43-30 .. .. ..
.
97. hydraulic
cylinders
after
reassembling
keep idling. cylinder
to operate After
when
air bleeding
for
2
43-l
and pipings.
hydraulic
finishing
of the gear pump,
43-l
PIN
HINGE
Removal
and assembly
0
43-16
Disassembly...........................
of disassembly
8
43-l
43-14
. . .._._____._._._..__.........
Removal
CENTER
43-
CYLINDER
STEERING
For details
2
43-
Assembly
*
43-
Installation
above
cylinder steps,
long storage,
4 -
5 cycles,
3 -
but do not exceed until stroke
4 cycles
keep normal
engine
same procedure
beyond
100
mm of stroke
end.
end.
speed.
is required.
43-l 0
GEAR
Stop the machine on level ground and install the safety bar on the frame. Lower the bucket and stop the engine.
to the ground
to prevent
wheels
stopping
After
several
put
the machine
the engine, the
to
times
and
brake
parking
the
*
STEERING
OF STEERING
REMOVAL
a
ASSEMBLY
AND
DISASSEMBLY
left
blocks
the
under
from moving.
wheel
turn the steering and
apply
Then
right
the
set
to
steering valve in NEUTRAL. .
1. Pitman
arm
I) Disconnect
wiring
then
(I),
nuts (3) of pitman arm (2).
removing,
Sr Before
of
connector
mounting
remove
check that the pitman
arm
is horizontal. sector
2) Disconnect
shaft
(4)
of
gear
steering
and pitman arm (2). *
Before
removing,
sector
shaft
make match
of the steering
marks on the
gear and pitman
arm.
2. Steering
column
Loosen lock bolt (5). and increase
clearance
“a” of
column joint (6). *
Make
match
steering
3. Steering Remove
marks
on the
column
joint
and
gear.
gear mounting
bolts (71, then remove
steering
gear (8).
43-2 0
WA350-1
GEAR
STEERING
ASSEMBLY
AND
DISASSEMBLY
OF STEERING
INSTALLATION
GEAR
GEAR
1 Steering gear (6)
and gear
of
gear (8);and
steering
insert joint. Set steering
marks
match
Align
then
position,
in mounting
column
joint
install mounting
bolts
(7). Mounting
w
bolt:
11.53~ 1 .O kgm
2. Steering column Tighten
lock bolt (5) of column joint (6).
w
Lock bolt:
5.720.7
kgm
arm
3. Pitman Align
match
marks
shaft
(4).
install
mounting
of pitman pitman
nuts and connect
arm (2) and sector arm,
then
connector
tighten of wiring
(I). Mounting
B
nut:
1923
kgm
4. Checking steering linkage After
completion
of assembly,
check
the linkage
and adjust if necessary. t
For details,
see
52
TESTING
AND
ADJUST-
ING.
WA350-1
43-3 @I
DISASSEMBLY
AND
ASSEMBLY
DISASSEMBLY
STEERING
OF STEERING
GEAR
1. Side cover 1) Loosen
lock nut (3) of adjustment
then remove
2) Hold
mounting
side cover
tighten
so that
adjustment
screw
(21,
bolts (4) of cover.
screw
it cannot to remove
rotate,
and
side cover
(1).
2. Sector shaft Turn steering
gear shaft
in vertical position, t
Be careful
(6) so that sector shaft is
and remove
not to damage
sector shaft (5).
the bushing or thread
of the sector gear.
3. Rear cover, shaft, ball nut assembly Remove
rear cover
nut assembly
43-4 @
(7). then remove
shaft and ball
(8).
WA350-1
GEAR
DISASSEMBLY
AND
ASSEMBLY
STEERING
ASSEMBLY
OF STEERING
GEAR
GEAR
1. Bearing outer race I) Press fit bearing
outer race (10) on gear box (9)
and rear cover (7).
2) Press
fit oil seals
(I I),
(12)
on gear
box and
rear cover. *
If bushing
(13)
of
the
gear
box
is badly
worn, replace the gear box. &
Lip of oil seal:
2. Shaft, ball nut assembly, Assemble
shaft
Grease (G2-LI)
rear cover
and ball nut assembly
(8) in gear
box, then install rear cover (7).
RCZL
Shaft,
ball nut assembly,
bearing
(I 4):
Grease (G2-LI)
*
If there
is any problem
with
shaft
(I 6) or ball
nut (I 5) of the shaft and ball nut assembly, place the whole
WA350-1
re-
shaft and ball nut assembly.
43-5 @
DISASSEMBLY
AND
STEERING
ASSEMBLY
GEAR
3. Adjusting shim Select
shim
thickness
so that
shaft is within standard *
First
*
assemble
a
larger
then reduce the thickness
Measure
the
of
starting
torque
than
to adjust.
with
torque
A.
Standard
range for starting torque: 3.5
w
torque
thickness
necessary, wrench
*
starting
range.
Mounting
6.5 kgcm
-
bolt (16) of rear cover: -. 4.5 f 1 kgm
4. Sector shaft, side cover Assemble
so that sector
gear is meshed
at center
of ball nut. t
If bushing
(3) of the gear box is badly worn, re-
place the gear box. w
Mounting
bolt:
5. Adjusting adjustment
1) Temporarily
2) Turn
arm (I 7). move arm
adjustment
screw
(2) so that
is “0”.
adjustment
of shaft
kgm
screw
install pitman
lightly and tighten backlash
4.5+-l
is within
screw
so that starting
standard
torque
range, then tighten
lock nut. t
Standard
range for starting torque: 3.5
w
43-6 0
Lock nut:
2.5kO.5
-
7.0 kgcm
kgm
WA350-1
DISASSEMBLY
WA350-1
AND
ASSEMBLY
STEERING
GEAR
43-7 0
DISASSEMBLY
AND
REMOVAL
A
Stop
the
OF STEERING machine
the safety parking
wheels
Q!
Loosen
blocks
the machine
wheel
to release
hydraulic filter,
put
several
the
to release
plug (I)
pressure
at the top of the hydraulic
the
cable
from
tank
out.
the
negative
(-1
of the battery.
linkage,
cover
floor cover (3) of floor frame.
2) Remove
mounting
nut of steering
linkage (4).
piping
I) Disconnect steering
in the
piping to prevent
1) Remove
2. Hydraulic
the
piping.
Disconnect
1. Steering
the
times to the left and
remaining
and plug (2) of the pump
terminal
apply
under
tank. Then operate
the oil inside the tank from flowing *
and install the bucket
from moving.
cap slowly
inside the hydraulic
the steering
l
and
the oil filler
pressure
Lower
VALVE
VAL
and stop the engine. Then brake
to prevent
Loosen
right
on level ground
bar on the frame.
to the ground the
STEERING
ASSEMBLY
tube (5) between
pump at steering
2) Disconnect hydraulic
tube (6) between pump at steering
steering
valve and
valve end. steering
valve and
valve end.
3) Disconnect
hose (7) between steering valve and main control valve at steering valve end. 4) Disconnect tube (8) between steering valve and steering
cylinder
(bottom
end) at steering
valve
end.
43-8 0
WA35071
DISASSEMBLY
AND
5) Disconnect hydraulic
tube (9) between tank at steering
6) Disconnect
tube
and steering
STEERING
ASSEMBLY
(IO)
cylinder
steering
VALVE
valve and
valve end.
between
steering
(rod end) at steering
valve valve
end. *
After
disconnecting
each
cover the port to prevent
or
tube,
dirt or water
hose
from
entering.
3. Steering valve Remove
mounting
bolts,
then
remove
steering
to the mounting
surface,
valve (1 I). +
If the valve tap with
is stuck
a plastic
hammer.
Do not use a steel
hammer. *
The
valve
slippery, +
body
is covered
in oil and
is very
so be careful when removing.
Be careful
not to damage
the tubes,
and pull
the valve out to the right. Steering
WA350-1
valve:
32 kg
43-9 0
DISASSEMBLY
AND
INSTALLATION
STEERING
ASSEMBLY
OF STEERING
VALVE
VALVE
1. Steering valve Raise steering valve (1 I), set in mounting position, then tighten mounting bolts. Sr Tighten the mounting bolts partially, and tighten fully after installing the hoses and tubes. * Be careful not to damage the mounting surfaces of the tubes and hoses when installing.
2. Hydraulic piping I) Connect tube (IO) between steering valve and steering cylinder (rod end) at steering valve end. 2) Connect tube (9) between steering valve and hydraulic tank at steering valve end. 3) Connect tube (8) between steering valve and steering cylinder (bottom end) at steering valve end. 4) Connect hose (7) between steering valve and main control valve at steering valve end. 5) Connect tube (6) between steering valve and hydraulic pump at steering valve end. 6) Connect tube (5) between steering valve and steering pump at steering valve end. * Fit the O-ring securely in the groove, and make sure that it is not caught when installing.
3. Steering linkage, cover 1) Tighten mounting nut of steering linkage (4). m
43-10 0
Mounting nut: 28.5k3.0
kgm
WA3561
DISASSEMBLY
AND
STEERING
ASSEMBLY
VALVE
2) Install floor cover (3) of floor frame.
..
4. Refilling with oil
1 at top of hydraulic tank filter, and
Tighten-plug
(I
plug
pump
(2)
through
of
Sr Run the engine system.
WA350-1
piping,
and
oil filler to the specified to circulate
add
hydraulic
oil
level. the oil through
the
Then check the oil level again.
43-11 0
DISASSEMBLY
AND
ASSEMBLY
DISASSEMBLY
STEERING
OF STEERING
1. Remove
tubes (I) and (2).
2. Remove
main relief valve assembly
valve assembly
VALVE
VALVE
(3) and safety
(4).
3. Case assembly I) Remove
case assembly
(51, then remove
collar
(6). 2) Remove
covers (26) and (27).
3) Remove
dust seal (28).
4) Loosen
bolt
(30)
shaft (31). 5) Remove
of
lever
(29).
then
remove
-oil seal
(32)
and
bearings
(33)
and
(34). 4. Spool assembly 1) Remove
case (7). then remove bolt
(91, then
spring (1 1) and retainer t
spool assembly
-
(8). 2) Remove When
loosening
the
spool assembled
remove
retainer
(I 0).
(I 0) from spool (I 2). bolt,
loosen
with
the
in the body.
5. Remove
plate (I 3). then remove valve (I 4).
6. Remove
plate (I 31, then remove
seat (I 5). spring
(I 6) and valve (I 7). 7. Remove
valve (I 81, then remove
(201, washer 8. Remove
plate (I 3). then remove
(24) and poppet
1. Assemble
OF STEERING
poppet
back-up
423F441
seat (231, spring
(25).
ASSEMBLY
and
boss (I 91, spring
(21) and spool (22).
(25)
ring,
and spring (24).
install
seat
VALVE
fit O-ring
(23).
then
washer
(21).
spring
fit O-ring
and
install
4 6. Case assembly 1) Install bearings
plate (I 3). 2. Assemble and
spool
boss
(191,
(221, then
install
e
(20) cover
valve
back-up
(I 7) and
ring,
install
spring seat
(I 61, fit O-ring (15).
then
install
plate (I 3). 4. Fit O-ring
and back-up
1) Assemble When
retainer
(I 01, spring (I I) and retainer
tightening
spool assembled 2) Assemble
spool
install shaft
the
bolt (9).
bolt, tighten
with
the
(8)
then fit O-ring and install case (7).
to lever
and install covers (27) and (26).
5) Assemble
collar
case assembly
(6), then fit O-ring
and install
(5).
and install
safety
valve assembly:
valve
assembly
(4)
(3).
m
Safety
D
Main relief valve assembly:
4.5f0.5
kgm
8.5 +- 1.5 kgm
in the body. assembly
(31)
bolt (30).
and main relief valve assembly
(IO) to spool (I 2). then tighten
(G2-LII
3) Install dust seal (28).
7. Fit O-rings
install plate (I 3).
Grease
4) Fit O-rings
ring, install valve (I 41, then
5. Spool assembly
43-12 0
key, then
(29) and tighten
3. Assemble
+
Lip of oil seal:
2) Assemble
(I 8). and
(33) and (34). and oil seal (32)
in body
(351,
8. Fit O-rings
and install tubes (2) and (I ).
WA350-1
DISASSEMBLY
AND
STEERING
ASSEMBLY
VALVE
1
4 \
\
423F440
WA350-1
43-13 0
machine
the
Stop
Q!
wheel
Loosen filter,
plug
at the top of the hydraulic
(I)
and plug (2) of the pump
out.
piping
1. Hydraulic I) Remove
hose (4) from cylinder. parts.
Cover the disconnected
3) Disconnect
(3).
bolt of tube support
mounting
2) Disconnect
2. Steering
tank
piping to prevent
the oil inside the tank from flowing
*
in the
pressure
remaining
piping. .
hydraulic
l
times to the left and
several
the
right to release
the
to release
tank. Then operate
inside the hydraulic
the steering
the
under
from moving.
oil filler cap slowly
the
pressure
apply
Then
blocks
put
the machine
to prevent
Loosen
the bucket
and
brake
parking
wheels
and install
Lower
and stop the engine.
to the ground the
on level ground
bar on the frame.
the safety
CYLINDER
CYLINDER
OF STEERING
REMOVAL
A
STEERING
ASSEMBLY
AND
DISASSEMBLY
tube (5) from cylinder.
cylinder
I) Remove
lock bolt at rod end, then remove
pin
(6). *
If there
are any
number
and
inserted,
shims
of
thickness
the
check shims,
the and
keep in a safe place.
2) Sling
steering
bottom
cylinder,
end, then remove
Sr If there number
are any and
remove
lock
bolt
at
pin (7). inserted,
shims
of
thickness
the
check shims,
the and
keep in a safe place. 3) Remove *
steering
Be careful
Steering
43-14 0
cylinder
(8).
not to damage cylinder:
the cylinder rod. 27 kg
WA350-1
DISASSEMBLY
AND
INSTALLATION 1. Steering
STEERING
ASSEMBLY
OF STEERING
CYLINDER
CYLINDER
cylinder
1) Raise steering
cylinder
(8) and set in mounting
position. 2) Install
pin (7) at bottom
end, then
install
lock
bolt. 3) Install pin (6) at rod end, then install lock bolt. Use a bar to align the pin holes. Never use
A
your fingers. +
Adjust
clearance
frame
2. Hydraulic
between
to become
cylinder
and
0 to 0.5 mm with shim.
piping
1) Connect
hose (4) to cylinder.
Zr Install
the
hose
without
twisting
or
fully after
in-
interference. m
Hose:
2) Connect *
8*2
kgm
tube (5) to cylinder.
Tighten
partially,
then tighten
stalling the tube support. m
Tube:
g.5+1
3) Install tube support
kgm
(3) to cylinder.
3. Greasing Grease cylinder pins well. *
Wipe
WA350-1
off any grease which comes out.
43-15 @
STEERING
ASSEMBLY
AND
DISASSEMBLY
OF STEERING
DISASSEMBLY
CYLINDER
CYLINDER
Special tools
1 790-502-l
A B
00-l
796-l
000
1 Cylinder
200
Wrench
1. Set cylinder assembly 2. Straighten using
tool
IQ’tv
Part name
Part number
1
repair stand/
1
(I) on tool A. of
lock
tab
B,
remove
cylinder
head
(2).
then
cylinder
head
(2)
from
cylinder. 3. Pull cylinder
head
from cylinderJ4) *
and
rod assembly
piston
(3)
and lift off.
Oil will come out when the piston rod assembly so have a the cylinder, from is removed contrainer
ready.
cylinder
4. Remove
5. Set cylinder
(4) from tool A.
socket
Power wrench:
*
Width
16 times
across flats of socket
nut (51, then remove
and cylinder head assembly
43-16 0
@and
0.
*
6. Remove
on tool
head and piston rod assembly
A. and loosen nut (5) with power wrench
@
: 50 mm
piston assembly
(6)
(7) from rod (8).
WA350-1
DISASSEMBLY
7. Disassemble
AND
STEERING
ASSEMBLY
piston assembly
CYLINDER
as follows:
1) Remove
wear ring (9).
2) Remove
piston ring (I 0) from piston (I 1).
,’
125P387A
8. Disassemble 1) Remove
cylinder
head assembly
,’_
“..“.“l(_.._) J .
125P388A
as follows:
snap ring (I 6), then remove
dust seal
(17). 2) Remove
rod packing
(18).
retainer
(141,
snap
ring (15). 3) Remove
bushing (I 9) from cylinder head (20).
4) Remove
O-ring
(21) and back-up
ring (22).
__ .._
xl~-.“l,.l”
125P3SOA
WA350-1
43-17 0
CYLINDER
CYLINDER
OF STEERING
ASSEMBLY
tools
Special
Part number
Clean
for dirt or damage.
installing.
packing,
dust seals or O-rings
(19)
on
head (20).
cylinder Take
*
as follows: bushing
fit
press
tool,
installing.
when
head assembly
cylinder a push
I) Using
oil
damage
to
not
careful
Be
before
Coat
engine
with
all parts
of
surfaces
Assemble
IQ'W
Part name
and check
all parts,
sliding
the
STEERING
ASSEMBLY
AND
DISASSEMBLY
bushing 2) Assemble
not
particular
care
when
press fitting.
rod packing
(18).
deform
to
the
(I 41, snap
retainer
ring (15). Be careful
t
the correct
to install
the rod packing
facing
in
direction.
Rod packing \
20 125P389A
125P388A
2OXF130
3) Using
a push
tool,
install
dust seal (I 7) on head
(20). 4) Install
snap ring (I 6).
5) Install
back-up
*
Do not force (50
-
SO’C)
ring (22) and O-ring back-up before
(21).
ring. Heat in hot water inserting.
_ ., 125P390A
43-18 0
WA350-1
DISASSEMBLY
2. Assemble
AND
piston assembly
I) Using tool C, expand *
After
setting
STEERING
ASSEMBLY
CYLINDER
as follows:
piston ring (I 0).
the piston ring in tool C, rotate
the handle 8 to 10 times to expand. 2) Remove
piston
assemble
ring
(10)
from
tool
C
and
on piston (I 1).
-.
.,
3) Fit tool D on piston ring with clamp
ring and compress
.
piston ’
0.
j’
”
:
* Parts No. of clamp @ 07281-00909 4) Assemble
wear ring (9).
;._.
3. Set piston rod (8) in tool A.
4. Assemble assembly
cylinder
head
5. Using power wrench nut (5) to the following t
Power wrench:
* t
Width
0
(7) and piston
and socket specified
0,
torque:
16 times 50 mm 11 O+ 11 kgm
across flats of nut (5):
Tightening
WA350-1
assembly
(6) on rod, then install nut (5).
torque:
tighten
.‘_”
i.“..
‘”
“.
AND
DISASSEMBLY
6. Remove
piston
STEERING
ASSEMBLY
rod and
cylinder
head
CYLINDER
assembly
from tool A. 7. Set cylinder 8. Sling
piston
(4) in tool A. rod and cylinder
and install in cylinder 9. Using tool B, tighten m
Cylinder
head
assembly
(3)
(4). cylinder head nut (2).
head nut:
60?6
kgm
10. Bend lock into notch on cylinder. 11. Remove
43-20 0
cylinder assembly
from tool A.
WA350-1
DISASSEMBLY
AND
REMOVAL
CENTER
ASSEMBLY
OF CENTER
HINGE
HINGE
PIN
1
2 Ladder .
43-22 0
WA350- 1
PIN
DISASSEMBLY
*
AND
Before starting
the operation,
For
see
details,
CENTER
ASSEMBLY
63
remove
HINGE
PIN
the bucket.
REMOVAL
OF
WORK
EQUIPMENT.
A
Stop
the
machine
the safety
to the ground the
parking
wheels
0!
the
pressure the
Loosen filter,
put
blocks
the machine
wheel
Then
apply
under
to release
and control
levers
the remaining
the the
several
pressure
in the
piping.
plug (I)
at the top of the hydraulic
and plug (2) of the pump
Disconnect terminal
install
tank. Then operate
the
cable
from
tank
piping to prevent
the oit inside the tank from flowing *
and
the bucket
from moving.
oil filler cap slowly
to release
hydraulic l
and
inside the hydraulic
steering
times
Lower
and stop the engine. brake
to prevent
Loosen
on level ground
bar on the frame.
out.
the
negative
(-1
of the battery.
Open hood (3) and fit lock (4).
a
1. Draining air Loosen drain valve (5) and drain air from air tank.
2. Ladder Sling
ladder
(61, remove
mounting
bolts, then lift
off. *
Remove
the ladders
on both the left and right
sides. Ladder:
3. Vinyl
65 kg
tube for window
Disconnect
WA350-1
washer
vinyl tube (7) for window
washer.
43-23 0
DISASSEMBLY
AND
4. Electric wiring 1) Disconnect connectors (13),
(14),
(15)
floor frame *
After
CENTER
ASSEMBLY
(91,
and (16)
(10).
(I 1).
at mounting
HiNGE
(12).
plate for
(8).
removing
distinguish
the wiring,
mark with tag to
when installing.
2) Disconnect
ground
3) Disconnect
connector
connection
and connector.
of wiring
for brake sole-
noid valve.
5. Brake valve 1) Disconnect
hoses (17)
and (18)
valve and brake chamber
between
at connection
brake of hose
and tube. 2) Disconnect valve
hoses (I 9) and (20)
and air tank
at connection
between
brake
of hose and
tube.
6. Fuel control cable 1) Disconnect
fuel
control
cable
(21)
from
ball
joint (22). 2) Remove
fuel
control
cable
(21)
from
bracket
(24)
of work
(23). *
Remove the strap correctly.
7. Floor frame, cab assembly I) Remove equipment
43-24 0
control control
lever
lock plate
lever box inside cab.
WA350-1
PIN
DISASSEMBLY
AND
2) Remove
plate
ASSEMBLY
(25)
of work
CENTER
equipment
HINGE
PIN
control
lever box. Sr Remove
3) Sling
the plate with the boot attached.
floor
remove
frame
mounting
After
lifting
assembly,
and
off
lifting
assembly, check
the
off
that
(261,
frame
and
cab
marks on the steering
it from the gear box. the
floor
raise about
disconnected.
assembly
floor
make match
shaft and remove When
cab
bolts, then lift off assembly.
20
everything
frame
and
cab
mm, then stop to has
If everything
been
is correct,
properly lift off
the assembly. If
shims
are
installed,
check
numbers
of
shims. 2
Floor frame
fi kg
and cab assembly:
250
kg
8. Steering cylinder Remove
left
and
right
pins
(27)
at
steering
cylinder rod end. *
If there thickness
are any shims,
check
the number
and
of the shims, and keep in a safe place.
9. Drive shaft Remove
WA350-1
center drive shaft (28).
43-25 0
DISASSEMBLY
10. Electric
AND
wiring,
CENTER
ASSEMBLY
HINGE
piping
1) Remove clamp of wiring (29) for front frame. air hoses (301, (3 I) and (32).
2) Disconnect t
Release
the
parking
brake
and
disconnect
the lever of the linkage. 3) Disconnect
hose
(33)
between
brake
chamber
and slack adjuster.
11. Hydraulic
piping
1) Disconnecf
dump
at rear frame 2) Disconnect rear frame
12. Steering
cylinder
hoses (34)
and (35)
end. lift cylinder
hoses
(36)
and (37)
at
connection.
linkage
Disconnect
steering
linkage
at ball joints
(38)
and
(39).
13. Support I) Disconnect
work
trol linkages
equipment
control
lever con-
(40) and (41) at main control valve
end. 2) Remove steering
43-26 0
work
equipment
gear support
control
lever
and
(42).
WA350-1
PIN
DISASSEMBLY
AND
CENTER
ASSEMBLY
14. Disconnecting frame 1) Adjust height of rear frame
(43)
and
HINGE
PIN
insert
stand. t
Insert
stands
under
the frame
on both
left
and right sides. 2) Adjust
height
of front
frame
(44)
and
insert
stand. Sr insert
stands
under
the frame
on both
left
and right sides. Sr Be
extremely
careful
when
adjusting
the
height of the frame. 3) Insert stand Sr Block
@under
both
the
counterweight left
and
(45).
right
rear
tires
securely. *
Use a stand with adjustable
4) Remove
5) Remove
safety
*
bar.
mounting
then remove
bolts
of
lower
the
frames
enough
removed
height
without
mounting
so
of
the
that
pin,
and
rear
front
the
bolts
of
upper
pin (47) from bottom.
*
not to drop the pin.
Be careful
pins
can
be
forcing.
then remove
WA3561
hinge
pin (46) from top.
Adjust
6) Remove
height.
hinge
pin,
43-27 0
DISASSEMBLY
AND
CENTER
ASSEMBLY
7) Remove mounting bolts, then remove (48) at rear frame end. *
There
are
number
shims
and
installed,
thickness
of
so the
HINGE
retainer
check
the
shims,
and
keep in a safe place. 8) Remove
9) Jack
spacer (49).
up front
differential
and
pull out
front
frame to front. *
Taking
care
bottom
of the upper
hinge bite into the rear
disconnect
the
frame, remove *
to
let the
spacer
frame
at
the
and
then
parts in balance
when
the spacer.
Be careful carrying
not
to maintain
out the operation.
15. Lower hinge
1) Remove dust seals (50) at top and bottom.
2) Remove bearing
snap rings (51)
and (52).
then remove
(53).
423F465
43-28 0
l52
WA350-1
PIN
DISASSEMBLY
16. Upper
AND
ASSEMBLY
CENTER
HINGE
PIN
hinge
1) Remove
mounting
bolts,
then
remove
retainer
(54). Remove Sr There front
dust seal (55) from are
shims
frame,
thickness
so
of the
between check shims,
retainer. the the and
retainer number
keep
and and
in a safe
place.
2) Reinove of front
3) Remove
spacer
(56)
and seal (57) from
bottom
frame.
bearing
(58).
423F467
WA350-1
423 F466
43-29 0
DISASSEMBLY
AND
CENTER
ASSEMBLY
INSTALLATION
OF CENTER
I
HINGE
HINGE
PIN
3
WA350-1 wheel loader ]
Connecting
Y
Lowerhinge
r
ToA
V
1n
IA
Brakevalve
1 I//
17 Bleeding air, checking
43-30 0
423 F468
WA350-1
PIN
DISASSEMBLY
AND
CENTER
ASSEMBLY
HINGE
PIN
Special tools
D
793-520-2370
Push tool
1
D,
793-520-2350
Push tool
1
D2
793-520-2540
Guide
1
D,
793-520-2360
Bar
2
Push tool
1
Grip
1
E
793-840-I
F
792-l
310
03-0400
1. Upper hinge Ii /“stall
58
tools A, B, C, D1, D2, and D3 to top of
upper
hinge of front
tool D, set from
frame.
above
Set bearing
in press-fitting
(58)
58
in
position,
then press fit. When
press fitting,
Make
sure
that
use tool D2 as a gude. the
bearing
is
423F469
installed
straight. Fill inside of bearing When
assembling
(58) with grease. the bearing,
do not forget
to install the spacer. The clearance do not change (59).
When
of bearing
(58)
is adjusted,
the combination
replacing
with
the bearing,
so
spacer
replace
as
a set. 2) Press fit dust seal (55) on retainer *
Replace
the dust seal with
(54).
a new
part, and
press fit so that the lip face is on the outside. a
Lip of dust seal:
3) Tighten then
retainer
insert
between
w
shims
retainer
Mounting
(54)
Grease
with
so that
(G2-LII
3 mounting maximum
and hinge is less than 0.1 mm.
bolt (when adjusting
shim):
2.020.2
w
WA350-1
Mounting
bolts,
clearance
bolt:
11.5+
1 .O kgm
kgm
423F470
DISASSEMBLY
4) Install
AND
dust
seal
ASSEMBLY
(57)
and
CENTER
spacer
(56)
HINGE
PIN
from
under front frame.
Grease (G2-LI)
a
Lip of dust seal:
JC&
Inside circumference
of spacer:
Grease (G2-LI) $r Replace
the dust seal with
a new
part, and
press fit so that the lip face is on the outside. *
Assemble that
the
the
spacer
large
(56)
chamfered
from
below
so
side
is on
the
bearing side.
2. Lower hinge 1) Assemble
snap
hinge of front press
rings
frame,
fit bearing,
(51)
and
(52)
at lower
then using tools E and F,
(53)
then
secure
with
snap
ring. *
When
press fitting,
press fit so that the sur-
face is level with snap ring (52).
423F471
2) After
installing
snap
ring
seals at top and bottom +
Replace
(511,
press
fit dust
hinge.
the dust seal with
a new
part,
and
press fit so that the lip face is on the outside. PC?%
Lip of dust seal:
Grease (G2-LI)
423F472
52
423F465
WA350-
1
DISASSEMBLY
AND
3. Connecting I) Jack
HINGE
PIN
frame
up front
towards *
CENTER
ASSEMBLY
differential,
rear frame
Be careful
move
front
frame
and align pin holes.
not to let the lower spacer
of the
upper hinge hit the rear frame. *
Align the pin holes correctly. Use a bar to align the pin holes. Never use your fingers.
2) Assemble *
spacer (49) to upper hinge (60).
Assemble that
the
the
spacer
large
(49)
chamfered
from
below
so
side
is on
the
bearing side. *
Be careful
not to damage
the lip of the dust
seal. a
Outer circumference
of hinge pin: Grease
KI&
Inner circumference
(G2-LI)
of spacer: Grease
3) Assemble 4) Tighten that
upper hinge pin (47) from below. retainer
mounting
(G2-LI)
(48)
bolts
clearance
to upper hinge pin with 3
(621,
then
assemble
“b” between
shims
so
hinge and retainer
is less than 0.2 mm. w
Mounting shim):
*
When
bolt of pin (when
tightening
clearance
adjusting
423F473
kgm
2.020.2
mounting
bolt (61).
leave a
of about 5 mm from the face of re-
tainer (48). 5) After (61) torque,
adjusting of
retainer
shim, to
then tighten
tighten the
mounting
specified
mounting
bolts
tightening
bolts (62)
of pin
fully. m
Mounting
bolt of pin: kgm
28.5e3.0 21.O*l.Okgm QF
Mounting
(10001
-
10514)
(10515andup)
bolt of retainer: 11.5?1.0
kgm
48 \
=I
Clearance “b”
423F474
WA350-1
DISASSEMBLY
6) Insert
AND
lower
CENTER
ASSEMBLY
hinge
pin (46).
then
secure
HINGE
with
lock bolt. &
Outside
circumference
of hinge pin: Grease
7) Remove
(G2-LI)
stands from front and rear frames,
and
from counterweight. 8) Install safety
bar.
4. Support I) Install
work
steering
equipment
gear support
2) Connect
work
linkages
(40)
equipment and
control
lever
and
(42). (41)
control at main
lever control control
valve
end.
5. Steering linkage Connect
steering
linkage
at ball joints
(38)
and
(39).
6. Hydraulic
piping
1) Connect frame
lift cylinder
2) Connect rear frame
43-34 0
hoses (36) and (37) at rear
connection. dump
cylinder
hoses
(34)
and (35)
at
connection.
WA350-1
PIN
DISASSEMBLY
7. Electric
AND
wiring,
I) Connect
CENTER
ASSEMBLY
piping
hose
(33)
and slack adjuster,
between
brake
then connect
chamber
parking
brake
linkage to lever. 2) Connect
air hoses (30).
(31) and (32).
3) Install clamp (29) of wiring for front frame.
8. Drive
shaft
Install center drive shaft (28). B
Drive shaft:
9. Steering Install
11.5*
1 .O kgm
cylinder
left and right pins (27)
at steering
cylinder
rod end. Sr Do not forget *
Adjust
to become
WA350-1
to install the shims.
clearance
between
cylinder
0 to 0.5 mm with shim.
and frame
HINGE
PIN
DISASSEMBLY
10.
AND
Floor frame,
ASSEMBLY
mounting
and cab assembly
position,
then tighten
Align the match insert then
secure
(26),
set in
mounting
bolts.
marks of the steering
in the spline
coming
with
of the steering wire
to
shaft,
column,
prevent
it from
out.
68
67 423 F484
6”s 2) Select number Ua” and “b”. 3) Loosen
of
mounting
shim (67). retighten *
HINGE
cab assembly
I) Raise floor frame *
CENTER
423F485
shims
matching
bolts,
and
mounting
Install shims. The
lower
should
after
not bulge
clearance
after
inserting
bolts.
rubber
mounts
tightening
(68)
mounting
bolts. t
There
should
not
stalled
portion
of shim. Move
be any
clearance
at in-
shim by hand
if there is clearance.
4) Install
lever lock plate (24)
of work
equipment
lever box. 5) Install
floor
surface
plate
(25)
of work
equip-
ment lever box inside cab. *
Coat the outside
circumference
of the lever
with
assemble
boot
soap,
then
the
to the
plate first. 11. Fuel control
cable
1) Install fuel control 2) Connect *
Secure
cable (2 I) to bracket
(23)
fuel control cable (21) to ball joint (22). with the strao.
WA350-1
PIN
DISASSEMBLY
12.
Brake
AND
CENTER
ASSEMBLY
valve
1) Connect
hoses
(19)
and
(20)
between
brake
valve and air tank at brake valve end. 2) Connect
hoses
(17)
and
valve and brake chamber
13.
Electric
(18)
between
brake
at brake valve end.
wiring
1) Connect
connector
of
brake
solenoid
valve
wiring. 2) Connect
ground connection
3) Connect
connectors
(141, (15) frame
and (16)
and connector.
(91, (I 01, (I I), at mounting
(I 21, (I 31,
plate for floor
(8).
Sr Fit the O-rings
of the connectors
securely
in
the grooves.
14. Vinyl
tube for window
Connect
washer
vinyl tube (7) for window
washer.
15. Ladder Raise tighten *
ladder
(61, set
mounting
Install sides.
WA350-1
the
in mounting
position,
then
on both
left
right
bolts.
ladders
the
and
HINGE
PIN
DISASSEMBLY
16.
AND
Refilling
with
oil
Tighten
plug
(63)
and plug (64) oil through *
CENTER
at top of hydraulic
of pump
piping,
to circulate
HINGE
tank filter,
and add hydraulic
oil filler (65) to the specified
Run the engine system.
ASSEMBLY
level.
the oil through
the
Then check the oil level again.
.
17. Bleeding
air, checking
Bleed air from brakes, then check operation. Sr For details of bleeding air, see 52 TESTING AND ADJUSTING. A
43-38 0
Close hood, then lock with catch.
WA350-1
PIN
STEERING SYSTEM 44
MAINTENANCE
STANDARD
...................... .......... Steering valve ........................ Steering cylinder mount ............... Steering cylinder ...................... Center hinge pin ...................... Diverter valve (if equipped) ............. Steering
linkage
Steering
column and gear box
Emergency Security
WA350-1
steering
pump (if equipped)
valve (if equipped)
............
.
. . 44. . 44. 44-
4
44-
8
2 6
. . 44. 44-l
9
44-l
2
0
. 44-14 . . 44-l 5
44-l @
MAINTENANCE
STEERING
STANDARD
STEERING
LINKAGE
LINKAGE
Serial No. 10001 - 10186 5,
0
h
‘\ 0
Serial No. 10187 -
n
Section A-A
articulate stopper
423F218~
44-2 0
WA350-1
MAINTENANCE
STANDARD
STEERING
LINKAGE
Unit: No.
I
Criteria
Check item
StanIciysize 1
Interference of press-fitting level bearing
Clearance of articulation
1
;;;;
mm
Remedy
1
Repaymit
1 Replace
part of center
25.0 -C 2.0 (at engine speed 1,200 rpm)
stopper
19.5 ? 2.5 kgm
11.25?
1.25 kgm
Tightening
torque of lock nut
5
Tightening
torque of mounting
6
Tightening
torque of lock nut
7.25 I? 1.75 kgm
7
Tightening
torque of lock nut
7.25 +- 1.75 kgm
8
Tightening
torque of mounting
nut
9
Tightening
torque of mounting
bolt
10
Tightening
torque of lock nut
WA350-1
28.25
nut
I
2 3.25 kgm
18.0 t
3.15 t
2.0 kgm
Retighten
I
0.35 kgm
11.25 ? 1.25 kgm
44-3 0
MAINTENANCE
STEERING
STANDARD
COLUMN
STEERING
AND
COLUMN
AND
GEAR BOX
GEAR BOX
Saction D-D
Section B-B
No.
1
423F217A
1’
Unit:
Check item
Criteria
I
Remedy
Clearance between sector shaft and bushing
2
Clearance between sector shaft and bushing
3
Clearance between steering shaft and column bushing
4
Tightening torque of mounting nut
5
Tightening torque of mounting bolt
35
-0.034 -0.009
+0.025 0
0.009 0.059
30
-0.007 -0.028
+0.021 0
0.007 0.049
-
Replace bushing
-
44-4 0
WA350-1
mm
MAINTENANCE
STEERING
STANDARD
STEERING
VALVE
VALVE
10
8 \
423F219A
WA350-1
MAINTENANCE
STEERING
STANDARD
VALVE
Unit: No.
Criteria
Check item
mm
Remedy
Clearance limit Clearance between steering spool and valve bodv
2
Clearance between demand spool and valve body
19
- 0.006 -0.012
+0.015 -ho.007
0.017 0.023
19
- 0.006 -0.012
+0.015 i-o.007
0.017 0.023 Repair limit
Standard size
3
Steering spool return spring
Replace assembly
Free length
Installation length
installation load
Free length
Installation load
93.5
53.5
24 kg
-
22.6 kg IReolace
4
Demand spool return spring
5
Check valve return spring
6
Check valve return spring
7
Trghtening torque of main relief valve
8.5?
8
Tightening torque of safety valve with suction
4.520.5
9
Tightening torque of plug
7.0% 1 .O kgm
10
Tightening torque of plug
3.7t0.3
-
-
1.5 kgm
kgm
-
IRetighten
kgm L
WA350-1
44-7
MAINTENANCE
STEERING
STEERING
STANDARD
CYLINDER
CYLINDER
MOUNT
MOUNT
Serial No. 10001
-
11117
=Ea-0
Serial No. 11118 Section
and up
U42301008
B-B
423F220
Unit: No.
Check item
Criteria
Remedy
Tolerance Standard size Clearance between mounting pin and bushing at connection of steering cylinder rod and frame
1
Shaft
50
2
Clearance between mounting pin and bushing at connection of steering cylinder bottom and frame
3
Connection
50
-:.025
+0.20 +0.10
0.100 0.225
-
-:.025
+0.150 +0.050
0.050 0.175
-
Width of hinge
Connection
44-8 0
Standard Clearance (Clearance a + b)
of steering cylinder and front frame 80+0.8 0
I
Clearance limit
Hole
Width of boss
4
Standard clearance
of steering cylinder and rear frame
I
80+0.8 0
I
63+2.0 -2.0
After adjusting with shim: Less than 0.5
83+2.o -2.0
Atter adjusting with shim: Less than 0.5
WA350-1
mm
MAINTENANCE
STEERING
STEERING
STANDARD
CYLINDER
CYLINDER
423F221
Unit: No
1
Criteria
Check item
mm
Clearance limit 1
Clearance between rod and bushing 0.594
2
Clearance between piston rod mounting snd diameter of hole
3
Clearance between cylinder bottom oin and bushing
4
Cylinder bore
5
Tightening torque of cylrnder head
pin
mounting
-
50
-:.025 -
80
+0.142 +0.080 +0.3 0
Replace bushing
0.080 0.167 -
602
6 kgm Retighten
6
Tightening torque of piston nut
WA350-1
110-t
11 kgm (Width across the flats 50 mm)
44-9 0
STANDARD
MAINTENANCE
CENTER
HINGE
CENTER
HINGE
PIN
PIN
-..-.
_
7
Serial No. 10001
-
11117
Serial No. 11118
U42301005
7
18
and up
8
Section A-A
11’
Section B-B E423F232
Serial No. 11118
and up
8
Section B-B
I
Section A-A U42401010
WA350-1
MAINTENANCE
CENTER
STANDARD
HINGE
Unit: No
Check item
PIN
mm
Criteria
Clearance between upper hinge pin and rear frame
2
Clearance between upper hinge pin and spacer (small)
3
Clearance between upper hinge pin and bearing
-
- 0.030 - 0.049
80
4
Clearance between upper hinge pin and spacer (large)
80
-0.049 0.030
5
Clearance between rear frame and spacer (large)
95
-0.071 0.036
-EL015
0.015 0.049
-
+ +0.030 0.060
0.060 0.030
-
+0.071 -10.036
0.072 0.142
I
I
6 -
Clearance between front frame and upper hinge bearing
130
82.55 7
-;.025
-0.048 -0.080
0.023 0.088
-
-0.036
+0.054
0.036 0.112
-
Clearance between lower hinge pin and rear frame
Replace
(80.00) I
I
-0.036 -0.058
82.55
8
I
Clearance between lower hinge pin and bearing
+0.061 +0.030
0.066 0.119
-
(80.00)
107.95 9
+0.035 -0.013
- E.020
Clearance between front frame and lower hinge bearing (130.00)
~
Gi.025)
0.013 0.055
/ (%:i:)
1‘-“,“,“,3,;
-
1
-
-
10
Clearance at press-fitted lower hinge pin
-0.071 0.036
82.55
part of seal of
(105.00) 11
Height of upper hinge spacer (small)
24%
1
12
Height of upper hinge spacer (large)
561
1
1:
Shim thickness and retainer
for upper hinge
1L
Shim thickness and retainer
for upper hinge
15
Tightening torque of upper hinge retainer mounting bolt
(+;:A;;)
-
0.036 0.125-
+0.054 0 (+;.054)
‘--“;,&y
-
-
-
3.0
1
.o
-
-
-
0.05
I - 1 2.0 t
When adjusting with shim:
1 1.5
Final value:
]-02-l
0.2 kgm
I
? 1 .O kgm
When adjusting with shim: 1t
0.1
0.1
2.0 & 0.2 kgm
Tightening torque of upper hinge retainer mounting bolt
Retighten 28.5 +- 3.0 kgm
Final value: -
1;
Tightening torque of upper hinge pin mounting bolt
It
Tightening torque of lower hinge pin mounting bolt
-
11.5 ? 1.0 kgm 28.5
*
3.0 kgm
(11.5
2
1 .O kgm)
I
-
( WA350-1
): Serial No. 11 118 and up
44-11
MAINTENANCE
DIVERTER
DIVERTER
STANDARD
VALVE
VALVE
(If equipped)
I--
I-
Section B-S
A
A
Section A-A 419F493
44-12 @
WA350-1
MAINTENANCE
DIVERTER
STANDARD
VALVE
Unit: No.
Remedy
Criteria
Check item
mm
Tolerance Standard size
Clearance limit
0.017 0.027
-
Hole
Shaft 1
Standard clearance
Clearance between body and spool 26
-
-
+0.015 +0.009
Reolace
2
Spool spring
3
Check valve spring
4
Tightening
torque of mounting
bolt
5
Tightening
torque of mounting
bolt
6
Tightening
torque of mounting
bolt
7
Tightening
torque of plug
ll.O?
1.5kgm
a
Tightening
torque of plug
21.5 f
3.0 kgm
-
2.5 ? 1 .O kgm
Retig hten
WA350-1
44-13 @
MAINTENANCE
EMERGENCY Model
l
PUMP
STEERING
PUMP
STEERING
EMERGENCY
STANDARD
(If equipped)
SAM(2)-40
Section A -A 419F492
Unit: Remedy
Criteria
Check item
NO.
Clearance limit
Standard clearance ,
Clearance between gear case and side plate, gear 0.10
- 0.15
0.19
- 0.043
0.075
- Replace 2
Clearance between inside diameter of needle bearing and outside diameter of gear shaft
3
Insertion depth of pin
4
Rotating torque of spline shaft
5
Tightening
I
-
0.3 z? 0.7 kgm
16.5?
ReyrolutTon P 55°C
-1
l2-g.5
torque of bolt
Discharge Oil: EOl O-CD 45 Temperature:
44-14 @
0.020
3,000
rr;;$iT 210
Retighten
1.5 kgm Standard yiTpamr;,e 106
64
WA350-1
mm‘
MAINTENANCE
SECURITY
STANDARD
SECURITY
VALVE
VALVE
(If equipped)
Section A-A 419F494
Unit: Remedy
Criteria
Check item
No.
mm
Tolerance Standard size Clearance between
Spool spring
Tightening
torque of plug
I
Free length
I
116.7
+0.015 +0.009
-
Standard
3
0.017 0.027
-
body and spool 26
2
Clearance limit
Hole
Shaft 1
Standard clearance
size
Repair limit
Replace
I
-
WA350-1
44-15 @I
BRAKE AND AIR SYSTEM 51
STRUCTURE
AND
FUNCTION
General .................... Air tank .................... Safetyvalve ................ Brake valve. ................ Brake actuated ........... . Operating in balance ...... . Brake released ........... Air governor. ............... Two-way valve ............. Brake chamber ............. Slack adjuster .............. Brake ...................... Parking brake .............. Parking brake solenoid valve Spring cylinder ............. Brake caliper ...............
.. .
l
WA350- 1
. . .
. .
.
51- 2 51- 5 51- 5 51- 6 51- 7 51- 8 51- 9 51-10 51-12 51-13 51-15 51-19 51-21 51-23 51-24 51-25
51-1
STRUCTURE
AND
FUNCTION
GENERAL
GENERAL
423F090A
Outline . The air compressed enters
the
wet
by the
tank
(5)
air compressor
and
the
(1)
moisture
.
is
removed.
The air then enters the left and right dry (61, (7) and also flows to the parking brake valve (21). The air in the left and right dry tanks (61, (7) flows to the brake valve (I I), (I 2). tanks
l
When
the air produced
by the air compressor
(I)
fills the circuit and the air pressure in the wet tank (5) reaches the maximum set pressure of the air governor (2), the air governor (2) is actuated. It opens
the
unloader
the compressor
valve
of the compressor,
(1) is put in a no-load
so
condition
When
the brake valve (1 I), (I 2) are actuated, the air in the dry tank (6). (7) flows to the brake chamber and applies pressure to the brake oil in the
master
cylinder.
through
the slack adjuster
the wheel .
loader valve of the compressor sor (I) work
is actuated. properly,
reaches opens
the and
atmosphere.
51-2 @
set the
the
by air pressure. Therefore, if the air is less than the force of the spring in the spring cylinder (231, the brake is kept applied. When the air pressure rises and the parking brake
air
the
pressure
This protects
is reached, a solenoid valve is actuated to air to the spring cylinder (23). This release
the parking brake (24).
(2) does not
inside
safety
the tank
valve
is released
to
by
It is designed
and the compres-
pressure
pressure,
(23).
It closes the un-
If the air governor
and
piston to apply the brake (I 91, (20). brake (24) is applied mechanically
pressure
release
(2) is actuated.
passes
to be released
supply
the air governor
oil
(I 71, (I 8) and pushes
the spring in the spring cylinder
and no air is compressed. the minimum
pressurized
The parking
and the air pressure
When the air is used inside the tank drops below set pressure of the air governor (21,
The
(28) the
the air circuit. WA350-1
1. Air compressor 2. Air governor 3. Tire inflation 4. Drain cock 5. Air tank (wet) 6. Air tank (dry) 7. Air tank (dry) 8. Check valve 9. Check valve 10. Drain cock 1 1. PH. brake valve 12. L.H. brake valve 13. Two-way
valve
14. Two-way valve 15. Front brake chamber 16. Rear brake chamber 17. Front slack adjuster 18. Rear slack adjuster 19. Front brake 20. 2
1
Rear brake
Parking 22. Parking
brake solenoid brake sensor
valve
23. Spring cylinder 24. Parking brake 25. Horn valve 26. Horn 27. Brake oil tank 28. Safety valve 29. Air pressure sensor 30. Stop lamp switch 3 1 Transmission
rl 3
WA350-1
cut-off
switch
423F127
51-3
51-4
STRUCTURE
AIR
AND
AIR TANK,
FUNCTION
SAFETY
VALVE
TANK A
WET
DRY
TANK
TANK
A.
To air governor
B.
To air tank
C.
Air pressure
sensor
Pick-up
D.
Air pressure
sensor
Pick-up
E.
From air compressor
F.
To drain cock
G.
To safety
H.
To brake valve
I.
To drain cock
J.
From air tank
Name
423FO94
(dry)
valve
(wet)
Capacity
Maximum
9.4Q
Wet tank Dry tank
(L)
Dry tank
(RI
20.3
pressure
9.5 kg/cm2 II
1 20.311
9.5 kg/cm2 1
9.5 kg/cm2
423FO95 l
The air tank
consists
of one wet tank
tanks.
air from
the
the
The
wet
then
tank
divided
and
the
and
sent
and two
compressor
moisture to
first
is’ removed.
the
left
and
dry
enters It is
right
dry
tanks. l
A safety
valve
and air pressure
sensor
are installed
in the wet tank.
1. Adjustment 2. Spring
SAFETY
3. Spring
VALVE
4. Ball 6
Function l
The
safety
valve
acts as a safety
is installed device
Operation l If the air governor
not work
pressure
inside
pressure,
ball (4) is pushed
to the atmosphere.
WA3561
in the wet
tank,
and
for the air circuit.
does the
nut
cage
air tank
rises
properly above
5. Locknut 6. Relief valve
7. Body
and the the
set
up and the air escapes 423FO96
51-5 0
STRUCTURE
AND
BRAKE
VALVE
Outline . There the
are two bottom
FUNCTION
brake valves of
the
These are operated .
When the
installed
operator’s
by depressing
the right pedal
brake
BRAKE
chamber
the
at
compartment. the pedal.
is depressed, and
in parallel
VALVE
air is sent to
brake
is actuated. the left pedal is depressed, the brake is actuated in the same way as with the right pedal, but
When
at the same time, the transmission is actuated
electrically,
solenoid
and the transmission
valve is put
in neutral.
6’ 1. Brake pedal
A.
From air tank
2. Plunger
B.
From air tank
3. Piston
C.
To front brake chamber
4. Inlet valve
D.
To rear brake chamber
423FO97
5. Piston 6. Inlet valve 7. Rubber spring
51-6
WA350- 1
STRUCTURE
BRAKE
AND
FUNCTION
VALVE
ACTUATED
Upper part l When pedal (1) is depressed, passes through
plunger
and is transmitted moves down, time
BRAKE
to piston
(3).
When
force
spring
(7).
piston
(3) port (9) is closed, and at the (4) is moved down and air from
exhaust
inlet valve
the air tank (1 1) flows actuates
the operating
(2) and rubber
from port A to port C. This
the front brake chamber
(I 2).
._... wet tank
_
-To front slack adjuster
Lower part l When pedal (1) is depressed, passes through
plunger
and is transmitted moves
down,
air from
to piston
inlet valve
the air tank flows
This actuates
the operating
(2) and rubber (3).
When
(4) is moved from
force
spring piston down,
(7). (3) and
port B to port D.
e To rear slack adjuster 423FO98
the rear brake chamber.
Operation of brake when lower valve fails l Even if there is leakage of air in the lower piping, the upper part will operate
normally.
adjuster
WA350-1
STRUCTURE
Operation l
AND
of brake
when
pedal
(1)
down
operate
normally.
mechanically
Upper
IN
VALUE
fails
of air in the upper piping, if
is depressed,
pushed
OPERATING
BRAKE
upper valve
Even if there is leakage the
l
FUNCTION
piston
(5)
will
be
and the upper part will
BALANCE
part
When and
the pressure the
air
become
in the space
pressure
from
high, the pressure
below
the
piston
brake
pushes
(3)
chamber
rubber
spring
-(7). and piston (3) moves up to close inlet valve (4). When
this
closed.
The air pressure
happens,
ber is retained
exhaust
port
entering
(9)
stays
the brake cham-
and the brake is kept applied.
ear slack ster 423FlOO
Lower l
part
Upper
piston
(3)
moves
up, and
inlet
valve
closes.
Piston (3) is pulled up by an amount
to the
amount
closes.
The
pressure
of movement
exhaust
valve
is maintained
and inlet valve is closed,
and
the
so the
brake
(4)
equal (6) air
is kept
applied. The air pressure
in the space at the upper part bal-
ances the operating sure in the space pressure When stroke,
force
of the pedal.
at the lower
The pres-
part balances
the
in the space at the upper part.
pistons
(3) and (5) move to the end of their
inlet valves
The spaces air pressure become
to the
air pressure
the braking
the amount
the brake
the pistons
move down
effect pedal
opened.
parts, and the
in the left and right brake
equal
Therefore,
(4) and (6) are fully
in the upper and lower
chambers
in the
tank.
can be adjusted is depressed.
on- front slack
by
When
to the end of their stroke,
the brake is applied fully. From rear slack
423FlOl
51-8 0
WA350-1
STRUCTURE
BRAKE
AND
FUNCTION
pressure
(1) is released
is removed
from
the air at the bottom spring
is opened
move
piston haust
of the piston, the piston
is released
(5) is let out,
(5) and spring port
chamber
top
of the
piston,
and the piston
up. Exhaust in the brake
port
(9)
cham-
to the atmosphere.
Lower part . When the pedal piston
and the operating
the
and the air pressure
ber is released
of
VALVE
RELEASED
Upper part . When the pedal
return
BRAKE
(13)
(10) opens is released
and the air at the top
the
air at the
bottom
pull the piston
and the air pressure
to the atmosphere.
up.
of Ex-
in brake slack
E423F102
WA350-1
51-9 0
STRUCTURE
AIR
AIR
FUNCTION
AND
GOVERNOR
GOVERNOR 5. Exhaust
1. Spring 2. Exhaust
7. Tank port
3. Piston 4. Unloader
stem
6. Inlet valve
port port
8. Filter
Specifications pressure:
l
Cut-out
l
Cut-in pressure:
8.3 f
0.3 kg/cm2
7.0 + 0.3 kg/cm2
423F091A
Function The air governor
maintains
cuit to the specified
the pressure
in the air cir-
range.
OPERATION
Compressor working l
The air pressure
in the wet tank passes from
tank port (7) through
of the piston (3).
bottom When
the
the filter (8) and acts on the
the
specified
air pressure pressure
in the tank
(cut-out
pressure)
is below the
the
piston
(3) is pushed down by the spring (1). l
When
this happens,
passes through
the air at the unloader
the exhaust
sphere and the compressor
port (4)
stem (5) to the atmois actuated.
+ To dr
423 F092A
Compressor loaded
51-10 0
WA350-1
STRUCTURE
AND
Compressor When
FUNCTION
AIR GOVERNOR
stopped the
reaches
pressure
the
set
in the
pressure
wet
tank
(cut-out
rises,
and
pressure),
the piston (3) is pushed up against the spring (I 1. When the piston (3) is pushed up, the exhaust stem (5) is closed and the inlet valve (6) opens. The
pressure
inlet valve
from
the
tank
(6) and unloader
the unloader
through
the
valve of the compressor.
This puts the compressor When
passes
port (4). and acts on
the air pressure
in a no load condition. inside the tank
drops, the piston (3) is pushed down by the spring (I 1. When then pressure drops below the specified pressure (cut-in pressure), the inlet valve (6) closes and the exhaust
stem (5) opens.
sure at the unloader
port
exhaust
and
stem
atmosphere,
(5)
so the
(4) passes is
the
into
the
released
compressor
The pres-
through
starts
to work
To wet tank
again.
423FO93A
Compressor no-load
WA350-1
51-11 0
STRUCTURE
AND
TWO-WAY valve
is installed
valves.
It acts
from
escaping
from
other
brake valve
Operation . The air circuit connected are
VALVE
VALVE
Function . The two-way brake
TWO-WAY
FUNCTION
between
prevent
one
the
brake
the
two
air pressure
valve
when
the
is depressed.
of the left and right
so that
actuated
to
the
when
brakes either
brake
valves
on all four of
the
is
wheels
pedals
is
depressed. The air pressure way
valve
entering
moves
port
A of the two-
seat (2) and shuts
from
off the circuit
to port 6. Therefore,
the air pressure
port C and actuates
the brake chamber
flows (5).
only to
1
2
3
4 423F103
1. Body
3. Plug
2. Seat
4. Cap
5. Brake chamber
51-12
WA350-1
STRUCTURE
AND
BRAKE
CHAMBER
FUNCTION
BRAKE
Section
mm
CHAMBER
A-A
m 423F105A
1. 2. 3. 4.
Air cylinder Air piston Rod Spring
5. Body 6. Piston
WA350-1
7. 8. 9. 10.
Master cylinder Piston valve Bleeder Brake chamber stroke sensor
Specifications 1. Air cylinder Cylinder bore: 180 mm Stroke: 85.5 mm Cylinder capacity: 2380 cc 2. Master cylinder Cylinder bore: 68 mm Stroke: 84.5 mm Delivery: 297 cc
51-13 a
STRUCTURE
AND
FUNCTION
BRAKE
CHAMBER
OPERATION Brake
operated
When
the brake
is
supplied
chamber. piston
pedal
from Air
piston
(6) of master
is sent by piston
is depressed,
the
brake
(2) moves cylinder
compressed
valve rod
to
the
(3) and
pushes
(7) to the right.
(6) to the brake piston
air brake
Brake oil
to actuate
the
brake.
I, To slack adjuster
423F106
Brake
held in position
When
the brake
force,
the hydraulic
pedal is kept depressed pressure
at a constant
is kept constant,
so the
brake is kept applied.
e To slack adjuster
423F107
Brake
released
When
the operating
released, piston
(2) of the brake
brake valve, cylinder further, sent force
force
on the brake
the compressed
chamber
and the hydraulic
(7)
drops.
the brake
back
air supplied
If the
is released pressure
brake
of the brake return
of master spring.
is partly from
inside
pedal
oil sent to the piston
to the inside
pedal
to the back of the
master
is released
of the brake
cylinder
is
(7) by the
To t,ze valve
423F108
51-14
WA350-1
STRUCTURE
AND
SLACK
ADJUSTER
FUNCTION
Function . The slack adjuster from
the
acts
to
piston
brake keep
and
is installed chamber
the
discs
are worn.
clearance
stant
time lag when
In this
in the brake
to the
constant
discs
SLACK
between even
way
the brake
brake when
oil line
piston. the the
it acts to keep
ADJUSTER
It
brake brake a con-
is operated.
A
1. Bleeder
A. Inlet port
2. Cylinder 3. Check
423F109
B. Outlet
port
valve
4. Piston 5. Spring
WA350- 1
51-15
STRUCTURE
AND
SLACK
FUNCTION
ADJUSTER
OPERATION 1. Brake pedal depressed The
oil pumped
flows port
in from
out
from
E the oil is divided
cylinders
the
brake
P of the slack
port
and sent
(2) and moves
piston
chamber
adjuster. to left
(6) From
and right
(4) a distance
of S
to the right. 4
2
4
423FllO
Because stroke
of this, an amount S flows
from
(7).
When
this
the
brake
piston
braking
force
port
happens, and
of oil corresponding C to the brake the
disc
clearance becomes
to
cylinder between
0,
so
no
is generated.
423FlllA
51-16 0
WA350-1
AND
STRUCTURE
If the oil pressure specified
certain
and the oil flows
FUNCTION
SLACK
in the chamber check
pressure, through
a
(7) goes above (3) opens
valve
pilot circuit
D and applies
to port C. This gives the braking
pressure
ADJUSTER
force.
423F112A
pedal
2. Brake the
back
of the
pressure
draulic back
released
the brake
When
stroke
is released, brake
piston
of the brake.
S and
the
disc
pressure because
is applied of the
to hy-
Piston
(4) is moved
clearance
returns
to
normal.
423F113A
WA350-1 %”
STRUCTURE
AND
FUNCTION
BRAKE
BRAKE Function l
The brakes
are wet-type
multiple
disc brakes,
and
are fitted to all four wheels.
7
8
Detail P
423F116A
1. Guide pin
5. Inner gear (Teeth
2. Return spring
6. Cylinder
3. Brake piston 4. Outer gear (Teeth
WA350-1
112)
7. Plate 164)
8. Disc
51-19 0
STRUCTURE
AND
BRAKE
FUNCTION
Operation .
When
the brake pedal is depressed,
pressure
is ap-
cylinder
of the
(4) is moved
to the
plied to the brake oil by the master brake chamber. right,
and
plate (7). when
disc
Brake (8)
piston
is kept
Disc (8) rotates
it is held, the
in close together
rotation
contact
with
with wheel,
is stopped
so
and the
brakes are applied to stop the machine. Frc,lTl adj us
423F117
.
When
the brake pedal is released,
the pressure
the rear of brake piston (4) is released. is then
moved
to the left by the force
2
on
4
The piston of return
spring (2) and the brake is released.
To slack adjuster
423F118
51-20
WA350-1
AND
STRUCTURE
PARKING
FUNCTION
BRAKE
PARKING Outline l
The parking the front
l
The (I
force
brake
is a disc type
and is installed
on
axle. of the
l
The
spring
inside
the spring
cylinder it is re-
brake
parking
differential
1 is used to apply the brake mechanically;
leased
BRAKE
The disc is installed tates
caliper
(3) is fixed
to the front
case.
together
with
to the differential
yoke
and ro-
the coupling.
by air pressure.
423F122A
1. Spring
cylinder
2. Rod 3. Brake caliper
WA350-1
51-21 0
STRUCTURE
Brake
AND
PARKING
FUNCTION
BRAKE
operated
When
the parking
ON, solenoid
brake switch
lever is moved
valve (6) is actuated
the air tank is shut off by valve time,
the
released
air
from
the
(8).
spring
to the atmosphere
to
and the air from At the same
cylinder
from
(3)
between
is
valve
(7) and body (3). Therefore,
the piston (5) of spring cylinder
the rod (1) are pulled by the tension so when
lever
(9) is pulled,
(3) and
of the spring,
the parking
brake
applied. Part A is the fulcrum
of the lever, which
pulls the
bolt, so the left and right pads are pushed
.7
is E$- Exhaust From air tank
against
the disc, and the parking brake is applied. The
clearance
different because
the
and it draws amount
between
at the
bottom
and
pad and the disc is the
bottom.
of the caliper
a circle as it moves.
of movement
clearance
the
top
is greater
This
is
is the center
As a result, the at the top, so the
must also be greater at the top.
423F125A
Brake l
released
When the
the parking
solenoid
brake switch
valve
closes the exhaust
(6)
is turned
is actuated
to OFF,
and valve
(7)
port.
At the same time, the air in the air tank enters the top part of the piston
(5) of spring cylinder
(3).
It
overcomes
the force
of the spring (4) and pushes
the piston
(5).
pushes
This
rod (I)
and releases
the brake. Therefore,
air pressure
is applied
to the
spring
cylinder and the parking brake is kept released. l
However,
if the air pressure
to a level where
it cannot
operation
brake,
installed solenoid circuit,
of the
maintain
the
the
normal
air pressure
sensor
to the tank sends an electric valve. and
the
This
releases
parking
tank
inside the tank drops
signal to the
the spring
brake
cylinder
is automatically
applied.
423 F126A
51-22 0
WA350-1
STRUCTURE
AND
PARKING
PARKING
FUNCTION
BRAKE
SOLENOID
BRAKE
SOLENOID
VALVE
VALVE 1. Coil
2. Body
3. Outlet
port
4. Inlet valve
5. Outlet valve
1
6. Exhaust
port
solenoid
valve
7. Inlet port
FUNCTION
5
2
l
The
parking
switch
brake
air to the parking
controlled
and actuated
brake
is a valve
air chamber.
by a switch
to It is
in the opera-
tor’s compartment.
6
3
7 Spri 423F119 From wet tank
OPERATION l Parking brake ON When
the parking
compartment switched enters
brake
is turned
OFF,
and
switch
in the operator’s
ON, the solenoid
air from
the
valve
spring
is
cylinder
It passes around valve (51, enters
port A.
port B and is drained.
In addition,
air from the tank
enters port C, but it is shut off by valve (4). so the air does not flow. As a result, the parking
brake is applied
by spring
To brake valve
force in the spring cylinder. 423F120
l
Parking brake OFF When
the parking
compartment switched
brake
is turned
ON,
(5) moves
From wet tank
valve is
down.
Valve
by a rod, so valve (5) and valve
(4) both move down. port C, but valve around
in the operator’s
OFF, the solenoid
and valve
(5) is connected
passes
switch
The air from the tank enters
(4) has moved
valve
down,
(4) and enters
sent to the spring cylinder
so the air
port A.
and the parking
Air is
brake is
released.
I$ To brake valve 423F121
WA350-1
51-23 0
STRUCTURE
SPRING
AND
FUNCTION
SPRING
CYLINDER
CYLINDER
423F124
1. Rod
Outline
2. Boot
.
The
air pressure
3. Cylinder
valve
pushes
4. Spring 5. Piston
from
spring
release
the parking
brake.
Usually
the parking
(4). so the machine
51-24
the parking
the
brake
and
brake
is kept applied
is prevented
solenoid
compresses
from
it to
by spring
moving.
WA350-1
STRUCTURE
AND
BRAKE
CALIPER
FUNCTION
BRAKE
CALIPER
423F123A
1 Pad carrier 2. Pad 3. Adjustment 4. Lever 5. Disc
WA350- 1
bolt
Outline l The parking brake caliper is fixed to the front differential case. The disc is installed to the coupling of differential, and rotates together.
51-25 0
BRAKE AND AIR SYSTEM 52 TESTING
AND ADJUSTING
Standard
.
value table
Tool list for testing Measuring
brake
. ......
. .
air.
Measuring
wear
Air bleeding Parking
.
.
. . . . . . _. Brake performance Checking brake piston leakage .
Measuring
brake
Checking
The following
precautions
troubleshooting
or during
I. The values
in these
used as target 2. The standard standard
and adjusting
.
WA350-1
values
repairing
in these
tables
for the machine
values
tables
using
the Standard
on the values or when
must
shipped
for
estimating
for judgement
when
be used as reference value
when
Value
3
. ...... . ......
52-
4
52-
5
......
52-
8
......
52-
9
52-l
0
. . ...... ......
52-l
1
.
......
52-l
2
brake
......
52-l
3
52-l
5
..
line
.
parking
.
.
.
Tables
to make
judgements
leaving
the plant,
so they
during
and adjusting.
are based
when
standard
use these
tables
values
values
they should 3. These
are necessary testing
brake
performance
Troubleshooting
*
.
of brake disc
from
2
52-
.
and adjusting pedal
52-
......
when
from
in combination
with
new
machines
wear
after
troubleshooting
repair and operating values
when
should
be
of use. are estimated
the plant, and on the results
not be used for standard
alone to make simple
a period
values
of various
records
when
judging
claims.
based
tests.
making
on the
Therefore, judgements.
In addition,
do not
judgements.
52-l @
TESTING
AND
STANDARD
Testing
STANDARD
ADJUSTING
VALUE
and measuring
Measurement l
Coolant
Operating
l
Angle
force
Unit
condition
%trd
‘ermissible value
temperature:
Inside operating l
TABLE
TABLE
item
Brake pedal
VALUE
speed:
range
l
Engine
l
Air pressure:
Specified
l
Air pressure:
7 kg/cm2
kg
Low idling pressure
39-47
Max. 55
degree
6.5 - 20.5
7.OkO.3
7.020.3
kg/cm2
8.3kO.3
8.320.3
9.5kO.4
9.520.4
6.0?0.1
6.0fO.l
Air system l
Air governor
cut-in
l
Air governor
cut-off
l
Safety
actuating
valve
Warning
pressure pressure pressure
buzzer
l
Actuating
starting
l
Actuating
stopping
pressure
l
Air pressure:
l
Road surface:
pressure
Speed
6.0+;.4
6.0+8.4
Flat, horizontal,
dry, paved l
kg/cm2
7kg/cm2
surface
when
applying
brakes:
20 km/h l
Time lag when
pressing 0.1 set
the pedal: Brake performance
l
Air pressure:
l
Brake pedal operating
l
Tire inflation
m
7 kg/cm2
5
Max. 5
Max. 5
Max. 5
Max.
force:
38kg Specified l
of brake
disc
temperature:
Inside operating
Drop in brake oil pressure
Wear
Coolant
pressure:
pressure
l
Test pressure
l
Coolant
kg/cm2
range
53 kg/cm2
temperature:
mm
Inside operating Parking
brake performance
l
Tire inflation
pressure
Road surface: surface
2.3-3.1
Max. 4.7
range
pressure:
Specified l
5 min.
with
Machine
Flat, dry, paved l/5
stopped
(I l”20’)
-
gradient l
l
Thickness
Machine:
In operating
condition 13.7
of pad
(a,b,c) Min. 7.0
mm
l
Clearance
between
disc
1 1.7 (d)
0.1 -0.4
Max. 2.6
and pad 419F315
52-2 0
WA350-1
TESTING
AND
TOOL
TOOL
ADJUSTING
LIST
FOR TESTING
AND
of brake disc
Vernier
Commercially
calipers
-
carrying
out testing,
bar on the frame,
adjusting
I
or troubleshooting,
lower the bucket to the ground,
available
O-IlOkg 0 - 100
kg/cm2
150mm
- 200mm
I
Feeler gauge
When
ADJUSTING
Remark
tester
Tape measure
A
AND
ADJUSTING
799-l 01-l 001
Push gauge
Wear
FOR TESTING
Part number
Tool
Hydraulic
LIST
Commercially
available
30m
1Commercially
available
0.1 -3.0
stop the machine
on level ground,
mm
install the safety
and stop the engine.
Then apply the parking brake and block the tires. LU
When
WA350-1
taking measurements,
do not allow unauthorized
persons near the machine.
52-3 0
TESTING
AND
ADJUSTING
MEASURING
BRAKE
t
Measurement
l
Coolant
l
Engine speed: Low idling
l
Air pressure:
Inside operating
1
Operating force
39-47
Permissible value
I
kg
I
Max. 55 kg
I -
16.5” - 20.5”
tool
Part number 799-l
01-l
1. Measuring
Part name
001
operating
Align
Q’ty 1
Push gauge
force
of pedal
1) Fit push gauge A to the operator’s t
PEDAL
range
Standard value
Operating angle
A
PEDAL
7 kg/cm2
Item
Special
BRAKE
condition
temp:
Brake pedal
MEASURING
the center
foot.
of the push gauge
with the
center of the pedal. 2) Start the engine and run at low idling, then depress the pedal and measure 2. Measuring
travel
the operating
1) Fit push gauge A to the operator’s *
Align
force.
of pedal
the center
foot.
of the push gauge
with the
center of the pedal. 2) Start the engine and run at low idling, then depress the pedal with an operating and measure
the travel
force
of 43 kg
L of the pedal with
an
angle meter. 3. Measuring
play of pedal
1) Start the engine. 2) Push the brake pedal in lightly by hand, and use an angle pedal
meter
to the
to measure
point where
the
travel
its starts
of the
to become
heavy.
423F316
52-4 0
WA350-1
TESTING
AND
MEASURING
ADJUSTING
MEASURING
AIR
AIR
*
Measurement
l
Coolant temp: Inside operating
condition range
Air governor Unit:
Standard value
Item
7.0*
Cut-in pressure Cut-off
Warning
7.OkO.3
( 8.3kO.3
buzzer
Unit:
Standard value
Item Actuating pressure
starting
Actuating oressure
stopping
Safety
Permissible value
0.3
( 8.3kO.3
pressure
6.0+
kg/cm2
Permissible value 6.OkO.l
0.1
6.0+“.4
6.0+“.4
0
0
valve
Special
kg/cm2
Unit:
kg/cm2
tools
‘;
D
1 790-301-1110
E
790-301-I
I 1
Nipple
1
Connector
1
190
Commercially available
F
+
1 Nipple
When
measuring,
connect
D, E, and connector the tire inflation 1. Measuring
nipple B. hose C, nipple
F to gauge
coupler
set pressure
A, then insert in
on the machine. of air governor
1) Open the drain valve and drain air from the tank. 2) Start
the engine
and raise the pressure
inside
the tank. Measure
the pressure
is actuated (no-load WA350-1
at which
the air governor
and the air compressor
is cut-off
rotation).
52-5 0
brake
the
the
Measure
in
cuts
air compressor
the
at which
pressure
use
idling,
air pressure.
the
lower
to
pedal
at low
engine
the
3) With
AIR
MEASURING
ADJUSTING
AND
TESTING
of operation).
(Start
Adjusting
I) Stop the engine. (2)
screw
and turn adjustment
lock nut (I),
2) Loosen to adjust. *
screw
To DECREASE
set pressure, set pressure,
To INCREASE *
as follows.
Turn the adjustment
1.4 kg/cm2
Approx.
alarm
pressure
cut-off
2. Measuring
and
again
are standard.
that all values
check
measure
as above.
adjusting
-k After
screw.
for 1 turn of screw
of adjustment
Amount
screw.
TIGHTEN LOOSEN
air
of
pressure
buzzer
I) Start brake
and run at low
the engine
to lower
pedal
sure the pressure
at which
Use the
idling.
and mea-
the air pressure, the buzzer
to
starts
sound. 2) Lower
the
which *
pressure
the buzzer
If the
pressure
the switch. *
After
and
speed
engine
further, measure
stops
the
increase
the
pressure
at
sounding.
is not
standard
If necessary,
replacing
then
the switch,
replace
value,
check
the switch.
measure
the pres-
sures again.
425F206
52-6 @I
WA3.50-1
TESTING
AND
3. Measuring
safety
1) Loosen nor
set
governor safety
*
After If the
screw
actuating
above
the
the
engine
air comes
of the air gover-
pressure
actuating
of the
pressure
and
do
not
to the specified
safety
measure
out of the safety
measuring,
governor *
the
air
of the
valve.
2) Start when
AIR
valve
the adjustment
and
MEASURING
ADJUSTING
valve
forget
the
pressure
valve.
to return
the
air
pressure.
is defective,
replace
the valve
assembly:. Do not try to adjust *
Hook
the
removing. *
Install-so
tool Never
on
it. “a”
when
use part “b”
part
when
that the exhaust
port “c”
tightening
or
tightening. faces
down.
423F318A
WA350-1
52-7 @
TESTING
AND
BRAKE
ADJUSTING
BRAKE
PERFORMANCE
PERFORMANCE
Measurement
condition
Time lag when pressing the pedal: 0.1 sec. Air pressure:
Inside operating
Road surface:
range
Flat, horizontal,
straight,
dry, paved
surface. Machine
speed: Speed when applying
brakes:
20 km/h Tire inflation
pressure:
Specified
pressure
Standard value
item Brake performance
Permissible value
Max. 5 m
Max. 5 m
I
Special tool Part number
Part name
Commercially available
Q’ty 1
Tape measure
Conditions for measurement I) Start the engine and then start the machine. 2) Place the speed
control
lever in the highest
speed
range and drive the machine. 3) When ress
the machine the
left
selector
switch
is traveling
brake
pedal
ON) with
at 20
km/h,
(transmission the
specified
dep-
cut-off operating
force. *
Decide
the
brakes,
then
point 4) Measure the point *
Carry
run-up apply
road
and point
the brakes
when
to apply
the
the braking
is reached. the where
distance
from
the machine
out the test three times
the
braking
point
to
stops. and take the average
value.
A
A
Stopping point
L
Braking point
Braking distance
A Brake pedal operating position
Runup
road 423F319
52-8 0
WA350-1
TESTING
AND
ADJUSTING
CHECKING *
Measurement
l
Coolant
l
Test pressure:
l
Air pressure:
CHECKING
BRAKE
PISTON
LEAKAGE
condition
temp: Inside operating
range
53 kg/cm2 Inside operating
range
Standard value
Permissible value
Drop in pressure
Max. 5.0 kg/cm2
Max. 5.0 kg/cm2
tool
Part name
Part number
1 Hydraulic
A
PISTON
LEAKAGE
Item
Special
BRAKE
Q’ty
) 1
tester
Block the tires securely.
Measuring
procedure
1. Remove
bleeder
screw
(I),
then
install
tool A in
bleeder screw mount. 2. Start the engine and bleed the air. *
Two workers depresses
are needed
the
pedal
air from bleeder screw *
Turn the transmission
3. Depress 53
the left brake.
kg/cm2,
leave
measuring,
one
bleeds
the
(2). cut off switch
When
ON.
the gauge reading
for 5 minutes
much the pressure 4. After
for this operation:
and the other
and check
is
how
drops. stop the engine,
and loosen
the
bleeder screw. Lower the pressure, *
After
completing
then remove operation,
tool A. bleed the air from
the brake circuit again.
WA350-1
52-9 @
TESTING
AND
MEASURING *
Measurement
l
Coolant
l
Air pressure:
MEASURING
ADJUSTING
WEAR
BRAKE
condition
temp:
Inside operating
range
Inside operating
range mm
tool
Stop
Q’ty
Part name
Part number Commercrally available
A
OF
OF BRAKE
Unit:
Special
WEAR
Vernier
the machine
1
calipers
on level ground
and block
the
tires. Method
of testing
1. Remove
plug (1).
2. Depress
the brake
3. Measure
depth
ing to the spring *
Keep
the
pedal to the end of its travel.
“a”
from
the end face
of the hous-
guide.
brake
pedal
depressed
when
mea-
suring. 4. Install
a vinyl
hose to bleeder
(2). loosen
the bleed-
er and bleed the air brake oil. *
After
bleeding
brake
piston
the has
brake returned
oil, to
check the
that end
the
of
its
stroke. 5. Measure
depth
ing to the spring
Calculating
“b”
from
the end face
of the hous-
guide.
wear
S=a-b S = Max. 4.7 mm a Piston stroke S
b
J q+=cZY-I
II IllIll 423F320
52-10 @
WA350-1
DISC
TESTING
AIR
A
AND
AIR
ADJUSTING
BLEEDING
FROM
BRAKE
BLEEDING
FROM
BRAKE
LINE
LINE
Block the tires securely.
Order of operation Remove
cap (1) of the bleeder
hose (2) into the screw
screw,
insert vinyl
and put the other end in a
container. Start the engine. Two
workers
depresses
are needed
the pedal
for this operation:
and the other
bleeds
one
the air
from bleeder screw. Tighten
the bleeder
screw,
then release
the brake
pedal slowly. *
Depress
-f
Keep
the left brake pedal.
adding
brake
oil so that
the oil circuit
is
always full. Repeat
this operation
out from
the hose.
and tighten
until no more bubbles Then
the bleeder
depress
screw
come
the pedal fully
while
oil is flowing
out. *_ Follow
the
same
procedure
to bleed
the
air
from each cylinder. After
bleeding
all the cylinders,
check
the level
of the oil tank and add oil. t
To bleed the air completely,
bleed the air first
from
from
the
cylinder
furthest
the
master
cylinder. t
When
the
cylinders, stroke
air
sensor
If it is out
been that
rod
bled (4)
of brake chamber
of place,
sensor installation
WA350-1
has
confirm
push
from for
the
all
the
over-
(3) is in place.
it in as far as the
end face “a”.
52-11 0
TESTING
AND
ADJUSTING
PARKING
BRAKE
Measurement
BRAKE
PERFORMANCE
PERFORMANCE
condition
Tire inflation Road
PARKING
pressure:
surface:
Specified
Flat, dry, paved
(I l”20’)
gradient.
Machine:
In operating
pressure surface
with
II5
condition
423F321
Measuring procedure 1. Start the engine and drive the machine straight up a 1 I5 gradient
2. Depress
the
with the bucket unloaded. brake,
place
the directional
lever
in
neutral, then stop the engine.
3. Turn
the
release
parking
the
brake
brake pedal
switch and
ON, keep
then the
slowly
machine
must be kept stopped. l
The
measurement
must be made with the ma-
chine facing either up or down the slope.
52-12 0
423F322
WA350-1
TESTING
AND
CHECKING.
ADJUSTING
CHECKING
AND
*
Measurement
condition
.
Air pressure:
Maximum
ADJUSTING
PARKING
AND
ADJUSTING
PARKING
BRAKE
BRAKE
set pressure
Unit: mm
Thickness
A
11.7
7.0
(d)
423F322A
the tires securely.
Measuring
procedure
1. Turn the main switch 2. Turn
(a,b,c)
13.7
of pad
Block
Permissible value
Standard value
Item
ON.
the parking
brake
switch
the engine,
and measure
OFF to release
the
brake. 3. Stop
the disc to the backing Be
extremely
switch
careful
OFF during
If the
measurement
value,
replace
For details
the thickness
from
plate of the pad. not
to
turn
the
main
operation. is not within
the two
the
standard
pads as one set.
of replacement,
see DISASSEMBLY
AND ASSEMBLY.
Measuring
clearance Unit: mm
Measurement
procedure
1. Turn the main switch 2. Turn
the
parking
ON. brake
switch
OFF
to
release
brake. 3. Insert
a feeler
and measure
gauge
between
the clearance
disc (I
1 and pad (21,
A,B.
423F323
WA350-1
52-13 0
TESTING
AND
CHECK
ADJUSTING
AND
ADJUSTING
OF
PARKING
BRAKE
Adjusting *
Be extremely
careful
not to turn the main switch
OFF during operation. *
If the
measurement
is not
within
the
standard
value, adjust as follows. 1. Turn the parking
brake switch
OFF to release
the
brake. 2. Loosen
nuts (2) and (3) of turnbuckle
the cotter
pin from
and remove 3. Adjust
pin (5). then
(1). remove
remove
pin (5)
from caliper lever (4).
with adjustment
A and B between
bolt (6) so that clearances
the pad and disc are 0.05
-
0.2
mm.
F42301003
4. Turn turnbuckle
(11, align the hole of caliper
lever
(4) with the hole of pin (5). then insert pin (5) and lock with the cotter pin. 5. Turn
turnbuckle
then tighten *
Be careful
(1)
until there
is no more
play,
nuts (2) and (3). not to tighten
adjustment
bolt (6) too
much. *
After
adjusting,
in adjustment
make sure that there is no play
bolt (6) in the axial direction.
1 2F42301004
52-14 8
WA350-1
TROUBLESHOOTING .
1. Air pressure
does not rises at all
2. Air pressure
does not rise to the
specified
52-I
6
52-l
6
.
52-l
7
.
52-18
table
Troubleshooting
.
range
3. Brake is ineffective
.
effective
..
or not very
.
. or drags
4. Brake does not release, 5. Parking brake does not release,
*
Before
carrying
out
2, “METHOD
page 22-l
RENCE OF TROUBLE”
WA350-
the
1
troubleshooting OF READING
in this
section,
TROUBLESHOOTING
read
“PRECAUTIONS
TABLE”
page
22-l
9
52-20
.
or drags
52-l
WHEN
TROUBLESHOOTING”
4 and “PREVENTING
RECUR-
page 22-16.
52-15 a
TROUBLESHOOTING
TROUBLESHOOTING
TROUBLESHOOTING 1. Air pressure
the following
Did the air pressure --L Damage
l
Was time?
questions.
suddenly
cease to rise?
in air circuit or equipment.
the air pressure -+
TABLE
does not rise at all.
Ask the operator l
TABLE
Air
leakage,
difficult
to raise for some
performance
drop
in air
equipment. Checks l
before troubleshooting
Damaged equipment
l
air hose or tube, external associated
damage
to
with air system.
Is the drain cock completely
closed?
Fault check l
Check the-air pressure
l
If the pointer panel
remains
pressurized,
by air gauge
of the air gauge on the instrument at “0”
despite
opening
the air
the gauge is faulty.
e circuit between the air go
The following symbols are used to to be taken when a cause of failure X: Replace A: Adjust
52-16 a
indicate the action is located. A: Repair C: Clean
WA350-1
TROUBLESHOOTING
2. Air pressure range. Checks
TABLE
does not rise to the specified
before
Check
TROUBLESHOOTING
for
troubleshooting possible
air leakage
from
air hose,
tube and air equipment. Is the drain cock Check
for
intake
hose.
completely
deformation
closed? of
compressor
or
air
Fault check l
Install a pressure measure measured table
the
air
value
gauge with
to see whether
specified
in the
pressure, the
then
air circuit
and
compare
the
judgement
criterion
or not it deviates
from
the
value.
No. Problems 1 2 3
Air discharge from compressor when engine is running.
discharge
pipe is weak
Compressor starts to build up pressure when circuit between air governor and unloader is disconnected. Air comes out of discharge pipe of compressor when enaine is runnina but oressure does not build up.
0
0
0
The following symbols are used to to be taken when a cause of failure X: Replace A: Adjust
WA350-1
0
indicate the action IS located. A: Repair C: Clean
52-17 a
TROUBLESHOOTING
TROUBLESHOOTING
3. Brake is ineffective
TABLE
or not very effective.
Ask the operator the following questions. Did the brake suddenly cease to be effective? l -) Damage in air or brake equipment. Did brake gradually deteriorate? - Deterioral tion of seal or packing, wear of lining. Checks before troubleshooting Is kind of brake oil correct? (SAEI OW-CD) Is air pressure and brake oil quantity sat-isfactory? Is there any leakage of air or brake fluid when the brake is operated? Is there any external damage to air or brake piping or equipment? Check residual thickness of brake lining. Check tire pressure and tire tread. If there Measure the pressure in the air circuit. is an abnormality, refer to item 1 “Air pressure is completely ineffective” and item 2 “Air pressure does not rise to the specified range”. If the measured value is normal, move on to the following problems. Fault check Check it against the valve in the judgement l criterion table to see whether or not braking performance is bad. The left and right wheels at both front l
8
When the machine is raised using a 4-wheel jack, the wheel axles placed on a stand and the brake operated with the engine in the forward 1st speed position, however a particular turns fast.
0000
0
The following symbols are used to indicate the action to be taken when a cause of failure is located.
52-18 0
WA350-1
TROUBLESHOOTING
TROUBLESHOOTING
4. Brake
does not release,
TABLE
or drags.
Checks before troubleshooting l
Does brake pedal return completely?
l
Does parking
brake completely
disengage?
Fault check l
Abnormal
l
Inertial travel on flat ground.
heat generation
in brake.
I
I
I
I
No. Problems 1 2
3
Air comes out and brake disengaged if brake chamber air input is disconnected when brake pedal is released. Circuit pressure fails off and brake disengages if 011is bled from air bleeder when brake pedal is released.
O
0
A particular wheel rotates sluggishly when the machine is raised with a 4-wheel jack, the wheel axles placed on a stand, the engine shut down and the tires rotated by hand with the parking brake released.
I
WA350-1
The following symbols are used to to be taken when a cause of failure X: Replace A: Adjust
0
0
000
Indicate is located. a: Repaw C: Clean
52-19 a
TROUBLESHOOTING
TROUBLESHOOTING
TABLE
5. Parking brake does not release, or drags. (Applies to machines equipped with air parking brake.) Checks l
before
troubleshooting
Is the pressure fied
range?
kg/cm2
in the air circuit
(if the
or less, the parking
will automatically
within
air circuit
operate
brake
the speci-
pressure solenoid
to engage
is 4.0 valve
the parking
brake.)
The following symbols are used to to be taken when a cause of failure X: Replace A: Adjust
52-20 0
indicate the action is located. A: Repair C: Clean
WA350-1
BRAKE AND AIR SYSTEM 53
DISASSEMBLY
AIR GOVERNOR Disassembly..... Assembly . . BRAKE VALVE Removal . . . . . Installation .. . Disassembly..... Assembly . . .
. . . ..
BRAKE CHAMBER Removal .. . . . .. Installation . Disassembly . . Assembly . . . . . . . SLACK ADJUSTER Removal .. Installation . . Disassembly Assembly .: .
*
.
5353-
2 3
BRAKE ASSEMBLY Disassembly . . Assembly . . ..
.
53535353-
4 5 6 8
SPRING CYLINDER Removal . .. . Installation ..... Disassembly . . . Assembly . .
... ..
...... ...... ...... ......
. . ..
. . .
. .. . .. ..
. . . .. .. ...... . .. .. . ...... .
. .
53-10 53-l 2 53-l 3 53-l 6
.
.
AND ASSEMBLY
.
PARKING BRAKE Removal . . . .. Installation ... .. PARKING BRAKE PAD Removal . . . Installation .. . .
53-22 53-29
. . . . . . . . . . . . . .. .. ..
53-37 53-38 53-39 53-41
. .
53-43 53-45
.. . ..
53-47 53-48
..
.
.. .
53-l 9 53-l 9 53-20 53-21
Take the following method for air bleeding when you start to operate hydraulic cylinders after reassembling cylinders, pumps and pipings. 1. Start engine, keep idling. 2. Operate hydraulic cylinder 4 - 5 cycles, but do not exceed beyond 100 mm of stroke end. 3. Continue to operate cylinder 3 - 4 cycles until stroke end. 4. After finishing above steps, keep normal engine speed. NOTE: After long storage, same procedure is required.
WA350-1
53-l 0
DISASSEMBLY
AND
AIR GOVERNOR
ASSEMBLY
DISASSEMBLY
OF AIR
GOVERNOR
1. Cover Remove
cover
(I 51, then
remove
retaining
assemblies
(IO),
ring
(I 4). 2. Spring
seat
1) Remove
spring
seat
(I I),
(I 21, (I 31, (I 6) and (I 7). Sr Remove
lock nut (I 6) inside the spring seat
assembly 2) Remove
before removing
exhaust
stem
the assembly.
(9) and spring
(8) from
top of piston (3).
3. Piston
_
1) Turn
body
(I
1 upside down and tap to remove
piston (3) from bottom. 2) Remove *
spring (4) and valve (5) from piston (3).
If the piston does not come
out, blow
in air
lightly from port “a”.
2
= 423 F442A
53-2 0
WA350-1
DISASSEMBLY
AND
ASSEMBLY KI&
AIR GOVERNOR
ASSEMBLY
OF AIR
Inside
surface
piston,
O-ring
of body, groove,
GOVERNOR
outside spring
surface
guide,
of
adjust-
Grease (G2-LI)
ment screw:
1. Piston assembly 1) Insert O-ring (6) in stem hole of piston (3). then install washer
and insert spring (8) and exhaust
stem (9). 2) Insert
valve
spring -(4),
(5) in bottom
of piston
fit in groove,
(18) and assemble
then
(3), insert
install on O-ring
piston assembly
in body (I).
2. Spring seat assembly Assemble (IO), spring (17).
lower
spring
seat
seat
(I 3)
Tighten
bottom
face
in order
spring
on adjustment
lock nut (16)
guide
Check
of adjustment
that exhaust
stem
screw
so that distance screw
upper spring seat (I 3) is 47.6 *
(I 1 A),
rower spring seat (I I), spring (I 2) and upper from
to top face
of
mm. (9) and spring (8) are
correctly
fitted on piston (31, then insert the ad-
justment
screw assembly
in the body.
3. Cover Stop
423F443
cover
(I 5)
with
retaining
ring
(14),
then
install.
17
4. Filter
16
15
Insert filter (2). *
Install the governor
on the machine
the air piping. Check air compressor pressure.
and connect
the air pressure
is increasing
If the pressure
and
when
the
decreasing
is outside the specified
value, adjust it.
10 9 6 7 6 5 4 3 1
2 423 F444A
WA350-1
5%3
DISASSEMBLY
AND
REMOVAL &
Stop
the
OF BRAKE machine
the safety parking
wheels to prevent
1. Draining
Lower
and stop the engine. brake
and
put
and
install
the bucket Then
blocks
the machine
VALVE
VALVE
on level ground
bar on the frame.
to the ground the
BRAKE
ASSEMBLY
apply
under
the
from moving.
air
Drain air from air tank, then remove
2. Air piping,
cover of pedal.
wiring
Disconnect
air piping
connector
(I 1, (2), (3). (4), (5) and (6),
(7j and wire (8).
3. Pedal Pull out cotter remove
4. Brake
pin, then
valve
Remove body
pin (10) of pin (9). remove
pedal (1 I).
mounting
(I 3)
and
bolt
mount
(121,
flange
disconnect (141,
then
valve remove
plunger (I 5).
423F445
53-4 Q
WA350-1
DISASSEMBLY
AND
BRAKE
ASSEMBLY
OF BRAKE
INSTALLATION
VALVE
VALVE
Brake valve (I 5) on mount flange
plunger
Assemble
install in valve body (I 3) with mounting Plunger:
&
(14).
then
bolt (I 2).
Brake oil (See page 01-l
0)
423F445
Pedal Set pedal
(I I) in mounting
align stopper
position,
insert pin (91,
hole on left side of pin and assemble
on right side with cotter pin. *
Bend the cotter
pin securely.
Air piping, wiring Connect
air piping
(I),
wiring (7) and connector
(21, (31, (4).
(5) and
(61,
(8).
4. Air leakage check Stand
engine,
operation
WA350-1
check
of brakes.
for leakage
of air, and check
DISASSEMBLY
AND
BRAKE
ASSEMBLY
DISASSEMBLY
OF BRAKE
VALVE
VALVE
1. Body assembly I) Make
match
mark “a” on upper body and lower
body.
2) Loosen
mounting
bolts (I 1, remove
upper body
(2) and lower body (31, then disconnect
2. Upper
valve
assembly
I) Hold slot-head fit
them.
in slot
screwdriver
in stem
inside
@
in vice 0,
exhaust
and
passage
of
relay piston. 2) Loosen
nut (4), then
washer
(61, spring
upper piston spring
remove
seat
washer
(7). rubber
(51, plain spring
(8).
(91, return spring (I 01, relay piston
(1 I), relay piston (I 2), and stem assem-
bly (I 3). When fly
loosening
out
spirng,
under
force
so hold the piston
loosening
53-6 0
the nut, the piston the
of
the
may return
by hand when
the nut.
WA350-1
DISASSEMBLY
AND
3) Remove valve
snap
mary
(21). valve
II
(14),
upper
snap
valve
ring into
(I 8). O-rings
3. Lower
ring
(1 5) from
4) Remove
ASSEMBLY
BRAKE
then
(I 6). then washer
(I 9) and
retainer
remove
primary
body.
disassemble
(17).
O-ring
(201, upper
(22). and upper
pri-
retainer
valve
sping
valve
(23).
valve assembly
Remove
exhaust
secondary
valve
2) Remove
O-ring
3) Remove
snap
secondary O-ring
cover
(25).
(26) from
lower
ring
valve
retainer
lower
valve
spring
lower
valve
(34).
WA3561
(241,
assembly
then body.
(27).
then
assembly
into
(291,
O-rings
(321, valve
remove
disassemble washer
(30) retainer
and (33).
(28). (31). and
VALVE
DISASSEMBLY
AND
ASSEMBLY
ASSEMBLY
BRAKE
VALVE
VALV ‘E
OF BRAKE
1. Lower valve assembly 1) Set lower valve (34) with valve seat at bottom, assemble
valve retainer
(321, O-ring
retainer
(33).
lower valve spring
(29) and washer
(28).
then
secure with snap ring (27). *
Assemble O-ring
O-rings
retainer
2) Assemble
(30)
and
(31)
on
the
first.
secondary
valve
assembly
lower body, then install exhaust
(25)
in
cover (24).
2. Upper valve assembly
1) Set upper valve (23) with valve seat at bottom, assemble spring
valve
(21),
retainer
O-ring
retainer
(22). (I 8)
upper and
valve washer
(17). then secure with snap ring (16). t
Assemble O-ring
2) Assemble
O-rings
(19)
and
(20)
on
the
retainer first.
primary
valve assembly
(15) in upper
body, then secure with snap ring (I 4).
53-8 0
WA350-1
DISASSEMBLY
3) Hold
slot-head
assemble (12)
AND
screwdriver
relay piston
and
stem
BRAKE
ASSEMBLY
@
spring
assembly
in vice
0,
(1 1). relay piston
(13)
in bottom
of
upper body, then set with screwdriver. t
Do not forget
to fit an O-ring
on the relay
piston.
4) Assemble rubber
return
spring
spring
(IO),
upper
Piston
(91,
(81, spring seat (71, and washers
(5) and (6) from top of upper body, then tighten with nut (4). *
Do not forget
to fit an O-ring
on the upper
piston. ! ‘ss
The piston
may fly out under the force
of
the
spring,
by
return
so hold the
piston
hand when assembling. m
Nut:
0.55kO.15
kgm
3. Body assembly
I) Install O-ring (35) on lower body (3). 2) Align match body (1).
WA350-1
marks on upper body (2) and lower
(31, assemble
and tighten
mounting
bolts
VALVE
DISASSEMBLY
AND
REMOVAL
A
Stop
the
machine
parking
A
to prevent
Disconnect terminal
1. Draining
the
and
put
from
install
the bucket Then
blocks
the machine cable
and
Lower
and stop the engine. brake
CHAMBER
CHAMBER
on level ground
bar on the frame.
to the ground wheels
BRAKE
OF BRAKE
the safety the
ASSEMBLY
apply
under
the
from moving. the
negative
(-1
of the battery.
air
Loosen drain valve (1) and drain air from air tank.
2. Hydraulic
piping,
1) Disconnect
wiring
2) Disconnect
hose
and brake chamber 3) Disconnect
Disconnect
(2).
between
slack
at brake chamber
adjuster
end.
brake oil tank and
at brake chamber
end.
(rear) tube
brake chamber
53-l 0 0
(3)
hose (4) between
brake chamber
3. Air piping
(rear)
wiring connector
(5)
between
at brake chamber
brake
valve
and
end.
WA350-1
DISASSEMBLY
AND
ASSEMBLY
BRAKE
CHAMBER
4. Brake chamber (rear) Sling
brake
chamber
(6). remove
mounting
bolts
(7). then lift off brake chamber. *
Be careful
not to damage
the hoses and tubes
when removing. *
Be careful
not to damage
the steering
cylinder
rod when removing.
5. Brake chamber (front) t The front brake chamber brake chamber,
so remove
is behind
the
ber first, then
repeat
the same procedure
Steps
4
remove
2
-
to
rear
the rear brake chamthe
front
as in brake
chamber.
WA350-1
53-11 0
DISASSEMBLY
AND
BRAKE
ASSEMBLY
INSTALLATION
OF BRAKE
CHAMBER
CHAMBER
1. Brake chamber (rear) Set brake chamber tighten
mounting
(1) in mounting
position,
then
bolts.
t
Sling the brake chamber.
t
Be careful
not to damage
the steering
cylinder
rod. +
Be careful
not to damage
the
hose
and tube
when assembling.
2. Hydraulic
piping,
1) Connect
hose
brake chamber *
Install
wiring
brake
at brake chamber
front
bending
(rear)
(4) between brake
and
chamber
twisting,
then
oil tank
and
end. hose
without
install
strap
securely. 2) Connect
hose
brake chamber 3) Connect
3. Air piping
(3) between
slack adjuster,and
at brake chamber
wiring connector
end.
(2).
(rear)
Connect
tube
chamber
at brake chamber
(5) between
brake valve and brake end.
4. Air check I) Check
for
leakage
of
air
from
piping
connections. 2) Bleed air from brakes and check operation. *
For details
of bleeding
air, see 52 TESTING
AND ADJUSTING. 5. Brake chamber Use the same
(front)
procedure
as for installing
the front
brake chamber.
53-12 @
WA350-1
DISASSEMBLY
AND
BRAKE
ASSEMBLY
DISASSEMBLY
OF BRAKE
CHAMBER
1. Accessories Remove
breather
!I 1. bleeder (2) and sensor (3)
2. Cylinder Loosen lock nut (41, then remove t
There
is an O-ring
cylinder,
3. Piston
cylinder
(5).
on the thread
of the
it.
assembly
1) Move
retainer
remove +
so remove
fitted
(6) to right, remove
piston assembly
pin (71, then
(8).
Use a guide pin (Dia. 2.5 mm, length 50 mm) to remove
the pin.
423F446
2) Remove
4. Disassembly I) Remove
rod (91, then remove
of piston
O-ring.
assembly
snap ring (I 0). then remove
seat (I I),
spring (I 2) and valve (I 3). Sr Spring
(12)
is small, so be careful
not to lose
it. 2) Remove
WA350-1
packing
(I 5) from piston (I 4).
CHAMBER
DISASSEMBLY
AND
ASSEMBLY
BRAKE
CHAMBER
5. Body Hold body (I 6) with then remove *
hand, remove
The tension Remove
bolt,
of the spring on the body is 25 kg,
so be careful when removing *
mounting
body.
the O-ring
from
it.
the contact
surfaces
of the body and air cylinder.
6. Disassembly 1) Remove packing
of body snap ring (171, then remove (I 91, seat (20) and packing
ring (I 8).
(2 I).
423F448
2) Remove
snap ring (22),
then remove
ring (23)
and seal (24).
53-14 0
WA350-1
DISASSEMBLY
AND
ASSEMBLY
BRAKE
CHAMBER
2) Remove nut, then remove piston (28) and rod (29). 3) Remove packing (30) and ring (3 I) from piston.
4) Remove O-ring (321 and washer (33) from rod
WA350-1
53-15 0
DISASSEMBLY
AND
ASSEMBLY 1. Assembly
ASSEMBLY
OF BRAKE
of piston
1) Install washer Sr When
BRAKE
the threads
CHAMBER
assembly
(33) and O-ring
fitting
CHAMBER
the
O-ring,
(32) on rod (29). wind
tape
of the rod to prevent
around
damage
to
the O-ring. a
O-ring:
2) Assemble
Brake
packing
(30)
and ring (31)
0)
on piston
-
(28).
&&
Packing:
3) Insert
oil (See page 01-l
rod (29)
Grease
(G2-LI)
in mount
of piston
(281,
then
secure with nut. *
After
tightening
no clearance
the nut, check
between
that there
the
stepped
part
hole:
Grease
(G2-LI)
is of
the rod and the piston. a
Piston mounting
w
Nut:
2. Assembly
14-+2
kgm
of body
1) Install seal (24)
and ring (23)
in body (I 61, then
secure with snap ring (22). * *
Install the seal with the lip facing the outside. Check
that the snap ring is fitted
securely
in
the groove. &
53-16 0
Seat:
Brake
oil (See page Cl-1
0)
WA350-1
DISASSEMBLY
AND
BRAKE
ASSEMBLY
2) Turn over body, assemble packing (21). seat (20) and packing (19). insert ring 1181, then secure with snap ring (I 7). Sr Install the seal with the lip facing the outside. Sr Check that the snap ring is fitted securely in the groove. a
Packing:
Brake oil (See page 01-I
0)
423F450
3. Piston assembly Insert piston assembly
(27) in air cylinder
(25).
Coat inside of air cylinder with grease. When
inserting
angle
of about
the piston 30”,
the air cylinder
assembly,
insert about
tilt at an
l/3,
then lay
on its side and insert the piston
fully. Check
that
the
piston
assembly
moves
smoothly.
4. Body assembly Insert spring (26) in mount of air cylinder, fit O-ring (34) in body assembly (I 61, then install in air cylinder. *
Push
in the
bolts
in diametrically
body
tighten together B
Mounting
by hand,
with bracket bolt:
install
opposite
4.4kO.6
2 mounting
positions,
then
(35). kgm
5. Assembly of piston I) Insert
valve
(131,
spring
(I 2) and seat
(I I) in
piston (14), then secure with snap ring (I 0). t
Be careful correct
Sr Check
that
the groove.
WA350-1
to insert the spring facing
in the
direction. the
snap
ring fitted
securely
in
CHAMBER
DISASSEMBLY
AND
2) Assemble *
packing
install
the
BRAKE
ASSEMBLY
CHAMBER
(I 5) on piston.
packing
with
the
lip facing
the
outside. E??E
Packing:
Grease
(G2-LI)
6. Piston assembly
Blow air into air cylinder piston
assembly
connect *
(8)
and blow
in mounting
out rod. Set position,
then
with pin (7).
The pin hole is hidden
by the retainer,
so move
the retainer to the right and insert the pin. *
After
inserting
has moved
the pin, check
that the retainer
back to its original place and the pin
is hidden.
7. Cylinder Install
nut
(4)
and
O-ring
(36)
on cylinder
(51,
screw into mount, then secure with nut. Sr Screw
the cylinder
the breather E???E
in fully, then turn back until
and bleeder are in a straight
Inside surface
line.
of cylinder:
Brake oil (See page 0 I- IO) m
Nut:
14-+3
kgm
8. Sensor Fit O-rings mounting
on rod (9) and sensor (3). then install in position.
Sr Insert the rod until it is level with the body. m
Sensor:
5.6kO.6
kgm
9. Accessories Install breather B
53-18 0
(I
Bleeder:
) and bleeder (2) 0.95kO.25
kgm
WA350-1
DISASSEMBLY
AND
REMOVAL
QT
Stop
the
OF SLACK machine
the safety
1. Brake
and
Lower
brake
to prevent
and
put
Then
blocks
the machine
install
the bucket
and stop the engine.
parking
wheels
ADJUSTER
on level ground
bar on the frame.
to the ground the
SLACK
ASSEMBLY
apply
under
the
from moving.
piping
1) Disconnect
tube (1) between
slack adjuster
brake c.hamber at slack adjuster t
and
end.
Hose (2) at rear.
2) Disconnect left
and
tube (3) between right
brake
pistons
slack adjuster at slack
and
adjuster
end. 2. Slack
adjuster
Remove
mounting
bolts, then remove
slack adjust-
er (4). +
There
is
little
space,
so
be
careful
when
working.
INSTALLATION ADJUSTER 1. Slack Set
OF SLACK
adjuster slack adjuster
tighten
mounting
Sr Tighten
(4) in mounting
position,
then
bolts.
the mounting
bolts partially,
en fully after connecting
then tight-
the piping
2. Brake piping I) Connect left and
tube
(3) between
right
brake
tube
(I)
slack
pistons
adjuster
at slack
and
adjuster
end.
2) Connect
brake chamber t
slack
adjuster
and
Hose (2) at rear.
3. Bleeding
air
Bleed air from is no leakage +
between
at slack adjuster end.
For details
brake system,
and check that there
of oil from connections. of
bleeding
air, see
52
TESTING
AND ADJUSTING. *
Bleed the air from juster end.
WA350-1
the brake end and slack ad-
ADJUSTER
DISASSEMBLY
AND
SLACK
ASSEMBLY
DISASSEMBLY
OF SLACK
ADJUSTER
ADJUSTER
1. Bleeder Remove
bleeder
(2) from body (I
1
..
2. Cylinder Remove
mounting
and cylinder There hold
bolts, then disconnect
(4) together
with bracket
is spring tension the
contact
body (I
inside the cylinder,
surfaces
1
(3).
and
so
be careful
when removing.
3. Piston I) Remove
spring (5) and O-ring
2) Remove
piston (71, then remove
*
(6). O-ring.
Use a rod of 10 mm diameter
and push out
the piston slowly. *
Be careful
not to damage
the thread
with the
rod.
4. Poppet 1) Remove remove t
When
cover
(8)
from
cylinder
(41,
plug (9). spring (I 0) and poppet removing
the poppet,
then
(I I).
blow in air from
the oil hole in the cylinder. t
Hold the oil port of the cylinder
by hand, and
do not pump in air suddenly. *
Do not change (I 1) and cylinder the cylinder,
the combination
of poppet
(4). If replace the poppet
replace
the poppet
or
and cylinder
as a set. 2) Remove
53-20 @
O-ring
(I 2) from poppet. WA350-1
DISASSEMBLY
AND
ASSEMBLY
ASSEMBLY
SLACK
OF SLACK
ADJUSTER
ADJUSTER
1. Poppet 1) Fit O-ring 2) Install
(I 2) on poppet
poppet
(I I),
(I I).
spring
cover (81, then assemble
(10).
cylinder
plug
(9)
and
(4).
2. Piston
I) Install O-ring (I 3) on piston (7). 2) Insert piston (7) in cylinder *
(4).
Check that the piston moves smoothly.
3. Cylinder 1) Install O-ring t
Installed
2) Install bracket
body
(6) and spring (5) in cylinder. load of spring: (I)
4.4 kg
and cylinder
(4) together
with
(3).
4. Bleeder Install bleeder
WA350-1
(2).
53-21 0
DISASSEMBLY
AND
BRAKE
ASSEMBLY
DISASSEMBLY
OF BRAKE
ASSEMBLY
WA350-1 Wheel loader
7 Brake, wheel hub assembly
Special
A
Stop
the
the
parking
wheels
on level ground
bar on the frame.
to the ground
2
Fixture
machine
the safety
Q’ty
Part name
793-520-2320
1. Tire,
ToA
tool
Part number A
)
Lower
and stop the engine. brake
to prevent
and
put
the machine
blocks
and
install
the bucket Then
apply
under
the
from moving.
wheel
Jack up axle, put stand under axle, then lift off tire and wheel
(I).
Tire, wheel:
53-22 @
310
kg
WA350-1
AND
DISASSEMBLY
ASSEMBLY
BRAKE
2. Draining oil plug
drain
Remove
(2)
drain
and
axle
oil from
assembly. +
Set with the drain plug at the bottom. 45 II
Axle assembly:
&
3. Cover cover (31, then remove
Remove
O-ring
(4).
4. Axle shaft assembly axle shaft assembly
Remove *
(5) from axle.
a hook to the gear when
Attach
removing
the
shaft.
5. Planetary
carrier assembly 3 mounting
Remove
bolts (6). then l’ift off plan’e-
tary carrier (7). *
match
Make
marks
to act
as a guide
when
assembling. *
Be careful
of the center
of gravity,
and remove
slowly. Planetary
WA350-1
carrier:
68 kg
53-23
DISASSEMBLY
AND
BRAKE
ASSEMBLY
6. Ring gear assembly I) Using tool A, hold wheel
hub (8) and brake
(9)
in position. Zr Install tool A to points on opposite use washers
sides, and
to adjust clearance.
__
2) Remove remove *
mounting
bolts
of retainer
ring gear assembly
There axle
are shims housing,
thickness
of
reference
between
so
wheel
I) Remove 2) Sling remove
8. Axle
the
shims,
then
retainer
and
number
and
and
use
for
when installing.
Ring gear assembly:
7. Brake,
the
check
the
(IO),
(I I).
29 kg
hub assembly
brake tube (I 2).
brake
and
mounting
wheel
hub
assembly
(13).
bolts, then lift off assembly.
housing
Remove
bearing
(15)
and retainer
(16)
from
axle
housing (I 4).
53-24 0
WA350-1
AND
DISASSEMBLY
BRAKE
ASSEMBLY
9. Piston, cylinder with
I) Set 2) Using
wheel
at
(17)
hub
then
bottom,
tool A.
remove
forcing
screw,
lift off
assembly
piston
(I 8). O-rings
3) Remove
and
(19)
from
(20)
piston
assembly.
4) Remove
plug
out pin (22)
from
(21) and
piston
remove
assembly,
rod (23)
pull
and piston
return spring (24). *
The pin is small, so be careful not to lose it.
5) Pump
in air through
brake
(25)
and
by hand
and
oil filler
push out piston (26). *
Hold pump
one
end
of the
in the air slowly
piston
to prevent
the piston
from flying out. Sr Be careful
not to damage
the piston.
423F453
6) Remove
WA350-1
oil seal (27) from piston (26).
DISASSEMBLY
AND
7) Remove
BRAKE
ASSEMBLY
mounting
bolts,
then
remove
sleeve
(28). *
Be careful
8) Remove
not to damage
O-ring
(29)
the cylinder.
and seal (30)
from
sleeve
-
(28).
10. Discs, plates Loosen
stop
bolt
(311,
then
remove
plates
(32)
and discs (33) in order. *
When
removing
the discs,
on the inner gear
make
match
marks
and discs, and on the outer
gear and plates. *
The
plates
are made
careful not to damage
of a soft
material,
11. Disassembly of outer gear I) Sling outer gear (341, then remove (35) and O-ring
53-26 0
so be
them when removing.
seal ring
(36).
WA350-1
DISASSEMBLY
2) Using
AND
forcing
screw,
(34) and retainer *
Be careful
BRAKE
ASSEMBLY
disconnect
outer
(371, then remove
O-ring
not to damage
gear (38).
the “a” face of the
retainer.
12.
Inner gear Remove
mounting
bolts,
then
remove
inner gear
(39).
13. Wheel
hub assembly
I) Remove wheel
2) Remove
WA350-1
seal
ring
hub assembly
retainer
(41)
and O-ring
(42)
from
(40).
(431, then remove
O-ring
(42).
53-27 0
DISASSEMBLY
3) Remove
AND
bearing
ASSEMBLY
BRAKE
caps (45) and (46) from wheel
hub (44).
53-28 0
WA350-1
DISASSEMBLY
ASSEMBLY
BRAKE
ASSEMBLY
AND
OF BRAKE
ASSEMBLY
7 Brake, wheel hub assembly
t
TOA
12 Refilling with oil
13 Tire, wheel
423 F454
tools
Special
Part name
Part number A
) 793-520-2680
1 Installer
8
1 791-580-1600
1 Push tool
C
793-520-2320
1. Wheel
Q’ty
I ’ 2
Fixture
hub assembly
I) Press fit bearing
cups
(45)
and (46)
on wheel
hub (44).
WA350-1
53-29 0
DISASSEMBLY
AND
ASSEMBLY
BRAKE
2) Fit O-ring (47) on retainer (43)
3) Fit O-ring (43)
(42)
on seal ring (41).
in insertion
position,
set retainer
then use tools A and
to insert. Remove
all white
powder
from
the surface
of the O-ring with methyl alcohol. Thoroughly mating
remove
surfaces
all
grease
from
the
in the
seal
prevent
the
of the O-rings
rings and retainers. Tighten
B uniformly
tool
to
O-ring from being twisted. After four
press-fitting, places
around
confirm-that
measure
height
‘9”
the circumference,
the difference
at and
in dimensions
is
less than 1 mm.
’
423F455
Do not hit the seal ring with a hammer J=??Y=
Brake oil (See page 01-l
Seal ring:
4) Install retainer (43) on wheel t
After fitting,
aligning check
the contact
0)
hub (44).
the dowel
pin hole
that
is no clearance
there
and press at
faces.
2. Inner gear
t
Install inner gear (39) on wheel
hub (44).
&
Mounting
bolt:
Thread tightener
m
Mounting
bolt:
28.523.0
53-30 0
(LT-2)
kgm
WA350-1
BRAKE
ASSEMBLY
AND
DISASSEMBLY
gear
3. Outer
(37)
on seal
in insertion
position,
set
(351,
ring
(36)
Fit O-ring
(37).
(38) on retainer
O-ring
I) Install
retainer A and
use tools
then
to insert.
less than
1 mm.
Tighten
tool
B
the
prevent
to
uniformly
O-rings
the
of
surfaces
grease
all
remove
Thoroughly mating
is
being twisted.
from
O-ring
and
in dimensions
the difference
that
confirm
at
“t”
circumference,
the
around
places
four
surface
height
measure
press-fitting,
After
the
alcohol.
methyl
with
of the O-ring
from
powder
all white
Remove
from
the
in the
seal
rings and retainers.
423F455A
the “a”
not to damage
Be careful
surface
of
the retainer. gear
outer
2) Install
on wheel
(34)
hub assembly
(40). plates
4. Discs, Align
marks
match
of
outer
gear
(34)
plate
and
(321, and disc (33) and inner gear (391, and assemble elates
and discs in turn. the
Loosen pletely The
stop
free from
final
plate
so that
bolt
the outer must
it is pulled
com-
gear spline.
be fitted
securely
on the
at least
30
spline of the inner gear. discs
Soak
the
nutes
before
WA350-1
in brake
assembling.
oil for
mi-
DISASSEMBLY
5. Piston,
AND
BRAKE
ASSEMBLY
cylinder
I) Fit seal (29) and O-ring EEL
(30) on sleeve (28).
Seal, O-ring: Brake
2) Align
match
marks,
housing
(471,
mounting
bolts.
Sr Be careful
then
oil (See page01
-10)
install
sleeve
(28)
in
partially
tighten
with
3
not to let the cylinder O-ring
come
out. *
Tighten
the mounting
bolts fully after
press
fitting the piston. m
Mounting
3) Assemble *
bolt:
kgm
seal (27) on piston (26).
Fit the seal securely
&IL
18*2
Seal:
Brake
in the groove. oil (See page 01-l
0)
4) Press fit piston (26) in housing (47). *
When
press
fitting
plastic hammer.
the piston,
hit it with
a
Do not use a steel or copper
hammer. *
Coat
the press-fitting
assembly
portion
and the outside
of the piston
circumference
of
the piston with brake oil. &?&=
Sliding surface
of piston:
Brake
oil (See page 01-l
0)
,,,,, ,,
53-32 0
WA350-1
DISASSEMBLY
AND
ASSEMBLY
5) Insert piston return spring (241 and rod (23) in piston assembly (18). then lock with pin (22) and install plug (21).
6) Fit O-rings (I 9) and (20) on piston assembly (I 8), set outer gear assembly in position, then tighten mounting bolts. w
Mounting bolt: 18 ?2 kgm
0
Mounting bolt: Thread tightener (LT-2)
6. Axle housing Press fit retainer (I 6) and bearing (I 5) on axle housing (14). * After press fitting the retainer and housing, and the retainer and bearing, check that there is no clearance at any point.
7. Brake, wheel hub assembly 1) Use tool C to hold brake assembly (48) and wheel hub (44) in position. * As far as possible, install tool C to points at diametrically opposite positions. * Install tool C so that the circumference is uniform.
WA3561
BRAKE
DISASSEMBLY
AND
2) Raise brake in position
and wheel
hub assembly
on axle housing
mounting *
BRAKE
ASSEMBLY
mount,
(I 3), set
then tighten
bolts.
Be careful
of the center
of gravity,
and raise
horizontally. *
Do
not
O-ring
force
into
position
will be twisted.
because
the
Align the centers
and
install slowly. &&
Mounting
bolt: Thread
w
Mounting
bolt:
tightener
56*6
(LT-2)
kgm
3) Install brake tube (1 2).
8. Ring gear assembly 1) Raise ring gear assembly
(1 I),
set in mounting
position, and insert in axle housing. k Align
the
assembly
2) Tighten
retainer
then remove *
spline
Remove Do
(IO)
Rotate
hole
with
3 bolts,
and oil from the bolt hole
shims
the wheel
a depth
of retainer. sr Measure
when
the bearing,
torque.
bolt of retainer:
(IO),
and
3.0 kgm
through measure
measuring clearance
end face of housing and end face at 2 places and take the average.
*
Shim thickness
*
Use
the
retainer
hub to settle
micrometer
of retainer
“a” between
in the
to a uniform
Mounting
3) Insert
the
temporarily.
then tighten m
insert
mount.
insert
tightening *
temporarily
all grease
not
and
tool C.
of the retainer t
groove
slowly.
is clearance
smallest
number
“a” + 0.2 mm. of
shims
which
gives the required thickness. *
Be careful
that the total shim thickness
is no
than “a” + 0.2 mm. *
Shim thickness:
1 .O mm, 0.3 mm, 0.2 mm
423F456
53-34 0
WA350-1
DISASSEMBLY
4) Install and
AND
tool C to brake remove
of shims, +
assembly
retainer.
Install
then install
retainer
Always
BRAKE
ASSEMBLY
install
and wheel
required
hub,
thickness
again.
tool
C before
wheel
hub
assembling
the
shims. *
Rotate
the
mounting
bolts
tightening
torque.
&?YS
Mounting
and
uniformly
to
Mounting
9. Planet Fit
carrier
O-ring
carrier
the
specified
bolt: Thread
m
tighten the
bolt:
tightener
11.5f
(LT-2)
1 .O kgm
assembly
(24)
to
assembly
wheel
(71,
set
hub in
(81,
mounting
raise
planet
position,
then install. *
Align
mounting
holes
that the O-ring
10. Axle Install t
shaft
install
carefully
so
assembly
axle shaft
assembly
If the position rotate
and
does not slip out of place.
the wheel
(5).
of the sun gear does
not match,
hub to align.
11. Cover Fit O-ring
(4) in groove
in cover,
then
(3). m
WA350-1
Mounting
bolt:
7.020.5
kgm
install
cover
DISASSEMBLY
AND
ASSEMBLY
BRAKE
12. Refilling with oil Tighten
drain
plug and add oil through
(25) to the specified
level.
*
so that
Set the machine final drive
level plug
the level plug of the
is at the bottom
when
refilling
with
oil. Axle assembly:
%2
45 II
13. Tire, wheel Install tire and wheel m
Mounting
(I 1, then remove
nut:
4825
stand.
kgm
14. Checking for leakage of brake oil After
completing
all operations,
check for leakage
of brake oil. *
For details,
see
52
TESTING
AND
ADJUST-
ING.
53-36 Go
WA350-1
DISASSEMBLY
AND
REMOVAL
Q7
Stop
the
OF SPRING machine
the safety parking
wheels t
Check
to prevent
again
properly,
that
then
and
put
the
main
the bucket Then
blocks
the machine
the wheels
turn
and install
Lower
and stop the engine. brake
CYLINDER
CYLINDER
on level ground
bar on the frame.
to the ground the
SPRING
ASSEMBLY
apply
under
the
from moving.
have been switch
blocked
to ON,
and
release the parking brake. 1. Cover
.
Remove
cover (I) at front of front frame.
2. Linkage Disconnect +
The
ball joint (2) of parking brake linkage.
ball joint
can not be disconnected
if the
parking brake is applied.
3. Air piping Disconnect
air piping (3) of spring cylinder.
*
Drain the air.
*
After
removing,
cover
to prevent
dust
or dirt
from entering.
4. Spring
cylinder
Remove cylinder
WA350-1
mounting
nut,
then
remove
spring
(4).
53-37 0
DISASSEMBLY
AND
INSTALLATION 1. Spring
SPRING
ASSEMBLY
OF SPRING
CYLINDER
CYLINDER
cylinder
Set spring
cylinder
(4) in mounting
position,
and
install. m
Mounting
nut:
28.5A3.0
kgm
2. Air piping Connect *
air piping (3) to spring cylinder.
Turn the main switch
ON and apply the parking
brake.
3. Linkage Connect *
ball joint (2) of parking brake linkage.
For details TESTING
*
of
adjusting
Check the operation
m
the
linkage,
see
52
AND ADJUSTING.
Mounting
nut:
of the parking brake. 11.5f
1 .O kgm
4. Cover Install cover (I) at front of front frame.
53-38 0
WA350-1
DISASSEMBLY
AND
SPRING
ASSEMBLY
DISASSEMBLY
OF SPRING
CYLINDER
1. Boot and retainer Remove
boot (I ), then remove
retainer
(2).
2. Boot Remove
boot (3).
3. Filter Remove
filter
holder
(4).
then
remove
filter
and
retainer.
4. Rod Remove
lock nut (5) and mounting
then remove
WA350-1
rod (7).
nut (6) of boot,
CYLINDER
DISASSEMBLY
5. Spring Using
AND
SPRING
ASSEMBLY
CYLINDER
and support a press,
remove
(81, then remove When there
the
mounting
bolt of support
spring (9).
pressure
is danger
of the
pr ess i s released,
that the spring
may fly out, so
release the press slowly.
.
6. Piston 1) Remove
2) Remove
piston (1 I) from cylinder (10).
wiper
ring
(I 2)
and
seal
(I 3)
from
piston.
7. Cylinder Remove
53-40 0
bushing
(14) and seal (15) from cylinder.
WA350-1
DISASSEMBLY
AND
ASSEMBLY
SPRING
ASSEMBLY
OF SPRING
CYLINDER
1. Cylinder Install bushing
(I 4) and seal (I 5) in cylinder
2. Piston 1) Install wiper
Ii. SrUse a
ring (12)
and seal (13)
(I 0).
on piston
(I
new
part for the wiper
and soak in oil before a
Wiper
2) Assemble ia
ring:
ring and seal,
installing.
Engine oil (See page 01-l
piston (1 1) in cylinder
(I 0).
Piston seal, inside of seal and bushing, sliding
surface
of piston
and cylinder:
Silicon grease
3. Spring, Using
support a press,
assemble
spring
(81, then tighten
mounting
bolt.
*
Align the mounting
*
Installed
m
bolt holes correctly.
load of spring:
Mounting
bolt:
Tighten
the
removing
the press.
WA350-1
(9) and support
310
1.4kO.4
mounting
kg kgm bolt
fully
before
0)
CYLINDER
DISASSEMBLY
AND
ASSEMBLY
SPRING
CYLINDER
4. Rod 1) Install flange
nuts (I 6) and (17)
lock nuts (I 8)
and (19). +
Tighten
+
Installed distance
m
the flange nut partially.
L, of lock nut:
Lock nut:
2) Install flange
5+
55 mm.
1 kgm
nuts (I 6) and (17) to give installed
L2.
distance
Sr Installed distance L, of flange nut: m
Flange nut:
5f
100
mm
1 kgm
3) Install boot to rod, then install nut (6) and lock nut (5) to give specified Clearance *
After
“a”:
1.6 -
installing,
clearance
“a”.
2.6 mm
check
that
clearance
“a” is
correct. m
Mounting
nut of boot, lock nut: 5fl
kgm
5. Filter Set
retainer
(4)
and
filter
(21)
in
mounting
position, then install filter holder (20).
6. Boot Install boot (3).
7. Retainer,
boot
Install retainer
53-42 0
(2) and boot (1)
WA350-1
DISASSEMBLY
AND
REMOVAL
a
Stop
the
OF PARKING machine
the safety parking
wheels
*
on level ground
bar on the frame.
to the ground the
PARKING
ASSEMBLY
Lower
and stop the engine. brake
and
put
blocks
to prevent the machine
Turn the starting
switch
BRAKE and
install
the bucket Then
apply
under
the
from moving.
ON and release the park-
ing brake. _.
1. Linkage Disconnect
2. Drive
parking
brake lever (I) and linkage (2).
shaft
Disconnect
3. Caliper Remove assembly
front drive shaft (3) from differential.
assembly mounting
bolts
(4). then
remove
caliper
(5).
4. Disc Remove
mounting
from coupling.
WA350-1
bolts
(6), then remove
disc (7)
BRAKE
DISASSEMBLY
AND
ASSEMBLY
PARKING
BRAKE.
5. Disassembly of caliper 1) Remove adjustment screw (8). 2) Extend lock plate (9) with a chisel, remove bolts, then disconnect retraction plate (I 0) and calipers (1 1) and (I 2). 3) Remove nut from caliper, then remove pads (13) and (I 4). 4) Remove spring (I 6) and pin (I 5) from caliper (I 2).
53-44 0
WA350-1
DISASSEMBLY
AND
PARKING
ASSEMBLY
INSTALLATION
OF PARKING
BRAKE
BRAKE
1. Assembly of caliper 1) Install pin (I 5) and spring (16) on caliper (I 2).
423F457
2) Install
pads
(I 3)
and
(14)
to
caliper,
then
secure with nut.
3) Set calipers install
(I 1) and (12)
retraction
then tighten
plate
mounting
in mounting
(IO)
position,
and lock plate
Sr Knock the tip of the retraction
plate into the
caliper mount hole up to the root. m
Mounting
bolt:
1.2-tO.l
kgm
4) Bend lock plate with a chisel to lock bolt. *
Bend the lock plate securely.
5) Install adjustment
WA350-1
(91,
bolts.
screw
(8).
DISASSEMBLY
AND
ASSEMBLY
PARKING
BRAKE
2. Disc I) Set
disc (7) in position
(I 7). then tighten m
Mounting
on mount
mounting bolt:
of coupling
bolt.
11.5f
1 .O kgm
3. Caliper assembly caliper
assembly
then tighten
Set
mounting
m
Mounting
bolt:
(5)
in mounting
position,
bolt (4). 1822.0
N$ Q
kgm
j)
4. Drive shaft Connect
front drive shaft (3) at differential
m
Mounting
53-46 0
bolt:
11.5*
end.
1 .O kgm
WA350-1
DISASSEMBLY
AND
REMOVAL
a
OF PARKING
Stop the machine the safety parking
wheels t
Lower
and stop the engine. brake
to prevent
BRAKE
on level ground
bar on the frame.
to the ground the
PARKING
ASSEMBLY
and
put
PAD
PAD
and install the bucket Then
blocks
the machine
BRAKE
apply
under
the
from moving.
Check that the blocks are set properly
under
the wheels. Linkage Remove
lock
nut
(I),
then
disconnect
parking
brake lever (2) and linkage (3). *
Before disconnecting
the linkage, turn the start-
ing switch to ON and release the parking brake. Pads 1) Extend
lock plate (4) with a chisel, and remove
bolts (5).
2) Remove
calipers
(6) and (7).
/4
3) Remove
nut (I 0) from calipers
remove pads (8) and (9).
WA350- 1
(6) and (7), then
423F458
DISASSEMBLY
AND
INSTALLATION
PARKING
ASSEMBLY
OF PARKING
BRAKE
BRAKE
PAD
PAD
1. Pads 1) Set pads (8) and (9) in position on mounts of calipers (6) and (71, then secure with nut (I 0).
..
0 -
2) Set calipers (6) and (7) in mounting position, install lock piate (41, then tighten bolts. t Knock the tip of the lock plate into the caliper mount hole up to the root. w
Mounting bolt: 1.220.1
-_I
kgm
4
423F458
3) Bend lock plate (4) with a chisel to lock bolt (5). t Bend the lock plate securely.
53-48 0
0
WA350-1
BRAKE AND AIR SYSTEM 54 MAINTENANCE
STANDARD
Brake valve.
.
54-2
Brake chamber
54-4
Slack
54-5
adjuster
54-6
Brake
WA350-1
Parking
brake
Spring
cylinder
54-8
.
54-9
54-l
MAINTENANCE
STANDARD
BRAKE VALVE
BRAKE VALVE
9
13' 423F222
54-2
WA350-1
MAINTENANCE
STANDARD
BRAKE VALVE
Unit: No.
1
Clearance between pedal mounting and mount plate
pin
2 3
4 etween relay piston and
5 -
6
Outside diameter of roller
7 -
8
Piston return spring
9
Primary valve spring
10 11
Outer stem spring
41.0
16.0
4.0 kg
34
-
12
Relay piston spring
39.5
12.1
4.7 kg
33
-
13
Secondary
valve spring
16.5
10.2
3.0 kg
14
Tightening
torque of nut
14
WA350-1
0.5520.15
kgm
Retighten
mm
MAINTENANCE
BRAKE CHAMBER
STANDARD
BRAKE CHAMBER
3
r
-i
Section
mm
A-A 423F223
m
Unit: No.
Check item
Criteria
Remedy
Tolerance Standard size 1
Standard clearance
Clearance limit
Shaft
Hole
-0.030 -0.076
+0.046 0
0.030 0.122
0.15
-0.5 -0.3
+0.046 0
1.254 1.1
1 .O
Clearance between cylinder and piston 68
2
Outside diameter of oil seal
3
Air piston stroke
4
Tightening
69.6
-
torque of nut
69.2 -
75.2 (Normal pressure:
14.0&
Max. 9.5 kg/cm*)
Replace
-
2.0 kgm Retighten
5
Tightening
54-4
torque of nut
4.4?
0.6 kgm
WA350-1
mm
MAINTENANCE
SLACK
STANDARD
SLACK ADJUSTER
ADJUSTER
\
1
‘kc= I I I
_&=. -
4 423F224
Unit:
No.
Check item
Criteria
mm
Remedy
Tolerance Standard size 1
Shaft
Hole
-0.030 -0.076
+0.074 0
Standard clearance
Clearance limit
0.030.15
0.25
Clearance between body and piston 55
Replace
2
Spring
3
Spring
4
Tightening
5
Tightening torque of plug
6.8 kg
torque of bolt
6.720.7
kgm
5.7eO.7
kgm
-
Retighten
WA350-1
54-5 0
MAINTENANCE
STANDARD
BRAKE
BRAKE
CI’Y
\ \
‘,
f
9 I
10 /
,P
Detail P
14
11 12
423F225A
5i6
WA350-1
MAINTENANCE
BRAKE
STANDARD
Unit:
1
Return spring
2
Thickness of plate
Remedy
Criteria
Check item
No.
mm
Standard size
t-
Repair limit
I I
2.3 * 0.1
1.7
3.8 * 0.1
3.5
3
Thickness of disc
4
Total thickness of plate and disc
26.7 f
5
Wear of surface in contact with piston seal
355+0.05J 0
6
Wear of surface in contact with piston seal
3, 5+0.214 +0.125
7
Deformation of friction surface of plate and disc
a
Backlash between outer gear and plate
I
0.23 -
0.65
9
Backlash between inner gear and disc
I
0.31 -
0.74
0.9
23.1
Replace
-
-
-
I
0.50
0.30
10
Tightening torque of bolt
11
Tightening torque of bolt
11.5*
12
Tightening torque of bolt
26.5 ‘- 3.0 kgm
13
Tightening torque of bolt
18?2kgm
14
Tightening torque of bolt
56 f
18*2kgm
l.Okgm
1 Retighten
-
6 kgm
-
WA350- 1
54-7 0
MAINTENANCE
STANDARD
PARKING
BRAKE
PARKING
/i
a
I\
BRAKE
423F226
b
Unit: No.
Criteria
Check item
Wear of pad (remaining thickness of friction material) 1
Remedy
Standard size
Repair limit
10.5 (a, b, c), 8.5 (d)
3.8
13.7 (a, b, cl, 11.7 id)
7.0
0.25
0.5
Replace (including backing plate) -
2
Face runout of disc
Rebuild 3
Wear of disc (thickness of disc plate)
Thickness of plate must be under 18 mm 20.0 Less than 18 mm
0.1 -
4
Clearance between pad and disc
5
Tightening torque of nut
0.2720.5
6
Tightening torque of bolt
1.220.1
0.4
Replace
Adjust
kgm
kgm
WA350-1
mm
MAINTENANCE
SPRING
STANDARD
SPRING
CYLINDER
CYLINDER
423F2278
Unit:
No
Check item
Criteria
mm
Remedy
Tolerance Standard size 1
Clearance between cylinder and piston
Standard clearance Shaft
l&lg
59
Hole
Jz.35
158.65 2
Clearance between piston insert and center boss
Hole: 38.8 Shaft: 38
-
-
Piston spring
4
Play of rod in axial direction
5
Installed dimension of rod
6
Tightening torque of rod, lock nut
7
Setting dimension of lock nut
8
Tightening torque of mounting bolt
Free length
Installation length
280
110.5
Replace
-0q8
Standard size 3
Clearance limit
Repair limit
I Installation load 310kg
Free length
I
Installation load
-
1.6 - 2.6 Adjust
WA350-1
244
5.0 ? 1 .O kgm
55 -
58
1.4 & 0.4kgm
54-9 @
WORK EQUIPMENT SYSTEM 61 STRUCTURE
AND FUNCTION
61- 2 General .................................. 61- 4 Hydraulic circuit system ................... 6 I- 5 Hydraulic circuit diagram [for 2-Spool) ...... Hydraulic circuit diagram 61- 5-l (for 3-Spool)(if epuipped). ................ 61- 5-2 Bucket linkage ............................ 6 1- 8 Bucket positioner and boom kick-out ....... 61-I 0 Hydraulic tank ............................ 61-l 1 Oil filter bypass valve ................... l 61-11 Breather ............................... l 61-l 2 Hydraulic and steering pumps .............. 61-I 4 Main control valve (for 2-Spool) ............ Main control valve (for 3-Spool)(if equipped) . 61-I 5-l 61-22 Relief valve ............................ l 61-23 Safety valve (with suction valve) ......... l 61-24 Suction valve .......................... l 61-25 Hydraulic cylinder .........................
WA350-1
61-1 0
STRUCTURE
AND
FUNCTION
GENERAL
GENERAL Outline The
work
equipment
draulic
circuit
circuit
controls
system
and steering the
consists
circuit.
operation
of the hy-
The
of the
hydraulic
bucket
and
pump dump
oil in hydraulic (2)
to main
tank
the oil passes
of the main control
valve.
filter in the hydraulic When
(1) is sent by hydraulic
control
valve
(7).
When
and lift spools of the main control
at neutral,
the levers-are
through
the
valve are
the drain circuit
It is then filtered
by the
valve.
pressure
of the hydraulic
circuit
is
by the relief valve inside the main control
There
is a safety
valve (with suction
valve)
operated,
the dump
flows
valve to lift cylinder
the main control
(3) or dump
cylinder
then moves.
-
tank (1) is a pressurized,
has a breather pressurize negative
with
a relief
sealed type and
valve.
This
acts to
the tank and at the same time prevents pressure.
This
protects
the pump
cavitation.
spool or
valve moves,
from
Hydraulic
tank, and returns the tank.
lift spool in the main control
61-2
maximum
regulated
in the dump cylinder circuit to protect the circuit.
attachment. The
The
(4).
The
and oil
lift arm or bucket
WA350-1
from
STRUCTURE
AND
GENERAL
FUNCTION
F4230007
1. Hydraulic 2. Hydraulic
tank and steering
pump
3. Lift cylinder 4. Dump
cylinder
5. Lift lever 6. Dump
lever 7. Main control
WA350-1
valve
61-3
HYDRAULIC
STRUCTURE AND FUNCTION
CIRCUIT
HYDRAULIC
SYSTEM
CIRCUIT SYSTEM
(For S-SPOOI)
Engine low idling, hydraulic control lever in “HOLD”,
Steering wheel at Neutral
... .A. .\. .A. :j:; :.:. : ::
j ::: I :ii
j,jj
0.. . .. .I-
::: ::: ::: ::: ::: ii; :!: ::. ::.
::: ::: ::: ::: .:. ::: ;:I
::.
I
Water outlet -Water
inlet
423F152A
WA350-1
STRUCTURE
DIAGRAM
CIRCUIT
HYDRAULIC
DIAGRAM
CIRCUIT
HYDRAULIC
FUNCTION
AND
(For P-~~0011
)(/
---------1
_J
7
45 A3
19
83
SAR(3)-50
kil
A2
;AR(3)-80
1
-__--7
r-i
423F153B
1 Hydraulic 2
Oil filter
3
Hydraulic
4. Steering
tank pump (SAR(3)-80) pump (SAR(3)-50)
(SAR(3)-40: 5. Steering
Serial No. 1 11 18 and up)
valve
14. Relief valve 15. Safety
valve (with suction)
16. Dump spool 17. Lift spool valve
18. Suction
7. Demand
19. Lift cylinder
spool
9. Steering 10. Steering 11. Safety
valve
cylinder
6. Check valve
20.
Dump cylinder
relief valve
21.
Oil cooler
spool
22.
Main control valve
8. Check valve
WA350-1
restrictor
12. Two-way 13. Steering
valve (with suction)
61-5 8
STRUCTURE
AND
HYDRAULIC (For 3-Spool,
with
HYDRAULIC
FUNCTION
CIRCUIT emergency
CIRCUIT
DIAGRAM
DIAGRAM
steering
(if equipped))
Engine stopped
28
r-----(6
423F5088
1. Hydraulic
2. Oil filter 3. Hydraulic 4. Steering
16. Dump spool pump (SAR(3)-80) pump (SAR(3)-50)
(SAR(3)-40: 5. Steering
Serial No. 1 1 1 18 and up)
17. Lift spool 18. Suction 20.
valve
valve
19. Lift cylinder Dump cylinder
6. Check valve
2 1 Oil cooler
7. Demand
22.
spool
Main control valve
8. Check valve
23. Attachment
spool
9. Steering
relief valve
24. Attachment
cylinder
spool
25. Safety
10. Steering 1 1. Safety
valve (with suction)
12. Two-way 13. Steering
restrictor cylinder
14. Relief valve
61-5-1 0
15. Safety valve (with suction)
tank
valve
valve (with suction)
26.
Float valve
27.
Security
valve
28.
Diverter
valve
29.
Emergency
pump
WA350-1
STRUCTURE
AND
BUCKET
FUNCTION
BUCKET
LINKAGE
LINKAGE
Serial No. 10001 -
11117
423F 155
I. Tilt lever 2. Dump cylinder 3. Lift cylinder 4. Lift arm 5. Bucket link 6. Bucket
WA350-1
6 l-5-2
STRUCTURE
AND
BUCKET Serial
FUNCTION
BUCKET
LINKAGE
LINKAGE
No. 11118
and up
1. Tilt lever 2. Dump cylinder
U42301006
3. Lift cylinder 4. Lift arm 5. Bucket link 6. Bucket
61-6 0
WA350-1
STRUCTURE
AND
.
FUNCTION
Section A-A
BUCKET
LINKAGE
Section B-B Section C-C
Section E-E
Section F-F
Section D-D
Section G-G
Section H-H
Section J-J 423F156
WA350-1
61-7
STRUCTURE
AND
BUCKET
FUNCTION
POSITIONER
BUCKET
AND
BOOM
POSITIONER
AND
BOOM
KICK-OUT
KICK-OUT
5
_--f-
i
T
-
-
.1 423F158
Section A-A
1. Proximity 2. Plate
61-8
switch
3. Lever
5. Proximity
switch
4. Cylinder
WA350-1
STRUCTURE
Bucket
AND
BUCKET
FUNCTION
POSITIONER
AND
BOOM
KICK-OUT
positioner
The
bucket
positioner
is electrically
is used to automatically
obtain
actuated
and
the optimum
dig-
ging angle for the bucket. When tion
the bucket to
the
desired
is moved
TILT
angle,
from
position,
the
the DUMP
and
dump
it
lever
posi-
reaches
the
is automatically
moved from the TILT position to the neutral. Lever (3) is secured A proximity When
is moved position,
moves to the left. moves
to the
l
from
the DUMP
the dump
left.
When
it reaches
lever (3) separates
rod
the
desired
from proximity
switch
lever returns to neutral.
kick-out
The
boom
acts
to
kick-out
stop
reaches
the
is electrically lift
the desired
arm.
When
position
before
height, the lift arm lever is returned l
posi-
cylinder
At the same time, lever (3) also
(5). and the bucket
Boom
rod.
is fixed by bolts to the cylinder.
the bucket
tion to the TILT
position,
by bolts to dump cylinder
switch
Plate
(2) is secured
switch
from
position,
the
the LOWER lift arm
position,
come into contact
the
rises.
the
A proximity
When
When
and arm
the maximum
position
proximity
lift
to neutral.
lift arm.
(1) is fixed to the frame.
is moved desired
to the
operated
the lift arm
to the RAISE it reaches
switch
and
the lever
and the lift arm lever is returned
to neutral.
WA350-1
61-9
STRUCTURE
AND
FUNCTION
HYDRAULIC
through
In the
return
merges.
Part
passes through
TANK
TANK
Outline . The oil from the hydraulic pump
HYDRAULIC
the control circuit, of
the
tank
is sent from
the
. The oil filter (2) filters all the oil in the circuit. If the
valve to the cylinders.
oil filter
oil from
acts to allow
it is cooled
various
in the
parts
oil cooler,
the oil filter (2) and returns
to the
(4).
(2) becomes
This
bypass
prevents
valve
damage
a bypass directly
valve (1)
to the tank
to the filter
(1) is also actuated
pressure is generated
tank (4).
clogged,
the oil to return
when
(2).
in the circuit.
Section A-A
423F130
1. Bypass valve 2. Oil filter 3. Breather 4. Hydraulic
tank
5. Drain valve 6. Oil level sight gauge
61-10
The
negative
WA350-1
STRUCTURE
OIL
AND
FILTER
When
BYPASS
the filter
HYDRAULIC
FUNCTION
TANK
VALVE
is clogged
Bypass valve (I)
opens and the oil returns
the tank without
passing through
Bypass valve set pressure:
1.27
When
is formed
negative
pressure
directly
to From main control valve
the filter. kg/cm2
in the
return
circuit.
I
423F131
Valve (2j moves up and acts a check valve. Check valve set pressure:
0.26
kg/cm2
To main Control valve
423F132
BREATHER Preventing The
tank
pressure the
oil
is formed level
happens, and
negative
drops
outside (3).
Preventing When
hydraulic
rises.
the hydraulic
WA350-1
pressure
this
the tank
opens
the
is let into the
inside the tank
cylinders circuit
the breather
pressure
when
pressure.
If the hydraulic
the set pressure,
tank When
between
the outside
rise in pressure
level in the
so negative
operations.
in pressure
negative
type,
hydraulic
atmospheric
the hydraulic
perature
the
during
and air from
tank to prevent
inside the tank
sealed
inside
the-difference
the
poppet
pressure
is a pressurized,
are being used, the oil changes
and the tem-
pressure is actuated
rises above to release
1. Body 2. Filter element 3. Poppet 4. Sleeve
inside the tank.
61-l 1
STRUCTURE
AND
FUNCTION
HYDRAULIC
AND
HYDRAULIC
STEERING
AND
STEERING
PUMPS
PUMPS
I
\9
10 Section
\8
A-A 423F ‘134
Hydraulic pump
I
Steering pump
,
I
SARC31-050
SARi3)-080
(SAR(3)-040)
Specifications I,
Drive
gear (for hydraulic
pump)(Teeth
12)
Hydraulic
pump SAR(3)-080
2. Front cover
Model
3. Gear case
Theoretical
4. Rear cover
Max. pressure
2 10 kg/cm’
5. Front cover
Max. pump
2,500
6. Drive gear (for steering
pump)(Teeth
speed
9. Driven
gear (Teeth
12)
10. Driven
gear (Teeth
12)
rpm
pump SAR(3)-050
Model
8. Rear cover
80 cc/rev
12) Steering
7. Gear case
discharge
(SAR(3)-040) Theoretical
discharge
49.8
cc/rev
(40.0 Max. pressure
210
Max. pump
2,500
(
61-12 0
):
speed
cc/rev) kg/cm’ rpm
Serial No. 1 1 1 18 and up
WA350-1
STRUCTURE
MAIN
AND
MAIN
FUNCTION
CONTROL
VALVE
CONTROL
VALVE
(For 2-SPOOI)
Section X-X
i-W
‘F
Section Y-Y 423F135
1. Body 2. Lift spool
6. Lift spool return spring
A.
Pump
7. Safety
valve
(with
suction)
B.
To dump
3. Dump
8. Safety
valve
(with
suction)
C.
To lift cylinder
spool
9. Suction
4. Main relief valve 5. Dump
61-14 @
spool
return
spring
valve
port cylinder
D.
Drain port
E.
To lift cylinder
F.
To dump
G.
Drain port
H.
Drain port
rod side
rod side bottom
cylinder
side
bottom
side
WA350-1
STRUCTURE
AND
FUNCTION
MAIN
CONTROL
VALVE
Section U-U
\
7
Section W-W
Section Z-Z Section V-V 423F136
Outline . The main control
valve
the attachments
and the
system. .
It has a tandem
to the bucket
circuit.
The
the
oil from
mum
controls
pressure
passes
through
is set the
passes
actuated,
the
oil
which
enters
port
bypass
the drain
circuit,
circuit
by the
(2).
to the tank.
actuation
in the
However,
of
so when
hydraulic
gives
relief circuit
It then
flows
through.the
If the dump flows
to
A.
The
valve.
maxiThe
of dump from filter
spool
port
dump
B to
and re-
and lift spools the
oil
and
the
There
circuit
the dump
the lift spool
priority .
pump
(3) and lift spool turns
the
buckets
gives spool
is operated,
are two
safety
(7) and (8) to protect sure
is generated
the two other
safety
valve
to the
bucket,
operated,
even if
the lift arm will not move. valves
(with
the circuit
in the
valves
priority
is being
bucket
is acting
acts as a suction
suction
valves)
if abnormal circuit.
pres-
If one of
as a relief valve, valve
to make
the
up any
lack of oil.
are lift
cylinders.
WA350-1
61-15
STRUCTURE
MAIN
AND
MAIN
FUNCTION
CONTROL
VALVE n
n
CONTROL
VALVE
(For 3-Spool (if equipped))
n
Section F-F
e
h
f
9
Section D-D
F424CO119
1. Check
valve
6. Spool 7. Spool
return
3. Main relief valve
8. Valve
body
4. Spool
9. Safety
2. Suction
5. Spool
61-15-l 0
valve
valve
spring (with
suction)
a.
From steenng
b.
To attachment
C.
To dump
cylinder
cylinder
d.
To lift cylinder
e.
To hydraulic
f.
To lift cylinder
gh.
To attachment
To dump
valve
tank
cylinder cylinder
WA350- 1
STRUCTURE
AND
FUNCTION
MAIN
CONTROL
VALVE
Section C-C
Section A-A
Section B-B
Section E-E
F424CO120
Outline l
The
main
control
the attachments system.
It has a tandem
to the attachment l
The oil from mum passes
valve
the actuation
However,
of
ment
in the hydraulic
are
circuit which gives priority
through
the bypass
circuit of dump
The
being
operated,
even
l
There
are two safety
valves
(9) to protect
the circuit
the drain circuit,
generated
the
turns to the tank.
WA350-1
the filter and re-
If the attachment,
spools are actuated, lift cylinders.
through
dump and lift
the oil flows to the dump and
if
to the attach-
the dump the
lift
the lift arm will not move.
(5) and lift spool (6). It then flows from port “e” to passes
priority
so when
spools
spool
The
is
attachat the
same time.
oil
spool
gives
ment and the dump spools can be operated
enters port “a”. The maxi-
is set by the relief valve.
the circuit
and the bucket,
operated,
and the bucket circuit.
the pump
pressure
controls
and the buckets
circuit. a relief
in
(with
attachment
If one of the two safety valve,
the
other
suction
if abnormal
valve
and
valves)
pressure the
is
bucket
valves is acting as acts
as a suction
valve to make up any lack of oil.
61-15-2 @
STRUCTURE
AND
LIFT AND
DUMP
MAIN
FUNCTION
SPOOLS
AT
“NEUTRAL
CONTROL
VALVE
POSITION”
>n..:.>&+,
4
0
Steering valve
E423F144
Operation . The oil flows valve
.
Dump
spool
is open spool
61-16
from
and enters
pump
(1) through
and the oil from
The circuit
(2) is at neutral,
and flows
the steering
port A. so the bypass
port A passes
circuit
around
the
lift spool is open.
the spool, oil cooler
flows
(3) is also at neutral, The oil from from
and filter,
port
the drain
so the bypass
B passes
circuit
around
through
and goes back to the tank.
to port B.
WA350-1
the
STRUCTURE
LIFT
AND
SPOOL
AT
FUNCTION
“RAISE
MAIN
CONTROL
VALVE
POSITION”
Water
E423F145
Operation . When lift control lever (4) is pulled, lift spool (3) is .
The oil flows valve.
from
pump
(1) through
It then passes through
dump spool (2) and flows
.
At the same time, the oil from the cylinder flows
pushed into the RAISE position. the steering
the bypass circuit of
to the bypass
from
port
E to drain
through
the
happens,
the lift arm goes up.
oil cooler
port
to the
rod end
F and returns
tank.
When
this
circuit of
lift spool (3). The bypass circuit is closed by dump spool (2). so the oil pushes The
oil from
check
enters the cylinder
WA350-1
valve
open check valve (5).
(5) flows
to port D and
bottom.
61-17
STRUCTURE
LIFT
AND
SPOOL
AT
MAIN
FUNCTION
“LOWER
CONTROL
VALVE
POSITION”
Water
E423F146A
Operation l
When
lift control
lever (4) is pushed,
is pulled out to the LOWER l
The oil flows valve.
from
pump
(I)
It then passes through
dump spool (2) and flows lift spool
(3).
The
through
the steering
the bypass circuit of
circuit
from
check
valve (5) to port E
and enters the rod end of cylinder.
to the bypass
bypass
spool (3). so the oil pushes
61-18 @
The oil then flows
lift spool (3)
position.
circuit of
is closed
by lift
l
At the same time, the oil from the cylinder flows
from
passes tank.
port D and enters
through
When
the
oil cooler
this happens,
bottom
drain port F. It then and return
to the
the lift arm goes down.
open check valve (5).
WA350-1
STRUCTURE
LIFT
AND
SPOOL
FUNCTION
AT
“FLOAT
MAIN
CONTROL
VALVE
POSITION”
Water
Float e
E423F147
Operation When
lift control
from
the LOWER
into the FLOAT The oil flows
lever (4) is pushed position,
further
(3) is pulled
from
It then flows
dump
spool
pump
The oil in the bypass
(1) through
around
(2) to the
In addition,
RAISE
of
cylinder
the
circuit,
position.
valve.
cuit because
down
lift spool
the steering
the bypass
lift spool
circuit
bypass
of
circuit.
circuit flows to the drain cir-
of the spool, but it cannot
lift
circuit are
D and LOWER connected
so the lift arm goes
down
circuit E
to the under
drain
its own
weight. When can
the bucket move
is in contact
up and down
with the ground,
in accordance
with
it
the
shape of the ground.
push open
check valve (5).
WA350-1
61-19
STRUCTURE
DUMP
AND
SPOOL
FUNCTION
AT
“TILT
MAIN
BACK
CONTROL
VALVE
POSITION”
E423F148
Operation When
dump
lever (6) is pulled, dump
spool (2) is
The
pushed into the TILT position. The bypass
circuit is closed by dump spool (2), so oil from port A pushes open check valve (7).
61-20
.
port A flows from check port G to the cylinder bottom.
oil from
through
valve
At the same
(7)
time, the oil at the cylinder rod end port H to drain port F. It then passes through the oil cooler, and flows back to the tank. When this happens, the bucket tilts. flows
from
WA350-1
STRUCTURE
DUMP
AND
SPOOL-
FUNCTION
AT
MAIN
CONTROL
VALVE
“DUMP”
Dump
Steering Pump
E423F149A
Operation l
When
the dump
lever
(6) is pushed,
(2) is pushed into the DUMP .
The
bypass
circuit
(6). so the oil front
dump
spool
position.
is closed
by the dump
port A pushes
up check
.
At the same end flows
spool
turns
valve
dumped.
to
time,
from the
the oil at the cylinder
bottom
port G to drain port F and then retank.
As
a result,
the
bucket
is
(7). The oil from port A flows from port D into the spool.
It then
flows
from
port H to the cylinder
rod end.
WA350-1
61-21 @
STRUCTURE
AND
MAIN
FUNCTION
CONTROL
VALVE
RELIEF VALVE
1. Main valve 2. Valve seat 3. Pilot poppet 4. Pilot poppet spring 5. Adjustment
1
2
screw
3
423F137
Function l
The relief valve is installed control
valve.
pressure,
When
at the inlet of the main
the
oil goes
above
the set 5608
the relief valve drains the oil to the tank.
In this way, hydraulic
it sets the maximum
circuit and protects
pressure
FO70
in the
the circuit.
3
Operation Port A is connected is connected through
to the pump circuit and port C
to the drain
the orifice
port B. Pilot
circuit.
The
of main valve (I)
poppet
oil passes
and flows
(3) is in close
contact
to
with
valve seat (2). When
the
hydraulic
pressure
port A and port B reaches pilot poppet
the pressurized the
effect
of main valve
pressure
between
is pushed
passes through set
tension
pressure of pilot
set pressure, turn adjustment
61-22
B drops,
(1) generates
the
orifice
a difference
port A and port B. The and
the
oil
port C and flows
cuit to release the abnormal The
port D
from
at port B drops.
at port
open
can poppet
remove screw
56OBF071
(3) opens, and
port B flows
oil from
When
valve
inside of the
spring (41, pilot poppet
to port C, so the pressure
pressure
in the circuit
the set pressure
from
in
main
port
A
to the drain cir-
pressure.
be varied spring
by changing
(4).
To change
cap nut, loosen (5) as follows.
the the
lock nut and 56OBFO72
WA350-1
STRUCTURE
SAFETY
AND
FUNCTION
VALVE
(with
MAIN
suction
CONTROL
VALVE,
valve)
I. Valve 2. Suction
body valve
3. Main valve 4. Main valve
spring
5. Pilot piston 6. Suction
valve
spring
423F138
Function . The safety dump
valve
cylinder
causes
suction
in the
any abnormally
high
der when valve
(with
circuit
the
(with
pressure
main
valve
suction
Operation As a safety valve . Port A is the cylinder
is in the
valve.
pressure
If shock
in the cylin-
is at neutral,
valve)
and protects
valve)
main
releases
the cylinder
circuit
the safety
the
abnormal
from
damage.
and port B is the drain
circuit. The pressure
oil in port A flows
a hole
pilot
in the
through
piston.
an orifice
consisting
and the pilot piston The pilot lock
piston
nut.
to the safety
diameter
(cross-sectional
to port
of the main valve
C (3)
(5).
is secured
The
D through
to port
It also flows
of
area) gives
the
valve
cross
a relationship
by a
section of d2 >
dl > d3 > da.
.
If abnormally the
suction
high valve
the relationship However, port
oil pressure (2) is not
because
(3)
between poppet
is
of the
actuated, WA350-1
A, of
equivalent force
d3 > d4 in
relationship
hydraulic
pressure to
the
d3 and da. If this pressure spring
in port because
d2 > dl.
A and C, the
valve
occurs
actuated
(set pressure),
and the oil in port A flows
on the main
area goes the
difference up to the poppet
into port B.
is 423F139
61-23
STRUCTURE
AND
MAIN
FUNCTION
CONTROL
VALVE
As a suction valve If negative
pressure
also has negative are connected
with
each
in port B is applied
in port A, port
is generated pressure,
because
other.
D D and A
port
The tank
pressure
to port E.
Hydraulic
pressure
“a”
difference
between
d2 and dl is applied
safety
valve
Therefore, valve
because
valve
pressure pressure
hydraulic
smaller
than oil pressure
When
oil
valve from
pressure +
“a” port
in port E.
acts to open the acts to close
This
(approaching
pressure becomes
spring
causing
A.
the
“a”
negabecomes
larger
(6) force,
the oil to flow
prevents
than
oil
the suction from
negative
port
pressure
up in port A.
building
SUCTION
“a”
area to the
“e”.
“e”
valve
(2) opens,
B into
“e”
in port A drops,
pressure)
pressure
the
(2):
If the pressure tive
to
of the tank pressure
hydraulic
and hydraulic
suction
equivalent
VALVE
1. Main poppet 2. Sleeve 3. Spring
:
,,,
Operation . If negative cylinder port opens
,,,,
,,““’
423F142
,, ,,,
pressure
rod end)
B in the because
is generated
(if the
tank
pressure
circuit),
the
of the difference
dl and d2 . Oil then flows end to port A at the cylinder
from
in port is lower main
A
(lift
than
poppet
in (I)
in area between port C at the tank
port end.
423F143
61-24
WA350-1
STRUCTURE
AND
FUNCTION
CYLINDER
HYDRAULIC
CYLINDER
HYDRAULIC CYLINDER
LIFT
1
\s
2
I
423F150
Lift cylinder
1. Head 2. Rod
Cylinder
I.D.
I
150mm
3. Cylinder 4. Piston
Rod dia.
I
90 mm
5. Lock ring Cylinder
max. length
Cylinder
min. length
Stroke
WA350-1
I I
I
2050
mm
1337
mm
713mm
61-25
STRUCTURE
DUMP
AND
HYDRAULIC
FUNCTION
CYLINDER
CYLINDER
423F151
Dump cylinder 1. Head 2. Rod
Cylinder
I.D.
180mm
3. Cylinder 4. Piston
Rod dia.
90 mm
5. Lock ring Cylinder
max. length
1550
mm
Cylinder
min. length
1062
mm
Stroke
61-26 @
I
488
mm
WA350-1
WORK EQUIPMENT SYSTEM TESTING
62
AND ADJUSTING
Standard
..
value table
. .
. ..
Tool list for testing and adjusting Measuring Adjusting
3 4
dump and lift control levers
62-
5
. .
62-
6
62-
8
62-
9
Measuring
hydraulic
Measuring
lift arm and bucket
Measuring
hydraulic
troubleshooting The values
precautions
are necessary
standard
.. .
Adjusting
boom kick-out
using the Standard
in these
tables
are based
Value
values
on the values for new machines or when estimating
in these tables for judgement
values for the machine
when shipped
they should be used as reference
in combination
These
drift of lift
bucket
..
. .
positioner
.
.
.
.
Tables
..
62-10
. .
..
62-l
1
. 62-l
3
to make judgements
during
or during testing and adjusting.
used as target values when repairing The standard
when
pressure
Adjusting
Troubleshooting
The following
2
62-
.
dump and lift control levers
arm and bucket
+
6262-
standard
leaving the plant, so they should
be
wear after a period of use.
when troubleshooting
are estimated
values based on the
from the plant, and on the results of various tests. with repair and operating
value tables must not be used for standard
Therefore,
records when making judgements.
values when judging
claims.
In addition,
do not
use these values alone to make simple judgements.
WA350-1
62-1 0
TESTING
ADJUSTING
AND
VALUE
STANDARD
VALUE
TABLE
Permissible
value
TABLE
item
and measuring
Testing
STANDARD
condition
Measurement
Unit
Standard
value
Dump lever and lift lever l
force
Lift lever operating
(Hold-Raise)
1.7 -4.7
Max. 7.1
(Raise-Hold)
1.7 -4.7
Max. 7.1
1.5 -4.5
Max. 6.8
1.5 -4.5
Max. 6.8
2.8 - 5.8
Max. 8.7
1.7 -4.7
Max. 7.1
(Hold-Dump)
1.5 -4.5
Max. 6.8
(Hold-Tilt)
1.5 -4.5
Max. 6.8
(Tilt-Hold)
1.3 -4.3
Max. 6.5
(Hold+Raise)
70-90
60 -
100
(HolddLower)
70-90
60
-
100
108-128
98 -
138
(Hold-Dump)
70-90
60 -
100
(Hold-Tilt)
70-90
60 -
100
210*5
210
(HolddLower)
.
(Lower-Hold)
temperature:
Hydraulic 45
-
55°C
kg
(Lower-Float) (Float-Hold) l
l
Dump lever operating
force
l
Engine speed:
Low idling
Lift lever travel
(Hold-Float) l
mm
Dump lever travel
Main valve
l
45 l
Main relief oil pressure
l
temperature:
Hydraulic -
kg/cm2
55°C
Lift arm and bucket operating
Hydraulic
speed.
45 -
temperature:
55°C
l
Lift arm lifting time
l
Lift arm lowering
l
Bucket dumping
l
Bucket tilt back time
Inside operating
(Full stroke)
Bucket:un
l
Engine speed: High idling
time
temperature:
Coolant
range.
Hydraulic
drift of lift arm
Hydraulic 45
Retraction cylinder
of lift
-
Max. 7.2
2.7 - 3.3
Max. 4.0
1.3 - 1.9
Max. 2.3
2.1 -2.7
Max. 3.2
0.9 - 1.5
Max. 1.8
Max. 10
Max. 28
Max. 10
Max. 48
Max. 5
-
loaded
temperature:
55°C temperature:
Coolant
rod
Inside operating
range
Stop engine, lever for 5 minutes, Retraction
5.4-6.0
position of bucket)
and bucket
l
sec.
Bucket tilt back time (Horizontal
l
position:Neutral
Steering
time
f
Engine speed: High idling
mm
then measure
for next 15 minutes.
of dump cylinder rod
Lift arm horizontal Bucket horizontal Unloaded Bucket positioner l
Clearance
of switch
Hydraulic 45
-
temperature:
55°C mm
Boom kick-out l
Clearance
62-2 0
of switch
Max. 5
WA350-1
10
TESTING
TOOL
No. Testing
AND
LIST
Hydraulic
2 3 4
FOR TESTING
and measuring
1
TOOL
ADJUSTING
Hydraulic
tester
Oil temperature
Thermistor
kit
Engine speed
Tachometer
pressure
Dump lever and lift
I
A
Measuring
When
Convex
travel
carrying
cut testing,
bar on the frame,
Push-pull
scale
Commercially
or troubleshooting,
AND
ADJUSTING
ADJUSTING
Remark
I
O-25
7AO-262-0020
scale
adjusting
FOR TESTING
Part number
Tool
item
I lever operating force 5
AND
LIST
available
stop the machine
kg
0 - 2 mm
on level ground,
install the safety
lower the bucket to the ground, and stop the engine.
Then apply the parking brake and block the tires.
A A
Do not allow unauthorized When
measuring
operator’s
A
persons near the machine.
the engine speed,
seat to operate
Be careful not to get caught
WA350-1
one worker
the controls. in rotating
Always
should
measure
the engine
check that the operation
speed while the other sits in the
is safe, and use agreed signals.
parts.
62-3 0
TESTING
AND
MEASURING
ADJUSTING
MEASURING
DUMP
*
Measurement
l
Coolant
l
Hydraulic
l
Engine speed: Low idling
AND
LIFT
DUMP
CONTROL
AND
LIFT
CONTROL
LEVERS
LEVERS
condition
temp: Inside operating oil temperature:
range
45 -
55°C Unit: kg(mm)
Item (
)
Hold-Raise
1
1.7-4.7
Max. 7.1
Float-Hold
1.7-4.7
Max. 7.1
Hold-Dump
1.5-4.5
Max. 6.8
Hold-Tilt
1.5-4.5
Max. 6.8
Tilt-Hold
1.3-4.3
Max. 6.5
Hold-Raise
(70-90)
(60 - 100)
Hold-Lower
(70-90)
(60-100)
Hold-Float
(108-128)
(98-138)
Hold-Dump
(70-90)
(60 - 100)
Hold-Tilt
(70-90)
(60 - 100)
Dump control lever
Lift control lever
Permissible value
Standard value
* Dump control lever
i,
Special tool Part number A
n !
Part name
7AO-262-0020
Push-pull
Install the safety
Fit push-pull Hook
scale
the
Tilt
I
1
scale
bar on the frame.
levers and measure *
t
Q’ty
423F324
Measuring procedure 1. Operating force of dump and lift control levers l
Raise
#
A
on dump
operating
push-pull
scale
and lift control
force. on the
center
of
the knob. *
Operate
at the
measure
the minimum
same
speed
as normal
force needed
and
to oper-
ate the knob.
2. Travel of dump and lift control levers l Measure the travel X of the control
levers
at
each position. t
Mark the knob of the lever and use a scale to measure.
62-4 0
WA350-1
TESTING
AND
ADJUSTING
ADJUSTING
DUMP
ADJUSTING
AND
LIFT
* Disconnect all the linkage before starting the adjustment procedure. 1. Put the dump control lever in the TILT position, and the lift control lever in the RAISE position. * Check the positions of the dump and lift lever as shown in the diagram below.
DUMP
CONTROL
AND
LIFT CONTROL
LEVERS
LEVERS Lift lever “raise” position -
2. Adjust the position of the magnetic switch so that the clearance between plate (1) for connecting the magnetic switch and lever pin (2) is the standard value. * Standard clearance: 0 - 2 mm
423F325
3. Put the dump and lift control levers in NEUTRAL, adjust the length of rod (4) and connect main control valve and lever (3). Sr Check the neutral positions of the dump and lift control levers as shown in the diagram below. * Check that the main control valve is in the NEUTRAL position. *
After making the above adjustment, measure again and check that the measurements are the standard value.
I
423F326
WA350-1
62-5 0
TESTING
AND
MEASURING * l l l
MEASURING
ADJUSTING
HYDRAULIC
HYDRAULIC
PRESSURE
PRESSURE
Measurement condition Coolant temp: Inside operating range Hydraulic oil temperature: 45 - 55°C Engine speed: High idling Unit: kg/cm*
S tva,n,d;d
Item Main relief pressure
Special
210*5
799-l
1, Measuring
A
210 f
10
tool
Part number
A
Pervqimible
01-5000
procedure
Part name
Hydraulic tester
(Main
relief
Q’ty
Serial No. 10001 - 11 1 17
Serial No. 1 1 118 and UD
1
valve)
Loosen the oil filler cap slowly to release the pressure inside the hydraulic tank. Then operate the control levers several times to release the remaining pressure in the hydraulic piping.
I) Remove
plug (I) for measuring pressure of dump cylinder circuit. 2) Install hydraulic tester A to measuring port. * Check that there is no oil leakage from any connection. * Use a hose (2) which is long enough to reach the operator’s compartment. 3) Start the engine, raise the lift arm 400 mm from the ground and operate the dump control lever (TILT). Measure the pressure when the relief valve is actuated. * Be careful not to apply any sudden pressure to the pressure gauge.
Serial No. 10001 - 11 1 17
Serial No. 1 1118
andUD
removing the hydraulic pressure gauge, A When release the
pressure inside the circuit in the same way as-when installing.
62-6 0
WA350-1
TESTING
AND
To INCREASE
pressure,
To DECREASE *
If
the
accurately,
relief
MEASURING
ADJUSTING
TIGHTEN
pressure,
pressure
do not try to adjust
PRESSURE
screw.
LOOSEN cannot
HYDRAULIC
be
screw. measured
the pressure.
3
2 423F315A
WA350-1
62-7 0
TESTING
AND
MEASURING
ADJUSTING
MEASURING
LIFT ARM
LIFT
ARM
AND
BUCKET
CKET
AND
Lifting time of lift arm
Measurement Coolant
condition
temperature:
Steering
position:
Hydraulic
Inside operating
range
Neutral
temperature:
45
-
55°C
Bucket: Unloaded Engine speed: High idling Unit: set Permissible value
Standard value
Item
Lifting time of lift arm
._
Lowering time of lift arm
I
Dumping time of bucket
5.2-5.8
Max. 7.4
2.5 -3.5
Max. 4.2
1.0-1.6
Max. 1.9
I
Special tool Part name
Part number 7AO-262-0550
Q’ty 1
Stop watch
423F328 Dumping time of bucket
Measuring procedure 1. Lifting time of lift arm Set the bucket near the maximum and at the lowest the bucket
position
and measure
to reach the maximum
tilt back position
on the ground.
Raise
the time taken for bucket height of the lift arm.
2. Lowering time of lift arm Set the bucket maximum the taken
horizontal
height,
lower
with
the lift arm at the
the bucket
for the bucket
and measure
to reach the lowest
posi-
tion on the ground. 423F329
3. Dumping time of bucket
Tilt back time of bucket
Raise the lift arm to the maximum sure the time taken the maximum
height and mea-
for the bucket
tilt back
position
to move
from
to the maximum
dump position.
4. Tilt back time of bucket 1) Raise the lift arm to the maximum measure
the maximum 2) Set the bucket
and
to reach
tilt back position. horizontal
taken for the bucket
and measure
the time
to move from the horizon-
tal position to the maximum
62-8 0
height
the time taken for the bucket
tilt back position.
423F330
WA300-1
TESTING
AND
MEASURING
ADJUSTING
MEASURING HYDRAULIC AND BUCKET Measurement Coolant Stop
DRIFT
DRIFT
OF
LIFT
ARM
AND
BUCKET
OF LIFT ARM
condition
temperature:
Hydraulic
HYDRAULIC
Inside operating
temperature:
engine,
leave
45
for
-
range
55’C
5 minutes,
then
measure
for next 15 minutes. Lift arm horizontal Bucket horizontal Unloaded Unit: mm Standard value
Permissible value
Retraction of lift cylinder rod
Max. 10
Max. 28
Retraction-of dump cylinder rod
Max. IO
Max. 48
Ttem
Special
tool
Part number
Part name
Commercially available
Convex
Q’ty 1
scale
a.
Frt the safety
A
Do not go under the work equipment.
locks on the control levers.
Measuring procedure I) Set the lift arm and bucket
horizontal,
then stop
the engine. 2) Stop
the
engine,
wait
for
5 minutes,
then
start
measuring. 3) Measure
the
amount
the
lift and dump
cylinder
rods retract during 15 minutes.
* Use the same orocedure bucket is unloaded
* When
measuring
to measure
when
the
and loaded. with
bucket
loaded,
may spill, so be careful.
A. Retraction
of lift cylinder rod
B. Retraction
of dump cylinder rod
the load 423F331
423F332
WA350-1
62-9 @
TESTING
AND
ADJUSTING
ADJUSTING Sr Measurement l
Coolant
l
Hydraulic
ADJUSTING
BUCKET
POSITIONER
Inside operating
oil temperature:
45
-
range
55°C Unit:
Standard value
Item Clearance between proximity switch and angle
1. Inspection
between
standard 2) Start the
mm
Permissible value
Max. 5
procedure
the engine
ance
POSITIONER
conditions
temperature:
I) With
BUCKET
stopped, switch
check
(I)
that the clear-
and angle
(2) is the
value.
the engine, actuation
run at high idling and check
position.
(Measure
three
times
and take the average.)
2. Adjusting I) Lower
the
bucket
the bucket the
lever
to the ground
to the desired to
the
hold
and operate
digging angle. position
and
Return
stop
the
engine. 2) Adjust
nut (4) of the proximity
clearance
(a) between
proximity
switch
imity switch
(I)
sensor
switch
so that
the tip of protector
(3) of
and the face of the proxis the standard
value, then
U42301OOg
lock in position. *
Clearance
m
a:
Mut:
3) Use shim clearance protector Check
0.5
-
1.8 f
1 .O mm 0.2 kgm
(5) and adjust (b) between
protector
angle
(3) is the standard that
protector
(3) so that
(2) and the tip of value.
(3) and angle
(2) are
not in contact. Adjust tween
with
shims
so that the clearance
angle (2) and the tip of protector
the standard
value
at the full stroke
be(3) is
of the
2/
angle, then lock in position. Check face
that of the
the centers proximity
of the sensing switch
and angle
-Il-b
sur(2)
U42301010
are in line, then lock in position. After check
adjusting,
operate
that the bucket
the bucket positioner
lever and
is actuated
at the desired position.
62-10 0
WA350-1
TESTING
AND
ADJUSTING
ADJUSTING
ADJUSTING
BOOM
1. Inspection procedure I) With the engine stopped, ance
between
standard 2) Start the
switch
mm
Standard value
Permissible value
Max. 5
-
Clearance between proximity switch and plate
KICK-OUT
KICK-OUT Unit:
Item
BOOM
check that the clear-
(2) and plate
(I)
is the
value.
the engine, act&ion
run at high idling and check
position.
(Measure
three
times
and take the average.)
2. Adjusting 1) Raise
the
Return
lift
arm
to
the
desired
position.
the lever to the hold position
and stop
the engine.
A 2) Align
Always trol
apply
the marking
adjust
the safety
lock to the con-
lever.
the plate
(2) center
with
the switch
(1) position
and the
plate
center
and
so that the switch
lower
end are in line
with each other. 3) Fix the switch the sensing
so that
surface
the clearance
of the switch
between
(2) and plate
423F335
(1) is Max. 5 mm. B
Switch
* After check
mounting
adjusting, that
the
nut:
operate kick-out
1.8 f
the
lift
0.2 kgm lever
is actuated
and
at the
desired position.
* Check that the sensing surface of the proximity switch and plate (I ) are not in contact.
WA350-1
62-11 0
TROUBLESHOOTING Troubleshooting
. .. .
table
. .
... ...
.. ..
62-l
4
62-l
4
62-l
5
.
62-l
6
. . ... .
62-l
6
62-l
6
62-l
6
. . . . . . . . . 62-l . .. .. .. 62-l
7
1. Lift arm does not rise
2. Lift arm moves slowly or does not have sufficient
lifting power
3. Lift arm movement
.
.
becomes
. .. ..
reaches a certain height 4. Bucket cannot cylinder.
..
be held down with lift
....
.
..
.
.
5. Lift arm has large hydraulic 6. Lift arm movememt during work
.
slow after it
is unsteady
.
.
7. Lift arm descends when control
drift
. .. .. ....
momentarily
lever is shifted
from “Hold” to “Raise” 8. Bucket does not tilt back
6
9. Bucket moves slowly or has insufficient
.
tilt back power 10. Bucket movement
.
tilt back.
11. Bucket cannot cylinder.
..
.
. .
becomes
..
.
.
62-l
8
62-l
9
slow during
.
.
..
be held down by the dump
... .. ..
12. Bucket has large hydraulic 13. Bucket moves unsteadily
..
..
.
...
drift
when machine
62-l
9
62-l
9
travels
under load (Main control vave in “Hold”) 14. Bucket dumps momentarily is shifted 15. Cantrol
. . . . . . . . 62-l 9
when control lever
from “Hold” to “Roll back”
move stiffly and sluggishly
*
Before
carrying
page 22-l
out the troubleshooting
2, “METHOD
RENCE OF TROUBLE”
WA35071
OF READING
in this section, TROUBLESHOOTING
read “PRECAUTIONS TABLE”
.
62-l
.
62-20
levers of lift arm and dump
page 22-l
WHEN
TROUBLESHOOTING”
4 and “PREVENTING
RECUR-
page 22-16.
62-13 0
9
TROUBLESHOOTING
TROUBLESHOOTING
TROUBLESHOOTING
TABLE
TABLE
1 Lift arm does not rise. Ask the operator the following l
Did the boom or damage Was Were
questions.
fail to rise? +
Seizure
to various units.
an unusual
emanate l
suddenly
noise produced?
(where
dit it
from?)
there
previous
down. -L Wear
signs of the boom slowing
of parts or flattening
of spring.
Checks before troubleshooting l Is oil level in hydraulic tank correct? l
Is stroke of lift control lever and spool correct?
a
No.
1
b A
C
c
Bucket cannot operate and lift arm is unable to ascend.
r
lololololol
The following symbols are used to to be taken when a cause of failure X: Replace A: Adjust
62-14 0
e
f
g
A
A
xx
Problems
d
xx
xx
I
indicate the action is located. A: Repair C: Clean
WA350-1
TROUBLESHOOTING
TROUBLESHOOTING
2. Lift arm sufficient Checks
moves lifting
before
slowly power.
or does
not
TABLE
have
troubleshooting
Is the amount
of oil in the hydraulic
tank
and
also the type of oil correct? Is the stroke of the lift control
lever and also the
spool of the main control valve correct? Seizure
of bucket
linkage bushing.
(Does emits unusual noise)
Fault check There
is a strong
relationship
volving
lifting force
appear
initially
in the
speed._ Measure when
loaded
the
between
and lifting speed. form lifting
faults
of insufficient speed
whether
lifting
of the
and refer to the judgement
table to determine
in-
Such faults lift arm criterion
or not there is a
No. 1 2 3 4 5 6 -
7 a
The following symbols are used to indicate the action to be taken when a cause of failure is located.
WA350-1
62-15 0
TROUBLESHOOTING
TROUBLESHOOTING
3. Lift arm movement reaches
becomes height.
a certain
slow
after
it
Check before troubleshooting l
Visible deformation
of lift cylinder.
6. Lift arm work.
movement
TABLE
is unsteady
during
During excavation
or ground
leveling when
arm
is in the
“Hold”
control
bucket
lever
and lift arm move
the lift
position,
up and down
the
in accor-
dance with the terrain.
Cause
. Swollen or internally damaged lift cylinder tube. + Regarding other faults occurring during lift arm ascent,
refer to item 2 “Lift arm moves
or does not have sufficient ._
slowly
Problem and cause Check
the amount
the standard
4. Bucket cannot be held down with lift arm cylinder. _ the lift cylinder arm moves
in the circuit at the bottom
is insufficient,
slowly
drift and whether
body can be lifted up by the lift
cylinder. 1. If the amount
If the relief pressure
of hydraulic
or not the machine
lifting power”.
large hydraulic cylinder,
of lift-
drift is greater
than
drift”.
2. If the machine
body can be lifted up by the lift
refer to tiem 4 “Bucket
cannot
be held
down with lift cylinder”.
refer to item 2 “Lift
or does not have sufficient
of hydraulic
value, refer to item 5 “Lift arm has
3. If the amount machine
of hydraulic
is normal
Checks before troubleshooting
times to cause the lift cylinder to move through
l
Is level of oil in the hydraulic
l
Is stroke
of main
control
the
lift
its entire stroke 4
tank correct? valve
after
can be lifted
and
the
cylinder
body
drift
ing power”.
*
correct?
If
a
vacuum
is moved
the trouble
eration of a vacuum
and lift spool
arm
up by the lift several
is due to the gen-
in the cylinder.
is generated
frequently,
+
faulty suction valve on lift cylinder rod side.
Cause l
Faulty
main control
valve or suction
valve seat
on lift cylinder rod side. l
7. Lift arm descends momentarily when control lever is shifted from “Hold” to “Raise”.
Oil leakage from lift cylinder piston seal.
The
5. Lift arm has large hydraulic drift.
lift arm descends
shifted
from the “Hold” position to the “Raise”
control
l
Did the hydraulic +
l
Did the hydraulic +
drift suddenly
become
Dirt lodged in valve or damaged Worn
drift gradually
large?
the engine
lever is gradually
is at low idling. When
is put completely
position, the lift arm behaves
into the
large?
normally.
l
Faulty seating
of main control
valve or lift arm
load check valve.
parts.
Is the type and temperature
of the oil in the hy-
draulic tank correct? l
Is the lift arm spool in the neutral Seized
position?
+
link bushing, faulty spool detent.
Problem and cause l
When
measuring
cylinder
produces
hydraulic oil leak
drift, noise
internal -,
of lift
Damaged
piston packing.
62il’ 6
the
“Raise”
Checks before troubleshooting l
po-
Cause
parts. become
lever
the lift arm control
under its own
when
sition while
Ask the operator the following questions.
momentarily
weight
WA350-1
TROUBLESHOOTING
8. Bucket
TROUBLESHOOTING
does not tilt back.
Ask the operator the following l
Did the Seized Was Were
bucket
suddenly
or damaged any
emanate l
TABLE
unusual
questions.
cease
to move?
-L
equipment. noise
emitted
(where
dit it
from)?
there
ing down?
previous +
Worn
signs of the bucket parts or flattened
slow-
spring.
Checks before troubleshooting l Is amount of oil in hydraulic tank satisfactory? l
Is the
stroke
of the
bucket
control
lever and
spool correct?
a
I
b
c
d
Lift arm cannot operate and bucket is unable to tilt back.
10101010101
2
The machine can be lifted up by the bucket but the bucket cannot tilt back. Alternatively, the lift arm operates but the bucket cannot tilt back.
I
3
The bucket can tilt back under no load but cannot excavate or scoop.
0
0
4
The hydraulic
0
0
5
Bucket cylinder has large hydraulic drift.
pump produces an unusual noise.
I
g
h
A
xxX
1
7
f
A
No.
6
e
xx 101
I
I
I
loI
loI
000
Steering action is light and excessively fast when the engine is at full throttle. Steering action is heavy and slow when the engine is
0 A
The following symbols are used to to be taken when a cause of failure X: Replace A: Adjust
indicate the action is located. A: Repair C: Clean
62-17 0
TROUBLESHOOTING
TROUBLESHOOTING
9. Bucket moves tilt back power. Checks l
l
Is the stroke
of the bucket
main control
valve
Seizure
of bushing
Check
tank
and the
Measure
in bucket
lever and the
linkage.
noise)
amount
of deficient
actual
speed
the judgement
whether
tilt
back
force
work.
the operating
it against
determine
control
correct?
_-
the
by performing check
spool
unusual
Fault checks
l
in the hydraulic
of oil satisfactory?
(Does emits
l
or has insufficient
troubleshooting
Is the oil quantity type
l
before
slowly
TABLE
of the bucket criterion
table
and to
or not it is normal.
The following symbols are used to Indicate the actlon to be taken when a cause of fatlure IS located.
62-18 0
WA350-1
TROUBLESHOOTING
TROUBLESHOOTING
10. Bucket movement tilt back. Checks .
before
External
becomes
slow
during
13. Bucket moves unsteadily travels under load. (Main “Hold”).
of dump
Checks
cylinder.
Cause Swollen
or internally
Regarding bucket
other
damaged
faults
operates,
slowlyor
11. Bucket bucket
dump
cylinder
occur
when
to item 9 “Bucket
has insufficient
cannot cylinder.
Refer-to
which
refer
before
Is oil
troubleshooting
level
in hydraulic
l
the
held
down
l
Excessive
play
equipment
linkage.
item 9 “Bucket
Check
before
moves
slowly
by
the
l
Faulty
piston
l
Faulty
safety
or has insuf-
If
the
other
Is oil level in the hydraulic
l
Is the
stroke
spool
correct?
of the
tank satisfactory?
main
control
valve
dump
seat of safety
trol valve
with
for the bottom
Oil leakage
12. Bucket
from
suction
valve
side of dump
seal of dump
valve
above
of con-
Dirt lodged
l
drift
in valve
with
oil
bushing
of
work
cylinder. suction
valve
for
the
cylinder. occur
refer
to the
together problems
with items
to each fault.
from
position position,
Did the hydraulic
the
momentarily
dump
control
the “Hold”
while lever
when control to “Tilt back”.
position
the engine
its
own
is gradually
to the “Tilt
back”
is at low idling. When
is put completely
the bucket
under lever
behaves
into the “Tilt
the
back”
normally.
Cause Faulty spool
become
or damaged
drift
momentarily from “Hold”
dumps
shifted
piston.
questions.
suddenly
bucket
control
drift,
the following
Did the hydraulic
Check
and
symproms
symptoms,
when
l
Ask the operator
l
of
noise produced?
side of dump
weight
cylinder.
cylinder
has large hydraulic
--L Worn
pin
seal of dump
14. Bucket dumps lever is shifted The
Cause
l
type
troubleshooting
l
+
and
Cause
corresponding
Faulty
in
Was an unusual
bottom
tilt back power”.
l
tank
moves
roll back power”.
be
ficient
l
machine valve in
correct?
tube.
l
when control
troubleshooting
deformation
l
l
TABLE
seating check
of
main
control
valve
dump
valve.
large?
parts.
gradually
become
large?
parts.
before
troubleshooting
Is the type
and temperature
draulic
tank correct?
Is the
dump
Seized
link bushing,
spool
of the oil in the hy-
in the faulty
neutral spool
position?
--L
detent.
Fault check l
Use
the
judgement
whether is actually l
l
drift drift
Faulty
in dump
returns seating
or suction
WA350-1
to
check
of the bucket
is large.
Oil leakage
If hydraulic Cause:
table drift
large.
If hydraulic Cause:
criterion
or not the hydraulic
valve
Faulty
oil
control
valve.
cylinder.
to normal, of overload
relief
valve
of
dump
on rod side.
sealing
on
spool
62-19 0
TROUBLESHOOTING
TROUBLESHOOTING
15. Control levers of lift arm and dump stiffly and sluggishly.
TABLE
move
Fault check Using
the judgement
or not the operating
criterion force
table.
check
whether
of the lever is large.
The following symbols are used to to be taken when a cause of failure X: Replace A: Adjust
62-20 0
indicate the actIon IS located. a : Repair C: Clean
WA350-1
WORK EQUIPMENT SYSTEM DISASSEMBLY
63
HYDRAULIC
TANK
Removal
LIFT
.
HYDRAULIC
.
.
Removal
63-
4
Installation
63-
6
Disassembly
63-
6
Assembly
. 63-
7
..
..
HYDRAULIC,
STEERING
Removal
WORK
PUMP
. . . . . . . . . . . .._.....
.
Installation CONTROL
Installation
.
. .
.
.
. .
.
.
Assembly
.
63-26
ASSEMBLY
._..........._____..
63-27
. . . . . . . . . . . .._........
63-29
EQUIPMENT 63-32
. . . . . . . . . . . .._.........
. .
. .. .
...
63-35
COUNTERWEIGHT
.
.
Disassembly
CYLINDER
Installation
63-10
63-25
.
Removal
VALVE
. .
Removal
. . . .._..............__
HYDRAULIC
_........__........_
Installation
DUMP
2
FILTER
Removal
CYLINDER
63-
. . . . . . . . . . . . . ..__...
Installation
MAIN
AND ASSEMBLY
63-13
Removal
63-16
Installation
..____...........____..
.
.
..
. .
63-38 63-38
63-18
. 63-20
.
CYLINDER
.
Removal
63-22
.
Installation
*
For details of disassembly
*
Take
the following
cylinders,
1. Start engine, 3. Continue NOTE:
WA350-1
method
of the gear pump, see SECTION
for air bleeding
when
you start to operate
97. hydraulic
cylinders
after
reassembling
pumps and pipings.
2. Operate 4. After
and assembly
63-24
keep idling.
hydraulic
cylinder 4 -
to operate
finishing After
5 cycles, but do not exceed
cylinder 3 -
beyond
100
mm of stroke end.
4 cycles until stroke end.
above steps, keep normal engine speed. long storage,
same procedure
is required.
63-1 0
Stop
the machine
wheels to prevent Loosen
Loosen filter,
several
levers pressure
remaining plug
to release to release
times
in the hydraulic
the the
piping. tank
(I)_ at the top of the hydraulic
and plug (2) of the pump
piping to prevent out.
the oil inside the tank from flowing
A
the
tank. Then operate
inside the hydraulic
the control
apply
under
from moving.
cap slowly
the oil filler
pressure
l
blocks
put
and
brake
parking
Then
and stop the engine.
to the ground the
the bucket
Lower
bar on the frame.
install
and
on level ground
machine
the
the safety
TANK
TANK
OF HYDRAULIC
REMOVAL
A
HYDRAULIC
ASSEMBLY
AND
DISASSEMBLY
Open hood (3) and fit lock (4).
I) Remove
clamps
window
washer,
of wiring then
and
remove
vinyl
tube
window
for
washer
tank (5) from hood (6).
2) Sling hood (6). remove
mounting
bolts, then lift
off. *
Be careful
not to hit the rear window
of the
cab when lifting off the hood. Hood:
63-2 0
62 kg
WA350-1
HYDRAULIC
ASSEMBLY
AND
DISASSEMBLY
TANK
2. Hydraulic piping I) Loosen
clamp
(8)
between
hydraulic
and main control valve from hydraulic and work equipment
3. Brake
hydraulic
tank tank.
oil tank
(IO),
between
oil tank
Remove
tank (I I).
from hydraulic
the hose clamp of the brake oil tank.
Remove
4. Hydraulic
of brake
bolts
mounting
then remove t
tank
tank.
circuit from hydraulic
(9)
hose
3) Disconnect
hydraulic
pump.
hose
2) Disconnect
(7) between
of hose
tank and hydraulic
tank
Sling hydraulic
tank
(I I),
remove
mounting
bolts,
then lift off. *
Be careful
not to hit the rear window
when lifting off the hydraulic *
The bottom
of the hydraulic
use blocks when standing Hydraulic
WA350-1
tank:
of the cab
tank. tank is not flat, so
it on the floor.
147 kg
63-3 0
DISASSEMBLY
AND
ASSEMBLY
INSTALLATION
HYDRAULIC
OF HYDRAULIC
TANK
2. Hydraulic tank I) Raise
hydraulic
tank
(I I),
set
position, then install mounting t
The
rear window
careful when *
Align
the
mounting
of the cab is close, so be
lifting the hydraulic
connections
setting in mounting *
in
bolts.
of the
tank. hoses
when
position.
Fit the tip of the oil drain hose in the clamp on the rear frame. Hydraulic
tank:
147
kg
2. Brake oil tank Install brake oil tank (I 0) to hydraulic
tank, then in-
stall hose clamp.
3. Hydraulic
piping
I) Connect
hose
(9) between
work equipment *
Fit the make
O-ring sure
hydraulic
circuit at hydraulic securely that
it
is
in the not
tank and
tank end. groove,
caught
and when
installing. *
Install
the
hose
without
twisting
or
interference. 2) Connect
hose
(8) between
hydraulic
main control valve at hydraulic
3) Connect hydraulic
hose pump
then tighten
63-4 0
(7) between
tank
hydraulic
tank and
at tube (I 2) of hydraulic
clamp
and
tank end.
tank,
(I 3).
WA350-1
TANK
2) Install window stail
Tighten plug *
with
vinyl
and
tube
for
oil
of pump
piping,
then
system.
to circulate
tank filter, and
add
oil filler (I 4) to the specified
Run the engine
WA350-1
tank (5) to hood, then in-
wiring
plug (I) at top of hydraulic
(2)
through
TANK
washer.
window
5. Refilling
washer of
clamps
HYDRAULIC
ASSEMBLY
AND
DISASSEMBLY
hydraulic
oil
level.
the oil through
the
Then check the oil level again.
63-5 0
DISASSEMBLY
AND
REMOVAL ! -ss
Loosen
OF HYDRAULIC
the
pressure
HYDRAULIC
ASSEMBLY
oil filler cap
slowly
inside the hydraulic
FILTER
FILTER
to release
the
tank.
1. Cover Remove !
mounting
The
0
bolts, then remove
tension
of
the
spring
cover (I 1.
is pushing
the
cover, so be careful when removing.
t
Be careful
not to damage
the O-ring on the con-
tact faces of the cover and tank.
2. Filter Remove
spring
remove
filter (4).
(2)
and
bypass
valve
(31, then
INSTALLATION OF HYDRAULIC FILTER 1. Filter Install
filter
(41, then
install
bypass
valve
(3) and
spring (2).
2. Cover Fit O-ring (I
(5) in groove
of cover, then install cover
1to tank.
*
Replace the O-ring
*
Fit the O-ring
with a new part.
securely
in the groove,
and make
sure that it is not caught when installing.
63-6 0
WA350-1
DISASSEMBLY
AND
REMOVAL
A
Stop
the
OF HYDRAULIC, machine
the safety parking
wheels
0!
Loosen
on level ground
bar on the frame.
to the ground the
HYDRAULIC,
ASSEMBLY
and
put
the
the control remaining
oil filler levers
pressure
several
Then
blocks
to release
times
to release
in the hydraulic
and plug (2) of the pump
the the
piping. tank
piping to prevent
the oil inside the tank from flowing
A
the
tank. Then operate
. Loosen p!ug (I) at the top of the hydraulic filter,
apply
under
from moving.
cap slowly
inside the hydraulic
install
the bucket
and stop the engine. brake
to prevent the machine
pressure
and
Lower
STEERING
out.
Open hood (3) and fit lock (4).
2) Sling hood (6). remove
mounting
bolts, then lift
off. *
Be carerul
not to hit the rear window
cab when lifting off the hood. 2.. m
WA350-1
Hood:
62 kg
of the
PUMP
STEERING
PUMP
DISASSEMBLY
AND
2. Hydraulic
HYDRAULIC,
ASSEMBLY
PUMP
piping
I) Disconnect
hose
(7)
and work equipment 2) Disconnect
hose
hydraulic
tank
circuit from hydraulic
between
tank.
(8)
between
hydraulic
and main control valve from hydraulic 3) Loosen
clamp
of tube
tank and hydraulic hydraulic
3. Brake
STEERING
(9)
pump,
between
tank
tank. hydraulic
and disconnect
from
brake
(IO),
tank.
oil tank
Remove
mounting
then remove
4. Hydraulic
bolts
of
from hydraulic
oil tank
tank.
tank
Sling hydraulic
tank (1 I),
remove
mounting
bolts,
then lift off. * k
Be careful
not to hit the rear window
of the cab
when lifting off the hydraulic
tank.
The bottom
tank is not flat, so
of the hydraulic
use blocks when standing Hydraulic
63-8 0
tank:
147
it on the floor. kg
WA350-1
AND
DISASSEMBLY
HYDRAULIC,
ASSEMBLY
STEERING
PUMP
5. Steering, hydraulic pump
I) Disconnect and
hose
(12)
valve
steering
between
steering and
steering
at
pump
hydraulic
pump end. 2) Disconnect and
hose (13)
between
valve
at steering
steering
hydraulic and
pump
hydraulic
pump end. 3) Disconnect and
tube
hydraulic
114) between
tank
hydraulic and
at steering
pump
hydraulic
pump (15) end.
around
4) Fit sling (15),
and
raise.
steering Remove
and
hydraulic
mounting
bolts,
pump then
lift off. Steering,
WA350-1
hydraulic
pump:
26 kg
63-9 0
DISASSEMBLY
AND
HYDRAULIC,
ASSEMBLY
INSTALLATION
OF HYDRAULIC,
1. Steering, hydraulic pump 1) Raise pump (15). set in mounting tighten
mounting
w
position,
STEERING
STEERING
PUMP
PUMP
then
bolts.
Mounting
bolt:
28.523.0
kgm
..
2) Install
tube
hydraulic 3) Connect steering
(14)
between
tank at steering
hydraulic
hose (I 2) between valve
pump
and
pump end.
at steering
steering
pump and
and hydraulic
pump
end. *
Fit the make
O-ring sure
securely
in the
that
it
is
not
(13)
between
groove,
and
caught
when
hydraulic
pump
installing. 4) Connect
hose
and steering
2. Hydraulic Raise
valve at pump end.
tank
hydraulic
tank
(1 I),
position, and install mounting *
The rear window
set
Align
the connections
ting in mounting t
mounting
of the cab is close, so be care-
ful when lifting the hydraulic t
in
bolts. tank.
of the hoses when
set-
position.
Fit the tip of the oil drain hose in the clamp
on
the rear frame. Hydraulic
63-10 0
tank:
83 kg
WA350-1
HYDRAULIC,
ASSEMBLY
AND
DISASSEMBLY
STEERING
PUMP
3. Brake oil tank 1) Install
brake oil tank
2) Install
hose clamp
tank.
(10) to hydraulic
of brake oil tank.
4. HI fdraulic piping I) Tighten
clamp
hose
2) Connect
pump
hose
3) Connect work *
O-ring
Fit the make
sure
hydraulic
in the
securely it
that
hydraulic
at hydraulic
circuit
is
and
tank
tank end.
at hydraulic
(7) between
equipment
hydraulic tank end.
at hydraulic
(8) between
valve
main control
(I 6) between
of hose
tank and hydraulic
not
and
tank
tank end. groove, caught
and when
installing. *
Install
the
hose
without
twisting
or
interference.
5. H ood II1Raise install
WA350-1
hood
(6). set
mounting
in mounting
position,
then
bolts.
63-11 0
DISASSEMBLY
AND
2) install window stall
washer
clamps
window
of
HYDRAULIC,
ASSEMBLY
STEERING
PUMP
tank (5) to hood, then in-
wiring
and
vinyl
tube
for
washer.
.
6. Refilling with oil Tighten plug
through t
plug 11) at top of hydraulic
(2)
of pump
then
Run the engine
to circulate
tank filter, and
add
oil filler (17) to the specified
system.
63-12 0
piping,
hydraulic
oil
level.
the oil through
the
Then check the oil level again.
WA350-1
DISASSEMBLY
AND
REMOVAL
A
Stop
the
machine
parking
CONTROL
on level ground
bar on the frame.
to the ground wheels
MAIN
OF MAIN
the safety the
ASSEMBLY
Lower
and
put
blocks
Loosen
the oil filler
pressure
the control remaining
levers
several
pressure
VALVE
install apply
under
the
from moving.
cap slowly
inside the hydraulic
VALVE
the bucket
and stop the engine. Then brake
to prevent the machine
! -r(
and
CONTROL
to release
the
tank. Then operate
times
to release
in the hydraulic
the
piping.
. Loosen
l
filter,
plug
(1) at the top of the
and plug (2) of the pump
the oil inside the tank from flowing
Q
)
hydraulic
tank
piping to prevent out.
Open hood (3 ;) and fit lock (4).
1. Hood I) Remove
clamps
window
washer,
of wiring then
and
remove
vinyl tube
window
for
washer
tank (5) from hood (6).
2) Sling hood (61, remove
mounting
bolts, then lift
off. *
Be careful
not to hit the rear window
of the
cab when lifting off the hood. Hood:
WA350-1
62 kg
63-13 0
MAIN
ASSEMBLY
AND
DISASSEMBLY
CONTROL
VALVE
2. Brake oil tank I) Remove hose clamp from brake oil tank (7). 2) Remove
bolts of brake oil tank, then
mounting
of hydraulic
put brake oil tank on top of bracket tank (8).
3. Hydraulic piping 1) Disconnect
(9)
hose
valve and hydraulic
between
2) Remove
clamp
(I 0) of tube.
3) Remove
clamp
(I
4) Disconnect
control
main
tank at hydraulic
tank end.
1) of tube.
dump
cylinder
tube
(I 2) and hose
(13) from main control valve. 5) Disconnect
lift
tubes
cylinder
(14)
and
(I 5)
from main control valve. 6) Disconnect valve
(I 6)
tube
and steering
between
main
at main control
valve
control valve
end. 7) Disconnect
hose
valve and work
(17)
between
equipment
main
control
circuit at main con-
trol valve end.
63-14 0
WA350-1
DISASSEMBLY
4. Main
AND
control
ASSEMBLY
MAIN
CONTROL
VALVE
valve
1) Disconnect
control
linkage
(18) from main con-
trol valve.
2) Sling main control valve (19).
remove
mounting
boks, then lift off. t
When
using a nylon sling to lift off the main
control
valve,
be
careful
to
maintain
the
balance.
el kg
Main control valve:
74 kg
_
WA350-1
63-15
DISASSEMBLY
AND
MAIN
ASSEMBLY
INSTALLATION
CONTROL
VALVE
CONTR ;OL VALVE
OF MAIN
1. Main control valve
1) Raise main control valve (19). set in mounting position, *
then tighten
Tighten
mounting
the mounting
bolts.
bolts fully after install-
ing the tubes and hoses.
2) Connect
control
2. Hydraulic
(18)
to main
control
piping
1) Connect and
linkage
-
valve.
hose (17)
work
between
equipment
main control
circuit
at
main
valve
control
valve end. 2) Connect
tube
and steering 3) Connect
(I 6) between
main control
valve
valve at main control valve end.
lift
cylinder
tubes
(14)
and
(I 5)
at
main control valve end. 4) Connect
dump
cylinder
tubes
(I 2)
and
hose
(13) at main control valve end. (I I) of tube.
5) Install clamp
6) Install clamp (IO) 7) Connect
hose
and hydraulic t
of tube.
(9) between
Fit the O-rings make
main control
valve
pump at main control valve end. securely
sure that
they
in the grooves,
are not caught
and when
installing. *
Install
the
hoses
without
twisting
or
interference.
63-16 0
WA3561
DISASSEMBLY
AND
MAIN
ASSEMBLY
CONTROL
VALVE
3. Brake oil tank 1) Install brake oil tank (7) to hydraulic
tank (8).
2) Install hose clamp on brake oil tank.
4. Hood I) Raise
(61, set in mounting
hood
install mounting
2) Install window stall
window
5. Refilling Tighten plug +
of
with
and
vinyl
at top of hydraulic piping,
then
tube
for
to circulate
tank filter, and
add
oil filler (20) to the specified
Run the engine
WA350-1
tank (5) to hood, then in-
wiring
oil
of pump
system.
then
washer.
plug (I)
(2)
through
washer
clamps
position,
bolts.
hydraulic
oil
level.
the oil through
the
Then check the oil level again.
63-17 0
MAIN
ASSEMBLY
AND
DISASSEMBLY
CONTROL
OF MAIN
DISASSEMBLY
1. Case assembly 1) Remove bolt (I ), then remove
CONTROL
VALVE
VALVE
case assembly
(2). bolt (5) of lever
(31, then loosen
plate
2) Remove
z
(4). 3) Remove
shaft (6) from lever (4).
4) Remove
oil seal (7) and bearings
(8) and (9).
0 27---Q .
26---B
2. Spool assembly
1) Remove case (IO), then remove spool assembly
24
(I I). 2) Remove
(I 3).
(I 3) from spool (I 5).
spring (141, and retainer *
retainer
remove
then
(I 2).
bolt
bolt (I 2) with the spool still assem-
Remove
bled in the valve body.
(with suction) 1) Remove main relief valve assembly (1 7).
3. Main relief valve assembly
holder (I 9).
2) Loosen nut (I 81, then remove 3) Remove
poppet
(201,
and retainer
(21)
spring
(22). (251,
then
in sleeve
(25).
sleeve
spring (24).
remove t
from
(23)
seat
4) Remove If there valve
is any
abnormality
or plug (27).
(26)
These
assembly.
parts
replace are
not
the whole available
individually.
4. Safety valve with suction valve assembly Remove
safety
valve assembly
(28).
5. Suction valve assembly Remove
suction valve assembly
(29). 423F460
6. Check valve Remove
plug (30).
then
remove
spring
(31)
and
valve (32).
63-18 0
WA350- 1
DISASSEMBLY
AND
ASSEMBLY
MAIN
CONTROL
VALVE
423F459
WA350-1
63-19 0
DISASSEMBLY
AND
ASSEMBLY
ASSEMBLY
MAIN
OF MAIN
CONTROL
CONTROL
VALVE
VALVE
1. Check valve Assemble
valve (32)
and spring (31)
fit O-ring, then tighten D
Plug:
in body (331,
plug (30).
kgm
47.5zb2.5
2. Suction valve assembly Fit O-ring
and
back-up
valve assembly w
ring, then
install
z
suction
(29).
Suction
valve:
0
1 kgm
14f
27-G 264 3. Safety valve with suction valve assembly Fit O-ring
and
back-up
valve assembly
(28).
Qz
valve:
Safety
ring,
then
install
safety
24
1 kgm
142
0
4. Main relief valve assembly 1) Assemble
spring (24) in sleeve (251, then install
seat (23). 2) Assemble
poppet
(201, spring (21)
and retainer
(23) in sleeve (25). 3) Screw
nut
into
holder
sleeve (25), then tighten 4) Fit O-ring
and back-up
(I 91, fit O-ring,
install
20-il a
nut (I 8). ring, then
install
main
relief valve (I 7). w
23-g 21-s 22--z
Main relief valve:
15.5k2.5
kgm
,*A 5. Spool assembly 1) Assemble retainer (I 31, spring (I 4) and retainer (13) in spool (I 5), then tighten B
*
Bolt: When
7kO.5
tightening
spool assembled 2) Assemble
spool
E
19 3
0
0
bolt (I 2).
kgm bolt (121, tighten
with
the
in the valve body.
assembly
(I 1) in body,
fit O-
ring, then install case (10).
423 F460
6. Case assembly 1) Install
bearings
(9) and (8). and oil seal (7) in
case. 2) Assemble
lever (4) inside case, fit key, then in-
stall shaft (6) to lever (4) inside case. 3) Tighten
bolt (5).
4) Fit O-ring,
align lever (4) with spool, then install
case assembly
63-20 0
(2).
WA350-1
DISASSEMBLY
AND
ASSEMBLY
MAIN
CONTROL
VALVE
a 423 F459
WA350-1
63-21 0
DISASSEMBLY
AND
REMOVAL
a
9!
1
DUMP
ASSEMBLY
OF DUMP
CYLINDER
CYLINDER
Stop the machine on level ground and install the safety bar on the frame. Lower the bucket to the ground and stop the engine. Then apply the parking brake and put blocks under the wheels to prevent the machine from moving. Loosen the oil filler cap slowly to release the pressure inside the hydraulic tank. Then operate the control levers several times to release the remaining pressure in the hydraulic piping.
Bucket
positioner
Disconnect connector (I 1.
2. Rod pin
Sling cylinder, remove lock bolt, then remove pin (2).
* When raising the cylinder, sling at two places and be careful to maintain the balance.
3. Hydraulic piping I) Disconnect hose (3) at rod end from cylinder
63-22 0
WA350-1
DISASSEMBLY
AND
ASSEMBLY
DUMP
CYLINDER
2) Disconnect tube (4) and hose (5) at bottom from connector.
.
4. Dump cylinder 1) Remove lock bolt, then remove pin (6) at bottom end. + There are shims installed, so check the number and thickness of the shims, and keep in a safe place.
2) Remove dump cylinder (7). * Be careful not to damage the cylinder rod. Dump cylinder:
WA350-1
185 kg
63-23 0
AND
DISASSEMBLY
DUMP
ASSEMBLY
CYLINDER
OF DUMP
INSTALLATION 1. Dump cylinder I) Raise dump cylinder
(7)
CYLINDER
and set in mounting
position. end, assemble
2) Align pin hole at bottom
cylindei
“a” between
that clearance
on left and right is within
shim so
and frame range, then
specified
install pin (6) and lock with bolt. Clearance
3 mm
Max.
“a”:
423F461
3) Align pin hole at rod end, then install pin (2) and lock with bolt. a
Use a bar to align the pin holes. Never use your fingers.
piping
2. Hydraulic 1) Connect
tube (4) and hose (5) at bottom
2) Connect
hose (3) at rod end.
*
Fit the O-rings
+
Install
the
securely hose
end.
in the grooves.
without
twisting
or
bucket
positioner,
see
interference.
3. Bucket Connect
positioner connector
Sr For details 62 TESTING
63-24 0
(I ).
of adjusting
AND ADJUSTING.
WA350-1
machine
the
Stop
inside the hydraulic
Place a support
the
to release
tank. Then operate the
to release
times
piping.
in the hydraulic
pressure
remaining +
several
levers
the control
the
under
from moving.
cap slowly
oil filler
the
pressure
apply
Then
blocks
put
and
the machine
to prevent
Loosen
the bucket
brake
parking
wheels
and install
Lower
and stop the engine.
to the ground the
on level ground
bar on the frame.
the safety
CYLINDER
CYLINDER
OF LIFT
REMOVAL
a
LIFT
ASSEMBLY
AND
DISASSEMBLY
under the lift arm.
1. Rod pin I) Sling lift cylinder
lock
(I ), remove
then
bolt,
pin (2).
remove
* If shims
are
numbers
inserted,
check control
of
shims. 2) Start
engine,
and operate
tract
cylinder
rod on side where
levers
to re-
pin has been
removed.
piping
2. Hydraulic
tube
1) Disconnect
and
(3)
hose
(4) at rod end
from connector. tube (5) and hose (6) at bottom
2) Disconnect
end
from connector.
3. Lift cylinder then
remove
pin
(7)
at
end.
bottom *
bolt,
lock
I) Remove
are
There number
installed,
shims
thickness
and
of
so the
check
the
shims,
and
gravity,
and
keep in a safe place. 2) Remove +
Be
remove *
(I 1.
lift cylinder careful
of
the
center
Be careful not to damage Lift cylinder:
WA350-1
of
slowly.
149
the cylinder rod. kg
63-25 @
DISASSEMBLY
AND
LIFT CYLINDER
ASSEMBLY
INSTALLATION
OF LIFT
CYLINDER
1. Lift cylinder 1) Raise
lift
cylinder
(1)
and
set
in
mounting
position.
2) Align pin hole at bottom end, assemble that clearance
“a” between
on left and right is within
cylinder specified
shim so
and frame range, then
install pin (7) and lock with bolt. A
Use a bar to align the pin holes. Never
use your
fingers. Clearance
Max. 3 mm
“a”:
a
a
423F461
2. Hydraulic piping 1) Connect
tube (5) and hose (6) at bottom
2) Connect
tube (3) and hose (4) at rod end.
t
Fit the O-rings
securely
*
Install
hoses
the
end.
in the grooves. without
twisting
or
levers to extend
rod,
align pin holes, insert shims so that clearances
“b”
interference.
3. Rod pin Start engine,
operate
control
are even. Then install pin (2), lock with bolt. *
Remove
the
support.
Clearance
“b”
must
be
less than 2.0 mm
63-26 @I
WA350-1
DISASSEMBLY
AND
DISASSEMBLY
ASSEMBLY
HYDRAULIC
OF HYDRAULIC
CYLINDER
CYLINDER
ASSEMBLY
Special tool Part number A
790-502-l
Part name
001
1. Set cylinder assembly 2. Remove
mounting
Cylinder
wty
repair stand
1
(1) tool A.
bolts (2) of cylinder head.
3. Pull cylinder
head and piston rod assembly (3) mm out of cylinder (4) and lift off. Oil will come out when the piston rod assembly is removed from the cylinder, SO place a
about 900 t
container
4. Remove piston
in position to catch the oil.
piston assembly
bolt
(51, then
remove
(7) and cylinder
head
spacer
(6),
assembly
(8).
WA350-1
63-27 0
AND
DISASSEMBLY
piston assembly
6. Disassemble Remove
wear
HYDRAULIC
ASSEMBLY
as follows. ring (13)
and piston
ring (12)
CYLINDER
from
piston (I 4).
.
7. Disassemble
cylinder
head assembly
(I 5) and back-up
1) Remove
O-ring
2) Remove
snap ring, then remove
as follows. ring (16).
dust seal (I 7).
207P495A’
207P494A
3) Remove
rod packing
4) Remove
bushing
(I 8)
(I 9).
207P496A
63-28 0
I8
79
207P497A
WA350-1
DISASSEMBLY
AND
ASSEMBLY
HYDRAULIC
ASSEMBLY
OF HYDRAULIC
CYLINDER
CYLINDER
ASSEMBLY
Special tools
1 796-720-1690
*
1 Ring
II
Clean all parts, and check for dirt or damage. Coat the sliding surfaces of all parts with engine oil before installing. Be careful not to damage packing, dust seals or O-rings when installing.
1. Assemble cylinder head assembly as follows.
press fit bushing (19) on I) Using push tool 0, cylinder head (20). + Be careful not to deform the bushing when press fitting. 2) Assemble rod packing (I 8). * Be careful to install the rod packing facing in the right direction.
207P498A
19
207P497A
208F240A
3) install back-up ring (I 6) and O-ring (I 5). * Do not try to force the back-up ring into position. Warm it in warm water (50 to 60°C) before fitting it.
4) Using push tool @, install dust seal (17) on head, then secure with snap ring.
207P495A”
WA350-1
63-29 0
DISASSEMBLY
2. Assemble
AND
ASSEMBLY
piston assembly
1) Using tool B, expand *
CYLINDER
as follows.
piston ring (131.
Set the piston ring on the tool C and turn the handle 8 to 1 1 times to expand the ring.
2) Remove
piston
assemble
tool
B and
ring and compress
piston
ring
(13)
from
on piston (14).
3) Fit tool C on piston ring with clamp
+
HYDRAULIC
0,
Parts No. of clamp
0,
07 28 1-O 19 19 (Lift cylinder) 07281-02169 4) Assemble
3. Assemble
(Bucket cylinder)
wear ring (12) on piston.
O-ring
(IO)
and
back-up
ring (I I)
on
piston rod (9).
423F484
4. Assemble assembly *
Apply
cylinder
head
assembly
(8) and piston
(7) on piston rod. the grease to rod to prevent
back-up
ring
(I 1) from stick out.
5. Assemble Zr Width
B
63-30 0
spacer (6) then tighten across flats of socket: Piston bolt:
10 -
piston bolt (5).
19 mm
12.5 kgm
WA350-1
DISASSEMBLY
6. Set cylinder sembly
and
AND
HYDRAULIC
ASSEMBLY
(4) in tool A, then raise cylinder piston
assembly
(3)
and
install
CYLINDER
asin
cylinder.
7. Tighten
mounting
6. Remove
cylinder assembly
WA350- 1
bolt (2) of cylinder head.
(I
1from tool A.
63-31 0
DISASSEMBLY
AND
RE MOVAL B
Stop
the
OF WORK machine
the safety
wheels
1. Bucket
and install
Lower
the bucket
and stop the engine.
parking
brake
to prevent
and
put
the machine
EQUIPMENT
EQUIPMENT
on level ground
bar on the frame.
to the ground the
WORK
ASSEMBLY
Then
blocks
apply
under
the
from moving.
link
I) Remove mounting pin (I) of bucket link. +
Tie the bucket link to the tilt lever with wire.
2) Remove
left
and
right
mounting
pins
(2)
of
bucket hinge. Do not put your fingers in the pin hole.
A
3) Drive machine
in reverse to disconnect
Bucket
2. Dump cylinder Sling
dump
disconnect +
(with teeth):
1,900
bucket.
kg
pin cylinder
(31,
remove
pin
(41, then
cylinder rod and tilt lever.
Insert a block between
the cylinder
bottom
and
frame. Dump cylinder:
3. Lift cylinder
185
kg
pin
Sling lift cylinder
(51, remove
pin (61, then remove
lift cylinder. +
If shims are inserted,
t
Place a support
check numbers
of shims.
*
Place a block on top of the axle, and lower the
under the tip of the lift arm.
cylinder onto it. Lift cylinder:
63-32 @
149
kg
WA350-1
DISASSEMBLY
AND
WORK
ASSEMBLY
EQUIPMENT
4. Lift arm, tilt lever, bucket link assembly Sling lift arm, tilt lever and bucket link assembly (71, remove
mounting
pin (8) of lift arm, then lift
off lift arm. ks C!Yl
Lift arm, tilt lever, bucket link assembly:
1,290 *
If there
are any shims,
thickness
check
the number
kg and
of the shims, and keep in a safe place.
5. Tilt lever, bucket link assembly 1) Remove
pin (I 0) from tilt lever (I I) and bucket
link assembly and bucket
(9). and disconnect
link assembly
2) Sling tilt lever (I I),
tilt lever (I I)
(I 2).
remove
mounting
pin (131,
then lift off from lift arm (I 4). &?Ikg
Tilt lever:
248
Bucket link:
kg
52 kg
6. Dust seal, bushing 1) Remove
dust seal (I 5) and bushing
(I 61 from
lift arm (I 4).
423F475
WA350-1
63-33
DISASSEMBLY
AND
WORK
ASSEMBLY
2) Remove dust seal (I 7) and bushing tilt lever (1 1).
EQUIPMENT
(18) from
423F476
3) Remove dust seal (I 9) and bushing (20) from bucket link (12).
423F477
63-34 0
WA350-1
DISASSEMBLY
AND
INSTALLATION
Q1
WORK
ASSEMBLY
OF WORK
EQUIPMENT
Use a bar to align the pin holes. Never use your
fingers.
1. Dust seal, bushing Using a press, press fit bushing (16) in bucket link, tilt lever, and lift arm, then assemble &
dust seal (I 5).
Grease (G2-LI)
Bushing:
423F478
2. Tilt lever, bucket link I) Align holes of tilt lever (I I) and lift arm (141, assemble
shim
so that
clearance
“a”
and right is equal, then install mounting
on left pin (13)
and lock with bolt. *
Clearance
“a”:
Max. 1.5 mm
F42301009
2) Assemble
cord
ring on bucket
holes of tilt lever (1 I),
link (121,
align
then install pin (I 0) and
lock with bolt. t
Tie the bucket
*
Make sure that the cord ring is not caught.
WA350-1
link to the tilt lever with wire.
EQUIPMENT
WORK
ASSEMBLY
AND
DISASSEMBLY
EQUIPMENT
3. Lift arm, tilt lever, bucket link assembly
holes
of
mount
at
and
frame
front
clearance
so that
shim
assemble
link Align
position.
and set in mounting
assembly,
bucket
and
lever,
tilt
arm,
lift
1) Raise
lift arm, on left
“b”
pin and
and right is equal, then install mounting lock with bolt. +
installing
When
Clearance
*
After
kick-out
and set
switch,
position.
in mounting +
not to
the lift arm, be careful
boom
the
damage
“b”:
installing
1.5 mm
Max.
under
the pin, set a support
the tip of the boom.
b
423F479
4. Lift cylinder (5). start engine and align cylinder
Sling lift cylinder rod with so that
boom
mounting “e”
clearances
hole. Then are even.
install shims
Install
pin (61,
then lock with bolt. Before
A
starting
the engine,
check
that the gear
shift levers are locked.
5. Dump cylinder Sling dump
cylinder
(3) and operate
control
lever
to align pin holes. Install pin (4), then lock with bolt. *
After
63-36 &I
installing the pin, remove the block.
WA350-1
DISASSEMBLY
AND
ASSEMBLY
WORK
6. Bucket 1) Operate control lever to align hole of bucket mounting pin (2). Assemble shim so that clearance “c” on left and right is equal, then install mounting pin (2) and lock with bolt. + Clearance “c”: Max. 1.5 mm
i:
423F480
2) Install cord ring (20).
7. Bucket link 1) Raise bucket link (I 21, align hole of mounting pin (IO). Assemble shim so that clearance “d” on left and right is equal, then install mounting pin (IO). and lock with bolt. Sr Clearance I’d”: Max. 1.5 mm
d
2) Install cord ring. 8. Greasing Grease all pins.
WA350-1
423F481
EQUIPMENT
DISASSEMBLY
AND
REMOVAL
a
Stop
the
machine
on level ground
bar on the frame.
to the ground parking
wheels
COUNTERWEIGHT
OF COUNTERWEIGHT
the safety the
ASSEMBLY
and stop the engine. brake
to prevent
and
and install
Lower
put
the bucket Then
blocks
the machine
apply
under
the
from moving.
1. Grille Remove
grille (I 1.
2. Counterweight Sling
counterweight
(Z), remove
mounting
bolts,
then lift off counterweight. +
Be careful
to maintain
the balance when remov-
ing the counterweight. *
Be careful
not to damage
Counterweight:
the back-up
785
INSTALLATION TERWEIGHT
lamp.
kg
OF COUN-
1. Counterweight Raise counterweight then tighten *
Be careful
w
(2). set in mounting
mounting
not to damage
Mounting
bolt:
position,
bolts. the back lamps.
94.5*
10.5
kgm
2. Grille Install grille (1).
63-38 0
WA350-1
WORK EQUIPMENT SYSTEM 64 MAINTENANCE
STANDARD
Main control valve (for 2-Spool)
............
64-
2
64-
3-l
Dumpcylinder
64-
4
Lift cylinder
64-
5
64-
6
64-
8
Main control valve (for 3-Spool)lif
equipped)
............................ .............................. Bucket linkage ............................ Bucket positioner
and boom kick-out
.......
Bucket ................................... Hydraulic
WA350-1
and steering
pump
...............
64-
9
64-l
0
64-l @
MAINTENANCE
MAIN
MAIN
STANDARD
CONTROL
CONTROL
VALVE
VALVE
For 2-Spool
6 16 1 5 11 10
2
18
17
3
Section A-A
423F229
64-2 a
WA350- 1
MAINTENANCE
MAIN
STANDARD
.
CONTROL
VALVE
Unit:
mm
Standard size
Spool return spring (for DUMP, LIFT)
Check valve spring
rque of plug at end of spool
g torque of adjustment
lever
7.0*
1 .O kgm
15
Tightening
torque of plug
16
Tightening
torque of case mounting
17
Tightening
torque of plug
47.522.5
18
Tightening
torque of plug
37 5* 2.5 kgm
WA350-1
bolt
3.2kO.3
kgm
kgm
64-3
MAINTENANCE STANDARD
MAIN
CONTROL
For 3-Spool
MAIN CONTROL VALVE
VALVE
(If equipped)
9 \
F424CO126
64-3-l 670
WA350-1
MAINTENANCE
CONTROL
MAIN
STANDARD
.. No
Unit:
Repair limit
Standard size Spool return spring (for DUMP, LIFT. ATTACHMENT)
Free length
installation length
installation load
Free length
76.3
49
9 kg
-
Installation load
2
Main valve spring of main relief valve
39.5
25
3 kg
-
-
3
Check valve spring
32.6
24.5
4.5 kg
-
-
4
Suction valve spring
27.9
18
0.7 kg
-
5
Poppet spring of relief valve
49.3
41.9
26.4 kg
47.8
6
Tightening torque of plug at end of spool (DUMP, LIFT, ATTACHMENT)
-
7
I
Tightening torque of joint at end of spool
6.8 f
I
6.8 2 0.7 kgm
8
9
Tightening torque of cover mounting bolt
3.2 2 0.3 kgm
10
Tightening torque of main relief valve
15.5 ? 2.5 kgm
11
Tightening torque of adjustment screw lock nut
,2
Tightening torque of safety valve with suction valve
14.02
13
Tightening torque of suction valve
14.0 2 1.0 kgm
14
Tightening torque of plug
15.5 ? 2.5 kgm
15
Tightening torque of plug
7.0 ? 1 .O kgm
16
Tightening torque of case mounting bolt
3.2 2 0.3 kgm
17
Tightening torque of plug
18
Tightening torque of plug
WA350-1
I
I
Replace possibly to use again if no damage or deformation
I 21.2 kg
Replace
0.7 kgm
Tightening torque of adjustment lever lock bolt
I
mm
Remedy
Criteria
Check item
1
VALVE
I
3.2 -C 0.3 kgm
3.2 ? 0.3 kgm
1
Retighten
l.Okgm
47.5 t
2.5 kgm
37.5 f
2.5 kgm
I
64-3-2 @
MAINTENANCE
DUMP
STANDARD
DUMP
CYLINDER
CYLINDER
@~ v~ i 10 0
r____~
0
lo
,,,
4
0
.tJ
L----J
0
~
,,,,,,, ys
,,
,,
I
c_________-____,
423F230
Unit: No.
Check item
Criteria
Remedy
Clearance limit
fi 1
Clearance between rod and bushing 0.777
2
Clearance between piston rod mounting and bushing
3
Clearance between cylinder bottom pin and bushing
4
Cylinder bore
pin
mounting
110
-0.036 -0.090
+0.207 +6.120
0.156 0.297
1 .o
110
-0.036 -0.090
+0.207 +0.120
0.156 0.297
1 .o
180
-
+0.4 0
-
-
Replace bushing
Replace
I
5
Tightening torque of cylinder head mounting bolt
6
Tightening
64-4
torque of piston mounting
2002
bolt
11.5fl.O
50 kgm
kgm
WA350-1
mm
MAINTENANCE
LIFT
STANDARD
CYLINDER
LIFT CYLINDER
423F231
Unit: Check item
No.
1
Criteria
Clearance between rod and bushing
1
2
Clearance between piston rod mounting and inside diameter of hole
3
Clearance between cylinder bottom pin and bushing
4
Cylinder bore
5
Tightening torque of cylinder head mounting bolt
6
Tightening
pin
mounting
Remedy
,
1
90
-0.120 -0.207
-10.270 +0.061
0.181 0.477
0.777
95
-0.036 -0.090
+0.35 +0.20
0.156 0.297
1 .o
Replace
95
-0.036 -0.090
+0.207 +0.120
0.156 0.297
1 .o
Replace bushing
-
Replace
150
-
mm
-
+0.35 0 12Oi30
kgm Retighten
WA350-1
torque of piston mounting
bolt
11.5%1.0kgm
64-5
MAINTENANCE
BUCKET
STANDARD
BUCKET
LINKAGE
LINKAGE J-l
Serial No. 11118
and up
%&I
i-i
U42301011 1,
-SerialNo. 10001
-
11117
1
I
\
a
b
a
Section A-A
Section B-B
5
b
Section C-C
4
a
il
Section
a
a
b
a
b
Section E-E
D-D
b Section G-G
a
Section F-F
b
Section H-H
a
b Section J-J 423F233
64-6 0
WA350-1
MAINTENANCE
BUCKET
STANDARD
LINKAGE
Unit: No.
Remedy
Criteria
Check Item
mm
Clearance between pin and bushing at boss ends of bucket link
6
9
Joint of bucket cylinder and frame
on both sides
11
12
12 14
Joint of tilt lever and bucket link
15
Joint of tilt lever and lift arm
IE
Joint of tilt lever and bucket cylinder
11o+o.* 0
113+;
li
Joint of lift cylinder and lift arm
103 *
106 f
1 14i
1.2
200 t
0.5
0.6 - 4.2
116:;
-
WA350-1
1.5
203 2 0.5
2-4
Replace
2.2 - 4
1.5
O-6
64-7 0
MAINTENANCE
BUCKET
STANDARD
BUCKET
POSITIONER
AND
BOOM
POSITIONER
AND
BOOM
KICK-OUT
KICK-OUT
423F235 Section
A-A Unit:
No.
Check item
Criteria
1
Clearance of bucket positioner
switch
2
Clearance of boom kick-out
3
Tightening
torque of mounting
bolt for adjuster
4
Tightening for switch
torque of mounting
bolt
Remedy
3-6 Adjust
64-8 0
switch
3-6
9.0 ?z 3.5 kgm Retighten 1.8 f
0.2 kgm
WA350-1
mm
BUCKET
STANDARD
MAINTENANCE
BUCKET Serial No. 10001
-
11117
Section B-B Section C-C
Section A-A Serial No. 11118
423F234
and up
B
65 -
87 kgm
U42301007 Section K-K Unit: No.
I 1
Standard size
I
Repair limit
I Replace
Wear of bucket tooth 18.5
50 2
Remedy
Criteria
Check item
Clearance of bucket tooth mounting
WA350-1
mm
I
Less than 0.5
I
Replace or adjust
64-9 0
MAINTENANCE
HYDRAULIC SAR(S)-80 (SAR(3)-80
HYDRAULIC
STANDARD
AND
STEERING
AND
STEERING
PUMP
PUMP
+ 50 + 40)
i
2
5 Section
I I
Hydraulic pump SAR(3)-80
423F228
A-A
Steering pump
I I
SAR(3)-50
1 I
(SAR(3)-40) k. Unit: No.
1
Clearance between gear case and side plate, gear
2
3 4 5
Discharge Oil: EO-CD
64-10 0
(
1: Serial No. 1 11 18 and up
WA350-1
mm
81
ELECTRIC AND ELECTRONIC SYSTEM STRUCTURE
AND
FUNCTION
Electric
and electronic wiring
diagram
Electrical
wiring
diagram
Engine
starting
Engine
stop circuit
Preheating l
circuit
..................... ......................
circuit
Preheating with
..................
switch
l
Preheating
with
l
Automatic
preheating
Combination
starting
switch
transmission
.................... control ...........
l
Transmission
cut-off
switch
l
Transmission
cut-off
selector
l
Neutralizer
transmission
control
5
81-
6
81-
7
81-
8
81-
8
81-
9
81-12
. .
diagram
.......... switch
vehicle
..........
brake control monitoring
81-14
81-17
system
l l
Sensor
l
Wiring
l
Operation
81-26
Monitor
_.___.__________,___.____.___ harness of proximity
81-13
. 81-15 . 81-16
.
relay
parking
.............................. panel ....................... Indication on monitor panel ........... Controller ..........................
l
3
81-
81-11
(EVMS) .
2
81-10
Electrical
Electronic
.......
switch
l
Electrical
.
8181-
and after-heating
heater
Electrical
........... ................ circuit. .........
system
Electrical
81-26
. .
81-28 81-30 81-31 81-37
switch
........
81-38 81-38
WA350-1
81-l
STRUCTURE
AND
ELECTRIC
ELECTRIC
FUNCTION
AND
ELECTRONIC
AND
ELECTRONIC
SYSTEM
SYSTEM
Outline The WA350-1 ic systems
is equipped as
shown
with electric and electron-
in Fig.
423F167
and
Fig.
423F168. These
systems
can be broadly
divided
into the fol-
lowing two groups. 1. The
“Electric
system”
which
is found
on most
vehicles. 2. The which
“Electronic detects
vehicle
and shown
monitoring
system”,
any abnormalities
in the
machine.
81-2
WA350-1
ELECTRICAL
WIRING
relay
1. Air compressor
DIAGRAM
2. Radio switch
3. Rear wiper
Serial No. 11118 and up
switch
4. Front wiper
I
lamp
5. Warning
select switch
cut-off
6. Transmission
brake switch
7. Parking
lamp switch
8. Working
9. Glow switch switch
10. Starting ll.Fusebox
lighter
12. Cigarette
buzzer
13. Caution 14. Controller 15. Work
solenoid
equipment
valve
16. Head lamp lamp
17. Front combination 18. Front wiper
washer
19. Front window
20. Brake oil level sensor washer
2 I. Rear window 22. Rear wiper 23. Torque
oil temperature
converter
sensor
24. Main breaker 25. Engine oil level sensor 26. Battery
relay
27. Alternator 28. Coolant
level sensor
29. Coolant
temperature
sensor
30. Air compressor
View Z
lamp
31. Rear working 32. Air governor 33. Battery
sensor
34. Engine oil pressure 35. Fuel level sensor 36. Heater relay 37. Fuel cut solenoid 38. Air pressure 39. Rotational
valve
sensor speed sensor
40. Brake chamber
stroke
sensor
stroke
sensor
41. Brake chamber 42. Brake chamber
Serial No. 11118 and UD
423F167
lJ42401014 WA350- 1
81-3 0
81-4
STRUCTURE
AND
ENGINE
FUNCTION
STOP
Operation . When the starting Battery
starting
(+I
switch
+
switch
is turned
ON,
electric
circuit.
starting
switch
terminal
B +
BR + fuel cut solenoid 4
terminal
electric
solenoid,
current
flows
to
engine starts. .
the
the starting
but the engine
still voltage
at terminal
reason, the following
BR-
is put in the FREE posi-
The
to
the
fuel
CIRCUIT
fuel
injection
pump
and
the
is turned
OFF, circuit (I)
is rotating,
so there
R of the alternator.
is
For this
circuit is formed.
terminal
R +
battery
relay terminal
ground connection. battery
relay
the diode inserted
linkage.
switch
is shut off,
cut
flows
the fuel governor
tion by the fuel control Fuel
When
(2) Alternator
ground connection. When
STOP
CIRCUIT
current flows in following (I)
ENGINE
rent flows
is maintained, into the circuit,
to the fuel cut solenoid,
but because no electric
of cur-
so the engine
stops.
Fuel cut solenoid
Alternator
Starting switch
Battery
42lFI
WA350- 1
IS
81-7 6%)
STRUCTURE
AND
FUNCTION
PREHEATING
PREHEATING
CIRCUIT
PREHEATING
HEATER
WITH
CIRCUIT
SWITCH
Operation l
When
the starting
switch is at ON, and the preheat is set to ON, the following circuit is formed. (1) Starting switch BR - heater switch - heater
switch
relay signal terminal
+
heater relay coil -
ground
connection.
The starting
switch
also closed,
so electric
ing circuit. (2) Battery electrical
The heater relay is closed.
is ON, and the battery relay is current flows in the follow-
(+I
-
air intake
battery heater
and the engine is preheated If the heater switch
relay -
heater
ground
relay -
connection,
(or after-heated).
is released,
it automatically
turns to AUTO.
Preheat swttch AUTO
Electrical air intake heater Heater relay Startq
switch
To electronic
vehicle
(for pilot display)
Battery
42lFl20
81-8 &I
WA350- 1
re-
AND
STRUCTURE
PREHEATING
PREHEATING
FUNCTION
WITH
STARTING
SWITCH
Operation . If the starting switch is turned one stage to the left from
the OFF position
electric
current
to the HEAT
from terminal
BR and R,. The electric flows in the following (1) Starting terminal connection, The electric following
switch
BR
the
to terminals
from terminal
BR
from
(2)
Starting
signal
BR + relay
battery
coil
-+
relay
ground
connection, Because
R, flows
R, -t
terminal heater
relay
heater
coil
+
relay ground
and the heater relay is CLOSED.
of circuits
(3) Battery electrical
-
(1) and (2). the electric
flows through (+)
4
air intake
battery heater
the following relay -t -t
heater
ground
current
circuit. relay -
connection,
and the engine is preheated.
relay is closed. terminal
switch
terminal
from battery
terminal
and the battery current
position,
circuit.
battery
-
B flows
current
CIRCUIT
in the
circuit.
Preheat switch
423F186
Starting switch connection
WA350-1
table
81-9
STRUCTURE
AND
AUTOMATIC .
FUNCTION
PREHEATING
PREHEATING
In cold areas, when the starting ON, the bimetal contacts
switch
is turned to
timer is at low temperature,
so the
current
flows
in the following
(1) Battery
(+)
-t
switch
nal “2” -
switch
BR -t
terminal
bimetal
B -t
timer termi-
this happens,
timer
Bimetal “3”
terminal .
timer +
circuit
the resistor
so the resistor
heats
bimetal
terminal
timer
up and the bimetal
“3” -
connec-
As a result, after ambient
terminal glow
ground
“1”
switch
relay signal terminal
and
curtimer,
between
terminal
“1 ” is
-
+
glow
terminal heater
switch “2”
+
relay coil +
current
continues
rent flows in the following
and “3” of the bimetal
in circuit
circuit.
after
the
Preheat switch
(opens)
to the heater relay coil
preheating
to flow
stops,
between
electric
terminals
timer, so the bimetal
heated.
Therefore
straight
until the starting
the bimetal
after the engine is started,
While preheating
on the
bends
stops, so the heater relay is opened and preheating Even
current
bimetal
and circuit (3) is shut off. The flow of electric
current
The electric
(the time depends
the
stops.
connection.
“2”
a time
temperature)
(3) closes the heater relay. As a result, electric cur-
ground
(2) sends electric
inside the bimetal
heated.
(2) and (3).
(2) Bimetal
heater
starting
terminal
tion (3)
When
rent through
circuit.
terminal
(4) Battery (+I 4 battery relay + heater relay 4 electrical air intake heater + ground connection, and the engine is preheated.
are closed.
As a result, electric
starting
CIRCUIT
switch
does
“2”
is kept
not become
is turned
OFF, so
there is no preheating.
Bimetal timer
To electronic vehicle monitoring system
Bimetal timer
After preheating
Electrical air intake heater
To electronic vehicle monitoring system (for pilot display)
423F187
81-10 @
WA350-1
STRUCTURE
AND
FUNCTION
COMBINATION
COMBINATION
SWITCH
SWITCH
423F188
Outline . The
FORWARD-REVERSE
contacts;
the speed
contacts.
The
mechanism. bination
lever
control
switch
The detent
switch
itself.
palaces by pins.
alone
to the base by three
has
mechanism Each switch
In addition,
has
lever switch
When
three
no
and
detent
is held
lever
is moved
which
electric
move
is in the com-
each switch
the
the switch,
has four
to the desired
position,
is connected
by a shaft,
flows
that
current
in only
moves
circuit
to
the machine.
at two
is secured
screws.
Function FORWARD,
Selecting
machine
FORWARD-REVERSE
2
Speed
control
lever switch
3
Speed
control
lever stopper
4
Direction
5
Self cancel
6
Lamp switch
Selects
clearance
7
Dimmer
Selects
travel
8
Emergency
flasher
switch
Makes
mergency
flasher
pilot lamp
Flashes
WA350-1
indicator
lever switch
Selecting
1
lamp
Prevents during
speed
control
or NEUTRAL
range
lever from
going
into 3rd or 4th speed
operations
Indicates Returns after
switch
speed
REVERSE
direction direction
turning
when
turning
indicator
lamp lever to neutral
automatically
left or right lamps,
beam,
headlamps,
parking
lamps
low beam
left and right winkers when
left or right
emergency
flash
flasher
at the same time lamp is ON
81-l 1
STRUCTURE
CONTROL
TRANSMISSION
ELECTRICAL
CONTROL
TRANSMISSION
ELECTRICAL
FUNCTION
AND
Transmission cut-off selector switch
Combination FOR
switch
\RD-REVERSE lever
Transmission
hut-off
switch
reaker
wiring harness
Tranimission
Function 423F189
of FORWARD,
Selection
REVERSE
FORWARD-REVERSE
range
Speed
lever
and NEUTRAL of travel
Selection
speed
cut-off
Transmission
control
left brake pedal is
when
to neutral
returned
Transmission
function
lever
operated cut-off
Transmission
selection
function
Neutralizer
function
the left brake pedal can be used to get even
this function,
better
is used or not used.
function
cut-off
if transmission
Selects With
loading
or ease of steering
when
To prevent
the operator
from
driving
is still applied
and causing
transmission
is returned
seizure to neutral
in digging
loaders
than conventional
performance
operations
on to trailers. the parking
off when
when
brake
the parking
brake
the
brake,
of the parking
is
applied. 6
Neutral
safetv
function
The engine
can only be started
lever is in neutral. will not start. suddenly. Warning
fuction
When
In any other
This prevents
(For detalis,
the machine
and a back-up
horn
if the FORWARD-REVERSE
the machine
see STARTING
is driven sounds
the engine
position
in reverse, to warn
from
startig
CIRCUIT.) a back-up people
lamp lights
standing
machine.
81-12
up
near the
WA350-1
STRUCTURE
ELECTRICAL
AND
FUNCTION
TRANSMISSION
ELECTRICAL
CONTROL
TRANSMISSION
CONTROL
DIAGRAM
Neutralizer relay Parking brake (installed switch (manual) Parking brake in operator’s relay _ comoartment) -OFF ---ON -,, 1
Parking safety relay (installed in operator’s compartment)
Alternator terminal R
Parking brake valve To machine monitor
Emergency brake switch (installed to wet tank)
Transmission cut-off selector switch (manual) Transmission cut-off switch
Starting motor (terminal E)
controt switch Madhine monitor system neutral terminal
Back-up lamp relay
U42401016
WA350-1
81-13 0
STRUCTURE
AND
TRANSMISSION l
FUNCTION
CUT-OFF
ELECTRICAL
TRANSMISSION
CONTROL
SWITCH
When the left pedal is operated, the switch detects the air pressure in a brake circuit. It shuts off the power supply of the solenoid valve circuit for the FORWARD-REVERSE clutch, and returns the transmission to neutral.
-
From rear air tank
brake valve (right)
Two-way check valve Stop-lamp switch
I /
c
From rear brake tank
-
To rear brake
-
From front brake tank
-c
To front brake
-
From front air tank
Two-way check MIYI
w I
Diaphragm To transmission
directional circuit
ON
--T--l---IOFF Restored Low voltage c-t
Actuated High voltage 421F123
81-14 Q
WA350-1
STRUCTURE
AND
TRANSMISSION
ELECTRICAL
FUNCTION
CUT-OFF
SELECTOR
The
CONTROL
SWITCH
Outline l
TRANSMISSION
Operation transmission
circuit
waterproof
series with
cut-off
selector
toggle
switch.
the transmission
switch
It is installed
cut-off
switch
power supply side of the transmission REVERSE
*
is a 2in
at the
If the transmission cuit of the
FORWARD-REVERSE
when
circuit.
selector
there is always
valve
FORWARD-
cut-off
to CLOSED,
passing
through
will flow
switch
is moved
to the solenoid
24V
switch.
is put
in the cir-
clutch
this
the left brake is operated
sion cut-off
switch
the (+)
solenoid
Therefore,
and the transmis-
to OPEN,
no electric
valve, and the transmis-
sion will be placed in neutral.
~-~.-~---c_-i:
B
Neutralizer relay (battery power source)
‘“-
“7
I
L
$
Neutralizer relay (battery power source)
Transmission cut-off selector switch (manual)
Transmission cut-off selector switch (manual)
Transmission cut-off (actuated by air pressure)
Starting motor (terminal E)
Starting motor (terminal E)
To Buck-up lamp relay
Machine monitor system neutral terminal
To Buck-up lamp relay
Machine monitor system neutral terminal
421 F124
WA350-1
STRUCTURE
AND
NEUTRALIZER l
When current
TRANSMISSION
CONTROL
RELAY
the parking flows
is connected
ELECTRICAL
FUNCTION
For this reason,
brake is being used, no electric
to output terminal
no electric
FORWARD-REVERSE
to the relay coil. The input terminal
which
“6”.
is connected
the parking
brake
current
circuit to output is being
is kept in neutral. Therefore,
flows
to the
of the transmission terminal
“5”.
When
used, the transmission the machine
does not
start.
Parking brake switch (manual)
Parking brake Parking brake relay safety relay
Neutralizer relay
OFF
Battery relay
Starting switch
Parking brake valve I ransmlsslon cut-off selector switch (manual) OFFTN
:
3”.IL,,ll (with wet tank)
:
!z? Transmission cut-off switch (actuated by air pressure)
Starting motor (terminal E)
Machine monitor system natural terminal
power source Back-up horn
Back-up lamp
421F125
WA350-1
STRUCTURE
AND
ELECTRICAL
FUNCTION
ELECTRICAL
PARKING
BRAKE
PARKING
BRAKE
CONTROL
CONTROL
Outline l
When
electric
valve
(solenoid
tank
(wet
tank)
and the parking
current
flows
valve),
to the parking
air pressure
is applied
from
to the spring
.
brake the
When
the electric
sure from
air
current
inside the spring cylinder
cylinder
is stopped,
the air tank is cut off.
passes through
ing brake valve and is released.
brake is released.
is then actuated
the air pres-
The air pressure the park-
The parking
brake
by the force of the spring.
423F194
1. Parking brake switch
5. Parking brake valve
2. Parking safety
6. Air tank (wet)
relay
3. Parking brake relay 4. Neutralizer
WA350-1
relay
7. Emergency
brake switch
8. Spring cylinder
81-17 0
STRUCTURE
AND
ELECTRICAL
FUNCTION
PARKING
BRAKE
CONTROL
Function
Actuation Automatic
and release of parking brake parking
Parking brake switch
used
Parking brake is automatically
brake
(starting
switch
applied when engine is stopped
is turned to OFF). This prevents
from running away when the operator Emergency
The parking‘brake
brake
to maintain
is automatically
applied when it is impossible
braking power because
inside the tank caused by damage
of a drop in the air pressure to the air circuit.
the parking brake acts as an emergency After
Parking brake safety
the automatic
switch
In this way,
brake.
parking brake is actuated,
the parking brake can be released
the machine
leaves his seat.
it is dangerous
if
simply by turning the starting
to ON.
Therefore,
after the starting
parking brake switch
switch
has been turned ON, the
must be operated
to release the brake.
This ensures safety. If the machine
Neutralizer
is driven with the parking brake still applied, the
parking brake will seize up. Therefore,
the caution lamp lights up and the caution
sounds to warn the operator same time, when the parking
of this mistake brake is applied,
is moved to neutral, so it is impossible However,
At the
the transmission
for the machine
to move.
when the parking brake is used as an emergency
brake, if the transmission distance
buzzer
in operation.
is returned
to neutral, the braking
will increase and the machine
place (for example, circuit is designed
may stop in a dangerous
on a railroad crossing). so that the transmssion
neutral when the emergency
For this reason, the is not returned
to
brake is applied.
Parking brake switch Connection
table
Large size multi-pin connector
(3 pole blue) with lock
Soft polyvinyl chloride
I View 2
81-18
Water proof O-ring for panel face
OFF (released)
423F195
WA3W1
STRUCTURE
PARKING
AND
FUNCTION
BRAKE
VALVE
Port ho.3
ELECTRICAL
PARKING
P0rt’No.l
BRAKE
CONTROL
423F196
PARKING BRAKE RELAY PARKING SAFETY RELAY NEUTRALIZER RELAY
Relay connection
chart
Terminal No.1 Terminal No.2
Relay actuation
Port No. 5
table
mi
, Black
EMERGENCY
BRAKE
423F197 Terminal No. 6
SWITCH
Diaphragm \
Contact
\
423F198
WA350-1
81-19 0
STRUCTURE
AND
1. STARTING l
When
SWITCH
the starting
starting
switch
the
brake
parking
OFF (released). actuated.
valve switch
flows
For this reason,
is OFF, no electricity
brake
regardless
CONTROL
is ON
to
if the
flows
to
of whether (actuated)
As a result, the parking
(Automatic
BRAKE
is turned OFF, the bat-
so no electricity
brake circuit.
the parking
PARKING
OFF
switch
tery relay is opened, the parking
ELECTRICAL
FUNCTION
or
brake is
parking brake)
Parking brake switch (manual) --
OFF
Parking brake relay ___-
1
Parking brake safety relay -__ -
Neutralizer
relay
ON
Batten/ relay
Starting switch
To transmission speed circuit
Emergency brake switch (with wet tank)
421 F126
81-20 0
WA350-1
STRUCTURE
AND
2. STARTING 2-l.
FUNCTION
SWITCH
ELECTRICAL
Electric current
flows as follows.
(1) Battery
+
(+)
relay coil +
starting
ground
switch
connection,
+
ON
(2) Battery
circuit of the parking safety relay remains closed because of circuit “3” until the starting switch is turned OFF.
battery
l
brake
switch
switch
“1 ” -
battery
“2”
relay -+
“3” + -,
safety
this happens,
is actuated the following (3) Battery
mission,
+
relay
terminal
relay
terminal
“5”
“2” +
and
the
circuit
of
transmission
the
trans-
is kept
in
neutral.
is closed.
safety
relay
Therefore,
circuit is formed. (+)
safety terminal
the circuit between “3” and “5” of the neutralizer relay so no electric current flows to the
FORWARD-REVERSE
relay
relay terminal
the parkig
and circuit
in this condition,
is open,
brake
safety
Also,
terminal
parking
parking
parking
parking
l
“2” -+ ground connection. When
no electric current flows to brake valve, so the parking brake
is actuated.
terminal
terminal
terminal
-+
In this condition, the parking
so the bat-
also flows as follows.
(+)
CONTROL
The
tery relay is CLOSED. Electric current
BRAKE
ON
When parking brake switch is turned before starting switch is turned ON l
PARKING
“1”
+
battery “3” -
parkig
relay + +
parking safety
parking
parking
safety
safety
relay
relay terminal
ground connection.
Parking brake switch (manual) --
OFF
ON
r
Parking brake relay
Parking brake safety relay
Neutralizer relay
I
Starting switch
f
I
t TO transmission speed circuit
I
To transmission FORWARD-REVERSE circuit
Parking brake valve Emergency brake switch (with wet tank)
ii 421F127
WA350- 1
81-21 0
STRUCTURE
2-2.
AND
ELECTRICAL
FUNCTION
valve.
Parking brake switch turned OFF (released) before starting switch is turned ON l
Electric current (1) Battery
(+)
+
starting
ground
relay coil +
switch
switch
connection,
+
switch safety no
in this is OFF
case,
the
(released), flows
is turned
l
so the bat-
In addition,
BRAKE
to
the
parking so
the
transmission,
brake
CONTROL
the automatic even
if the
parkstarting
to ON, the parking
brake is
released.
no electric
current
FORWARD-REVERSE
relay is not actuated.
electricity
after
is actuated,
not automatically
battery
tery relay is CLOSED. However,
Therefore,
ing brake
flows as follows.
PARKING
flows
circuit
so the machine
to the
of
the
does not move.
parking
For this reason, parking
brake
Parking brake switch (manual)
--
OFF
ON
r
Parking brake relay
Parking brake safety relay
Neutralizer
relay
-6
Battery relay
Starting switch
To transmission speed circuit 421F128
*l&22
WA350- 1
STRUCTURE
AND
FUNCTION
ELECTRICAL
PARKING
BRAKE
CONTROL
3.PARKlNG BRAKE SWITCH TURNED OFF (released) AFTER STARTING SWITCH IS TURNED ON l
parking (4) Battery (+I + battery relay brake relay terminal 3 + parking brake relay terminal 5 + parking brake valve + ground connection. The parking brake is released, and at the same the following circuit is formed. (5) Battery (+I + battery relay -. neutralizer relay terminal 3 + neutralizer relay terminal 5 + transmission FORWARD-REVERSE circuit. When the transmission switch is put to FORWARD or REVERSE, the machine will move.
If the parking brake switch is turned OFF (released), circuits 1 and 2 of the parking brake switch are connected. When this happens, electric current flows as follows. (I) Battery (+) + battery relay -, parking safety relay -L parking brake switch + (2) and (3). (2) Emergency brake switch 4 parking brake relay cdii + ground connection. (3) Neutralizer relay coil - ground connection. The parking brake relay and neutralizer relay are actuated, and the circuit between terminals 3 and 5 of each relay is closed. As a result, the following circuit if formed.
Parking brake switch (manual)
Battery -
----
Parking brake relay -_1 r
Parking brake safety relay
Neutralizer relay
I---
Battery relay
Starting switch
Lf
t
I
L
n,rarnaror
.A
terminal R
BR
w1
To transmission speed circuit
I-
I
To transmission FORWARD-REVERSE circuit
Emergency brake switch (with wet tank)
421F129
WA350-
1
81-23 0
STRUCTURE
AND
FUNCTION
ELECTRICAL
4. PARKING BRAKE SWITCH (operated) After
operating
with
at OFF (released),
the parking
to ON (operated),
shown
below.
No electric valve,
switch
the circuit becomes
flows
to the parking
air pressure
acting
on the spring cylinder
same
time,
cylinder
brake
l
At the same
is
restored,
as
and “5”
brake switch
the
current
so the the
air pressure
passes through
and is released,
BRAKE
CONTROL
ON
if the parking
turned
PARKING
from
the
is shut off. inside
the parking
time,
is OPEN.
neutral. electric
brake valve
so the parking brake is actuated
terminals
current circuit
so the transmission
the
when
neutralizer
current
to
the
of
to the
is placed
the parking relay
“3”
flows
shuts
transmission
in
brake is off
the
solenoid
valve and puts the transmission
in neutral.
result,
of the parking
there
brake caused
by the force of the spring.
relay is also
between
No electric
In this way,
operated,
At the
the spring
neutralizer
FORWARD-REVERSE
transmission,
brake
air tank
the
so the circuit
will be no seizing by the machine
As a
being driven with
the parking brake still applied.
Parking brake switch (manual) --
OFF
Parking brake relay ----
n
ON
Parking brake safety relay ---1
Neutralizer relay ---
-
I
Battery relay .-_I
Battery ----
Starting switch
To transmission speed circuit
Emergency brake switch (with wet tank)
421 F130
81-24 0
WA350- 1
STRUCTURE
5. WHEN
AND
AIR
FUNCTION
PRESSURE
(Emergency
brake
ELECTRICAL
PARKING
BRAKE
CONTROL
DROPS
actuated)
Operation l
If the
air
switch
installed
For this
pressure
reason,
relay is restored, “3”
and
“5”
to the
sure
brake
brake
different
from
emergency
current
relay.
and the circuit
becomes parking
inside- the spring
parking
the
no electric
coil of the parking
flows
drops,
brake
l
OPEN. brake
when
turned
ON (operated).
current
flowing
the
flows
to the
parking
brake
between
brake
In this case, there
to the coil of the neutralizer
electric
makes
case
and
switch
the
to
engine
the
also
flows
the
transmission
emergency
acts
braking
distance
shorter,
if the
emergency
brake
is necessary
to
if the emergency
is
a railroad
crossing),
operating
the transmission
move brake
the machine
brake
as a brake.
the
it
the
transmission,
time,
example,
to
of the
connect
when
is
is electric
current
circuit
is possible Therefore,
same
and the
this
it
actuated,
current
is released
parking
reason,
clutch.
so the air pres-
However,
this
and
terminals
No electric
valve,
cylinder
is actuated.
The
For
FORWARD-REVERSE
to the wet tank is opened.
the
and
is
This at the
is actuated, machine
(for
was actuated
on
can be driven
by
lever.
relay.
Parking brake switch (manual)
-OFF
ON
Parking brake relay
Parking brake safety relay ---1
Neutralizer relay ---
1
Battery
Starting switch
A
!
Parking brake valve
To transmission FORWARD-REVERSE circuit
To transmission speed circuit
Emergency brake switch (with wet tank)
421 F131
WA350-1
8’:5
STRUCTURE
AND
ELECTRONIC
FUNCTION
ELECTRONIC
VEHICLE
MONITORING
VEHICLE
MONITORING
SYSTEM
MONITOR
SYSTEM
(EVMS)
PANEL
Outline The
electronic
system the
vehicle
to inform
machine.
various
parts
condition tion
It consists
of the machine and
panel,
buzzer, warning displays
observe
the
situation
monitoring
module meter),
on the
l
system
consists warning
items
and gauges (9). which
always
module module
following
(11,
CAUTION
(3). gauge
module
(including
service
the case, and various other components.
Each module
(excluding
microcomputer
CHECK
the service
which
(11, and CAUTION
use common
into CHECK
(51, speedometer
the
meter)
processes
has its
the signals
The panel uses a liquid crystal display. l
arises
(21, CAUTION
of module
from the sensor and gives a display.
The
(2) and (3). which
if any abnormality
consists CHECK
speedometer
(5).
the
controller, divided
monitor
in
lamp and power source.
can be broadly
warnings meter
The
components.
and process the informa-
sensors,
(1) and CAUTION
machine; service
which
installed
l
of
own vehicle
display
of sensors
display
of the monitor
items
is a
panel.
The electronic
The
system
of the condition
of the machine,
speedily,
monitor
monitoring
the operator
(2) and (3) modules
microcomputer
judges
which
from the wiring harness to which
in the
module
(71, and
tion of the machine.
Warning buzzer
Controller 24V .Qzq C Buzzer signal
Q e..
a
Battery
+
-
/YYYzTI
-XL
421F116A
81-26 0
it is
it is connected.
display the condi-
Warning lamp
all
parts.
WA350-1
STRUCTURE
AND
ELECTRONIC
FUNCTION
VEHICLE
MONITORING
SYSTEM
View 2
423F170
1. Check
3E. Coolant
1 B. Engine oil level
3F. Torque
1 C. Coolant 2. Caution
level charge
(Emergency
WA350-1
5B. Coolant
warning)
4C. Work
cut-off
lamp
4D. Preheat
temperature converter
oil
temperature
4A. Transmission
3A. Brake line failure level
oil
5C. Torque
4B. Parking brake
3B. Engine oil pressure 3C. Coolant
converter
4. Pilot indicator
Fuel level
3. Caution
5A. Air pressure
temperature
temperature
(Warning)
2A. Battery 28.
5. Gauge
3D. Air pressure
1 A. Brake oil level
monitor
50.
6. 7. 8. 9.
Fuel level
Winkers
pilot lamp
Speedometer Head lamp pilot lamp (High beam) Service
10. Serivce
meter meter indicator
81-27 0
STRUCTURE
AND
INDICATION Cate-
ON
ELECTRONIC
FUNCTION
MONITOR
Symbol
VEHICLE
MONITORING
SYSTEM
PANEL
Indication
item
Indication
range
Description
gory
Brake oil level
Below
low mark
Engine
Below
low mark
Displayed oil level
when
Display
8
Coolant
level
Below
low mark
-+ u
Battery
charge
When
charging
m (3) I.
Emergency
is defective
Fuel level
Below
Displays
low mark
Coolant
stroke
When
stroke
Air pressure
switch
is turned
when
steering
actuated
engine
when
operated
is running
Display
goes out when
Display
flashes flash
abnormal
when
normal abnormal
and
at the same time
is
over
Below
level
flashes
when
lamps Brake chamber
starting
to ON with engine stopped. Display goes out when normal
Below
low mark
specified
Displays
when
engine
is running
Display
goes out when
Display
flashes
buzzer
when
normal abnormal;
and lamp actuated
pressure
Coolant
Tornue
temperature
converter
oil
temperature
Parking
Work
brake
105°C
Above
105°C
When
lamp
Transmission
Above
cut-off
operated
When
operated
When
operated
Displays when starting switch Lights up when operated
is turned
ON;
Displays
is turned
ON;
select
PREHEAT
81-28 0
When
preheating
lights
when
up during
starting
switch
preheating
WA350-1
AND
STRUCTURE
Gate,
item
indication
Symbol
VEHICLE
ELECTRONIC
FUNCTION
Indication
range
SYSTEM
MONITORING
Description
gory 0 Travel
lOOkm/h
speed
display
Digital O-l&MPH
---
0
High beam
When
operated
a-- D
Winkers
CID
Hazard
left)
(right,
0
Service
meter
0
Service
meter
When
operated
When
operated
0 -
Lights
up when
operated
Lights
up when
operated
1 for every
Advances
indicator
Flashes
Air pressure
when
service
is turned
oil pressure
engine
when
Actuated
99999/h
displayed
switch
starting
when
Displays
ON;
is normal
hour of operation
meter
is operating
One lamp lights
up to indicate
level
One lamp lights
up to indicate
level
One lamp lights
up to indicate
level
Red N
Red
$
temperature
Coolant
3reen
White
H Red
Torque
converter
temperature
oil Sreen
9o”c 70°C 5o”c
C
FULL keen
Fuel level
All lamps
light up below
indicated
level
Red
WA350-1
81-29 0
ELECTRONIC
FUNCTION
AND
STRUCTURE
VEHICLE
MONITORING
SYSTEM
CONTROLLER Function l
The auxiliary
controller
The power
power to the panel.
(battery,
source
chine has a large difference converts
iliary controller
source
acts as the power
electric
box and provides
alternator)
for the ma-
in voltage,
so the aux-
this to a stable
voltage
and supplies it to the panel. Even if excessive the alternator
voltage
or regulator,
controller.
is generated
by failure in
it is cut by the auxiliary
_-
423F171
Controller
Lamp Buzzer Battery
Battery relay terminal E 423F172
81-30
WA350-1
STRUCTURE
AND
FUNCTION
from
the sensors
ELECTRONIC
VEHICLE
MONITORING
SYSTEM
SENSORS Function . The signals the monitor
panel.
With
side is always
grounded
contacts
closed,
are
signal as a normal
are directly
contact
type
to the chassis. the
panel
input
sensors, When
recognizes
to one the the
signal.
Sensor actuation table Check
Sensor
item
Brake oil level
I
Contact
Fuel level
Resistor
Engine
Contact
oil pressure temperature
Torque
converter
Travel
speed
WA350-1
When
normal ON
I
Contact
level
Coolant
When
Contact
Engine oil level Coolant
type
ON
abnormal OFF
I
OFF
ON
OFF
ON
OFF
Resistor Resistor
oil temperature
I
Solenoid
I
I
81-31 0
STRUCTURE
BRAKE
AND
FUNCTION
ELECTRONIC
VEHICLE
MONITORING
SYSTEM
OIL LEVEL SENSOR 1. Connector 2. Wire
2
1
3
4
5
3. Plug 4. Float 5. Switch
0 0 0J@JFunction
ON (UP)
_-
OFF (DOWN)
e Circuit structure
423F173
Function l
The brake brake
oil level sensor
oil tank.
specified switch
level, is turned
then lights
ENGINE
When
is installed
the brake
the
float
OFF.
The
up to indicate
on top of the
oil goes
goes
down
machine
below
the
and
monitor
the lamp
the abnormality.
OIL LEVEL SENSOR 1. Connector 2. Wire 3. Plug 4. Float 5. Switch
e ON -
UP)
Circuit structure
OFF (DOWN) 423F174
Function . The engine the
engine
below the
oil level oil
the specified
switch
is turned
lamp then lights
81-32 0
pan.
sensor When
is installed the
level, the float OFF.
up to indicate
The
engine
on top oil
goes down machine
of
goes and
monitor
the abnormality.
WA350-1
STRUCTURE
AND
COOLANT
FUNCTION
ELECTRONIC
VEHICLE
MONITORING
SYSTEM
LEVEL SENSOR 1. Connector 2. Wire 3. Plug 4. Float 5. Switch
0N (UP)
e
OFF (DOWN)
Circuit StructUre
423F175
Function . The coolant level sensor is installed on top of the radiator. float
When
goes
off.
The
the coolant
down
level goes down,
and the electric
machine
monitor
current
the
is shut
lamp then lights up to
indicate the abnormality.
BRAKE
CHAMBER
STROKE
SENSOR 1. Ball 2. Shaft 3. Switch 4. Harness 5. Connector
w
Circuit structure
423F180
Function l
The the
brake brake
chamber
stroke
sensor
chamber.
When
the stroke
piston in the brake chamber fied
stroke
brake
(over-stroke),
chamber
electric
pushes
current.
machine
monitor
is installed
goes above the specithe rod installed
to the
the ball and shuts off the
This turns the switch lamp
to
of the air
lights
OFF and the
up to indicate
the
abnormality.
WA350-1
81-33 0
STRUCTURE
AND
FUNCTION
ELECTRONIC
VEHICLE
, COOLANT TEMPERATURE TORQUE CONVERTER OIL TEMPERATURE SENSOR
MONITORING
SYSTEM
1. Connector 2. Wire
1
3
2
5
4
3. Tube 4. Plug 5. Thermistor
(beat type)
2
*
Circuit structure 423F176
Function l
These
sensors
are installed
block and transmission tor to detect perature
They
the temperature,
goes
the machine
on the engine cylinder
case.
above
monitor
the
use a thermis-
and when
specified
the tem-
temperature,
lamp lights up to indicate
the
abnormality.
ENGINE
OIL PRESSURE,
PARKING
BRAKE
SENSOR 1. Connector 2. Wire 3. Switch 4. Diaphragm 5. Plug
c:@z=B Circuit structure 423Fl77
Function . These are installed ing brake the goes
on the engine valve.
oil and air pressure, below
monitor
81-34 0
solenoid the
specified
The
block and park-
diaphragm
detects
and when
the
pressure
pressure,
the
machine
lamp lights up to indicate the abnormality.
WA350-1
STRUCTURE
AND
SPEED
ROTATIONAL
ELECTRONIC
FUNCTION
VEHICLE
MONITORING
SYSTEM
SENSOR
Function .
The
rotational
speed
transmission
output
generated signal
by
the
is then
this displays
sensor A
rotation
sent
is installed
gear. to the
the travel
of
pulse the
machine
on
the
voltage
gear
is
teeth,
monitor,
Section
A-A
a
1
and
speed.
@a3
I-. Connector 2. Magnet 3. Case
Circuit
structure
423F178
FUEL GAUGE
SENSOR
Function . The fuel gauge
is installed
The
float
fuel
level.
through
moves
up and
The
movement
a gear to actuate
sends
a signal
to the
on top of the fuel tank. down of
according the
a variable
machine
to the
float
is sent
resistor.
monitor
This
to display
the fuel level. When
the
display
on the
to a certain
level,
the
inside
the
lamp lights
up.
modules
warning
a signal
machine
monitor
is generated
machine
monitor,
drops
between and the
1. Connector 2. Variable
resistor
3. Lever 4. Float Circuit
structure
423F179A
WA350-1
81-35 0
STRUCTURE
AIR
FUNCTION
AND
PRESSURE
ELECTRONIC
VEHICLE
MONITORING
SYSTEM
SENSOR
1. Connector tube
2. Ventilation 3. Wire 4. Resistor 5. Resistor
con-
selector
tact
Function . The air pressure It converts
tank.
changes
sensor
to the wet
air
in the air pressure
to
is installed
the changes
in resistance.
It then sends a signal to the machine pressure.
dicate
the
air
below
the
specified
the
machine
warning
81-36
pressure, generates
monitor
lamp lights
If the
monitor
to in-
air pressure
goes
the
module
a signal
&x
2
Circuit structure
423F181
inside and the
up.
WA350- 1
STRUCTURE
WIRING
AND
ELECTRONIC
FUNCTION
VEHICLE
MONITORING
SYSTEM
HARNESS
CNP8 (16P) CNP9 (5P) CNP2 (16P)
423F182
Operation of monitor panel If the monitor
panel
on the monitor
panel will work as follows.
1) When
is working
the starting
a)- All monitor
switch
c) The
a) All monitor if there
item,
that
will light up for 3 seconds,
is any abnormality
item will flash.
ON, then 0.8 seconds
in any check
(About
0.8
seconds
running
lamps
will go out when
(Judge
whether
see if there
is a voltage
the
the engine
by the rise in the engine oil pressure,
air temperature
- 1 O’C),
the flashing
is low
3) CAUTION a) All
MONITOR
monitors
engine
of over IOV
is or
from
the
time
the
(below
interval will change
If there lamp
GROUPS
are working
starts
the starting
OFF repeated.)
outside
slightly, but this is not an abnormality.
WA350-1
item
is started.
alternator.)
GROUP
lamps
then
CHECK
engine
is turned to ON.
buzzer will sound for 2 seconds.
2) CHECK MONITOR
about
the lamps
lamps will light up for 3 seconds.
b) The warning
b) If the
normally,
switch
seconds
the
that
stops and
is turned to OFF.
is any abnormality for
from
to the time the engine
item
will
ON, 0.8 seconds
in the machine, start
to
flash
the (0.8
OFF).
81-37 0
STRUCTURE
AND
OPERATION
ELECTRONIC
FUNCTION
OF PROXIMITY
VEHICLE
MONITORING
SYSTEM
SWITCH
Lift arm RAISE l
When
the lift arm is lower than the set position
the boom
kick-out,
the detection
is on the sensing
surface
Electricity
through
flows
The relay switch of the magnet
of the proximity the
proximity
Proximityswitchfor
switch.
boom kick-out .,-,_+-
switch.
is at OFF and the electric
switch
for
unit (steel plate)
To battery relay
current
coil is shut off.
Solenoid for kick-out
Lift lever Solenoid II\ Proximity
switch
Lift a ain control valve
423F205A l
When
the lift control
position,
lever is moved
to the RAISE
the lever cam and the cam follower
the lift spool in the RAISE
position,
keep
Proximity switch for boom kick-out
so the lift arm
To battery relay
goes up.
Lift lever _/
/
II
Solenoid
ller
am Detection
unit. 423F206A
81-38 @
WA350-1
STRUCTURE
l
AND
ELECTRONIC
FUNCTION
When
the lift arm goes
up and reaches
sition
for
(that
(steel
plate)
the
kick-out
is separated
of the proximity relay
circuit
magnet pulled
switch),
act
coil.
to
This actuates
out of the cam
returned
to
the
the sensing
the proximity
send
electric
detent,
neutral
unit and
to
the
the cam is
and the lift spool
position
by
SYSTEM
surface
switch
current
the magnet,
MONITORING
the set po-
is, the detection
from
VEHICLE
the
is
return
spring.
Proximity switch for boom kick-out
To battery
Kick-out
Solenoid for
relay
relay
Lift lever Solenoid
Lift arm Proximity
-
switch
423 F207A
Movement
of proximity
switch
Position
Proximity
switch
display
Proximity
switch
load circuit
(relay switch
circuit)
Relay switch
load circuit
(solenoid
circuit)
WA350-1
Sensing
surface
is in contact
of magnet
with
detection
switch
Sensing
unit
is separated
surface
of proximity
from
detection
switch unit
OFF
ON
Current
flows
Current
flows
Current
Current
shut off
shuts
off
81-39 @I
STRUCTURE
AND
FUNCTION
ELECTRONIC
VEHICLE
MONITORING
SYSTEM
Bucket TILT l
When the
the bucket bucket
plate)
is lower
positioner,
is on the
than the set position the
sensing
switch.
No electricity
switch.
The relay
current
from
the
magnet
switch
coil.
detection
surface
flows
switch
unit
of the
through
for (steel
proximity
Proximity switch for bucket positioner
the proximity
To battery relay
is at ON and the electric
battery
flows
through
the
Solenoid for bucket positioner
Dump lever
Solenoid -
ain control valve
Detection
unit
Proximity
switch 423 F208
. When
the
bucket
TILT
position,
keep
the
bucket
dump
control
the lever spool
lever
is moved
Proximity switch for bucket positioner
to the
,,,
cam and the cam follower in the TILT
position,
so the
To battery relay
~$1
tilts.
Solenoid for
Positioner
relay
Dump lever Solenoid
Roller
Cam
Detection
unit
Proximity
switch 423 F209
81-40 a
WA350-1
STRUCTURE
l
When for
AND
the bucket
the
bucket
unit (steel plate)
tilts and reaches positioner
magnet pulled
circuit coil.
to the
the proximity current
the magnet,
detent,
neutral
MONITORING
SYSTEM
detection
the sensing
act to send electric
This actuates
VEHICLE
the set position is, the
from
switch),
out of the cam
is returned
(that
is separated
face of the proximity and relay
ELECTRONIC
FUNCTION
sur-
switch to the
the cam is
and the dump
position
by the
spool return
spring.
Proximity switch for bucket positioner _-
To battery relay
Solenoid for bucket positioner
Dump lever Solenoid
Detection
unit
Proximity
switch 423F210
Movement
of proximity
switch Sensing
Position
Proximity
switch
display
Proximity
switch
load circuit
(relay switch
circuit)
Relay switch
load circuit
(solenoid
circuit)
WA350-1
surface
is in contact
of magnet
with
detection
switch
Sensing
unit
is separated
surface
Current
Current
detection
switch unit
OFF
ON
I
of proximity
from
flows
shut off
Current
Current
shut off
flows
81-41 0
ELECTRIC AND ELECTRONIC SYSTEM
82 TESTING AND ADJUSTING
Adjusting
speedometer
in the vehicle
The following
precautions
troubleshooting
or during
1. The values
in these
used as target 2. The standard standard
tables when
are based repairing
in these
tables
for the machine
values
value
tables
when
using
the Standard
Value
.
.
82-2
.
.
.
82-5
during
Tables
to make
judgements
leaving
the plant,
so they
and adjusting. on the values or when
must
shipped
for
estimating
for judgement
when
be used as reference
standard
use these
WA350-1
values
values
they should 3. These
values
are necessary testing
.
.
Troubleshooting
t
module
monitor
when
from
in combination
with
new
machines
wear
after
troubleshooting
the plant,
values
when
should
be
of use. are estimated
and on the results
repair and operating
not be used for standard
alone to make simple
a period
values
of various
records
when
judging
claims.
based
tests.
making
on the
Therefore, judgements.
In addition,
do not
judgements.
82-1 0
TESTING
AND
ADJUSTING SPEEDOMETER THE VEHICLE MONITOR The speedometer in all models. speed
differs
speeds
of the vehicle
However,
monitor
IN
MODULE
is the same
the input signals for vehicle
on each model.
will differ
ADJUSTING SPEEDOMETER IN THE VEHICLE MONITOR
MODULE
ADJUSTING
In addition,
according
types, so the speedometer
the vehicle
to the diameter
and tire
must be adjusted
for each
model. It is not necessary new
machine,
to adjust
because
the speedometer
of
it has been completed
by
Komatsu. When
replacing
speedometer,
the
or
speedometer
replacing
the
module
tires,
in
adjust
the
speedometer. Speedometer
which
supplied
as
parts
route, is setted the position of switch Switch
position
Switch
position Ill: D
Switch
I has
supply
as follows:
II: 5
no
relation
to
the
speedometer
adjustment. Do not touch this switch
HOW
TO
Remove make
ADJUST
the
the
this switch.
The normal
position
of
is F.
THE
vehicle
SPEEDOMETER
monitor
adjustment
from
on the
the
back
vehicle
of the
and
I
Driver (-1
423F336A
Parts No. here
speed-
ometer. Adjustment I) Remove
rubber
the speedometer 2) When
caps II and Ill on the rear side of module.
the rubber
cap is removed,
can be seen inside.
Then,
turning
with
this switch
a rotary
switch
make the adjustment a screwdriver
Rotary Switch
I
by
as shown
below. PER KILOMETER Switch Tire size
position
I
II
20.5-25
STD
B
8 (B)
23.5-25
OP
B
C
423F337
Reference:
PER MILE Speedometer
Tire size
Module Parts No.
Switch II
position Ill
Switch position Correction factor (%)
Switch position Correction factor (%)
3) After rubber
completing
the
cap to its original
adjustment, position
Correction
,
factor
(o/o)of switch
Ill
0
1
2
3
4
5
6
7
-14
-12
-10
-8
-6
-4
-2
0
8
9
o
A I
I
+2
B I
+4
C I
+6
D
+8
E I
1
+lO
+I2
the restore and install the
vehicle monitor.
82-2 0
F I
WA350-1
+14
TROUBLESHOOTING .. .
Before troubleshooting Method
of using YES-NO
.
flow chart Connector Precautions
when handling
wiring diagram
Electrical
circuit system
(E-l
(Electronic monitoring
carrying
page 22-l
out the troubleshooting
2, “METHOD
RENCE OF TROUBLE”
WA350- 1
OF READING page 22-l
in this section, TROUBLESHOOTING
.
..
.
.
. .
6
82-
8
82-l
0
. 82-l
5
82-l
7
. 82-l
8
. .
system
. 82-23 82-56
table system)
chart for electronic
system
read “PRECAUTIONS TABLE”
.
vehicle monitoring
Troubleshooting
. .. .
connector..
. .
vehicle monitoring
Troubleshooting
. 82-
chart for electric system
to E-l 5)
Electronic
Before
numbers
Electrical
Troubleshooting
*
.
terminal
.
Troubleshooting
page 22-l
(M-l
.
to M-33)
WHEN
82-57
vehicle 82-59
TROUBLESHOOTING”
4 and “PREVENTING
RECUR-
6.
82-5 0
TROUBLESHOOTING
CHECKS
CHECKS
BEFORE TROUBLESHOOTING
BEFORE TROUBLESHOOTING
item
Standard
-
1. Check fuel level 2. Check for dirt or water
in fuel
3. Check hydraulic
oil level
4. Check hydraulic
oil strainer
5. Check brake oil level 6. Check engine oil level (Level of oil in oil pan) 7. Check cooling water 8. Check condition
level
of dust indicator
9. Check for loose or corroded
battery
value
Add fuel Clean, drain Add oil Clean, drain Add oil Add oil Add water Clean or replace
terminals
10. Check for loose or corroded
alternator
1 I-. Check for loose or corroded
starting
-
terminals motor
Remedy
Tighten
or replace
Tighten
or replace
Tighten
or replace
terminals 12. Check for abnormal
-
noise or smell
13. Check for oil leakage 14. Bleed air from system 15. Check battery voltage
(engine stopped)
16. Check level of battery
electrolyte
17. Check for discolored,
burnt, or bare wiring
18. Check for missing wiring clamps, 19. Checks
for water
fully water 20.
Check for broken or corroded
Repair Bleed air Replace
3ov
-
hanging wires
leaking onto wiring (check care-
leakage at connectors
2 1. Check alternator
20 -
Repair
Add or replace Replace Repair Xsconnect
-
fuses
voltage
connector
and dry connection
and terminals) 27.5
-
Replace 29.5
V
Replace
(engine running at over half throttle) 22. Noise when battery (switch
82-6 a
relay is operated
-
Replace
starting switch from on to off)
WA350-1
METHOD
OF
USING
YES-NO
TROUBLESHOOTING FLOW CHART
TROUBLESHOOTING
METHOD OF USING FLOW CHART
YES-NO
TROUBLESHOOTING
The electric system
can be broadly divided into the following
1. Starting
transmission
system,
2. ELECTRONIC
VEHICLE
electrical
MONITORING
The charts for these systems
control system,
two parts.
brake system.
SYSTEM.
ars marked
as E-xx, and M-xx
respectively.
Troubleshooting chart No.
Item
E-xx
Troubleshooting
M-xx
1 Troubleshooting
1. Method
of starting
system,
of electronic
or measure
the items
electrical
vehicle monitoring
for troubleshooting
Check
transmission
brake system.
system
YES
-1
inside the rectangle
control system,
H
I. NO
According The
to the result, follow
number
given
the YES arrow
at the top right
or the NO arrow
of the rectangle
and proceed
is a reference
number.
to the next rectangle.
It does
not indicate
(Note:
the order
for
troubleshooting.) If the result
of the check
action
in the REMEDY
given
The value for the check the answer Below ment
the rectangle,
the YES arrow;
there
for checking
or handling
is used,
always
operations
in the order given. when
The precautions scription 3. Tools
needed
The tools
column,
note the cause
and take the
work,
methods
is wrong, before
the rectangle.
or the answer
If the preparatory
or the judgement carefully
inside
this
starting
If the value
is no, follow
of operating work
could
the check
and handling,
is ignored,
result
is correct,
and judge-
or the wrong
in damage
or
the NO arrow. method
of
to the equipment.
or measurement,
and carry
out the
out troubleshooting
to be followed
of the failure.
is given
is not correct,
preparatory
and measuring.
read the procedure carrying
to the CAUSE
method
if the value
is a list giving
needed
Therefore, 2. Precautions
leads directly
column.
and the measurement
is yes, follow
values
operating
or measurement
Always
when
carrying
out troubleshooting
follow these precautions
when
for each failure
making
is marked
t
under
the de-
measurements.
for troubleshooting
needed
for troubleshooting
for each problem
are listed as follows.
1
I
Troubleshooting tools
Prepare
these
I
tools
Place to install When each
before
connectors,
troubleshooting step
connector, together
during
some the
connector with
starting
the
troubleshooting
connector
pin numbers
problems,
measurements
troubleshooting pin number)
YES-
NO
type
procedure.
is shown
have to be made The
location
in a photograph
troubleshooting
flow
for
or diagram. charts
to
of continuity,
measurement
voltage at each
For this reason, carry
out
and resistance
at
step
of
use these
troubleshooting
(location photographs quickly
accurately.
82- 8 0
WA350-1
and
METHOD
OF USING
YES-NO
TROUBLESHOOTING FLOW CHART
TROUBLESHOOTING
Example
*
When
disconnecting
disconnecting *
When
Sr When
or connecting
the connector
connecting
the T-adapter
disconnecting
after checking,
the
for checking,
T-adapter
(or socket adapter),
connectors
(or socket
turn the starting
or connecting
adapter)
switch
connect
T-adapters,
or short
OFF to prevent
to the connector return
them
specified.
1) 2)
q
Short-circuit CN18 (femaleI(3) and (4). Turn starting switch ON.
I 2)
3)
Is there contuwity betwew CN18 Imale) and chassis
Turr startng OFF
_
immediately
switch
Remedy
transmlsslon
cut-off
BEFORE
eplace
*
Defective CHECKS STARTING module
.
Disconnection I” wiring harness, or defective contact between CN18 (female)(3) ano CNP4 (fernale)
ifter inspectlon, epair (clean) or eplace
c
Dlsconnectlon I” wiring harness. ordefectlve contact betwew CN18 (female) (4) ant chass6 ground
4fter inspection, repair (clean) or replace
:eplace
Is there continuity between CNP4 (fernale) and chaws ground?
YES
goout’
Troubleshooting tools
()I
condition
Cause
IES
fiij
or when
then go to the next check.
Defective swtch
Does
adapter,
(CNxx
to the original
q IighKup.
a)
socket
accidents.
NO
Connect T-adapter to CNP4 (female). Turn starttrrg swtch OFF
NO
Tester T-adapter
(for DLI)
T-adapter or socket (for Frono+,=nll
adapter
CN18
WA350-1
82-9 0
CONNECTOR
TROUBLESHOOTING
CONNECTOR
Connector
TERMINAL
NUMBERS
NUMBERS
-r
ECONOSEAL Female terminal
TERMINAL
CONNECTOR
(Socket)
Male terminal
(Pin)
CN21 ,CN35 CN47,CN83 CN84.CN86 CN87.CN88 CN92.CN93 CN96,CNlOl CN105.CN107 CN163 142F400A
142F401A
2 CN41
3
I
CN42
1 J""]
1 142F403A
142F402A
CN14 CN43
142 F404A
142F405A
-
5’ 2’
'1
B ”
142F407A
142F406A
CN15 CN16 CN60 CN61
3
82-10 @
142F408A
WA350-1
CONNECTOR
TROUBLESHOOTING
r
Connector
--
NUMBERS
DLI CONNECTOR (For monitor panel) Female terminal
CNPI CNP3 CNP5 CNP7
TERMINAL
Male terminal
(Socket)
(Pin)
5
6
1
4
1
4
5
6
142F418
142F419
6 CNP2
142F420
142F421
CNP4 CNP6 CNP8 CNPI 0
142F422
WA350-1
142F423
82-11 @
TROUBLESHOOTING
Connector
CONNECTOR
T
NUMBERS
N-SLC CONNECTOR Male terminal (Pin)
Female terminal (Socket)
PEI
CN12 CN17 CN25
TERMINAL
1
423F349
423F350
1
CNI 1 CN13 CN48 CN102 CNI 04
3
423F351
2
CN18
423F354
423F353
CN40
4
423F355
6
‘4
423F356
-
423F357
82-12 @
5’
423F358
WA350-1
CONNECTOR
TROUBLESHOOTING
TERMINAL
NUMBERS
MIC CONNECTOR Connector Male terminal
Female terminal (Socket)
(Pin)
1
CNP9
3
1
5
4
4
I3
142F410
142F411
-
J
142F412
I
142F414
142F413
142F415
-
142F416 i
WA350-1
423F417
82-13 0
CONNECTOR
TROUBLESHOOTING
TERMINAL
NUMBERS
BENDIX CONNECTOR
connector Female terminal
(Socket)
Male terminal
(Pin)
CN85
E
MF
G
423F346
RELAY CONNECTOR
Connector
CN51 CN52 CN53 CN54
423F347
5
3 423F348
82-14 @
WA350-1
PRECAUTION
TROUBLESHOOTING
PRECAUTION I. If the
connector
WHEN has a lock,
lock before disconnecting
When connecting, align this arrow and push in. Be sure to fit rubber cover tightly. n
HANDLING
always
release
HANDLING
CONNECTOR
CONNECTOR
the
the connector.
When removing, press this part in and pull the connector out.
When connecting, align the guide inside the
emoving. press In on both sides a%d pull the connector out.
F 142A092
2. Never pull the cord to disconnect
F 142AO93
the connector.
F142A094
3. If the connector
WHEN
is difficult
to disconnect,
to
by hand,
F 142A095
do not
try to pull it out. (If it is difficult
reach
remove
the
clamp and move the wiring harness.) This must be removed.
\ F 142A096
WA350-1
82-15 0
TROUBLESHOOTING
4. After
pulling
PRECAUTION
out the connector,
bag to protect
the contacts
cover
from
with
WHEN
HANDLING
CONNECTOR
a vinyl
dirt or oil.
. 5. When
cleaning
the connector,
such
agents
as
trich-loroethylene.
If the
use a neutral-cleaning which
use cleaning
connector
agent.
well and dry completely any connector
never
trichloroethane After
is very cleaning
immediately. has deposits
F 142A097
or dirty, wash
(Do not use left
on it after
drying.) Coat with (When
contact
drying,
restorer. be particularly
careful
to
dry
the
gaps in the rubber.)
6. When
assembling
the
connector,
be sure to fit it F 142A098
correctly. (For connectors to hear the locks
with click
locks,
it should
as they
be possible
fit completely
into
position.)
F 142A099
l
Correct
82-16 a
any protrusion
F142AlOO
of the boots.
WA350-1
ELECTRICAL
WIRING
DIAGRAM
/
\
View
CNIOI
(CN80),
2
,,,,ac163cN’75 CNP\8
CNP6
, / CNP’
CNPIO
,
,,., .. i
,
CplP4
,,.\
I
\
\
ChiP5
CtiP9
CrjPl
View
(
CyP2
\
C‘NP3
LI\Jb \
_’
Y
) : Connector number of diode
423F345A
WA350- 1
82-17 0
ELECTRICAL
TROUBLESHOOTING
ELECTRICAL 1. ENGINE
CIRCUIT
STARTING
Startino
CIRCUIT
CIRCUIT
SYSTEM
SYSTEM SYSTEM
switch
Transmission control swtch
III
To meter panel
control
w 12”140mlx2
solenoid
Main breaker
Alternator
otor
2. ENGINE Startmg
STOP switch
CIRCUIT
SYSTEM 423F338A CWS
Ill Fuel cut solenofd
Alternator
423F339
82-18 0
WA350-1
ELECTRICAL
TROUBLESHOOTING
3. TRANSMISSION
CONTROL,
TRANSMISSION
CUT-OFF
Neutralizer
To parking brake switch
CIRCUIT
CIRCUIT
SYSTEM
SYSTEM
relay
J
I
I Transmission cut-off switch Cllll
Main breaker
To battery relay Transmission
control
Reverse Forward 4th 3rd :ns: Transmission cut-off selector switch
Monitor panel
423F34OC
WA350-1
82-19 8
TROUBLESHOOTING
ELECTRICAL
BRAKE
4. PARKING
CIRCUIT
CIRCUIT
SYSTEM
SYSTEM
Parking brake switch OFF (Parking) ON
Parking brake safety relay
To main breaker
II
Monltor panel
Park11“g brake valve
Parking brake indicator switch 423F341
5. PREHEATING
CIRCUIT
B
SYSTEM
Relay breaker
Glow switch
timer
Auto-preheating
cm*
AUTO OFF ON 2OA
relay
CNFa
ml64
0497
1
I
-
Monitoring
U
,
Electrical air intake heater
panel
423 F342A
82-20 8
WA350-1
TROUBLESHOOTING
6. ELECTRICAL
CIRCUIT
ELECTRICAL
CIRCUIT
SYSTEM
SYSTEM
Serial
423F344A
WA350-1
82-21 0
TROUBLESHOOTING
Serial No. 11118
82-22 0
and up
ELECTRICAL
/G-l
CIRCUIT
SYSTEM
rx
423 F3448
WA350-1
TROUBLESHOOTING
CHART FOR ELECTRIC (E-l. to E-15.)
SYSTEM
. . . . . . ............................................... E- 3. Engine stops when traveling. ......................................... E- 4. Parking brake does not work. ........................................ E- 5. Parking-brake is applied when traveling. ...............................
E-
1.
Engine does not start.
E-
2.
Engine does not stop.
.
.
.
...............
. . ..........
E-
6.
Parking brake is released
E-
7.
Transmission
is not returned
E-
8.
Machine
E-
9.
Machine
.................................... ..................................... does not shift gear (F-R switch normal). ..................
82-24
...............
82-27
...............
82-27
...............
82-28
...............
82-32
...............
82-36
. ...............
82-36
does not travel Forward.
...............
82-38
does not travel Reverse.
...............
82-42
E- 10.
Transmission
E-l 1.
Machine
does
E-l 2.
Transmission
E-l 3.
Transmission
E-l 4.
Preheating
E-l 5.
Preheating
WA350-1
.
not travel
when starting to Neutral
when
switch
is turned to ON.
when parking brake is applied.
transmission
cut-off
switch
....................................... .............................. does not return to Neutral. display does not go out. ................................... does not work. ........................................... cannot
is ON.
...
.
....
be cut-off
. . .
.
...............
82-46
...............
82-48
...............
82-48
...............
82-50
...............
82-54
...............
82-54
82-23 0
E-l
TROUBLESHOOTING
E-l.
ENGINE
DOES
NOT
* When disconnecting
START
or connecting
necting the connector
the T-adapter
for checking,
(or socket
turn the starting
switch
adapter)
or short socket
OFF to prevent
* When connecting the T-adapter (or socket adapter), connect to the connector * When disconnecting connectors or connecting T-adapters, return them
to the original
condition
immediately
after
checking,
adapter,
or when discon-
accidents. specified.
then go to
(CNxx
Cause
(1) Remedy
the next check.
(a)
Checking
star_ting circuit
YES ) I
IS
voltage between 1)
CN102 (female1 (11 and chassis ground 20 - 3OV? I 1
I
2)
2) 31
Disconnect CN102 (safety relay inlet). Measure with starting swtch at START.
YES between CN14 (3) (female) and
1) 2)
(b)
Checking
battery
1) 21 Is there sound of battery relay working?
Disconnect CN14 Measure with starting switch at START.
-
)
0
battery
relay 2 YES
IS voltage between both ,hlCk term,r,a,s Of battery relay and ChaSSlSground 20 - 3OV?
YES
1) Turn starttng ON - OFF.
Connect T-adapter (or socket adapter) to CN16. Place F-R lever at N. Turn starting switch OFF.
starting
w
*
NO
YE! a YES
-
NO Is voltage
Defective F-R switch, or defective contact or dtsconnection in wiring harness between F-R switch and chaws ground.
lfter :hecklng, .epair or
Defective contact or disconnection in wiring harnes between CN102 (1) (female) F3y!37 (4) - CN63 (5) - CNl
lfter :hecking, .epair or
Defective
+eplace
starting
switch
x?Place
‘eplace
Defective contact or disconnection in wiring harnes between battery relay and starting mortar assembly.
If NO for both terminals Defective contact or disconnection in wiring harnes between battery and battery relay. If NO for one terminal Defective battery relay
4fter :hecking, .epair or ‘eolace 4fter :hecking, .epair or ‘elIlaCe
_ 1)
CN14 (1) yodch;;&;ground
1)
Defective contact or disconnection in wiring harnes between CN104 (3) ifemalel CN95 (1) - (diode) - CN95 (2) - CN63 (2) - CN14 (2)
ReplaCe After checking, repair or reDlace
between
hx+d
-
5
Is voltage between CN14 (2) (female) and chassis ground 20 -3OV?
4-
F _
1) Disconnect CN104. 2) Turn starting switch ON.
Tester
4fter :hecklng, .epair or replace
iep1ace
3
TroubleshootIng
ieplace
Defective contact, or disconnection I” wiring harnez between CN102 (3) (female) CN97 (7) - CN64 (9) - CNl (9) (female).
Defective contact or disconnection between CN104(3) - battery relay chassis ground, or defective battery relay.
YES
NO
motor
switch
switc h
!
starttng
-
Turn starting switch ON. Measure voltage between two terminals connected by thick insulated cable
Is voltage between CN104 (3) (female) and chassis ground 20 - 3ow
Defective assembly
Connect T-adapter (Or socket adapter) CN14ifemale).
2) to
Connect T-adapter (Or socket adapter) tO$ CNld(female). Turn starting switch ON. D
,,,(,
T-adapter or socket (for Econoseali
Replace
Defective contact or disconnection in wiring hame> between batterv r&v CN104 (2) - 6~63 17) CN58 (1) - fuse - CN58 (21 - CN14 (1)
After checking repair or WPlFG?
adapter
tools
82-24 8
WA350-1
TROUBLESHOOTING
BATTERY
E-l
RELAY
CN14
CN16
CN102
1
B WA350-1
82-25 0
E-l
TROUBLESHOOTING
CN104
1
B
82-26 0
1
EiD
WA350-1
TROUBLESHOOTING
E-2. ENGINE *
*
When
E-2, E-3
DOES
disconnecting
NOT
or connecting
or short
socket
checking,
turn the starting
When
adapter,
connecting
connector
STOP
Sr When
disconnecting
them
to the original
(CNxx
(or socket
disconnecting
switch OFF to prevent
the T-adapter
specified.
the T-adapter
or when
(or socket
the
adapter)
connector
for
accidents.
adapter),
connect
to the
(1)
connectors condition
or connecting
immediately
T-adapters,
after checking,
return
Cause
then go to
Remedy
the next check.
YES
m
efective adjustment of linkage etween fuel-cut solenoid vaIv( nd fuel injection pump
idiust
L
lefective fuel solenoid
tep1ace
1 3 Is fuel-cut solenoid valve spool operating normaly? _
-
YES 2
1) Visual check when starting switch ON * OFF No
1)
_
bbnormal contact, or mistaken (iring between +24V termina nd wiring harness of CN 14 (2 $e) - CN63 (2) - CN97
_m
~u~;n starting
1)
Is voltage between starting switch BR and chassis ground OV?
YES
Is voltage between both terminals of fuel cut-off solenoid OV?
switch
NO
Turn starting switch OFF.
m
after inspection. epair or replace
lefective starting switch.
leplace
defective adjustment of linkage etween fuel-cut solenoid valve nd fuel injection pump
idjust
NO
E-3. ENGINE
STOPS
WHEN
TRAVELING
)isconnection in wiring harness or defective contact n?tween starting switch erminal BR - CN 14 (2) :N63 (2) - CN97 (11). orfue ut solenoid - CN97 (12) hassis ground
Is fuel-cut solenoid valve spool operating
I)
After inspection. ep1ace
Is voltage between
Visual check when starting switch ON OFF
YE terminal BR and
1)
Turn starting switch ON.
2)
fuel cut-off solenoid. Turn starting switch NC1 OFF.
defective fuel cut solenoid
iep1ace
lefective
?eplace
starting switch
chassis ground 20 -
1I
Troubleshooting tools
WA350-1
Turn starting switch OFF.
Tester
lisconnection in wiring hames ,r defective contact between tarting switch terminal Band ,attery relay
Sfter inspection. .eplace
I
82-27 8
TROUBLESHOOTING
E-4
E-4. PARKING BRAKE DOES NOT WORK. (Even when air pressure drops, parking brake When
disconnecting
necting the connector When
connecting
When
disconnecting
after checking,
or connecting
the T-adapter
for checking,
the T-adapter
(or socket
turn the starting
(or socket adapter),
connectors
or connecting
does not work) adapter)
or short socket
switch OFF to prevent connect
T-adapters,
to the connector return
them
adapter,
or when discon-
accidents. specified.
to the original
(CNxx
( 1)
condition
immediatelv
then go to the next check.
Parking brake does not work when parking brake switch is ON.
Remedy
Cause Defective parking brake solenoid
Defective
c
1) Connect
perking brake relay
1 T-adaDter
(Orsocket ada&)
t(
2
NO
CN35. 2) Turn parking brake switch ON (Parkmg) 31 Start engine (Air charge).
Is problem
removed YES
1)
2) 3)
Replace CN54 (back-up lamp relayiand CN51 (parking brake relay) Turn parklng brake switch ON (parking). Start engine (Au pressure gauge).
YE
between CNl 1 (male) (1) and (21 as shown in table?
Abnormal contact or mistaken wiring between CNl 1 (male)(l - CN93(li, (2) - CN6316) CN51 (2)
ifter inspection, epair or replace
Defective
FlepL3X
1
NO
parklng brake swltct
Is problem removed when disconnect
1) 2)
Disconnect CN5 1. Start engine (Air pressure gaugel. Abnormal contact or mistaken winng between CN51 (5)(mal< - CN39 (11) - CN35 11)
After inspection, repair or replace
c
Defective switch
emergency
Reolace
c
Defective
parking brake
b) Parking brake does not work when air pressure drops. (Does not work as emergency brake.) YES
1
brake
Doesparking brake work when CN93 is disconnected? 1) 2)
Starting switch ON Parking brake switch OFF
TroubleshootIng tools
NO
T-adapter or socket adapter (for Econoseall
Repair
Short socket adapter
Tester
82-28 8
WA350-1
TROUBLESHOOTING
E-4
CNll
1
Eia 2
CN35
CN51
6’
‘3
CN93
WA350-1
82-29 8
TROUBLESHOOTING
E-5.
PARKING
* When
E-5
BRAKE
disconnecting
disconnecting
IS
APPLIED
or connecting
the connector
WHEN the
for checking,
TRAVELING
T-adapter
(or socket
turn the starting
switch
adapter)
or short
OFF to prevent
socket
adapter,
or when
accidents.
* When connecting the 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.
1 YE:
1
YES
H
Is there continuity between CN35 (2)(male) and chassis gyound,
NO
1) Connect T-adapter (or socket adapter) to CN35. 21 Turn starting switch OFF.
Is voltage between CN35 (1 )(male) and chassis ground 20 I 1
I
2) 3)
I Connect T-adapter (or socket adapter) to CN35. Start engine (Air pressure charge). Turn parking brake switch ON + OFF.
YES
NO
3
Is problem removed when relays are
I) 2) 3)
Interchange CN54 (back-up lamp relay and CN5 1 (parking brake relay). Start engine (Air pressure charge). Turn parking brake switch ON - OFF.
2) 3)
NO
Is problem removed when short socket adapter IS connected?
un
Ifemalel. Start engine (Air oressur&charael. iurn parking b;ake switch ON - OFF
11
Disconnect CN51. Turn starting switcl ON.
2) 3)
I
21 3)
T-adapter Troubleshooting
or socket
(for
Econoseal)
Short
socket
7
d
Is voltage between ~~51 (3)(male) and chassis ground 20 3OV? II !I
Start engine (Air pressure charge). Turn parking brake switch ON - OFF.
_._ =._ .-.
adapter
tools
82-32 8
I
Interchange CN54 (back-up lamp relay) and CN52 (oarkina brake relay): Start engine (Air pressure charge). Turn parking brake switch ON - OFF.
adapter
WA350-1
E-5
TROUBLESHOOTING
Cause
Remedy
w
Defective parking solenoid valve
a
Disconnection in wiring harness, or defective contact between CN35 I2)(male) and chassis ground
After inspection. replace
Defective
ReplaG?
v
parklng
brake
ReplaCe
brake relay
.
DisconnectIon in winng harness. or defective contact between CN51 (5)(malel CN39 (11) - CN35 (1)
After uxpection. replace
14
tl;:l,c,t’ve
emergency
Replace
Defective
parkmg
safety
relay
Replace
Defective
parking
brake switch
Replace
YES
-
NO
8 _
-
Is there continuity between CNl 1 (male)(l) and (2). CNl 1 (male)l2) and (3). as shown in Table 1 ? 1) 2)
.
YES
NO
Disconnection in wiring harness, or defective contact between 1 (female) (1) CN93 11J.12) - CN63 16) CN51 (2),orCN51 (3) CN52 (51,(2) - CNl 1 (2)
CNl
Disconnect CNl 1. Turn starting switch OFF.
Table
brake
After i”speCti0”. replace
1 Terminal
Operation (l)-(2) ON (Park) OFF (Travel)
WA350-1
NO continuity Continuity
1
No. (21-(3) Continuity No continuiW
82-33 8
TROUBLESHOOTING
E-5
CNll
%
I 2
IriB
2
CN35
CN51 CN52 CN54
82-3 4 @
‘iVA350-1
TROUBLESHOOTING
E-5
* CN93
1
1
”
WA350-1
82-35 0
TROUBLESHOOTING
E-6, E-7
E-6. PARKING BRAKE IS RELEASED SWITCH IS TURNED TO ON When
disconnecting
or short checking, When
them
or connecting
adapter,
turn the starting
connecting
connector When
socket
(CNxx
disconnecting to the original
the T-adapter
or when
(or socket
STARTING
(or socket
disconnecting
switch OFF to prevent
the T-adapter
specified.
WHEN
the
adapter)
connector
for
accidents.
adapter),
connect
to the
(1)
connectors condition
or
connecting
immediately
after
T-adapters, checking,
return
Cause
Remedy
then go to
the next check.
Y‘ES
*
)efecttve &V
parkIng brake safety
YES Defective parklng brake relay
Isproblem
2
I
21 31
Interchange parkIng brake safety relay lCN52) and back-up lamp relay (CN54). Start engnne and charge au pressure. Turn startnng switch ON.
)efectwe
3)
charge arpressure. Turn startlng swatch ON.
E-7. TRANSMISSION WHEN PARKING 1
1) 2 31
Disconnect CNl 1. Start engine and charge air pressure. TUT starzg switch
IS NOT RETURNED BRAKE IS APPLIED.
c NO
TO
,i_
21 31
Interchange NO neutralizer relay KN53) and back-up lamp relay (CN54). Start engnne and charge ar pressure. Turn starting swtch ON.
82-36 8
parking brake swtct
:ontact between +24V Grins iane~s between CN35 (1) :N39Il l)CN51 (51,orCNl 1) - CN51 (2),or &taken wiring.
Sfter Inspection, WlaCe
:ontact between +24V wiring harness between CN53 (5) :N21 (1). (21 - CN85 (A),or nistaken wiring.
\fter inspection, eDlace
NEUTRAL
Is problem removed when relay is replaced?
1)
ReplZG?
removed NO
1)
Replace
)
Iefective
neutralizer
relay
WA350-1
E-6, E-7
TROUBLESHOOTING
CNII
1
B
2
3
3
FB
2
CN51 CN52 CN54
WA35071
82-37 0
TROUBLESHOOTING
DOES
E-8. MACHINE *
When
E-8
When
* When
disconnecting
T-adapters,
or connecting
adapter,
or when discon-
accidents.
OFF to prevent
connect
(or socket adapter),
connectors
switch
or short socket
adapter)
(or socket
turn the starting
for checking,
the T-adapter
connecting
FORWARD
the T-adapter
or connecting
disconnecting
necting the connector *
TRAVEL
NOT
to the connector
(CNxx
specified.
()I
condition
to the original
return them
immediately
then go to the next check.
after checking,
Is there continuity betweenCN16 (male) (1) and l2)?
YES 3 Is there contiruty between CN16 (female) (8) and chaws ground?
)
2)
NO Place F-R lever I” FORWARD. Turn startlrrg swtch ON.
Connect T-adapter (or socket adapter) to CN16 (female). Turn starting switch OFF. NO
)
YE
1) -
-
between CN85 0) (female) and chassis
1) 2)
Place F-R lever tn FORWARD. Turn startlng swtch OFF.
YES 5
I) 2)
3)
Disconnect CN85. Turn starting switch ON.(Do not start engine). Turn parking brake switch ON - OFF.
Is problem removed when relay 1s replaced?
Ir
-NO
6 YES
1)
2) 3)
Interchange neutralizer relay (CN53) and back-up lamp relay (CN54). 1) Start engine. Turn parking brake switch ON - OFF.
Is problem removed when relay IS replaced?
2) 3)
7
NO
Interchange parking L brake safety relay lCN52) and back-up lamp relay iCN54). Start engine. 1I Turn parking brake switch ON - OFF. 2) 3)
YES
Is problem removed when short socket adapter is connected7 Connect short socket adapter to CN2 1 (female). engine. Turn parking brake switch ON - OFF.
3
Start
YES
_ NO
Is problem removed when CN53 (female) (3) and 15) are shortcircuited? 1) 2)
Troubleshooting tools
82-38 8
T-adapter or socket adapter (for Econoseal)
-
8
. _
Is problem removed when CNl 1 (female) (1) and (3) are shortclrculted?
1) 2)
Disconnect CNl Start engine
Disconnect CN53. Start enghne.
Short socket adapter
WA350-1
YES
_
1.
_ NO
TROUBLESHOOTING
E-8
-
in wiring Disconnection harness. or defective contact between CN16 (2) (female) CN75 (51 - CN85 (D) CN85 (A) (female)
F
Defective
t
in wiring Disconnection harness. or defective contact and between CN16 (1) chassis ground
.
Replace
F-R switch
hale)
WA350-1
After inspecton, repair or replace
After inspection, repair or replace
solenoid
RepliKe
relay
ReplaCe
w
Defective
Forward
=c
Defective
neutralizer
t
Defectwe relay
parking
c
Defectwe swtch
transnxss~on
-
Defective
parklng
brake safety
Replace
cut-off
Replace
brake swtch
Replace
82-39 8
TROUBLESHOOTING
E-8
CNII
CN16
CN21
2
1
CN52 CN53 CN54
82-40 @
WA350-1
TROUBLESHOOTING
E-8
CN85
..
WA350-1
82-4 1 @I
E-9
TROUBLESHOOTING
E-9.
MACHINE
DOES
* When disconnecting
NOT
TRAVEL
or connecting
necting the connector
IN
REVERSE
the T-adapter
for checking,
(or socket
turn the starting
switch
adapter)
or short socket
OFF to prevent
adapter,
or when discon-
accidents.
* When connecting the T-adapter (or socket adapter), connect to the connector specified. (CNxx (1) * When disconnecting connectors or connecting T-adapters, return them to the original condition immediately after checking,
then go to the next check.
YES -
Is there continuity betweenCN16 (male1 (1) and l3)?
3 IS there cont,“u,ty betweenCN16 (11 Ifemale) and chaws ground’
1
1)
2)
1)
2)
Connect T-adapter (or socket adapter) to CN16 (female). Turn starting switch OFF.
-
Place F-R lever I” REVERSE. Turn starting switch OFF.
NO
NO
2
CN85 (A) Ifemale) and chassis ground
1) 2)
3)
Y ES
Disconnect CN85. Turn starting switch ON. (Do not start enginei Turn parking brake switch ON - OFF.
YES
Id I I Is problem removed 1) interchange neutralizer relay h (CN53) and back-up t _, lamp relay (CN54). 1) Interchange parking ZJ brake safety relay 3) Turn parking brake (CN52) and back-up switch ON - OFF lamp relay (CN54). 2) Start engine. 3) Turn parking brake switch ON - OFF
YES
i Is problem removed when short socket
startengnne.
2) 3)
9
adapter CN21 (female). Start engine. Turn parking brake switch ON - OFF
Is problem removed YE$_ when CN53 (female) (3) and 151 are shortcircuited? _ Is problem removed Disconnect when CN53 (femalei _ 2) start eng,ne. (3) and (5) are shortcircuited?
8
_
NO
1)
1) 2)
Troubleshooting tools
Tester
CNl1.
Disconnect CN53. Start engine.
T-adapter or socket adapter (for Econoseal) NO
Short socket adapter
82-42 8
WA350-1
NO
TROUBLESHOOTING
E-9
Remedy
Cause
Iisconnectlon In winng harness. or defective contact xtween CN16 (female) (31 1N75 16) - CN85 (0 CN85 iA) (male1
4fter inspection, .epair or replace
Defective
Replace
harness, or defective c&tact between CN16 (male) (1) and chassis ground
After inspection, epair or replace
>efectwe
Reverse solenoid
ReplaCe
Defective
neutralizer
Iefectwe ?lay
parking brake safety
Iefective witch
transmission
Defectwe
WA350-1
F-R switch
relay
cut-off
Replace
Replace
Replace
parking brake switc
Disconnection in wr!ng harness, or defective contact between main breaker - CN6 (3) - fuse - CN60 14) CN52 - CNll - CN52
After Inspecton. repair or replace
Disconnection in wiring harness, or defective contact between main breaker - CN5 - CN21 (11, (2) - CN85 (A) (female)
After inspection, repair or replace
82-43 CD
E-Q
TROUBLESHOOTING
CNll
1
1
b?I
3
3
EB
CN16
CN21
CN52 CN53 CN54 ‘?
82-44 @
/’
WA350-1
TROUBLESHOOTING
E-9
CN85
WA350-1
82-45 @
E-10
TROUBLESHOOTING
E-IO.
TRANSMISSION SWITCH NORMAL)
When
disconnecting
or short checking, When
socket
turn the starting
connector
NOT
or connecting
adapter,
connecting
DOES
specified.
disconnecting
them
to the original
(CNxx
the T-adapter
or when
GEAR
(or socket
disconnecting
switch OFF to prevent
the T-adapter
When
SHIFT
(or socket
the
(F-R
adapter)
connector
for
accidents.
adapter),
Cause
connect
Remedy
to the
(1)
connectors condition
or connecting
immediately
after
T-adapters, checking,
return
then go to
the next check
Defective
3)
OFF. Palace speed lever in 1 St.
1 st solenoid
Disconnection in wring harness, or defective contact between CN85 (H) (female) an CN16 (4). or defective speed switch YES
Defective
2nd solenoid
) between Ifemale)
OFF. i%l!,ce speed lever in
3) )
)
Connect T-adapter lor socket adapter) t( CN16 lfemalel Turn starting switch OFF.
YES
Is there continuity between CN85 (F) and chassis ground?
CN85 (B) (female) and chassis ground
1) 2) 3)
Disconnect CN85. Turn starting switch ON. Turn parking brake switch ON-OFF.
Disconnection in wiring harness, or defective contact between CNB5 (G) (female) :;11~;;16 (5). or d-d speed
CN16 (8) and chassis
I) 2) 3)
H
Disconnect CN85. Turn starting switch ‘INO OFF. ;;l$ce speed lever in
YES
2 1) 2)
Disconnect CN85. Turn starting switch nFF
3)
Palace speed lever in 4th
_.
Defective
3rd solenoid
Disconnection in wirtng harness, or defectw contact Detween CNB5 (F) (female) ant ZN16 16). or defective speed switch
Defective
4th solenobd
>isconnection in wnng lames% or defective contact xtween CN85 (E) (female) ant XNl6 (7). ordefect~ve soeed witch Iisconnection in wiring larness, or defective contact xtween CN16 (8) (female) an, :hassis ground Dlsconnect!on in winng harness, ordefect~ve contact between man breaker - CN7! (1) - CNB5 (B) (female)
Troubleshooting
WA350-1
TROUBLESHOOTING
E-10
CN16
CN85
WA350-1
82-47 @
E-l 1, E-l 2
TROUBLESHOOTING
E-II.
MACHINE (MACHINE
When
disconnecting
or short
socket
checking, When
them
or connecting
adapter,
connecting
the T-adapter
or when
turn the starting
connector When
DOES NOT TRAVEL WHEN TRANSMISSION TRAVELS WHEN TRANSMISSION CUT-OFF
switch
OFF to prevent
the T-adapter
specified.
disconnecting to the original
(CNxx
(or socket
the
SWITCH IS OFF)
IS
ON
adapter)
connector
for
accidents.
adapter),
connect
to the
()I
connectors condition
(or socket
disconnecting
CUT-OFF SWITCH
or
connecting
immediately
after
T-adapters, checking,
then
return
Remedy
Cause
go to
the next check.
YES
I
Iwxnnection in wiring wrness, or defective contact xtweenCN21 (1) - CN53 :5). or CN21 (2) - CN75 (8)
I
Iefective ;wltch
transmlsslon
cut-off
Iefectwe witch
transmission
cut-off
Iefective transmission ielector switch
cut-off
4fter inspectlon, .epLxe
1 Is there
continuty between CN21 (female) (1) and (21?
1)
2)
*
Connect T-adapter (or socket adapter) to CN21 (female). Turn starting switch ON. Do not press the left brake pedal.
E-12.
NO
TRANSMISSION
CANNOT
BE
CUT-OFF.
ES
L
YES 1) 2) Table
Disconnect CN18 Start engine
Troubleshootmg tools
82-48 8
e
3 Iscontinuity between CN76 (male1 (1) and (2) as shown in table, 1) 21
leplace
4bnormal contact, or mistaken Ninng between +24V termina snd wiring harness of main sreaker - CN53 (3). 15) ZN21 (11, (2) - CN85 (A)
Gplace
?eplace
ifter Inspection. epalr or replace
-
Disconnect CN76. Turn starting switch OFF.
I
1efectlve
diode (CN76)
NO
T-adapter or socket adapter (for Econoseal)
WA350-1
TROUBLESHOOTING
E-11, E-12
CN21
CN18
1
1
f!tFI 4
WA350-1
4
82-49 0
E-13
TROUBLESHOOTING
E-13. TRANSMISSION When
the connector
connecting
When
disconnecting
after checking, If the head switch
for checking,
T-adapter
connectors
TO NEUTRAL (or socket
turn the starting
(or socket adapter),
the T-adapter
When
the
or connecting
disconnecting
disconnecting
RETURN
NOT
DOES
or connecting
switch
connect
T-adapters,
adapter)
to the connector return
socket
or short
OFF to prevent
(CNxx
specified.
(1) immediately
condition
to the original
them
or when
adapter,
accidents.
then go to the next check.
lamps
and other
electrical
parts are working
normally,
check
battery
-
battery
relay
-
starting
first.
YE
OFF.
1) 2)
Disconnect CN85. Turn starting switct OFF.
5
NO
Iscontinuity
between CN76 (male) (1) and (2) as shown in table?
Y
r-l
L-t
Is transmission to NEUTRAL when parking brake is applied?
; returned
1)
2)
II 21
Turn startlna swtch ON. Turn transmission cut-off selector switch ON.
Connect T-adapter (or socket adapter) tc CN76 (male). Turn starting switch OFF.
1 returned to NEUTRAL when left brake is J
I
1) 2)
3)
Turn starting switch ON. Turn transmission cut-off Selector switch OFF. Turn parking brake switch ON - OFF.
Troubleshooting toots
82-50 0
0
T-adapter or socket adapter (for Econoseal)
WA350-1
E-13
TROUBLESHOOTING
-
Defectwe
Cause
F-R switch
Remedy
Replace
After inspection. repair or replace
After inspection. repair or replace
See E-7 “Transmission is not returned to NEUTRAL when parking brake is applied”.
See E-l 2 “Transmission cannot be cut off”.
WA350-1
82-51 a
TROUBLESHOOTING
E-13
CN16
‘3
3’
CN85
82-52 @
WA350-1
E-14,
TROUBLESHOOTING
E-14.
PREHEATING
When
DISPLAY
disconnecting
or connecting
or short
socket
checking,
turn the starting
When
connector When them
adapter,
connecting
DOES
the T-adapter
specified.
(CNxx
disconnecting to the original
the T-adapter
or when switch
NOT
disconnecting
OFF to prevent (or socket
GO
E-15
OUT
(or socket the
adapter)
connector
for
accidents.
adapter),
Cause
connect
Remedy
to the
(1)
connectors condition
or
connecting
immediately
after
T-adapters, checking,
return
then
go to
the next check.
Iefectlve
glow switch
IeplXe
Iefectlve
heater relay
leplace
Defective
glow switch
%?pb2
II Is there contlnulty between CN13 (male) (1) and 121?
1) 2)
-
Turn glow switch OFF IAUTO). pisc;ryct CN13 m
E-15.
,
PREHEATING
DOES
NOT
WORK
S
m
ES Is there continuity between CNI 3 (male) (I) and (2)’ 1) 2)
xep1ace
Defective
bSpk%
4 YES
Turn glow switch OFF (AUTO). ~;isc~;nect CN13
r
Is voltage CN48 (I - 3OV?
between and (3) 20
1
YES
jjjjzJ( o&put
1I _, 2)
Troubleshooting
Defective automatic preheating timer
,
Turn glow switch OFF (AUTO). Measure voltage after 2 minutes when starting switch is ON.
1
terminal?
r L 1) Is there continuitV between CN48 (3)
L Turn starting OFF.
switch
NC
heater relay
Contact between wiring harness of f24V terminal and heater relay output terminal nput terminal of electrical air intake heater, or CN13 (2) heater - automatic preheating timer
7epair or replace
Iefectiue contact or disconnection in wiring harries! xtween CN48 (3) and chassis ground
?epair or replace
relay
Tester
tools
82-54 8
WA350-1
E-14, E-15
TROUBLESHOOTING
CN13
CN48
1
fz3
WA350-1
3
3
TROUBLESHOOTING
ELECTRONIC
ELECTRONIC
VEHICLE
MONITORING
VEHICLE
MONITORING
SYSTEM
__,_”
SYSTEM
Air pressure
----
Jain switch
?
Fuel level sensor
CNBS
T_
2I 11
Brake stroke sensor -_
-0>
Brake stroke CN8’ sensor __ / Transmission
cut-off
1 Brake oil capacity sensor
Engine oil
relay
Speedometer
sensor
I
Parking brake indicator switch
Monitor
82-56 0
Engine oil sensor
CN,63 pressure
temperature
panel
WA350-1
sensor
TRouBLEsHOOTlNG
(ELECTRONIC VEHICLE MONITORING
TABLE
Module HXnes5 Trouble
No.
Even when
and there is no abnormality
in machine,
2
Even when engme is stopped, level) flashes.
and there is no abnormahty
IR machine.
3
Even when engine level) flashes.
and there IS no ablormallty
4 q 1
q
1
5
(Battery
IS stopped,
Even when engine is stopped, pressure) flashes.
and there is no abnormality
in machlne
8
is stopped,
and there is no abnormality
in machIne
9
Even when engme is stopped, air pressure) flashes.
and there is no abnormality
in machine
10
Even when engine is stopped, temperature) flashes.
and there IS no abnormality
(Fallwe
steerinq
(T ransmmission lamps,
normal)
cut-off)
liqhts
lights
LID abnormallv.
(Torque
high beam light up abnormally,
19
Speedometer
display
20
Servicemeter
does no? work
21
All or part of monitor If any fuse is broken,
22
E;;;g;;;,“sy:;ne
23
No IamPS On monitor engrne stopped)
24
Central
warning
lamp does not go out.
25
Central
warning
buzzer
-
0
0 0 0
up.
0
n
0
n
n
101
IOlOj
0 0 0
up.
0 0
0
0
0 0
00000 flashes,
or
(Battery
after turning
starting
switch
0 0
00000
!ol
light up (Immediately
to “ON”, 00000
None of panel lamps
on monitor
27
Some of panel lamps
light up.
28
Emergency
Item is flashing,
29
Emergency
item or non-emergency
30
Abnormality
in x
(Fuel gauge)
31
Abnormality
in a
(Air pressure
32
Abnormality
* in &,
(Coolant
33
1Abnormality
on monitor
do not hght up.
but alarm buzzer
00 ,o,o;
but warning
lamp does not flash.
;
/
:
:
I
:
:
/
)
I
IO
0 On,
0 0 0 gauge)
;
00000
gauge)
oil temperature
;
00
0
00000
gauge)
temperature
0
000000
does not sound.
Item is flashing,
(Torqu e converter
00 00
0 .0 0
does not stop.
26
F1
0
n
0
panel does not work normally. replace after checking. (Engine oil pressure)
Tg$. f"W
--I/
00 00
0
normally
q
Speed
0
0
does not work normally.
1s stopped.
ira”%lX :,“v”,‘,
00
or does not liaht UD. (If
or do not light
Engine Brake A1r water H”,;rnw- Pressure line failure
Ezn?i &erlng
0
up
or does not light
Coolant.$glne Parkmg level pressure brake
0
0 0
or does not light up (If equIppedI
up abnormally,
Turn slgnal
,&
up abnormally,
~~~~~~~~~Engine Brake Contro”er 011level oil level
0
0
1lights
18
WA350-1
0
hghts up abnormally.
(Emerqencv
in
-
,x!I
(Fatlure in main steering
I
IOI
0
(Coolant
m
M
loI
0
00
13
17
loI
(Drop in
12
(Preheat)
Lamp buzzer
in
(coolant
in machine
or does not light
D. d lo e
bb”n”“,? ~f~$~~~ off SWliChheater
0 0
(Engine 011
when engine IS stopped, and there IS no abnormality in machine ,[e converter 011temperature) flashes. b( (Park1 ng brake) lights up abnormally, or does not light up. up abnormally,
switch
0
0
+zj
lights
y$:‘“g
group
0
00
,I
lamp)
Alternatar
00
,a
Even
Speed0 meter
(coolant
in machine
Even when engine level) flashes.
Service meter
Sensor
00
flashes.
and there IS no abnormality
Gauge
parts group
(Engine 011
(Fuel level) flashes
(Working
Caution 2
Electrical
group
(Brake 011
•I
charge)
1 .I4 i73F I5 IZT .r II
1
co,
III machme,
7
11
I
q rg
Even when engine is stopped, brake Ilne) flashes.
6
Caution 1
engine is stopped, level) flashes.
1
Checks
phenomenia
SYSTEM)
IOI
0 0 0 I
I
lOI
0 0 0 I
I
I
1
I
I
1
I
I
I
I
I
I
I
I
I
I
I
82-57 0
82-58
TROUBLESHOOTING
M-
1. Even when
engine
is stopped,
brake oil level display M-
2. Even when
M-
3. Even when
M-
4. Battery
M-
5. Fuel le.vel display
engine
engine
and there
failure
M-
8. Even when
M-
9. Even when
M-l
0. Even when
M-l
1. Even when
engine
engine
display
level display engine
coolant
engine
display
temperature
torque
engine
converter
is no abnormality
2. Parking
and there
is no abnormality
lights
M-l
5. Failure in main steering
and there
is no abnormality
display
flashes
M-l
6. Emergency
M-l
7. Transmission
M-l
8. Turn signal lamps,
M-l
9. Speedometer
up abnormally,
display
lights
normal
display
.
display
...................
display
M-20.
Servicemeter
M-21.
All or part of monitor
M-22.
Even when
lights
M-23.
No lamps
stopped,
charge
display
on monitor
.
..................... ............................
normally.
normally. after
engine flashes.
display
Emergency
item is flashing,
Emergency
item or non-emergency
M-30.
Abnormality
but alarm
buzzer
does not sound.
. .
.
M-3 1. Abnormality
in air pressure
Abnormality
in coolant
M-33.
Abnormality
in torque
68
.
82-
68
82-
69
82-
70
82-
72
82-
74
82-
76
82-
78
82-
80
82-
82
82-
86
82-
88
82-
90
82-
92
82-
93
82-
94
82-
96
.......
sensor.
............................... gauge. ....................... oil temperature gauge. ............
gauge.
temperature converter
82-
98
82-l
02
82-l
04
82-l
06
item is flashing,
................................ .......................................
in fuel gauge
M-32.
WA350-1
stopped).
lamp does not flash.
Abnormality
M-30-1.
to ON, engine
lamp does not go out.
in fuel gauge.
82-
after
M-29.
but warning
.
flashes,
...............................
light up (Immediately
switch
.
.......................
checking
oil pressure
M-28.
M-26.
starting
warning
66
normally.
M-27.
M-25.
Central
82-
up abnormally,
................... ............................ ............................ Central warning buzzer does not stop. None of panel lamps on monitor light up. .......................... Some of panel lamps on monitor do not light up. ................... turning
M-24.
.
light up abnormally,
replace
engine
66
up abnormally,
panel does not work
If any fuse is broken,
82-
up abnormally,
does not work
does not work
64
.
.
...............................................
ordonotlightup
or battery
lights
high beam
82-
.
...........................................
or does not light up.
64
or does not light up
................................
or does not light up (if equipped). cut-off
62
82-
in machine,
................................
or does not light up (if equipped). steering
62
82-
in machine,
..............................
flashes
oil temperature
brake display
82-
in machine,
....... M-l 3. Working lamp display lights up abnormally, or does not light up. ..... ............................. M-l 4. Preheat display lights up abnormally. M-l
. .
in machine,
..............................
flashes.
display
60
in machine,
....................................
is stopped,
82-
in machine,
is no abnormality
and there
is stopped,
..
.
is no abnormality
and there
flashes.
drop in air pressure
.
..............................
flashes.
is stopped,
60
.
is no abnormality
and there
is stopped,
82-
..............................
flashes.
is stopped,
oil pressure
coolant
and there
.
in machine,
.................................... ................................... ........................................
line display
engine
..
is no abnormality
flashes.
flashes.
in brake
7. Even when
.
in machine,
flashes.
display
M- 6. Even when engine is stopped, M-
.
is no abnormality
and there
VEHICLE
in machine,
..................................
flashes.
is stopped,
level display
is no abnormality
...................................
is stopped,
engine
charge
and there
flashes.
oil level display
coolant
CHART FOR ELECTRONIC MONITORING SYSTEM (M-l. to M-33.)
.
.
82-l
08
82-l
09
82-l
IO
82-l
12
82-l
14
82-59 0
M-l ,M-2
TROUBLESHOOTING
t
When
or connecting
disconnecting
the connector
disconnecting
IS
AND THERE IS STOPPED, OIL LEVEL) FLASHES.
ENGINE EVEN WHEN (0, (BRAKE MACHINE, I_
M-l.
the
for checking,
T-adapter
(or socket
turn the starting
adapter)
or short
switch OFF to prevent
IN
ABNORMALITY
NO
socket
or when
adapter,
accidents.
* When connecting the T-adapter (or socket adapter), connect to the connector specified. (CNxx (1) * When disconnecting connectors or connecting T-adapters, return them to the original condition immediately after checking,
then go to the next check.
Remedy
Cause
YES
oil level sense
Replace
BEFORE
Replace
Defective
brake
Defective STARTING
CHECKS module
Y g 1)
2)
short socket Connect adapter to CN86 oil (femak?)(brake level sensor). Turn starting switch ON.
2 ISthere
N
1 I 1I
continuitv CN86 between and (female)(2) chassisground?
IDoes
1,
2)
c
1
3)
T-adapter Connect tc (or socket adapter) (female). CN86 Turn starting switch OFF.
ENGINE EVEN WHEN AND IS STOPPED, IN MACHINE, IS NO ABNORMALITY (ENGINE OIL LEVEL) FLASHES.
THERE $)
q
q
After inspection, repair (clean) or replace
in wiring harnes Disconnection (femaleI(2) CN86 between (2) - fuel cut solenoid CN163 (12) - chassis grow - CN97
After inspection. repair (clean1 or replace
Defective
engine
Defective STARTING
CHECKS module
oil level sew,
Replace
BEFORE
Replace
goout?t
short sockel Connect adaDter to CN96 oil (female)kangine level sensorl. Turn starting switch ON.
2 Is there continuity CN96 between and (famale)(2) chassis ground?
NE
1)
Connect T-adapter (or socket adapter)
2)
?~r?l”,t!~~~$&h
3)
(female). to T-adapter Connect CNP3 (female). Turn starting switch OFF.
Troubleshooting tools
Tester T-adapter
After inspection, repair (clean) or replace
in wiring 3isconnection contact or defective ,arness, (female)(2) CN96 x?tween - fuel cut (femaleI(2) 3N163 (12) solenoid - CN97 :hassis ground
After inspection, repair (clean) or replace
to &NO
c
Short (for DLI)
in wiring Disconnection harness, or defective &tact (female)(l) CN96 between (1) - CNP. (5) - CN62 CN97 (female)(3)
-
OFF
82-60 0
in wiring Disconnection contact harness, or defective (female)(l) CN86 between (1 1) - CNP4 (female)C CN64
I
2)
M-2.
2)
’
(female). T-adapter Connect to (or socket adapted CNP4 (female). Turn starting switch OFF.
socket
T-adapter
adapter
or socket
adapter
(for Econoseal)
WA350-1
M-l ,M-2
TROUBLESHOOTING
CN86
CN96
2
1
CNP3
CNP4
4
8
8
4
WA350-1
82-61 0
M-3,M-4
TROUBLESHOOTING
M-3.
*
EVEN WHEN MACHINE, 0 /_
When
disconnecting
disconnecting *
When
or
connecting
the connector
connecting
* When after
ENGINE IS (COOLANT
checking,
the
for checking,
the T-adapter
disconnecting
STOPPED, AND LEVEL) FLASHES.
(or socket
connectors
T-adapter
(or
socket
turn the starting adapter),
or connecting
THERE
adapter)
switch
connect
T-adapters,
IS
them
ABNORMALITY
or short
OFF to prevent
to the connector return
NO
socket
IN
adapter,
or when
accidents.
specified.
to the original
(1)
(CNxx
condition
immediately
then go to the next check.
Cause
Defective ieneor
radntor
Defective jTARTlNG
CHECKS module
Remedy
water
level
YES
Replace
BEFORE
VI
~~7
21
adapter to CN107 Ifemalel~Radiator water level sensor). Turn starting swtch ON.
2) 3)
Iisconnectlon In wiring urness. or defective contact ,etween CN107 (female)(l) 3N106 (1) - CN62 (21 3NP3 (femalel(5)
(female). Connect T-adapter to CNP3 (female). Turn starting switch OFF.
After inspection. repar (clean1 or -
WPlXX
Is there continuity between CN 107 chassis
ground,
1) Connect T-adapter Ior socket adapter1 tc CN107 (femaleI, 21 Turn starting watch OFF. Xsconnection in wiring nmess. or defective contact ,etween CN107 (female) (21 ZN106 (21 - chassis ground
After inspection, repair (clean) or replace
*
defective
Replace
c
IIsconnection in wiring larness, or defective contact Ietween alternator terminal R CN97 (Ii - CN64 11) :NP5 (1)
c
Iefectwe
M-4.
w
(BATTERY
CHARGE)
FLASHES.
YES CAUTION
module
1
2 ISvoltage YES
1 Is voltage et alternator termlIla 20 - 3ov7
R _
1) Turn start,ng ewltch ON. Start engine. 2) Measure voltaoe between alter&tor termne R and chassis ground.
between CNP5 (female) and chassis ground 20 3OV?
1 i Disconnect connector CNP5. 2)
NO Connect T-adapter to
3)
CNP5 (female). To?; starting swtch
NO
Troubleshooting tools
82-62
Tester
Short
T-adapter
T-adapter or socket (for Econosealj
(for DLI)
socket
After Inspect,on, repar (clean1 or replace
alternatol
adapter adapter
WA350-1
M-3,M-4
TROUBLESHOOTING
CN107
2’
\
1
1
2
CNP3
CNP5
WA350-1
82-63 0
M-5,M-6
TROUBLESHOOTING
M-5.
sr
m
(FUEL
I_
When
disconnecting
disconnecting
* *
LEVEL)
or connecting
the connector
When
connecting
When
disconnecting
after checking,
FLASHES. the
for checking,
the T-adapter
T-adapter
(or socket
turn the starting
(or socket adapter),
connectors
or connecting
connect
T-adapters,
adapter)
or short
switch OFF to prevent to the connector return
them
socket
adapter,
specified.
to the original
( ))
(CNxx
condition
jee M-30 gauge”.
-
Does fuel gauge display show EMPTY?
Turn starting switch ON.
immediately
then go to the next check.
Remedy
Cause
1)
or when
accidents.
YES
I
Does 101
goout?
“Abnormality
Defective CAUTION
1
in fuel
module 1
&place
Defective gauge module
Gaplace
Iisconnection in wiring lames% or defective contact xtween CNP2 (femalej(3) and :NP5 (female)(6)
lfter inspection, xpalr (clean) or eplace
Defective CAUTION
?eplace
I Interchange CAUTION modules 1 and 2. Turn starting switch ON.
, ~~.
2)
M-6.
CNP5 (female). Turn starting switch OFF.
ENGINE IS STOPPED, EV ‘EN WHEN IN MACHINE, IS NO ABNORMALITY IN BRAKE LINE) FLASHES.
AND THERE (a) (FAILUREYE: 1 r
module 1
4 Is there continuity between CNP8 (femalel(1 1) and chassis ground?
YES
3p Is there continuity between CN87 (female)(2) and chaws ground?
YES 2 -
Is there
continuity between CN87 hale)(l) and (2)7
2)
1 Connect T-adapter (or socket adapter) tc CN87 (male). !I Turn starting switch OFF.
2)
11 Connect II
Is there continuity between CN88 (male)ll) and l2)?
1 1)
3)
short socket adapter to CN88 (female). Connect T-adapter (or socket adapter) to CN87 (female). Turn starting switch OFF.
Connect T-adapter to CNP8 (female). Turn starting switch OFF. c N(
)isconnection in wiring Iarness, or defective contact letween CN87 (female)(l) :N64 (12) - CNP8 female)il 1)
After inspection, repair (clean) or replace
Disconnection in wiring harness, or defective contact between CN87 (female) 121 CN88 (female)(l), or CN88 (female)(21 - chassis graounc
After inspection, repair l&an1 or replace
Defective %?“SW
brake line failure 1
Replace
Defective Se”SOr
brake I~ne failure 2
-
(or socket adapter) tl CN88 (malel. Turn starting switch OFF.
. NO
c 3
Troubleshooting tools
82-64 0
Tester
Short socket adapter
T-adapter
T-adapter or socket adapter (for Econoseal)
(for DLI)
WA350-1
TROUBLESHOOTING
M-5,M-6
CN87
CN88
1
1
CNP5
CNP8
11 \
WA350-1
82-65
M-7,M-8
TROUBLESHOOTING
M-7.
EVEN WHEN MACHINE, + I
* When
ENGINE (ENGINE
disconnecting
disconnecting
IS STOPPED, AND THERE OIL PRESSURE) FLASHES.
or connecting
the connector
the
for checking,
T-adapter
(or socket
turn the starting
IS
adapter)
to the original
condition
immediately
after
checking,
ABNORMALITY
or short
switch OFF to prevent
* When connecting the T-adapter (or socket adapter), connect to the connector * When disconnecting connectors or connecting T-adapters, return them
NO
socket
adapter,
or when
accidents.
specified.
(1)
(CNxx
Cause
then go to
IN
Remedy
the next check.
_ I3efective
engine oil pressure
sensor
YES
IDefective
31
CAUTION
module
2
I3isconnection I” wring I?arness, or defective contact
I)
21 31
lfeniale)(engine oil pressure sensor). Turn starting switch ON. Start engine.
_
!I
2
3)
Is there
continuity between CN163 (femalel(2) and chassis ground?
NO
I~etweenCN163 (femaleI ! ,SN97 (81 - CN64 (6) ,Ifemale) (2)
Connect short socket adapter to CN163 (engine oil preessure sensor). Connect T-adapter to CNP7 (female). Turn starting switch OFF.
CNP7
After inspection, repair (clean1 or replace
---I 1)
Connect T-adapter (or socket adapter) tc CN163 (female). Turn starting switch OFF. (Engine stopped)
2)
C)isconnection
in vwring lames% or defective contact letween CN163 (female1121 f uel cut solenoid - CN97 I1 2) - chassis ground
0
Note:
: see M-22 “Even when engine _ i,s stopped, engine oil pressure amp or battery charge lamp (;lashes”.
If flashes when the engine is stopped, is defective.
q
M-8.
EVEN WHEN ENGINE IS STOPPED, AND IS NO ABNORMALITY IN MACHINE, (COOLANT LEVEL) FLASHES.
After inspection, repair (clean) or replace
After inspection, repair (clean) or replace
THERE 0 sl 3efective
coolant
Defective
CAUTION
level sensor
Replace
2 module
Replace
Does
I
I
1)
Connect short sockel adapter to radiator water level sensor CN107 (female). 2) Turn starting switch ON. 31 Start engine.
Is there continuity between CNP7 (femaMl2) and chassis ground?
YES
2
NO
-
Is there contwity between CN107 (femalej(2) and chassis ground?
-
11 Connect
2)
3)
Troubleshooting tools
82-66 0
Disconnect short 31 socket adapter to CN107. Connect T-adapter 1 (or socket adapter) to NO CN107 (female). Turn starting switch OFF.
(female). Connect T-adapter to CNP7 (female). Turn starting switch OFF.
i
IO
Short socket
Tester T-adapter
short socket
adapter to ~107
2)
1)
-
(for DLII
c
Defective contact, or disconnection in wiring harness between CN107 (female)(l) CN106 (1) CN62 (2) CNP7 (female)(6)
*
Defective contact, or disconnection in wiring harness between CN107 (femalel(2) CN106 (2) - chassis ground
-
After inspection, repair (clean) or replace
After inspection, repair (clean) or replace
adapter
T-adapter or socket (for Econoseal)
adapter
WA350-1
M-7,M-8
TROUBLESHOOTING
CNI 07
CN163
i
‘1
1
2
CNP7
WA350- 1
82-67 0
M-9,M-lO,M-11
TROUBLESHOOTING
M-9.
EVEN WHEN ENGINE MACHINE, @+ (DROP n
* When disconnecting
IS STOPPED, AND THERE IN AIR PRESSURE) FLASHES.
or connecting
necting the connector
the T-adapter
for checking,
(or socket
turn the starting
adapter)
IS
NO
ABNORMALITY
or short socket
switch OFF to prevent
adapter,
IN
or when discon-
accidents.
* When connecting the T-adapter (or socket adapter), connect to the connector specified. (CNxx (1) * When disconnecting connectors or connecting T-adapters, return them to the original condition immediately after checking,
then go to the next check.
Cause ke M-31
Remedy
“Abnormality
in air
?eDlace
module 2
k?place
Iressure”.
Does air pressure gauge move to red level?
11 Turn
starting switch
ON.
efective CAUTION
t
II
I~~~
N
1)
2)
M-10.
Connect T-adaoter to CNPZ (female)‘and CNP7 (female). Turn starting Switch OFF.
NO
EVEN WHEN ENGINE IS STOPPED, AND IS NO ABNORMALITY IN MACHINE, (COOLANT TEMPERATURE) FLASHES.
*
‘efective gauge module
kzplace
~lsconnection in wiring arness, or defectwe contact etween CNP2 (fern&)(71 and :NP7 (female)(3)
\fter inspection, .epair (clean) or splace
THERE m
;ee M-32 “Abnormality &ant temoerature”.
lefective CAUTION
kfective 1)
2)
Interchange CAUTION modules 1 and 2. Turn starting watch ON. 1)
21
Troubleshooting tools
826% 0
Connect T-adapter to CNP2 (female) and CNP7 (female). Turn starting switch OFF.
in
module 2
gauge module
Iisconnectwn in wiring Iarness, or defective contact CNP2 lfemale)(2) ant :NP7 ifemale)(7)
etween
Replace
qeplace
Redace
After inspection, repar Wan) or replace
Tester T-adapter
(for ‘Xl)
WA350-1
M-9,M-lO,M-11
TROUBLESHOOTING
M-11.
* When
EVEN WHEN ENGINE IS STOPPED, MACHINE, , (TORQUE CONVERTER i%fJ disconnecting
disconnecting
or connecting
the connector
the
for checking,
T-adapter
AND OIL
THERE
(or socket
turn the starting
IS
adapter)
to the original
condition
immediately
after checking,
ABNORMALITY
IN
FLASHES.
or short
switch OFF to prevent
+ When connecting the T-adapter (or socket adapter), connect to the connector * When disconnecting connectors or connecting T-adapters, return them
NO
TEMPERATURE)
socket
adapter,
specified.
(1)
(CNxx
Cause
then go to
or when
accidents.
Remedy
the next check.
See M-33 “Abnormality torque converter oil temperature gauge”.
in Replace
.. /ES
converter 011 temperature gauge move to red level? 1)
Turn starting
swtch
NO 4
1)
Does
q
b
Defective
CAUTION
Defective
gauge
module
2
Replace
go out?
Interchange CAUTION modules
module
1
11
21
Connect T-adapter (or socket adapter) to CNP2 (female) and CNP7 (female). ‘0”;~” starting swtch
Dlsconnectlon in wiring harness. or defective COntaCt between CNPP (femal418) ant CNP7 ifemaleI(5)
After Inspection. repair (clean) or replace
CNP2
CNP7
5
7
3
WA350-1
82-6 9
TROUBLESHOOTING
M-12.
w
When
M-12
(PARKING disconnecting
disconnecting
BRAKE) or connecting
the connector
When
connecting
When
disconnecting
after checking,
LIGHTS the
for checking,
the T-adapter
UP ABNORMALLY,
T-adapter
(or socket
turn the starting
(or socket adapter),
connectors
or connecting
adapter)
switch
connect
T-adapters,
OR DOES or short
OFF to prevent
to the connector return
them
NOT
LIGHT
socket
adapter,
or when
accidents.
specified.
to the original
(CNxx 0) condition
immediately
then go to the next check. Remedy
Cause
M
UP.
does not go out. ”
I Connect short sockei adapter to CN36 (female)(parki”g brake sensor). Turn starting switch ON.
I )
.)
when parkIng brake switch is turned to I 1)
Is there contlnulty between CNPB lfemale)(Zl and chaws ground?
YES 3 Is there continuity between CN36 (femalel(2) and chassis ground?
i
r
1)
2)
Replace
Defective
CAUTION
Replace
-
Connect T-adapter (or socket adapter) to CN36 (female) (parking brake sensor). Turn starting switch OFF.
*
Disconnection in wiring harness. or defective contact between CN36 (female)(l CN38 (4) - CNP8 lfemale112)
After inspection, .epair (clean) or .eplace
Disconnection I” wring harness, or defective contact between CN36 (female)W and chassis ground
After inspection, repair (clean) or replace
I-
See troubleshooting machine.
‘;‘z
Does
q
light up)
YES
_
3Is there
DoA%oo”t
when parklng brake switch IS turned to ON? PI,”
_ 1)
c
2)
connectorCN36. NO Turn starting switch ON.
starting switch
continuity between CNP8 (femalel(2) and chassis ground?
1) 21 31
Tester T-adapter
82-70 a
After inspection. repair (clean) or replace
parking brake sensor
Short circuit between chassis ground and wiring harness between CN36 (female)(l) CN38 (4) - CNPB (femalel(2)
After inspection, repair (clean) or replace
Defective
Replace
-
Connect T-adapter to CNP8 (female). NO Disconnect CN36. Turn starting switch OFF.
+
CAUTION
See troubleshooting machine
Troubleshooting to015
for
not light up. Defective
)
module 2
-
* 1) Connect short connectorto CN36 No lfemalellparklng brake sensor). 2) Connect T-adapter to CNP8 (female).
NO
q does
parklng brake sensor
YES
4,
Turn starting switch ON.
b)
Defective
module
for
Replace
Short socket adapter (for DLI)
T-adapter or socket adapter (for Econoseall
NA350-1
M-12
TROUBLESHOOTING
CN36
CNP8
2 \
2
WA350-1
82-71 a
TROUBLESHOOTING
M-13.
M-13
1,,Q 1 (WORKING
* When
disconnecting
disconnecting
LAMP)
LIGHTS
or connecting
the connector
the
for checking,
UP ABNORMALLY,
T-adapter
(or socket
turn the starting
OR DOES
adapter)
or short
switch OFF to prevent
NOT socket
LIGHT adapter,
UP. or when
accidents.
t When connecting the T-adapter (or socket adapter), connect to the connector specified. (CNxx ()I * When disconnecting connectors or connecting T-adapters, return them to the original condition immediately after checking, Note:
a)
then go to the next check.
Is all working contact
or
working
lamp,
lamp
bulbs
are broken,
a disconnection
q (working
q does not go out.
in the
or there wiring
is defective
harness
of
the
Cause
lamp) will stay on.
YES
Remedy
Contact between +24V terminal and working lamp switch assembly lCNl2 (2)) CN40 (female)(l
After fnspectlon. repair (clean) or
c
Defective
working
lamp swtch
Replace
*
Defective
CAUTION
module 2
ReplaCe
c
Disconnection in wiring harness, or defective contact between CNP8 ifemale) and CN40 (female)(5)
c
I
E&Ce
IScontinuity between CN12 (male)lll and (2) as shown in table?
2) 1) 2)
3)
Disconnect CN40. Turn starting switch ON.
NO
Turn starting switch OFF. Operate working lamp switch.
3
h
Is there continuity between CNP8 (female) I1 0) and CN40 (female)15)?
r
1) 2)
b)
q
d
YES
Connect T-adapter to NO CNP8 (female). Turn startina switch OFF. 4
oes not light up.
Y
CN40 (male)(l) and chassis ground 20 2)
YES , Is voltage between CN60 (male)(l) and chassis ground 20 3OV? 1)
_
Connect T-adapter Ior socket adapter) to CN60 (male). Turn startina switch ON. -
Is continuity between CN12 (male)(l) and (2) as shown I” table?
1I 2) 3)
11
~isc~ynectCN12
2)
T:rn starting switch OFF. Turn working lamp switch OFF - ON.
3)
.
Disconnect CN40 (female). Turn starting switch ON. Turn working lamp switch ON.
3)
Turn starting swatch ON. Turn working lamp switch ON.
IL
I Working
82-72 0
Defective
CAUTION
module 2
Disconnection in wiring harness, or defective contact between CN40 imale) I1 CN40 (5) - CNP (81 Ifemale)
After inspection, repair (clean) or
Iisconnection in winng ?arness, or defective contact ,etween CN60 (female)(l) fuse - CN60 (2) - CN12 :N40 (female)(l)
After inspection. repair (clean) or replace
Iefectlve
Qpkace
1-
working
lamp switch
Xxonnection in wlnng ,amess. or defective contact 3etween main breaker and 3N60 imale)
NO Table
CN12 connector (1) - (2)
YE
Continuity
After inspection. repair (clean) or replace
replaCe
After Inspection. repair (clean) or replace
lamp switch
No cont,nuty
Troubleshooting tools
Tester T-adapter
(for DLII
T-adapter or socket adapter (for Econoseall
WA350-1
TROUBLESHOOTING
M-13
CN12
2 \
CN40
CN60
CNP8
WA350-1
82-73 0
M-14
TROUBLESHOOTING
~-14. *
153-v/ (PREHEAT)
When
disconnecting
disconnecting *
When
a)
or connecting
the connector
connecting
* When
checking,
q
lights up.
up the
for checking,
the T-adapter
disconnecting
after
LIGHTS
(or socket
connectors
ABNORMALLY. T-adapter
(or socket
turn the starting adapter),
or connecting
adapter)
switch
connect
T-adapters,
to the connector return
them
1) Turn starting ON.
less
Note:
2)
I Connect T-adapter t, CNP8 (female). Turn starting switch OFF.
JO
switch
b) @does
socket
adapter,
or when
accidents.
specified.
to the original
()I
(CNxx
condition
Cause
1 1)
intake air
chassis ground
short
immediately
then go to the next check.
YES
electrical
or
OFF to prevent
Remedy
*
Iefectwe
c
Diconnectlo” I” wiring harness DTdefectwe contact between electrical Intake a~ heater heater relay terrmnal - CN97 (9) - CN64 (7) - CNP8 lfemale)(3)
ifter Inspection. epar (clean) or ep1ace
2efectwe heater
7erhce
CAUTION
electrical
module
Wake
2
air
7eplace
not light up. If the engine preheating
oil pressure
and battery
charge
are abnormal,
the
will not work.
1
Contact between +24V terminal and electrical Intake a~ heater (+I - CN97 (9) CN64 17) - CN98 lfemale)(3)
4fter inspection, repair (clean) or reLIace.
Defective
Replace
ISthere
continuity between CNP8 (femalej(3) and chassis ground? 1)
2)
_
Disconnect elect”cal intakeair heater (+) terminal. Connect T-adapter to CNP8 (female).
Troubleshooting tools
NO
module
2
’ Tester T-adapter
82-74 0
CAUTION
(for DLli
T-adapter
or socket
adapter
(for Econoseali
WA350-1
TROUBLESHOOTING
ELECTRICAL HEATER
AIR
M-14
INTAKE
HEATER
RELAY
CNP8
WA350-1
82-75 0
M-15
TROUBLESHOOTING
M-15.
(FAILURE iU-’ LIGHT UP&F
IN MAIN EQUIPPED)
disconnecting
or connecting
* When
disconnecting
the connector
STEERING)
the
for checking,
T-adapter
LIGHTS
(or socket
turn the starting
UP
ABNORMALLY,
adapter)
or short
switch OFF to prevent
OR
socket
DOES
adapter,
NOT
or when
accidents.
* When connecting the T-adapter (or socket adapter), connect to the connector specified. (CNxx (1) * When disconnecting connectors or connecting T-adapters, return them to the original condition immediately after checking,
then go to the next check.
Remedy
Cause a) w
(failure in main steering) lights up.
YES
1) 2)
Connect short sockei adapter to CN200 (femalel(main steering sensor). Turn starting switch ON.
2)
3)
Connect short socket adapter to CN200 (female). Turn starting switch OFF.
main steering
Defective
CAUTION
failure
module
teplace
1
Iisconnection in wiring wness. or defective contact xtween CN200 (femalell2i ZN150 (connector) - CN45 female)(l) CN45 femalej(2) - CNP6 female)(2), or defective diode ZN45 (male)
ifter Inspection, epair or replace
Iisconnection in vwng wness. or defective contact >etween CN200 (female)121 gnd chassis ground
rfter Inspection, epair (clean) or eplace
-
Is there continuity between CN200
1)
Defective sensor
Connect T-adapter (or socket adapted t( CN200 (female). Turn starting swtch OFF.
2)
NO c
b) w
(failure in main steering) does not light up.
YES
Defective sensor
I-
Does ZT I
light up?
YES
-
D
2 Isthere
1)
2)
Disconnect CN200 (female)(main NE steering sensor). Turn starting switch ON. I)
continuity between CNP6 (femaleI(2) and chassis ground?
2)
TroubleshootIng tools
82-76 a
_
steering
failure
Short circuit between chassis ground and CN200 (female)(l - CN150 (connector) CN45 (1). (2) - CNP6 (fern&)(21
?eplace
After inspection, repair (clean) or replace
-
Connect T-adapter to NO CNP6 (female). Turn start!“g switch OFF.
Defective
Tester
Short
T-adapter
T-adapter or socket (for Econoseal)
(for DLli
ma,”
socket
CAUTION
module
1
Replace
adapter adapter
WA350-1
TROUBLESHOOTING
M-15
CNP6
WA350-1
82-77 0
M-16
TROUBLESHOOTING
M-16.
* When
-LJ- (EMERGENCY STEERING cl NOT LIGHT UP. (IF EQUIPPED) disconnecting
disconnecting
or connecting
the connector
the
for checking,
NORMAL)
T-adapter
LIGHTS
(or socket
turn the starting
switch
UP ABNORMALLY,
adapter)
or short
OFF to prevent
socket
OR DOES
adapter,
or when
accidents.
* When connecting the T-adapter (or socket adapter), connect to the connector specified. (CNxx (1) * When disconnecting connectors or connecting T-adapters, return them to the original condition immediately after checking,
a)
q
then go to the next check.
(emergency
steering
normal)
lights
up.
Cause
YES
1
YF
1) 2)
3)
Disconnect CN201 and CN202. Connect CN201 (female) and CN202 lmalel. Turn starting switch ON. ’ Is there continuity CN202 (male connector) chassis ground?
2)
Connec?CNPOl ~rn$ly, and CN202
31
T?n starting OFF.
switch
Remedy
imergency steering ;ensordefective
NORMAL
Iefectlve
module
CAUTION
1
Disconnection in wiring harness, or defective contact between chassis ground CN202 (male) - CN201 (female) - CN149 connector - CNP6 lfemalel(3)
4fter inspection. -epair (clean) or
Disconnection in wnng harness, or defective contact between CN202 (male) connector and chassis ground
4fter inspection, ,epair (clean) or .eolace
Emergency steering sensordefectlve
After inspection. repair (clean) or reDlace
~~Pl~C~
i between )
and
t1)
b) w
(emergency
Turn starting OFF.
switch
steering
normal)
does not light up.
YES
I
-
II
YES
I 1I 2) 3)
Troubleshooting tools
82-78 0
c
0
NORMAL
Contact between chassis ground and CN201 (female1 CN149 (connector) - CNP6 (female1 (3)
After inspection. repair (clean1 or replace
I Connect T-adapter to CNP6 (female). Disconnect sensor connector CN20 1. Tun starting switch OFF.
NO c
Defective
CAUTION
module
1
Replace
Tester T-adapter
(for DLI)
T-adapter or socket (for Econoseal)
adapter
WA350-1
TROUBLESHOOTING
M-16
CNP6
WA350-1
82-79 a
TROUBLESHOOTING
M-17.
18 (TRANSMISSION LIGHT UP.
* When
disconnecting
disconnecting
sr *
M-17
or connecting
the connector
When
connecting
When
disconnecting
after checking,
CUT-OFF) the
for checking,
the T-adapter
LIGHTS
T-adapter
(or socket
turn the starting
(or socket adapter),
connectors
or connecting
UP ABNORMALLY,
connect
T-adapters,
adapter)
or short
switch OFF to prevent to the connector return them
OR DOES socket
adapter,
NOT or when
accidents.
specified.
(CNxx
to the original
())
condition
immediately
then go to the next check.
Cause
Remedy
a) 181 lights up. ‘fective transmission ritch
IES
1 1I 2)
1)
Short-circuit CN18 (female)(3) and (41. Turn starting swtch ON.
21 3)
NO
*
!fective CHECKS -ARTING module
BEFORE
c
sconnection in wiring ~mess, or defective contact tween CN18 lfemalel(3) and 1P4 (fernale)
ter inspection, xair (clean1 or )lace
sconnection in wiring wness, or defective contact ?tween CN18 (femaleI(4) and lassis ground
fter inspection. pair (clean) or place
Is there continuity between CNP4 (femaleIll 01 and chassisground? Transmission cut-off switch ON. Connect T-adapter to CNP4 (female). Turn starting switch OFF.
NO
--1
Is there continuity between CN18 (m&)(4) and chassis ground?
1
Turn starting OFF.
b) m
cut-off
switch
does not light up. efectwe Nitch
YES
transmission
cut-off
eplace
1 YES
1) 2)
Disconnect CN18. Turn starting switch ON.
. 1) 21
Troubleshooting tools
82-80 0
Is there contwity between CNP4 (fernale) and chassis ground?
4
:ontact between chassis round and CNlB (female)(3) - CNP4 (femaleI
Prfter inspection, napair (clean) or naplace
)efectwe CHECKS ;TARTING module
FIeplace
-
Connect T-adapter to CNP4 (female). Turn starting swtch ON.
NO
.
BEFORE
Tester T-adapter
(for DLI)
T-adapter or socket (for Econoseal)
adapter
WA350- 1
M-17
TROUBLESHOOTING
CN18
fzI
4
4
CNP8
10
WA350-1
82-8 1 0
M-18
TROUBLESHOOTING
M-18.
TURN LIGHT
SIGNAL UP.
LAMPS,
HIGH
BEAM
LIGHT
UP
ABNORMALLY,
OR
DO
NOT
* 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. * When connecting the T-adapter (or socket adapter), connect to the connector specified. (CNxx (1) * When disconnecting connectors or connecting T-adapters, return them to the original condition immediately after checking, then go to the next check.
3)
Remedy
Cause
a) Pilot display of turn signal lamp (right) lights up.
ontact between +24V line ?d wiring harness between NPlO (femaleI(3) and CN15 nale) (3)
After inspection, repair (clean) or replace
efective
Replace
speedometer
module
Turn turn signal switch OFF.
b) Pilot display of turn signal lamp (left) lights up. YES
*
I
2) 3)
Turn starting switch ON. Turn turn slgnal switch OFF.
C)
ontact between +24V line ?d wiring harness between NPlO (female111 1) and CN15 nale)(6)
fter inspection, ipair (clean) or !place
efective
speedometer
module
eplace
efectlve
speedometer
module
NO
Pilot display of turn signal lamp {right) does not light up.
CNPlO Ifemale) (3) and chassis ground
Dofront slgnal
and rear turn lamps work
:onnect T-adapter :NPlO (female).
to *
NO I Operate right turn signal lamp.
I
efective contact, or isconnection in wiring harness etween CNPlO (female)(3) nd CN15 (male)(3)
Iefective
turn slgnal
cfter inspection, ?pair (clean) or splace
Replace
NO
Troubleshooting tools
Tester T-adapter
82-82 0
(for DLI)
T-adapter or socket (for Econoseal)
adapter
WA350-1
M-18
TROUBLESHOOTING
d) Pilot display
of turn signal
lamp (left)
does not light up. Cause
YES
Remedy
C
Defective
-
Defective contact. or disconnection in wiring harness between CNPlO (female)(l and CN15 (malel(6)
After inspection, repair (clean) or reolace
Defective
Replace
speedometer
module
Replace
2 Isresistance between CNPlO (female)(3) and chassis ground less than 5I1.
YES
1-
I)
Do front and rear turn signal lamps work _normally?
I
-
Connect T-adapter CNP~O (female).
to NO
1)
Operate left turn signal lamp.
Troubleshooting
turn signal
Tester
tools T-adapter
(for DLI)
T-adapter or socket (for Econoseall
adapter
CN15
CNPlO
WA350-1
82-83 0
M-18
TROUBLESHOOTING
e) HIGH
BEAM
pilot lamp does not light up. Cause
Remedy
ISvoltage
between CNPlO (female)(4) and chassisground 20 - 3OV?
YES
1-
Do both left and right head lamps light up7
11 Connect T-adapter to CNPlO (female) 21 Turn starting switch
-
1) 2h.nmrmg sW,tch 2)
3)
iurn combination switch to head lamp posltlon. Turn dimmer switch to LOW BEAM.
3)
f)
HIGH
-
NO c
%” comblnatio” switch to head lamp position Turn dimmer switch to HIGH BEAM
41
Defective contact. or disconnectw” I” wiring harries: between CNPl 0 (female)(4) and CN39 (female) (1)
r\fter inspection, ‘epalr (clean) or
Bulbs broken I” both head lamps (low beam lamps) (If the low beam bulb 1s broken, the pilot lamp wll not light up eve” If the switch IS turned to HIGH BEAM.)
4fter inspection, .epair (clean) or
-
BEAM
speedometer
module
YES
DO both left and right head lamps light up?
3)
WlCaCe
pilot lamp does not go out.
Defectwe
2)
TPkKX
*
Turn combination switch to head lamp positlon. Turn dimmer switch to LOW BEAM.
Iefect1ve contact. or %sco”nection in wiring harness xtwee” CN15 (fern&)(91 and dimmer switch
Sfter inspection. ,epair (clean) or zplcace
2 YES Does head lamp light “patHIGHBEAM?
NC
1) 2)
Turn starting switch _ NO ON. Turn comblnatlon sbwtcn
3)
Troubleshooting tools
to
Ilea3
Is there cont,“u,ty between CN15 (m&)(1 2) and chaws ground?
Defective contact. or disconnection in wiring harries! between CN15 (fern&)(1 2) and dimmer switch
After Inspection,
Defectwe contact, or disconnection in wring between CN15 (m&)(1 chassis ground
After inspection. repair (clean) or replcace
repair (clean) or WplC.%X
lamp
posltio”. Turn drnmer swtch to HIGH BEAM
1) Connect
T-adapter
harries! 2) and
Tester T-adapter
82-84 0
-
(for DLI)
T-adapter or socket (for Econoseai)
adapter
WA350-1
TROUBLESHOOTING
M-18
DIMMER SWITCH COMBINATION SWITCH
CNPlO
WA350-1
82-85 0
M-19
TROUBLESHOOTING
M-19. * When
DISPLAY
SPEEDOMETER disconnecting
or connecting
the connector
disconnecting
DOES the
for checking,
NOT
T-adapter
WORK (or socket
turn the starting
NORMALLY. adapter)
or short
switch OFF to prevent
socket
adapter,
or when
accidents.
* When connecting the T-adapter (or socket adapter), connect to the connector specified. (CNxx (1) t When disconnecting connectors or connecting T-adapters, return them to the original condition immediately then go to the next check.
after checking,
Cause
Remedy
lefective
speedometer
module
FIeplace
lefectwe
speed sensor
mount
Frdjust
YI
of the speed sensor, and turn the sensor If it clockwise. contacts the gear within one turn, the gap is within 1.5 mm.
Is resistance between CNPIO (fernale) 3OOQ y;di;’
h
YES -
1)
tc Connect T-adapter CNPlO (female). Turn starting switch OFF.
i
in wring lisconnection lamess. or defective contact letween CNPlO - CN22 female)~10l,~21 3).(4) - CN83 (female)(ll,(2)
N’
Is resistance
between and CN83 (male)(l) (2) 3OOa - 1 kfl?
lefective
Troubleshooting tools
82-86 0
L\fter inspection, r epair (clean) or r eplace
speed sensor
Tester T-adapter
(for DLI)
or socket T-adapter (for Econoseal)
adapter
WA350-1
TROUBLESHOOTING
M-19
CN83
2
11
2
CNPIO
WA350-1
82-87 0
M-20
TROUBLESHOOTING
M-20.
t
SERVICEMETER
When
disconnecting
disconnecting
DOES
NOT
or connecting
the connector
the
for checking,
WORK
NORMALLY.
T-adapter
(or socket
turn the starting
adapter)
or short
switch OFF to prevent
socket
adapter,
or when
accidents.
* When connecting the T-adapter (or socket adapter), connect to the connector specified. (CNxx ()I + When disconnecting connectors or connecting T-adapters, return them to the original condition immediately after checking,
then go to the next check.
Remedy
Cause
Iefective jensor
YES
1 Does servicemeter move, or display lamp flash? 1)
2)
engna
oil pressure
3eplace
ToA
-
Connect short
socket adapter to CN 163 (female)lengine oil pressure sensed. Turn starting switch ON.
between chassis
Isvoltage
between CN43 (female)(l and (4) 20 - 3OV?
-
1)
ISvoltage between CNP9 (female)(l) and (3120 - 3Ov?
2
NO
I
2)
-
1) 2)
CN163
3
YES
ground?
CN163 (female). Turn startrng switch
Connect CNP9 (female). Turn starting switch ON.
.o B
Connect T-adapter (or adapter) to CN43 (female). Turn starting swtch ON.
socket
2)
NO
+
)wonnection ,n wlnng ~arnass. or defective contact Wvveen CN43 (male)(l) and :NP9 (female)(l), 13)
4fter inspection, .epair l&an1 or ‘eplace
r ice M-21 “All or part of nonltor panel does not work iormally”.
3efectlve
between CNP9 (femaleI(4) and chassis ground?
A--c
2) 3)
Disconnection in wiring harness, or defective contact between CN163 (femaleill 1ZN97 18) - CN64 (6) - CNPS [female)(d)
adapter to CN163 (female). Connect T-adapter to CNP9 (female). Turn starting switch OFF.
B-
N
Tester
Short
Troubleshooting tools
service meter module
T-adapter
(for DLI)
socket
T-adapter
vmng
)Isconnection m ?amass, or defective contact )etween CN163 (female)121 3N97 (male)(l2) - chassis around
-
After inspection, repair (clean) or replace
After inspection, repair (clean) or replace
adapter
or socket
adapter
(for Econoseall
82-88
WA350-1
M-20
TROUBLESHOOTING
CN43
4
4
1
I
CNI 63
CNP9
WA350-1
82-89 0
M-21
TROUBLESHOOTING
M-21.
When
ALL OR PART OF MONITOR PANEL DOES NOT WORK IF ANY FUSE IS BROKEN, REPLACE AFTER CHECKING. disconnecting
disconnecting When
connecting
connector When
or connecting
the connector
the T-adapter
specified.
(CNxx
disconnecting
the
for checking, (or socket
T-adapter
(or socket
turn the starting adapter),
adapter)
or short
switch OFF to prevent
connect
socket
adapter,
Cause
connectors
or connecting
immediately
T-adapters,
after checking,
or when
accidents.
to the
(1)
them to the original condition
NORMALLY.
Remedy
return then go to
the next check.
a) None of monitor
panel
works.
ES
YES -
1
Is voltage between CN43 (female)(l) and (4) 20 - 3OV?
I
I
1)
Connect T-adapter (or socket adapter) tg CN41 (female). Turn startbng switch ON.
2)
11 Er4rgctT-adapter ti
I
1
Is voltage between CN41 lfemale)ll) and (2) 20 - 3OV?
11) Connect T-adapter I (or socket adapter) t( > CN43 (female). !I Turn starting swtch ON.
2 1 Turn starting ON.
1
is voltage
t
CN43
between (1) and (4) 20
One of modules defective. (Contact connectors in turn. there is no voltage for any module, check it.)
After Inspection, repair (clean) or replace
If
switch
connectors ICNPl, P4, P6. P8. P9 and 2)
Turn starting ON.
switch
NC
I
Short circuit between CN43 connector (1) and (4) (Power shut off to orotect
After inspection, repair (clean) or replace
Awllaw
Reolace
_I
-_
i ;
After inspection, repair (clean) or
3
Is voltage between CN43 (1) and 14) 20 - 3OV?
;
_
Defective contact or disconnection in wiring harness between CN43 Imale) - all modules (+24). and CN43 (male)/4) - all modules (ground connection)
N
YES
controller
defective
DIsconnection in wlrlng harness. or defective contact between CN41 - (female)(l) - CN60 (6) - fuse - C~60 (5) - fuse - main breaker,
After inspection. repair (clean) or replace
Disconnection in wiring harness, or defective contact between CN41 (femaleI(21 CN64 (5) - chassis ground
After inspection, repair (clean) or
Dlsconnectlon I” wiring harness between CN43 (female)il and (4)
Replace
One of modules defective (connect connectors one at a time to check)
After inspection. repair (clean) or reolace
Defective contact or disconnection in wiring harness between CN43 (male)(l all modules 24). and CN43 (male)(B) - all modules (ground connection)
After inspection, repaIr (clean) or replace
~~~.:
2)
CN41 (female). Turn starting swtch OFF.
-_
r
Socket adapter
c
YES
YES
t
3 Is there contlnu,ty between CN43 (male)(l) and l4)?
El
1)
, ’ 2) 3)
Table
Disconnect connectors (CNPl, P4, P6. P8, P9 and PlO). Connect socket to CN43 (male). Turn starting switch OFF.
1 between CN43 connector (4) and (1) and all connectors r
1)
Connect to CN43 connector. Connect sockets to CNP connectors. _-_A
I-
1 CNPl
CNP4
CNP6
CNP8
CNP9
CNPlO
- (8)
- (8)
- (8)
-(8)
--13)
-116)
CN43 connector (female)(l)
-
-116)
-116)
-116)
--il)
- (8)
82-90 0
I
(+
I
i-
1
CN43 connector (male) (4)
14)
i
WA350-1
M-21
TROUBLESHOOTING
b) Part of monitor panel does not work.
Cause
Remedy
Defective module
voltage
Is at power source pin of module 20 - 3OV?
1)
-
Connect T-adapter to connector of module ;vich does not light ND p KNP connector) Turn starting switch ON.
2)
Disconnection in wiring harness, or defective contact al power source pin
After inspection. repair (clean) or WpliXe
Table 2 CNPl Power source pin if)
(4)
Power ~ourc.5 pin (-)
(8)
I
Troubleshooting
tools
CNP4
CNP6
CNP8
CNP9
CNPlO
6)
(16)
(16)
(I)
(8)
(8)
(8)
(8)
(3)
(16)
(I
Tester T-adapter
(for DLII
T-adapter or socket adapter (for Econoseal)
CN41
CN43
WA350-1
82-91
M-22,M-23
TROUBLESHOOTING
M-22.
EVEN WHEN 0 (BATTERY
I
When
disconnecting
disconnecting
connecting
When
disconnecting
after checking, (Engine
1I 21
b)
q
the
T-adapter
or connecting
(ENGINE
(or socket
turn the starting
(or socket adapter),
connectors
)a/ -
OIL
adapter)
PRESSURE)
or short
switch OFF to prevent
connect
T-adapters,
to the connector return
them
FLASHES,
socket
adapter,
OR
or when
accidents.
specified.
to the original
(CNxx
(1)
condition
immediately
then go to the next check. flashes,
lamp also lights
1 Remove wring harness of alternatol terminal R. Turn starting switch ON. (Do not start engine.)
STOPPED, FLASHES.
for checking,
the T-adapter
oil pressure)
warning
I
or connecting
the connector
When
& /
ENGINE IS CHARGE)
Is problem removed when modules are Interchanged?
caution
buzzer
sounds
and
Cause
up.
Defective
alternator
Defective
module
Remedy
eplace
tl
1
1
I J Turn starting switch OFF. 1) CHECKS, CAUTION 1 and CAUTION 2 modules are interchangeable, so interchange them. 3) Turn starting switch ON. (Leave terminal R disconnected)
NO
c
Contact between + 24V ermlnal and alternator terminal 1 - CN97 (1) - CN64 (1) :NP3. P5, P7 (1)
fter inspection, qair (clean) or !place
(Battery charge) flashes and warning lamp lights up. )efective sensor
engine oil pressure
Defective
module
leplace
Replace
11 Disconnect 2)
CN163 (engine oil pressure SellsOr). Turn startmg switch ON.
3)
82-92 a
modules are interchangeable, so interchange them. Turn starting swtch ON.
Contact between chaws ground and CN163 (femalelI1 I - CN97 (81 - CN64 (6) CNP3 (21, CNP5 (2). CNP7 (21
After inspection, repair (clean) or replace
NA350- 1
M-22,M-23
TROUBLESHOOTING
MODULE
1, MODULE
2
CN163
M-23.
NO LAMPS ON MONITOR LIGHT UP (IMMEDIATELY SWITCH TO “ON”, ENGINE STOPPED)
AFTER
TURNING
STARTING
* When * *
disconnecting or connecting the (T-adapter or socket adapter) or short connector, or when disconnecting the connector for checking, turn the starting switch OFF to prevent accidents. When connecting the T-adapter (or socket adapter), connect to the connector specified. (CNxx (1) When disconnecting connectors or connecting T-adapters, return them to the original condition immediately after checking, then go to the next check.
Cause a) No lamps on any module light up when starting
switch
is turned
Remedy
ON.
All lamps go out when engine is started. c
b) Lamps
on some
WA350-1
modules
See M-21
and M-22
Defective
module
do not light up.
82-93 0
M-24
TROUBLESHOOTING
M-24.
CENTRAL
When
WARNING
disconnecting
disconnecting
connecting
When
disconnecting
after checking, Monitor
or connecting
the connector
When
LAMP the
for checking,
the T-adapter
DOES
NOT
T-adapter
or connecting
OUT.
(or socket
turn the starting
(or socket adapter),
connectors
GO
connect
T-adapters,
adapter)
or short
switch OFF to prevent to the connector return
them
socket
adapter,
or when
accidents.
specified.
to the original
(CNxx
(1)
condition
immediately
then go to the next check.
displays
no abnormality,
but central
warning
lamp lights
Cause
Remedy
up intermittently.
.
Defective CAUTION
2 module
Defective CAUTION
1 module
eplace
2
Does central warrung
I) 2)
4) 21 31
5)
Turn starting swtch ON. Start engine.
Stop engine. Connect CN43.
Turn starting witch ON. Start engine.
NO
b) Central
warning
lamp lights
1) 2)
Stop engine. Connect CN43.
4)
Turn starting switch ON. Start engine.
5)
2) 3)
in
Turn starting swtch ON. Start engine.
Troubleshooting tools
82-94 0
YES I
Does central warning lamp go out?
;;is3ry”ection
-
Defective CAUTION
2 module
replace
Defective CAUTION
1 module
leplace
Does central warning
1
t
leplace
up continuously.
YES
Y
Defective Auxiliary controller
*
:ontact between chassis ground and wiring harness )etwee” CN42 (male)131 and :N17 (female)(2)
\fter inspection, epair (clean) or eolace
Iefective
?eplace
is there continuity between CN42 (m&e)(3) and chassis
1) 2)
Stop engine. Connect T-adapter (or socket adapter) t( CN42 (male).
auxiliary controller
Tester T-adapter
(for Econoseal)
NA350-1
TROUBLESHOOTING
M-24
CN17
CN42
CN43
CNP7
/*
1
1
'8
WA350-1
82-95
M-25
TROUBLESHOOTING
M-25.
CENTRAL
When
WARNING
disconnecting
disconnecting When
connecting disconnecting
after checking, Monitor
connecting
the connector
When
sounds
or
BUZZER the
for checking,
the T-adapter
(or socket
connectors
DOES T-adapter
NOT (or
STOP. socket
turn the starting adapter),
or connecting
adapter)
switch
connect
T-adapters,
or
to the connector return
short
OFF to prevent them
socket
adapter,
or when
accidents.
specified.
to the original
(CNxx
0)
condition
immediately
then go to the next check.
displays
no abnormality,
but central
warning
buzzer
Remedy
Cause
intermittently.
m
efective
)
Nefectlve auxiliary
.
lefectwe
CAUTION
module
2
leplace
2
leolace
YES
Does central warning
1) 2) 3)
DIsconnection in CN43. Turn starting switch ON. Start engnne.
b) Central
NO
warning
buzzer
sounds
continuously.
YES
I
1) 2) 3)
Dwonnection CN43. Turn starting ON. Start engine.
in
tools
82-96 0
CAUTION
module
:ontact between chassis round and wring harness etween CN42 lmalej(3) and N131 (male)
rfter inspection, epalr (clean) or epiace
switch
(or socket adapted CN42 (male).
Troubleshooting
-
2
NO
I
controller
to NO
.
lefectwe
auxlllary
controller
Tester T-adapter or socket (for Econoseall
adapter
WA350-1
TROUBLESHOOTING
M-25
MODULE 1, MODULE 2
CN42
3
3
D @hiI
ad
c? +[
CN43
WA350-1
82-97 0
M-26
TROUBLESHOOTING
M-26. * When
NONE
OF
disconnecting
disconnecting t
When
* When
PANEL
LAMPS
or connecting
the connector
connecting
the
LIGHT
(or socket
turn the starting
(or socket
connectors
MONITOR
T-adapter
for checking,
the T-adapter
disconnecting
after checking,
ON
adapter),
or connecting
switch
connect
UP.
adapter)
or short
OFF to prevent
to the connector
T-adapters,
return them
socket
adapter,
or when
accidents.
specified.
to the original
(1)
(CNxx
condition
immediately
then go to the next check. Remedy
a) No panel
lamps
combination
light up even when
only small
lamp in
lamp is used. Defective contact or disconnection in wiring harness between CN26 (female)(l) CNPl (femalel(3). CNP4 (female)(l5). CNP6 (femaleIll 51. CNPE (female)(l5); CNPG (female)(2). CNPlO (fern&)(1 5) (in a rare case, all panel lamps may be broken)
.fter inspection, ?pair (clean) or 3place
Disconnection I” wiring harness, or defective contact between CN15 (maleI(8) CN58 (1 1). (12) - CN26 (fe”lale)(2), or defective diode assembly
Gfter inspection, spa? (clean1 or splace
Disconnection in wiring harness. or defective contact between CN15 (female)(4) front lamp and parking lamp switch - CN15 (femalel(8). or defective switch
,fter inspection, spair (clean) or ,place
-
YES
H 1)
Turn combination lamp switch to side IhlPS.
2)
T-adapter
Is voltage
1) Connect
between
T-adapter
2) Turn starting
YES _
NO
2)
1) I
J
IL_-__
4
Is there continuity between T-adapter CN15 (femaM(4) and (8)?
.
(orsocket
w
tc
switch
Is voltage between CN15 (male)(2) and chassis ground 20 -
adapter) to CNI 5 (male). $II starting switch
IO
Check voltage between CN26 (female) wiring harness end (1) and chassis ground with diode assembly still connected.
2)
‘NO
-
Disconnect CN15 (female). Turn starting switch OFF. Combination lamp switch Continuity
1
NO
Sidelamps
1
YES
NO
Socket adapter
2) Operatewmbinationl i lampswtch.
Troubleshooting tools
82-98 0
t
Defective contact of front and parking lamp switch
lamp
t
Disconnection in wiring harness, or defective contact between battery relay output CN59 (1). (21 - CN15 (male)(4)
-
4fter inspection, .epair (clean) or .eplace
r\fter inspection, .epair (clean1 or vplace
1
OFF Table
YES
-
1
To step 3
Defective front lamp and parking lamp switch
)
Tester T-adapter
or socket
adapter
(for DLI)
T-adapter or socket (for Econoseall
adapter
JVA350-1
TROUBLESHOOTING
b) No panel
lamps
M-26
light up even working
lamp is switched
on.
Remedy
. cbefective
contact or clisconnection in wiring harness jetween CN25 (female)(l) : :NPl (female)(3). CNP4 (female)11 51 CNP6 fern&)(1 5). CNP8 Ifemale)(l51, CNP9 (female)(2), CNPlO female)(l5) (in a rare case, all panel lamps rnay be broken)
YES
pijjijg\
YES M Is voltage between CN12 (2) and chassis ground 20 - 3OV?
I
1) t
I)
!) 1)
2)
Connect T-adapter (Or socket adapter) t CN12 (female)(l). Turn starting switch ON.
!I
2)
Connect T-adapter (or socket adapter) t( CNI 2 (female)(2). Turn starting swtch ON. Turn working lamp switch ON.
.fter inspection. spair Mean) or 3place
I Turn working lamp switch ON. Check voltage between CN25 (female) winng harness end (1) and chassis ground with diode assembly still connected.
. I:)Isconnection in wiring tjarness, or defectwe contact petween CN 12 Ifemale) (2) : :N40 (1) - CN40 15) - CNZE (femaleI(2). or defective diode alssemblv
UO
-[ IIsconnectlon in wiring t larness, or defective contact tletween CN12 Imale) -
ifter inspectlon. epair (clean) or eolace
\fter inspection, epair (clean) or eplace
vorking lamp switch - CN12 or defective working Iamp switch
; m&l(2).
uo
- [)Isconnection in wiring larness. or defective contact tMween battery relay output (:N60 (1). (2) - CN12 (female) (I
-
rfter inspection, spair (clean) or eplace
1
Side lamps
YES
OFF
NO
Table 2
WA350-1
82-99 a
M-26
TROUBLESHOOTING
CN12
B
1
CN15
CN25
82-100 0
WA350-1
TROUBLESHOOTING
M-27.
* When
SOME
M-27
OF
disconnecting
disconnecting
PANEL
LAMPS
or connecting
the connector
ON the
MONITOR
T-adapter
for checking,
DO
(or socket
turn the starting
NOT
LIGHT
adapter)
UP.
or short
switch OFF to prevent
socket
adapter,
or when
accidents.
* When connecting the T-adapter (or socket adapter). connect to the connector specified. (CNxx ()I + When disconnecting connectors or connecting T-adapters, return them to the original condition immediately after checking,
then go to the next check.
a) Panel lamps of gauge module do not light
up. *
3)
Turn light switch ON.
b) Panel lamps of CHECKS, CAUTION 1 and 2, speedometer 2 YES do not light up. YES
, -
Is voltage between chassis ground and cOnnector pf module which does not light up 20 - 3OV? 1)
2) 3)
-
Islamp bulb broke”?
1)
Connect T-adapter to connector of module w$ch does not light
Remove lamp socket of module and check resistance of small bulb. If it is over 1 OOn. bulb if broken.
lamp
leDlaCe
Defective
gauge module
3eplXe
oleconnectlon I” wmng harness, or defective contact between CN26 Ifemalel(li - 0425 (female)(l) CNPl ifemale)Oi - CNP4 (femaiel(l5) - CNP6 (female)<1 5) - CNP lfemale)ll51 - CNP9 lfemaieiill - CNPlO lfemale)(l51
4fter inspection, ,epair (clean) or ,eplGXe
Defectwe
lamp
%?pl?lCe
Defectwe
module
%SpkG3
Dlsconnectlo” I” wmng harness, defecwe contact between CN26 ifemalelll) - CN25 (female)il) CNPl (femaI413) - CNP4 (temalel~l5l - CNP6 (femaleill - CNP ifemalei~l5l - CNP9 lfemaleli2) - CNPlO (femaleill
w
or -
\fter inspection, epair (clean) or eDlace
5) 51
Co”“ector
CHECKS CAUTION
1
CAUTION
2
1 1
CNP4(15) CNP6 (15)
1 I
CNP8 I1 5)
Speedometer c)
)
,NO,
Module
I I
module
Defective
-
I NO
Turn starting switch ON. Turn light switch ON.
Remedy
Cause
CNPlO(15)
Panel lamps of service meter do not light up. Defectwe
lamp
Defective
service
?eplXe
Is lamp bulb broken?
“+ggijgi INO
Is voltage between CNP9 (femaleI(2) and chassis ground 20 - 3ow 1) 2) 31
Connect T-adapter tc CNP (female. Turn starting switch ON. Turn light swtch ON.
_
IfitisoverlOO~, bulb is broken.
meter
modult
oisconnectlon I” wlrlng harness. or defectwe contact between 0426 ifemalel(ll - CN25 (female)(l CNPl Ifemale - CNPL lfemale)il51 - CNP6 (fern&)(1 51 - CNP lfemal4~15~ - CNPS ifemale)lZl - CNPlO lfemaIe)(l5)
I-
ReplXe
After inspection. repair Iclean) Or replaCe
Tester Troubleshooting to015
82-102 0
T-adapter
lfor DLI)
T-adapter or socket (for Econoseal)
adapter
WA350-1
M-27
TROUBLESHOOTING
MONITOR
PANEL
LAMP
CNPI
CNP9
WA350-1
82- 103 0
M-28
TROUBLESHOOTING
M-28.
EMERGENCY
* When disconnecting necting the connector $r When
connecting
*
disconnecting
When
after checking,
ITEM
IS
FLASHING,
or connecting
the T-adapter
for checking,
the T-adapter
BUT
(or socket
turn the starting
switch
(or socket adapter),
connectors
or connecting
ALARM
BUZZER
adapter)
or short socket
OFF to prevent
connect
T-adapters,
DOES
SOUND.
adapter,
or when discon-
accidents.
to the connector return them
NOT
specified.
to the original
())
(CNxx
condition
immediately
then go to the next check.
Cause
Xefective
Remedy
f3eplace
buzzer
Does voltage between CNl30 Ifemale and CN131 (female) change between ov and 20 -
! I I)
Disconnect CN130, 13 1 (buzzer ‘I connector). Disconnect CN107 (coolant levell. Turn starting swtch ON (Start engine.)
2)
3)
between CN42 (female) (1) and (2) change between OV
1)
2) 3) 4)
Connect T-adapter Ior socket adapted CN42 (female). Disconnect CN107 (coolant levell. Turn starting switch ON. Start engine.
No
Iisconnection in wiring wness, or defective contact retwee” CN42 (male1 (1) IN1 30 (female), or CN42 male)(Z) - CN131 (male)
_.
‘ES
3 i
NO
I
) )
3)
4)
Stop engine. Connect T-adapter (or socket adapted to CN43 (female). Short circuit when CN 43 (female)(l) and (2). Turn starting switch ON.
Defective
module
21
emergency display item CAUTION module and CHECK module. Turn starting switch ON.
Disconnection in wiring harness, or defective contact between CNP7 (femalel(8) ant CN43 (male)(Z)
NO Defective auxiliary controller contact between CN42 (female)(l) and (2) (CN42 (female) (1) and (2) are in contact, so protection device in auxiliary controller is actuated)
voltage,
positions,
can
be checked
and when the power
Replace
I-----+ Is problem removed when modules are replaced?
sound when CN43 (female) (1) and (2) are shortcircuited?
The
I I
I
YES
*
I tfter inspection, epair (clean) or eplace
in parking,
FORWARD
is ON (starting
switch
socket
After inspection, repair (clean) or
i /replace
. I+eplace
01
(repaIr or replace)
and REVERSE at ON).
Tester
Short
T-adapter
T-adapter or socket (for Econoseal)
adapter
Troubleshooting tools
82-104 0
(for DLI)
adapter
1WA350-1
TROUBLESHOOTING
M-28
CN42
CN43
WA350-1
82-105 0
TROUBLESHOOTING
M-29.
* When
M-29
EMERGENCY LAMP DOES disconnecting
disconnecting
ITEM OR NON-EMERGENCY NOT FLASH. or connecting
the connector
the
for checking,
T-adapter
ITEM
(or socket
turn the starting
IS FLASHING,
adapter)
or short
switch OFF to prevent
BUT
socket
WARNING
adapter,
or when
accidents.
* When connecting the T-adapter (or socket adapter), connect to the connector specified. (CNxx (1) * When disconnecting connectors or connecting T-adapters, return them to the original condition immediately after checking,
then go to the next check.
Cause
Iefectw
Juno 3)
Does voltage between CN42 (fern&l(l) and (31 change between OV and 20 - 3OV?
YES
1 Connect T-adapter (or socket ada&) tc CN42 Ifemale). 2) Disconnect CN107 (coolant level). 3) Turn starting switch ON. 4) Start engme.
) 3
NO
r-l
Does warning lamp light up?
:‘, 3)
*
The voltage
lamp
lisconnection in wiring harness, or defective contact etween CN42 (m&)(1 I :N17 (female)(l). or CN43 m&)(3) - CN17 (female)(2)
koolant level) Start engine.
2)
up with other module. Turn starting switch ON.
Stop engine. Connect T-adapter (or socket adapter) to CN43 (female) Short circuit CN43 (female)(l) and (3).
can be checked
is ON (starting
switch
after inspection. apaw (clean1 or &3X
defective module
7eplace
:ontact with chassis ground, c lisconnection in wiring harnas: letween CNP7 (femaleI(4) :NP5 (female)(4) - CNPJ m&)(3)
ifter inspection, epair (clean) or eplace
ruxiliary controller defective 01 ontact between CN42 female)(l) and (3) (CN42 (female)(l) and (3) are in contact, so protection device in auxiliary controller is actuated)
when the power
Remedy
3eplace
.epair or replace)
at
ON).
Troubleshooting tools
82-106 0
Tester T-adapter or socket adapter (for Econoseal)
WA350-1
TROUBLESHOOTING
M-29
CN17
CN42
CN43
3
a
1
CN107
WA350-1
82.107 co
M-30
TROUBLESHOOTING
M-30.
ABNORMALITY
IN m
(FUEL
-
GAUGE)
* 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. * When connecting the T-adapter (or socket adapter), connect to the connector specified. (CNxx (1) * When disconnecting connectors or connecting T-adapters, return them to the original condition immediately after checking, then go to the next check. Cause
Remedy
a) Nothing shown in display area
YES
I
1) Connect short 2)
1
Is there continuity between CNP2 (female)(6) and (12)?
I
sccket adaptertoCN105 (female)(fuel level sensor), Turn starting switch ON.
IOr Socket adapterJ CNP2 Ifemale). Connect short connector to CN105 Ifemale). Turn starting switch OFF.
2)
3)
Defective
fuel level sensor
Ieplace
L
Defective
gauge module
Ieplace
>
Iisconnection in wiring namess, or defective contact between CN105 (female)(2) CN64(4) - CNP2 (femalell61. or CN105 Ifemale) CN64(3) - CNP2 (female) I1 2)
Jfter inspection, epair (clean) or eDlace
Defective
3epkCe
h to NO
-
b) Stays at FULL and does not move.
1 Doesallof
YES
NO
1) 2)
Disconnect CN105 (fuel level sensor). Turn starting switch ON.
1)
I
*
Defective
2
Connect T-adapter to CNP2 (female). Disconnect CN105. Turn starting switch OFF.
T-adapter I
4fter inspection, Ppair (clean) or .eplace
NO
Short
Tester
Troubleshooting
tools
82-108
Contact between chassis ground and wiring harness between CNP2 (femalel(6) CN64 (4) - CN105 Ifemale)l2), CNP2 Ifemale)(l21 CN64 131 - CN105 (female)(l)
Is there continuity between CNP2 (femalel(6) and (12)?
-
2) 3)
I
c
I
display area for fuel gauge
fuel level sensor
socket
gauge
module
adapter
(for DLI) I
I
WA350-1
TROUBLESHOOTING
M-30
CN105
CNP2
6
6
M-30-1. l
ABNORMALITY
If there shown fuel
IN
is a big difference on the monitor
actually
example,
the tank
resistances
The standard
at the
l/2
10?2R
nal 0,
fuel
tank
of (for
display
the sensor and measure
following
three
points
to
value.
values are given as only a guideline.
FULL (top)
Put on probe
the
SENSOR
the fuel level
is full but the monitor
check if they are the standard *
LEVEL
and the amount
in
lamps are all out), remove the
between
display
remaining
FUEL
(horizontal)
EMPTY (bottom)
36250
in contact
and measure
95k
with
Econoseal
the resistance.
1oa
terminal EMPTY (bottom)
423F179A
WA350-1
82-109 0
TROUBLESHOOTING
M-31.
M-31
ABNORMALITY
* When
disconnecting
disconnecting
IN m
(AIR
or connecting
the connector
the
for checking,
PRESSURE T-adapter
GAUGE)
(or socket
turn the starting
adapter)
or short
switch OFF to prevent
socket
adapter,
or when
accidents.
* When connecting the T-adapter (or socket adapter), connect to the connector specified. (CNxx (1) * When disconnecting connectors or connecting T-adapters, return them to the original condition immediately after checking,
then go to the next check.
Cause
Remedy
al Nothing shown in display area
YES NO
1) Connect short connector to CN92 (air pressyre senior) 2) Turn startmg swtch ON.
,
2’
Xfective
air pressure
defective
gauge module
7eplaCe
sensor
Replace
Is there continuity between CNP2 Ifemalej(4) and W7 ,
1)
Connect T-adapter to CNP2 (female). Connect short socket adapter to CN92 (female). Turn starting switch OFF.
2)
3)
NO
4fter inspection, vzpair (clean) or
Iisconnection in wiring wrness, or defective contact between CN92 (female)(l) CN63 (1) - CNP2 (femalel(9). w CN92 (female)(2) - CN62 (101 - CNP2 (female)(4)
-
Wpl.Xe
b) Stays at top level and does not move.
(ES
YES
-
Iefective
w
:ontact between chassis ground and wiring harness xtween CNPP (fern&l@) :N63 (11 - CN92 (female)(l). x contact between chassis yound and wiring harness x!tween CNP2 (femalel(4) EN62 (I 0) - CNg2 (fern&)(2
Does all of display area for air pressure
2
NO
1) 2)
Disconnect CN92 lair pressure sensor). Turn starting switch ON.
Is there .
continuity between CNP2 (female1 (41 and M?
1) 2) 3)
Troubleshooting tools
82-110 0
Connect T-adapter to CNP2 (femaleI. Disconnection CN92. Turn starting switch OFF.
;r
Short
Tester T-adapter
NO
socket
Iefectlve
air pressure
gauge
sensor
module
After inspection, repair Mean) or replaCe
I
ReDlace
adapter
(for DLI)
WA350-‘I
TROUBLESHOOTING
M-31
CN92
CNPP 9,
WA3504
82-i’ ’
M-32
TROUBLESHOOTING
M-32. t
ABNORMALITY
When
disconnecting
disconnecting *
When
* When
IN
after checking,
the
for checking,
the T-adapter
disconnecting
(COOLANT
or connecting
the connector
connecting
w
TEMPERATURE
T-adapter
(or socket adapter),
connectors
(or socket
turn the starting
or connecting
switch
connect
T-adapters,
GAUGE)
adapter)
or short
socket
adapter,
or when
OFF to prevent accidents.
to the connector return them
specified.
to the original
(CNxx
()j
condition
immediately
then go to the next check.
Cause
Remedy
a) Nothing shown in display area YES *
Iefective ia”SClr
c
:ontact with wiring harness ,etween CNl 01 (female)il) :N97 (3) - CN62 (9) - CNP: femaleI and CNlOl femalel(2) - CN97 (2) :N62 (10) - CNP2 (female)V
After inspection. epair (clean) or eplace
c
Iefective
gauge module
qeolace
lefective Z”SW
coolant temperature
Xfective
gauge module
1 DoesCoolant
temperature gauge_
2
display bottom position? 1)
2)
Is there continuity DisconnectCNlOl _ between CNPZ (coolant fiD (female)(d) and IlO)? temperature). Turn starting switch 11 Connect T-adapter to ON. CNP2 (female). 21 Disconnect CNl 01. 3) Turn starting switch OFF. NO
coolant temperature
?eplace
b) Stays at bottom position and does not move.
YES
IDoes all of display area for coolant temperature gauge go out? 1)
2)
YES
_
Connect short socket adaptertoCNlO1 NO (female). Turn starting switch ON.
Is there continuity between CNP2 (femaM(4) and (lo)! 1) 2)
3)
Troubleshooting tools
Connect T-adapt&& CNP2 (female) Connect short connector to CNlO 1 (female). Turn starting switch OFF.
Tester T-adapter
82-112 a
*
2
Xsconnection in wiring larness. or defective contact Ktween CNPP (femalel(lO1 :N62 (9) - CN97 (3) :NlOl (femalel(l).orCN92 fern&)(41 - CN62 (10) ZN97 (2) - CNlO (femalej(2)
ND
After inspection, xpair (clean) or eplace
Short connector (for DLI)
T-adapter or socket adapter lfnr Frnnn+wll
WA350- 1
M-32
TROUBLESHOOTING
CNlOl
CNP2 -
WA350-1
10
4
82-113 0
M-33
TROUBLESHOOTING
M-33.
ABNORMALITY
When
disconnecting
disconnecting
or connecting
the connector
When
connecting
When
disconnecting
after checking,
q
IN
(TORQUE the
for checking,
the T-adapter
CONVERTER
T-adapter
(or socket adapter),
connectors
(or socket
turn the starting
or connecting
OIL TEMPERATURE adapter)
or short
GAUGE)
socket
adapter,
connect
T-adapters,
to the connector return
them
specified.
to the original
(CNxx
in display
L
Defective torque converter temperature sensor
)
Contact wtth wiring harness between CN84 (female)(l CN22 (1) - CNP2 (female)(l 1). orCN84 (femaleIl2) - CN22 (2) CNP2 (fern&)(51
After inspection, repair (clean) or replaca
w
3efective
Replace
1 _ -
oil Replace
I-
YES
2
1) Disconnect CN84 (torque converter oil NC temperature). 2) Turn starting switch ON.
Remedy
area
YES
Is there continuity ~et~~,elee;,$Na~~ (,
, )? -
11 Connect 2) 3)
b) Stays
immediately
then go to the next check.
shown
Does torque converter oil temperature gauge display bottom position?
(1)
condition
Cause
Nothing
or when
switch OFF to prevent accidents.
T-adapter to CNP2 (female). Disconnection CN84. Turn starting switch OFF.
at bottom
position
NO
gauge
module
and does not move. Iefective torque converter :emperature sensor
Defective
oil
Replace
gauge module
1s 2)
Turn starting ON.
switch
I
I
1)
Connect T-adapter to CNP2 (female). Connect short socket adapter to CN84 (female). Turn startlog switch OFF.
2)
3)
Troubleshooting tools
82-114 0
Tester T-adapter
NO )
Short socket
Iisconnection in wiring Tarness, or defective contact 9etween CNP2 (female)(l 1) :N22 (1) - CN84 (female)(l), xCNP2 (female)(5) - CN22 21 - CN84 (female)(2)
After inspection. repair (clean) or replace
adapter
(for DLI)
WA350-1
TROUBLESHOOTING
M-33
CN84
_/ 1
1
CNP2
WA350-1
82-115 0
83
ELECTRIC AND ELECTRONIC SYSTEM DISASSEMBLY
AND ASSEMBLY
MACHINE MONITOR Removal . . . . . .._......_................ Installation . . . . .
WA350-1
83-2 83-2
83-l 0
Stop
the machine
the bucket
from
apply
under
the
from moving.
the machine cable
the
Disconnect
Then
blocks
put
and
brake
parking
wheels to prevent
A
and install
Lower
and stop the engine.
to the ground the
on level ground
bar on the frame.
the safety
MONITOR
MONITOR
OF MACHINE
REMOVAL
A
MACHINE
ASSEMBLY
AND
DISASSEMBLY
negative
the
(-1
of the battery.
terminal
1. Covers Remove 2. Electric
covers (I) and (2) of machine
following
the
from
wiring
the
Disconnect
monitor.
--
wiring
connectors. Connectors
(3) and (4) of CAUTION
2 module.
Connectors
(5) and (6) of CAUTION
1 module.
Connector
(7) of speedometer
Connector
(8) of service meter.
Connectors
(9) and (I 0) of gauge module.
Connectors
(I I) and (I 2) of CHECK module.
After
when
monitor When
installing.
monitor
3. Machine Remove
mark with a tag
the connectors,
removing
to distinguish
*
module.
mounting
remove
machine
monitor,
be care-
then
bolts,
(I 3). removing
the machine
it from any shock.
ful to protect
OF INSTALLATION MONITOR MACHINE 1. Machine
monitor monitor
machine
Set
(I 3)
in mounting
position
and install. *
Do not tighten
2. Electric Connect
the screws too tight.
wiring the wiring to the following
connectors.
(I I) and (I 2) of CHECK module.
Connectors
(9) and (I 0) of gauge module.
Connectors Connector
(8) of service meter.
Connector
(7) of speedometer
module.
Connectors
(5) and (6) of CAUTION
1 module.
Connectors
(3) and (4) of CAUTION
2 module.
After
inserting
connector
the
connectors,
locks securely.
apply
Install the wiring
the so
that there is no strain on the wires. 3. Cover Install covers
83-2 0
(I
) and (2) of machine monitor.
WA350-1
91
OTHERS
Cab ..,,_.._.._............... Air conditioner (if equipped) . . Piping . Air conditioner wiring diagram . Air conditioner electric circuit Air conditioner unit l
WA350- 1
91-2
91-3
.
91-3 91-4
. .
91-4 91-5
91-1 @
STRUCTURE
AND
FUNCTION
CAB
CAB ~_I--______~ ---------7,
‘I
; :
/I
~I
’/ / 1
:.‘
1 / , L__~~___--‘j---A, I
<_>
/j
II II
:-----_______‘,
I I I ~
/j II
423F159
1. Front glass 2. Front wiper 3. Rear wiper 4. Door
View 2
91-2
WA350-1
AND
STRUCTURE
FUNCTION
AIR CONDITIONER Model:
DAIKIN
CO.
AIR CONDITIONER
(if equipped)
LTD..
PIPING
423F160A
1. Compressor
2. Hot water outlet port 3. Hot water
inlet port
4. Dry reservoir 5. Air vent 6. Condenser 7. Air conditioner
WA350-1
unit
91-3 0
AIR
FUNCTION
AND
STRUCTURE
CONDITIONER
AIR CONDITIONER
DIAGRAM
WIRING
Screw 3/4-l
Cabin unit
nl
Side condenser
6UNF
unit Screw 7/8-l
Screw
I
518-l 8UNF f
q I
-423F165 Screw 7/8-14UNF
AIR
CONDITIONER
ELECTRIC
CIRCUIT Blower box
n
--
m
___ Cab unit
-..Therm0 protector L:_h
i__
CL
Compressor
91-4 @
Condensor
fan motor 423Fl66A
WA350- 1
4UNF
STRUCTURE
AIR
AND
AIR
FUNCTION
CONDITIONER
UNIT Cooling
Function l
The air conditioner
acts to reduce operator
by
operator
providing
operating
the
with
.
fatigue
The refrigerant
gas is compressed
in air conditioner
a comfortable
air conditioner
environment.
compressor.
condenser
goes to air conditioner The heating system Hot water water
and pressurized It then
where
enters
the
it is cooled,
and
unit.
The fan blows out cold air, the temperature
Heating .
CONDITIONER
enters the air conditioner
outlet
temperature
refrigerant
uses the engine cooling water. unit from
gas
rises
and
it
returns
of the to
the
compressor.
hot
port (2). A fan blows hot air out. The of the cooling water
turns to inlet port (I)
goes down,
and then flows
it re-
back to the
engine cooling circuit. /xl
5
423F161
7
1. Hot water
inlet port
5. Refrigerant
gas inlet port
2. Hot water
outlet port
6. Refrigerant
gas outlet port
3. Electrical wiring 4. Outside
WA350-1
6
7. Condensation
drain port
air intake filter
91-5
STRUCTURE
AND
FUNCTION
AIR CONDITIONER
COMPESSOR
1
A
1.
Charge valve
2.
Clutch
3.
Front head
4.
Case
A.
Air outlet port
B.
Air inlet port
423F163
CONDENSOR
Condenser motor
3
I
2 /
1. Electrical
wiring
2. Fan 3. Refrigerant
gas inlet port
4. Refrigerant
gas outlet port
423F162
91-6
WA350-1
STRUCTURE
DRY
AND
FUNCTION
AIR CONDITIONER
RESERVOIR
View Z
423F164
1. Body 2. Side glass 3. Drier 4. Filter
WA350-1
91-7
OTHERS 93
DISASSEMBLY
AND ASSEMBLY
CAB Removal Installation
. .
. ..
.
AIR CONDITIONER UNIT Removal . . . . . . Installation . . . .
.
. . ..
9393-
2 3
. . . 93. . . 93-
4 6
CONDENSER FOR AIR CONDITIONER Removal . ... . .. .. .. Installation .. .. . . DRY RECEIVER Removal . . Installation .. .
.. .. . .. .. .. ..
.
.
.
COMPRESSOR FOR AIR CONDITIONER Removal . . . . . . . . . . ....... Installation . . . .. ... ...
WA350-1
9393-
8 8
93. 93-
9 9
93-10 93-l 0
93-1 0
DISASSEMBLY
AND
REMOVAL A
Stop
the
OF CAB machine
the safety parking
wheels
1. Electric
on level ground
bar on the frame.
to the ground the
CAB
ASSEMBLY
Lower
and stop the engine. brake
to prevent
and
put
and Then
blocks
the machine
install
the bucket apply
under
the
from moving.
wiring
1) Disconnect
cab wiring
(1) from connector
(2) at
rear left of seat. t
Remove
the-cap for the mounting
bolt.
vinyl tube (3) for window
washer.
2. Cab
I) Disconnect 2) Remove
cap
mounting
at
rear
of
seat,
then
remove
bolts (4) and (5).
3) Remove
mounting
bolts
(6) and (7) under
cab
(6) on left and right. 4) Sling
cab
(6).
remove
mounting
bolts
(8) and
(91, then lift off cab. *
When
lifting off the cab, be careful
the window Cab:
93-2 0
not to hit
on the front frame. 305
kg
WA350- 1
DISASSEMBLY
AND
ASSEMBLY
INSTALLATION
OF CAB
1. Cab
1) Raise cab (6), set in mounting position, then tighten mounting bolts (8) and (9). * Be careful not to hit the window with the front frame when installing. Zr Coat all the seals evenly with gasket sealant. 6
Gasket sealant
2) Install mounting bolts (6) and (7) under cab (61 on left and right. 3) Install mounting bolts (4) and (5) at rear of seat.
4) Connect vinyl tube (3) for window washer
2. Electric wiring Connect cab wiring (I) to connector (2) at rear left of seat. * Install the cap for the mounting bolt.
WA350-1
CAB
DISASSEMBLY
AND
REMOVAL m
Stop
the
OF AIR machine
the safety parking
wheels
on level ground
and install
Lower
the bucket
and stop the engine. brake
to prevent
Disconnect
CONDITIONER
bar on the frame.
to the ground the
AIR
ASSEMBLY
and
put
Then
blocks
the machine
apply
under
the
from moving.
the cable from the negative
(-)
termi-
nal of the battery. Loosen air conditioner
1 and (2). and drain
hoses (I
the gas from the air conditioner. *
When
draining
connect
Air conditioner,
heater
1) Disconnect After
disconnecting
hoses,
cover
2) Loosen
the
(I)
and
(2)
unit.
the
air
openings
to
conditioner prevent
dirt
(31 and
(41,
from entering.
clamps
of
then disconnect Operator’s
hoses
of air conditioner
and water
heater
hoses
hoses.
seat
Remove
operator’s
seat (5).
& kg
Operator’s
seat:
Arm
dis-
hoses
air conditioner
from bottom *
the gas, do not completely
the hoses. Loosen them slightly.
40 kg
rest, covers
Remove
arm rest (61, then remove
covers
(7) and
(8).
4. Electric
wiring
Disconnect
the
following
wiring
from
the
connectors. l
Wiper
l
Air conditioner *
wiring (9) and (I 0).
After
relay wiring (I I).
disconnecting
the connectors,
discon-
nect the clamps. l
Radio wiring (I 21, (I 3) and (I 4).
l
Air conditioner
l
Radio antenna
l
Air blower wiring
unit wiring (I 5). wiring
(I 6).
(17).
5. Air duct Disconnect
clamp
(18)
of cable,
(19) of blower wiring, then remove
93-4 0
and
connector
air duct (20).
UNIT
CONDITIONER
UNIT
DISASSEMBLY
AND
AIR
ASSEMBLY
CONDITIONER
6. Air blower Remove
mounting
bolts,
then
remove
air blower
(21). *
Be careful
not to damage
face between
the seal at the contact
the air blower
and the air condi-
tioner unit.
7. Air conditioner Remove remove *
unit
mounting
bolts (221, (23)
air conditioner
Move
and (24),
then
unit (25).
the air conditioner
unti outside
the cab,
then lift off. *
Be careful
not to damage
air conditioner
Air conditioner
& kg
the connectors
of the
hoses. unit:
80 kg
423 F482
t
When
repairing
unit, follow l
When
Steps
temperature
WA350-1
inside
of the air conditioner
1 - 4, then remove
removing
connectors cover.
the
the
cover,
of the air conditioner regulator
cable,
cover (26).
disconnect
the
wiring and the
then
remove
the
UNIT
DISASSEMBLY
AND
INSTALLATION
AIR CONDITIONER
ASSEMBLY
OF AIR
CONDITIONER
UNIT
UNIT
1. Air conditioner unit Set air conditioner unit (25) in mounting position, then tighten mounting bolts (221, (23) and (241.
23 22
423 F482
2. Air blower Set air blower (21) in mounting position, then tighten mounting bolts. Sr Be careful not to damage the seal at the contact face between the air blower and the air conditioner unit.
3. Air duct Set air duct (20) in mounting position, then connect clamp (18) of cable, and connector (19) of blower wiring.
4. Electric wiring Connect the following wiring to the connectors. l Air blower wiring (I 7). l Radio antenna wiring (I 6). l Radio wiring (121, (I 3) and (14). l Air conditioner unit wiring (15). l Air conditioner relay wiring (1 1). Sr After connecting the connectors, install the clamps. 9 Wiper wiring (9) and (10).
93-6 0
WA350-1
DISASSEMBLY
AND
AIR
ASSEMBLY
CONDITIONER
UNIT
5. Arm rest, covers Install covers (7) and (81, then install arm rest (61 6. Operator’s
seat
Install operator’s
seat (5).
7. Air conditioner, I) Connect
heater hoses
heater
hoses
(3) and (4), then tighten
clamps. 2) Connect bottom t
air conditioner
To prevent
do not remove
before
installing.
prevent
the
them securely
(I)
and
from
entering
the covers
hoses
from
with a wrench
twisting,
Hose connector,
m
Hose nut (I):
7.Okl.O
kgm
w
Hose nut (2):
3.720.4
kgm
with
hold
Compressor
oil
gas
Fill air conditioner Connect
flare:
the
until just
tightening.
&IL
8. Refilling
(2) to
unit.
dirt and water
hoses, Sr To
l
hoses
of air conditioner
cable
with gas. to
negative
(-)
terminal
of
battery.
WA350-1
93-7 0
machine
the
Stop
and install
Lower
the bucket
AIR
CONDITIONER
CONDITIONER
the
from moving.
the machine
to prevent
under
blocks
put
and
brake
parking
FOR
apply
and stop the engine. Then
to the ground wheels
on level ground
bar on the frame.
the safety the
FOR AIR
OF CONDENSER
REMOVAL
A
CONDENSER
ASSEMBLY
AND
DISASSEMBLY
1. Cover Remove
(1)
cover
remove
then
bolts,
mounting
under cab. for air conditioner
2. Condenser I) Remove
cover (2).
bolts, then remove
mounting
*
Loosen air conditioner
*
When
hoses (3) and (41, and
drain the gas from the air conditioner. the hoses. Loosen them slightly. (3) and (4). dirt
prevent
to
openings
cover
hoses,
the
disconnecting
After
(5).
electric wiring from connector
2) Disconnect
3) Disconnect-hoses *
gas, do not completely
the
draining
disconnect
and
the from
water
entering. mounting
4) Remove
conden-
bolts, then remove
ser (7) for air conditioner
from bracket
(6).
OF CONDENCONDITIONER
INSTALLATION SER FOR AIR 1. Air condenser
(7) of air conditioner
I) Set condenser
hoses (3) and (4).
2) Connect
To prevent
*
do not remove
before
installing. the
prevent
entering
the covers
hoses
securely
them
from
dirt and water
hoses, To
*
in mounting
bolts.
mounting
position, then tighten
a
hold
twisting,
from
with
the
until just
when
wrench
tightening. flare:
Compressor
a
Hose connector,
B
Hose nut (3):
5.620.6
kgm
m
Hose nut (4):
3.7f0.4
kgm
electric wiring at connector
3) Connect
4) Set cover (2) in mounting
position,
oil
(5). then tighten
bolts.
mounting 2. Cover Set
cover
mounting 3. Refilling
in mounting
(I) with
then
tighten
gas
Fill air conditioner
93-8 0
position,
bolts. with gas.
WA350-1
DISASSEMBLY
AND
REMOVAL
A
Stop
the
OF DRY machine
the safety parking
wheels
A l
on level ground
and
Lower
to prevent
and
put
Then
blocks
the machine
install
the bucket
and stop the engine. brake
RECEIVER
RECEIVER
bar on the frame.
to the ground the
DRY
ASSEMBLY
apply
under
the
from moving.
Open the hood, then fit the lock. Loosen air conditioner
hoses (I
) and (2). and drain
the gas from the air conditioner. t
When
draining
connect-the
the gas, do not completely
INSTALLATION DRY RECEIVER 1. Install dry receiver mounting 2. Connect t
To
OF
(4) on plate with clamp,
position, then tighten
mounting
set in
bolts.
hoses (I) and (2).
prevent
hoses,
dis-
hoses. Loosen them slightly.
do
dirt not
and
water
remove
from
the
entering
covers
until
the just
before installing. *
To prevent
the hoses from twisting,
securely with a wrench a
Hose connector,
flare:
w
Hose connector
nut:
3. Connect
WA350-1
hold them
when tightening. Compressor
oil
3.7 -t 0.4 kgm
electric wiring at connector
(3).
93-9 0
DISASSEMBLY
AND
REMOVAL
Qt l
ASSEMBLY
COMPRESSOR
OF COMPRESSOR
FOR AIR
FOR AIR CONDITIONER
CONDITIONER
Open the hood, then fit the lock.
Disconnect
the cable from the negative
(-1
termi-
nal of the battery. 1. Remove
bolt (1) and V-belt,
then remove
alterna-
tor (2).
t
To remove wiring,
the alternator
locate
the
without
removing
SO that
clamps
there
the is no
strain on the wiring. 2. Remove
bracket
3. Disconnect 4. Loosen
(3) of alternator.
electric wiring from connector
hoses
(5).and
(4).
(61, and drain gas from
air
conditioner. t
When
draining
connect *
After
the gas, do not completely
dis-
the hoses. Loosen them slightly.
draining
the
gas,
disconnect
hoses
(5)
and (6). *
After
disconnecting
the hoses, cover the opendirt and water from entering.
ings to prevent 5. Remove remove
bolts
(7)
and
compressor
Sr There
is
(81, remove
V-belt,
then
(9) of air conditioner.
little
space,
so
be
careful
when
working.
INSTALLATION COMPRESSOR CONDITIONER 1. Set compressor position,
OF FOR AIR
(9) of air conditioner
fit V-belt,
then secure with
in mounting bolts (7) and
(8). *
Clearance
“a” between
for air conditioner: B
Mounting
bracket
and compressor
“a” = Within
0.6 mm
bolt of bracket: 5.5kO.5
2. Connect k
To
kgm
hoses (5) and (6).
prevent
hoses,
do
dirt not
and
water
remove
the
from
entering
covers
until
the just
before installing. *
To prevent securely
x2,
the hoses from twisting,
with a wrench
Hose connector
hold them
when tightening. thread,
flare: Compressor
m
Hose nut (5):
7.020.7
kgm
w
Hose nut (6):
5.6kO.6
kgm
3. Connect
electric wiring at connector
4. Set alternator then tighten *
(2) in mounting
(4).
position,
fit V-belt,
bolt.
For details of adjusting ING AND ADJUSTING.
5. Fill air conditioner
93-10 @
oil
V-belt,
see 12 TEST-
4 r-jkl
423F483
with gas. WA350-
1
OTHERS 97 GEAR PUMP
GENERAL General
................................
Principle
of operation
Pressure
loaded
type gear pump.
Fixed side plate type SA
gear pump
......... ..........
97-003 97-006 97-008
SERIES
Structure Testing
.............................. and adjusting
Disassembly Assembly Maintenance
WA350-1
97-002
...................
...................
........................... .............................. standard
...................
97-102 97-105 97-l
08
97-112 97-l
17
97-l 0
GEAR PUMP 97 GENERAL
General
..........................
Principle
of operation
Pressure Fixed
WA350-1
loaded
side plate
97-002 97-003
.................
type
gear pump
..........
97-006
type
gear pump
..........
97-008
97-00 1 0
GEAR
GENERAL
PUMP
GENERAL The hydraulic
pump
is a device which
receives mechani-
Gear pumps
installed
cal energy from a prime mover such as an engine, converts
KOMATSU
standard
the energy
follows.
into
fluid
energy,
and functions
of energy in a hydraulic
system.
The
be divided
fluid
energy
velocity,
can
pressure, and potential.
energy used for hydraulic The hydraulic through a high
pressure of
ratherthan
The pump load)
pressure
against
S: For high pressure:
itself
by the
enclosed
by
(210 kg/cm2
makes
Therefore,
(155 kg/cm2
pressure.
by the resistance
into rotary they
pumpsand
pumps
G: For medium
when there is no
and variable
displacement
The
hydraulic
are
external
displacement External
into
fixed
pumps
displacement
pumps
fixed
c-
and
pressure:
125 kg/cm2,
side plate type 30 kg/cm2,
side plate type
A: Flange type mount B: Foot type mount
pumps. used in construction
gear pumps rotary
classified
pumps. Functionally,
fixed
140 kg/cm2
for some pumps)
F: For low pressure:
can be broadly
reciprocating
can be classified
pressure:
pressure loaded type (the
resistance, no pressure is produced. hydraulic
175 kg/cm2,
for some pumps)
pressure loaded type P: For medium
a device to produce
210 kg/cm’,
K: For high pressure:
the
is not changed
is a device whicti
is generated
the oil flow.
Structurally,
section section
machinery
are classified
as fixed
pumps.
gear pumps
employ
involute
spur gears, and
can be structurally classified into the following 0 Type of side plate adjustment Fixed side plate type Pressure loaded type
(FAL,
types.
E-
L: Counter-clockwise R: Clockwise
rotation
rotation
FAR)
(GAL,
GAR)
(PAL,
PAR)
(KAL,
KAR)
(SAL, SAR)
Theoretical
pump delivery
at
1,000 rpm (liters/min)
Pressure plate type l
Type of bearing Ball or roller bearing type t
97-002 0
as
pressure loaded type
in the load.
that the pump
the oil flow,
the energy
is determined
the pump delivery
with variations
It follows
are designated
of
and easily produces
displacement
wails. Therefore,
energy
machines are called
They
all of the fluid
and transmits
since its delivery
volumetric
significantly
the
pumps.
pressure is pressure energy.
receives
the static pressure of a fluid,
transfer fixed
pump
into
Almost
as the source
on KOMATSU
Plain bearing type
WA350-1
GEAR
PRINCIPLE
PUMP
PRINCIPLE a
OF OPERATION
OF OPERATION
MECHANISM
FOR DELIVERING
OIL
The drawing at right shows the operational of an external
principle
gear pump in which two gears are
rotating in mesh. The oil entering through the suction port is trapped in the space between two gear teeth, and is delivered
Suction
Discharge
to the discharge port as the gear rotates. Except
for the oil at the bottom
of the gear teeth,
the oil trapped
between the gear teeth is prevented
from
to the suction side with
returning
the gears
230F 137
in mesh. Since the gears are constantly delivered
to
the
discharge
delivering oil, the oil port
is forced
out of
the port. The-amount
of discharge increases with
the speed
of rotation of the gear. If there is no resistance in the oil passage into which the
discharged
through
the
oil
flows,
passage,
the
producing
oil
merely no
flows
increase
in
pressure. If, however, thing
like
the oil passage is blocked a hydraulic
cylinder,
there
with somewill
23OF138
be no
other place for the oil to flow, so the oil pressure will
rise. But the pressure which
will
never go higher,
rises in this way
once the hydraulic
cylinder
piston starts moving because of the oil pressure. As described flow,
earlier,
the
pump
produces
the oil
but not the oil pressure. We can therefore
conclude
that
pressure is a consequence
of load.
In other words, the pressure depends on a counterpart.
23OF139
23OF140
WA350-1
97-003 0
GEAR
l
PRINCIPLE
PUMP
INTERNAL Oil
OF OPERATION
01 L LEAKAGE
leaks from
a place under higher pressure to a
place under lower pressure, provided that a gap or a clearance exists in between. In the
gear pump,
small clearances
are provided
between the gear and the case and between the gear and the side plate to allow the oil to leak out and to serve as a lubricant
so that
the pump will
be
protected from seizure and binding. The
drawing
flows
at
right
in the pump.
shows how
the leaked
oil
is always
oil
As such, there
leakage in the pump from the discharge side (under higher
pressure)-to
the suction side. The delivery
of the pump is reduced by an amount equal to the pump discharge. In
addition,
decrease
the
delivery
of
as _the amount
of
the oil
pump leakage
will
also
increases
because of expanded
radial clearance resulting from
the
parts, the lower
wear
of
pump
oil viscosity
resulting from increases in the oil temperature,
and
the initial use of low viscosity oil. 0
FORCES The
ACTING
230F 141
ON THE GEAR
gear, whose outer
surface
is subjected to oil
pressure, receives forces poining towards its center. Due to the action of the delivery
pressure, the oil
pressure is higher on the delivery side of the pump, and, due to suction pressure, is lower on the suction side. In the intermediate gradually delivery
lower
as the
section, the pressure will position
moves from
the
side to the suction side. This phenomenon
is shown in the drawing at right. In addition,
the gears in mesh will receive interact-
ing forces. These forces pushing the gears toward
the suction sc harge side
side are received by the bearings. Since the gears are pressed toward the suction side by these forces, the radial clearance becomes smaller on the suction side in the case. In some pumps (PAL, PAR, KAL,
KAR),
the clearance may become zero, thus allowing the gear teeth and the case to come into light contact. For this reason, an excessive increase in the delivery pressure must be avoided,
since it will
produce
a
large force which will act on the gears, placing an overload on the bearings, and resulting in a shortened service life of the bearing or interference
‘Pressure distribution
of the gear
with the case. 23OF142
97-004 a
WA350-1
0
PRINCIPLE
PUMP
GEAR
OF THE OIL
PHENOMENON
“TRAPPING”
OF OPERATION
When a gear pump is rotating with the gears in mesh as shown in the drawing at right, in some instances two
sets of gear teeth are in mesh while
in other
instances only one set of the gear teeth is in mesh.
Suction side
When two sets of the teeth are in mesh simultaneousthe meshed gear
ly, the oil in the space between be trapped
will
teeth
exits will be completely
the front
inside -
and rear
shut.
This is called the “trapping”
phenomenon
of oil.
The space in which the oil is trapped moves from the suction
side to the delivery
Trapping starts
side as the gears
rotate. The volume of the space gradually decreases from the start of trapping until the space reaches the center
section,
and then
gradually
increases after The space reaches the minimum
leaving the center section until the end of trapping. Since-the
oil itself is non-shrinkable,
the volume
of space will
greatly
a reduction of increase the oil
pressure, unless some prosion is made to relieve oil
Trapping ends
pressure. The high pressure oil will cause the pump to make noise and vibrate. To prevent this, relief notches are provided on the side plates to release the oil to the delivery side. As shown in the drawing below, the relief notches are provided
in such a way
that
the oil can be
relieved from the trapping space to the delivery side when the volume of the space is reduced. Relief notches are also provided on the suction side to prevent the formation by
allowing
23OF143
of a vaccum in the space
the oil to enter
the space from
the
suction side when the space is expanded.
Fixed side plate type
Pressure loaded type
Side plate Bushing
230F144
WA350-1
23OF145
97-005 0
GEAR
PRESSURE
PUMP
PRESSURE
LOADED
TYPE
GEAR
LOADED
TYPE GEAR
PUMP
PUMP
8
‘9 23OF146
GENERAL
DESCRIPTION
Hydraulic
pumps
hydraulic
units
1.
Drive gear
are
2.
Bracket
pressure loaded type gear pumps. Some gear pumps
3.
Bushing
of this type
pressure of
4.
Gear case
5.
Cover
The pressure loaded type gear pump is designed so
6.
Seal plate
that
the gear and the side
7.
Collar
adjusted
to
8.
Back-up ring
leakage
9.
Driven gear
210 kg/cm*
plate the from the
used for on
the
construction
have a maximum
work
equipment
machinery
delivery
or higher.
the clearance
between
can be automatically delivery
pressure.
Therefore,
the
according oil
the side plate is less than that in the case of fixed
side plate type
pressure. Consequently, the pump delivery
under
a high discharge
no significant
reduction
of
occurs, even when the pump is
operated under high pressure.
97-006 0
WA350-1
GEAR
PRESSURE
PUMP
STRUCTURE
AND
LOADED
TYPE GEAR
PUMP
OPERATION
In a pressure loaded type pump, two bushings acting as side plates are inserted into the pump case, and are pressed toward
the sides of the gears. The oil
leakage from the gear sides is thus minimized. Since the bushings are constantly
pressed toward
the gears by the oil pressure, there is no fear of an increase
in oil
leakage,
even when
the
bushings
are worn out and the clearances are expanded many hours of operation. The bushings are pushed towards the gears from the cover side by the oil pressure, and they are pushed from
the gear side by the pressure of oil trapped
between
the gear teeth and that which
out from
the clearance between
has leaked
the gear and the
bushing. Since the oil pressure in the gears is higher on the pump delivery side and is lower on the suction side, provisions are made so that the pressing force acting on the bushings from
the cover side is regulated
in such a way that the delivery side is pressed harder and the suction side weaker
to match the counter
pressure. More specifically, discharge
side
the area of the bushing on the
is made
larger than
suction side by partitioning
that
on the
the area of the bushing
subjected to pressure on the cover side, with a backup
ring
installed
to
the
seal plate
as shown
in
the drawing at right. When
the
pump
is operated
at
high speed,
the
pressure on the suction side is lowered and the distribution
of
pressure around
the
periphery
of the
gear will change into the state shown in the drawing at right below. Pressure balance grooves are therefore the
provided on
bushings to keep the balance of the force on
Suction
the cover side against the pressure acting on the
\
bushing
from
pump rotation
the
gear side that
varies with
and the pressure distribution.
rotational
is stabilized
(low speed)
wthout balance groove (high speed)
the Thus
the delivery pressure is led as shown in the drawing and the pressure distribution
>
05F
I40
at any
speed.
WA350-1
97-007 0
GEAR
PUMP
FIXED
SIDE
GENERAL
pumps
mission,
and
side
classified FAR
TYPE
used for
steering
plate
GEAR
TYPE
GEAR
PUMP
30 kg/cm2
having
gear
on
1.
are
2.
Bracket
can be
3.
Gear case
called FAL or
4.
Cover
5.
Driven gear
which
pumps generally a maximum
a maximum
clutch, bulldozers
pumps
delivery
and pumps generally
having
trans-
the main
system
type
as follows:
pumps
pumps
PLATE
SIDE PLATE
DESCRIPTION
Hydraulic fixed
FIXED
pressure of
Drive gear
called GAL or GAR delivery
pressure
of
125 kg/cm2. Since the bracket plates the
outer
fixed
and the case cover serve as the side
and the gear teeth race of the
side plate type
bottom
bearing
land is closer to in the
gear pump,
to occur at the clearance
between
side plate.
is only
as the operated
97-008 0
However,
pump
this
is used for steering
case of the
oil leakage is liable the gear and the a small
problem,
control
which
is
at a low service pressure.
WA350-1
PUMP
GEAR PUMP 97
SA SERIES
Structure
.........................
Testing and adjusting Disassembly Assembly Maintenance
WA350-1
.................
.......................
......................... standard
.................
97-102 97-105 97-108 97-112 97-117
97-101 0
STRUCTURE
SASERIES
STRUCTURE
Side plate
FEATURES The gear pump is a high quality, specially
designed
for
reliable product that is
use in construction
equipment
which works under severe conditions. 0
The side plate, given its matching
0
alloy,
ensures
wear
resistance.
With
the
the
pump
surface
characteristics minimum
improved offers
treatment with
torque
hydraulic stable
to improve
the special loss and balance
performance
copper excellent
mechanism, and
high
durability.
2OOF132
STRUCTURE 5 \
g,\l”
Y
1.
Drive
2.
Driven
3.
Snap
4.
Oil seal
5.
Plate Bracket
7.
O-ring
8.
Side plate
10.
18
i 15
\ 11
gear ring
6.
9.
\
gear
Back-up
ring
Seal ring
11.
Gear case
12.
Side plate
13.
Back-up
14.
Seal ring
15.
Cover
16.
O-ring
17.
Bolt
18.
Dowel
ring
pin
21 F023
97-102 0
WA350-1
SA SERIES
STRUCTURE
SA-1 Series single pump rF;;::4”--,
-,
q$ipth: H
Del ivery port
(The drawing above shows a pump of the counterclockwise
rotation type. In a clockwise
rotation pump, the positions of the suction and delivery ports are reversed.)
SA-2 series single pump l
Side port type
A
%eepth:
H
Delivery port (The drawing above shows a pump of the counter-clockwise
rotation type. In a clockwise
rotation pump, the positions of the suction and delivery ports are reversed.) l
Rear port type
2-14,
1-m 65-l--65--l (The drawing above shows a pump of the counter-clockwise
rotation type. In a clockwise
rotation pump, the positions of the suction and delivery ports are reversed.)
WA350-1
97-103 0
STRUCTURE
SA SERIES
SA-3 series single PUIIIP l
Side port type
Delivery port --75---85-
(The drawing above shows a pump of the counter-clockwise
rotation type. In a clockwise
rotation pump, the positions of the suction and delivery ports are reversed.) 0
Rear port type f::
l-75-1--88-/
(The drawing above shows a pump of the counterclockwise
rotation type. In a clockwise
rotation pump, the positions of the suction and delivery ports are reversed.)
SA-4 series single pump
-l81-I
l4.5-
35.8 +L-J2
(The drawing above shows a pump of the counter-clockwise
rotation type. In a clockwise
rotation pump, the positions of the suction and delivery ports are reversed.)
(Note)
Dimensions A through H in the drawings vary with the pump capacity.
97-104 0
WA350-1
TESTING
SA SERIES
TESTING
AND ADJUSTING
AND ADJUSTING
Measure the pump delivery with a test bench or flow meter kit (790-303-1001).
%
The capacity codes marked
See Note on page 97-107.
No.
Check item
Series No.
apacity code
‘erformance Hydraulic oil: EOlO-CD Oil temperature:
1
Rotation (rpm)
010
32
29
012
38
34
47
43
016
52
48
020
66
61
025
83
76
44
40
210
020
55
50
l
025
67
62
028
77
71
032
88
210
040
111
103
045
121
111
050
138
128
l
020
45
42
l
025
55
51
* 040
90
82
l050
112
102
129
210
134
071
158
146
080
184
170
100
231
214
112
212 2000
192 2000
125
236
213
112
233
215
253
140
234 2200
287
266
328
303
180
336
310
200
373
345
224
411
385
250
460
425
160 4
WA350-1
119
145
2200
at a service
2500
063
125
operating
82 92
140
SA pumps
3000
100
056
For
Delivery (liters/min) 23
036
No. 2. (Examples:
Rotation (rpm)
l
2
3
Delivery (liters/min)
Reoair limit
25
*016
1
l-
Standard
008
014
50°C
Delivery pressure (kg/cm*)
* are for triple pumps.
210
pressure
of 50 kg/cm2
or less, see the standard and the repair limit in Table,
Pumps for power traines and servo-hydraulic
pumps for excavators)
97-105 0
TESTING
SA SERIES
NO.
Check
item
Series No.
Zapacity code
Performance
Delivery pressure (kg/cm*
T 1
Rotation (rpm)
Delivery (liters/min)
Repair Rotation (rpm)
_
limit Delivery (liters/min)
008
27
25
010
33
30
EOIO-CD
012
40
37
Oil temperature:
014
48
44
016
54
50
020
68
63
025
86
79
008
23
21
l 016
47
43
020
59
53
* 025
72
66
Hydraulic
oil:
5o”c
l
l
028
30
30
3500
3000
3000
032
92
84
104
95
040
115
106
045
126
115
050
144
132
* 020
49
44
* 025
60
55
l 040
96
88
056
109
119 30
2500
134
2500
123
063
151
138
071
164
150
080
192
176
100
241
221
112
4
74
80
036
* 050
30
2000
217 2000
198
125
240
220
112
242
222
125
264
242
140
300
275
342
314
160 30
350
321
200
389
357
224
434
398
250
480
440
180
97-106 0
T
Standard
AND ADJUSTING
WA350-1
SA SERIES
TESTING
AND ADJUSTING
Note 1,) If it is impossible to raise the pump speed to the value shown in the table because of limitations of the test bench, calculate the allowance for the delivery from the following formula:
Q
=
however, N => where,
N:
Q.
(No - N) Qth 1000
_
1000 rpm RPM of test bench Repair
Q:
limit
for
delivery
at
N
rpm
(liters/min) No:
RPM in the table
Qo:
Repair
Qth:
(liters/min) Capacity code
limit
for delivery
in the table
Note 2.) If the test bench allows the pump to raise its delivery pressure above 140 kg/cm2 but not above
210 kg/cm2,
use the
repair
limit
for
delivery given in Table, No. 1. Note 3.) For
pumps
50 kg/cm2
whose in
service
operation,
pressure use
Table,
exceeds No. 1.
(Do not use Table, No. 2) Note 4). The volumetric
efficiency of a pump decreases after the pump is reassembled. After reassembly, therefore, perform the following tests with a
test bench or flow-meter
(1)
kit (790-303-1001).
Shock test 20 times
t
252 kg/cm’ max.
Time
Performance test (measure the delivery)
WA350-1
97- 107 0
SA SERIES
DISASSEMBLY
DISASSEMBLY (1)
c Match mark
Single pump *
Cautions before disassembly To
avoid confusion
in the reassembly,
match marks on connecting
stamp
sections of bracket
(6) to gear case (11) and gear case (11) to cover (15).
I OOPO50
1)
Put the pump assembly on a work bench with the
bracket
side
facing
down,
and
loosen
mounting bolts (17) for cover (15).
*
Use the bracket mounting
bolt holes to secure
the pump assembly.
‘j I OOPO5
2)
Remove cover assembly (15).
*
Place the internal
I
parts in line in the order of
removal, taking care not to damage the contacting surfaces or sliding surfaces of the parts. *
Pull out cover assembly (15).
taking care not
to damage the hole for the dowel pin. Do not pry the cover.
IOOP052
3)
Remove O-ring (16) from the cover.
I OOPO53
97-108 0
WA350-1
SA SERIES
4)
DISASSEMBLY
Pull out side plate (12) on the cover side.
/
I OOPO54
5)
Remove backup ring (13) and seal ring (14).
23OF221
6) *
Remove drive gear (1) and driven gear (2). Pull
out
the
gears by
hand.
Do
not
use a
hammer.
*
1
If the oil seal is not replaced, tape the drive gear and the spline section to protect the oil seal from damage.
I OOPO55
7)
Remove bracket (6) from gear case (II).
*
When removing bracket (6) from gear case (111, take care not to let side plate (8) on the bracket side fall down and leave the side plate-installed as is to the gear case.
*
Do not hit the side plate surface.
j6
_, IOOP056
WA350-1
97- 109 0
SA SERIES
DISASSEMBLY
8)
Pull out side plate (8) from gear case (1
9)
Remove-backup
I).
ring (13) and seal ring (14).
IOOP058
IO)
Remove O-ring (7) from the bracket.
I OOPO59
97-110 0
WA350-1
(2)
Tandem pump 1) 2)
Stamp match marks. Put the pump on a work bench with the front pump bracket surface facing down, and remove the four
bolts that connect the front
pump to
the rear pump.
,, Match n&k
3)
4)
Disconnect the front pump from the rear pump.
For the disassembly
of single pumps, see the
section on single pumps.
(3)
P7050
I003
Triple pump Follow the same procedure for tandem pumps.
WA35071
97-111 0
ASSEMBLY (1)
Single pump *
When a used gear case is assembled, remove the burrs from the case and make sure that the side plate can be slided smoothly.
*
Make
sure that
the
dowel
pin
on the
case
has specified length (II).
c
R = Length of dowel pin 3
2
,:::‘I OOPO60
..
1)
Put cover (15) on a work bench.
:,IOOP06
2)
Install side plate
(12)
into gear case (II)
with
the seal groove facing outside. *
Do not install the backup ring and the seal to side plate (12) at this stage.
*
Do not confuse
the suction
side of the side
plate with the delivery side. *
Do not damage the periphery
of the side plate,
especially around the seal section.
Measurement
of side clearance
Temporarily
assemble bracket
(6) and gear case (II)
as shown in the drawing at right. Place the assembly on a work stack
bench and measure the difference height
including
drive
between the
gear (I ), side plates
(8)
and (12) and the height of gear case (I I). Measure with a depth dial gauge or depth micrometer. Judgement criteria Confirm
that the measurements conform to the standard
clearance given in the Maintenance
97-112 0
Standard Table.
WA350-1
I
SA SERIES
3)
ASSEMBLY
Install
gear case (11)
to cover
(15) with
the
match marks aligned.
.
4)
5)
Install drive gear (1) and driven gear (2).
Install side plate (8) with the backup and seal ring grooves facing upward.
IOOP065
l\ 6) *
Install backup ring (9) and seal ring (10). Install them with care to prevent gaps between the ring and the gear case as shown in Fig. P.
*
If it is impossible to eliminate
the gap, replace
the seal ring and the backup ring.
Gap
23OF223
WA350-1
97-113 0
ASSEMBLY
SA SERIES
7)
Apply (I)
some hydraulic
oil to the shafts of gears
and (2) and also to the sliding section of
the side plate. *
Take care to keep the gear case free from oil.
8)
Install O-ring (7) to bracket (6).
9)
Install bracket (6).
*
Align
the
match
marks
when
installing
the
bracket. *
Before
installing
the bracket,
make sure that
the seal and backup rings are properly installed according to the precautions in item 6. * *
Make sure O-ring (7) is fit properly. Confirm
that the contact
surface is free from
dirt and dust.
10)
Carefully
turn the gear pump assembly upside
down so that the bracket side will face downward,
and put the gear pump assembly on a
work bench. *
When turning the pump upside down, take care not to let the contact surfaces open out and not to let the O-ring and seal come off.
97-114 0
WA350-1
SASERIES
ASSEMBLY
II )
Remove the cover (I 5) and install O-ring (16).
12)
Install backup
ring and seal ring to side plate
i15
(I 2) in the manner described in item 6). 13) * *
Install cover (15). Align the match marks when installing the cover. Before installing
12
:16
the cover, make sure backup
ring and seal ring are properly
installed accord-
ing to the precautions given in item 6). *
Make sure O-ring (I 6) is fit properly. :lOOP053A
14) Tighten mounting bolts (I 7). *
Use
a torque
wrench
and
to the specified torque
tighten
the
bolts
in the order shown in
the drawing. For the tightening torque,
see the Maintenance
Standard Table on page 97-l 17.
Tightening order
15) After the
assembly,‘check pump
the rotational
torque of
shaft to see if it conforms
to the
value given in the table. *
After
the
pump
is assembled,
carry
out the
Series
Rotational torque
1
0.2 - 0.5 kgm
2
0.3 - 0.7 kam
performance
test (measure the pump delivery)
3
I
0.7 -
1.2 kam
with
bench
4
I
l.O-
1.5 kgm
a test
303-1001).
or flow
Confirm
that
meter
kit
(790-
the performance
is
with the repair limits.
(2)
Tandem pump 1)
For
the
assembly
of
individual
units of the
front and rear pump, follow the same assembly procedure as for the single pump. 2)
Put the front pump on a work bench.
WA350-1
97-115 0
SA SERIES
3)
ASSEMBLY
,\,,,,,
Install the coupling to the front pump.
Coupling
..
4)
Fit the O-ring to the rear pump bracket.
5) *
Put the rear pump on top of the front pump. Take care-not to let the O-ring come off.
*
Align the match marks.
6) *
Tighten four mounting bolts.
O-ring
~7050
Tighten
the
bolts
with
a torque
wrench
IO06
to
the specified torque in the order shown in the drawing below. I,::
[R]
Tightening order
*
After
the
pump
performance with
a test
303-1001).
is assembled,
carry
out the
test (measure the pump delivery) bench Confirm
or
flow-meter
that
the
kit
(790-
performance
is within the repair limits.
3)
Triple pump Follow
the same assembly procedure as for the
tandem pump.
97-116 0
WA350-1
SA SERIES
MAINTENANCE
MAINTENANCE
STANDARD
STANDARD
2 Unit:
NC
mm
Remedy
\
Clearance between the gear case and the gear
SA;020-080
0.10 - 0.15
0.19
3
plus the side plate
SAk 100 -
125
0.13 - 0.18
0.22
SA;
180
0.11 - 0.16
0.19
0.14-
0.22
112 -
Replace the side plate or the pump assembly
4 SA:, 200 - 250
0.19
2
Replace
I
4
I
I
1
I
0.06 - 0.140 10 -
12.5 kgm 12.5 kgm
Tightening torque for
2
10 -
the case mounting 3olts.
3
23.5 - 27 kgm
I
WA350-1
4
I
15 -
18 kgm
I I
I
97-117 0
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: