WA350-1

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

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by the

indicated

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WA350-1

l

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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

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