No. SEW-655DE TCM SERVICE MANUAL WHEEL LOADER Le7-3 C32 -3 €35 -3 £dO-s TCM CORPORATIONNo. SEW-855DE FOREWORD TCM offers a wide variety of wheel loaders which have been enthusiastically welcomed by users all over the world. TCM Models L.27-s, 1.32, L35., and L40- articulated type wheel loaders, are the latest products: developed from years of reseurch and experience. To get the most of the loader, it is required that you and maintenance procedures. become familiar with its features, construction, ope This Service Manual explains the structure of the above loaders for service personnel and shop workers. We hope it will be your reference guide during servicing jobs For the standard service values and the procedure for inspection, see the Inspection Manual and for the procedure for maintaining each component unit, see the Shop Manual of their respective components, ‘The descriptions and specitications described in this manual are subject to change without noti July, 2004 TCM CORPORATION This Service Manual applies to the following loaders: L275: #02101 and after #02101 and after #07101 and after #05101 and afterNo, SEW-855DE TABLE OF CONTENTS 0. SPECIFICATIONS 0.1 OUTER VIEWS 0.2 SPECIFICATIONS ...sssssscsses 1. ENGINE AND RELATED COMPONENTB.......... 1.1 ENGINE... 1.2. LUBRICATING SYSTEM 1.3 COOLING SYSTEM ... 14 FUEL SYSTEM ....... ce 1.5 INTAKE AND EXHAUST SY: 16 ELECTRICAL SYSTEM 17 ENGINE CONTROL UNI! 19 2, POWER TRAIN... 2.1 DRIVE UNIT 2.2 TORQUE CONVERTER ... 2.3 TRANSMISSION «0.0.0.0 CLUTCH SHAFT POWER FLOW .. 23.3 TRANSMISSION CONTROL VALVE TRANSMISSION CONTROL .. 2.3.5 ATC (AUTOMATIC TRANSMISSION CONTROLLER)... 2.4 OIL CIRCULATION ROUTE 2.5 PROPELLER SHAFTS... 2.6 AXLES (FRONT AND REAR). 2.6.1 DRIVE AXLE 6.2. DIFFERENTIAL 3 FINAL REDUCTION GEAR a 2.7 WHEEL ASSEMBLY (TIRE AND WHEEL) 91 3. BRAKE SYSTEM... 3.1 SERVICE BRAKE 3.1.1 GENERAL DESCRIPTION (BRAKE LINE) 3.1.2, BRAKE VALVE 3. DISK BRAKE..........No. SEW-655DE 3.1.4 ACCUMULATOR: 3.1.5 CHARGING VALVE 3.2. PARKING BRAKE coe 3.2.1 GENERAL DESCRIPTION (BRAKE LINE).. 3.2.2 DISK BRAKE oossssese 4A. STEERING SYSTEM (L27-s, LX130-7 - 4A.1 GENERAL DESCRIPTION 44.2 OIL. CIRCULATION ROUTES 4A.3 STEERING WHEEL UNIT. 4A.4 STEERING VALVE (ORBITROL) 4A.5 PRIORITY VALVE «0... 4A.6 CUSHION VALVE 4A.7 STEERING CYLINDER L323, LX160-7) 4B. STEERING SYSTEM (L35.s, LX190-7 - L40-3, LX230-7). 4B.1 GENERAL DESCRIPTION .... 4B.2 OIL CIRCULATION ROUTES 3 STEERING WHEEL UNIT 4B.4 STEERING VALVI 4B.5 CONTROL LINKAGE ... 4B.6 STEERING CYLINDER 5. FRAME AND COCKPIT . 5.1 FRAME 5.2. CENTER HINGE PIN 6. HYDRAULIC SYSTEM .. 5 a 6.1 OIL CIRCULATION ROUTES (HYDRAULIC CIRCUIT DIAGRAM) . cocosennee 6.2. PUMP 63 VALVE 6.3.1 MAIN VALVE... 63.2 PILOT VALVE 64 VALVE CONTROLS 6.4.1 SYSTEM IN OPERATION 64.2 STOP VALVE... 6.5 OTLTANKNo. SEW-655DE 7, LOAD HANDLING SYSTEM soe a 201 7.1 BOOM, BELLCRANK AND BUCKET .. 202 7.1.1 GENERAL DESCRIPTION... 202 7.1.2 BUCKET 205 7.1.3 BUCKET LEVELER 7.14 BOOM KICKOUT 7 7.1.5 FLOATING PINS (OPTION) 206 207 208 BS GVCINDER sstecsnscipis sstirinnee co oceactenenenene - 209 7.2.1 BOOM CYLINDER ee ivecicnasenustonnvoarieirasitetemstemecasseeste ZOD. 7.2.2 BUCKET CYLINDER ... aie ie ascasveene sssesscees 209, 7.3, ANTI-PITCHING SYSTEM (APS) [OPTION] a 216 8. ELECTRIC SYSTEM... 8.1 LIGHTING EQUIPMENT 8.2. METERS AND SWITCHES. coon 8.2.1 MONITOR LAMPS (CLUSTER GAUGE UNIT). 8.2.2. MONITOR LAMPS (EXCEPT CLUSTER GAUGE UNIT! 8.2.3. LIGHTING SWITCH........ 8.2.4 TURN SIGNAL SWITCH . 8.3 LOCATION OF RELAYS... 84 ELECTRIC CIRCUIT DIAGRAM 22 . 221 202 9. AIR CONDITIONER 9.1 GENERAL DESCRIPTION ... 9.1.1 OPERATING PRINCIPLE . 9.1.2. ATR CONDITIONER UNIT 9.1.3, COMPRESSOR 9.14 RECEIVER TANK 9.1.5 CONDENSER = 9.1.6 ATR CONDITIONER PIPING ...0.1 OUTER VIEWS —. 5250/2067) 3800 [153.1] 2770 (109.11 0. SPECIFICATIONS 0. SPECIFICATIONS (L273, LX130.7) Unit: mm [in.] 2690 [105.9] [ a = re bs ff VARY a j AF Sell 38 J] =I oso tr20.8) 7480 [292.9] 7520 [296.1] Fig. 0.1 Outer Views (L273, LX1307) “ie0. SPECIFICATIONS (L323, Lx160-7) Unit: mm [in] —. | | —4 Siro 1124.81 3005 [190.1 +165, 1859) | LTE) sesorrzeo | | aos} 2089 [818-1] T || || Fig. 0.2. Outer Views (L323, LX 160-7) ale0. SPECIFICATIONS (L35-3, LX190-7) Unit: mm f[in.] J g ge 3 g8 8 8 0267 ~ a , a | s|E 3 2 173) i 4 saotesdl i 4400823) 8510 [335.0] Fig. 0.3 Outer Views (L35.3, LX1901)0, SPECIFICATIONS (L40-s, LX230-7) Unit: mm [in] 31601240) ™ ¥ me 1210 147.6), 5925 238.3) |g) | snot) | 18600 [330.6] c eso 2008 ‘| Fig. 0.4 Outer Views (L403, LX230-7) cis0. SPECIFICATIONS. 0.2 SPECIFICATIONS Loader Models 1.273, LX1303) 1322, LX160] 135.3,LX1902] L403, LX2302 Type ! Front-enk! articulated loader with diesel engine Bucket Type DEB DEB DEB Bucket eapaeity. heaped my] 2.7185) 3214 35 [46] 40 Breakout foroe, bucket cylinder KN [kgf] [bf] | 124.5 (12700) | 153.9 (15700) | 165.6 {16900} | 198,0 20200) 128000] (34620) 137260| 144540 SAE rated operating load, {ull turn kg [Ibs|_ | 4320 [9530] | 5120(11290] | 5600 [12350] | 6400 [14112] : 58 60 62 64 Lowering time s 38 3A 33 36 Bucket dumping time s \4 la La 1s ‘Travel speed, fwd Ist koh imphl | 7.5 14.71 7514.11 75 [4.7] 7314.7 fwd 2nd koh mpal | 12.07.51 125 (781 (2018.11 BOI fwd 31d kovhimpay | 220037) | 25040) | 21030) | 210/130) fwd ih kinhimphl | 3451241 | 34stena) | Msn) | 345214) rev Ist kmvh ipa) | 8.0 (5.0) 851531 85/531 85 [5.3] rev 2nd kevh (mph | 13.5 (84) 14.0187] 14.5 [DO] 145 (9.61 rev rd kmihmphl | 2401149) | 24stIs2) , 230U43] | 23043) rev 4th kv (mph) | 37.0 (230) | 37.0 123.0) | 37012301 | ws (22.7) Max. waction force KN {kef] [Tbr] | 125.4 (12800) | 156.8 (16000) | 179.3 (18300) | 192.1 £19600} [28220] (35280) (40350) 183220) Gradeabitity. fd Ise | ase ie 25° tt 25° tilt Minimum turning radius outermost part of bucket mm fin | 6100 230.2) | 6530125711 | 6800(267.7) | 6890 [271.3] | center of outermost whee! sm [in| | 5230 (205.9) | 5560 1218.9) 5820 [229.1] 20 [229.1] ] Overall Teneth, bucket on ground ln fin) | 752072961) | RORDTSIE.A] | AS01330) | N60 [40.01 in earry position anm lin | 7440 [292.9] 8035 1316.31 | 8440 1332.a1 | 8600 (338.6) Overall width, loader body mm in) | 2610 (102.8) | 2819111061 | 2980(115.41 | 2980 1117.31 bucket mm [in| | 2690/1089} 2910/1146) | 3050 [120.1] | 3150 [124.0] Overall height, bucket on ground, t top of cah rm [in| | 3240/1276) | 3805 1130.11 | 3410 [134.3] | 3470 [136.6] Overall operating height, | bucket fully raised mm [in] | 5280/2067] | 5480121501 | S640 [222.0] | 5925 [283.3] Wheelbase mm fin] | 3050 [120.7 | 3250(128.07 | 3400 1133.9} | 3400 (183.91 “Tread, front wheels mm in| | 20S0(80.7] 2160185.0} | 2300 (90.6) | 2300 (90.6) rear wheels mim [in| | 2050 180.71 2160(85.01 | 230019061 | 23001906)0. SPECIFICATIONS L274, LX1Ws | L328, LX1603) L383, EX1907| LAs LX230 Front overhang, in carry position mining | 2550 (100.4) T 2720/107.1) | 2790(109.8] | 2900 (114.2) Rear overhang angle aE | al wy Tl vit fod dea | center hinge pin mmfin] | 408|159) | 4701185) | 460118.) 0 (20.5) | puis hin pin height mm fing | 3890 1153.11 | 4040 (159.1) | 4180 (164.6) |) 4385 [172.6] 2, Dumping beight. a1 45" discharge | | 2) angle som Lin] | 2770 [Ho9.A] ) 2875 (113.21 | 29851175] | 3135 123.41 Reach, at 45° discharge angle pam tin] | 1080 4171 | (180 (46.5) | 1135447] | 1210 147.6) 5] Bucket roll-hack angle, in ery postion vo | » 0 % Bucket dumping angle. | rucket ally raised 50 30 50 50 | Digging depth. bucket tilted | forward 10 mm fin) | 320(12.61 ) 330U1R.0) | aas p32] | 3501138) | Towing pin height mm fin) | 1oxo 42.51 | ties 43.97 | 1285 [S061 | 1345 153.01 =| | 3 Weight of loader ke ltbs} | 13700 (30210] | 17000 [37490} | 19700 [43440] | 21700 [47850]1, ENGINE AND RELATED COMPONENTS: 1. ENGINE AND RELATED COMPONENTS 1.1 ENGINE 1. General Description The engine mounted on this loader is a 4-cyele, water-cooled, in-line direct-injection type diesel engine. Each engine is equipped with a turbocharger, ‘The engine is mounted at the rear of the loader and its power is transmitted through the flywheel, coupling gear, and the torque converter, into the transmission, On the Models L27-3 and LX130-, the flywheel and torgue converter are connected through the input plate instead of the coupling gear4, ENGINE AND RELATED COMPONENTS (1) 127, LX130+ - L323, LX1607 (ISUZU “6HKIT” Diesel Engine) Name ‘Type Number of cylinders — bore x stroke Total displacement Compression ratio Engine performance Rated speed Rated output Maximum torque Full-load min. fuel consumption ratio Dry weight Dimensions (overall length x overall width x overall height) Firing order Rotational direction Unloaded max. speed (when separately measured) Unloaded min. speed (when separately measured) Allowable Maintenance data Valve opening and closing time ing angle Valve clearance Injection timing Injection start pressure ‘Compression pressure ISUZU “BB-6HK1T™ Diesel Engine 4-cycle, water-cooled, in-line vertical, direet-injection type with turbocharger 6 — 115 mm [4.53 in] x 125 mm [4.9 in] 7.790 L [475.4 in] 173 2300 rpm for L27-3, LX 1303, 2200 rpm for L32., LX1609 129 kW [175 ps} for L27., LX 1307 143 kW [195 ps} for L32.3, LX 1607 599 N-m [61 kef-m) [441 Ib€-ft] (at approx. 1600 spm) for L273, LX 1307 735 N-m {75 kef-m} {542 Ibf-ft] (at approx. 1500 rpm) for L324, LX1602 208 g/kWh {153 g/psh) {at approx. [500 rpm) for L27-3, LX1307 214 g/kWh [157 g/psh) {at approx. 1600 rpm) for L32.s, LX 1607 About 650 kg [1433 Ibs] 1330.5 mm x 846.5 mm x 1403.0 mm [52.38 in. x 33.33 in. x 55.24 in.) 1-3-3-6-2-4 Clockwise when viewed from cooling fan 2600 rpm or less for L27.3, LX1307 2440 rpm or less for L323, LX160-7 850 # 25 rpm 30° in four directions when viewed from flywheel Intake valve (open): 15° before TDC Intake valve (closed): 44° after BDC Exhaust valve (open): 58° before BDC Exhaust valve (closed): 11° after TDC. Intake valve (cold): 0.4 mm [0.016 in.] Exhaust valve (cold): 0.4 mm [0.016 in.] 7° before TDC 18.1 MPa (185 kgf/em?} [2631 psi] 3.2 MPa (33 kgf/em?} [469 psi] (at 200 rpm) Note: For the maintenance of the engine proper, see the Model BB-6HK1 Engine Workshop Manual (No. IDE-2380) published by Isuzu Motors LTD. -8-1. ENGINE AND RELATED COMPONENTS (2) 1.355, LX1907 - L403, LX230+ (MITSUBISHI *6D24-TL” Diesel Engine) Name Type Number of cylinders — bore x stroke Toral displacement Compression ratio Engine performance Rated speed Rated output Maximum torque Fall-load min. consumption ratio Dry weight Dimensions (overall length x overall width x overall height) Firing order Rotational direction Unloaded max. speed (when separately measured) Unloaded min, speed (when separately measured) Allowable tilting angle Maintenance data Valve opening and closing time Valve clearance Injection timing Injection start pressure Compression pressure 980 N-m [100 kgf-m) [723 Ibf-fi] (at approx. 1400 rpm) Clockwi Exhaust valve (closed): 18° after TOC Electronic control MITSUBISHI “6D24-TL” Diesel Engine 4-cyele, water-cooled, in-line vertical, direct-injection type with wrbocharger and inter-cooler 6 ~ 130 mm [5.1 in.] x 150 mm [5.9 in.J 11.94 L [727.1 in] 175 2100 rpm 165 KW {225 ps} (at 2100 rpm) for L35.s, LX 190-7 198 KW [270 ps} (at 2100 rpm) for L405, LX230-7 for L35.a, LX 1907 1176 N-m {120 kaf-m} [868 Ibf-ft) (at approx. 1400 rpm) for L402, LX2302 212 g/kWh | 156 g/psh} (at 1300 to 1400 rpm) About 1020 kg [2249 Ibs] 1497 mm x 931 mm x 151] mm [58.9 in, x 36.7 in. x 59, 1-5-3-6-2-4 ise when viewed from cooling fan 2250 = 20 rpm 800 + 30 rpm 30° in four directions when viewed from flywheel Intake valve (open): 18° before TDC Intake valve (closed): 50° after BDC Exhaust valve (open): 50° before BDC Intake valve (cold): 0.4 mm [0.016 in] Exhaust valve (cold): 0.6 mm [0.024 in. | 15.7 MPa {160 kgf/em?} [2276 psi] 2.7 MPa {28 kgf/em’} [398 psi] (at 200 rpm) Note: For the maintenance of the engine proper, see the Model 6D2 Engine Shop Manual (No. 97841- 02021) published by Mitsubushi Fuso Truck & Bus Co.1. ENGINE AND RELATED COMPONENTS 2, Outer Views FUEL FILTER . COOLING FAN OIL PAN WATER SEDIMENTER |. NOZZLE HOLDER INJECTION PUMP PRIMING PUMP GAUZE FILTER ). FLYWHEEL HOUSING Serene 10. TURBOCHARGER ll. OIL LEVEL GAUGE 12. OTL FILLER CAP 13, WATER DRAIN COCK 14. STARTER MOTOR 15, EXHAUST MANIFOLD 16, ALTERNATOR 17. OLL PRESSURE SWITCH 18. DRAIN PLUG Fig. 1.1 6HKIT Diesel Engine (L27-3, LX 1302 « L32-3, LX160-7) -10-TURBOCHARGER: EXHAUST MANIFOLD . WATER DRAIN COCK . OIL LEVEL GAUGE . STARTER MOTOR OIL FILLER CAP COOLING FAN ALTERNATOR . OIL PAN |. DRAIN PLUG ENGINE AND RELATED COMPONENTS INLET MANIFOLD . GAUZE FILTER 3. OIL PRI . NOZZLE HOLDER |. PUEL FILTER URE SWITCH INJECTION PUMP, PRIMING PUMP FLYWHEEL HOUSING OIL FILTER, (DIVIDED FLOW) OIL FILTER (FULL FLOW) Fig, 1.2 6D24-TL Engine (135.3, LX190-7 L403, LX230-7) -ll-1. ENGINE AND RELATED COMPONENTS: 3. Engine Mounting The engine is connected to the drive unit and supported tothe rear frame at 4 points on the Fight and left sides, with mounting rubbers at both sides of the eylinder body. Detail of arse viewed from "A" Note: {> QL 83 Nun [8.5 kef-m] [61 Ibf-ft] for L273. LX130-7 Nem (22.8 kgf-m} [165 Ibf-ft] for L32-3, LX 1607 > G7 224 Nem (22.8 kef-m) [165 bf] > GT 56 Nem (5.7 kef-m) [41 Ibe], Xe Threaded area: LOCTITE #262 \. BRACKET 4, MOUNTING RUBBER 7. OILFILTER 2, ENGINE 5, PLATE 3. DRIVE UNIT 6. BRACKET Fig, 1.3 Mounting of Engine (127.3, LX130-7 - L32-3, LX 1602) -12-1. ENGINE AND RELATED COMPONENTS, Note: [>> QT] 224 N-m (22.8 kgf-m [165 Ibf-fi] > A 88 N-m (9 kef-m} (65 Ibt-ft] 1. BRACKET 3. DRIVE UNIT 5. PLATE 2. ENGINE 4, MOUNTING RUBBER: 6. BRACKET Fig. 1.4 Mounting of Engine (L35.3, LX190.7 : L408, LX230.7) -B-4, ENGINE AND RELATED COMPONENTS: 4.2 LUBRICATING SYSTEM | 1273, LX1307 + 1323, LX1607 (6HKIT) [L380 1X190-7 + L40.s, LX23027 (6D24-TL) Lubrication | Forced circulation method by oi! pump! e Lubricating pump | Gear pump, crankshalt driven | Gear pump, gear driven Filtration | Pull-flow and divided-flow paper, | Combination of full-low paper type cartridge type and bypass flow type. center bolt type Cooling Water-cooling type e Oil pressure adjuster Regulator valve & Lubricating oil capacity Max. 19 L [5.0 US. gal.] | Max. 38 L [10.0 U.S. gal. Min. 14 L [3.7 U.S. gal. Min. 25 L [6.6 U ‘The engine parts are lubricated by forced circulation method by the oil pump. The engine oi! is picked up from the oil pan by the oil pump and directed under pressure, through the oil filter and the oil cooler, o the oi gallery from which the engine oil is delivered to each section for lubrication, before returning back into the oil pan. The occurrence of an abnormal engine oil pressure is monitored by the oil pressure switch and displayed by way of the “engine oil pressure” warning light of the cluster meter on the dashboard, -14-4. ENGINE AND RELATED COMPONENTS re causnatt 9 perpen IDLE GEAR. 2 Powe sieERNG LE GEA] | 2 wan on GALLERY Sakon posse: — 8.0 kgticm’ [71 psi) BYPASS PIPE (BUILT-IN) Ok, HERVONETES a AIR COMPRESSOR I iaitete ne EF muccnon rune oLcooter wif] ina EPPS Een = i ah we H (7 \ St Bate J ei CRANKSHAFT ES peel 7 PAATIAL OIL FILTER FULLFLOW OIL FLIER, STRAINER onpan yarunguio OL PRESSURE Gauce O-——— 1 ou pacssune ott paessune a SwiTeH AEE I ‘OIL MAIN GALLERY. 1 ‘SYPASS VAL\ | T t | ee Bh wae | TY Pig Lecce _ gS wi) hue ones) | i E ae same. | a a = eet | aol ee ES | 1 To aes | a | | ng | i hI — oi STRAINER = ou pan = Fig. 1.5. Schematic Diagram of Engine Lubricating System 15.