Wa420 1

CEBMW24020
SHOP
MANUAL
WA4204 LC
WHEEL LOADER
MACHINE MODEL SERIAL NUMBERS
WA420-1 LC A25001 and up
It is our policy to improve our products whenever it is possible and practical to do so. We
reserve the right to make changes or add improvements at any time without incurring any
obligation to install such changes on products sold previously.
Due to this continuous program of research and development, periodic revisions may be
made to this publication. It is recommended that customers contact their distributor for
information on the latest revision.
DEC 91
REQUISITION FOR TECHNICAL SERVICE PUBLICATIONS AND SERVICE FORMS
COMPLETE FORM
AND RETURN TO - Komatsu America International Company
440 North Fairway Drive
Vernon Hills, IL 60061-8112 U.S.A.
Attn: Technical Publications
Fax No. (847) 970-4186
Tel No. (847) 9704887
COMPANY NAME
SHIP TO l
ATTN.
STREET ADDRESS
TYPE or PRINT
ONLY . CITY, STATE, ZIP CODE
COUNTRY
PHONE NO. FAX NO. SHIPPING METHOD DISTR/BRANCH CODE
IMPORTANT - TO ASSURE SHIPMENT OF THE CORRECT PUBLICATION(S), THE MODEL NUMBER AND MACHINE
SERIAL NUMBER MUST BE SHOWN.
PARTS BooK PUBLICATION

QTY. PUBLICATION FORM NUMBER I: ~;~;pe; DESCRlPTlON MODEL NUMBER SERIAL NUMBER
KDC91 D 081696 CURRENT PRICES WILL BE CHARGED

CONTENTS
No. of page
10 ENGINE
12 TESTING AND ADJUSTING .................................................. 12-1

13 DISASSEMBLY AND ASSEMBLY .............................................. 13-1
20 POWER TRAIN
21 STRUCTURE AND FUNCTION ................................................ 21-1

22 TESTING AND ADJUSTING .................................................. 22-l
23 DISASSEMBLY AND ASSEMBLY .............................................. 23-l
24 MAINTENANCE STANDARD ................................................. 24-l
40 STEERING SYSTEM

42 TESTING AND ADJUSTING ................................................... 42-l
44 MAINTENANCESTANDARD .................... . ............................ 44-l
50 BRAKE AND AIR SYSTEM
51 STRUCTURE AND FUNCTION ................................................ 51-l

52 TESTING AND ADJUSTING .................................................. 52-1
54 MAINTENANCESTANDARD ................................................. 54-l
60 WORK EQUIPMENT SYSTEM

64 MAINTENANCESTANDARD ................................................. 64-l
80 ELECTRIC AND ELECTRONIC SYSTEM

90 OTHERS
93 DISASSEMBLY AND ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93-l

97 GEAR PUMP 97-l
99 METRlCCONVEdSlbNiABiE’::::::::::::::::::::::::::::::::::::::::::::::: 99-1
00-l
SAFETY
A WARNING! IMPORTANT SAFETY NOTICE
Proper service and repair is extremely important for the safe operation of your machine. The service and repair
techniques recommended and described in this manual are both effective and safe methods of operation. Some
of these operations require the use of tools specially designed for the purpose.
To prevent injury to workers, the symbol shown is used to mark safety precautions in this manual. The cautions
accompanying these symbols should always be followed carefully. If any dangerous situation arises or may
possibly arise, first consider safety, and take the necessary actions to deal with the situation.
SAFETY
PREPARATIONS FOR WORK

GENERAL PRECAUTIONS
7. Before adding oil or making repairs, park the
Mistakes in operation are extremely dangerous. Read machine on hard, level ground, and block the
the Operation and Maintenance Manual carefully BE- wheels or tracks to prevent the machine from
FORE operating the machine. moving.
1. Before carrying out any greasing or repairs, read all 8. Before starting work, lower blade, ripper, bucket
the precautions given on the decals which are fixed or any other work equipment to the ground. If this
to the machine. is not possible, insert the safety pin or use blocks
to prevent the work equipment from falling. In
2. When carrying out any operation, always wear addition, be sure to lock all the control levers and
safety shoes and helmet. Do not wear loose work hang warning signs on them.
clothes, or clothes with buttons missing.
-Always wear safety glasses when hitting parts with 9. When disassembling or assembling, support the
a hammer. machine with blocks, jacks or stands before
-Always wear safety glasses when grinding parts starting work.
with a grinder, etc.
10. Remove all mud and oil from the steps or other
3. If welding repairs are needed, always have a places used to get on and off the machine.
trained, experienced welder carry out the work. Always use the handrails, ladders or steps when
When carrying out welding work, always wear getting on or off the machine. Never jump on or
welding gloves, apron, glasses, cap and other off the machine. If it is impossible to use the
clothes suited for welding work. handrails, ladders or steps, use a stand to provide
safe footing.
4. When carrying out any operation with two or more
workers, always agree on the operating procedure
before starting. Always inform your fellow workers PRECAUTIONS DURING WORK
before starting any step of the operation. Before
starting work, hang UNDER REPAIR signs on the 11. When removing the oil filler cap, drain plug or
controls in the operator’s compartment. hydraulic pressure measuring plugs, loosen them
slowly to prevent the oil from spurting out.
5. Keep all tools in good condition and learn the Before disconnecting or removing components of
correct way to use them. the oil, water or air circuits, first remove the
pressure completely from the circuit.
6. Decide a place in the repair workshop to keep tools
and removed parts. Always keep the tools and parts 12. The water and oil in the circuits are hot when the
in their correct places. Always keep the work area engine is stopped, so be careful not to get
clean and make sure that there is no dirt or oil on burned.
the floor. Smoke only in the areas provided for Wait for the oil and water to cool before carrying
smoking. Never smoke while working. out any work on the oil or water circuits.
00-2
13. Before starting work, remove the leads from the 19. Be sure to assemble all parts again in their origi-
battery. Always remove the lead from the negative nal places.
(-) terminal first. Replace any damaged part with new parts.
l When installing hoses and wires, be sure that
14. When raising heavy components, use a hoist or they will not be damaged by contact with
crane. other parts when the machine is being oper-
Check that the wire rope, chains and hooks are free ated.
from damage.
Always use lifting equipment which has ample 20. When installing high pressure hoses, make sure
capacity. that they are not twisted. Damaged tubes are
Install the lifting equipment at the correct places. dangerous, so be extremely careful when install-
Use a hoist or crane and operate slowly to prevent ing tubes for high pressure circuits. Also check
the component from hitting any other part. Do not that connecting parts are correctly installed.
work with any part still raised by the hoist or crane.
21. When assembling or installing parts, always use
15. When removing covers which are under internal the specified tightening torques. When installing
pressure or under pressure from a spring, always protective parts such as guards, or parts which
leave two bolts in position on opposite sides. Slowly vibrate violently or rotate at high speed, be partic-
release the pressure, then slowly loosen the bolts to ularly careful to check that they are installed
remove. correctly.
16. When removing components, be careful not to 22. When aligning two holes, never insert your fingers
break or damage the wiring, Damaged wiring may or hand. Be careful not to get your fingers caught
cause electrical fires. in a hole.
17. When removing piping, stop the fuel or oil from 23. When measuring hydraulic pressure, check that
spilling out. If any fuel or oil drips on to the floor, the measuring tool is correctly assembled before
wipe it up immediately. Fuel or oil on the floor can taking any measurements.
cause you to slip, or can even start fires.
24. Take care when removing or installing the tracks
18. As a general rule, do not use gasoline to wash of track-type machines.
parts. In particular, use only the minimum of gaso- When removing the track, the track separates
line when washing electrical parts. suddenly, so never let anyone stand at either end
of the track.
00-3
FOREWORD
This shop manual has been prepared as an aid to improve the quality of repairs by giving the serviceman an
accurate understanding of the product and by showing him the correct way to perform repairs and make
judgements. Make sure you understand the contents of this manual and use it to full effect at every opportunity.
This shop manual mainly contains the necessary technical information for operations performed in a service
workshop.
For ease of understanding, the manual is divided into chapters for each main group of components; these
chapters are further divided into the following sections.
STRUCTURE AND FUNCTION
This section explains the structure and function of each component. It serves not only to give an
understanding of the structure, but also serves as reference material for troubleshooting.
TESTING AND ADJUSTING
This section explains checks to be made before and after performing repairs, as well as adjustments
to be made at completion of the checks and repairs.
Troubleshooting charts correlating “Problems” to ‘Causes” are also included in this section.
DISASSEMBLY AND ASSEMBLY
This section explains the order to be followed when removing, installing, disassembling or
assembling each component, as well as precautions to be taken for these operations.
MAINTENANCE STANDARD
This section gives the judgement standards when inspecting disassembled parts.
00-4
HOW TO READ THE SHOP MANUAL
HOW TO READ THE SERVICE MANUAL
VOLUMES REVISIONS
Service manuals are issued as a guide to carrying Revised pages are shown at the LIST OF RE-
out repairs. They are two manuals for each machine, VISED PAGES on the between the title page and
Chassis volume and Engine volume. SAFETY page.
These volumes are designed to avoid duplication

of information. Therefore to deal with all repairs for
any model, both chassis and engine volumes are SYMBOLS
needed.
So that the shop manual can be of ample practi-
DISTRIBUTION AND UPDATING cal use, important places for safety and quality are
marked with the following symbols.
Any additions, amendments or other changes will
be sent to your distributors. Get the most up-to-date
information before you start any work.
Symbol Item Remarks
FILING METHOD
A
Special safety precautions
See the page number on the bottom of the page. are necessary when perform-
File the pages in correct order. ing the work
Safety Extra special safety precau-
Following examples show how to read the page Y Y tions are necessary when
number: performing the work because
$
it is under internal pressure.
Example 1 (Chassis volume):
Special technical precautions
or other precautions for pre-
Caution serving standards are neces-
-rt sary when performing the
Item number (21. Structure
and Function) work.
Consecutive page number Weight of parts or systems.

for each item Caution necessary when
Weight selecting hoisting wire or
when working posture is
Example 2 (Engine volume): important, etc.
Refer to the pertinent engine manual. Places that require special
Tightening
attention for tightening
Additional pages: Additional pages are indicated torque
torque during assembly.
by a hyphen (-) and numbered after the page
number. File as in the example. Places to be coated with
& Coat
adhesives and lubricants etc.
Example: Places where oil, water or
Oil, water fuel water must be added,
I&1
21-4 and the capacity.
21-4-1 Added pages
Places where oil or water
21-4-2
Drain must be drained, and quan-
21-5
tity to be drained.
REVISED EDITION MARK ([l] [2] [3] ....)
When a manual is revised, an edition mark is

recorded on the bottom outside corner of the pages.
00-5
HOISTING INSTRUCTIONS
HOISTING INSTRUCTIONS
Hooks have maximum strength at the middle

portion.
1 Heavy parts (25 kg or more) must be
lifted with a hoist etc. In the Disas-
semblyand Assembly section, every
part weighing 25 kg or more is indi-
cated clearly with the symbol
103% 88% 79% 71% 41%
FSOO64
1. If a part cannot be smoothly removed from the

machine by hoisting, the following checks should 3) Do not sling a heavy load with one rope
be made: alone, but sling with two or more ropes sym-
metrically wound on to the load.
A
l Check for removal of all bolts fastening the
part to the relative parts. Slinging with one rope may cause turning
of the load during hoisting, untwisting of
l Check for existence of another part causing the rope, or slipping of the rope from its
interface with the part to be removed. original winding position on the load,
which can result in a dangerous accident.
2. Wire ropes
4) Do not sling a heavy load with ropes forming
1) Use adequate ropes depending on the weight a wide hanging angle from the hook.
of parts to be hoisted, referring to the table When hoisting a load with two or more ropes,
below: the force subjected to each rope will increase
with the hanging angles. The table below
shows the variation of allowable load (kg)
Wire ropes
when hoisting is made with two ropes, each
(Standard ‘7” or “S” twist ropes without galvaniz- of which is allowed to sling up to 1000 kg
ing) vertically, at various hanging angles.
Rope diameter (mm) 1 Allowable load (tons) When two ropes sling a load vertically, up to
2000 kg of total weight can be suspended.
10.0 1.0
This weight becomes 1000 kg when two
11.2 1.4
ropes make a 120” hanging angle. On the
12.5 1.6
other hand, two ropes are subject to an
14.0 2.2
excessive force as large as 4000 kg if they
16.0 2.8
sling a 2000 kg load at a lifting angle of 150”.
18.0 3.6
20.0 4.4
22.4 5.6
30.0 10.0
46.0 18.0
50.0 28.0
60.0 40.0
The allowable load value is estimated to be

one-sixth or one-seventh of the breaking
strength of the rope used.
2) Sling wire ropes from the middle portion of 30’ 60’ so’ 17.0” 150’
the hook. Lifting angle : a
FSOO65
Slinging near the edge of the hook may

cause the rope to slip off the hook during
hoisting, and a serious accident can result.
00-6
STANDARD TIGHTENING TORQUE
1. STANDARD TIGHTENING TORQUE OF BOLTS AND NUTS
The following charts give the standard tightening torques of bolts and nuts. Exceptions are given in sections of
“Disassembly and Assembly”.
Thread diameter Width

of bolt across flat
(mm) (mm)
kgm I Nm
6 10 1.3520.15 -L 13.2k1.4
8 13 3.2kO.3 31.4k2.9
10 17 6.7kO.7 65726.8
12 19 11.5kl.O 11229.8
14 22 18.Ok2.0 177219
16 24 28.5+3 279r29
18 27 39?4 383239
20 30 56+6 549 f 58
22 32 7628 745 + 78
24 36 94.5+10 927r98
27 41 135+15 1320+140
30 46 175?20 1720+190
33 50 225 a 25 22102240
36 55 280230 2750 + 290
39 60 335 + 35 3280+348
This torque table does not apply to the bolts with which nylon packings or other non-ferrous metal washers are
to be used, or which require tightening to otherwise specified torque.
t Nm (newton meter): 1Nm & 0.1 kgm
2. TIGHTENING TORQUE OF SPLIT FLANGE BOLTS
Use these torques for split flange bolts.
Thread diameter Width Tightening torque

of bolt across flats
(mm) (mm) kgm Nm
10 14 6.720.7 65.726.8
12 17 11.5+1 11229.8
16 22 28.5 +3 279*29
00-7
3. TIGHTENING TORQUE FOR NUTS OF FLARED FllTlNGS
Use these torques for nut part of flared.
Thread diameter Width across flats Tightening torque

of nut part of nut part
(mm) kgm Nm
(mm)
14 19 2.520.5 24.524.9
18 24 5?2 49k19.6
22 27 8?2 78.5219.6
24 32 1423 137.3 229.4
30 36 1823 176.5k29.4
33 41 20+5 196.1+49
36 46 25+5 245.2+49
42 55 30+5 294.2 + 49
COATING MATERIALS
The recommended coating materials prescribed in the shop manuals are listed below.
Nomenclature Code Applications
LT-1A Used to apply rubber pads, rubber gaskets, and cork plugs.
Adhesives LT-1 B Used to apply resin, rubber, metallic and non-metallic parts when a
fast, strong seal is needed.
LT-2* Preventing bolts, nuts, and plugs from loosening and leaking oil.
LT3 Provides an airtight, electrically insulating seal.

Used for aluminum surfaces.
LG-1 Used with gaskets and packings to increase sealing effect.
LG-3 Heat-resistant gasket for precombustion chambers and exhaust

piping.
Liquid gasket
LG-4 Used by itself on mounting surfaces on the final drive and trans-
mission cases. (Thickness after tightening: 0.07 - 0.08 mm).
LG-5 Used by itself to seal grease fittings, tapered screw flings and
tapered screw fittings in hydraulic circuits of less than 50 mm in
diameter.
Antifriction compound Applied to bearings and taper shafts to facilitate press-fitting and to
(Lubricant including LM-P prevent sticking, burning or rusting.
molybdenum disulfide)
Grease (Lithium G2-LI Applied to bearings, sliding parts and oils seals for lubrication, rust
grease) prevention and facilitation of assembling work.
Vaseline ___ Used for protecting battery electrode terminals from corrosion.
*LT-2 is also called LOCTITE in the shop manuals.
00-8
ELECTRIC WIRE CODE
ELECTRIC WIRE CODE

In the wiring diagrams, various colors and symbols are employed to indicate the thickness of wires. This wire
code table will help you understand WIRING DIAGRAMS.
Example: 05WB indicates a cable having a nominal number 05 and white coating with black stripe.
CLASSIFICATION BY THICKNESS
Applicable circuit
CLASSIFICATION BY COLOR AND CODE
Prioritv Classification Circuits Starting Charging Lighting Signal Instrument Other

Code B W R G Y L
1 Primary .
Color Black White Red Green Yellow Blue
Code BW WR RW GW YR LW
2 Black 81 Green & Yellow & Blue &
Color White 81Red Red & White
White White Red White
Code BY WB RB GR YB LR
3 Black & Yel- White & Green & Yellow & Blue &
Color Red 81Black Red
low Black Black Red
Code I
BR I
WL I
RY I
GY I
YG LY
Auxiliary Yellow & Blue &
Color Black & Red White & Blue Red 81Yellow Gc::$
I I I I I
Green Yellow
t Code I -- WY I RG I GB I YL LB
White & Yel- Green 81 Yellow 81 Blue &
Color -- Red & Green
low Black Blue Black
Code -- WG RL GL YW
White & Green & Yellow 81
Color -- Red & Blue
Green Blue White
00-9
GENERAL WEIGHT TABLE
WEIGHT TABLE
A This weight table is a guide for use when transporting or handling components.
Unit: kg
Engine assembly 655

Radiator assembly 166
Torque converter assembly 165
Transmission assembly 718
Center drive shaft 30
Front drive shaft 40
Rear drive shaft 20
Front axle assembly 1,173
Rear axle assembly 1,186
Front differential assembly 210
Rear differential assembly 185
Wheel hub assembly (1 piece) 69
Planetary hub assembly (1 piece) 68
Axle pivot (Rear axle) 106
Wheel (1 piece) 216
Tire (1 piece) 243
Steering valve 24
Steering cylinder (1 piece) 28
Brake (1 piece) 128
Hydraulic tank 270
Hydraulic pump 45
Main control valve 57
Lii cylinder (1 piece) 170
Dump cylinder 200
Engine hood 128
Front frame 1,470
Rear frame 1,220
Bucket link
Tilt lever z3
Lii arm (with bushing) 1145
Bucket 1,502
Counterweight 885
Fuel tank 215
Battery (1 piece) 45
Operator’s seat 37
Floor plate 115
Cab 305
Air Conditioner Unit 40
00-l0
GENERAL
LUBRICANTS, FUEL AND COOLANT

PROPER SELECTION TABLE
AMBIENT TEMPERATURE CAPACITY

RESERVOIR FLUID (Top line “F, Bottom line “C)
TYPE -22 -4 14 32 50 68 86 104 lli Specified Refill
-30 -20 -10 0 10 20 30 40
Engine oil
Engine with filter See
NOTE 1
,;... ~.,.j::,.:::.,.:..‘.‘.
‘:’ s~_,~~~:;,,;,~:_~~,:_:,:..~:I’.~~
Torque converter .... . ,.. :; .”“:
Transmission & 54 e 47 e
Service brakes Engine oil ::?X::
:: : ::::aAE:jew.
.::.. .\ ,j;,:,:;,:;,
See
NOTE 2
Hydraulic system
(Incl. brake sys.) .\:..::..:::.::.
.. .:.: ::..:I.
::*i,Jz()yI :,,,,
:j::::,.j
.. .::,..,,
.::,,,,
:::;:,:~:,,;~,;jj:,.:~:, 165e 103 e
... .‘...I.;i,::,: .. .... y:,..: : ..: :: :: :. :.:
Drive axles - Axle oil See NOTE 3 55 e 55 e

Front & rear each each
All lubrication Grease See NOTE 4 Fill as in- --

fittings strutted
Fuel tank Diesel fuel See NOTE 5 305 e --
Cooling system Coolant See NOTE 6 50 e -_
Specified capacity: Total amount of oil including oil for components and oil in piping.
Refill capacity: Amount of oil needed to refill system during normal inspection and maintenance.
API: American Petroleum Institute

ASTM: American Society of Testing and Material
SAE: Society of Automotive Engineers
SAE 15W-40 multi-viscosity oil meeting the Ameri-
NOTES: can Petroleum Institute (API) Classification of
CE/SF is recommended. CD/SF oil may be used in
1. ENGINE OIL areas where CE/SF oil is not available.
Normal Operation A sulfated ash limit of 1.O mass percent is suggest-

ed for optimum valve and piston deposit and oil
Oil performance recommendations are as follows: consumption control. The sulfated ash must not
exceed 1.85 mass percent. The sulfated ash limit of
The use of a quality engine lubricating oil combined 1.85 mass percent has been placed on all engine
with appropriate oil and filter change intervals are lubricating oils recommended for use in the engine.
critical factors in maintaining engine performance Higher ash oils can cause valve and/or piston
and durability. damage and lead to excessive oil consumption.
00-l 1
GENERAL
The API service symbol displays the following 2. ENGINE OIL

information. The upper half of the symbol displays
the appropriate oil categories; the lower half may Use API classification CE engine oil. If API classifi-
contain words to describe oil energy conserving cation CD is used, reduce the oil change interval to
features. The center section identifies the SAE oil half.
viscosity grade.
3. AXLE OIL
Oil viscosity recommendations are as follows:
For axle oil, use only the recommended oil as
The use of a multi-graded lubricating oil has been follows:
found to improve oil consumption control and
improve engine cranking in cold temperatures while SHELL: DONAX TT or TD
maintaining lubrication at high operating tempera- CALTEX: RPM TRACTOR HYDRAULIC FLUID
tures. CHEVRON: TRACTOR HYDRAULIC FLUID
TEXACO: TDH OIL
While SAE 15W-40 multi-viscosity oil is recom- MOBIL: MOBIL AND SUPER UNIVERSAL
mended for most operating climates, refer to the
previous chart for oil viscosity recommendations for * It is possible to substitute engine oil SAE 30W API
extreme climates. classification CD for axle oil. If noise comes from
the brake, it is no problem of durability.
Limited use of low viscosity oils, such as SAE lOW-
30 may be used for easier starting and providing 4. GREASE
sufficient oil flow at ambient temperatures below
+23”F (-5°C). However, continuous use of low The recommended lubricating grease is No. 2 multi-
viscosity oils can decrease engine life due to wear. purpose lithium grease with 3% molybdenum disulfide.
Do not use special “break-in” lubricating oils for a 5. DIESEL FUEL

new or rebuilt engine. Use the same type of oil
A
during the “break-in” as specified for normal opera- WARNINGI Do not mix gasoline or
tion. alcohol with diesel fuel. This mixture
can cause an explosion.
Arctic Operation
IMPORTANT: Due to the precise tolerances of
If an engine is operated in ambient temperatures diesel injection systems, it is extremely important
consistently below -10” F (-23” C) and there are no that the fuel be kept clean and free of dirt or water.
provisions to keep the engine warm when it is not Dirt or water in the system can cause severe
in operation, use a synthetic CE/SF or CD/SF damage to both the injection pump and nozzles.
engine oil with adequate low temperature properties
such as SAE 5W-20 or 5W-30. The use of ASTM No. 2-D diesel fuel with a mini-
mum Cetane number of 40 is recommended. The
The oil supplier must be responsible for meeting use of No. 2-D diesel fuel will result in optimum
the performance service specifications. engine performance under most operating condi-
tions. Fuels with Cetane numbers higher than 40
IMPORTANT: The use of a synthetic base oil does may be needed in high altitudes or extremely low
not justify extended oil change intervals. Extended ambient temperatures to prevent misfires and
oil change intervals can decrease engine life due to excessive smoke.
factors such as; corrosion, deposits and wear.
At operating temperatures below +32”F (O’C),
Additional information regarding lubricating oil acceptable performance can be obtained by using
availability throughout the world is available in the a blend of No. 2-D and No. 1-D fuels. The use of
“E.M.A. Lubricating Oils Data Book for Heavy Duty lighter fuels can reduce fuel economy.
Automotive and Industrial Engines.” The data book
may be ordered from the Engine Manufacturers Use a low sulfur content fuel having a cloud point
Association, One Illinois Center, 111 East Wacker that is at least 10 degrees below the lowest expect-
Drive, Chicago, IL U.S.A. 60601. The telephone ed fuel temperature. Cloud point is the temperature
number is (312) 644-6610. at which crystals begin to form in the fuel.
The viscosity of the fuel must be kept above 1.3

cSt to provide adequate fuel system lubrication.
00-12
GENERAL
6. COOLANT Total Hardness - Not to exceed 170 parts per

million (10 grains/gallon maximum) to prevent
Heavy duty diesel engines require a balanced scale deposits. Water containing dissolved
coolant mixture of water, antifreeze, and supple- magnesium and calcium (the usual reason for
mental coolant additives. Supplemental coolant water hardness) above the specified amount will
additive recommendations are included in the cause scale deposits to develop in the engine.
section entitled “CHANGE THE COOLANT AND
FLUSH THE COOLING SYSTEM”. The coolant Chlorides - Not to exceed 40 parts per million
should be changed at the specified service interval (2.5 grains/gallon maximum) to prevent corro-
shown in the “MAINTENANCE TABLE”. sion.
DCA4 is recommended to inhibit corrosion in the Sulfites - Not to exceed 100 parts per million
cooling system. (5.8 grains/gallon maximum) to prevent corro-
sion.
In climates where the temperature is above -34°F
(-37”(C), use a coolant mixture that contains 50 Dissolved Solids - Not to exceed 340 parts per
percent antifreeze. Antifreeze is essential in any million (20 grains/gallon maximum) to minimize
climate. It broadens the operating temperature sludge deposits, scale deposits, corrosion or a
range by lowering the coolant freezing point and by combination of these.
raising its boiling point. Do not use more than 50
percent antifreeze in the mixture unless additional If any of the above requirements cannot be met,
freeze protection is required. Never use more than use distilled, de-ionized, or de-mineralized water.
68 percent antifreeze under any condition. To determine if local water supplies meet these
standards, water samples can be tested by water
Low silicate ethylene glycol antifreeze is recom- treatment laboratories. “Softened” water that is
mended. The antifreeze should contain no more prepared using common salt (sodium chloride)
than 0.1% anhydrous alkali metasilicate. Low contains excessive amounts of chlorides and
silicate antifreeze is recommended to avoid the should not be used.
formation of silica-gel (hydro-gel). This gel forma-
tion can occur when the cooling system contains NOTE: Never use water alone in the cooling
an over concentration of high silicate antifreeze system because corrosion will occur.
and/or supplemental coolant additive. DO NOT use
methanol or alcohol as an antifreeze because of its Maintain supplemental coolant additive levels at 1
low boiling point. unit DCA4 per 1 U.S. gal (3.8 liters) of coolant.
Antifreeze may retain its freeze protection for more Use antifreeze during all seasons to protect the
than one season but coolant conditioners must be cooling system from corrosion as well as freezing
added to maintain corrosion protection. damage.
Antifreeze formulated with methoxy propanol, or A mixture of 50% water and 50% ethylene glycol
propylene glycol, is not recommended for this base antifreeze is required for operation of the
system. engine in temperature environments above -34.6“ F
(-37°C). A mixture of 40% water and 60% anti-
NOTE: Do nor mix types of antifreeze solurions. freeze is recommended for temperatures below -
Mixed so&ions make it impossible to 34.6“ F (-37” C).
determine the prorecrion against freezing.
Antifreeze containing sealer or anti-leak In tropical climates where antifreeze availability may
additives should NOT be used in this be limited, use a corrosion inhibitor (Cummins
system. Sealer or anti-leak additives will liquid DCA), or an equivalent to protect the engine
cause plugging problems in the cooling cooling system.
sysrem.
Do not operate the engine without a thermostat.
Check the solution periodically and at normal
operating temperature, to be sure the cooling
system has sufficient protection against freezing.
Use water which has a low mineral content. Water

used in conjunction with antifreeze, coolant filters
and inhibited water must meet the following stan-
dards:
00-I 3
GENERAL
This page is blank.
00-l 4
ENGINE
12 TESTING AND ADJUSTING
STANDARDVALUETABLE ............... ............ ........... .... .... ...... ...... 2
TOOL LIST FOR TESTING AND ADJUSTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
VALVE CLEARANCE .......... .... ... .. ... ....... .. ......... ...... .... ...... ...... 7
FUEL INJECTION TIMING ... ......... ... ... ... ............... ...... .... ..... ....... 8
ENGINE OIL PRESSURE AND TEMPERATURE ... .... .... ........ .. ...... .... ...... ...... 9
BLOW-BYPRESSURE ...... ............ ....... ............ ... ..... .... ..... ...... 11
EXHAUST GAS COLOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
ACCELERATOR PEDAL, OPERATING FORCE AND OPERATING ANGLE . ...... ... ..... ....... 13
+ The following precautions are necessary when using the Standard Value Tables to make judgements during
troubleshooting or during testing and adjusting.
1. The values in these tables are based on the values for new machines leaving the plant, so they should
be used as target values when repairing or when estimating wear after a period of use.
2. The information in the Standard Value Tables are estimates, based on standards from the production
plant when the machines were shipped. Therefore, when troubleshooting they should be used as
reference in combination with repair and operating records when making judgements.
3. These standard value tables must not be used for standard values when judging claims. In addition, do
not use these values alone to make simple judgements.
12-1
TESTING AND ADJUSTING STANDARD VALUE TABLE
STANDARD VALUE TABLE

. FOR ENGINE ON TEST BENCH
Engine T 614T
Category Item Condition, etc.
High idling speed

I Unit
Standard
value
2420 + 50
Permissible
value
Engine speed
Low idling speed 825+50
Performance 0°C Min 150
Necessary starting
-20” C (Using starting Min 120
speed
aid) Ether used
Intake resistance All speed mmH20 Max 380 Max 635

Exhaust pressure At rated output mmHg Max 76
Exhaust temperature All speed (Intake air “C 660 (Turbine
temp.: 20°C) inlet)
Intake and Bosch

exhaust system At abrupt acceleration index Max 6.5 Max 7.0
Exhaust gas color
At high idling Bosch Max 1.0 Max 2.0
index
Valve clearance Intake valve mm 0.30

(Engine cold) Exhaust valve mm 0.61
Compression Oil temperature 4060” C kg/cm*

None
pressure (Engine speed) (rpm)
BUY 457
Blow-by pressure At high idling, oil
mmH20 (:w (Used
Orifice size 7.67 mm temperature min. 80°C
engine) engine)
Oil pressure
At rated speed kg/cm* 2.1-3.5
(SAE 15W-40
At low idling kg/cm” 0.7-2.2
Oil temp.: 80°C min.)
All speed
Lubrication Oil temperature “C 80-110 Max 120
(Inside oil pan)
system
At continuous rated
horsepower
Oil consumption ratio % Max 0.3 Max 0.5
(Proportion of fuel
consumption)
Fuel injection
Nozzle tester kg/cm* 209
Fuel system pressure
Fuel injection timing Before top dead center Degree 22
Whole speed range (At

Cooling system Coolant temperature “C 83-95 Max 100
engine outlet)
12-2
Engine 614T
Standard Permissible
Category Item Condition, etc. Unit
value value
Valve cracking “C
temperature
Thermostat function Temperature when fully “C 95
open
Cooling system
Lii when fully open mm 7.5
(Continued)
Deflection when pushing
Fan belt tension Refer to the Operation
with finger force approx. mm
(Alternator-fan pulley) 6 kg Manual
NOTE: The values given in the Testing and Adjusting data are NOT for adjustment of the output.
Do not use these values as a guide to change the setting of the fuel injection pump.
12-3
l FOR ENGINE ON CHASSIS
Engine I 614T
Category Check item Conditions Unit
value value
Performance Engine speed

High idling speed wm 2420 + 50
Low idling speed rm 825 + 50
Sudden acceleration Bosch Max 6.5 Max 7.0

index
Exhaust gas color
At high idling Bosch Max 1.0 Max 2.0
Intake and
exhaust system index
Intake valve (20” C) mm 0.30

Valve clearance
Exhaust valve (20°C) mm 0.61 I
Compression Oil temp.: 4060°C

kg/cm*
pressure Engine speed: Idle
Max 89 Max 457

At high idling (Water temp.
B&Y Blow-by pressure mmH20 (New (Used
inside operating range)
engine) engine)
Oil pressure
At rated speed kg/cm* 2.1-3.5
(SAE 15W-40, oil
Lubrication At low idling kg/cm* 0.7-2.2
temp.: min. 80°C)
system
Whole speed range (Inside
Oil temp. “C 80-110 Max 120
oil pan)
Fuel injection
Fuel system Compression B.T.D.C. Degree 22
timing
Alternator drive belt

Cooling system tension Refer to the Operation Manual
12-4
TESTING AND ADJUSTING TOOL LIST FOR TESTING AND ADJUSTING
TOOL LIST FOR TESTING AND ADJUSTING
No. Testing and measuring item Tool name Part number Remarks
1 Engine speed Tachometer 799-203-8000 Digital display 60-l 9,999 rpm
2lXttery specific gravity 1.100 - 1.300

Battery coolant tester 795-500-l 000 -5 - -50°C
3 Coolant freezing
I temperature
4 Water temperature, oil temp- 790-500-l 300 0 - 200°C

erature, intake temperature Thermistor
temperature gauge
799-1oo1r-6ooo 0 - 1,ooo”c
5 Exhaust temperature
6 Lubricating oil pressure 0 - 10 kg/cm2
7 Fuel pressure 0 - 20 kg/cm2
8 Intake pressure, exhaust Engine pressure 799-203-2002 0 - 1,500 mmHg

pressure measuring kit
9 Blow-by pressure 0 - 1,000 mmH20
10 Intake resistance -1,000 - 0 mmH20
11 Compression pressure Compression gauge 795-502-l 204 0 - 70 kg/cm2

I
12 Blow-by pressure Blow-by checker 799-201-l 503 0 - 500 mmHe0 or use
0 - 1,000 mmH20 gauge
13 1 Valve clearance I Feeler gauge 795-l 25-l 330
14 Exhaust gas color Smoke meter Commercially Discoloration 0 to 70%

available standard color (Discoloration
% x l/10 + Bosch index)
799-2016000 Water content O.l%, 0.2% in

standard sample
799-202-7001 PH, nitrous acid ion

concentration
799-202-9001 0 - 2 kg/cm2
Commercially 0 - 300 kg/cm2

available
Commercially Current, voltage,

available resistance
7AO-262-0020 Commercially available

0 - 25 kg
When carrying out testing, adjusting or troubleshooting, stop machine on level ground, insert the safety pins
A and block the tracks.
12-5
A When working in groups, use agreed signals and do not allow unauthorized persons near the machine.
A When checking the water level in the radiator, wait for the water to cool. Do not remove the radiator cap
while the water is hot. Boiling water may spurt out.
A Be careful not to get caught in rotating parts.
12-6
TESTING AND ADJUSTING VALVE CLEARANCE
VALVE CLEARANCE
t Condition: Engine is cold.
+ Adjust clearance between valve and rocker lever as
foliows.
Unit: mm
I Intake valve I Exhaust valve
Cold 0.30 0.61
Soecial tool
I Part number I Part name I Q’ty
A 1 795-125-1330 1 Feeler gauge I 1
1. Remove catch, then open hood.
2. Loosen band (1) of air cleaner assembly (2), dis-

connect from turbocharger (3), then remove air
cleaner (2).
t When removing the air cleaner, remove the
intake hose first.
3. Loosen band (4) and remove bolt (5) of exhaust

muffler (6). Disconnect turbocharger (3) then
remove exhaust muffler (6).
4. Remove brackets (7 and 8) of air cleaner and ex-

haust muffler.
5. Remove air connector (9) from engine.
6. Adjusting valve clearance

+ For details of the engine, see the Engine Shop
Manual.
12-7
TESTING AND ADJUSTING FUEL INJECTION
FUEL INJECTIONTIMING
+ Measurement condition
+ Coolant temperature: Inside operating range
Unit: Dearee
item
value value
Fuel injection timing 22
2. Disconnect control cable rod (1).
3. Remove the fuel filter (2) and disconnect fuel tube

(4).
t For details of the fuel injection pump, see the
Engine Shop Manual.
4. Disconnect fuel return hose (3). Remove injection

pump (5) side.
5. Adjusting fuel injection pump timing

t For details of the engine, see the Engine Trou-
bleshooting and Repair Manual.
12-8
TESTING AND ADJUSTING ENGINE OIL PRESSURE AND TEMPERATURE
ENGINE OIL PRESSURE AND

TEMPERATURE
1. Measuring engine oil pressure
t Measurement condition
l Coolant temperature: Inside operating range
Unit: kg/cm2
Item
value value
Special tool
Part number Part name Q’ty
A 799-203-2002 Engine pressure 1

measuring kit
A When measuring, be careful not to get caught

in rotating parts.
A install and remove the plug and oil pressure

gauge with the engine stopped.
t Measure the engine oil pressure when the oil

temperature is at the specified temperature.
1) Remove switch (1).
2) Install oil pressure gauge A (25 kg/cm*).
t Install the oil pressure gauge so that it is
affected as little as possible by the engine
vibration.
3) Start engine and measure oil pressure.
12-9
TESTING AND ADJUSTING ENGINE OIL PRESSURE AND TEMPERATURE
2. Measuring oil temperature

* Measurement condition
l Coolant temperature: inside operating range
Item
value value
Oil temperature 80-110°C 120°C
Special tool
Part name Q’ty
1) Remove dipstick (2).

2) Insert sensor of thermistor temperature gauge
in dipstick guide.
Connect sensor to thermistor temperature
gauge A and measure temperature of oil in oil
pan.
12-10
TESTING AND ADJUSTING BLOW-BY PRESSURE
BLOW-BY PRESSURE
o Engine valve clearance: Standard valve
l Engine speed: Rated speed
Unit: mmHa0
I Standard value
Item used
New engine
engine
Blow-by 89 457
pressure
Soecial tools
A 799-201-l 503 Blow-by 1

checker
B 3375788 Cummins Pipe tee 1

part number I
A When taking measurements, be careful not to

touch the exhaust manifold, muffler, or to get
caught in rotating parts.
1. Measuring blow-by
1) When measuring the blow-by, warm the engine
up thoroughly. (oil temp: min. 8O“C)
2) Stop engine and install pipe tee of blow-by
checker on engine breather hose (1).
3) Connect adapter and pressure gauge A (O-
1,000 mmHs0) to hose.
4) Run the engine at rated output and measure
the blow-by pressure. Jib III
Manometer
2. Precautions when measuring blow-by
+ The blow-by may vary greatly according to the
condition of the engine, so if there is any abnor-
mality in the reading, check for any problem
related to defective blow-by, such as excessive
oil consumption, defective exhaust gas color, or
early deterioration or contamination of the oil.
UACOOOB
12-11
TESTING AND ADJUSTING EXHAUST GAS COLOR
EXHAUST GAS COLOR

o Coolant temperature: Inside operating range
e Valve clearance: Standard value
Special tool
A Commercially Smoke meter 1

available
A When measuring the exhaust gas color,

careful not to touch the exhaust pipe.
be
1. Insert probe @ in outlet of exhaust pipe (1) and

secure to exhaust pipe with clip.
2. Connect probe hose, connector hose @of accelera-

tor switch and air hose to smoke meter A.
-or The pressure of the air supply should be under
15 kg/cm2.
3. Connect power cord to AClOOV socket.

* Check that the power switch is OFF before
connecting the cord.
4. Loosen cap nut of suction pump and insert filter

paper.
5. Turn power switch ON.
6. Accelerate engine suddenly. At the same time,

depress accelerator pedal of smoke meter, operate
relief valve and catch exhaust gas color on filter
paper.
7. Lay filter paper used to catch exhaust gas color on

top of unused filter papers (10 sheets or more)
inside filter paper holder, and read indicated value.
12-12
TESTING AND ADJUSTING ACCELERATOR PEDAL
ACCELERATOR PEDAL, OPERATING

FORCE AND OPERATING ANGLE
e Coolant temperature: Inside operating range
Unit: ka
Item
value value
Operating force of
4-8.5 Max. 10.5
accelerator pedal I
Special tool
Part number Part name cxty
A 7AO-262-0020 Push-pull scale 1
OPERATING FORCE
1. Measuring
1) Set push-pull gauge @ at a point 150 mm from
the fulcrum of the pedal.
t The center of push-pull gauge @ must
contact at a point 150 mm from the fulcrum
of the pedal.
2) Start the engine, depress the pedal, and mea-
sure the maximum reading from the point
where the pedal is first depressed (low idling) to
the end of the pedal travel (high idling).
2. Inspection
1) Stop the engine.
2) Disconnect cable (1) at the bottom of the
accelerator pedal, and check that linkage of the
accelerator pedal itself moves smoothly.
3) Connect cable (1) at the bottom of the pedal,
disconnect it again at the connection of the
injection pump, and check that the cable moves
smoothly.
+ Carry out the above inspection, and adjust
or replace the parts if necessary, then
measure the operating force again to check
that it is within the standard value.
4) Check that radius of the curve in the cable is at
least 260 mm.
12-13
TESTING AND ADJUSTING ACCELERATOR PEDAL
OPERATING ANGLE
Unit: mm
Item
value value
at 45” To
Operating angle of
accelerator pedal ap 32”
1. Measuring
1) Stop the engine.
4 Put an angle meter in contact with the accelera-
tor pedal, measure low idling angle al and high
idling angle ap, then calculate angle of depres-
sion a = at - as.
2. Adjusting
1) Remove the cover at the bottom of the cab,
open the engine hood, and apply the safety
lock.
2) Loosen nut (1) and adjust with bolt (2) so that
installed height L of the accelerator pedal
stopper is 4825 mm.
3) Loosen lock nut (3) and adjust the length of the
cable so that the injection pump governor lever
contacts the high idling stopper when the
accelerator pedal is fully depressed (high
idling).
* Check that the injection pump governor
lever contacts the low idling stopper when
the accelerator pedal is released (low
idling).
t Adjust the travel of the governor lever at
joint (4).
+ After carrying out the above adjustment,
measure each part again to check that they
are within the standard value.
12-14
ENGINE
13 DISASSEMBLY AND ASSEMBLY
STARTING MOTOR ..................................................................

REMOVAL .....................................................................
INSTALLATION .................................................................. 3
ALTERNATOR ..................................................................... 4
REMOVAL ..................................................................... 4
INSTALLATION .................................................................. 4
FUELINJECTION PUMP.. ............................................................ 5

REMOVAL ..................................................................... 5
INSTALLATION .................................................................. 5
WATER PUMP ..................................................................... 6

REMOVAL ..................................................................... 6
INSTALLATION .................................................................. 6
INJECTORS ....................................................................... 7
REMOVAL ..................................................................... 7
INSTALLATION.. ................................................................ 8
CYLlNDER HEAD ................................................................... 9

REMOVAL ..................................................................... 9
INSTALLATION.. ................................................................ 10
TURBOCHARGER ................................................................... 11
REMOVAL ..................................................................... 11
INSTALLATION .................................................................. 12
COMPRESSOR 13
REMOVAL .:::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::: 13
INSTALLATION .................................................................. 13
AFTERCOOLER .................................................................... 14
REMOVAL ..................................................................... 14
INSTALLATION .................................................................. 15
RADIATOR ........................................................................ 16
REMOVAL ..................................................................... 16
INSTALLATION .................................................................. 19
OILCOOLER ...................................................................... 21
REMOVAL ..................................................................... 21
INSTALLATION.. ................................................................ 21
13-1
ENGINE .......................................................................... 22
REMOVAL ..................................................................... 22
INSTALLATION .................................................................. 28
FUELTANK ....................................................................... 34
REMOVAL ..................................................................... 34
INSTALLATION .................................................................. 34
t 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.
13-2
DISASSEMBLY AND ASSEMBLY STARTING MOTOR
STARTING MOTOR
REMOVAL
A Disconnect the cable from the negative

terminal of the battery.
(-)
Remove catch, then open hood.
Disconnect wires (1, 2, and 3).
Remove the safety relay (4) from engine mounting

bracket.
Remove the starter motor (5) from engine flywheel

housing.
t For details, see the Engine Shop Manual.
STARTING MOTOR
INSTALLATION
1. Install the starter motor (5) to flywheel housing.

+ For details, see the Engine Shop Manual.
2. Install the safety relay (4) to engine mounting

bracket.
3. Connect wires (3, 2, and 1).
4. Close hood, then lock wlth catch.
5. Connect cable to negative (-) terminal of battery.
13-3
DISASSEMBLY AND ASSEMBLY ALTERNATOR
ALTERNATOR
REMOVAL
A Disconnect the cable from the negative (-)

2. Disconnect wires (1, 2, and 3).
3. Remove the alternator assembly (4).

* For details, see the Engine Shop Manual.
ALTERNATOR
INSTALLATION
1. Install alternator assembly (4), then partially tighten

mounting bolt and nut.
t For details of the alternator, see the Engine
Shop Manual.
2. Fit belt in pulley groove and install.

3. Connect wires (3, 2, and 1).
4. Close hood, then lock with catch.
5. Connect cable to negative (-) terminal of battery.
13-4
FUEL INJECTION PUMP
REMOVAL
2. Disconnect control cable rod (1).
3. Remove the fuel filter (2) and disconnect fuel tube

(4).
4. Disconnect fuel return hose (3). Remove injection

pump side.
5. Remove the fuel injection pump (5).

FUEL INJECTION PUMP

INSTALLATION
1. Install the fuel injection pump (5).

2. Connect fuel return hose (3).
3. Install the fuel filter (2) and connect fuel tube (4).
4. Connect control cable rod (1).
13-5
DISASSEMBLY AND ASSEMBLY WATER PUMP
WATER PUMP
REMOVAL

(-)
1. Remove catch, then open hood. Loosen drain valve

(l), and drain cooling water.
t If the coolant contains antifreeze, dispose of it
correctly.
Cooling water: 50@

L12AH008
2. Disconnect wires (2, 3, and 4) from the alternator.
3. Remove the fan guard (5) from the radiator.
4. Remove the fan belt (6) and the alternator (7).

5. Remove the water pump (8) from engine.

WATER PUMP
INSTALLATION
1. Install the water pump (8) to engine.

2. Install the alternator (7) and the fan belt (6) to

engine.
3. Install the fan guard (5) to radiator.
4. Connect wires (4, 3, and 2) to the alternator.
5. Tighten drain valve (1) and add water through water

filter to specified level.
Q Cooling water: 5OP
t Run the engine to circulate the water through

the system. Then check the water level again.
7. Connect cable to negative (-) terminal of the bat-

tery.
13-6
DISASSEMBLY AND ASSEMBLY INJECTORS
INJECTORS
REMOVAL
A Stop the machine on level ground and install

the safety bar on the frame. Lower the work
equipment to the ground and stop the engine.
Then apply the parking brake and put blocks
under the wheels to prevent the machine from
moving.
2. Loosen band (1) of air cleaner assembly (2). Dis-

cleaner (2).
intake hose first.

muffler (6). Disconnect from turbocharger (3) then

haust muffler.
6. Remove the injector (10) from the engine.

13-7
DISASSEMBLY AND ASSEMBLY INJECTORS
INJECTORS
INSTALIATION
1. Install the injectors (10) to the engine cylinder head.

2. Install air connector (9) to the engine.
3. Install brackets (7 and 8) to the air cleaner and the

exhaust muffler.
4. Tighten band (4) and install bolt (5) to exhaust

muffler (6). Connect to turbocharger (3), then install
exhaust muffler.
5. Tighten band (1) to air cleaner (2). Connect hose to

turbocharger (3), then install air cleaner.
13-8
DISASSEMBLY AND ASSEMBLY CYLINDER HEAD
CYLINDER HEAD
REMOVAL

moving.

cleaner (2).
+ When removing the air cleaner, remove the
intake hose first.

muffler (6). Disconnect from turbocharger (3), then

haust muffler.
6. Remove the engine head cover (10) and cylinder

head (11).
13-9
DISASSEMBLY AND ASSEMBLY CYLINDER HEAD
CYLINDER HEAD
INSTALIATION
1. Install the engine cylinder head (11).

2. Install the engine head cover (10).

3. Install brackets (7 and 8) to air cleaner and exhaust

muffler.

exhaust muffler.

13-10
DISASSEMBLY AND ASSEMBLY TURBOCHARGER
TURBOCHARGER
REMOVAL

the safetv bar on the frame. Lower the work
moving.

cleaner (2).
intake hose first.

muffler (6). Disconnect from turbocharger (3), then
remove exhaust muffler.

haust muffler.
5. Remove air connector (9) from the engine.
6. Remove the turbocharger (3) from the engine.

13-11
DISASSEMBLY AND ASSEMBLY TURBOCHARGER
TURBOCHARGER
INSTALLATION
1. Install the turbocharger (3) to the engine.

2. Install air connector (9) to engine.

muffler.

exhaust muffler.

turbocharger (3) then install air cleaner (2).
13-12
DISASSEMBLY AND ASSEMBLY COMPRESSOR
COMPRESSOR
REMOVAL

the safety bar on the frame. Lower the bucket
to the ground and stop the engine. Then apply
the parking brake and put blocks under the
wheels to prevent the machine from moving.
1. Remove catch, then open hood (1) and fii lock (2).
2. Loosen drain valve (5) and drain air from air tank.
3. Disconnect hose (3) and tubes (4, 6, 7, and 8) from

the air compressor.
4. Remove the air compressor (9) from the engine.

COMPRESSOR
INSTALLATION
1. Install the air compressor assembly (9) to the

engine.
2. Connect hose (3) and tubes (4, 6, 7, and 8) to air

compressor.
13-13
DISASSEMBLY AND ASSEMBLY AFTERCOOLER
AFTERCOOLER
REMOVAL

the safetv bar on the frame. Lower the work
moving.
2. Loosen band (1) of air cleaner assembly (2), dis-

cleaner (2).
+ When removing the air cleaner, remove the
intake hose first.

muffler (6). Disconnect from turbocharger (3) then

haust muffler.
6. Remove the air intake cover (IO).

* When removing the air intake cover, remove the
air crossover tube.
13-14
DISASSEMBLY AND ASSEMBLY AFTERCOOLER
AFTERCOOLER
INSTALLATION
1. Install the air intake cover (10) to engine cylinder

head.
2. Install air connector (9) to engine air intake cover.

muffler.

exhaust muffler.
5. Tighten band (1)to air cleaner (2). Connect hose to

6. Close hood. then lock with catch.
13-15
DISASSEMBLY AND ASSEMBLY RADIATOR
RADIATOR
REMOVAL

a Y Loosen the oil filler cap slowly to release the

4 pressure inside the hydraulic tank. Then operate
the control levers several times to release the
L LlOBZOO2_
remaining pressure in the hydraulic piping.
l Loosen plug (1) at the top of the hydraulic tank

filter, and plug (2) of the pump piping to prevent the
oil inside the tank from flowing out.
t Disconnect the cable from the negative (-) terminal

of the battery.
1. Draining water
Loosen drain valve (3) and drain cooling water.
t If the coolant contains antifreeze, dispose of it
correctly.
Coolant water: 5OP
2. Radiator 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 connector (7) of working lamp
wiring.
13-16
4. Engine hood
1) Close engine hood (4) and install safety bolts
(8).
424P85 I
,, ,. -.
2) Remove mounting bolts (9) of engine hood, and

baffle seat (1OA).
3) Raise engine hood (4) about 300 mm, remove

mounting bolts (10) of left and right safety wires
(ll), then lift off engine hood (4).
Engine hood: 128 kg
5. Radiator hoses and tube

1) Disconnect radiator upper hoses (12 and 13).
2) Disconnect radiator hose (14).
+ Loosen the hose clamps at the connections
with the radiator.
6. Hydraulic piping
Disconnect oil cooler hoses (15, 16, 17, and 18)
from tube connector at bottom of radiator.
l Coyer to prevent dirt or water from entering.
7. support
Sling radiator, then remove mounting bolts at
radiator side of radiator support (19).
8. Fan guard, engine fan

1) Remove hose (20) and remove fan guard (21).
2) Remove the engine fan.
+ Be careful not to damage the radiator fins
when removing.
9. Radiator
Remove mounting bolts, then lift off radiator (22).
Radiator: 116 kg
13-18
RADIATOR
INSTALLATION
1. Radiator
Raise radiator (23) set in mounting position and
install mounting bolts.
+ Tighten the mounting bolts partially, then tight-
en them fully after installing the engine hood.
2. Fan, fan guard

1) Install the fan to engine.
2) Install the hose (20) and install fan guard (21).
t Be careful not to damage the radiator fins
when installing.
+ Install so that the clearances between the
fan and fan guard at the left and right, and
top and bottom are the same.
3. support
Install radiator support (19) to radiator.
5. Radiator hoses
1) Connect radiator lower hose (14).
Tighten the hose clamps at the connections
with the radiator.
2) Connect radiator upper hoses (12 and 13).
3) Install clamp of radiator cooling water drain
hose.
t Install the hose without twisting or interfer-
ence.
6. Engine hood
1) Raise engine hood, install left and right safety
wires (11) and set in mounting position, then
tighten the mounting bolt (10).
2) Install mounting bolts (9) of engine hood, and
baffle seat.
t Tighten the mounting bolts of the radiator
so that the clearances between the engine
fan and shroud at the left and right, and top
and bottom are the same.
and support fully.
3) Remove safety bolts, open hood and fit lock.
7. Wiring
1) Connect connector (6) of wiring of coolant level
sensor.
2) Connect connector (7) of working lamp wiring.
8. Radiator grille
Close hood, lock with catch, then install radiator
grille.
9. Refilling with oil, water

1) Tighten plug and add engine oil through oil filler
(23) to the specified level.
2) Tighten drain valve and add water through
water filler (24) to the specified level.
Q Coolant: 504
t Run the engine to circulate the oil and

water through the system. Then, check the
oil and water levels again.
LlOBZOO4 -
13-20
DISASSEMBLY AND ASSEMBLY OIL COOLER
OIL COOLER
REMOVAL
2. Remove the oil filter (1).

+ Use a filter wrench 118 to 131 mm.
3. Disconnect hose (2) between oil filter and turbo-

charger.
4. Remove oil cooler (3) from the engine.

OIL COOLER
INSTALLATION
1. Install the oil cooler (3).

2. Connect hose (2).
3. Install the oil filter (1).

13-21
DISASSEMBLY AND ASSEMBLY ENGINE
ENGINE
REMOVAL

iA Y Loosen the oil filler cap slowly to release the


+ Disconnect the cable from the negative (-) terminal

of the battery.
1. Draining water
Loosen drain valve (3) and drain cooling water.
+ If the coolant contains antifreeze, dispose of it
correctly.
Cooling water: 504
2. Radiator 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 connector (7) of working lamp
wiring.
13-22
4. Engine hood
1) Close engine hood (4), and install safety bolts
(8).
2) Remove mounting bolts (9) of engine hood, and

baffle seat (lOA).
3) Raise engine hood (4) about 300 mm, remove

mounting bolts (10) of left and right safety wires
(11) then lift off engine hood (4).
Engine hood: 128 kg
5. Radiator hoses and tube

1) Disconnect radiator upper hoses (12 and 13).
2) Disconnect radiator hose (14).
* Loosen the hose clamps at the connections
with the radiator.
13-23
6. Hydraulic piping
Disconnect oil cooler hoses (15, 16, 17, and 18)
from tube connector at bottom of radiator.
+ Cover to prevent dirt or water from entering.
7. support
Sling radiator, then remove mounting bolts at
radiator side of radiator support (19).

1) Remove hose (20) and remove fan guard (21).
2) Remove the engine fan.
t Be careful not to damage the radiator fins
when removing.
9. Radiator
Remove mounting bolts, then lift off radiator (22).
Radiator: 166 kg
13-24
10. Electric wiring

1) Disconnect wiring (24) between battery and
starting motor at starting motor end.
2) Disconnect wiring (25) between safety relay and
starting motor at starting motor end.
3) Disconnect connector (26), then safety relay.
4) Remove the safety relay (27) from engine
flywheel housing.
5) Disconnect wiring (28) between the engine and
frame at the engine end.
5) Disconnect wiring (29) from the alternator.
7) Disconnect connector (30) from the engine.
8) Disconnect connector (31) . , of the fuel cut sole-
noid.
9) Disconnect connector (32) of the engine oil
level sensor.
11. Fuel hoses

1) Disconnect hose (35) between fuel tank and
water sediment at water sediment end.
2) Disconnect fuel return hose (34) at the engine
injection pump end.
12. Air tube

Disconnect air tube (36) and hose (37) at air com-
pressor end.
13-25
13. Hydraulic piping

li Disconnect tubes (38 and 39) of charging pump
piping.
Remove the charging pump (40).
:I Disconnect tube (41) between oil cooler and
torque converter at torque converter end.
4) Disconnect tube (42) between oil cooler and
transmission at transmission end.
5) Remove tube clamp (43).
8) Disconnect hose (44) between hydraulic tank
and oil cooler at hydraulic tank end.
14. Fuel control cable

1) Disconnect fuel control cable (45) from ball joint
(48).
2) Remove fuel control cable (45) from bracket
(47) *
15. Brake hose

Disconnect hose (44) between slack adjuster and
brake chamber from slack adjuster.
13-26
16. Transmission stand

Put stand under transmission (45).
t Use a stand with adjustable height, and fix it so
that it cannot slip out of position.
17. Engine assembly

1) Remove muffler (46) and air cleaner (46-l).
* When removing the muffler and the air
cleaner, be careful not to damage.
Muffler: 20 kg
C?lkg Air cleaner: 12 kg
2) Remove bracket (47) for engine oil drain valve

from fuel tank (46).
3) Sling engine (49) then remove mounting bolts
(50) of engine and torque converter.
4) Remove engine mounting bolts (51), then lift off
engine assembly.
+ Note how the cushions and spacers are
installed, and used for reference when
installing.
+ The ring gear of the engine flywheel is
meshed with the ring gear of the torque
converter and the shaft, so when raising the
engine, keep the assembly horizontal when
removing.
+ When removing the engine, be careful not
to damage the suction tube of the fuel tank.
Engine assembly: 606 kg
13-27
ENGINE
INSTALlATlON
1. Engine assembly
1) Raise engine (49) set in mounting position and
tighten mounting bolts (50) of engine and
torque converter uniformly.
t Install the engine horizontally. Be careful to
mesh the flywheel ring gear and torque
converter ring gear, and tilt the torque
converter shaft correctly.
O-ring at contact face of engine and torque

converter: Grease (G2-Ll)
2) Install engine mounting bolts (51).

+ Be careful to assemble the cushions and
spacers facing in the correct direction.
Iz] Mounting bolt: 94.5+10.5 kgm

Width across the flats: 36 mm
3) Install bracket (47) for engine oil drain valve to

fuel tank (46).
4) Set muffler (46) in mounting position, then
13-28
2. Transmission stand
Remove stand from under transmission (45).
3. Brake hose
Connect hose (44) between slack adjuster and
brake chamber from slack adjuster.
23F

1) Install fuel control cable (45) to bracket (47).
2) Connect fuel control cable (45) to ball joint (46).
5. Hydraulic piping
1) Connect hose (44) between hydraulic tank and
oil cooler.
2) Install tube clamp (43).
3) Connect tube (42) between oil cooler and
transmission.
4) Connect tube (41) between oil cooler and
torque converter.
--
13-29
5) Install the charging pump (40).

* See installation of torque converter charg-
ing pump.
6) Connect tubes (38 and 39) to charging pump.
t See installation of torque converter charg-
ing pump.
6. Air tube
Connect air tube (36) and hose (37) to air compres-
sor.
7. Fuel hoses
1) Connect hose (35) between fuel tank and water
sediment.
2) Connect fuel return hose (34) to the engine
injection pump.
LlZBD006
6. Electric wiring
1) Connect connector (32) to the engine oil level
sensor.
2) Connect connector (31) to the fuel cut solenoid.
3) Connect connector (30) to engine water sensor.
13-30
4) Connect wiring (29) to the alternator.

5) Connect wiring (28) between the engine and
frame.
6) Install the safety relay (27) to engine flywheel
housing.
7) Connect connector (26) to safety relay.
8) Connect wiring (25) between safety relay and
starting motor.
9) Connect wiring (24) between battery and start-
ing motor.
9. Radiator
Raise radiator (72), set in mounting position and

1) Install the engine fan.
2) Install the fan guard (21) and connect hose (20)
to the radiator cap.
11. support
Install radiator support (19) to radiator.
t Tighten the mounting bolts partially, then tight-

Connect oil cooler hoses (15, 16, 17, and 18) to
tube at bottom of radiator.
t Fit the O-rings securely in the grooves, and
make sure that they are not caught when
installing.
13. Radiator hoses

1) Connect radiator lower hose (14).
Tighten the hose clamps at the connections
with the radiator.
2) Connect radiator upper hoses (12 and 13).
3) Install clamp of radiator cooling water drain
hose.
ence.
14. Engine hood

1) Raise engine hood, install left and right safety
wires (ll), and set in mounting position.
2) Install mounting bolts (9) of engine hood, and
baffle seat (10).
so that the clearances between the engine
fan and shroud at the left and right, and top
and bottom are the same.
* Tighten the mounting bolts of the radiator
and support fully.
3) Remove safety bolts, open hood and fit lock.
15. Wiring
1) Connect connector (6) of wiring of coolant level
sensor.
2) Connect connector (7) of working lamp wiring.
13-32
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
2) Tighten drain valve and add water through
water filler (53) to the specified level. 52
Coolant: 504
* Run the engine to circulate the oil and -@ j?EJ

water through the system. LlOBzoO4 -
Then check the oil and water levels again. i .._-- _
13-33
DISASSEMBLY AND ASSEMBLY FUEL TANK
FUEL TANK
REMOVAL

the safetv bar on the frame. Lower the bucket
Check that fuel is drained completely.

Remove engine oil drain valve and clamp for cool-
ant hoses.
Fuel: 3056
Disconnect fuel hoses from fuel tank.

Disconnect wiring for fuel unit from connector.
Lay a pallet below fuel tank. Lift off fuel tank with
care of balance.
Fuel tank: 215 kg
FUEL TANK
INSTALLATION
* When raising fuel tank, keep it horizontal and set in

mounting position.
t Tighten mounting bolts diagonally.
a Mpunting bolt: 94.5? 10.5 kgm

(width across flats: 36 mm)
tb Fuel tank: 3059
13-34
POWER TRAIN
21 STRUCTURE AND FUNCTION
GENERAL ......................................................................... 2
HYDRAULIC CIRCUIT FOR POWER TRAIN .............................................. 4
HYDRAULIC CIRCUIT DIAGRAM FOR POWER TRAIN ...................................... 5
TORQUE CONVERTER AND TRANSMISSION PIPING . 6
TORQUE CONVERTER ........................
TORQUE CONVERTER OIL FILTER ...............
TORQUE CONVERTER OIL COOLER .............
TORQUE CONVERTER RELIEF VALVE ............
TRANSMISSION .............................
TRANSMISSION CONTROL VALVE ............... 21

UPPERVALVE ........................... 22
LOWERVALVE.. ......................... 23
SOLENOID VALVE ......................... 25
EMERGENCY MANUAL SPOOL .............. 26
PRIORITY VALVE ......................... 29
MODULATING VALVE AND QUICK RETURN VALVE 30
ACCUMULATOR VALVE .................... 33
PILOT REDUCING VALVE ................... 36
TRANSMISSION PILOT FILTER .................. .......................................
TRANSFER . . ............................... ....................................... 38
DRIVE SHAFT ............................... ....................................... 39
AXLE MOUNT ............................... ....................................... 40
AXLE AND DIFFERENTIAL ..................... ....................................... 42

TORQUE PROPORTIONING DIFFERENTIAL ..... ....................................... 47
FINALDRIVE ............................... ....................................... 49
TIRE AND WHEEL ........................... ....................................... 50
21-I
STRUCTURE AND FUNCTION GENERAL
GENERAL
10
/ 13
I 15
I 6I \ \
16 21 423FOO3
Outline
l The power from engine (1) passes from the flywheel l The output shaft of transmission (5) transmits power
through the ring gear and is transmitted to torque through the gear of the transfer to the transfer
converter (2). The torque converter uses oil to output shaft. The power from the transfer output
convert the transmitted torque to correspond to shaft is then sent to the front and rear axles.
changes in the load. It transmits the power to the The power for the front axle passes through center
transmission input shaft. In addition, the power from drive shaft (15) and front drive shaft (13) and is
the engine passes through the pump drive gear of transmitted to front axle (10); the power for the rear
the torque converter and is sent to the hydraulic, axle passes through rear drive shaft (16) and is sent
switch and steering pump (4), and torque converter to rear axle (21).
charging pump (3) to drive these pumps. 0 The power transmitted to front axle (10) and rear
l Transmission (5) has six clutches which are ac- axle (21) is reduced by the pinion gear and ring
tuated hydraulically by operating the solenoid valve gear of differentials (11,20). It then passes from the
to move the directional spool and speed spool of differential to the sun gear shaft (axle shaft) of final
the control valve. The transmission has a speed drives (8, 18).
selection of four FORWARD and four REVERSE
speeds. The speeds are selected manually.
21-2
1. Engine 8. Final drive (Front) 15. Center drive shaft

2. Torque converter 9. Brake (Front) 16. Rear drive shaft
3. Torque converter charging pump 10. Front axle 17. Rear wheel
4. Hydraulic, switch and steering pump 11. Differential (Front) 18. Final drive (Rear)
5. Transmission 12. Parking brake 19. Brake (Rear)
6. Transfer 13. Front drive shaft 20. Differential (Rear)
7. Front wheel 14. Flanged bearing 21. Rear axle
21-3
HYDRAULIC CIRCUIT FOR POWER TRAIN
Engine running, gear shift levers at Neutral.
20 19 18
_ 17 16 15
423FO508
21-4
HYDRAULIC CIRCUIT DIAGRAM FOR POWER TRAIN 15

l-----i
16
T;A37-1A 1 Wj
1.
rlM
Transfer case
3 SAL(3)-056
13.
I
LL 23
Transmission lubrication relief valve

20
E423F006
2. Strainer 14. Transmission lubrication

3. Torque converter charging pump 15. Reverse clutch
4. Torque converter oil filter 16. Forward clutch
5. Priority valve 17. 4th clutch
6. Modulating valve 18. 3rd clutch
7. Quick return valve 19. 2nd clutch
8. Pilot oil filter 20. 1st clutch
9. Pilot reduction valve 21. Accumulator valve
IO. Torque converter relief valve 22. Reduction spool, F-R spool
11. Torque converter 23. Emergency spool
12. Oil cooler 24. Solenoid valve
21-5
STRUCTURE AND FUNCTION TORQUE CONVERTER AND TRANSMISSION PIPING
TORQUE CONVERTER AND

TRANSMISSION PIPING
\ :
423F602
1. Transmission pilot filter 5. Torque converter charging pump

2. Transmission 6. Radiator
3. Transmission control valve 7. Torque converter oil cooler
4. Torque converter 8. Torque converter oil filter
21-6
STRUCTURE AND FUNCTION TORQUE CONVERTER
TORQUE CONVERTER
Specifications
Model: TCA37-1 A
Type: 3-elemen It, single stage, single phase
Stall torque ratio 3.27
Mount of torque converter charging pump

Housing
Mount for hydraulic, switch and steering pump
Section X-X 424FOO6 21-7

Section Y-y
E424F007
4. Pilot 8. Pump A. Inlet port

5. Drive case 9. PTO gear (Drive) B. Outlet port
6. Turbine 10. Stator
7. Idler gear 11. Transmission input shaft
21-8
Flow of power
l The torque converter is installed between the engine
and transmission. The power from the engine
passes from the flywheel and enters drive case (5).
Drive case (5) pump (8) and PTO gear (drive) (9)
are fKed with bolts. They are rotated directly by the
rotation of the engine.
The power of pump (8) uses oil to rotate turbine (6).
This transmits power to transmission input shaft
(11).
l The power of drive case (5) passes through PTO
gear (drive) (9) and is also used as the power to
drive the gear pumps
Engine q
Flow of oil
l The oil pressure is adjusted by the torque converter
relief valve and then enters inlet port A, passes
through the oil passage in housing (7) and flows to
pump (8). In pump (8) centrifugal force is applied.
The oil enters turbine (6) and the energy of the oil
is transmitted to the turbine.
Turbine (6) is fixed to transmission input shaft (1 l),
so the power is transmitted to the transmission
input shaft.
The oil from turbine (6) is sent to stator (10) and
again enters the pump. However, part of the oil
passes from the stator through outlet port 6 and is
sent to the cooler.
424FOO9
STRUCTURE AND FUNCTION TORQUE CONVERTER OIL FILTER
TORQUE CONVERTER OIL FILTER

1. Relief valve
2. Element
3. Center bolt
4. Drain plug
Filtration area: 8,900 cm2

Relief pressure: 3.25 kg/cm2
To transmission
control valve
1111
423FOO9
Operation
0 The oil from the torque converter charging pump (5)
enters the filter inlet port A and passes from the
outside of element (2) to the inside. It then flows to
the outlet port B.
LI-LI 423FOlO
0 If the element (2) is clogged with dirt, or the oil To transmission

control valve
temperature is low, the pressure at the inlet port A
rises. When this happens, the oil from the inlet port
A opens relief valve (1) and flows directly to the
outlet port B. This prevents damage to the pump or
filter element (2).
423FOll
21-10
STRUCTURE AND FUNCTION TORQUE CONVERTER OIL COOLER
TORQUE CONVERTER OIL COOLER

Outline
l The oil which comes out from the torque converter
outlet port is at a high temperature because of the
energy used in transmitting the power. This torque
converter oil passes through torque converter oil
inlet port and enters the oil cooler. Here it is cooled
by the engine cooling water. The oil then flows out
from torque converter oil outlet port, lubricates the
transmission and returns to the transfer case.
423F603
1. Radiator A. Hydraulic oil inlet port

2. Torque converter oil cooler B. Hydraulic oil outlet port
3. Hydraulic oil cooler C. Torque converter oil outlet port
D. Torque converter oil inlet port
21-11
STRUCTURE AND FUNCTION TORQUE CONVERTER RELIEF VALVE
TORQUE CONVERTER RELIEF VALVE

Function
To each transmission SDOOI
l The torque converter relief valve acts to maintain
the pressure of the oil entering the torque con-
verter at a constant pressure. It drains the oil if ft
goes above the specified pressure.
Operation
l The oil from the pump passes through priority valve
(1) and actuates modulating valve (2). It then enters
port A and flows to the torque converter.
To transmission From pump

lubrication
423FO42
l If the oil at port A goes above the specified pres-
sure, it passes through orifice “a” of torque con-
verter relief valve (3) and enters port B. It then
moves torque converter relief valve (3) to the left. To each transmission spool
As a result, the oil from port A is drained, and the ...:.y.:
..........:.:.:.:
..,.
,.,.....,.,..,.....
:.+:...~...:llii
oil flowing to the torque converter is maintained at ;:I:

{jjj
....
..
2..
..,.
the specified pressure. . .

....
::::
....
.,
,o..
:j:j.
.A.
//
.:.:
....
.
.:.:
::;
w
:.:.
.:.:
::::
‘.‘.
:::::
..,,,.
...>:.:
..\.
Oil cooler
:.:.:.:.:.:::.:.I:.:.:
.;::
To transmission
lubrication
f;‘;
F
From pump
423FO43
21-12
STRUCTURE AND FUNCTION TRANSMISSION
TRANSMISSION
/ Section B-B
7
L07CR031
1. Oil filler
2. Transmission input shaft
L_ &J 3.
4.
Transmission
Transfer
5. Transmission control valve
View Z Pilot filter
6.
7. Strainer
8. Transfer output coupling
21-13
TRANSMISSION foldout
See foldout #l at end of book.
Rest of page is blank.
21-14
Outline
Speed range Clutch combination
l The transmission consists of a 4-FORWARD, 4-
REVERSE speed planetary gear transmission,
Fl No. 2, No. 6
transfer, and transmission control valve.
e In the transmission, the power of the input shaft is F2 No. 2, No. 5
I
changed by the combination of No. 1 or No. 2
clutch with No. 3, 4, 5 or 6 clutch to give FOR- F3 I No. 2, No. 4
WARD 1 - 4 or REVERSE 1 - 4 speed, and is
transmitted to the output shaft. F4 I No. 2. No. 3
Rl I No. 1, No. 6
R2 I No. 1, No. 5
R3 I No. 1, No. 4
R4 I No. 1. No. 3
Operation of Clutch
e Engaged
The oil sent from the transmission control valve
passes through the oil passage inside the trans-
mission. When it reaches the rear of piston (2), it
moves the piston (2).
e When the piston (2) moves, discs (4) and plates (5) 423FO18
are pressed together. Ring gear (6) is meshed with

discs (4), so the rotation of ring gear is stopped.
l Disengaged
When the supply of oil from the transmission control
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
discs (4) and plates (5) are separated. Ring gear (6)
then rotates freely, and no power is transmitted.
423FO19
21-15
FORWARD 1ST
LO7CRO32
l In 1st FORWARD, No. 2 clutch and No. 6 clutch are 0 The power from the torque converter is transmitted
engaged. The power transmitted from the torque to the input shaft (2). The rotation of the input shaft
converter by input shaft (2) is transmitted to output (2) is transmitted to planetary gear (15) through sun
shaft (28). gear (14).
0 No. 2 clutch is actuated by the hydraulic pressure l Ring gear (16) is held in position by No. 2 clutch,
applied to the clutch piston, and it locks ring gear so the rotation of planetary gear (15) rotates carrier
(16) in position. No. 6 clutch is actuated by the (34), which is on the inside of ring gear (16). This
hydraulic pressure applied to the clutch piston, and carrier is connected to No. 5 carrier (29) through
holds gear (26) in position. No. 4 ring gear (31), so when No. 6 clutch is
actuated, the rotation of carrier (29) is transmitted
to gear (26) and rotates output shaft (28).
21-16
FORWARD 2ND
0 In 2nd FORWARD, No. 2 clutch and No. 5 clutch 0 Ring gear (16) is held in position by No. 2 clutch,
are engaged. The power transmitted from the so the rotation of planetary gear (15) rotates carrier
torque converter by input shaft (2) is transmitted to (34), which is on the inside of ring gear (16). The
output shaft (28). rotation of carrier (34) is transmitted through ring
l No. 2 clutch and No. 5 clutch are actuated by the gear (31) to carrier (29).
hydraulic pressure applied to the clutch piston, and 0 Ring gear (23) is held in position by No. 5 clutch,
they hold ring gears (16) and (23) in position. so the rotation of carrier (29) rotates planetary gear
l The power from the torque converter is transmitted (24). The planetary gear rotates on the inside of ring
to the input shaft (2). The rotation of the input shaft gear (23), and rotates sun gear (27). The sun gear
is transmitted to planetary gear (15) through sun rotates output shaft (28).
gear (14).
21-17
FORWARD 3RD
CLUTCH NO. 1
CLUTCH POS. I!!!--
34 29 31 32
Y
0 Ring gear (16) is held in position by No. 2 clutch,

l In 3rd FORWARD, No. 2 clutch and No. 4 clutch are so the rotation of planetary gear (15) rotates carrier
engaged. The power transmitted from the torque (34), which is on the inside of ring gear (16).
converter by input shaft (2) is transmitted to output 0 Ring gear (31) is held in position by No. 4 clutch,
shaft (28). so the rotation of carrier (34) is transmitted to
l No. 2 clutch and No. 4 clutch are actuated by the planetary gear (32). The planetary gear rotates on
hydraulic pressure applied to the clutch piston, and the inside of ring gear (31), and rotates sun gear
they hold ring gears (16 and 31) in position. (29). The sun gear rotates output shaft (28).
l The power from the torque converter is transmitted
to the input shaft (2). The rotation of the input shaft
is transmitted to planetary gear (15) through sun
gear (14).
21-18
FORWARD 4TH
3 14 15 16 1Q 20 21
: I’
CLUTCH NO.
0 In 4th FORWARD, No. 2 clutch and No. 3 clutch are l Ring gear (16) is held in position by No. 2 clutch,
engaged. The power transmitted from the torque so the rotation of planetary gear (15) rotates carrier
converter by input shaft (2) is transmitted to output (34) which is on the inside of ring gear (19).
shaft (28). l Ring gear (19) is held in position by No. 3 clutch,
0 No. 2 clutch and No. 3 clutch are actuated by the so the rotation of carrier (34) is transmitted to
hydraulic pressure applied to the clutch piston, and planetary gear (20). The planetary gear rotates on
they hold ring gears (16 and 19) in position. the inside of ring gear (19), and rotates sun gear
0 The power from the torque converter is transmitted (21), which forms one unit with output shaft (28).
gear (14).
21-19
REVERSElST
L07CR036
0 In 1st REVERSE, No. 1 clutch and No. 6 clutch are 0 Carrier (35) is held in position by No. 1 clutch, so
engaged. The power transmitted from the torque the rotation of planetary gear rotates the ring gear.
converter by input shaft (2) is transmitted to output Ring gear (13) rotates in the opposite direction from
shaft (28). the input shaft. Ring gear (13) rotates carrier (34),
0 No. 1 clutch is actuated by the hydraulic pressure and the rotation of carrier (34) rotates ring gear
applied to the clutch piston, and it locks carrier (35) (31) which then rotates carrier (29). Carrier (29)
in position. No. 6 clutch is actuated by the hydraulic rotates No. 6 clutch. When No. 6 clutch is actuated,
pressure applied to the clutch piston and holds ring the rotation of carrier (29) is transmitted to gear (26)
gear (26) in position. and rotates output shaft (28).
0 The power from the torque converter is transmitted
gear (9).
21-20
STRUCTURE AND FUNCTION TRANSMISSION CONTROL VALVE
TRANSMISSION CONTROL VALVE
-z
View Z
\
10 423FO25C
1. Lower valve 6. Accumulator pressure pick-up

2. Upper valve 7. Priority pressure pick-up
3. Pilot reducing pick-up 8. Modulating pressure pick-up
4. Torque converter relief pressure pick-up 9. Transmission solenoid valve
5. Transmission lubricating pressure pick-up IO. Connector
21-21
UPPER VALVE
E423F027A
Section A-A
Outline
l The oil from the torque converter charging pump The other oil line flows to the modulating valve (3)
enters port A. It is then divided into two lines: one and quick return valve (2). The action of the modu-
to the clutch pistons, and the other to the pilot lating valve (3) and quick return valve (2) raises the
reducing valve (11). The priority valve (4) acts to clutch pressure smoothly. This reduces the shock
control so that the pilot reducing valve (11) is the when actuating the FORWARD, REVERSE and lst,
priority circuit. 2nd, 3rd, and 4th speed clutches to change gear.
0 The oil flowing to the pilot reducing valve (11) con- The accumulator valve (8) controls the oil flow at
trols the pilot pressure used to actuate the direc- the 2nd clutch and reduces the filling time when
tional and speed spools. The oil regulated by the shifting from 2nd to 1st or 3rd speed.
pilot reducing valve (11) passes through the orifice The lubrication valve (13) controls the lubrication oil
in each spool and fills the spool. inside the transmission.
21-22
LOWER VALVE
10 ‘8
423F028A
Section B-B
1. Torque converter relief valve 9. Pilot reducing valve

2. Quick return valve 10. FORWARD spool
3. Modulating valve 11. Lubrication valve
4. Priority valve 12. Reverse spool
5. Valve body 13. 3rd spool
6. 1st spool 14. Accumulator
7. 2nd spool
8. 4th spool
21-23
Reverse
Forward
4th
3rd
2nd
L
- 1St
1
M
N
9’
Section A-A
423FO26
Actuation table for solenoid valve and clutch

F R 1 2 3 4
1 I
1. Connector
2. 1st solenoid valve
3. 2nd solenoid valve
4. 3rd solenoid valve
5. 4th solenoid valve
6. FORWARD solenoid valve
7. REVERSE solenoid valve
8. Body 1 I I I
9. Emergency manual spool I
Rl 0 0
Structure
l The transmission solenoid valve is installed to the
transmission together with the transmission valve.
When the directional lever or speed control lever
are operated, the solenoid valve is actuated and
moves the spool inside the transmission valve.
21-24
SOLENOID VALVE
Function
e There is one solenoid valve installed for each
directional and speed spool in the transmission
valve.
When the directional lever and speed control levers
in the operator’s compartment are operated, the
solenoid valve is actuated, and oil is drained to
actuate the directional and speed spools.
Operation
1) Solenoid valve OFF
The oil of spool (1) enters port A. However, valve
(2) shuts off the oil, so directional and speed spool
(1) does not move.
reducing valve 423FO31
2) Solenoid valve ON
When the directional and gear shift levers are
operated, the solenoid valve is pulled up.
The oil from directional and speed spool (1) enters
port A and flows from port B to the drain circuit.
Therefore, port A becomes the low pressure circuit,
and directional and speed spool (1) is actuated.
423 F032
21-25
EMERGENCY MANUAL SPOOL
Function
l If there is any failure in the electrical circuit of the
transmission control system, and the solenoid valve
does not work, the emergency manual spoof is
used. This spool is attached to each directional and
speed spool and is used to operate the transmis-
sion valve mechanically. (It is used to drive the
machine to a place where it can be repaired.)
t When using this spool, use extreme caution.
From auick
Operation
1. When solenoid valve is normal:
(Emergency manual spool is at normal position)
When the solenoid valve is working normally, the
spool is maintained in this position.
Oil from directional and speed spool (1) enters port
A, but it is shut off by solenoid valve (2).
reducing valve 423FO44
From quick
2. When solenoid valve is abnormal: return valve
a. Clutch in engaged position
(Emergency manual spool is pushed to the
left)
Emergency manual spool (3) is pushed to the
left, and the oil at port A is shut off regardless
of the action of solenoid valve (2). The oil
cannot flow to port 8, so the clutch is not
actuated.
reducing valve
423 F045
From quick
return valve
b. Clutch in engaged position
(Emergency manual spool is pulled to the
right)
When emergency manual spool (3) is pulled to
the right, the oil at port A is drained to port B
regardless of the operation of solenoid valve
(2). As a result, the clutch is actuated.
,.
From pilot
reducing valve 423 F046
21-26
FORWARD 1ST
1 St 2nd F R
T/C: Torque converter
1. Solenoid valve
2. Solenoid valve
3. Oil filter
.-.
.............i.. 4. Priority valve
::::::::::::::::j::
:::::‘::::::::::::::
.,~I
..I.,.,........
J 5. 1st spool
423F047B 6. FORWARD spool
7. Spring
8. Spring
9. Piston
10. Quick return valve
11. Pilot reducing valve
21-27
Operation
o When the directional and speed control levers are l The other oil line flows from priority valve (4) to
moved to FORWARD and 1st position, solenoid quick return valve (10). It then flows through orifice
valves (1 and 2) are opened. “a”, and directional and speed spools (5 and 6), and
l The oil from the pump passes through filter (3) and flows to the FORWARD clutch and 1st clutch. When
enters priority valve (4). it starts to flow to the clutch, it passes through
o The oil from the pump is divided into 2 circuits: one orifice “a” and creates a difference in pressure
goes to pilot reducing valve (ll), and the other between port C and port D. Quick return valve (10)
goes to the clutches. However, when the gear is moves to the right, and the oil at the rear of modu-
shifted, priority is given to the oil flowing to the lating valve piston (9) flows to drain circuit E. When
clutches. each clutch is filled with oil, the difference in pres-
l One of the two oil lines flows from the pilot reduc- sure between port C and port D disappears. The
ing valve through the orifice of each speed spool to valve is pushed back to the left by the difference in
the solenoid valve. However, solenoid valves (1 and area of the valves, and drain circuit E is closed.
2) of FORWARD spool (6) and 1st spool (5) are At this point, each clutch is filled with oil, but the oil
open, so the oil passing through the orifice flows to has not reached the specified pressure. The oil at
the drain circuit. As a result, a difference in pressure port D flows through orifice “b” and reaches the
is created between port A and port B, and this over- back of modulating piston (9). The piston moves to
comes the force of springs (7 and 8). The port to the right and the clutch pressure rises slowly. When
the clutch is then engaged. the modulating piston reaches the end of its stroke,
the clutch pressure reaches the specified level, and
the clutch is completely engaged.
21-28
PRIORIlY VALVE
Function
l The priority valve (1) controls the minimum pressure
of the pilot reducing valve (2). In addition, the
priority valve (1) gives the oil flow to the pilot
reducing valve (2) priority over the other circuit.
To modulating valve To each transmission spool
Operation
l The oil from the pump flows to port A of priority
valve (1) and port B of pilot reducing valve (2).
Pilot
oil filter
&&
423FO33
To modulating valve To each transmission spool
0 The oil entering port A flows from oriiice “a” of

priority valve (1) to port D. The hydraulic pressure
and force of poppet spring (3) push back spring (4)
and move priority valve (1) to the right. When this
happens, port A and port C are connected, and the
oil flows from port C to the clutch spool.
423FO34
21-29
MODUlATlNG VALVE AND

QUICK RETURN VALVE
h/cm* 1
Function 40 - Shifting gear
l The modulating valve and quick return valve act
together to raise the transmission clutch pressure
30 -
slowly. In this way, they reduce the shock when E
shifting gear, and prevent the generation of peak 2
L
torque in the power train. As a result, operator 20 -
fatigue is reduced, and at the same time, operator i
comfort and the durability of the power train are in-
lo-
creased.
0
0
Immediately after shifting gear (Point A on Fig. 423FO35) Time (Set)

1)
423FO35
and speed spool
423 F036
To torque converter
Operation
l The oil sent from the pump flows from priority valve “a”, it creates a difference in pressure between port
(1) through port A, passes through modulating valve B and port C. The quick return valve moves to the
(2), and enters port B of quick return valve (3). The right and the oil flows to clutch (5). In addition,
oil passes through orifice “a” of quick return valve when quick return valve (3) moves to the right,
(3) and flows to the clutch piston, which has been drain port D is opened, and the pressurized oil at
actuated. However, when it passes through orifice the rear of piston (4) flows to the drain circuit.
21-30
2) Clutch pressure rising (Point B on Fig. 423FO35)
valve
To torque converter
423FO37
Operation
l As the pressure at the clutch piston rises, the At the same time, pressurized oil also passes
pressure at port C also rises. Quick return valve (3) through the orifice and enters poppet (7) of modu-
is pushed back to the left and drain port D is lating valve (2). It moves modulating valve (2) to the
closed. The oil from the pump flows from port C to left and some of the oil at port A flows to port G.
the clutch piston, and at the same time it flows from
orifice “b” through quick return valve (3) and enters
port E.
The oil at port E acts on the modulating piston (4).
It pushes back spring (6) and moves piston (4) to
the right.
21-31
3) Completion of rise in clutch pressure (Point C on Fig. 423FO35)
To torque converter 423FO38
Operation
e The oil entering port E continues to push piston (4).
When the piston reaches the end of its stroke, the
rise in pressure stops. When this happens, the
pressure reaches the set pressure of the modulating
valve. In addition, port F and port G are closed by
piston (4), so the oil at port A passes through port
G and flows to the torque converter.
21-32
ACCUMULATOR VALVE
Function
l The accumulator valve acts to reduce the filling time
when shifting gear by allowing the oil at the 2nd
clutch piston to escape slowly when shifting from
2nd to 1st. This allows the clutch to be engaged
smoothly when shifting from 2nd to 1st.
1. Shifting to 2nd
l When shifting to 2nd speed, the oil from the
pump passes through the quick return valve
and enters port A of the transmission spool (5).
When the 2nd transmission spool moves, port
A and port B are connected and the oil flows to
port c.
The oil at port C flows from check valve (2) and
orifice “a” to port D.
From quick return valve
423FO39A
From pilot
reducing valve
21-33
l As the pressure of the oil entering port D rises,

the oil continues to push accumulator valve (3)
to the left until it stops.
At the same time, oil is sent to the clutch piston
and actuates 2nd clutch (4).
I J?
423FQ40A
From pilot
reducing valve
21-34
2. Shifting from 2nd to 1st

l The oil from the clutch piston of 2nd clutch (4)
enters port D and acts on the rear of the check
valve (2). The oil from port D passes through
orifice “a” and flows to the drain circuit. In this
way the shock when shifting gears can be
reduced.

l-l
r
0
From pilot
J
423F041A
reducing valve
21-35
PILOT REDUCING VALVE
Function
l The pilot reducing valve acts to control the pressure
needed to actuate the transmission spools (2).
Operation
l The oil from the pump passes through the pilot filter
and enters port A of pilot reducing valve (1). The oil
passes through port B and enters through the
orifice of transmission spool (2) to fill the inside of
port c.
:yvalve
423FO30
l 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 (1) moves to the
right, and ports A and B are discontinued, so the
pressurized oil at port C is maintained at the same
pressure.
423FO29
21-36
STRUCTURE AND FUNCTION TRANSMISSION PILOT FILTER
TRANSMISSION PILOT FILTER
0
-______
-_______ 2
t I I
I I
1
423 F048
1. Oil filter head

2. Element
3. Case
Specification
Filtration area: 370 cm2
21-37
TRANSFER
TRANSFER
Outline
l The transfer is installed at the power output end of
the transmission and is secured to the transmission
case by bolts.
Transmission path
l Output shaft (1) of the transmission is coupled to 1. Transmission output shaft
transfer input gear (2) by a spline. The power is 2. Transfer input gear (Teeth 38)
transmitted to output gear (6) through idler gear (4) 3. Rotating pick-up sensor
and output shaft (7). 4. Transfer idler gear (Teeth 57)
Part of the power transmitted to the output shaft is 5. Housing
transmitted to the front axle through the center drive 6. Output gear (Teeth 52)
shaft and front drive shaft. The rest of the power is 7. Output shaft
transmitted to the rear axle through the rear drive a. Front coupling
shaft. 9. Rear coupling
lransmlsslon
w FROM
SMISSION
UTPUT SHAFT
FELT
AXLE
L07CR038
21-38
STRUCTURE AND FUNCTION DRIVE SHAFT
Outline
l The power from the engine passes through the When the body is articulated, or when there is
torque converter, transmission and transfer. Part of shock from the road surface during traveling, or
this power passes through rear drive shaft (4) and when there is shock during operations, the axles in
goes to the rear axle; the rest of the power passes front and behind the engine and transmission
through center drive shaft (3) flanged bearing (2) change position.
and front drive shaft (1) and is sent to the front axle. To allow the power to be transmitted without dam-
l In addition to transmitting the power, the drive age to parts of the machine when there is shock or
shafts have the following purposes. when the components move position, the drive
shafts have a universal joint and a sliding joint. This
allows them to handle changes in angle and length.
Front axle Transfer Rear axle

424FOlS
1. Front drive shaft

2. Flanged bearing
3. Center drive shaft
4. Rear drive shaft
21-39
STRUCTURE AND FUNCTION AXLE MOUNT
AXLE MOUNT
I \
I
i
1
3
/
Section A-A Section B-B
424F304
21-40
STRUCTURE AND FUNCTION AXLE MOUNT
View Z
View Y 424F305
Front axle
1. Front axle
l The front axle (1) receives the force directly during
2. Rear axle
operations, so it is fixed directly to the front frame
3. Front frame
(3) by axle mounting bolts (5).
4. Rear frame
5. Axle mounting bolt
Rear axle
6. Pivot
l The rear axle (2) has a structure which allows the
center of the rear axle to float, so that all tires can
be in contact with the ground when traveling over
soft ground.
21-41
STRUCTURE AND FUNCTION AXLE AND DIFFERENTIAL
AXLE AND DIFFERENTIAL

Front Axle
e The power from the engine passes through the 0 Inside the axles, the power passes from the bevel
torque converter, transmission, transfer, and drive pinion to the bevel gear and is sent at right angles.
shafts, and is then sent to the front and rear axles. At the same time, the speed is reduced and passes
through the front differential (1) to the axle shaft.
The power of the axle shaft is further reduced by a
planetary-gear-type final drive (5) and is sent to the
wheels.
1. Front differential 4. Brake

2. Parking brake 5. Final drive
3. Housing 6. Drain plug 424F302
21-42
Front Differential
B
L 3
LO7FVOlO
1. Side gear (Differential) (Teeth 12)

2. Bevel gear (Teeth 41)
4. Pinion (Differential) (Teeth 9)
5. Shaft
6. Bevel pinon (Teeth 10)
21-43
Rear Axle
_-
1. Rear differential
2. Housing
3. Brake
4. Final drive
21-44
Rear Differential
SECTION B - B LO7FZQO9
1. Shaft
2. Bevel gear (Teeth 41)
3. Bevel pinion (Teeth 10)
4. Side gear (Differential) (Teeth 12)
5. Pinion (Differential) (Teeth 9)
21-45
Outline
e The power from the drive shaft passes through
bevel pinion (1) and is transmitted to the bevel gear
(5). The bevel gear changes the direction of the
power by !30”, and at the same time reduces the
speed. It then transmits the power through the
differential (4) to the axle shaft (2).
I 4 423F059A
5
When driving straight forward

l When the machine is driven straight forward, the
rotating speed of the left and right wheels is the
same, so the pinion gear (4) inside the differential
assembly does not rotate. The power of the carrier
(6) is sent through the pinion gear (4) and the side
gear (3) and is transmitted equally to the left and
right axle shafts (2).
423F060A
When turning
l When turning, the rotating speed of the left and
right wheels is different, so the pinion gear (4) and
side gear (3) inside the differential assembly rotate
in accordance with the difference between the
rotating speed of the left and right wheels. The
power of the carrier (6) is then transmitted to the
axle shafts (2).
423FO61 A
21-46
Function
e Because of the nature of their work, 4-wheeldriie
loaders have to work in places where the road
surface is bad. In such places, if the tires slip, the
ability to work as a loader is reduced, and also the
life of the tire is reduced. The torque proportioning
differential is installed to overcome this problem.
l In structure it resembles the differential of an auto-
mobile, but the differential pinion gear (4) has an
odd number of teeth. Because of the difference in
the resistance from the road surface, the position of
meshing of the pinion gear (4) and side gear (3A),
(3B) changes, and this changes the traction of the
left and right tires.
Operation
When traveling straight (equal resistance from road

surface to left and right tires) 3A 3B
l If the resistance from the road surface to the left
and right wheels is the same, the distance between
the pinion gear and the meshing point “a” of the left
side gear is the same as the distance between the
pinion gear and meshing point “b” of right side gear
(38).
0 Therefore the left side traction TL and the right side 423FO63
traction TR are balanced.
21-47
When traveling on soft ground (resistance from road

surface to left and right tires is different)
l On soft ground, if the tire on one side slips, the side Direction of spider rotation
gear of the tire on the side which has least resis-
tance from the road surface tries to rotate forward.
Because of this rotation, the meshing of the pinion
gear and side gear changes.
l If left side gear (3A) rotates slightly forward, the
distance between the pinion gear and the meshing
point “a” of the left side gear becomes longer than
the distance between the pinion gear and the
meshing port “b” of the right side gear. The position
is balanced as follows:
axTL = bxTR
The ratio between the distances to “a” and “b” can 423 F063
change to 1 : 1.38.
l Therefore when the ratio of the distances to “a” and Direction of spider rotation
“b” is less than 1 : 1.38 (that is, the difference
between the resistance from the road surface to the
left and right tires is less than 38%), the pinion gear
will not rotate freely, so drive force will be given to
both side gears, and the tires will not slip.
Because of this effect, the tire life can be increased
by 20 - 30%, and at the same time the operating
efficiency is also increased.
423FO63
21-48
STRUCTURE AND FUNCTION FINAL DRIVE
FINAL DRIVE
l To gain a large drive force, the final drive uses a tar-y gear (2). The planetary gear rotates around the
planetary gear system to reduce the speed and inside of a fixed ring gear (3) and in this way
send drive force to the tires. transmits rotation at a reduced speed to the plane-
l The power transmitted from the differential through tary carrier (4). This power is then sent to the
axle shaft (1) to sun gear (6) is transmitted to plane- wheels (5) which are installed to the carriers.
424F3 I7
1. Axle shaft 4. Planetary carrier
2. Planetary gear (Teeth 24) 5. Wheel
3. Ring gear (Teeth 67) 6. Sun gear (Teeth 17)
21-49
STRUCTURE AND FUNCTION FINAL DRIVE
TIRE AND WHEEL

l The tire acts to absorb the shock from the ground
surface to the machine, and at the same time they
must rotate in contact with the ground to gain the
power which drives the machine.
l Various types of tires are available to suit the
purpose. Therefore it is very important to select the
correct tires for the type of work and bucket
E423F070
1. Tire
2. Side ring
3. Lock ring
4. Rim
5. Air valve
21-50
POWER TRAIN
c 0
STANDARDVALUETABLE ... ... ........... .. ............ ........... ..... ....... ....... 2
TOOLLlST . . . . . . ..______.......................................................... 3
ENGINESPEED ..................................................................... 4
OIL PRESSURE OF TORQUE CONVERTER AND TRANSMISSION ................................ 6
SHIFT LEVER.. ..................................................................... 8
METHOD FOR OPERATION OF EMERGENCY MANUAL SPOOL ................................. 9
TIREANDWHEEL .................................................................. 11
TROUBLESHOOTING ................................................................ 13
PRECAUTIONS WHEN TROUBLESHOOTING 14
METHODOFREADlNGTROUBLESHOOTlNG~~~iES.:::::::::::::::::::::::::::::::::::: 16
PREVENTING RECURRENCE OF TROUBLE ............................................ 18
JUDGEMENT ON POWER TRAIN .................................................... 19
TROUBLESHOOTINGTABLE ....................................................... 22
Machine does not move. ........................................................ 22
Excessive time lag when starting machine or shifting gear. ............................... 24
Torque converter oil temperature too high. .......................................... 25
+ The following precautions are necessary when using the Standard Value Table to make judgements during
1. The values in these tables are based on the values for new machines leaving the plant, so they should be
used as target values when repairing or when estimating wear after a period of use.
2. The standard values in these tables for judgement when troubleshooting are estimated values based on the
standard values for the machine when shipped from the plant, and on the results of various tests. Therefore,
they should be used as reference in combination with repair and operating records when making
judgements.
3. These standard value tables must not be used for standard values when judging claims. In addition, do not
use these values alone to make simple judgements.
22-1

-
Testing and measuring item Measurement condition Unit
value value
Shift lever operating force and l Torque converter oil tem-

stroke perature: 60 - 80°C
l Directional lever operating l Engine speed: Low idling kg 0.3-0.9 MaX. 1.4
force 0.3-0.9 MaX. 1 .4
N-F
N-R
0 Speed lever operating force
1st9nd kg 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
0 Directional lever travel
N-F mm 32-42 2747
N-R 3242 27-47
0 Speed lever
lst-2nd-3rd-4th mm 32-42 27-47
-
Engine speed Coolant temperature:
l Low idling Inside operating range 845*50
8 High idling Hydraulic temperature: 2410+50
45 - 55°C rpm 2300 + 100
l Torque converter stall
l Hydraulic stall Engine speed: High idling 2150+100
e Full stall 16443~100
-
Oil pressure of torque converter 0 Engine speed: High idling
and transmission 0 Coolant temperature:
0 Pilot reducing pressure Inside operating range 10.8+1.0 10.8+1.0
l Modulating pressure l Torque converter oil
Low idling temperature: 6060°C k:g/cmz 32.5” 1.5 32.5 + 1.5
High idling 34.5? 1.5 34.5 + 1.5
l Torque converter relief
pressure 6.Okl.O 6.Okl.O
e Lubrication oil pressure .7-l .5 .7-l .5

-
Tire and wheel Tire inflation pressure:
0 Fiiing of wheel lock Specified pressure
ring (A)
(R)
l Clearance of wheel lock mm Max. 2.5
ring (C) Max. 4.0
2-10
L15AR007
22-2
TOOL LIST FOR TESTING AND ADJUSTING
No. Testing and measuring item Tool name Part number Remark
1 Engine speed Tachometer 799-203-6000 Digital display

60 - 20,000 rpm
2 Oil temperature Thermistor kii 799-101-6000 0 - 1,OOo”c
3 Oil pressure Hydraulic tester 799-l 016000 0 - 25 kg/cm*

0 - 50 kg/cm*
Pedal and lever

4 operating force Push-pull gauge 7AO-262-0020 0 - 25 kg
5 Measuring clearance Feeler gauge Commercially available 0.1 - 3.0 mm
A When carrying out testing, adjusting or troubleshooting, stop the machine on level ground, install the safety
bar on the frame, lower the bucket to the ground, and stop the engine. Then apply the parking brake and
block the tires.
A Do not allow unauthorized persons near the machine.
A When measuring the engine speed, one worker should measure the engine speed while the other sits in the
operator’s seat to operate the controls. Always check that the operation is safe, and use agreed signals.
Becareful not to get caught in rotating parts.

A
22-3
TESTING AND ADJUSTING MEASURING ENGINE SPEED
ENGINE SPEED
l Coolant temperature: Inside operating
I Q’ty
A 1 799-203-8000 1 Tachometer
I 01-6000 I Thermistor kit I 1
I El 9014 Drive, Tach I 1
l 3907455 I Hub I 1
I. 3903475 I Seal I 1
. 3918215 I Cover I 1
1 I 0 3914132 I Adapter I 1
I Washer I 2
. 3027885 I Screw I 2
I l 3915800 I Gasket I 1
+ Check that the low idling and high idling speeds are
the standard value.
t Before measuring the stall speeds, install tacho-
meter A to engine speed pick up (1) on the engine
block.
t Check that the engine speeds are the standard
value. If any item is outside the permitted range,
check for any looseness for play in the linkage.
A Block the tires.
1. Measuring torque converter stall

1) Start engine and run at low idling.
2) Put the directional lever in FORWARD or RE-
VERSE, and speed control lever in the highest
speed range.
3) Using the brake, stop the machine and measure
the engine speed when the engine reaches high
idling.
t Turn the transmission cut-off valve switch to
OFF, and use the left brake. (Check that
the pilot lamp is OFF).
t Do not run at stall speed for more than 20
seconds, and do not let the torque
converter oil temperature rise above
120°C.
22-4
TESTING AND ADJUSTING MEASURING ENGINE SPEED
2. Measuring hydraulic stall

1) Start engine and run at high idling.
2) Operate the dump or lift lever to move the
cylinder to the end of its stroke and actuate the
relief valve of the main control valve.
3) Measure the engine speed at this point.
t Do not run the engine at stall speed for
more than 20 seconds, and operate the
control lever quickly.
3. Measuring full stall

Measure the engine speed when torque converter
stall and hydraulic stall are reached at the same
time.
t Measure full stall when both the torque
converter and hydraulic stall speeds are normal.
If either stall speed is abnormal, remove the
abnormality and measure the stall speed again.
22-5
TESTING AND ADJUSTING TORQUE CONVERTER AND TRANSMISSION
MEASURING OIL PRESSURE OF

TORQUE CONVERTER AND
TRANSMISSION
t Measurement conditions
l Torque converter oil temperature: 60 - 80°C
l Engine speed: High idling
Special tool
A 799-l 01-5000 Hydraulic tester 1
A Block the tires.
Measuring procedure
* The following preparatory work is necessary before
measuring any oil pressure.
l Remove the covers on both sides under the
cab.
l Turn the transmission cut-off valve switch to
OFF and use the left brake. (Check that the
pilot lamp is OFF).
l Remove the plug from the measuring port of 423P518.1
the transmission valve.
l Install hydraulic tester A to the measuring port,
pull the gauge to the operator’s compartment,
then start the engine and measure the pressure.
t Check that there is no leakage of oil from any
joints.
1. Measuring pilot reducing pressure

1) Measuring port (P5).
2) Put the F-R lever in neutral, and measure the
pressure when the speed control lever is
operated.
P5tPTk8)
423F306A
22-6
TESTING AND ADJUSTING TORQUE CONVERTER AND TRANSMISSION
2. Measuring modulating pressure

1) Measuring port (PI).
2) Put the F-R lever in neutral, and measure the
pressure when the speed control lever is
operated.
3. Torque converter inlet port oil pressure

2) Start the engine and measure the pressure at
high idling.
4. Measuring lubrication valve pressure

2) Start the engine and measure the pressure at
high idling.
P8 (PT’h) P9 (PT’h) Pi (PT’h) L07ED017
22-7
TESTING AND ADJUSTING SHIFT LEVER
MEASURING SHIFT LEVER

Measuring conditions
l Engine speed: Stop
Unit: kg
Stan- Permis-
Item dard sible
value value
Neutral- MaX.
Direc- 0.3-0.9
Forward 1.4
tional
lever Neutral- MaX.
0.3-0.9
Reverse 1.4
Oper-
MaX.
ating 1st-2nd 0.3-0.9
1.4
force
Speed MaX.
2nd-3rd 0.3-0.9
lever 1.4
MaX.
3rd-4th 0.3-0.9
1.4
Neutral- 32-42 27-47
Direc- Forward mm mm
tional
lever Neutral- 32-42 27-47
Reverse mm mm
Travel
In each
range
Speed 32-42 27-47
from 1st
lever mm mm
three 4th
speeds
Special tc
799-l 0 l-6000 Thermistor kit 1
A Be sure to set chocks firmly against the tires.
1. Measuring the lever operating effort

1) Attach push-pull scale A or a spring balancer to
the lever knob at the center and measure the
operating effort required to pull it in the operat-
ing direction.
+ The measurement should be made in each
speed range.
2. Measuring the lever travel

1) Put mark “1” on the center on the control lever
knob and measure the travel when the lever is
moved in the operating direction.
22-8
TESTING AND ADJUSTING EMERGENCY MANUAL SPOOL
METHOD FOR OPERATION OF

EMERGENCY MANUAL SPOOL
Outline
l The transmission valve is controlled electrically.
Therefore, the emergency manual spool is installed
to enable the machine to be moved if there is any
failure in the electrical system, or in the solenoid
valve and spool.
A The emergency manual spool is for use when

failure in the transmission control prevents the
machine from being moved. It allows the
machine to be moved from a dangerous place
to a place where repairs can be carried out
safely. The emergency manual spool must
never be used except when the transmission
control has broken down.
When operating the emergency manual spool,

A follow the correct order of operation exactly,
and pay full attention to safety when moving the
machine.
To prevent the machine from moving, lower the

A bucket to the ground, apply the parking brake,
and block the wheels. Check that the pressure
inside the air tank is above the specified pres-
sure.
1. Remove R.H. machine panel.

1
A Always stop the engine before operating

spool.
the I
2. Remove lock plate (1) of the emergency manual
spool of the transmission valve.
+ Simply loosen the mounting bolts to remove the
lock plate.
3. Decide the direction to move the machine (forward

or in reverse), then move the emergency manual REVERSE FORiVARD dth 2nd i St
spool to the operating position. spool spool spool spool spool spool
423 F339
FORWARD: Rotate FORWARD clutch spool and
1st spool counterclockwise, and
pull out approx. 10 mm to the ON
B
position.
REVERSE: Rotate REVERSE clutch spool and 0

1st spool counterclockwise, and 0
oull out aoorox. 10 mm to the ON
position. ’ ’
4. Check that the area around the machine is safe, Approx. 1OF
then remove the blocks from under the wheels. no,
Approx. 10 mm
423F340
22-9
TESTING AND ADJUSTING EMERGENCY MANUAL SPOOL
5. Sit in the operator’s seat, and depress the left brake

pedal fully.
6. Start the engine, release the parking brake, then

release the brake pedal gradually to start machine
movement.
A When the engine is started and the trans-

mission is engaged, the MACHINE WILL
MOVE !!!!I Therefore, before starting the
engine, always check that the direction of travel
is safe, and always keep the brake pedal
depressed.
t If the machine does not start, turn the 2nd

spool, 3rd spool, and 4th spool clockwise, and
screw in approx. 10 mm to the OFF 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.
22-10
TESTING AND ADJUSTING TIRE AND WHEEL
TIRE AND WHEEL’

Unit: ka/cm2
Item No.
I I value value
Fitting of A Max. 2.5

wheel lock
ring B Max. 4.5
Clearance of
wheel lock C 2-10
ring
Measuring procedure Tire inflation pressure:

Specified pressure
1. Fitting of wheel lock ring
Measure dimensions A and B with a feeler gauge.
2. Clearance of wheel lock ring

Measure dimension C.
O-ring I
L15AR007
22-11
TESTING AND ADJUSTING TIRE AND WHEEL
This page is blank.
22-12
TROUBLESHOOTING
22-13
TROUBLESHOOTING PRECAUTIONS WHEN TROUBLESHOOTING
PRECAUTIONS WHEN TROUBLESHOOTING

C. Did the breakdown occur suddenly, or had
1. SAFETY there been signs of trouble before?
A l Stop the machine on level ground, and check

that the safety pins and parking brake are
d. What was the machine doing when break-
down occurred?
correctly applied, and that the tires are blocked.
e. Had the machine been repaired before the
l When working in groups, use agreed signals breakdown? If so, who carried out the re-
and do not allow unauthorized persons near the pair, and when?
machine.
f. Had the same kind of failure occurred be-
l Be careful not to get burned by hot parts or get fore?
caught in rotating parts.
2) Check the following items which can be
l Always disconnect the cable from the negative checked simply by visual checks etc.
(-) terminal of the battery before disconnecting
any wiring. a. Check oil level.
Y Y 0 Always release the pressure before re- b. Check for leakage of oil from piping or
4 moving the plugs or caps of any place hydraulic equipment.
under hydraulic or air pressure, and con-
nect all measuring tools correctly. c. Check travel of control levers.
2. METHODS FOR TROUBLESHOOTING d. Check stroke of spool in control valves.
t Just because a failure occurs, do not im- 3) Reenact the failure and check the condition
mediately start to disassemble the machine. of the machine (particular conditions at the
time of failure).
If the machine is disassembled before making
the proper checks, a. Ask the user or operator if the decision
about the failure was made based on mea-
0 The machine may be disassembled in such sured values, or by comparison, or by
a way that the problem cannot be located, feeling.
so the cause of the problem will be un-
known. b. Compare extent of failure with standard
values.
As a result,
l EL;:: safety before carrying out any
l The customer and operator will lose confidence
in you.
l Do not make any check or measure-
l Time will be wasted, and unnecessary costs will ment that will make the condition
be incurred for excess parts and greasing. worse.
To avoid these problems, use the following pro-

cedure when troubleshooting.
1) Ask the customer and operator the following

questions about the breakdown.
a. Have there been any other problems apart

from the one reported?
b. Was there anything unusual before the

machine broke down?
22-14
TROUBLESHOOTING PRECAUTlONS WHEN TROUBLESHOOTING
4) Try to locate the possible causes for the 3. PRECAUTIONS WHEN REMOVING, INSTALLING,
failure. DISASSEMBLING OR ASSEMBLING PARTS
DURING TROUBLESHOOTING
The transmission system consists of the trans-
mission itself, the transmission control valve, If it is necessary to remove, install, disassemble
and the transmission electric control. or assemble parts for troubleshooting, remem-
ber the following points.
In particular, when trouble occurs in the trans-
mission system, the probable location of the Carry out the various testing and adjusting
failure can be divided as follows: while observing the items on quality control
given in resting and Adjusting”.
l Transmission itself, or transmission control
valve. When removing parts, check their condition of
l Transmission electric control. mounting, and distinguish between front and
rear, left and right, and top and bottom.
To decide which of the two is the location of
the failure, go to page 22 - 19. Check the match marks, or make match marks
to prevent mistakes when installing.
5) Carry out troubleshooting using the trouble-
shooting charts. If a part cannot be removed even when the
There are the following two types of trouble- nuts and bolts have been removed, do not use
shooting charts. excessive force to remove it. Check the part to
see if there is any problem with it, and remove
1. TROUBLESHOOTING TABLE . . . . . . . . the problem before trying to disassemble the
part.
. . . . . 22 POWER TRAIN
42 STEERING SYSTEM When installing or assembling, clean off all dust
52 BRAKE AND AIR SYSTEM and dirt and repair any scratches or dents.
62 WORK EQUIPMENT SYSTEM Remove all grease or oil before coating with
82 ELECTRIC AND ELECTRONIC gasket sealant.
SYSTEM
2. TROUBLESHOOTING FLOW CHART. . .

The troubleshooting charts consist of:
1) Items which can be checked easily.

2) Items which are likely to be the cause
of such failures.
Follow theses charts to carry out trouble-

shooting. At the same time, do not forget
the following points.
0 Check related items.

0 Check that there are no other failures
or breakdowns.
* For details of troubleshooting tables,

see page 22 - 16.
6) Investigate causes of breakdown.
0 Even if the breakdown is repaired, if the

original cause of the problem is not re-
moved, the same breakdown will occur
again. To investigate and remove the origi-
nal cause, see “Actions to take to prevent
failures from occurring again”.
22-15
TROUBLESHOOTING METHOD OF READING TABLES
METHOD OF READING
TROUBLESHOOTING TABLES
DESCRIPTION OF SYMBOLS USED IN TROUBLE-

SHOOTING TABLES
The following symbols are used in the “Remedy” column
to indicate the method of eliminating the cause of a
fault.
X: Replace A: Repair
A: Adjusting C: Clean
METHOD OF READING TROUBLESHOOTING TABLE

l The symbol o in the table is inserted only for
causes which can be diagnosed. If a cause cannot
be diagnosed, the corresponding box is left blank.
0 If the result of problem 1 using the troubleshooting

table shown at right is abnormal, the cause of the
trouble can be assumed to lie between “a” and “d”.
Because it is not passible to make a problem
regarding “e”, it is necessary to perform the next
problem (owing to the possibility of a multiple fault).
If the result of problem 1 is normal, the cause of the

fault does not lie between “a” and “d”. In such a a
3
case, before diagnosing the causes as “e”, however, 0”
carry out a check by means of problem 2 or 5. Example 1
in
0 If now the result of problem 1 is abnormal and the
result of problem 2 normal, the cause is one of “a”,
“b” or “d”. In addition, if the result of problem 3 is
abnormal, the cause will be narrowed down to one
of “b” or “d”. To determine which of “b” or “d” is the
actual cause, perform problem 4.
Unnecessary
problem
l If the result of problem is abnormal, blacken out the
corresponding o in the table and then perform the
next problem on these causes in order to narrow
the likely causes.
Example 1:
Problem 1 - Abnormal From the table
Problem 2 - Normal of example 1,
Problem 3 - Abnormal the cause of the
Problem 4 - Normal fault is “b”.
Unnecessa~
Example 2: problem
From the table of
Problem 1 4 Normal example 2, the cause
Problem 2 - Abnormal of the fault is “e”.
t In example 2, it is evident that the cause is “e”

without carrying out problem 2, however pro-
blem 2 is performed by way of an additional
check.
22-16
_.
TROUBLESHOOTING METHOD OF READING TABLES
Example 3:
Problem 1 Abnormal From the table of ex-
ample 3, the cause
Problem 2 Abnormal is one of “a”, “c” and
” II
Problem 3 Normal e.
Continue problems
Problem 4 Normal From table of ex- Example 3-l

ample 3-1, the cause
Problem 5 Normal is “15’.
Example 4:
Problem 1 Abnormal From table of exam-

ple 4, the cause is
Problem 2 Normal one of “a”, “b”, or “d”.
Continue problems
Problem 3 Abnormal From table of exam-

ple 4-1, the cause is
Problem 4 Abnormal “a” or “d”.
Problem 5 Normal
As can be seen from the above examples, it is not

necessary to perform all the problems.
Also, looking at a particular cause, no matter how many
l marks there are in the column corresponding to that
cause, it will cause to be an actual cause if there is even
one o mark in the same column.
22-17
TROUBLESHOOTING PREVENTING RECURRENCE OF TROUBLE
PRWENTING RECURRENCE OF TROUBLE
l The troubleshooting table is used to establish the direct cause of damage or breakdown of a part or piece of
equipment. It is not able to establish the root cause of the damage or failure, however.
l Also, this table only describes the action to be taken with the particular part or piece of equipment. It does not
mention what action should be taken to prevent a recurrence of the root cause.
l In order to remove the root cause of a fault so as to prevent a recurrence, carefully investigate the real cause
while referring to the following items.
l Regarding the method of checking and adjusting each part or piece of equipment, refer to “Testing and
Adjusting” in the Shop Manual.
HYDRAULIC EQUIPMENT
1. Oil checks Rubber: Cylinder packing, etc.

Metal: Wear or damage to hydraulic
l The fundamental cause of almost all faults occurring equipment such as pump and
in hydraulic equipment is the inclusion of water, air motor, as well as transmission and
or other foreign matter in the oil. Accordingly, it is torque converter, etc.
necessary to check the oil to see whether or not it
contains any of the above substances, and then 3) Oil cleaning and replacement
take appropriate action.
a If a large amount of metal particles or other
1) Oil checks foreign matter is discovered in the oil, either
wash the oil using an oil refresher or re-
l Check for water contamination. place it.
Check the oil for possible water contamination
by means of a diesel engine oil checker or a t If the oil is contaminated by water, it is
hot plate. not possible to remove the water by
means of an oil refresher.
0 Check for contamination of other foreign mat-
ter. Remove the drain plug and filter, then t When washing the oil, also wash or
check the bottom of the tank and also the filter replace the strainer and replace the
to see if any foreign matter has collected there. filter.
Check the degree of contamination by means
of a contamination checker. 2. Cleaning fragments of damaged parts
0 Viscosity check l If a part becomes damaged, fragments may pass

Check the viscosity of the oil using a viscome- into the oil line. It is thus necessary to wash the oil.
ter in order to confirm whether or not the oil is
satisfactory. l In addition, disassemble and wash such parts as
valves and cylinders which are liable to collect
2) Check of contamination point metal fragments and other foreign matter, thus
helping to prevent a recurrence of faults due to
If, as a result of the above checks, it is dis- such fragments becoming lodged in various parts of
covered that the oil is contaminated by water or the engine or hydraulic equipment.
other foreign matter, it is necessary to find out
where the contamination is occurring and also
to take steps to prevent it.
Water: Oil storage tank, breather, etc.

Sand: Oil replenishing or replacing meth-
od, etc.
22-18
TROUBLESHOOTING JUDGEMENT ON POWER TRAIN
JUDGEMENT ON POWER TRAIN
Use the following method to judge if the abnormality in the power train is in the electrical system of the transmission,
or in the power train itself. If the abnormality in the electrical system, go to troubleshooting items E-8; if the
abnormality is not in the electrical system, go to troubleshooting items T-l - T-4.
Judgement flow
YES
b Defective transmission solenoid valve
2
When emergency
YES Screw Of SpOOl Of
, - problem speed
_ range is loosened,
Carry out test for does machine move?
problem
transmission b Go to troubleshooting fortransmission.
solenoid. NO Items T-l - T-4
Is condition normal?
Go to troubleshooting for transmission

NO ) electrical system. Item E-8
Testing and inspection of transmission solenoid
A Stop the machine on level ground

blocks under the tires.
and put
+ Air tank at specified pressure
1. Install a T-adapter (or socket adapter) to connector

CN75, and check the voltage between the con-
nector pin and the chassis ground.
2. Turn the starting switch ON.
* Do not start the engine.
3. Turn the parking brake switch ON - OFF (release). Result of inspection
4. When depressing the foot brake, depress the R.H. Normal Go to T-l - T-4
brake so that the transmission is not cut off.
0 (continuous) at two places
Checking directional solenoid circuit Go to troubleshooting E-8 (d)
Standard condition No o (continuous)

I I I I Go to troubleshooting E-8 (b), (c)
Lever
1 Conpniencror1 ;; 1 ;; 1 &!ii;
position No l(battery voltage)
Go to troubleshooting E-8 (a)
FORWARD 0 l 0
REVERSE l 0 0
0: 0 - 09 (continuous)
0: 20 - 30V(batter-y voltage)
22-19
TROUBLESHOOTING JUDGEMENT ON POWER TRAIN
Checking speed solenoid circuit
Standard condition
7-pin
Lever Connector
1-pin 2-pin 3-pin 4-pin (Power
position pin
source)
1St 0 0 0 0 0
2nd l 0 l l 0
3rd l l 0 l 0
4th l l e 0 0
0: 0 - 0.5V (continuous)
0: 20 - 30V (battery voltage)
Result of inspection:
Normal Go to T-l - T-4
0 (continuous) at two places or more

Go to troubleshooting E-3 (9
No o (continuous)
Go to troubleshooting E-3 (e)
No l (battery voltage)
Go to troubleshooting E-3 (e)
22-20
TROUBLESHOOTING
This page is blank.
22-21
TROUBLESHOOTING TROUBLESHOOTING TABLE
TROUBLESHOOTING TABLE
1. Machine does not move.
Ask the operator the following points.

l Did the machine suddenly stop moving?
Yes = Component seized or damaged.
l Was there any abnormal noise when the machine
stopped moving?
Yes = Component broken.
Checks before troubleshooting.

0 Is oil level in transmission case correct?
l Is voltage of solenoid valve correct?
l Is monitor display normal?
0 Is drive shaft broken?
Transmission
I 1 I I I
8 Pilot reducing pressure defective 0
Note 1: If the solenoid valve and hydraulic pressure

are normal, the “I” in the Causes column
indicates that the valve spool does not
work.
Note 2: If the transmission clutch pressure is low,
but the cause cannot be found in the above
table, a possible cause is cracks in the
valve or transmission.
22-22
The following symbols are used to indicate the

action to be taken when a cause of failure is
located:
A: Adjust C: Clean
22-23
2. Excessive time lag when starting machine or

shifting gear.

0 Is oil level in transmission case correct?
e Is there any leakage of oil from joints of piping
or valves?
0 Is operation of control valve normal?
Checking for abnormalities.

l Check STANDARD VALUE TABLE to confirm
that time lag is actually excessive.
-
rdr
1 Abnormal Norse from between pump and filter 0
2 I Excesswe time lag I” every speed range

loldolold I I I
3 Machlne moves normally in certain speed ranges 0 0 0
4 Transmwon
in every speed moduiatlng
range pressure too low 0 0 0 0
5 As I” Item 4. lndlcator fluctuates wolently 0

Torque converter 011temperature IS above operating
6 range 0 0

located:
A: Adjust C: Clean
22-24
3. Torque converter oil temperature too high.
Ask the operator the following points.

l Does not torque converter oil temperature go
up during torque converter stall, and down
when the torque converter is not stalled?
Yes = Normal (Incorrect selection of gear
speed)
Checking before troubleshooting.

l Is oil level in transmission and steering case
correct?
0 Is filter clogged?

l Check STANDARD VALUE TABLE to confirm
that torque converter oil temperature is actually
high.
t If oil temperature is normal but the oil
temperature gauge is outside the operating
range, the oil temperature gauge is defec-
tive.
! /a/b/c/d/
No.
Problems
1 Pump makes abnormal noise when 011temperature is low. 0
2 High idlmg and low Idling speeds are too low. I I I Id

3 1 Hydraul’ IC pressure at Inlet port of torque converter too low
I I I4 I
pressure too low
lolol I I

located:
x: Replace A: k?pair
A: Adjust C: Clean
22-25
This page is blank.
22-26
POWER TRAIN
TORQUE CONVERTER CHARGING PUMP .................................................. 3

REMOVAL ...................................................................... 3
INSTALLATION.. ................................................................. 4
TORQUE CONVERTER, TRANSMISSION, TRANSFER

REMOVAL ....... ............. ......... ... ......... .. ....... ..... .... .... ....... i
INSTALLATION .................................................................. 12
TORQUECONVERTER ............................................................... 19
DISASSEMBLY .................................................................. 19
ASSEMBLY .................................................................... 23
TRANSMISSION .................................................................... 29
DISASSEMBLY.. ................................................................ 29
DISASSEMBLY OF INPUT SHAFT, NO. 1 CARRIER ASSEMBLY ........................... 37
DISASSEMBLY OF NO. 3,4 CARRIER ASSEMBLY ..................................... 39
DISASSEMBLY OF NO. 2 CARRIER, NO. 2 HOUSING ASSEMBLY ......................... 40
DISASSEMBLY OF NO. 4,5 HOUSING ASSEMBLY .................................... 41
ASSEMBLY .................................................................... 42
ASSEMBLY OF NO. 4,5 HOUSING ASSEMBLY ....................................... 42
ASSEMBLY OF NO. 2 CARRIER, NO. 2 HOUSING ASSEMBLY ............................ 43
ASSEMBLY OF NO. 3,4 CARRIER ASSEMBLY ....................................... 44
ASSEMBLY OF INPUT SHAFT, NO. 1 CARRIER ASSEMBLY .............................. 45
ASSEMBLY OF TRANSMISSION .................................................. 47
TRANSFER ASSEMBLY ............................................................... 55

DISASSEMBLY .................................................................. 55
ASSEMBLY .................................................................... 57
TRANSMISSION CONTROL VALVE ...................................................... 63

REMOVAL ..................................................................... 63
INSTALLATION .................................................................. 64
LOWERVALVE.. ................................................................ 65
DISASSEMBLY.. ............................................................. 65
ASSEMBLY 65
UPPERVALVE .::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::: 67
DISASSEMBLY.. ............................................................. 67
ASSEMBLY ................................................................. 67
FRONTDIFFERENTIAL.. ............................................................. 69
REMOVAL ..................................................................... 69
INSTALLATION.. ................................................................ 72
23-1
REAR DIFFERENTIAL ................................................................ 75
REMOVAL ..................................................................... 75
INSTALLATION .................................................................. 76
DIFFERENTIAL.. ................................................................... 77
DISASSEMBLY.. ................................................................ 77
ASSEMBLY .................................................................... 80
FRONT AXLE ...................................................................... 88

REMOVAL ..................................................................... 88
INSTALLATION.. ................................................................ 91
REAR AXLE ....................................................................... 93

REMOVAL ..................................................................... 93
INSTALLATION.. ................................................................ 97
DRIVE SHAFT ...................................................................... 101

DISASSEMBLY.. ................................................................ 101
ASSEMBLY .................................................................... 103
FINALDRIVE ...................................................................... 105

DISASSEMBLY.. ................................................................ 105
ASSEMBLY .................................................................... 108
+ For details of disassembly and assembly of the gear pump, see SECTION 97.
t Take the following method for air bleeding when you start to operate hydraulic cylinders after reassembling

23-2
DISASSEMBLY AND ASSEMBLY TORQUE CONVERTER CHARGING PUMP
TORQUE CONVERTER CHARGING PUMP

REMOVAL

the parking brake and put Mocks under the
Open hood (1) and fit lock (2).

A
1. Safety relay
1) Disconnect connector (3) of safety relay.
2) Remove the safety relay (4) from engine fly-
wheel housing.
2. Hydraulic piping
1) Disconnect tube (5) between torque converter
charging pump and torque converter filter at
torque converter charging pump end.
t Remove the U-clamp holding the tube.
charging pump and transfer at torque converter
charging pump end.
3. Torque converter charging pump

Remove mounting bolts, then remove torque con-
verter charging pump (7).
* There is little space, so be careful not to injure
your hands or fingers.
23-3
DISASSEMBLY AND ASSEMBLY TORQUE CONVERTER CHARGING PUMP
INSTALLATION
-I. Torque converter charging pump

Set torque converter charging pump (7) in mounting
position, then tighten mounting bolts.
+ Fii the O-ring securely in the groove, and make
sure that it is not caught when installing.
2. Hydraulic piping
1) Connect tube (6) between torque converter
charging pump and transfer to torque converter
charging pump.
charging pump and torque converter filter to
torque converter charging pump.
+ Fit the O-ring securely in the groove, and
make sure that it is not caught when
installing.
+ Secure the tube with a U-clamp.
Safety relay
1) Install the safety relay (4) at engine flywheel
housing.
2) Connect connectors (3) at safety relay.
Close the hood (1) and fit the catch (2).
23-4
DISASSEMBLY AND ASSEMBLY TORQUE CONVERTER, TRANSMISSION, TRANSFER
TORQUE CONVERTER,
TRANSMISSION, TRANSFER
REMOVAL ! \’

\

*A & Loosen the oil filler cap slowly to release the

-- . __ -
L10Bz002

t Disconnect the cable from the negative (-) terminal

of the battery.

filter, and the plug (2) of the pump piping to prevent
the oil inside the tank from flowing out.
A Open hood (3) and fit lock (4).
1. Draining air
Loosen drain valve (5) and drain air from air tank.
23-5
2. Ladder
Sling ladder (6), remove mounting bolts, then
remove ladder.
Remove the ladders on both the left and right
sides.
Ladder: 65 kg
c
3-7. Remove the hydraulic tank.

See shop manual, Section 63, DISASSEMBLY
AND ASSEMBLY.
Electric wiring
1) Disconnect connectors (23, 24, 25, 26, 27, 28,
29 and 30) at bracket of floor frame (22).
+ After removing the wiring, mark with a tag
to distinguish when installing.
2) Disconnect ground connection and connector.
3) Disconnect connector of wiring for brake sole-
noid valve.
23PO1217
_ -
9. Brake valve
1) Disconnect hoses (31 and 32) between brake
valve and brake chamber at brake valve end.
23-6

valve and air tank at brake valve
12. Steering piping

1) Disconnect hose (42A) between orbit-roll and
hydraulic pump from orbit-roll.
2) Disconnect hose (428) between orbit-roll and
hydraulic tank from orbit-roll.
3) Disconnect hose (42C) between orbit-roll and
stop valve from orbit-roll.
13. Floor frame, cab assembly

1) Sling floor frame, cab assembly (47).
2) Remove mounting bolts, then lit? off floor frame,
cab assembly.
Floor frame, cab assembly: 500 kg
14. Torque converter oil filter

charging pump and torque converter oil filter
from torque converter oil filter.
2) Disconnect hose (49) between torque converter
oil filter and transmission from torque converter
oil filter.
3) Disconnect hoses (50 and 51) between trans-
mission valve oil filter and transmission from
filter.
4) Remove mounting bolts of bracket, then re-
move torque converter oil filter (52) together
with bracket.
23-8

1) Disconnect tube (54) between transmission and
oil cooler from transmission.
2) Disconnect tube (55) between transfer and oil
cooler from transmission.
3) Disconnect outlet hoses (56, 56A, 57 and 58)

from hydraulic pump.

charging pump and torque converter oil filter
from torque converter charging pump.
charging pump and transfer from torque con-
verter charging pump and transfer.
6) Disconnect return hose (61) of hydraulic tank

and line hose (62) of oil cooler from tube.
16. Drive shaft

Disconnect center drive shaft (63) and rear drive
shaft (64) from transfer.
17. Torque converter, transmission, transfer as-

sembly
1) Disconnect clamp and connector of wiring for
torque converter and transmission solenoid
valve.
2) Put block 0 between rear axle and bottom of
engine to support engine.
t When inserting the block, be careful not to
damage the brake tube.
3) Rotate transfer mount (65) of oil supply tube,

move towards inside of machine body, then
secure with 1 bolt.
t Be careful not to let the mount come out of
the transfer, and tighten the bolts immedi-
ately after rotating the mount.
t Before moving to the inside of the rear
frame, remove the oil filler cap.
tube
A23FAQ7A
23-10
4) Sling torque converter, transmission and trans-

fer assembly (66), then remove connecting
bolts (67) of torque converter and engine.
5) Remove left and right mounting bolts (66), then

remove spacer (69) and cushion (70).
* Measure all the clearances of the position-
ing bolts.
t Make match marks on the mount of the
mounting bracket and rear frame, and
measure the protrusion of the positioning
bolts to give a guide when installing.
6) Raise torque converter, transmission and trans-

fer assembly (66) 20 to 30 mm, move to front to
disconnect, then remove left and right brackets
(71).
+ When raising the assembly, be careful of
the meshing of the engine and torque
converter ring gear shaft, and lift off the
assembly.
7) Lii off torque converter, transmission and

transfer assembly (66). Be careful not to hit rear
frame.
Torque converter, transmission, transfer

assembly: 660 kg
423P799 A
--.
23-11
DISASSEMBLY AND ASSEMBLY TORQUE CONVERTER, TRANSMISSION. TRANSFER
INSTALIATION
1. Torque converter, transmission, transfer assem-

W
1) Raise torque converter, transmission and trans-
fer assembly (66) and set in mounting position.
Align ring gear and shaft, then connect and
partially tighten mounting bolts.
t Raise the assembly horizontally and be
careful of the ring gear and shaft when
installing.
+ Use a new O-ring and fit it securely in the
groove.
e O-ring at contact face of engine and torque

converter: Soapy water
2) Install left and right brackets (71) to transmis-

sion, fit cushions (70) and spacers (69) behind
brackets, then tighten mounting bolts (68).
t Assemble the cushions so that the cham-
fered face is on the spacer side.
t Never use oil or soap when assembling the
cushions.
t Partially tighten the mounting bolts, then
set in position and tighten the bolts fully.
a Mounting bolt of bracket: 18.022.0 kgm
D Mounting bolt: 94.52 10.5 kgm
3) Install connecting bolts (67) of torque converter

and engine, then tighten fully.
4) Adjust clearances of positioning bolts (72) then

tighten nut.
m Nut: 28+3 kgm
23-12
5) Rotate transfer mount (65) of oil supply tube,

then pull to outside of machine.
* Be careful not to let the mount come out of
the transfer, and tighten the bolts immedi-
ately after rotating the mount.
+ When pulling to outside of the rear frame,
first remove the oil filler cap, then tilt over.
6) Remove block @ from between rear axle and

bottom of engine.
7) Connect clamp and connector of wiring for
torque converter and transmission solenoid
valve.
423P793
,\,\,w,‘
2. Drive shaft
Connect rear drive shaft (64) and center drive shaft
(63) to transfer.
m Mounting bolt: 11.5 f 1.O kgm
23-13
3. Hydraulic piping
1) Connect return hose (61) of hydraulic tank and
line hose (62) of oil cooler to tube.

charging pump and transfer to torque converter
charging pump and transfer.
charging pump and torque converter oil filter to
torque converter charging pump.
4) Connect outlet hoses (56, 56A, 57 and 58) to

hydraulic pump.
5) Connect tube (55) between transfer and oil

cooler to transmission.
6) Connect tube (54) between transmission and oil
cooler to transmission.
23-14
4. Torque converter oil filter

1) Set torque converter oil filter (52) in mounting
position, then tighten mounting bolts.
2) Connect hoses (50 and 51) between transmis-
sion valve oil filter and transmission to filter.
3) Connect hose (49) between torque converter oil
filter and transmission to torque converter oil
filter.
charging pump and filter to torque converter oil
filter.

1) Assemble top cushion (47A) and plate (478).
2) Raise floor frame and cab assembly (47) and
set in mounting position.
el ha
3) Assemble bottom cushion (47C) and plate

(47D), then tighten floor frame mounting bolts
(47E).
+ Tighten the bolts until the collar inside the
cushion comes into contact (until distance
between plates is 42 mm).
23-15
6. Steering piping
1) Connect hose (42C) between orbit-roll and stop
valve to orbit-roll.
2) Connect hose (428) between orbit-roll and
hydraulic tank to orbit-roll.
3) Connect hose (42A) between orbit-roll and
hydraulic pump to orbit-roll.
- 1 PU42302009 p
.I .-
-_
7. Work equipment control cable

1) Install clamps (41) of work equipment control
cable (38).
2) Connect work equipment control cable (38) to

bracket (40).
D Mounting nut: 0.720.1 kgm
3) Connect work equipment control cable (38) at

ball joint (39).

2) Connect fuel control cable (35) at ball joint (36).
23-16
12. Ladder
Sling ladder (6), set in mounting position, then
tighten mounting bolts.
* Install the ladders on both the left and right
sides.
13. Refilling with oil

1) Tighten plug (1) at top of hydraulic tank filter,
and plug (2) of pump piping, then add hydraulic
oil through oil filler (73) to the specified level.
+ Run the engine to circulate the oil through
the system.
Then check the oil level again.
2) Add transmission oil to the specified level.
%z Transmission oil: 53 4
+ Run the engine to circulate the transmission

oil through the system. Stop the engine and
wait for 15 minutes, then check the oil level
again.
14. Bleeding air, checking

Bleed air from brakes, then check ooeration.
For details of bleeding air, see SECTION 52, TEST-
ING AND ADJUSTING.
A Close hood, then lock with catch.
23-18
DISASSEMBLY AND ASSEMBLY TORQUE CONVERTER
TORQUE CONVERTER
DISASSEMBLY
Special tools
(.. Part number Part name Q’ty
A 79060 l-5000 Unit repair stand 1
A1 1 790-901-2110 1 Bracket I 1
A2 1 793-310-2140 l Plate I 1
B I 790-101-2501 I Push-puller (kit) I 1
B1 I 790-101-2102 I Puller (30 ton) I 1
B2 790-l 01-l 102 Pump 1
Preparatory work
Remove torque converter assembly (2) from torque
converter, transmission and transfer assembly (1).
For details, see SECTION 23, DISASSEMBLY OF
TRANSMISSION ASSEMBLY.
1. Turbine, case assembly

1) Set torque converter assembly (2) in tool A.
2) Remove mounting bolts (3) of case, then

remove turbine and case assembly (4).
+ When removing the mounting bolts, leave 2
mounting bolts on opposite sides, then turn
over the assembly (pilot side at the top)
and remove the remaining 2 mounting
bolts.
3) Disassemble turbine and case assembly as

follows:
i) Remove pilot (5).
ii) Remove snap ring (6), then remove spacer
(7).
iii) Using 2 forcing screws @ (Thread dia. =
10 mm, pitch = 1.5 mm), remove turbine
(8) from case (9).
* Pull out from bearing inner race side.
w W
w
423F410A
424P929
2. Stator
Remove snap ring (13), then remove stator (14).
3. Pump
Remove pump (15).
23-20
4. Case
Remove 12 bolts, then remove case (16).
5. Gear, bearing
1) Remove snap ring (17), then remove spacer
(18).
2) Using tool B, remove gear (19) and bearing

(20).
6. Stator shaft
Remove 8 mounting bolts, then remove stator shaft
(23).
t Tap the end of the shaft with a copper hammer
to remove.
23-21
7. Pump drive gear assembly

Screw in forcing screw and remove pump drive
gear assembly (25).
8. Idler gear shaft

Using 2 forcing screws @ (thread dia. = 10 mm,
pitch = 1.5 mm), remove shaft (38).
t Check the number and thickness of the shims,
and keep in a safe place.
9. Idler gear, bearing

Remove gear (39) and bearing (40).
23-22
ASSEMBLY
Special tools
A 1 790-501-5000 [ Unit repair stand 7 1
AI 1 790-901-2110 1 Bracket I 1
A2 1 m-31o-2140 I Plate I 1
1. Idler gear, bearing

1) Set torque converter case in tool A.
2) Install outer race (41) (O.D.: 110 mm) on gear
(39).
3) Assemble bearings (40) on both sides of gear

(39), then set in case.
2. Idler gear shaft

1) Fit O-ring, align with inner race of bearing and
install shaft (38).
23-23
2) Press fii shaft fully, then measure clearance

between case and shaft (38) with feeler gauge
0.
3) Select shims so that measured clearance is 0 to
0.05 mm (+).
4) Insert selected shims, then tighten mounting
bolts.
3. Pump drive gear assembly

1) Assembly gear assembly as follows:
i) Install bearing (35) (O.D.: 100 mm) in cage
(36).
ii) Install snap ring (42).
iii) Push inner race (I.D.: 55 mm) side of bear-

ing, and install cage (36) on shaft (34).
iv) Install snap ring (33).
v) Install inner race (31) (I.D.: 50 mm) on gear

(32).
vi) Install snap ring (30).
23-24
vii) Install gear (29) on shaft.
m Mounting bolt: 7.OkO.5 kgm
424P95 I
2) Install bearing (27) (O.D.: 90 mm) in case (28).

3) Install snap ring (26).
424P952
4) Fit O-ring and install pump drive gear assembly

(25).
4. Stator shaft
1) Using guide bolt @ (Thread dia. = 10 mm, pitch
= 1.5 mm), install stator shaft (23).
23-25
2) Install seal ring (24) on shaft (23).

+ Coat the seal ring with grease, and make
the protrusion from the shaft uniform.
424P955 -i
1
5. Gear, bearing
1) Install bearing (21) (O.D.: 160 mm) on gear
(1%
2) Push inner race end and install bearing (21) on
shaft together with gear.
6. Case
Install case (16).
D Mounting bolt: 3.2kO.2 kgm
7. Pump
Align bolt holes and install pump (15).
23-26
8. StatOr
1) Install stator (14).
424P93 I b
-,. .,
9. Turbine, case assembly

1) Assemble turbine and case assembly as
follows:
i) Assemble snap ring to bearing (10).
ii) Install bearing (10) (O.D.: 110 mm) in case
(9).
iii)Support turbine (8), push inner race (I.D.:

70 mm) of bearing, and install case (9) on
turbine (8).
iv) Assemble spacer (7) and install snap ring
(8).
v) Install pilot (5).
a Mounting bolt: 7.0+0.5 kgm
423F412
23-27
2) Align bolt holes, then install turbine and case

assembly (4).
3) Install 24 mounting bolts (3) of case.
10. Torque converter assembly

Install torque converter assembly on transmission
assembly..
For details, see ASSEMBLY OF TRANSMISSION
ASSEMBLY.
23-28
DISASSEMBLY AND ASSEMBLY TRANSMISSION
TRANSMISSION
DISASSEMBLY
Soecial tools
A 1 790-501-5000 1 Unit repair stand I 1
A1 1 790-901-2110 1 Bracket I 1
A2 79331 o-21 40 Plate 1
A3 793-31 o-21 50 Plate 1
B 799-301-l 500 Leak tester 1
C 796-5 14-2000 Remover 1

Raise torque converter assembly (1) and remove
from transmission assembly (2).
424P96
I --
2. Filter assembly
Remove filter assembly (3) together with tube.
424P964
23-29
3. Control valve assembly

Remove control valve assemblies (4 and 5).
4. Sleeve
Using eye bolts @ (Thread dia. = 16 mm, pitch =
2 mm), remove 5 sleeves (6).
424P966
5. Transfer assembly
1) Set transfer assembl at bottom.
2) Using 3 eye bolts (5 (Thread dia. = 12 mm,
pitch = 1.75 mm), sling transmission assembly
(7).
3) Screw in forcing screw and lift off transmission
assembly (7).
6. Transmission case
1) Remove 2 tie bolts (8).
t Remove 2 bolts on opposite sides.
2) Remove mounting bolts (9) of case, and lower
to ground.
3) Remove 2 housing lock bolts (10) each on left

and right.
4) Using 2 eye bolts @ (Thread dia. = 18 mm,
pitch = 2.5 mm), remove transmission assem-
bly (11) from case (12).
* There are threads for the eye bolts in the
holes from which the tie bolts were
removed.
23-30
7. Checking operation of piston

1) Set transmission assembly (11) on tool A.
2) Using tool B, check operation of piston before
disassembling.
8. Input shaft, No. 1 carrier assembly

1) Remove tie bolt (8).
pitch = 2.5 mm), lift off input shaft and No. 1
carrier assembly (13).
9. Spring, guide pin

Remove spring (14) and guide pin (15).
10. No. 1 clutch disc, plate, spring

Remove discs (16) plates (17) and spring (18).
t There are 3 discs and 2 plates.
11. No. 1 clutch ring gear

Remove ring gear (19).
23-31
12. No. 1 housing

Using 2 eye bolts @ (Thread dia. = 18 mm, pitch =
2.5 mm), remove No. 1 housing (21).
it Tap with a copper hammer to disconnect dowel
pin, then remove.

Remove discs (16), plates (17), and springs (18 and
14).
978
14. Ring gear for No. 2, 3 carrier

1) Remove snap ring (22).
2) Remove ring gear (23).

424P982
23-32
16. No. 2 carrier, No. 2 housing assembly

1) Remove snap ring (25) then remove collar (26).
2) Remove No. 2 carrier and No. 2 housing as-
sembly (27).
t Tap with a copper hammer to disconnect dowel
pin, then remove.

Remove discs (16), plates (17) and springs (18 and
28).
* There are 2 discs and 2 plates.

424P986
19. No. 3 housing

2.5 mm), remove No. 3 housing (31).
t Tap with a copper hammer to disconnect dowel
pin, then remove.
‘3f
424P987
-..
23-33
20. Spring, guide pin

Remove spring (28) and guide pin (32).

Remove discs (16), plate (17) and spring (18).
t There are 2 discs and 1 plate.
424P989
22. No. 3, 4 carrier assembly

Using bar @, push up No. 3,4 carrier assembly (33)
and remove.
it The inner race of the bearing comes out.
424P990
-.
23. Collar, No. 4 sun gear

2) Remove collar (35) and sun gear (36).

2) Remove ring gear (39).
23-34
^-
25. No. 4, 5 housing assembly
2.5 mm), lift off No. 4, 5 housing assembly (40).
424PSSS /
26. Collar, No. 5 sun gear

Remove collar (41) and No. 5 sun gear (42).
27. No. 5 carrier assembly

1) Remove mounting bolts (48).
2) Tap with copper hammer to disconnect dowel
pin, and remove No. 5 carrier assembly (44).
+ When disassembling the planet gear, see
DISASSEMBLY OF INPUT SHAFT, NO. 1
CARRIER ASSEMBLY, Step 7 for details.
28. Spring, pins

Remove spring (28) and pins (45 and 46).
23-35
29. Hub
Remove hub (47).
30. Disc, plate, spring

Remove discs (16) plate (17) and spring (18).
* There are 2 discs and 1 plate.
31. Output shaft

1) Remove output shaft assembly from tool A.
2) Support cage end, and push shaft (48) with
press to remove.
32. Cage
2) Support No. 6 housing (53), and push cage
(49) with press to remove.
23-36
,,,_--. ,- _*, -*~:,\,\,,

DISASSEMBLY OF INPUT SHAFT, NO. 1 CARRIER q, _*kb
_._e& 4&%p
,i
&?$
ASSEMBLY
1. No. 2 sun gear

c
Remove snap ring (60), then remove No. 2 sun gear
(60
2. No. 1 sun gear

1) Remove snap rings (62 and 63).
2) Remove No. 1 sun gear (64).
3. Spacer
Remove spacer (65).
4. Input shalt
Support housing (66) and push shaft (67) with
press to remove.

t Bearing inner race side.
2) Support housing (66) and push carrier assem-
bly (69) with press to remove.
23-37
6. Spacer
Remove spacer (71).
7. Planet gear
1) Remove shaft (76).
+ Be careful not to lose ball (77).
2) Remove planet gear (78), bearing (79) and

thrust washer (80).
23-38
DISASSEMBLY OF NO. 3,4 CARRIER ASSEMBLY
1. No. 3 carrier, planet gear

1) Using tool C, remove shaft (81).
* Be careful not to lose ball (77).
--
-
2) Remove planet gear (82) bearing (83) and
thrust washer (80).

1) Knock spring pin inside shaft (84).
2) Knock shaft (88) out from No. 3 carrier side.
424P1020
3) Remove planet gear (88), bearing (87) and

thrust washer (80).
424PlO22
23-39
DISASSEMBLY OF NO. 2 CARRIER, NO. 2 HOUSING

ASSEMBLY

t Bearing inner race side.
2) Support housing (90) and push carrier assem-
bly (91) with press to remove.
3) Remove spacer (92).
2. Planet gear
t When disassembling the planet gear, see DIS-
ASSEMBLY OF NO. 3,4 CARRIER ASSEMBLY,
for details.
23-40
DISASSEMBLY OF NO. 4,s HOUSING ASSEMBLY
1. No. 5 housing
Remove No. 5 housing (96).
Y
2. Spring
Remove spring (28).
424F'E026
-
3. No. 5 ring gear

2’
424PlO27
4. Discs, plates, springs

Remove discs (16), plate (17) and springs (18).
+ There are 2 discs and 1 plate.
8
424Pt028
5. Piston
Remove piston (20).
23-41
Special tools
Part number Part name Q'ty
A 790-501-5000 Unit repair stand 1
Al 790-901-2110 Bracket 1
A2 793-31 o-21 40 Plate 1
As 1 793-310-2150 I Plate
B 1 799-301-1500 1 Leak tester ___I
ASSEMBLY OF NO. 4,5 HOUSING ASSEMBLY

Set ring gear (97) on No. 5 housing (96).
2. Guide pin
Install guide pin (32).
424P IO70
3. Discs, plates, springs

Install discs (16), plate (17) and springs (18 and 28).
+ There are 2 discs and 1 plate.
+ Free length of spring (28): 40 mm
4. Piston
1) Install seal ring (100) on piston (20) and hous-
ing.
+ The seal ring must be installed facing in the
correct direction. Install with the side re-
ceiving the pressure facing the groove.
2) Align with spring and install piston (20).
424P1071
-.-.
Housing
AI 423F420
424Pt073
23-42
5. No. 4 housing
1) Assemble seal ring (99) on No. 4 housing.
t The seal ring must be installed facing in the
correct direction. Install with the side re-
ceiving the pressure facing the groove.
2) Align dowel pin and install No. 4 housing (98).
+ Tap the position of the dowel pin with a
copper hammer.
424P IO74 424P IO75 ‘48
ASSEMBLY OF NO. 2 CARRIER, NO. 2 HOUSING

ASSEMBLY
1. Bearing
1) install bearing (95) (O.D.: 180 mm) on housing
(9%
2. Planet gear
t When disassembling the planet gear, see DIS-
ASSEMBLY OF NO. 3,4 CARRIER ASSEMBLY,
for details.

1) Install spacer (92) on carrier assembly (91).
4iW025
2) Push inner race of bearing installed on housing

(90), and install carrier assembly (91) on No. 2
housing.
23-43
ASSEMBLY OF NO. 3,4 CARRIER ASSEMBLY 88 m
1. Bearing
Install bearing (88) (O.D.: 72 mm) on carrier.

1) Assemble bearing (87) on gear (88), then fit
thrust washers (88) on both sides and set in
carrier.
* Align the center of all parts with the shaft
hole.
424F 120
2) Align spring pin hole and install shaft (85).

t Check that the gear and thrust washer
rotate smoothly.
3) Install spring pin (84).
424PiO81 *’ - 424P1082

1) Assemble bearing (83) on gear (82) then fit
thrust washers (80) on both sides and set in
carrier.
t Align the center of all parts with the shaft
hole.
424P I083
2) Tap shaft (81) in with a plastic hammer, assem-

ble ball (77) and knock in completely.
3) Caulk tip of shaft at one point (housing end).
424P 8080 424P IO85
23-44
ASSEMBLY OF INPUT SHAFT, NO. 1 CARRIER

ASSEMBLY
1. Planet gear
Assemble planet gear.
* For details, see ASSEMBLY OF NO. 3, 4 CAR-
RIER ASSEMBLY.
2. Bearing
1) Install bearing (75) (O.D.: 90 mm) to No. 1
carrier (69).

1) Install bearing (72) (O.D.: 150 mm) to housing
(66).
3) Install spacer (71) in carrier assembly (69).
424P I090
4) Install carrier assembly (69) on housing (66).

t Press fit the inner race of the housing to
the carrier assembly. (I.D. of inner race: 110
mm)
23-45
4. Input shaft
1) Install snap ring (70) on shaft (67).
2) Install shaft (67) in carrier (69).
5. Spacer
htdl spacer (65).
424P I095
6. No. 1 sun gear

1) Install No. 1 sun gear (64).
2) Install snap rings (63 and 62).
424PlO10 424P I009
7. No. 2 sun gear

Install No. 2 sun gear (61), then install snap ring
(6w
424P6007
424P IO08
23-46
ASSEMBLY OF TRANSMISSION
1. Cage
1) Install bearing (56) (O.D.: 190 mm) and bushing
(57) to No. 6 housing (53).
-“----
I
L ._,: 424PlO96
- ,.
3) Install seal ring (54) in cage (49).
LJ 424F121
4) Install cage (49) in housing (53).

+ Support the inner race of the bearing in-
stalled to the cage.
2. Output shaft
1) Install seal ring (51) on shaft (48).
2) Install bearing (50) (I.D.: 65mm) on shaft (48).
3) Install output shaft (48) in cage (49).
+ Push the outer race (O.D.: 100 mm) of the
bearing installed to the output shaft.
23-47
3. Piston, hub
1) Fit seal ring and install piston (20).
+ When installing seal ring, see ASSEMBLY
OF NO. 4, 5 HOUSING for details.
2) Install hub (47).
3) Install pins (46 and 45).
4. No. 6 clutch discs, plate, springs

install discs (16), plate (17) and springs (18 and 28).
Q There are 2 discs and 1 plate.
t Free length of spring (28): 40 mm
424P 1 IO5

1) Align with dowel pin, and install No. 5 carrier
assembly (44).
* When assembling the planet gear, see
ASSEMBLY OF NO. 3, 4 CARRIER for
details.
* Knock in the dowel pin with a copper ham-
mer.
2) Tighten mounting bolts (43).
D Mounting bolt: 17+1 kgm
424Pf 106
6. No. 5 sun gear, collar

1) Install No. 5 sun gear (42).
2) Install collar (41).
23-48
7. No. 4, 5 housing assembly

Using 2 eye bolts 0 (Thread dia. = 18 mm, pitch =
2.5 mm), install No. 4, 5 housing assembly (46).
* Align No. 5 clutch ring gear with planet gear of
No. 5 carrier and install No. 4, 5 housing as-
sembly (49).
41.
424Pk 109

1) Install ring gear (39).
t Pull the ring gear up to check that the snap
ring is correctly fitted in the groove.
3) Install washer (29) in housing (40).
9. No. 4 clutch discs, plate, springs

Install discs (16) plate (17) and springs (18 and 28).
* There are 2 discs and 1 plate.
10. No. 3 housing

1) Install piston (20) in housing (31).
t For details of assembling the piston, see
ASSEMBLY OF NO. 4, 5 HOUSING AS-
SEMBLY.
2) Install No. 3 housing (31).
t Knock the dowel pin in with a copper ham-
mer.
3) Assemble sleeve (37) in housing (31).
11. No. 4 sun gear, collar

1) Install No. 4 sun gear (36). 36
12. No. 3, 4 carrier assembly

Install No. 3, 4 carrier assembly (33).
+ Press fit inner race of bearing on output shaft.

Install ring gear (30).
t Install with notched surface facing up.
14. Guide pin

Install guide pin (15).
15. No. 3 clutch discs, plates, springs

Install discs (16), plates (17) springs (18 and 28)
and washer (29).
t There are 2 discs and 1 plate.
* Free length of spring (28): 40 mm
* Set washer (29) on top of spring (18).
23-50
16. No. 2 carrier, No. 2 housing assembly

1) Install No. 2 carrier and No. 2 housing assem-
bly (27).
+ Knock the dowel pin in with a copper ham-
mer.


t Install with the side with internal teeth facing up.
,, . _
424Pt 1.26’
18. Ring gear for No. 2, 3 carrier

1) Install ring gear (23).

Install discs (16), plates (17) and springs (18 and
14).
* There are 3 discs and 2 plates.
20. No. 1 housing

1) Install piston (20) in housing (21).
t For details of assembling the seal ring, see
ASSEMBLY OF NO. 3, 4 HOUSING AS-
SEMBLY.
pitch = 2.5 mm), install No. 1 housing (21).
sr Knock the dowel pin in with a copper ham-
mer.

a Install with the side with internal teeth facing up.

Install discs (16), plates (17) and springs (18 and
14).
23-52
23. Input shaft, No. 1 carrier assembly

1) Using 2 eye bolts 0 (Thread dia. = 18 mm,
pitch = 2.5 mm), install input shaft and No. 1
2) Install tie bolts (8).
D Tie bolt: 17+ 1 kgm
24. Checking operation of piston

Using tool C, check operation and stroke of piston.
+ Air pressure: 3 - 5 kg/cm2
+ Piston stroke: (mm)
Piston Stroke
I
No. 1 3
I
No. 2 5
I
No. 3 2.5
I
No. 4 2.5
I
No. 5 4
I
No. 6 2
25. Transmission case

1) Using 2 eye bolts 0 (Thread dia. = 18 mm,
pitch = 2.5 mm), raise transmission assembly
(1 l), align dowel pin of cage and install to case
(12).
t Remove 2 tie bolts on opposite sides.
There are threads for the eye bolts in the
holes from which the tie bolts are removed.
2) Install housing lock bolts (10) and mounting

bolts (9) of case.
& Both faces of housing mounting bolt, wash-

er: Gasket sealant (LG-1)
3) Tighten removed tie bolts.
D Tie bolt: 17? 1 kgm
23-53
26. Transfer assembly

1) Fii O-ring on case side.
pitch = 1.75 mm), raise transmission assembly
(7).
3) Align output shaft with spline of gear and install
transmission assembly.
27. Sleeve
Fit O-rings and install 5 sleeves (6).
26. Control valve assembly

Fit gaskets and install control valve assemblies
(5 and 4).
D Mounting bolt: 520.5 kgm
424P I J42
29. Filter assembly

Fit O-ring on tube, then install filter assembly (3).
424P964

1) Install seal ring on input shaft.
2) Fit O-ring on transmission (2) side.
3) Align spline of input shaft with spline of turbine,
then install torque converter assembly (1).
423P 13
23-54
DISASSEMBLY AND ASSEMBLY TRANSFER ASSEMBLY
TRANSFER ASSEMBLY
DISASSEMBLY
I. Speedometer gear assembly

Remove speedometer gear assembly.
2. Cover
Remove cover (2).
3. Cage (transfer input side)

Screw in forcing screw and remove cage (3).
+ Check the number and thickness of the shims,
4. Gear assembly (transfer input side)

Remove gear assembly (5).
5. Idler gear cage

6. Idler gear assembly

Remove idler gear assembly (18).
7. Coupling (rear)
Remove coupling (21).
6. Cage (rear)
23-55
9. Coupling (front)
1) Remove bolt (22), then remove holder (23).
2) Remove coupling (24).
10. Cage
11. Output shaft

Using tool D, remove output shaft (33).
pto39
12. Gear, collar h
Remove collar (31) and gear (32). I
,,,,,, - _
23-56
Special tools
Part number Part name
B 1 799-301-1500 1 Leak tester I 1
1. Gear assembly (transfer side)

1) Install outer race (4) (O.D.: 130 mm) on case.
2) Install worm gear (9) and pin (8) to gear (10).
3) Install cover (7), then install snap ring (6).
423F416
4) Install bearing (11) (I.D.: 85 mm) on gear (10).

5) Install gear assembly (5).
424PIO43
2. Cage (transfer input side)

1) Install outer race (4) (O.D.: 130 mm) to cage
(3).
2) Install shims which were removed, fit O-ring and
install cage (3).
4 3
423F417
23-57
3) Rotate shaft with torque wrench @and measure

preload of bearing.
t Preload of bearing (rotating torque).
i) Alone: 0.01 - 0.1 kgm
ii) Combined with idler gear: 0.04 - 0.18
kgm
t Adjust with shims to obtain the above
rotating torque.
3. Idler gear assembly

1) Install outer race (20) (O.D.: 170 mm) on case.
2) Install bearing (19) (I.D.: 95 mm) on idler gear
assembly (17).
3) Install idler gear assembly (18).
4. Idler gear cage

(16).
2)’ Install shims which were removed, fit O-ring and
install cage (16).
423F418A
23-58
3) Rotate shaft (10) with torque wrench @ and

measure preload of bearing.
t Preload of bearing (rotating torque)
i) Combined with input shaft: 0.04 - 0.18
kgm
ii) Alone: 0.01 - 0.1 kgm
+ Adjust with shims to obtain the above
rotating torque.
5. Gear
1) Install outer race (40) (O.D.: 130 mm) to case.
2) Set gear (22) in case.
6. Output shaft
1) Install bearing (38) (I.D.: 75 mm) to shaft (33).
3) Align spline with gear (22), then install shaft
(33).
424F 124 FJ
424F 125
7. Cage
(28).
3) Install oil seal (35) (O.D.: 120 mm) in cage.
a Oil seal mounting surface: Gasket sealant

(Three Bond 1llOB)
+ Be careful not to damage or deform the

seal.
6 Lip of oil seal: Grease (G2-Ll)
4) Install cover (34) on case.
& Mounting bolt: Thread tightener (LT-2)
5) Fit O-ring and install cage (26).
8. Collar, bearing
1) Turn over transfer case.
2) Using hydraulic jack 0, hold output shaft in
mounting position.
4) Install bearing (29) (I.D.: 75 mm).

5) Install spacer (30).
23-60
6) Install bearing (29) (I.D.: 75 mm).

7) Install outer race (28) (O.D.: 130 mm).
9. Cage (front)
1) Install oil seal (42) (O.D.: 115 mm) to cage (27).
e Oil seal mounting surface: Gasket sealant

(Three Bond 1llOB)
t Be careful not to damage or deform the

seal.
e Lip of oil seal: Grease (G2-Ll)
2) Fit O-ring and temporarily install cage (27).
10. Coupling
1) Install coupling (24), then assemble O-ring (25).
2) Install holder (23), then install mounting bolts
(22).
D Mounting bolt: 50?5 kgm
11. Adjustment
Adjust the preload of the bearing as follows:
1) Tap cage (27) with a plastic hammer to settle
bearing. 424PIO66
2) Hold cage (27) down with fingertip and mea-

sure clearance between cage and case.
t If using bolts to hold down the cage, be
careful not to tighten the cage.
t Measure at 2 or 3 places and take the
average.
3) Select shims of following value: Measured value
- (0 - 0.05)
4) Fit shim and tighten cage (27).
23-61
12. Coupling (rear)

Install coupling (21).
t Install the coupling so that the difference be-
tween the positions of the front and rear cou-
plings is within 8”.
13. Cover
Fit O-ring and install cover (2).
14. Speedometer gear assembly

Install speedometer gear assembly.
23-62
DISASSEMBLY AND ASSEMBLY TRANSMISSION CONTROL VALVE
TRANSMISSION CONTROL VALVE

REMOVAL

iY Loosen the oil filler cap slowly to release the

the controi levers several times to release the
1. Hydraulic tank
Remove hydraulic tank.
For details, see SECTION 63, REMOVAL OF HY-
DRAULIC TANK.

1) Remove tube (2) between hydraulic tank and
pump (1).
2) Disconnect connector of wiring (3) for solenoid

valve, then disconnect wiring at top of valve.
3) Remove mounting bolts (5) of transmission

control valve (4), then lift off valve.
t When removing, be careful not to damage
or deform the threads of the connector
case.
Transmission control valve: 53 kg
23-63
DISASSEMBLY AND ASSEMBLY TRANSMISSION CONTROL VALVE
INSTALIATION

1) Raise transmission control valve (4) set in
mounting position, then tighten mounting bolts
(6).
+ To prevent the valve from twisting, tighten
the mounting bolts, in diametrically oppo-
site positions.
Repeat this procedure two or three times.
* Fit the O-ring securely in the groove.
2) Connect connector of wiring (3) for solenoid

valve, then secure wiring 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 (1).
2. Hydraulic tank
Install hydraulic tank.
For details, see SECTION 63, INSTALLATION OF
HYDRAULIC TANK.
23-64
DISASSEMBLY AND ASSEMBLY TRANSMISSION CONTROL - LOWER VALVE
LOWER VALVE
DISASSEMBLY
1. Remove solenoid valve assembly (1).

2. Remove stopper (2), spring (3) and valve (4).
3. Remove valves (5 and 6), and shim (7).
4. Remove spring (8) then remove shim (9), valves
(11, 12 and 13), and spring (14) as a set.
5. Remove covers (15 and 16).
6. Remove spacer (17).
7. Remove spring (18) and valve (19).
8. Remove plug (20) then remove collar (21) and
spring (22).
ASSEMBLY
1. Assemble spring (22) to collar (21), install body

(23) then fit O-ring and install plug (20).
2. Assemble spring (18) in valve (19) then install.
3. Install spacer (17).
4. Fit gasket and install covers (16 and 15).
5. Assemble valve (12), spring (14) valve (13), shim
(9) and spring (8) in valve (1 l), then install in body.
6. Assemble shim (7) in valve (6), then install in body.
7. Install valve (5).
8. Install valve (4), spring (3) and stopper (2).
9. Fit gasket and install solenoid valve assembly (1).
23-65
DISASSEMBLY AND ASSEMBLY TRANSMISSION CONTROL - LOWER VALVE
L07ED018
23-66
DISASSEMBLY AND ASSEMBLY TRANSMISSION CONTROL - UPPER VALVE
UPPER VALVE
DISASSEMBLY
1. Remove cover (1).

2. Remove guide (3), then remove spring (4), shim (5),
valves (6, 7 and 9), and spring (8) as a set.
3. Remove valves (10, 12 and 13), and spring (11).
4. Remove stopper (14), then remove quick return
valve (15).
5. Remove snap ring (17), then remove guide (18).
6. Remove spring (19) shim (20), valves (21, 22 and
24), and spring (23) as a set.
7. Remove cover (25), valve (26), shim (27), and
springs (28 and 29) as a set.
Note: See next page.
ASSEMBLY
1. Assemble shim (27) and springs (28 and 29) in

valve (26), then assemble in body, fit O-ring and
install cover (25).
2. Assemble valves (22 and 24), spring (23), shim (20)
and spring (19) in valve (21), then assemble in body
(33).
3. Install guide (18), then install snap ring (17).
4. Assemble valve (15), fit O-ring and install stopper
(14).
5. Assemble valves (12 and lo), and spring (11) in
valve (13) then install to body (33).
6. Assemble valves (9 and 7), spring (8), shim (5) and
spring (4) in valve (6) then install guide (3).
7. Fit gaskets and install cover (1).
23-67
DISASSEMBLY AND ASSEMBLY TRANSMISSION CONTROL - UPPER VALVE
L07ED019
23-68
DISASSEMBLY AND ASSEMBLY FRONT DIFFERENTIAL
FRONT DIFFERENTIAL
REMOVAL
Soecial tools
A 1 793-520-2410 1 Bracket I 1
B 1 793-520-2510 1 Bracket I 1

1. Draining oil
Remove drain plug (1) and drain oil from axle
assembly.
Axle assembly: Approx. 624
2. Tire, wheel
1) Using lift arm, raise front axle, then put stand
under left housing and put block 0 under front
frame.
2) Sling left tire and wheel (2), remove mounting
bolts, then lift off.
Tire, wheel: 458 kg
3. Covers
Remove left and right covers (3).
23-69
4. Axle shaft
Using forcing screw, pull out axle shaft (4) and sun
gear (5) about 200 mm.
5. Drive shaft
1) Disconnect grease tube (6).
2) Disconnect front drive shaft (7) at differential
and at center.
3) Remove flange bearing (8) then move front
drive shaft towards rear frame.
6. Parking brake
1) Release parking brake, then disconnect lever
(9) of linkage.
2) Remove parking brake caliper (10).
424P758
7. Hydraulic piping
Remove lift cylinder tube (11) from brackets (12) on
left and right of front frame, and bracket (13) inside
front frame, then move it towards rear frame.
23-70
8. Differential
1) Remove 2 mounting bolts of differential (14)
then install guide bolts (Thread dia. = 14 mm,
pitch = 2 mm, length = 50 mm).
t Screw the thread of the guide bolts in fully.
t After screwing in the guide bolts, remove
the remaining mounting bolts.
2) Fit lifting tool @to differential case (15).
3) Install forcing screw, and pull out differential

(14) along guide bolts about 20 mm from axle
housing (16).
+ Be careful not to damage the differential
O-ring.
4) Install tools A and B to garage jack, then insert
between differential and axle housing, and
install tool A to differential.
5) Adjust height of lifting tool and garage jack, and

remove differential (14) carefully.
Differential: 210 kg
6) Operate garage jack and pull differential out

from under machine body.
7) Remove O-ring (17).
+ To remove the rear differential, first remove
the axle assembly, then remove the
differential from the axle.
23-71
INSTALLATION
1. Differential
1) Install tools A and B to garage jack, then install
differential (14) in tool A.
2) Fit O-ring (17) to differential.
3) Operate garage jack and pull differential in
under machine body.
4) Install guide bolts (Thread dia. = 14 mm, pitch

= 2 mm, length = 50 mm) in axle housing.
5) Fit lifting tool to differential case (15).
6) Adjust height of lifting tool and garage jack, and

assemble differential along guide bolts.
+ Fit the O-ring (17) securely in the groove
and make sure that it is not caught when
installing.
7) When clearance between axle housing (16) and

differential (14) is about 20 mm, remove tool A
and tighten mounting bolts uniformly.
8) Remove guide bolts (18) and install mounting
bolts.
a Mounting bolt: 18.Ok2.0 kgm
9) Remove lifting tool from differential

case.
23-72
2. Hydraulic piping
Install lift cylinder tube (11) to brackets (12) on left
and right of front frame, and bracket (13) inside
front frame.
3. Parking brake
1) Install parking brake caliper (10).
2 Connect parking brake linkage to lever (9), then
apply parking brake.
4. Drive shaft
1) Temporarily install flange bearing (8).
2) Connect front drive shaft (7) at differential and
at center.
3) Connect grease tube (6).
4) Tighten flange bearing fully.
t When connecting the drive shaft, clean the
contact surfaces of the spider and coup-
ling, and mesh the pilot correctly to install.
a Mounting bolt: 28.523 kgm
5. Axle shaft
Push in axle shaft (4) together with sun gear (5).
23-73
DIS;ASSEMBLY 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 and make
7. Tire, wheel
1) Raise tire and wheel (2), set in mounting posi-
tion, then install mounting nuts.
D Mounting nut: 4825 kgm

Width across the fiats: 30 mm
2) Remove stand and block.

Tighten level plug (18) and add oil through oil filler
t Set the machine so that the drain plug of the
final drive is at the bottom when refilling with
oil.
Axle assembly: 55P

%i#
23-74
DISASSEMBLY AND ASSEMBLY REAR DIFFERENTIAL
REAR DIFFERENTIAL
REMOVAL

Rear axle
Remove rear axle.
For details, see SECTION 23, REMOVAL OF REAR
AXLE.
Draining oil
assembly.
b
Axle assembly: 55P
.(.
3. Axle shaft
1) Remove cover (2).
2) Using forcing screw, pull out axle shaft (3) and
sun gear (4) about 200 mm.
423P854 423P855
4. Differential assembly
Using forcing screw, remove differential (5).
Differential: 185 kg
23-75
DISASSEMBLY AND ASSEMBLY REAR DIFFERENTIAL
INSTALLATION
1, Differential
Raise differential (5) set in mounting position, then
+ Check that there is an O-ring fitted to the
mounting face of the differential.
D Mounting bolt: 18+2 kgm
2. Axle shaft
1) Push in axle shaft (3) together with sun gear
(4).
t If the axle shaft cannot be inserted, rotate
the differential coupling lightly. Never try to
force the shaft in.
2) Fit O-ring (6) on cover (2) and install cover.

+ Check that there is an O-ring fitted to the
mounting surface of the cover.
+ Make sure that the O-ring is not caught
when installing.
3. Rear axle
Install rear axle.
REAR AXLE.

Tighten drain plug and add oil through oil fillers (7
and 8) to the specified level.
* Set the machine so that the level plug of the
oil.
Axle assembly: 554

%i#
23-76
DISASSEMBLY AND ASSEMBLY DIFFERENTIAL
DIFFERENTIAL
DISASSEMBLY
1. Differential gear
1) Remove ring gear adjustment bolt.
2) Loosen adjustment ring lock bolt, then remove
lock plate (1).
t Rotate the adjustment ring and disconnect
the differential gear from the pinion gear.
3) Remove bearing cap (2).

+ Make match marks on the left and right
bearing caps.
4) Remove adjustment ring (3) and bearing cup

(4).
5) Remove differential gear (5) from carrier.

+ The pilot bearing will hit the carrier, so tilt it
slightly to the right when raising.
el kg
Differential gear assembly: 75 kg
23-77
2. Case
1) Remove bearing (6).
2) Remove case (7).
t Make match marks before
3) Remove side gear (8), spider (9), thrust washer

(10) and pinion gear (11).
3. Ring gear, flange half

2) Remove mounting bolts, then remove ring gear
(13) and flange half (14).
4. Turning over differential gear

Turn over differential gear.
23-78
5. Pinion gear
1) Loosen mounting bolts of yoke (15).
t Leave the yoke temporarily fiied.
2) Remove pinion gear (17) from differential case
(16).
+ There are shims installed, so check the
number and thickness of the shims, and
keep in a safe place.
6. Pinion shaft
1) Using press, remove pinion shaft (18).
2) Remove bearing cups (20 and 21) from cage
(1%
3) Remove pilot bearing (22) and bearing (23)

from pinion shaft (18).
t Do not remove pilot bearing (22) and bear-
ing (23) if not necessary.
+
El 19
423F424
2i i3 423F426
19
423F425
ASSEMBLY
Special tool
A [ 793-520-2620 1 Plate I 1
t If the pinion or ring gear are replaced, always

replace them both together 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 (18).
2) Press fit bearing (23) on pinion shaft (18).
t Press fitting force for bearing (23) and pilot
bearing (22): 5 ton
423F427
3) Press fit bearing caps (20 and 21) on cage (19).

t Press fitting force for bearing cap: 5 ton
& Inside circumference of cage, outside

circumference of cap: Axle oil (See page
00-l 1).
4) Assemble cage (19) to pinion shaft (18) and

install spacer (25).
423 F425
2. Adjusting preload
1) Press fit bearing (24) on pinion shaft (18).
23-80
2) Push bearing with a press, and measure rotat-

ing force of cage with a spring balance.
& Bearing: Axle oil (See page 01-l 1).
+ Coat the bearing well with oil and make

sure that it is settled before measuring.
+ Press fitting force: 20.6 ton
+ Reading of spring balance: Max. 15 kg
3) If the measurement is not within the standard

range, replace bearings (23 and 24), and spac-
er (25) with new parts and measure again.
4) Check the end play. End play must be within
the standard range.
+ End play: Max. 0.212 mm
423F428
3. Pinion gear
1) Press fit oil seal (27) on cage (26), and tempo-
rarily install coupling (15).
* Use a new oil seal.
& Lip of oil seal: Grease (G2-Ll)
m Coupling mounting bolt: 64.5 + 10.5 kgm
423F429
2) Assemble pinion gear (17) in differential case
(16) without fitting shims.
423F430 A
23-81
3) Install differential case (16) in tool A.

4) Measure distance ‘I.” from tool A to pinion gear,
and calculate shim thickness.
* If the bearing, pinion gear or ring gear have
been replaced, follow the procedure below
to adjust with shims.
Standard value =
Standard value - (L - thickness of tool) =
shim thickness
5) Assemble shim and install pinion gear (17) to

differential case (16).
e Mounting bolt: Thread tightener (LT-2)
m Mounting bolt: 1822 kgm
4. Ring gear
1) Press fit bearing (12) in flange half (14).
2) Knock pin (27) into ring gear (13).

3) Install flange half (14) on ring gear (13).
23-82
4) Tighten mounting bolts.
Mounting bolt: Thread tightener (LT-2)
D Mounting bolt: 28.5+3 kgm
5. Side gear
Install washer (28) then install side gear (8).
6. Pinion gear
Assemble pinion gear (11) and thrust washer (10)
on spider (9).
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: 1822 kgm
23-83
8. Differential gear
1) Raise gear (5), assemble bearing cap (4) on
bearing, then install in case.
2) Align with thread of differential case (16) and

install adjustment ring (3).
3) Align match marks and install bearing cap (2).
t Be careful not to damage thread of the cap.
D Mounting bolt: 94.52 10.5 kgm

9. Adjusting preload of bearing

1) Turn adjustment ring with a bar until bevel gear
contacts pinion gear, and adjust until there is
no backlash.
t Rotate the bearing well so that it is properly
in contact with all other parts, and tap the
ring gear with a copper hammer.
+ Coat the bearing well with oil.
* If the adjustment ring on one side is loos-
ened by one turn, tighten the ring on the
other side by one turn.
2) Install spring balance to bevel gear and mea-

sure the rolling resistance torque.
D Rolling resistance torque: 2.0-2.5 kg
+ Target: 2.5 kgm
23-84
10. Adjusting tooth contact, backlash

Adjust the backlash as follows:
1) Use adjustment ring to adjust ring gear.
* Always turn the adjustment rings at both
ends the same amount in the same direc-
tion.
2) Put dial gauge in contact with tooth face at
outside tip of ring gear, and turn adjustment
ring to adjust.
+ Measure at 3 or 4 places, and keep the
pinion gear fixed when measuring.
t Backlash: 0.3 - 0.41 mm
Adjust the tooth contact as follows:

1) Mix red lead with oil and coat face of 7 or 8
teeth of pinion gear lightly with red lead (mini-
mum).
2) Rotate the pinion gear forward and backward
and inspect the pattern left on the teeth.
t For details of tooth contact condition and
methods of adjustment, see page 2386.
23-85
11. Adjusting tooth contact

Coat face of7orI 3 teeth of bevel pinion lightly \ h red lead (minimum). Hold the bevel gear by hand to act as
a brake, rotate 1the3 pinion gear forward and bat ward and inspect the pattern left on the teeth.
Tooth contact Cause Procedure for adiustment
The tooth contact pattern Adjust the pinion gear by adjusting the shims at the cage.
should start from about 5 Adjust the bevel gear in the same way as when adjusting
mm from the toe of the backlash.
bevel gear and cover about
50% of the length of the
tooth. It should be in the
2OBF514
center of the tooth height.
Bevel pinion gear is too far 1. Reduce shims at pinion gear to bring closer to bevel
from bevel gear. gear.
2. Move bevel gear further away from pinion gear and
adjust backlash correctly.
rl
2
206F515
Bevel pinion gear is too

TiJ
?
1 u
1. Increase shims at pinion gear to move away from

2OBF519
close to bevel gear. bevel gear.

2. Move bevel gear closer to pinion gear and adjust
backlash correctly.
2
2OBF516
Bevel gear is too close to 1. Reduce shims at pinion gear to bring closer to bevel
pinion gear. gear.
2. Move bevel gear further away from pinion gear and
adjust backlash correctly. II
206F517
Bevel gear is too far from 1. Increase shims at pinion gear to move away from
pinion gear. bevel gear.
2. Move bevel gear closer to pinion gear and adjust
backlash correctly.
2OBF518
+ When adjusting ie bevel gear, do not change 1 ? preload of the bearing. Adjust by moving shims between the
. I.
left and right. Always keep the same total thickness of snims.
23-86
12. Lock plate

After adjusting tooth contact, wipe Offred lead
install lock plate (1).
13. Adjustment bolt

After adjusting, tighten bolt (29) until it contacts rear
face of ring gear, then loosen l/2 turn and tighten
lock nut (30).
e ;;l$nent bolt: Thread tightener
a Adjustment bolt: 94.5 + 10.5 kgm
m 423F431
23-87
DISASSEMBLY AND ASSEMBLY FRONT AXLE

l Put blocks under the rear wheels to prevent the

machine from moving, and apply the parking
brake secure1 .
0 Insert block t;I between frame (2) and the top
surface of rear axle housing (1).
0 Jack up the machine, and put blocks @ under

the front frame on the left and right sides.
1. Tire, wheel
Sling left and right wheels (3), remove mounting
nuts, then lift off.
Tire, wheel: 458 kg
2. Drive shaft
Disconnect drive shaft (4) at differential end.
23-88
3. Brake tube
Disconnect brake tube (5) from slack adjuster (6).
+ After disconnecting the piping, cover to prevent
dust or dirt from entering.
4. Parking brake
Release parking brake, then disconnect from lever
(7) of linkage.
424P765
5. Front axle
1) Sling front axle housing (8) on one side, and fit
garage jack under other side.
2) Fit garage jack under bottom of differential
case.
+ Be careful not to damage the side face of
the parking brake disc.
+ When installing the lifting tool, be careful
not to crush the brake tube.
23-89
3) Remove mounting bolts (9) of front axle.

4) Put block under front axle, then using hoist and
garage jack to maintain balance, lower front
axle.
Front axle: 1173 kg
5) Pull out front axle assembly from machine.
23-90
INSTALLATION
1. Front axle
1) Pull front axle under machine body.
424P766
2) Fii lifting tool to front axle (lo), set garage jack

under parking brake disc and maintain balance
while setting in mounting position.
3) Install mounting bolts (9) of front axle with
engine oil.
D Mounting bolt: 105alO kgm
&& Mounting bolt: Engine oil and water
2. Parking brake
Release parking brake, then connect lever (7) of
linkage.
A Apply the parking brake.
3. Brake tube
Connect brake tube (5) to slack adjuster (6).
+ Wipe the connection with a clean cloth.
4. Drive shaft
Connect front drive shaft (4) at differential
Iz_7 Mounting bolt: 11.521.0 kgm
5. Tire, wheel
1) Set left and right wheels (3) in mounting posi-
tion, then install mounting nuts.
m Mounting nut: 4625 kgm
2) Jack up machine, then remove block @ from

under front frame.
3) Remove block 0 from between frame and top
surface of rear axle housing.
6. Bleeding air from brakes

Bleed air from brakes, then check operation.
+ For details of bleeding air, see SECTION 52,
TESTING AND ADJUSTING.
23-92
REAR AXLE
REAR AXLE

l Put blocks under the front wheels to prevent the

machine from moving, and apply the parking brake
securely.
o Jack up the machine, put block @ under the rear
frame, and put a stand @ under the counterweight.
1. Tire, wheel
Sling left and right wheels (1) remove mounting
nuts, then lift off.
Tire, wheel: 495 kg
‘858
2. Drive shaft
Disconnect rear drive shaft (2) from rear axle.
3. Brake hose
Disconnect hose (3) between brake chamber and
slack adjuster.
DISASSEMBLY AND ASSEMBLY REAR AXLF
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, support assembly

1) Secure the rear axle support with chain.
2) Sling rear axle and support assembly (10) on

one side, and fit garage jack under axle hous-
ing.
23-94
DISASSEMBLY AND ASSEMBLY REAR AXLE
3) Remove mounting bolts (11) of axle support,

then using hoist and garage jack to maintain
balance, remove rear axle support (88) from
front support (8A).
+ Use garage jack at rear support (88).
Rear axle, support assembly: 1300 kg 11
‘9 8B
423FO1111
4) Pull out rear axle from rear frame.
7. Rear axle
1) Remove retainer (13) from front support of rear
frame.
2) Remove O-ring (14) from retainer.
3) Remove O-rings (15 and 16), and bushing (17)
from front support of rear frame.
23-95
5) Raise rear support (18) and remove cover (19).

18
Rear support: 106 kg
19
21
L .i‘
23 20 20 L07FK002
i
6) Remove thrust washers (20 and 21) from rear

axle.
7) Remove rear support (18).
8) Remove O-ring (22) and bushing (23) from rear
support.
23-96
INSTALIATION
18
1. Rear axle
19
1) Install bushing (23) and O-ring (22) on rear
support (18).
+ Assemble the bushing with the chamfered 21
edae on the axle housina side.
+ Fiithe O-ring securely ii the groove, and
make sure that it is not caught when install-
ing.
+ Check that the O-ring is on the axle hous-
ing side.
L-
I
-2
23 20 20 L07FK002
2) Raise rear support, and set in position on rear

axle mount.
3) Install thrust washer (20), thrust plate (21) and
thrust washer (20).
4) Install cover (19).
5) Install bushing (17) and O-ring (16) on front

support of rear frame.
+ Assemble the bushing with the chamfered
edge on the axle housing side.
6) Assemble O-rings (14 and 15) on retainer (13).
7) Install retainer on front support.
ing.
L07FK003
23-97
2. Rear axle, support assembly

1) Secure the rear axle (9) and the rear axle
support (88) with chains.
t Fit the chains on the right side where there
is no grease tube.
2) Raise rear axle and support assembly (10) on

one side, and fit garage jack under axle hous-
ing.
3) Pull rear axle and support assembly (10) under

machine.
4) Using hoist and garage jack to maintain bal-
ance, set in mounting position, and install rear
axle support (8B) at axle support (8A).
D Mounting bolt (11): 135+15 kgm
3. Engine oil drain valve

Install bracket (6) of engine oil drain valve to fuel
tank (7).
23-98
4. Grease tubes
Connect grease tubes (4 and 5) to rear axle sup-
port.
5. Brake hose
Install hose (3) between brake chamber and slack
adjuster.
6. Drive shaft
Connect rear drive shaft (2) at rear axle end.
+ When connecting the drive shaft, wipe the
contact surface of the spider and coupling, and
mesh the pilot correctly when installing.
a Mounting bolt: 11.52 1.O kgm
7. Tire, wheel
1) Set left and right wheels (1) in mounting posi-
tion, then tighten mounting nuts.
m Mounting nut: 5628 kgm

2) Remove block @ from under rear frame, and

stand @ from under counterweight, then lower
machine to ground.
8. Bleeding air from brakes

* For details of bleeding air, see SECTION 52,
23-100
DISASSEMBLY AND ASSEMBLY DRIVE SHAm
DRIVE SHAFI-
DISASSEMBLY

1) Remove coupling and tube (1).
+ Make match marks “a” before removing so
that the direction of the coupling does not
change.
2) Loosen bolt (2), then remove coupling (3) and

retainer.
+ 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 Center
Step 1).
Rear
42CP772
,23-l 01
DISASSEMBLY AND ASSEMBLY DRIVE SHAFT
3. Spider, bearing
1) Remove bolt (6) of spider and bearing assem-
bly (5), then tap with plastic hammer to remove
spider and bearing.
2) Remove strap (8) of spider (7), then remove

bearing cap (10).
+ Repeat the same procedure for the front,
center and rear drive shafts.
23-102
ASSEMBLY
1. Spider, bearing
1) Set bearing cap (10) to spider (7) in mounting
position, then install.
t If the spider and bearing cap are worn,
replace the spider and bearing.
* Heat will damage the bearing, so do not
weld strap (8) of the cap.
t Assemble so that the grease nipples face in
the same direction.
t Repeat the same procedure for the front,
center and rear drive shafts.
2) Install spider and bearing assembly (5), then

tighten bolt (6).
a Mounting bolt: 11.5tl.O kgm
& Bearing cap: Grease (G2-Ll)

1) Press fit flange bearing (4).
+ Do not hit the flange bearing directly with a
hammer.
2) Align match marks, install coupling (3) and

retainer (9) then tighten mounting bolt (2).
* Tighten the bolts to the specified tightening
torque after installing on the machine.
a Spline: Grease (G2-Ll)
m Mounting bolt : 94.5r 10.5 kgm
23-103
3) Align match marks and install coupling and

tube (1).
t Check that the couplings are facing in the
same direction.
t If the spline is worn, replace the whole
drive shaft assembly.
a Spline: Grease (G2-Ll)
Center
3. Center drive shaft, rear drive shaft

t Follow the procedure in 2. Front drive shaft
Step 1) to 3).
23-104
DISASSEMBLY AND ASSEMBLY FINAL DRIVE
FINAL DRIVE
DISASSEMBLY

Special tools
B 790-425-l 620 Fixture 3
C 790-425-l 630 Fixture 3
1. Tire, wheel
Jack up axle, insert stand under axle, then lift off
tire and wheel (1).
t After removing the tire and wheel, put a stand
under the axle.
Tire, wheel: 460 kg
2. Draining oil
assembly.
+ Set the drain plug at the bottom.
b
Axle assembly: 55P
&
3. Cover
Remove cover (3), then remove O-ring (4).
23-105
4. Axle shaft assembly

Remove axle shaft assembly (5) from axle.
5. Planet carrier assembly

Remove 3 mounting bolts (6), then lift off planet
t Make match marks to act as a guide when
installing.
t Be careful of the center of gravity, and lower
slowly.
Planet carrier assembly: 86 kg
6. Ring gear assembly

1) Using tools B and C, fix wheel hub (8) and
brake (9) in position.
t Fit tools B and C at three places equally
spaced around the circumference, then use
washers to install.
423FO1112
2) Remove mounting bolts of retainer (lo), then
remove ring gear assembly (11).
+ There are shims between the retainer and
axle housing, so check the number and
thickness of the shims, and use for refer-
ence when installing.
Ring gear assembly: 36 kg
23-106
7. Disassembly of planet carrier

Using a press, pull out shaft (12) and remove pinion
gear (13).
+ There is a lock ball (14) on the shaft, so be
careful not to lose the ball.
+ Write a number on the case and keep all the
removed parts separately in sets.
423FO1113
8. Disassembly of ring gear

1) Remove lock plates (21) from ring gear hub
(20) then remove ring gear (22).
21
22
423P939
2) Screw in forcing screws (Thread dia. = 12 mm,

pitch = 1.75, length 70 mm) from ring gear hub
(20) and remove bearing (23).
423P940
23-107
ASSEMBLY 26
/ ?3
Special tools
Part number Part name I cm
B 790-425-l 620 Fixture 3
C 790-425-l 630 Fixture 3
1. Assembly of ring gear

1) Press fit bearing (23) on ring gear hub (20).
f After press fitting the bearing, check that
there is no clearance between the rib and
bearing.
2) Set ring gear hub (20) on ring gear (22), then

install lock plates (21).
t Install the lock plates with the wider ones
on the inside.
* Remove all grease and oil from the bolt.
a Hub mounting bolt: Thread tightener (LT-2)
423P942
2. Assembly of planet carrier

1) Assemble bearing cone (17) on pinion gear
(13), then using lifting bar 0, set in position on
carrier mount.
t Insert all three pinion gears in the carrier.
2) Align holes of carrier and gear, then press fit r- _* 423P943; 423FO1114
cooled shaft (12). ._
Do not touch the cooled shaft directly with bare

A skin.
t Press fit so that the hole for the lock ball is

on the outside circumference, then stop
with the hole at the front and align the
holes.
t Cool the shaft at -30°C for 20 minutes.
23-108
3) Assemble lock ball (14). on shaft, then press fii

7,
shaft again.
t After press fitting the shaft, check that the
gear rotates smoothly.
423 :FO1115

1) Raise ring gear assembly (ll), set in mounting
position, and insert in axle housing.
+ Align the spline groove and insert the as-
sembly slowly.
23-109
2) Tighten retainer (10) temporarily with 3 bolts,

then remove tools B and C.
t Remove all grease and oil from the bolt
hole of the retainer mount.
t Do not insert shims in the retainer when
tightening temporarily.
+ Rotate the wheel hub to settle the bearing,
then tighten to a uniform torque.
D Mounting bolt of retainer: 3.0 kgm
3) Insert a depth micrometer through measuring

hole of retainer (lo), and measure clearance “a”
between end face of housing and end face of
retainer.
rt Measure at 2 places and take the average.
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.
* Shim thickness: 1.0 mm, 0.3 mm, 0.2 mm
423F439
5) Install tools B and C to brake assembly and

wheel hub, and remove retainer (10). Install
required thickness of shims, then install retainer
(10) again.
+ Always install tools B and C before assem-
bling the shims.
+ Rotate the wheel hub and tighten the
mounting bolts uniformly to the specified
tightening torque.
a Mounting bolt: 11.5?1.0 kgm
4. Planet carrier
Fit O-ring (24) to wheel hub (8) raise planet carrier
(7), set in mounting position, then install.
* Align mounting holes and install carefully so
that the O-ring does not slip out of place.
23-110
DIS ASSEMBLY AND ASSEMBLY FINAL DRIVE
5. Axleshaft
Install axle shaft (5).
4 If the position of the sun gear does not match,
rotate the wheel hub to align.
6. Cover
Fit O-ring (4) in groove in cover, then install cover
(3).
D Mounting bolt: 7.0205 kgm

Tighten drain plug and add oil through level plug
+ Set the machine so that the level plug of the
oil.
Axle assembly: 480
8. Tire, wheel
Install tire and wheel (l), then remove stand.
D Mounting nut: 48+5 kgm
23-111
POWER TRAIN
24 MAINTENANCE STANDARD
TRANSMISSION AND ENGINE MOUNT ................................................ 2
TORQUE CONVERTER CHARGING PUMP .............................................. 4
TORQUE CONVERTER . . . ..___.................................................... 6
TORQFLOW TRANSMISSION ... .......................... .. .. ...... . . . . . ........ 8

1.TRANSMISSION ...... . . . . . ........ 8
2.TRANSMISSION &iiibi’hilik :::::::::::::::::::::: :::: ...... . . . . . ....... 12
UPPERVALVE . . . . . . . . . . . . . . . .._...................... ...... . . . . . ....... 12
LOWER VALVE . . . . . . . ....... .... ....... ............. .. ...... . . . . . ....... 14
B.SOLENOID VALVE . . . . . ....... .... .. .... .............. .. ...... . . . . . ....... 16
TRANSFER . . . . . . . . . . . . . . . . . . . . . .._................_.____ ...... . ........ .... 18
DIFFERENTIAL . .._........._............................. ...... . ....... ..... ?O

FINAL DRIVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...... . ........ .... 22
DRIVE SHAFT .. ........ ............ ...... ............... . ...... ... ....... ... 23
AXLE MOUNT . ......... ............ ......... ... .......... ...... .... ....... .. 24
MAINTENANCE STANDARD TRANSMISSION AND ENGINE MOUNT
TRANSMISSION AND ENGINE MOUNT
I j -.. _
1 - --I
VIEW 2
6’ ‘6
L07CD003
24-2
MAINTENANCE STANDARD TRANSMISSION AND ENGINE MOUNT
Unit: mm
No. Check item Criteria Remedy
Clearance between transmission bracket and

1 Adjust
adjustment bolt
2 Tightening torque of mounting bolt 94.5+10.5 kgm
3 Not used
4 Tightening torque of bracket mounting bolt 18.Ok2.0 kgm Retighten
5 Tightening torque of mounting bolt 94.52 10.5 kgm
6 Tightening torque of clearance adjustment bolt 28.Ok3.0 kgm
24-3
MAINTENANCE STANDARD TORQUE CONVERTER CHARGING PUMP
TORQUE CONVERTER CHARGING PUMP

Model SAL(3)-56
Section A-A
\
423F206
Unit: mm
Clearance between gear case and side Standard clearance Clearance limit
1
plate gear
0.10-0.15 0.19
Clearance between inside diameter of

2 plain bearing and outside diameter of 0.06-0.15 0.20 Replace
gear shaft
3 Insertion depth of pin

14-i.5
4 1 Rotating torque of spline shaft I 0.95 +0.25 kgm I
5 Tightening torque of bolt 25.52 1.5 kgm Retighten
I I I I I I
Standard Repair limit
Discharge Revolution Pressure
discharge discharge
Oil: EOlO-CD (rpm) (kg/cmz) (elmin) (elmin)
Temperature: 45-55” C
2,500 30 134 123
24-4
This page is blank.
24-5
MAINTENANCE STANDARD TORQUE CONVERTER
TORQUE CONVERTER
‘\
\
‘\ H--J3
‘6
424FO86
24-6
MAINTENANCE STANDARD TORQUE CONVERTER
Unit: mm
Standard size Repair limit
1 Outside diameter of pilot

I 52 -0.010
r\ nrn
-u.uLtv
I
!
51.75 I Reoair
chiome
125 +0.040 plating or
2 Inside diameter of sliding surface of PTO +o I 125.5 I renlace
I 1 .-I-.---
I ^ ^^_ I
50 +u.uzs
3 Inside diameter of sliding surface of bushing 0 50.1
Width
3.56
3.95-i ,
4 Width and thickness of seal ring Replace
Thickness
8+1.0
4 4.32
. -0.1
5 Backlash of PTO gear (Drive gear) 0.181-0.493 Repair or

replace
6 Backlash of PTO gear (Driven gear) 0.181-0.493
7 1 Tightening torque of bolt I 7.0 20.5 kgm I
8 1 Tightening torque of bolt I 3.2kO.3 kgm I
9 1 Tightening torque of bolt I 3.2kO.3 kgm I

10 I Tightening torque of bolt I 7.0 +0.5 kgm I Retighten
11 I Tightening torque of bolt I 7.0 ~0.5 kgm I
12 I Tightening torque of bolt I 11.3k1.2 kgm I
13 I Tightening torque of bolt I 7.0 + 0.5 kgm I
24-7
MAINTENANCE STANDARD TORQFLOW TRANSMISSION
TORQFLOW TRANSMISSION
1. TRANSMISSION
26 23 1 2 21 4 22 3 6 24 5 10 9 25 27
24-8
Unit : mm
Backlash between No. 1 sun gear and

1 planetary gear 0.13-0.32
2 Backlash between No. 1 planetary

0.15-0.38
gear and ring gear


0.15-0.38
gear and ring gear

5 0.13-0.29
planetary gear
Backlash between No. 3 planetary

6 0.15-0.38
gear and ring gear


0.18-0.34
gear and ring gear

9 0.13-0.33
planetary gear
Backlash between No. 5 planetary

10 0.14-0.36
gear and ring gear Replace
I
Free Installation Installation Free Installation

11 No. 1 clutch springs length length load (kg) length load (kg)
53 43 9.1 50 7.7
12 1 No. 2 clutch springs 1 53 1 44.5 I 7.7 1 50.5 1 6.6 I
13 I No. 3 and No. 6 clutch springs 40 I 26 12.7 1 36 1 10.8 1
14 I No. 4 clutch spring I 40 1 28 I 10.9 1 36.5 1 9.3 1
15 I No. 5 clutch spring 1 40 1 32 1 7.3 1 37.5 1 6.2 1

16 Thickness of assembled 3 discs and
2 plates for No. 1 clutch 25+o.22
-0.22 22.2
17 Thickness of assembled 3 discs and 25 + 0.22 22.2

2 plates -0.22
18 Thickness of assembled 2 discs and ,5+o.17 13.3

1 plate for No. 3 and No. 4 clutches -0.22
19 Thickness of assembled 2 discs and 15+o.17 13.3

1 plate for No. 5 clutch -0.17
24-9
No. Check item Criteria 1Remedy

Thickness of assembled 2 discs and
20
1 plate for No. 6 clutch
Thickness of 1 disc
22 Thickness of 1 plate
90+0.016
23 Outside diameter of input shaft bearing
-0.006
Outside diameter of output shaft 72+o.013

24 72.018
bearing -0.006
Replace
Outside diameter of output shaft ,oo+0.016
25
bearing -0.006
Width
3-o.01
2.6
-0.03
26 Wear of seal ring for input shaft
Thickness
2 +O.l
,
1.8
. -0.1
3-o.01
2.6
-0.03
27 Wear of seal ring for output shaft
Thickness
2 1 +O.l
1.8
. -0.1
24-10
This page is blank.
24-11
2. TRANSMISSION CONTROL VALVE
UPPER VALVE
12L
7-
‘3
423F210-1
24-12
Unit: mm
Clearance between torque

1 converter relief valve spool
and body
Clearance between priority

2
valve spool and body
Clearance between quick

3 12 -0.035 +0.011 0.035 0.08
return valve spool and body -0.045 0 0.056
Clearance between
4 body
modulating valve spool and
I I I I
Standard size Repair limit Replace
5 Priority valve spring

I I
I 62 I 37.7 22.1 I 59.6 19.9 I

Torque converter relief valve
6 62 48 12.8 60.6 11.5
spring
Torque converter relief valve

7 26 19 0.58 25.3 0.52
spring (Inner)
Modulating valve spring

8 118 106.5 22.5 117 20.5
(Inner)
Modulating valve spring

9 145.7 141.5 4.14 145.3 3.7
(Outer)
Thickness of shim for

10 4 mm (pressure per 1 piece: 0.55 kg/cm*)
modulation valve
Thickness of shim for

priority valve
Thickness of shim for torque

converter valve I
13
Tightening torque of
modulation lock nut
4.25 r0.75 kgm lRetighten
24-13
LOWER VALVE
\ 423F211-1
12
24-14
Unit: mm
No. 1 Check item Criteria I Remedv
Clearance between FORWARD-

1
REVERSE spool and body
Clearance between 1st speed -0.035 +0.013 0.035-

2 spool and body 22 -0.045 0 0.058 0.08
Clearance between 2nd speed -0.035 +0.013 0.035

3 22 -0.045 0 0.058 0.08
spool and body
Clearance between 3rd speed -0.035 +0.013 0.035-

4 spool and body 22 -0.045 0 0.058 0.08
Clearance between 4th speed

5
spool and body
Clearance between pilot reduc-

6 ing valve and body 1 25 / I;:;;; 1 +;*“‘3 1 ;:;;;- 1 0.08
Replace
Clearance between lubrication

7 valve plunger and body 1 22 / ;;:$; 1 +;“13 1 ;:;;“8- 1 0.08
FORWARD-REVERSE, No. 1,
8 No. 2, No. 3 and No. 4 speed
spring
9 Accumulator spring 135.9 104 61.8 131.8 56
Pilot reducing valve spring

IO (Outer) 1 62 / 43.7 / 16.7 1 60.1 1 15
Pilot reducing valve spring

11 (Inner) 26 19 0.58 25.3 0.52
12 Lubrication valve spring 39.4 37 6.2 39.2 5.6
Thickness of shim for pilot re-

ducing valve
Thickness of shim for accumu- Adjust

14 1 mm (pressure per 1 piece: 0.25 kg/cm2)
lator
24-l 5
3. SOLENOID VALVE
Section A-A
423F212A
Unit: kgm
Tightening torque of solenoid valve mounting screw 0.165+0.015
Tightening torque of solenoid valve terminal screw 0.165+0.015
Tightening torque of solenoid valve terminal screw 0.075 kO.005

Retighten
4 Tightening torque of solenoid valve connector mounting screw 0.07a0.01
5 Tightening torque of terminal mounting screw 0.07~0.01
6 Tightening torque of solenoid valve assembly mounting bolt 4.75 kO.25
24-16
This page is blank.
24-17
MAINTENANCE STANDARD TRANSFER
TRANSFER
8.
14-
5 L07EV004
24-18
MAINTENANCE STANDARD TRANSFER
Unit: mm
Standard size Tolerance Repair limit

Oil seal sliding surface of
1 0
output shaft coupling (Rear) 85 95.18
-0.087
2
Oil seal sliding surface of
output shaft coupling (Front) I 0
-0.087 I
90.18
3
Clearance between shaft
bearing and housing
130 0 0 -0.040-
I Clearance
limit
-0.015 -0.040 0.015
Clearance between idler

4
shaft, bearing and housing Replace
Clearance between output
5 shaft, bearing and housing
13’ -:.018 1 -:.040
(Rear)

6
shaft and bearing

7
shaft and bearing
Clearance between idler shaft 95 + 0.045 0 -0.065-

8
and bearing (Rear) + 0.023 -0.020 -0.023
Clearance between idler shaft 95 + 0.045 0 -0.065-

and bearing (Front) + 0.023 -0.020 -0.023
Standard size Clearanc ! limit

Clearance between input
cover and case 2 Preload 0.0 -0.1 kgm

cover and case
2
I Less than 2.05
I
Adjust
Clearance between idler

2 Preload 0.01-0.1 kgm
cover and case
Backlash of input
. aear
_ I 0.20-0.51 I
I
Replace
Backlash of output gear 0.21-0.54
Tightening torque of coupling

50+5 kgm Retighten
mounting bolt
24-19
DIFFERENTIAL
DIFFERENTIAL
m 1812 kgm
94.5? 10.5 kgm
m 22.522.5 kgm
m 18&2kgm \ L. 1 ,--.J
B 28.523.0 kgm _
11.51+1.0kgm
1812 kgm
LO7FVOO9
24-20
MAINTENANCE STANDARD DIFFERENTIAL
Unit: mm
Tolerance
Standard Standard Clearance
size clearance limit
Shaft Hole
Clearance of side bearing of Outer race

1
differential gear assembly 160
Inner race
105
Outer race
146.05
Clearance of pinion shaft of
2
bearing Inner race + 0.051
69.85 + 0.038
Outer race
100 Replace
3 Clearance of pilot bearing
Inner race + 0.042
45 t 0.026
Clearance between differential

and cage ‘90
Clearance between shaft and -0.060
differential pinon oear -0.110 O-3
6 Not used
Backlash of bevel gear 0.3-0.41
8 Backlash of differential gear 0.1 O-O.25
End play of pinion gear Max. 0.212
Preload of pinion shaft bearing Rotating torque: Max. 5.2 kg
Preload of differential side Adjust

Rotating torque: 2.0-2.5 kg (Target: 2.5 kg)
bearing I
Rear face runout of bevel gear Max. 0.1
Standard size Tolerance I Repair limit

13 Thickness of side gear washer
4.0 It 0.05 3.8 Replace
I I
Thickness of pinion gear washer
24-21
MAINTENANCE STANDARD FINAL DRIVE
FINAL DRIVE
‘w 11.25+1.75kgm
\
w 18+2kgm
r&a 48F5kgm
424F3 I8
Unit: mm

-
Tolerance
Standard Standard Clearance
Clearance between planetary shaft Shaft Hole
1
and bearing
+0.013 0 -0.025-
45
0 -0.012 0
Replace
Clearance between ring gear hub and +0.040 0 -0.065-
2
bearing 180 +0.015 -0.025 -0.015
Standard size Tolerance Repair limit

.Thickness of spacer
26 kO.1 25.5
Backlash between planetary gear and

0.1 g-0.43
sun gear
Backlash between planetary gear and

5 0.1 g-o.53
ring gear
Thickness of standard shim for wheel

6 2.025? 1.25
hub
24-22
MAINTENANCE STANDARD DRIVE SHAFT
DRIVE SHAFT
Ii
424FO89
Unit: kgm
1 Tightening torque of mounting bolt 11.5+1.0
2 Tightening torque of mounting bolt 56?6
3 Tightening torque of mounting bolt 98.5 f 14.5
4 1 Tightening torque of mounting bolt I 11.5Ll.O I Retiahten
5 Tightening torque of mounting bolt 11.5+1.0
6 Tightening torque of mounting bolt 11.5hl.O
7 Tightening torque of mounting bolt 11.5-cl.O
24-23
MAINTENANCE STANDARD AXLE MOUNT
AXLE MOUNT

‘6 F424C1033
24-24
MAINTENANCE STANDARD AXLE MOUNT
423FC69
Unit: mm
Thickness of thrust plate
Clearance of shaft and hole

Front support side
105+ 10 kgm (coat engine oil)
24-25
STEERING SYSTEM
HYDRAULICPIPING ....... .............................. ... ..... ..... ...... ...... 2
HYDRAULIC CIRCUIT DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

NORMAL STEERING 3
GROUNDDRlVENSTiidlNG:::::::::::::::::::::::::::::::::::::::::::::::::::::: 3
STEERING CONTROLSYSTEM ...................................................... 4

STEERING VALVE .............................................................. 4
ORBIT-ROLLVALVE.. ........................................................... 5
RELIEFVALVE ................................................................. 6
STOPVALVE .................................................................. 7
STEERING CYLINDER .... ............................ ......... ...... .... ...... .... 8
STEERING COLUMN AND ORBIT-ROLL .................... .. ...... .... ...... ...... . 9
CENTERHINGEPIN ............................................................. lo
GROUND DRIVEN STEERING PUMP (OPTIONAL) ......................................... 11
DlVERTERVALVE(OPTIONAL)...................................................... 12
41-1
STRUCTURE AND FUNCTION HYDRAULIC PIPING
HYDRAULIC PIPING
F42301103
1. Steering cylinder
2. Steering valve
3. Orbit-roll valve
4. Gear pump
5. Hydraulic tank
6. Oil filter
7. Hydraulic oil cooler
8. Stop valve
41-2
STRUCTURE AND FUNCTION HYDRAULIC CIRCUIT DIAGRAMS
HYDRAULIC CIRCUIT DIAGRAMS

NORMAL STEERING
See foldout #2 at end of book.
GROUND DRIVEN STEERING
See foldout #3 at end of book.
41-3
STRUCTURE AND FUNCTION STEERING CONTROL SYSTEM
STEERING CONTROL SYSTEM

STEERING VALVE
P2
PI
U-J
Section D-D
‘Pb
Pl P2
\
Section X-X 5 F42301104
1. Safety valve (With suction) A: To steering cylinder

2. Check valve B: To steering cylinder
3. Steering spool Pa: From orbit-roll
4. Relief valve Pb: From orbit-roll
5. Flow control spool P1: From steering pump
P2: From switch pump
PB: To main control valve
T: Drain (To oil cooler)
41-4
ORBIT-ROLL VALVE
Section B-B
Detail C
3 .I I
Section A-A F42301105
1. Needle bearing 5. Rotor 9. Spool

2. Center spring 6. Ground 10. Stator
3. Drive shaft 7. Center pin 11. Lower cover
4. Valve body 8. Sleeve 12. Check valve
41-5
RELIEF VALVE
P
il i Section Y-Y
Section X-X
1. Filter 7. Inner valve spring L: To stop valve

2. Valve seat 8. Outer valve spring R: To stop valve
3. Ball 9. Ball P: From hydraulic pump
4. Ball guide 10. Orbit-roll valve T: To hydraulic tank
5. Spool 11. Body
6. Plug
Section Z-Z
F42301106
41-6
STOP VALVE
DR
1 2 3 4 5 6 7
Circuit diagram
Section X-X
421FO1090
1. Boot A: From orbit-roll

2. Wiper B: To steering valve
3. Seal DR: To drain
4. Poppet
5. Spring
6. Spool
7. Spring
41-7
STRUCTURE AND FUNCTION STEERING CYLINDER
STEERING CYLINDER
LlOBR027
1. Head Cylinder bore: 0 mm

2. Rod Rod diameter: 45 mm
3. Cylinder Stroke: 442 mm
4. Piston Cylinder max. length: 1,209 mm
5. Piston nut Cylinder min. length: 767 mm
Width across flats of piston nut: 50 mm
41-8
STRUCTURE AND FUNCTION STEERING COLUMN AND ORBIT-ROLL
STEERING COLUMN AND ORBIT-ROLL
Section A-A
3\
Section B-B
F42301107-1
1. Steering wheel
2. Center shaft
3. Steering column
4. Orbit-roll
41-9
STRUCTURE AND FUNCTION CENTER HINGE PIN
CENTER HINGE PIN

Outline
l The front frame (3) and rear frame (4) are connect-
ed through a bearing by the center hinge pin (5 and
6). The steering cylinders are connected to the left
and right front and rear frames, so when the cylin-
ders are operated, the frame bends at the middle to
give the desired angle, that is the desired turning
radius.
424F3 IO
1. Front axle
2. Rear axle
Section B-B 3. Front frame
4. Rear frame
5. Upper hinge pin
6. Lower hinge pin
41-10 Section C-C Section D-D

STRUCTURE AND FUNCTION GROUND DRIVEN STEERING PUMP
GROUND DRIVEN STEERING PUMP (OPTIONAL)

1 2 3 4
Section A-A
419F479
1. Drive gear (Teeth 12)

2. Front cover
3. Gear case
4. Rear cover
View 2
5. Driven gear (Teeth 12)
Specifications
0 Model: SAM(2)-040
l Direction of revolution: Possible to rotate both
directions
0 Theoretical delivery: 50.8 cc/rev.
l Max. delivery pressure: 210 kg/cm*
41-11
STRUCTURE AND FUNCTION DIVERTER VALVE
DIVERTER VALVE tOPTIONAL)
TV\,3 WCC,,,
Section
T
V-V D
Section X-X
419F490
1. Diverter valve A. From steering pump
2. Valve body B. To steering valve
3. Check valve C. To hydraulic tank
4. Check valve D. Sensor mounting port
E. Emergency pump port
Emergency pump port
G’: From hydraulic pump
Function
0 If the engine stops or the pump seizes during
machine traveling, and it becomes impossible to
steer, the rotation of the transmission is used to
turn the emergency steering pump to make steering
possible.
41-12
STEERING SYSTEM
STANDARDVALUETABLE ..... .................. ... ........ ....... .... ... ..... ..... ... 2
TOOLLIST......................................................................... 2
STEERINGWHEELPLAY ...... .................... ...... .. .... ... .... ... ...... ... ..... 3
OPERATING FORCE OF STEERING WHEEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
OPERATING TIME OF STEERING WHEEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
STEERING CONTROL................................................................. 6
STEERING OILPRESSURE . ...... ... .... ............... .. .... .. ..... .... .... .... ....... 7
GROUND DRIVEN STEERING PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
TROUBLESHOOTING ................................................................ 11
TROUBLESHOOTING TABLES ...................................................... 12
1. Steering wheel does not turn. .................................................... 12
2. Steering wheel is heavy. ........................................................ 13
3. Steering wheel wobbles or there is excessive shock. ................................... 14
4. Machine steers to one side when traveling. .......................................... 14
5. Turning radius to left and right is different. ........................................... 14
+ The following precautions are necessary when using the Standard Value Tables to make judgements during
2. The standard values in these tables are used when troubleshooting. They are estimated values based on
the standard values for the machine when shipped from the plant, and on the results of various tests.
Therefore, they should be used as reference in combination with repair and operating records when making
judgements.
42-1
I value value
Steering wheel mm Max. 20 Max. 50

Road surface: Flat, horizontal, dry,
o Steering wheel play kg 2.0-2.2 Max. 3.5
paved surface
l Steering wheel operating
l Hydraulic temperature: 45 - 55°C
0 Operating time of steering
l Machine posture:
wheel (Low idling) Sec. Max. 4.0 Max. 7.2
Facing straight
(High idling) Max. 3.0 Max. 4.0
Steering Linkage Tire inflation pressure:

l Clearance between front Specified pressure mm 40*5
frame and rear frame
Steering oil pressure Hydraulic temperature:

kg/cm* 210+ _; 210;,0,
l Main relief oil pressure 45 - 55°C
TOOL LIST
No. 1 Testing and measuring item I Tool name I Part number I Remark
1 1 Steering wheel operating force I Push-pull scale I 7AO-262-0020 I O-25 kg
2 Steering wheel operating play Convex scale Commercially available
l/10
3 Steering wheel operating time Stop watch 7AO-262-0550
I I second
Clearance between front frame and rear Convex scale

4
frame
A When carrying out testing, adjusting or troubleshooting, stop the machine on level ground, install the safety
bar on the frame, lower the bucket to the ground, and stop the engine.
Then apply the parking brake and block the tires.
When installing or removing gauges, loosen the oil filler cap slowly to release the pressure inside the
A hydraulic tank. Then operate the control levers several times to release the remaining pressure in the
hydraulic piping.
A When taking measurements, do not allow unauthorized persons near the machine.
The oil in the circuit is hot, so be careful not to get burnt.

A
42-2
TESTING AND ADJUSTING STEERING WHEEL PLAY
STEERING WHEEL PLAY

* Measurement conditions
l Engine speed: Stop
l Machine posture: Facing straight
How to measure
Turn the steering wheel lightly clockwise and +
H Play
counterclockwise two or three times and confirm
the neutral position of the steering mechanism. Put
mark “1” on the outer frame of the vehicle monitor.
Turn the steering wheel clockwise. Align the posi-

tion where the lever of steering control valve begins
to move with mark “l”, then put mark “2” on the
steering wheel.
Turn the steering wheel counterclockwise. Align the

position where the lever of steering control valve 419F302
begins to move with mark “l”, then put mark “3” on
the steering wheel. Measure the distance of a
straight line between mark “3” and mark “2”.
42-3
TESTING AND ADJUSTING OPERATING FORCE OF STEERING WHEEL
OPERATING FORCE OF
STEERING WHEEL
Q Conditions
o Road surface: Flat, horizontal, dry, paved surface
l Hydraulic oil temperature: 45 - 55°C
l Tire inflation pressure: Specified pressure
l Engine speed: Low idling (bucket unload)
Special tool
Measuring procedure
1. Hook push-pull scale A to the knob of the steering
wheel.
2. Start the engine.

t After starting the engine, raise the bucket about
400 mm and remove the safety bar.
3. Pull push-pull scale A at a tangent, and read the

value when the steering wheel is moving smoothly.
Do not read the value at the time the steering wheel
starts to move.
42-4
TESTING AND ADJUSTING OPERATING TIME OF STEERING WHEEL
OPERATING TIME OF
STEERING WHEEL
sr Measurement conditions
e Road surface: Flat, horizontal, dry, paved surface
e Engine speed: Low idling and high idling
Special tool
79A-262-0550 Stop watch 1
Measuring procedure
+ After starting the engine, raise the bucket about
400 mm and remove the safety bar.
2. Turn the steering wheel so that the 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 steering wheel as fast as possible
without forcing it.
* Measure at low idling and high idling, and when
turning to the right and to the left.
42-5
TESTING ADJUSTING STEERING CONTROL
it Measurement conditions
l Engine speed: 1200 rpm
l Road surface: Flat, horizontal, dry, paved surface
l Tire inflation pressure: Standard pressure
Testing procedure
1. Start the engine and operate the steering to set the
front and rear frames straight.
2. Check the looseness of lock nut (2) of stopper bolt

(1).
3. Start the engine and measure clearance “a” between

the front frame and rear frame stopper when the
steering wheel is turned fully to the left and right.
-rt When measuring the clearance, check that the
end face of the spool of stop valve (3) is in
contact with the head of the stopper bolt.
Adjusting procedure
1. Adjust the stopper bolt.
1) Screw in stopper bolt (1) to make it the mini-
mum length.
2) Run the engine at low idling and operate the
steering slowly to contact the frame stopper.
3) Turn the stopper bolt until the head of stopper
bolt (1) contacts the end face of the spool of
stop valve (3).
4) Set the machine facing straight, and stop the
engine.
5) Loosen stopper bolt (1) 8.5 turns, then lock it in
position with lock nut (2).
5) Carry out steps 1) - 5) for both the left and right
sides.
2. Start the engine and measure clearance “a” between

the front frame and rear frame stopper when the
4055mm
steering wheel is turned fully to the left and right.
-c.- a
+ When measuring the clearance, check that the
end face of the spool of stop valve (3) is in
contact with the head of the stopper bolt. L05AD004
42-6
TESTING AND ADJUSTING STEERING OIL PRESSURE
STEERING OIL PRESSURE

* Measurement conditions
Method of measuring main relief pressure
Y
AY Loosen the oil filler cap slowly to release the
1. Fit safety bar (1) on the frame, then remove cover

(2).
2. Remove plug (3) for measuring the right turn steer-

ing circuit.
3. Install hydraulic test kit 0 to the measurement port.
4. Start the engine, run at high idling, and turn the

steering wheel to the right. Measure the pressure
when the relief valve is actuated.
t If the plug for the left turn steering circuit is re-
moved, turn the steering wheel to the left when
measuring.
42-7
TESTING AND ADJUSTING STEERING OIL PRESSURE
Adjusting procedure
A Always stop the engine before carrying

adjustment of the hydraulic pressure.
out
1. Stop the engine.
2. Loosen lock nut (5), then turn adjustment screw (6)

to adjust.
t Pressure adjustment for one turn of adjustment

screw.
Adjustment for one turn: Approx. 151 kg/cm*
t Turn the adjustment screw to adjust the set

pressure as follows:
To INCREASE pressure, TIGHTEN screw.
To DECREASE pressure, LOOSEN screw.
42lFOI I IO
t If conditions make it impossible to adjust the
relief pressure accurately, do not carry out any
adjustment.
42-8
TESTING AND ADJUSTING . GROUND DRIVEN STEERING PUMP
GROUND DRIVEN
TESTING
Functional confirmation
A Accomplish this procedure only after the air is

bleed from the hydraulic piping.
A Check and make sure that machine can be

steered as desired before accomplishment of
this test.
A Before testing, make sure that environmental

(clear path for machine to move) operating
safety should be confirmed.
With the engine stopped, turn the key switch ON.

Then, it should be confirmed that the mark ’ ’
flickers in the red and when engine starts up again,
the mark goes out.
When the steering wheel is turned while a machine

is running by inertia in the flat area or on the down-
hill with the engine at rest, make sure that the
machine can be steered as desired.
As soon as the engine comes to a complete stop,

turn the switch ON. At this time, make sure that the
mark ’ ” on the monitor panel flickers in the
red color (to confirm that the mark ” ” flickers
while the ground driven emergency steering is in
operation).
42-9
TESTING AND ADUSTING
This page is blank.
42-10
TROUBLESHOOTING
42-11
TROUBLESHOOTING TROUBLESHOOTING TABLES
1. Steering wheel does not turn.
Ask the operator the following questions.

l Did the problem suddenly happen?
- Part broken in steering related equipment.
l Had the steering been heavy before, or had
there been any other symptom?
- Internal wear or defective seal in steering
related equipment.

l Is oil level and type of oil in the hydraulic tank
correct?
l Has the safety bar been removed from the
frame?
Valve Others
I I
I I / I I I
AAAAAoLIuL\
NO.
Problems X xxxxxxxx
1 Steering does not turn to in either direction I 0 I I I I I lol
Same as Item 1, but there is abnormality in movement
2
of work equipment. 0
3 Steering does not turn in one direction (left or right) 0 0
4 Steering wheel is heavy and does not turn. 0 0 0 0 0
5 There is no rise at all in steering circuit 0 0

pressure 0 0
Steering wheel turns, but steering does not turn in
6 either direction. 0 0 0 0
Steering wheel turns, but steering turns only in

7 one direction (left or right) 0 0
LO7ZZOO8
+ There is a close relationship between the steering circuit and work equipment circuit, so if any abnormality
is felt in the steering, check also the operating condition of the work equipment.
42-12
2. Steering wheel is heavy.

l Did the problem suddenly happen?
- Part broken in steering related equipment.
l Had the steering been heavy before, or had
there been any other symptom?
- Internal wear or defective seal in steering
related equipment.

correct?
l Is there any abnormality in the column?
l Is there any oil leakage from the hydraulic
hoses, valves, or cylinders?
l Is there any scuffing on the center hinge pin
bearing, steering cylinder pin or bushing?
l Tire inflation pressure.

Measure the operating force of the steering wheel
and the time taken for the steering to turn, and
compare with the Standard Values Table to judge if
there is any abnormality.
steer,ng valve
I /defectwe/
I a b c d e f g h i j k
Remedy ~l~l~~l~l~l~l~l~l~I~~l~~l
NO.
Problems L
~‘XXXXXXX I\
Steering wheel is heavy when turned in either dIrection

1
(left and rightl. 0 0 0 0
Steering is heavy when turned in one direction
2
(left and right). 0 00
Steering is particularly heavy when engine is running
3
at low speed 0
+ There is a close relationship between the steering circuit and work equipment circuit, so if any abnormality
is felt in the steering, check also the operating condition of the work equipment.
42-13
3. Steering wheel wobbles or there is excessive

shock.

l Is the oil level and type of oil in the hydraulic
tank correct?
l Is there any abnormality in the column?
l Is there any play in the center hinge pin bearing
and steering cylinder pin bushing?
l Is there any variation in the inflation pressure of
the tires?
l Is there any play in the steering?

Drive the wheel loader in a safe place, and check
how the steering wheel wobbles and under what
conditions.
t If there is wobble of the steering wheel, and in
addition the steering wheel is heavy or there are
other problems, go to “2. Steering wheel is
heavy.”
t Excessive shock when steering is turned to left or

right lock.
Cause: Improper adjustment of stop valve
stopper.
4. Machine steers to one side when traveling.

Cause: Defective steering valve
l Spool out of position
Leakage of oil inside steering cylinder
Variation in tire inflation pressure
5. Turning radius to left and right is different.

Cause: Dividing of steering to left and right,
lock position of stopper (At end of
steering, relief noise can be heard from
valve).
42-14
STEERING SYSTEM
STEERINGVALVE ................................................................... 2
DISASSEMBLY ................................................................... 2
ASSEMBLY ..................................................................... 5
STEERING DEMANDVALVE ........................................................... 10

DISASSEMBLY.. ................................................................ 10
ASSEMBLY .................................................................... 14
CENTER HINGE PIN.. ............................................................... 18

REMOVAL ..................................................................... 18
INSTALLATION .................................................................. 27
STEERING CYLlNDER ............................................................... 36

REMOVAL ..................................................................... 36
INSTALLATION .................................................................. 37
DISASSEMBLY.. ................................................................ 38
ASSEMBLY .................................................................... 40
* For details of disassembly and assembly of the gear pump, see SECTION 97.
+ Take the following method for air bleeding when you start to operate hydraulic cylinders after reassembling
43-1
DISASSEMBLY AND ASSEMBLY STEERING VALVE
STEERING VALVE
DISASSEMBLY
+ Use a wire brush to remove all the dirt and dust

stuck to the joint around the outside circumference
of the unit.
+ Carry out the operation in a clean place to prevent
dirt or dust from sticking to the valve.
+ As far as possible, hold the valve in a vice when
disassembling.
Disassembly of rotor
1. Set rotor side facing up, and hold mounting flange
lightly in vice 0.
t Put a copper plate in contact with the vice and
be careful not to tighten the vice too hard.
2. Remove screw (1) then remove end cap (2).
3. Remove O-ring (3) from end cap (2).
23EFOI 108
4. Pull out rotor set (4), then remove O-ring (5).

* Be careful not to drop the star inside the rotor
set.
5. Remove spacer (6).
23EFO I I OS
43-2
6. Remove drive shaft (7).
7. Remove spacer plate (8).
8. Remove O-ring (9) from housing (10).
23EF0 I I
Disassembly of control side

9. Remove housing (10) from vice, and place on a
clean cloth. Be careful not to damage the finished
surface.
10. Raise tip of snap ring (11) with screwdriver, and

remove from housing.
23EFOI I I I;
11. Turn spool and sleeve to place pin in a horizontal

position, then push in spool and sleeve with your
thumb, and remove bushing (12) from housing.
23EFOI I 12
12. Remove X-ring seal (13) from bushing (12).
13. Remove dust seal (14) from bushing (12) with

screwdriver.
+ Be careful not to damage the bushing.
23EFOI I I3
43-3
14. Remove 2 bearing races (15) and thrust needle (16)

from spool and sleeve.
23EFOI II4
15. Pull out spool and sleeve assembly (17) from

housing (10) in the direction of the arrow.
+ To prevent the spool and sleeve assembly from
catching in the housing, rotate the spool and
sleeve assembly slowly to the left and right
when pulling lt out from the housing.
16. Pull out pin (18) from spool and sleeve assembly
(17).
23EFOI I I5
17. Push spool (20) inside sleeve (19) slightly to front,

and remove 6 centering springs (21) from spool
(20) carefully by hand.
18. Turn spool (20) slowly and pull out from rear of
sleeve (19) (in the direction of the arrow).
23EFOI II6
19. Remove O-ring (22) from housing.
20. Remove set screw (23) from housing.
21. Screw a threaded bar into check sheet (24) and

pull out check sheet (24).
22. Remove O-rings (25 and 26) from check sheet (24).
23. Tap housing, and remove ball (27) and retainer (28).
a.”
23EFOI I17
43-4
+ Check all parts for damage or burrs.

+ Wash all metal parts in clean solvent and blow dry
with air.
* Do not use a file or polish any part with rough
sandpaper.
* Coat the O-rings with clean grease. (No need to put
grease on new X-ring seals.)
t Coat the O-ring for the rotor set with a small
amount of grease.
Assembly of control side

1. Insert retainer (28) in housing with tweezers. B-23
t Check that the retainer is not inserted at an
angle.
2. Insert ball (27).
3. Fit O-rings (26 and 25) in check sheet (24) and

push check sheet (24) into housing.
* Be careful to set the top and bottom of the
check sheet facing in the correct direction.
23EFOI !I8 i
4. Install set screw (23).

* Check that the set screw is set in slightly from
the end face of the housing.
D Set screw: 1.2 kgm
h Set screw: Adhesive (LT-2)
5. Assemble spool (20) and sleeve (19) so that spring

groove is on same side.
* Rotate the spool and slide it in.
* Grip the splined portion of the spool lightly and
check that the spool rotates smoothly inside the
sleeve. Spri
t If there are match marks, check that the match
marks are aligned.
23EFOI I -IS
43-5
6. Align spring groove positions of spool (20) and

sleeve (19) and set on flat plate, then insert spring
(21) in spring groove.
t Set so that the notches at both ends are at the
bottom.
23EFOI 120
7. Insert pin (18) in spool and sleeve assembly (17).
23EFOI 121
8. Insert spool and sleeve assembly (17) in housing

(10) in the direction of the arrow.
1) Keep pin horizontal and rotate to left and right
a little at a time to insert.
t Be extremely careful not to get it caught.
2) Make the spool and sleeve assembly flush with
the rear end face of the housing.
+ If it is inserted beyond the end face, the pin
will fall out.
3) Check that spool and sleeve rotates smoothly
inside housing.
23EFOI 122
9. Install O-ring (22) to housing (10).
10. Fit 2 bearing races (15) and thrust needle (16) in

case (10).
23EF0 I I23
43-6
._.
11. Insert dust seal (14) in bushing (12).
12. Insert X-ring seal (13) in bushing (12).
13. Insert bushing (12) in spool, and rotate to install.

l Tap with a plastic hammer to assemble to the
specified position.
l It must be in contact horizontally with the
bearing race.
14. Fit snap ring (11) in housing.
23EFO I I24
.~
‘01 125
Assembly of rotor
15. Hold flange of housing lightly in vice.
+ Be careful not to tighten the vice too hard.
+ Check that the spool and sleeve are set in
slightly from the housing surface with fourteen
holes.
FOI 126
16. Insert O-ring (9) in housing.
17. Put on spacer plate (8), and align positions of bolt

hole and tap hole of housing.
23EFOI 127
43-7
18. Turn spool and sleeve assembly to make pin (18)

and port surface of housing parallel, then mesh pin
and yoke of drive shaft (7).
* To position accurately, draw a line on the end
face of the drive shaft spline.
afallel
23EFOI 128
19. Insert O-ring (5) in rotor set (4).
23EFOI 129
20. Make O-ring (5) end of rotor set to spacer plate Inset portion of star of rotor set
end, then align inset portion of star of rotor (4) with
drive.
1) Check that lines A, B, C, and D are all parallel.
2) Without removing joint of drive (7), position bolt
holes of rotor set.
t This procedure is very important for determin-
ing the valve timing of unit.
Pin Port surface

23EF0 I I30
21. Insert spacer (6) inside rotor set.
22. Set end cap (2) on rotor set, and align bolt hole.
23EFOI I31
43-8
23. Coat thread of screw with grease, and tighten end Order for tightening of end cap
cap.
* Install the handle to the spool, and check that
the spool rotates.
D End cap mounting screw

First step: 1.5 kgm
Second step: 2.75kO.15 kgm
23EF0 I I32
1.:
43-9
DISASSEMBLY AND ASSEMBLY STEERING DEMAND VALVE
STEERING DEMAND VALVE

DISASSEMBLY
1. Remove safety valve assembly (1).

t The set pressure of the safety valve is fixed, so
do not disassemble it.
2. Remove main relief valve assembly (2).

+ The set pressure of the main relief valve is
fixed, so do not disassemble it.
3. Removal of demand spool

1) Remove plug (3).
2) Remove spring (4).
43-10
3) Remove demand spool (5).

+ Remove slowly, taking care not to damage
the spool.
+ If shims are fitted, check the number and
thickness of the shims, and keep in a safe
place.
4) Remove plug (6).
4. Removal of steering spool

1) Remove 2 bolts (7).
+ Remove on the opposite side in the same
way.
2) Remove case (8) and spring (9).

* Remove on the opposite side in the same
way.
3) Remove spring seat (10).

+ Remove slowly, taking care not to damage
the spool.
t Remove on the opposite side in the same
way.
4) Remove poppet (11) and spring (12).

* Remove on the opposite side in the same
way.
5) Remove steering spool assembly (13).

+ Remove slowly, and be careful not to bend
or damage the spool assembly.
t To prevent it from falling into the valve
body, remove the poppets at both ends.
5. Disassembly of steering spool assembly

1) Remove cap screw (14).
t The cap screw is coated with adhesive
(Loctite #271), so use an industrial dryer,
and heat (200” - 250°C) before removing.
2) Remove spring (15) and poppet (16).
+ Remove on the opposite side in the same
way.
43-12
,,.,,,,
,,_,,,,
,,, ,, _,, .,
P42101139
6. Disassembly of check valve

1) Remove plug (17).
2) Remove spring (18) and poppet (19).
7. Remove plug (20).

ASSEMBLY
1. Fit O-ring to plug (20) and install to valve body.

m Plug: 9.5kO.5 kgm
2. Assembly of check valve

1) Install poppet (19) and spring (18).
2) Fit O-ring to plug (17) and install to valve body.
m Plug: 6.5+0.5 kgm
3. Assembly of steering spool

1) Install poppet (16) and spring (15) to spool.
2) Fit O-ring to cap screw (14) and install to spool.
& Spool thread: Adhesive (Loctite #271)
‘D Cap screw: 0.9kO.l kgm
43-14
4. Installation of demand spool

1) Fit O-ring to plug (6) and install to valve body.
D Plug: 14.020.2 kgm
2) Install demand spool (5) to valve body.

t If shims were fitted, assemble shims.
t Install slowly, taking care not to damage
the spool.
3) Install spring (4).
4) Fit O-ring and back-up ring to plug (3), and

install to valve body.
a Plug: 14.01-0.2 kgm

5. Installation of steering spool assembly

1) Install steering spool assembly (13) to valve
body.
+ Be careful to install portion A of the spool
facing in the correct direction.
2) Install spring (12) and poppet (11).

t Check that the orifice at the tip of the pop-
pet is not clogged.
t Install on the opposite side in the same
way.
3) Install spring seat (10).

4) Install spring (9).
t Install on the opposite side in the same
way.
P42101149 P42EOI 150
5) Fit O-ring to case (8) and install to valve body.

6) Tighten bolt (2).
a Bolt: 4.220.2 kgm
+ Install on the opposite side in the same

way.
43-16
6. Install main relief valve assembly (2) to valve

body.
D Main relief valve assembly: 7.5205 kgm
7. Install safety valve assembly (1) to valve body.
cz_=l Safety valve assembly: 7.5205 kgm
\ P4210E ‘2~13
43-17
CENTER HINGE PIN

REMOVAL
* Before starting the operation, remove the bucket.

For details, see SECTION 63, REMOVAL OF WORK
EQUIPMENT.

the safety bar on the frame. Lower the bucket Ed
the parking brake and put blocks under the -- -_
wheels to prevent the machine from moving. i
LiOBZO02
iA k Loosen the oil filler cap slowly to release the

* Disconnect the cable from the negative (-)

1. Draining air
Pulling drain valve (5) and drain air from air tank.
43-18
DISASSEMBLY AND ASSEMBLY CENTER HINGE PIN
2. Ladder
Sling ladder (6), remove mounting bolts, then
remove ladder.
it Remove the ladders on both the left and right
sides.
Ladder: 65 kg
c
3. Electrical wiring
1) Disconnect connectors (23, 24, 25, 26, 27, 28,
29 and 30) at bracket of floor frame (22).
+ After removing the wiring, mark with a tag
to distinguish when installing.
2) Disconnect ground connection and connector.
3) Disconnect connector of wiring for brake sole-
noid valve.
4. Brake valve

valve and air tank at brake valve end.
+ Remove the clamp properly.

1) Disconnect fuel control cable (35) from ball joint
(36).
2) Remove fuel control cable (35) from bracket
(37).
t Remove the clamp properly.

1) Disconnect work equipment control cable (38)
from ball joint (39).
2) Disconnect work equipment control cable (38)
from bracket (40).
3) Remove clamps (41) of work equipment control

cable (38).
7. Steering piping
1) Disconnect hose (42A) between orbit-roll and
hydraulic pump from orbit-roll.
2) Disconnect hose (42B) between orbit-roll and
hydraulic tank from orbit-roll.
3) Disconnect hose (42C) between orbit-roll and
stop valve from orbit-roll.
\/,tg , PU42302009
& ------a
43-20

1) Sling floor frame, cab assembly (47).
2) Remove mounting bolts, then lift off floor frame,
cab assembly.
I+ llu Floor frame, cab assembly: 500 kg
Remove left and right pins (7) at steering cylinder
rod end.
sr If there are any shims, check the number and
place.
10. Drive shaft

Remove center drive shaft (8).
43-21
11. Electrical wiring, piping

1) Remove clamp of wiring (9) for front frame.
2) Disconnect air hose (10) and brake hose (11).

t Release the parking brake and disconnect
the lever of the linkage.
3) Disconnect hose (16) between main control
valve and hydraulic tank from rear frame.
4) Disconnect hose (17) between steering valve
and radiator from rear frame.
PULL2302014

1) Disconnect hoses (12 and 13) between hy-
draulic pump and steering valve from front
frame.
2) Disconnect hose (14) between hydraulic pump
and main control valve from main control valve.
valve and hydraulic tank from main control
valve.
4) Disconnect hose (18A) between steering valve

and stop valve from stop valve end.
5) Remove clamp (18).
\a2
‘423P100f
43-22
13. Disconnecting frame

1) Adjust height of rear frame (43) and insert
stand.
t Insert stands under the frame on both left
and right sides.
2) Adjust height of front frame (44) and insert
stand.
+ Insert stands under the frame on both left
and right sides.
+ Be extremely careful when adjusting the
height of the frame.
3) Insert stand @ under counterweight (45).

t Block both the left and right rear tires se-
curely.
t Use a stand with adjustable height.
4) Remove safety bar.
5) Remove mounting bolts of lower hinge pin, then

remove pin (46) from top.
+ Adjust the height of the front and rear
frames enough so that the pins can be
removed without forcing.
f-3) Remove mounting bolts of upper hinge pin,

then remove pin (47) from bottom.
* Be careful not to drop the pin.
+ Remove plate (47A).
41A
/
U42401018
43-23
7) Remove mounting bolts, then remove retainer

(48) at rear frame end.
8) Remove spacer (49).
9) Jack up front differential and pull out front

frame to front.
+ Taking care not to let the spacer at the
bottom of the upper hinge bite into the rear
frame, disconnect the frame and then re-
move the spacer.
+ Be careful to maintain parts in balance
when carrying out the operation.
14. Lower hinge

1) Remove retainer (60).
* There are shims between retainer and
frame, so check the number and thickness
of the shims, and keep in a safe place.
43-24
2) Remove dust seal (61) from retainer.

t Remove dust seal on frame side.
424P864
424P865
15. Upper hinge

1) Remove mounting bolts, then remove retainer
(54).
Remove dust seal (55) from retainer.
t There are shims between the retainer and
front frame, so check the number and
place.
Note: Refer to photos and line art on this
page and following page.
2) Remove spacer (56) and seal (57) from bottom

of front frame.
Note: Refer to photos and line art on this
page and following page.
43-25

Note: Refer to line art on this page and photo
on previous page.
423 F466
423F467
43-26
INSTALLATION
Soecial tools
I Part number I Part name CYty
A 790-101-l 102 Pump 1
B 790-101-2102 Puller 1
C 790-l 01-2300 Push-puller 1
D 793-520-2370 Push tool 1
4 793-520-2350 Push tool 1
D2 793-520-2540 Guide 1
D3 793-520-2380 Bar 2
1. Upper hinge
1) Install tools A, B, C, D,, D,, and D, to top of
upper hinge of front frame. Set bearing (58) in
tool D, set from above in press fitting position,
then press fit.
t When press fitting, use tool D, as a guide.
+ Make sure that the bearing is installed
straight.
* Fill inside of bearing (58) with grease.
+ When assembling the bearing, do not \- /
forget to install the spacer. 423F469
* The clearance of bearing (58) is adjusted,

so do not change the combination with
spacer (59). When replacing the bearing,
replace as a set.
2) Press fit dust seal (55) on retainer (54).
+ Replace the dust seal with a new part, and
press fit so that the lip face is on the out-
side.
e Lip of dust seal: Grease (G2-Ll)
3) Tighten retainer (54) with 3 mounting bolts, then

insert shims so that maximum clearance be-
tween retainer and final shim pack is less than
0.1 mm.
m Mounting bolt (when adjusting shim):

2.OkO.2 kgm
D Mounting bolt: 11.5? 1.O kgm
43-27
4) Install dust seal (57) and spacer (56) from

under front frame.
e Lip of dust seal: Grease (G2-Ll)
& Inside circumference of spacer:

Grease (G2-Ll)
+ Replace the dust seal with a new part, and

press fit so that the lip face is on the out-
side.
t Assemble spacer (56) from below so that
the large chamfered side is on the bearing
side.
423F471
2. Lower hinge
Dl
1) Using tools A, B, D, D, and De, press fit bearing
(62) and spacer (63) on front frame.
+ When press fitting, use tool D, as a guide.
+ Be careful not to fit the bearing at an angle.
+ Fill the inside of the bearing with grease. 63
t When assembling the bearing, do not
D2
forget to assemble the spacer.
+ The clearance of the bearing and spacer is D
adjusted, so do not change the combina- D3
tion. When replacing the bearing and spac-
er, replace as a set. 6
Block
I
421 F3050A
43-28
2) Press fit dust seal (61) on retainer.

+ When press fiiing the dust seal, fit with the
lip on the outside.
e Seal lip: Grease (G2-Ll)
424P864
3) Tighten retainer with 3 mounting bolts, then

select and insert shims (64) so that clearance
“a” between retainer and hinge is less than 0.1
mm.
D Mounting bolt (when adjusting shim):

2.0 50.2 kgm
m Mounting bolt: 11.5& 1 kgm
4 I SF465
424P666
4) Press fit dust seal (65) on frame.

+ When press fitting the dust seal, fit with the
lip on the outside.
Q Seal lip: Grease (G2-Ll)

3. Connecting frame
1) Jack up front differential, move front frame
towards rear frame and align pin holes.
* Be careful 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

A your fingers.
2) Assemble spacer (49) to upper hinge (66).

t Assemble the spacer (49) from below so
that the large chamfered side is on the
bearing side.
* Be careful not to damage the lip of the dust
seal.
h Outer circumference of hinge pin: *

Grease (G2-Ll)
- Inner circumference of spacer:

Grease (G2-Ll)
3) Assemble upper hinge pin (47) from below.

4) Tighten retainer (66) to upper hinge pin with 4
mounting bolts (68), then assemble shims (69)
so that clearance “a” between hinge and retain-
I t\ n J
423F473A
er is less than 0.2 mm.
* Install plate (47A).
Mounting bolt of pin (when adjusting shim):
D 2.OkO.2 kgm
t When tightening mounting bolt (67)
leave a clearance of about 5 mm from
the face of retainer (68).
5) After adjusting shim, tighten mounting bolts (67)
of retainer to the specified tightening torque,
then tighten mounting bolts (68) of pin fully.
D Mounting bolt of pin: 21 .O& 1.O kgm
Mounting bolt of retainer: 11.5 t 1.O kgm
4’8 67 68
U42401020
6) Insert lower hinge pin (46), then secure with

lock bolt.
& Outside circumference of hinge pin:

Grease (G2-Ll)
7) Remove stands from front and rear frame, and

from counterweight.
8) Install safety bar.
-_ 423POI198
1
4. Hydraulic piping
1) Install clamp (18).
2) Connect hose (18A) between steering valve and
stop valve to stop valve end.
3) Connect hose (15) between main control valve
and hydraulic tank to main control valve.
4) Connect hose (14) between hydraulic pump
and main control valve to main control valve.
5) Connect hoses (12 and 13) between hydraulic
pump and steering valve from front frame.
5. Electrical wiring, piping

1) Connect hose (17) between steering valve and
radiator to rear frame.
and hydraulic tank to rear frame.
3) Connect air hose (10) and brake hose (11).
PU423020 14
43-31
CENTER HINGE PIN
4) Install clamp (9) of wiring for front frame.
6. Drive shaft
Install center drive shaft (8).
D Drive shaft: 11.521.0 kgm
Install left and right pins (7) at steering cylinder rod
end.
* Do not forget to install the shims.
* Adjust clearance between cylinder and frame to
become 0 to 0.5 mm with shim.
43-32

1) Assemble top cushion (47A) and plate (478).
2) Raise floor frame and cab assembly (47), and
el kg
3) Assemble bottom cushion (47C) and plate

(47D), then tighten floor frame mounting bolts
(47E).
* Tighten the bolts until the collar inside the
cushion comes into contact (until distance
between plates is 42 mm).
Ye!!
423FO1103
9. Steering piping
1) Connect hose (42C) between orbit-roll and stop
valve to orbit-roll.
2) Connect hose (42B) between orbit-roll and hy-
draulic tank to orbit-roll.
3) Connect hose (42A) between orbit-roll and hy-
draulic pump to orbit-roll.

1) Install clamps (41) to work equipment control
cable (38).
43-33
2) Connect work equipment control cable (38) to

brat ket (40).
m Mounting nut: 0.7kO.l kgm
3) Connect work equipment control cable (38) at

ball joint (39).

2) Connect fuel control cable (35) to ball joint (36).
+ The length of the mating thread of the
cable ball joint should be at least 6 mm.
3) Tighten intermediate clamp so that the radius of
the curvature of fuel control cable (35) is at
least 260 mm.
12. Brake valve

1) Connect hoses (33 and 34) between brake
valve and air tank at brake valve end.
2) Connect hoses (31 and 32) between brake

43-34
13. Electrical wiring

1) Connect connector of wiring for brake solenoid
valve.
2) Connect ground connection and connector.
3) Connect connectors (23, 24, 25, 26, 27, 28, 29
and 30) at bracket of floor frame (22).
+ Fit the O-ring securely in the groove of the
connector.
14. Ladder
Sling ladder (6), set in mounting position, then
t Install the ladders on both the left and right
sides.

the system. Then check the oil level again.
Ia Transmission oil: 539
&__g
t Run the engine to circulate the transmission
I
L
--. - - __ _ __ A
LlOBZ005
wait for 15 minutes. then check theoil level
again.

t For details of bleeding air, see SECTION 52,
A Close hood, then lock with catch. \

DISASSEMBLY AND ASSEMBLY STEERING CYLINDER
STEERING CYLINDER
REMOVAL
A 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.
i
the steering wheel several times to the left and
right to release the remaining pressure in the
hydraulic piping.

1. Hydraulic piping
1) Remove mounting bolt of tube support (3).
2) Disconnect hose (4) from cylinder.
+ Cover the disconnected parts.
3) Disconnect tube (5) from cylinder.
1) Remove lock bolt at rod end, then remove pin
(8).
+ If there are any shims inserted, check the
2) Sling steering cylinder, remove lock bolt at

bottom end, then remove pin (7).
+ If there are any shims inserted, check the
3) Remove steering cylinder (8).
+ Be careful not to damage the cylinder rod.
Steering cylinder: 28 kg
43-36
INSTALLATION
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.
A Use a bar to align the pin holes. Never use your

fingers.
t Adjust clearance between cylinder and

frame to become 0 - 0.5 mm with shims.
2. Hydraulic piping
1) Connect hose (4) to cylinder.
+ Install the hose without twisting or interfer-
ence.
a Hose: 8+2 kgm
2) Connect tube (5) to cylinder.

it Tighten partially, then tighten fully after
installing the tube support.
a Tube: 9.52 1 kgm
3) Install tube support (3) to cylinder.
3. Greasing
Grease cylinder pins well.
+ Wipe off any grease which comes out.
43-37
DISASSEMBLY
Special tools
A 790-502-l 000 Cylinder repair stand 1
B 786-l 00-l 200 Wrench 1
1. Set cylinder assembly (1) in tool A.
2. Straighten lock tab of cylinder head (2), then using

tool B, remove cylinder head (2) from cylinder.
3. Pull cylinder head and piston rod assembly (3) from

cylinder (4), then lift off.
+ Oil will come out when the piston rod assembly
is removed from the cylinder, so have a
container ready.
4. Remove cylinder (4) from tool A.
5. Set cylinder head and piston rod assembly on tool

A, and loosen nut (5) with power wrench 0 and
socket 0.
+ Power wrench: 16 times
t Width across flats of socket 0: 50 mm
6. Remove nut (5), then remove piston assembly (6)

and cylinder head assembly (7) from rod (8).
43-38
7. Disassembly of piston assembly as follows:

1) Remove wear ring (9).
2) Remove piston ring (10) from piston (11).
125P387A 125P388A ’
8. Disassembly of cylinder head assembly as follows:

1) Remove snap ring (16) then remove dust seal
(17).
2) Remove rod packing (18), retainer (14) and
snap ring (15).
3) Remove bushing (19) from cylinder head (20).
4) Remove O-ring (21) and back-up ring (22).
125P390A
43-39
Special tools
Part number Part name CYty
B 790-l 00-1200 Wrench 1
C 790-720-l 000 Expander 1
D 796-720-l 650 Ring 1
l 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 pack-
ings, dust seals or O-rings when installing.
1. Assemble cylinder head assembly as follows:

1) Using push tool, press fit bushing (19) on
cylinder head (20).
+ Be careful not to deform the bushing when
pressing it in.
2) Assemble rod packing (18), retainer (14) and
snap ring (15).
t Be careful to install the rod packing facing
in the correct direction.
18
2OXF130 20
125P389A 125P388A
3) Using a push tool, install dust seal (17) on

head (20).
5) Install back-up ring (22) and O-ring (21).
t Do not force back-up ring. Heat in hot
water (50 - 6O“C) before inserting.
125P390A
43-40
2. Assemble piston assembly as follows:

1) Using tool C, expand piston ring (10).
+ After setting the piston ring in tool C, rotate
the handle 8 to 10 times to expand.
2) Remove piston ring (10) from tool C, and
assemble on piston (11).
I2W392’
3) Fii tool D on piston ring, and compress piston

ring with clamp 0.
+ Part No. of clamp 0:
07281-01159
4) Assemble wear ring (9).
125P3& 125P394
3. Set piston rod (8) in tool A.
4. Assemble cylinder head assembly (7) and piston

assembly (6) on rod, then install nut (5).
5. Using power-wrench @and socket 0, tighten nut

(5) to the following specified torque:
+ Power wrench: 16 times
+ Width across flats of nut (5): 50 mm
+ Tightening torque: 110 + 11 kgm
6. Remove piston rod and cylinder head assembly

from tool A.
7. Set cylinder (4) in tool A.
8. Sling piston rod and cylinder head assembly (3),

and install in cylinder (4).
I25P383 -
9. Using tool B, tighten cylinder head nut (2).
D Cylinder head nut: 69L6.9 kgm
10. Bend lock into notch on cylinder.
11. Remove cylinder assembly from tool A.
43-42
STEERING SYSTEM
STEERING COLUMN AND ORBIT-ROLL ................................. 2
STEERING VALVE ................ ................................. 3
STEERING CYLINDER MOUNT. ...... .. .......... ...... ..... .... ...... 4
STEERING CYLINDER ............. . .... ....... ...... ...... .... ..... 6
CENTER HINGE PIN .............. .. .......... ...... ..... ..... .. ... 8
DIVERTERVALVE ................ ............ ...... .... ..... ..... 10
GROUND DRIVEN STEERING PUMP .. ........... ...... .... .. .. .. ..... 12
44-1
MAINTENANCE STANDARD STEERING COLUMN & ORBIT-ROLL
STEERING COLUMN AND ORBIT-ROLL
m 3.0 5 0.3 kgm

\
B 5.7 * 0.7 kgm
421 FO1092-1 421FOlO92
No 1 Check item I Criteria Remedy

I I I
44-2
MAINTENANCE STANDARD STEERING VALVE
STEERING VALVE
421FO1093
Unit:mm
No Check item Criteria Remedy

I
1 Standard size Repair limit
Free Installation Installation Free Installation

1 Steering spool return
spring length length load kg length load kg
I 54.4 1 50.0 1 5.8 I 4.8

I I I I I
2 Poppet spring 21.7 16.0 3.6 2.8
3 Load check valve spring 20.9 13.2 .95+.5 .8

Demand spool return 75.1 68.5 13.88 11.7 Replace
spring
Relief valve spring 24.0 22.19 18.6 14.8
Check valve return 21.6 17.0 .23 .18

spring
44-3
MAINTENANCE STANDARD STEERING CYLINDER MOUNT
STEERING CYLINDER MOUNT
424FO94
Section B-B
Unit: mm
Check item Criteria Remedy

I I I I
1 Clearance between mounting Standard Tolerance Standard Clearance
pin and bushing connection of size clearance limit
steering cylinder rod and frame Shaft Hole
50 o-.025 +.150- .05-.1 75

.050
2 Clearance between mounting

pin and bushing at connection 50 0 +.150 + .050
of steering cylinder bottom and
frame
-.025 + .050 +.175
3 Connection of steering cylinder Width of boss Width of Standard clearance

and front frame hinge (Clearance a + b)
60+.8,-O 6322.0 After adjusting with shim:

Less than .5
4 Connection of steering cylinder 60+.8,-O 63k2.0 After adjusting with shim:

and rear frame Less than .5
44-4
This page is blank.
44-5
MAINTENANCE STANDARD STEERING CYLINDER
STEERING CYLINDER
/ \
LlOBR022
1 4
44-6
MAINTENANCE STANDARD STEERING CYLINDER
STEERING CYLINDER
Unit: mm
Standard Tolerance Standard Clearance

size ’ clearance limit
Shaft Hole Hole
1 Clearance between rod
and bushing
45 -.025 +.152 .032-.239 .539
-.087 + .007
Clearance between
2 piston rod mounting pin
1 50 1 _.;25 / u;g 1 .oao-.167 / 1.0 / :::;
and diameter of hole
Clearance between
cylinder bottom mount- +.142
3 50 0 .oao-.167 1.0
ing pin and bushing
-.025 +.oao
Standard size Tolerance Repair

limit
4 Cylinder bore
90 +.2 +.2
0 0
5 Tightening torque of 69 t 6.9 kgm

cylinder head Retighten
6 Tightening torque of 110 f 11 kgm (Width across the flats 50 mm)

piston nut
44-7
MAINTENANCE STANDARD CENTER HINGE PIN
CENTER HINGE PIN
Section B-B Section A-A
424F3 I5
44-8
MAINTENANCE STANDARD CENTER HINGE PIN
CENTER HINGE PIN

Unit: mm
Check item Criteria - Remedv
Standard Talc Standard Clearance

Shaft
1 Clearance between upper hinge

80 -.030 + .071 .066-.130
pin and rear frame
-.049 +.036
2 Clearance between upper hinge 80 -.030 + .060 .060-. 109

pin and spacer (small)
-.049 + .030
3 Clearance between upper hinge 80 -.030 0 .015-.049

pin and bearing -.049 -.015
4 Clearance between upper hinge 80 -.030 + .030 .030-.079

pin and spacer (large)
-.049 0
5 Clearance between rear frame 95 -.036 + .071 .072-.142

and spacer (large) -.071 + .036
6 Clearance between front frame 130 0

and upper hinge bearing -.025
7 Clearance between lower hinge 80 -.030

pin and rear frame -.076
8 Clearance between lower hinge 80 -.030

pin and gearing -.076
I
9 Height of upper hinge spacer (small) 1 Standard size 1 Tolerance 1 Reoair limit
25.5 k.1
10 Height of upper hinge spacer (large) 56 k.1
11 Shim thickness for upper hinge and Standard size Standard clearance Clearance limit
retainer
2.5 .05 .l
12 Shim thickness for upper hinge and 2.5 .l .2

retainer
13 Tightening torque of upper hinge and When adjusting with shim: 22.2 kgm
lower hinge retainer mounting bolt
Final value: 11.5~ 1 kgm
14 Tightening torque of upper hinge retain- When adjusting with shim: 22.2 kgm
er mounting bolt
Final value: 28.5~3 kam
15 Tightening torque of upper hinge pin 11.5~1 kgm Retighten

mountina bolt I
44-9
MAINTENANCE STANDARD DIVERTER VALVE
DIVERTER VALVE
5
-w.-----beM..y---
‘8
-2
Section A-A
Section B-B
419F493
44-10
MAINTENANCE STANDARD DIVERTER VALVE
DIVERTER VALVE
Unit: mm
1 Clearance between body and
4 Tightening torque of mounting 2.8 kgm

bolt
5 Tightening torque of mounting 2.5~1.0 kgm

bolt
6 Tightening torque of mounting 2.5kl.O kgm Retighten

bolt
7 Tightening torque of plug 21.523.0 kgm
8 Tightening torque of plug 52.5 kgm
44-11
MAINTENANCE STANDARD GROUND DRIVEN STEERING PUMP
GROUND DRIVEN STEERING PUMP

l Model SAM(2) 50
Section A-A
419F492

I I I
Standard clearance Clearance limit
1 Clearance between gear case and side .lO-.15 .19

plate, gear
Replace
2 Clearance between inside diameter of
needle bearing and outside diameter of 1 .020-.043 I .075 I
3 Insertion depth of pin 12 o-.5
4 Rotating torque of spline shaft .3+.7 kgm
5 Tightening torque of bolt 1822 kgm Retighten

I I I
Discharge
Oil: EOlO-CD
Temperature: 45-55” C
44-12
BRAKE AND AIR SYSTEM
AIRPIPING ..... ........ ........ ............ ........... ..... ...... ... .... .... ...... 2
AIR CIRCUIT DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
AIRTANK .......................................................................... 3
WETTANK ...................................................................... 3
DRYTANK.. .................................................................... 4
AIR DRYER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .._............................ 5
SAFETYVALVE ..... ..... ........ ............ ............ .... ...... .... ... .... ...... 8
BRAKEVALVE ...................................................................... 9
BRAKEACTUATED ............................................................... 10
OPERATINGINBALANCE ......................................................... 11
BRAKERELEASED.. ............................................................. 12
AIRGOVERNOR.................................................................... 13
TWO-WAYVALVE................................................................... 15
BRAKECHAMBER .... ..... ......... ........... ... ......... ... ....... ... .... ..... ... 16
SLACK ADJUSTER .... .... ........ ............ .......... ...... ...... ... ... ..... ..... 18
BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
PARKING BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
PARKING BRAKE SOLENOID VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
SPRINGCYLINDER .... .... ... ....... ............. ........ ...... ..... .... ... .... .... 26
BRAKE CALIPER .. ..... ..... ..... .. .. .. ........ .. ......... ..... ..... ... ... ..... .... 27
51-1
STRUCTURE AND FUNCTION AIR PIPING AND AIR CIRCUIT DIAGRAM
AIR PIPING
See Foldout #4 at end of book.
AIR CIRCUIT DIAGRAM
51-2
STRUCTURE AND FUNCTION AIR TANK
AIR TANK
WET TANK
1. Air tank
A. To safety valve, air pressure sensor
pick-up and air governor
B. Plug mount (PT-l/2)
C. To dry tank
D. Air pressure sensor pick-up
E. From air compressor
F. To drain cock
423F6 I I
l The air tank consists of one wet tank and two dry Specifications
tanks. (One tank [two chambers forming one unit]). Capacity: 10.0 P
The air from the compressor first enters the wet Maximum pressure: 9.5 kg/cm*
tank and the moisture is removed. It is then divided
and sent to the left and right dry tanks.
l A safety valve and air pressure sensor are installed
in the wet tank.
51-3
STRUCTURE AND FUNCTION AIR TANK
DRY TANK
1. Air tank
A. From wet tank
B. To brake valve
C. From wet tank
D. To brake valve
E. Plug mount (PT-l/2)
F. To drain cock
G. To drain cock
H. To solenoid valve
1. Tire inflation
J. Plug mount (PT-l/2)
423F6 I2
Specifications
Capacity : 19.75 0 (two chambers forming one unit)

Maximum pressure: 9.5 kg/cm2
51-4
STRUCTURE AND FUNCTION AIR DRYER
AIR DRYER
(Optional)
__
-P 9
10
11
-
2
L03BR002
1. Thermostat camp. 4. Drain 7. Purge Chamber 10. Desiccant case

2. Heater 5. Input port 8. Check Valve 11_ Oil filter
3. Valve assembly 6. Output port 9. Main Body
51-5
Function
1. Dehumidification
In the loading cycle of the compressor (3), the air While going up through the drying chamber (lo),
from the compressor (10) enters the inlet port (9) in the air is in contact with the more dried desiccant
the air dryer and is cooled along the external (5). Thus, the moisture content is further decreased
surface of the drying chamber (lo), allowing the and at the top end of the drying chamber (IO), the
water and oil to remain on the bottom. Further, the air is completely dried up. This dry air is supplied
air enters the drying chamber (lo), passing through into the wet tank (1) through the purge chamber (7)
the oil filter (4) provided with an oil mist separator and the check valve (8).
to remove oil droplets and dust particles from the
air. In the drying chamber (lo), the moisture con-
tent of the air is removed by the desiccant (5)
having the strong affinity for water.
DR-3U Air dryer

L03AH003
1. Wet tank 6. Check valve

2. Governor 7. Purge chamber
3. Compressor 8. Check valve
4. Oil filter 9. Inlet port
5. Desiccant IO. Drying chamber
51-6
2. Reclamation
(Reconditioning of the desiccant)
When the air pressure in the air drying system After the sudden decompression, the air in the
reaches the upper limit, the governor (2) causes the purge chamber (4) expands. This extra dry air flows
compressor (10) to be in the unloading position and through the drying chamber (12), absorbing the
to run idle. The same command (directions) is given moisture content from the desiccant (13) and going
by the governor (2) to a control port (9) in the air through the exhaust port (8) the open air. Thus, the
dryer, causing the purge valve (7) to open. Thus, desiccant (13) is reconditioned or reclaimed to be
the drying chamber (12) is opened to the air. Due the completely dry desiccant (13).
to this sudden opening, the oil filter (11) is cleaned
by the pressure in the drying chamber (12). The oily In the loading cycle of the compressor (lo), the
substance and the condensed water are also dis- purge valve (7) closes by the command from the
charged into the open air through the exhaust port governor (2), and the air dryer begins the humidifi-
(8). cation of the air.
DR-3U’ Air dryer

L03AH004
1. Wet tank 7. Purge valve

2. Governor 8. Exhaust
3. Check valve 9. Control port
4. Purge chamber 10. Compressor
5. Check valve 11. Oil filter
6. Orifice 12. Drying chamber
13. Desiccant
51-7
STRUCTURE AND FUNCTION SAFETY VALVE
SAFEIY VALVE
1. Cover
2. Lock nut
3. Spring seat
4. Ball
5. Wire
6. Lock terminal
7. Lock plate
8. Adjustment screw
9. Spring
10. Valve body
11. Valve seat
7'
421FO1020
Function Specification
l The safety valve is installed in the wet tank, and Cracking pressure: 9.5 kg/cm2
acts as a safety device for the air circuit.
Operation
l If the air governor does not work properly and the
pressure inside the air tank rises above the set
pressure, ball (4) is pushed up and the air escapes
to the atmosphere.
51-8
STRUCTURE AND FUNCTION BRAKE VALVE
BRAKE VALVE
Outline
l There are two brake valves installed in parallel at
the bottom of the operator’s compartment. These
are operated by depressing the pedal.
l When the right pedal is depressed, air is sent to the
brake chamber and the brake is actuated. When the
left pedal is depressed, the brake is actuated in the
same way as with the right pedal, but at the same
time, the transmission solenoid valve is actuated
electrically, and the transmission is put in neutral.
6’ 423FO97
1. Brake pedal A. From air tank

2. Plunger B. From air tank
3. Piston C. To front brake chamger
4. Inlet valve D. To rear brake chamber
5. Piston
6. Inlet valve
7. Rubber spring
51-9
BRAKE ACTUATED
Upper part
l When pedal (1) is depressed, the operating force
passes through plunger (2) and rubber spring (7)
and is transmitted to piston (3). When piston (3)
moves down, exhaust port (9) is closed, and at the
time inlet valve (4) is moved down and air from the
air tank (11) flows from port A to port C. This
actuates the front brake chamber (12).
c3
To front slack
adjuster
Lower part
l When pedal (1) is depressed, the operating force
passes through plunger (2) and rubber spring (7),
and is transmitted to piston (3). When piston (3)
moves down, inlet valve (4) is moved down, and air To rear slack
from the air tank flows from port B to port D. This adjuster
actuates the rear brake chamber. 423FO98
Operation of brake when lower valve fails e

Olll
0 Even if there is leakage of air in the lower piping, et tank
the upper part will operate normally.
@
To front slack
adjuster
423FO99
51-10
Operation of brake when upper valve fails

l Even if there is leakage of air in the upper piping, if
pedal (1) is depressed, piston (5) will be pushed
down mechanically and the lower part will operate
normally.
OPERATING IN BALANCE
Upper part
l When the pressure in the space below piston (3)
and the air pressure from the brake chamber
becomes high, the pressure pushes rubber spring
(7) and piston (3) moves up to close inlet valve (4).
When this happens, exhaust port (9) stays closed.
The air pressure entering the brake chamber is
retained and the brake is kept applied.
423F100
Lower part
l Upper piston (3) moves up, and inlet valve (4)
closes. Piston (3) is pulled up by an amount equal
to the amount of movement and inlet valve (6)
closes. The exhaust valve is closed, so the air
pressure is maintained and the brake is kept ap-
plied.
The air pressure in the space at the upper part
balances the operating force of the pedal. The
pressure in the space at the lower part balances the
pressure in the space at the upper part.
When pistons (3) and (5) move to the end of their
stroke, inlet valves (4) and (6) are fully opened. The
spaces in the upper and lower parts, and the air
pressure in the left and right brake chambers
become equal to the air pressure in the tank.
Therefore, the braking effect can be adjusted by the
amount the brake pedal is depressed. When the
pistons move down to the end of their stroke, the slack
brake is applied fully.
-slack
423FlOl
51-11
BRAKE RELEASED
Upper part
l When the pedal (1) is released and the operating
pressure is removed from the top of the piston, the
air at the bottom of the piston, and the piston return
spring move the piston up. Exhaust port (9) is
opened and the air pressure in the brake chamber
is released to the atmosphere.
Lower part
l When the pedal is released and the air at the top of
piston (5) is let out, the air at the bottom of piston
(5) and spring (13) pull the piston up. Exhaust port
(10) opens and the air pressure in brake chamber
is released to the atmosphere.
E423F 102
51-12
STRUCTURE AND FUNCTION AIR GOVERNOR
AIR GOVERNOR
1. Spring 5. Exhaust stem

2. Exhaust port 6. Inlet valve
3. Piston 7. Tank port
4. Unloader port 8. Filter
Specifications
l Cut-out pressure: 9.OkO.3 kg/cm2
0 Cut-in pressure: 7.72 0.3 kg/cm’
423F091A
Function
The air governor maintains the pressure in the air circuit
to the specified range.
Compressor
OPERATION
+ Check valve
Tod
Compressor working
l The air pressure in the wet tank (9) passes from the
tank port (7) through the filter (8) and acts on the
bottom of the piston (3).
When the air pressure in the tank (9) is below the
specified pressure (cut-out pressure), the piston (3)
is pushed down by the spring (1).
When this happens, the air at the unloader port (4) 423F092A
passes through the exhaust stem (5) to the atmo-
sphere and the compressor is actuated. Compressor loaded
51-13
STRUCTURE AND FUNCTION AIR GOVERNOR
Comrxessor stopped
When the pressure in the wet tank (9) rises, and
reaches the set pressure (cut-out pressure), the
piston (3) is pushed up against the spring (1).
When the piston (3) is pushed up, the exhaust stem
(5) is closed and the inlet valve (6) opens.
The pressure from the tank (9) passes through the
inlet valve (6) and unloader port (4) and acts on the
unloader valve of the compressor. This puts the
compressor in a no-load condition.
When the air pressure inside the tank (9) drops, the
piston (3) is pushed down by the spring (1).
When the pressure drops below the specified
pressure (cut-in pressure), the inlet valve (6) closes
and the exhaust stem (5) opens. The pressure at
the unloader port (4) passes through the exhaust
stem (5) and is released into the atmosphere, so
the compressor starts to work again. +:m
To wet tank
423F093A
Compressor no-load
51-14
STRUCTURE AND FUNCTION TWO-WAY VALVE
IWO-WAY VALVE
Function
l The two-way valve is installed between the two
brake valves. It acts to prevent the air pressure from
escaping from one brake valve when the other
brake valve is depressed.
Operation
l The air circuit of the left and right brake valves is
connected so that the brakes on all four wheels are
actuated when either of the pedals is depressed.
The air pressure entering from port A of the two-
way valve moves seat (2) and shuts off the circuit to
port B. Therefore, the air pressure flows only to port
C and actuates the brake chamber (5).
423F103
1. Body 4. Cap
2. Seat 5. Brake chamber
3. Plug
.5 423F104
51-15
STRUCTURE AND FUNCTION BRAKE CHAMBER
BRAKE CHAMBER
Section A-A
423F IO5B
Specifications
1. Air cylinder
1. Air cylinder 7. Master cylinder Cylinder bore: 180 mm
2. Air piston 8. Piston valve Stroke: 85.5 mm
3. Rod 9. Bleeder Cylinder capacity: 2380 cc
4. Spring 10. Brake chamber 2. Master cylinder
5. Body stroke sensor Cylinder bore: 68 mm
6. Piston Stroke: 84.5 mm
Delivery: 297 cc
51-16
STRUCTURE AND FUNCTION BRAKE CHAMBER
OPERATION
Brake operated
When the brake pedal is depressed, compressed air is
supplied from the brake valve to the brake chamber. Air
piston (2) moves rod (3) and pushes piston (6) of
master cylinder (7) to the right. Brake oil is sent by
piston (6) to the brake piston to actuate the brake.
-
L04BMOOl
Brake held in position

When the brake pedal is kept depressed at a constant
force, the hydraulic pressure is kept constant, so the
brake is kept applied.
z
slack
adjuster
L04BY002
Brake released
When the operating force on the brake pedal is partly
released, the compressed air supplied to the back of
piston (2) of the brake chamber is released from the
brake valve, and the hydraulic pressure inside master a
cylinder (A) drops. If the brake pedal is released further, Eake
the brake oil sent to the piston of the brake is sent back valve er
to the inside of master cylinder (A) by the force of the
brake return spring. BD L04BM003
51-17
SLACK ADJUSTER
SLACK ADJUSTER
Function
l The slack adiuster is installed in the brake oil line
from the braie chamber to the brake piston. In this
way, it acts to keep a constant time lag when the
brake is operated.
5 i Ii A 423F209
1. Bleeder A. Inlet port

2. Cylinder B. Outlet port
3. Check valve
4. Piston
5. Spring
51-18
STRUCTURE AND FUNCTION SLACK ADJUSTER
OPERATION
1. Brake pedal depressed

The oil pumped out from the brake chamber (6)
flows in from port P of the slack adjuster. From port
P the oil is divided and sent to left and right cylin-
ders (2) and moves piston (4) a distance of S to the
right or left.
4 2
Because of this, an amount of oil corresponding to

stroke S flows from port C to the brake cylinder (7).
When this happens, the clearance between the L04AROlO
brake piston and disc becomes 0, so no braking
force is generated.
L04AROll
51-19
STRUCTURE AND FUNCTION SLACK ADJUSTER
If the oil pressure in the chamber (7) goes above a

certain specified pressure, check valve (3) opens
and the oil flows through pilot circuit D and applies
pressure to port C. This gives the braking force.
3 3
L04AR012
2. Brake pedal released
When the brake is released, pressure is applied to
the back of the brake piston because of the hydrau-
lic pressure of the brake. Piston (4) is moved back
stroke S and the disc clearance returns to normal.
L04AR013
51-20
STRUCTURE AND FUNCTION BRAKE
7
6I i 8
424F30.9
1. Guide pin 5. Inner gear (Teeth 105)

2. Return-spring 6. Cylinder
3. Brake piston 7. Plate
4. Outer gear (Teeth 138) 8. Disc
51-21
STRUCTURE AND FUNCTION BRAKE
Operation
l When the brake pedal is depressed, pressure is 3 7 8
applied to the brake oil by the master cylinder of
the brake chamber. Brake piston (3) is moved to
the right, and disc (8) is kept in close contact with
plate (7). Disc (8) rotates together with wheel, so
when it is held, the rotation is stopped and the
brakes are applied to stop the machine.
From slack
adjuster
424F046A
l When the brake pedal is released, the pressure on

the rear of brake piston (3) is released. The piston
is then moved to the left by the force of return
spring (2) and the brake is released.
To slack
adjuster
4241
51-22
STRUCTURE AND FUNCTION PARKING BRAKE
Outline
l The parking brake is a disc type and is installed on l The parking brake caliper (3) is fixed to the front
the front axle. differential case.
l The force of the spring inside the spring cylinder (2) The disc is installed to the differential yoke and
is used to apply the brake mechanically; it is re- rotates together with the coupling.
leased by air pressure.
i L04EH004
1. Rod
2. Spring cylinder
3. Brake caliper
51-23
STRUCTURE AND FUNCTION PARKING BRAKE
1 To solenoid valva
Brake operated
l When the parking brake switch is turned to ON,
solenoid valve is actuated and the air from the air
tank is shut off by valve. At the same time, the air
from the spring cylinder is released to the atmo-
sphere from between valve and body.
Therefore, the piston of spring cylinder (1) and the
rod are pulled by the tension of the spring, so when
lever (2) is pulled, the parking brake is applied.
l Lever (2) rotates piston shaft (3) and moves piston
(4) to the axial direction. Therefore, the pads are
pushed against the disc, and the parking brake is
applied.
’ I L04BH005
Brake released From solenoid valve

l When the parking brake switch is turned to OFF,
the solenoid valve is actuated and valve closes the
exhaust port.
At the same time, the air in the air tank enters the
top part of the piston of spring cylinder (1). It
overcomes the force of the spring and pushes the
piston. This pulls rod (5), moves piston (4) 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 inside the tank drops to
a level where it cannot maintain the normal opera-
tion of the brake, the air pressure sensor installed to
the tank sends an electric signal to the solenoid
valve. This releases the spring cylinder circuit, and
the parking brake is automatically applied.
-1006
51-24
STRUCTURE AND FUNCTION PARKING BRAKE SOLENOID VALVE
PARKING BRAKE SOLENOID VALVE

1. Coil 5. Outlet valve
2. Body 6. Exhaust port
3. Outlet port 7. Inlet port
4. Inlet valve
Function
l The parking brake solenoid valve is a valve to
switch air to the parking brake air chamber. It is
controlled and actuated by a switch in the opera-
tor’s compartment.
4 423FI 19-l
._
OPERATION Spring
l Parking brake ON:

When the parking brake switch in the operator’s
compartment is turned ON, the solenoid valve is
switched OFF, and air from the spring cylinder
enters port A. It passes around valve (5), enters 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
force in the spring cylinder.
423F I 20 A
Spring
l Parking brake OFF:
When the parking brake switch in the operator’s
compartment is turned OFF, the solenoid valve is
switched ON, and valve (5) moves down. Valve (5)
is connected by a rod, so valve (5) and valve (4)
both move down. The air from the tank enters port
C, but valve (4) has moved down, so the air passes
tank
around valve (4) and enters port A. Air is sent to the
spring cylinder and the parking brake is released.
423F121A
51-25
STRUCTURE AND FUNCTION SPRING CYLINDER
SPRING CYLINDER
423F124
1. Rod Outline
2. Boot l The air pressure from the parking brake solenoid
3. Cylinder valve pushes the spring and compresses it to
4. Spring release the parking brake.
5. Piston Usually the parking brake is kept applied by spring
(4), so the machine is prevented from moving.
51-26
STRUCTURE AND FUNCTION BRAKE CALIPER
BRAKE CALIPER
Section B-B
’ I
Section A-A
424F049A
1. Outer carrier 6. Lever
2. Pad 7. Lever mounting bolt
3. Inner caliper 8. Adjustment bolt
4. Piston 9. Sleeve
5. Piston shaft
Outline
0 The caliper body consists of inner caliper (3) and 0 Using sleeve (9) as a guide, the caliper body moves
outer caliper (l), and is connected by bolts. according to the wear of the pad and slides in the
0 There is a piston guide provided on the inner axial direction. The sleeve is installed by bolts to the
caliper. Piston (4) and piston shaft (5) are fitted in caliper mount support.
this, and the rotation of the piston shaft makes the 0 Adjustment bolt (8) of lever (6) is used to adjust the
piston move in an axial direction to press against clearance between the pad and disc. With the lever
pad (2). kept stationary, the adjustment bolt is turned to
l Lever (6) is connected by a spline to the splined adjust the clearance.
end of the piston shaft.
l Pad (2) is held in the caliper body by the pad pin, To INCREASE clearance, turn COUNTERCLOCK-
and at one end it is fitted in a groove of the outer WISE.
caliper pad, and at the other end it is fitted in the To DECREASE clearance, turn CLOCKWISE.
groove of the caliper mount support.
51-27
STANDARDVALUETABLE ... ............... ................ ..... ..... .... ... .... ...... 3
TOOLLIST . .... ....... ......... ............... ............ ..... ... .... .... ........ 4
BRAKE PEDAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
AIR .............................................................................. 6
1. Measuring set pressure of air governor .............................................. 6
2. Measuring cut-off pressure of air pressure alarm buzzer .................................. 7
3. Measuring safety valve .......................................................... 8
AIRDRYER ........................................................................ 9
BRAKEPERFORMANCE .. .. .......... .. ... ............ ....... ........ ... ... ..... ..... 11
BRAKEOILPRESSURE ..... ............. .. ............. ..... ......... ... .. ... .... ... 12
WEAR OFBRAKE DISC .............................................................. 13
AIR BLEEDING FROM BRAKE LINE. ..................................................... 14
PARKINGBRAKE ................................................................... 15
PERFORMANCE ................................................................. 15
CHECKING AND ADJUSTING ....................................................... 16
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . ............. .. . . .
... . ... . ..... .... .... . .. . 19
TROUBLESHOOTINGTABLES .... ...... .............. .. . . .
... . ... . ..... ..... ... . .. . 20
1. Air pressure does not rise at all. . . . . . . ............... . . .
. . . ... . ..... .... .... . .. . 20
2. Air pressure does not rise to the specified range. . . . . . . . . . . . .
... . .... ..... ..... .... _. . 21
3. Brake is ineffective or not very effective. .. .............. ... . .... . .... ..... .... .. . 22
4. Brake does not release, or drags. . . . . . ........ ........ .. ..... .. .. . ..... ..... ... .. . 23
5. Parking brake does not release, or drags. (Applies to machines equipped with air parking brake.) . . 24
6. Air dryer troubleshooting . . . . . . . . . . . . . ............. .. .... . . ... . .. ....... ..... .. . 25
t The following precautions are necessary when using the Standard Value Tables to make judgements during
judgements.
52-1
t Before carrying out the troubleshooting in this section, read “PRECAUTIONS WHEN TROUBLESHOOTING”,
“METHOD OF READING TROUBLESHOOTING TABLE” and “PREVENTING RECURRENCE OF TROUBLE” in
SECTION 22 TROUBLESHOOTING.
52-2

value value
Coolant temperature:
Brake pedal
Inside operating range
l Engine speed: Low idling
0 Operating force
l Air pressure: Specified kg 39-47
Max. 50
l Angle degree 16.5-20.5
pressure
Air system pressure

l Air governor cut-in l Coolant temp. = Inside
kg/cm2
l Air governor cut-off operating range
0 Safety valve actuating
Warning buzzer pressure 6.OkO.l 6.0+0.1

l Actuating starting l Coolant temp. = Inside
kg/cm2 6.0+;.4 6.0 + i.4
l Actuating stopping operating range
l Road surface: Flat, horizontal,

dry, paved surface
Speed when applying brakes:
20 km/h
l Time lag when pressing the
Brake performance pedal: 0.1 sec. m Max. 5 Max. 5
l Air pressure: 7 kg/cm2
l Brake pedal operating force:
3% kg
l Tire inflation pressure:
Specified pressure
0 Coolant temperature:
Drop in brake oil pressure kg/cm2 Max. 5 Max. 5
l Test pressure:
53 kg/cm2/5 min.
0 Coolant temperature:
Wear of brake disc mm Max. 5.7
l Tire inflation pressure:

Specified pressure
l Road surface: Machine
Parking brake performance
Flat, dry, paved surface stopped
with l/5 (1 l”20’) gradient
0 Machine: In operating condition
l Thickness of pad 16 Min. 8.0
mm
0 Clearance between
Max. 2.8
disc and pad (a, b)
424F105A
52-3
TESTING AND ADJUSTING TOOL LIST
TOOL LIST
No. I Testing and measuring item Tool name I Part number I ~~~~ Remark
1 I Brake pedal operating force Push gauge 799-l 01-l 001 I~0 - 110 kg
2 1 Brake oil pressure Hydraulic tester 793-520-l 803 0 - 100 kg/cm*
21 Commercially Available p
a When carrying out testing, adjusting or troubleshooting, stop the machine on level ground, install the safety
bar on the frame, lower the bucket to the ground, and stop the engine.
a When taking measurements, do not allow unauthorized persons near the machine.
52-4
TESTING AND ADJUSTING BRAKEPEDAL
BRAKE PEDAL
l Air pressure: 7.7 kg/cm2
Item
value value
Brake
pedal h
Special tool
A 799-l 01-l 001 Push gauge 1
1. Measurina oDeratina force of pedal

1) Fit push gauge ito the operator’s foot.
+ Align the center of the push gauge with the
center of the pedal.
2) Start the engine and run at low idling, then de-
press the pedal and measure the operating
force.
2. Measuring travel of pedal

1) Fit push gauge A to the operator’s foot.
* Align the center of the push gauge with the
center of the pedal.
2) Start the engine and run at low idling, then de-
press the pedal with an operating force of 43 kg
and measure the travel 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 meter to measure the travel of the
pedal to the point where it starts to become
heavy.
423F316
52-5
TESTING AND ADJUSTING AIR
AIR
Special tools
Part number Part name GTty
A 790-301-l 370 Gauge 1
B 790-301-l 120 Nipple 1
C 07108-20203 Hose 1 d Ii’ 423P333
D 1 790-301-1110 Nipple I 1
E 1 790-301-l 190 1 Nipole I 1
Commercially
F Connector 1
available
* When measuring, connect nipple B, hose C, nipple

D, E, and connector F to gauge A, then insert in the
tire inflation coupler on the machine.
1. Measuring set pressure 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 at which the air governor
is actuated and the air compressor is cut-off
(no-load rotation).
423P334- I
3) With the engine at low idling, use the brake

pedal to lower the air pressure. Measure the
pressure at which the air compressor cuts in
(start of operation).
52-6
Adjusting
1) Stop the engine.
2) Loosen lock nut (l), and turn adjustment screw (2)
to adjust.
_* Turn the adjustment screw as follows.
To DECREASE set pressure, TIGHTEN
screw.
To INCREASE set pressure, LOOSEN
screw.
t Amount of adjustment for 1 turn of screw.
Approx 1.4 kg/cm2
t After adjusting as above, measure again and

check that all values are standard.
2. Measuring cut-off pressure of air pressure alarm

buzzer
1) Start the engine and run at low idling. Use the
brake pedal to lower the air pressure, and
measure the pressure at which the buzzer starts
425F206
to sound.
2) Lower the pressure further, then increase the
engine speed and measure the pressure at
which the buzzer stops sounding.
t If the pressure is not standard value, check
the switch. If necessary, replace the switch.
_* After replacing the switch, measure the
pressures again.
52-7
3. Measuring safety valve

1) Loosen the adjustment screw of the air gover-
nor and set the actuating pressure of the air
governor above the actuating pressure of the
safety valve. ,l
2) Start the engine and measure the pressure
when air comes out of the safety valve (1).
* After measuring, do not forget to return the air
governor to the specified pressure.
l If the safety valve (1) is defective, replace the valve
assembly.
Do not try to adjust it.
42lFOIIII
52-a
TESTING AND ADJUSTING AIR DRYER
AIR DRYER
PRECAUTIONS FOR REPLACING THE
a The air dryer desiccant needs to be replaced
periodically. If not accomplished on time, the
desiccant can melt out and get into the air
DESICCANT
circuit, thus causing malfunctioning of the air 1. Before and after installing the air dryer, drain water
equipment. from the piping and the tank.
a The desiccant replacement interval is 2000

hours, but check it as described below and if
needed, replace it.
2. Start up the engine and confirm that no air leaks
through each connection.
a If a air dryer kit was newly installed, it will take

about a week to drain all the residual fluid from
the wet tank (one place) or the dry tank (two
3. Run the engine and when the air pressure exceeds
the max. value so that the loading is changed over
places). to the unloading, air must be bled out through an
a Cold weather operation:

Temperature below -10°C and after stopping
machine for a few hours, start the engine, then 4.
exhaust port in the dryer.
At first, much air is bled out. In approximately 3

wait for more than 10 minutes before beginning seconds, so little air is bled that no sound is pro-
work again. duced.
NORMAL OPERATION CHECK 5. After the air pressure drops to the minimum pres-
sure so that the unloading is changed over to the
1. Start the engine and fill the air tank with air. loading, the leakage from the exhaust port in the
dryer must be 20 cc/min. maximum.
2. See that air is exhausted from the air dryer drain
hose when the governor operates to cause the 6. At a interval of approximately one week after instal-
compressor to be switched to the unload condition. lation of the dryer, see if any drainage comes out of
the wet tank.
3. Check that a lot of air is exhausted and to the
degree that no sound is produced after 3 seconds. 7. When operating the machine after a standstill for
(Your checking the dryer purge valve for opera- several hours in the cold weather below - lO”C, run
tions). the engine and at an interval of 10 minutes or
longer after the engine starts up, start off the ma-
4. Apply the brakes, see that air pressure goes down chine.
and that the compressor has switched to the load
condition.
5. Check that the air leak from the air dryer port is
small. (target: 20 cc/minute, max.)
6. Check that there are no leaks from any connections

or tubes.
52-9
TESTING AND ADJUSTING AIR DRYER
SERVING AND INSPECTION
a When the ambient temperature of the tank

lowers more than 16”C, a small quantity of
drain may sometimes remains in the tank.
1. Every 900 hours or 3 months of operation
1) Check the air dryer for the normal functioning

or for draining by opening a drain cock on the
tank.
2) If a small amount of drainage comes out under

the normal operating condition, confirm the
drainage, and refer to the troubleshooting guide
in this section.
If no abnormalities exist, disassemble the air

dryer body and see if the desiccant is saturated
by impurities. If more than l/5 in the volume,
replace the desiccant with a new one.
If the desiccant is attacked by oil, its moisture

absorbing power will be deteriorated.
3) Observe the drain coming out of the exhaust

port in the DR-3. If the oil is excessively drained
out, inspect the compressor and the oil to the
full mark.
2. Annually or every 2000 hours of operation
1) Disassemble the DR-3 air dryer and replace the

desiccant, oil filter and all rubber parts.
2) Inspect the piping and the wiring for abnormali-

ties.
52-10
TESTING AND ADJUSTING BRAKE PERFORMANCE
BRAKE PERFORMANCE
I I
t Measurement condition Standard Permissible
l Time lag when pressing the pedal: 0.1 sec. Item
I value I value
l Air pressure: Inside operating range
l Road surface: Flat, horizontal, straight, dry, paved Brake
surface Max. 5 m Max. 5 m
performance I
0 Machine speed: Speed when applying brakes: 20 I I
km/h
Conditions for measurement Special tool

1) Start the engine and then start the machine. Part number Part name Q’ty
2) Place the speed control lever in the highest speed
range and drive the machine. Commercially Tape
1
3) When the machine is traveling at 20 km/h, depress available measure
the left brake pedal (transmission cut-off selector
switch ON) with the specified operating force.
t When completing the road test, hold the steer-
ing wheel straight and apply the brakes as you
pass your marked point.
4) Measure the distance from the braking point to the
point where the machine stops.
t Carry out the test three times and take the aver-
age value.
Stopping point Braking point Brake pedal operating

position
I I
Braking distance Runup road
423F319
52-11
TESTING AND ADJUSTING BRAKE OIL PRESSURE
BRAKE OIL PRESSURE

l Test pressure: 53 kg/cm2
Special tool
A 793-520-l 803 Brake test kit 1
~170-21-11190 1 Nipple
Tool A
\
Tool B
! /
a Block the tires securely.
Measuring procedure
1. Remove nipple (3), then install tool B, nipple (3) and
tool A in turn to the bleeder screw mount.
2. Start the engine and bleed the air.

t Two workers are needed for this operation: one
depresses the pedal and the other bleeds the
air from the bleeder screw (2). u 1 42lFOI II2
-rt Turn the transmission cut-off switch ON.
3. Depress the left brake. When the gauge reading is

53 kg/cm”, leave for 5 minutes and check how
much the pressure drops.
4. After measuring, stop the engine, and loosen the

bleeder screw.
Lower the pressure, then remove tool A and tool B.
+ After completing operation, bleed the air from
the brake circuit again.
52-12
TESTING AND ADJUSTING WEAR OF BRAKE DISC
WEAR OF BRAKE DISC

Special tool
Commercially
Vernier calipers 1
available
a Stop the machine on level ground and block

the tires.
Method of testing
1. Remove plug (1).
2. Depress the brake pedal to the end of its travel.
3. Measure depth “a” from the end face of the housing

to the spring guide.
t Keep the brake pedal depressed when measur-
ing.
4. Install a vinyl hose to bleeder (2), loosen the bleed-

er and bleed the air brake oil.
+ After bleeding the brake oil, check that the
brake piston has returned to the end of its
stroke.
5. Measure depth “b” from the end face of the housing

to the spring guide.
Calculating wear
S=a-b
S = Max. 5.7 mm
b
-7
423F320
52-13
TESTING AND ADJUSTING AIR BLEEDING FROM BRAKE LINE
AIR BLEEDING FROM BRAKE LINE
a Block the tires securely.
Order of operation
1. Remove cap (1) of the bleeder screw, insert vinyl
hose (2) into the screw and put the other end in a
container.
3. Two workers are needed for this operation: one

depresses the pedal and the other bleeds the air
from bleeder screw.
Tighten the bleeder screw, then release the brake
pedal slowly.
* Depress the left brake pedal.
l Keep adding brake oil so that the oil circuit is
always full.
4. Repeat this operation until no more bubbles come

out from the hose. Then depress the pedal fully and
tighten the bleeder screw 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 the cylinder furthest from the master cylin-
der.
t When the air has been bled from all the cylin-
ders, confirm that rod (4) for the overstroke
sensor of brake chamber (3) is in place. If it is
out of place, push it in as far as the sensor
installation end face “a”.
52-14
TESTING AND ADJUSTING PARKING BRAKE
PARKING BRAKE
PERFORMANCE
-f Measurement condition
l Road surface: Flat, dry, paved surface with l/5
(1 l”20’) gradient.
l Machine: In operating condition
Item 423F321
value value
Parking brake Holds machine on l/5 (11’20’)

performance gradient
Measuring procedure
1. Start the engine and drive the machine straight up
a l/5 gradient with bucket unloaded.
2. Depress the brake, place the directional lever in

neutral, then stop the engine.
423F322
3. Turn the parking brake switch ON, then slowly

release the brake pedal and the machine must not
move at all.
l The measurement must be made with the ma-
chine facing either up or down the slope.
52-15
CHECKING AND ADJUSTING
l Air pressure: Maximum set pressure
Unit: mm
item
value value
Thickness of pad I 16 I 8
A Block the tires securely.
0 Raise lift arm (1) put support (2) under the lift arm,
then remove cover (3).
Measuring procedure
1. Turn the main switch ON.
2. Turn the parking brake switch OFF to release the

brake.
3. Stop the engine, and measure the thickness from

the disc to the backing plate of the pad.
t Be extremely careful not to turn the main switch
OFF during operation.
t If the measurement is not within the standard
value, replace the two pads as one set.
t For details of replacement, see DISASSEMBLY
AND ASSEMBLY.
Measuring clearance
Unit: mm
Item
value value
Clearance between
0.1-0.4 Max. 2.8
disc and pad
Measurement procedure
1. Turn the main switch ON.
2. Turn the parking brake switch OFF to release brake.
3. Insert a feeler gauge between disc (1) and pad (2),

then measure the clearance “a”, “b”.
424F105
52-16
Adjusting clearance
t Be careful not to turn the starting switch OFF during
the operation.
t If the value is not within the standard value, adjust
as follows.
1. Turn ON the starting switch and turn OFF the

parking brake switch to release the parking brake.
t Take care not to turn OFF the starter switch,
otherwise the parking brake will be actuated.
2. Turn adjustment bolt (4) on the caliper lever clock-

wise so that pad (5) slightly contacts discs (6).
it Do not turn the adjustment bolt so far that pad
(5) and discs (6) come into snug contact. If
they are in snug contact, the brakes may
“squeak” or overheat when applied.
3. Turn adjustment bolt (4) counterclockwise by one

notch, and the sum of the right and left clearances
between pads (6) and disc (5) will be 0.3 to 0.6
mm.
t Always replace pads (6) as a pair.
t Confirm that the brake performs up to specifica-
tion after finishing this adjustment.
424F106
52-17
This page is intentionally blank.
52-18
TROUBLESHOOTING
52-19
1. Air pressure does not rise at all.

l Did the air pressure suddenly cease to rise?
- Damage in air circuit or equipment.
l Was the air pressure difficult to raise for some
time? - Air leakage, performance drop in air
equipment.

l Damaged air hose or tube, external damage to
equipment associated with air system.
l Is the drain cock completely closed?
Fault check.
l Check the air pressure by air gauge.
l If the pointer of the air gauge on the instrument
panel remains at “0” despite opening the air
drain valve and confirming that the air is pres-
surized, the gauge is faulty.
Compressor starts tc~ build up pressure when c~rcu,t

3
between a,r aovernor and unloader IS cut. IO1 1
Compressor does not start to bulld up pressure despite
4 cutting the clrcult between the awgovemor and
0 0
the unloader
Compressor starts to build up pressure when the Intake

5
hose of the compressor IS dwonnected. 0
c AN comes out of dwharoe oiw of ccrntxessor when
0
engine IS running but pre&rd does not bulld up. I I I I u
I
I nn-,-,n”P
The followng symbols are used to Indicate the action
to be taken when a cause of fallure IS located
X, Replace A- Repaw
A- Adjust C: Clean
52-20
2. Air pressure does not rise to the specified range.

l Check for possible air leakage from air hose,
tube and air equipment.
l Is the drain cock completely closed?
l Check for deformation of compressor or air
intake hose.
Fault check.
l Install a pressure gauge in the air circuit and
measure the air pressure, then compare the
measured value with the judgement criterion
table to see whether or not it deviates from the
specified value.
NO
Problems I A I
-, ,
Air discharge from compressor discharge pope IS weak
1 0 0
when engine IS runnmg
Compressor starts to bulld up pressure when circuit
2
between air governor and unloader IS disconnected 0
Air comes out of dwharge pipe of compressor when
3
engine IS runmng but pressure does not buld up.
0
LO222047
The followng symbols are used to lndlcate the actlon

to be taken when a cause of fatlure IS located.
X. Replace A: Repatr
A: Adjust C, Clean
52-21
3. Brake is ineffective or not very effective.

0 Did the brake suddenly cease to be effective?
- Damage in air or brake equipment.
l Did brake gradually deteriorate? - Deterioration
of seal or packing, wear of lining.

0 Is kind of brake oil correct? (SAElOW-CD).
l Is air pressure and brake oil quantity satisfacto-
ry?
l Is there any leakage of air or brake fluid when
the brake is operated?
l Is there any external damage to air or brake
piping or equipment?
l Check residual thickness of brake lining.
l Check tire pressure and tire tread.
l Measure the pressure in the air circuit. If there
is an abnormality, refer to item 1. “Air pressure
does not rise at all” 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 checks.
l Check it against the valve in the judgement
criterion table to see whether or not braking
performance is bad.
l The left and right wheels at both front and rear.
~t,efo,,ow,ng
symbols are used to mdlcate the aCtIon
to be taken when a cause Of fa!luW 6 located
52-22
4. Brake does not release, or drags.

l Does brake pedal return completely’?
l Does parking brake completely disengage?
Fault check.
l Abnormal heat generation in brake.
l Inertial travel on flat ground.
AM comes out and brake dwangaged if brake chamber air

snout IS dwonnected when brake oedal IS released.
Grwt pressure falls off and brake disengages 11
2
bled from aw bleeder when brake oedal IS released I”I”l I I “I
A partwlar wheel rotates slugg6hly when the machme
IS raised wth a 4-wheel lack, the wheel axles placed on
3
a stand, the engme shut down and the tires rotated by
hand with the parking brake released I I /“lolol
L0222049
The followng symbols are used to mdlcate the actlon

x: Replace A Repalr
A Adjust c, Clean
52-23
5. Parking brake does not release, or drags. (Ap-

plies to machines equipped with air parking
brake.)
Check before troubleshooting.

l Is the pressure in the air circuit within the speci-
fied range? (If the air circuit pressure is 4.0
kg/cm* or less, the parking brake solenoid
valve will automatically operate to engage the
parking brake.)
The followng symbols are used to Indicate the action

52-24
TESTING AND ADJUSTING TROUBLESHOOTING TABLES
6. Air dryer troubleshooting
Symptom Probable cause Possible remedy
Drainage comes When a dryer is added in mid operation, Drain the piping and tank at inspection
out of the wet it takes time for the dryer condition to be after completing the machine operation
tank. changed from the saturated to the dry until the dryer is placed in the completely
state. drv condition.
Air consumption is so much under spe- Provide the loading and unloading cycles
cial operating conditions that neither for the compressor.
loading not unloading cycle is provided
for the compressor.
Governor (pressure regulator) relieving Set the governor pressure regulating

pressure is low (low (less than 5kg- value at 8.3 kg/cm2.
/cm2), leaving the purge valve opened.
Desiccant and oil filter have not been Replace the desiccant (with its kit) annu-
replaced over a long period of time. ally or every 2000 operating hours.
The purging function is nor fully effected. When the air purging is performed
through a relief valve: if the governor
relieving pressure and the relief valve
closing pressure low, the purging time will
be short, making it impossible to positive-
Iv recondition the desiccant.
No drainage co- The heater does not work, leaving the l Check the heater and replace, if
mes out of the dryer in the frozen state. necessary.
purge valve. 0 Replace the thermostat, if faulty.
Desiccant has not periodically been Annually or every 2000 operating hours,
replaced. replace the desiccant (with a repair kit).
The governor relieving pressure is low Set the governor regulating pressure at
(less than 5 kg/cm2), leaving the purge 8.3 kg/cm2 as specified.
valve unopened.
The valve does not work due to the Disassemble and inspect the valve. If
being clogged with foreign matter. necessary, replace with a valve kit. If the
valve body is damaged on its sliding
surface, replace the valve body complete-
Iv.
The dryer interior The heater is broken, eliminating the Check the heater for the continuity with a
is frozen. heating effect. tester.
0 If the heater is broken, replace.
The thermostat is broken, disabling the Check the thermostat:

heater from functioning. 0 at 0°C or less, make a continuity
test with a tester.
0 touch the thermostat with the palm
of the hand to see if it is OFF.
The snow and ice have stuck on the Remove the snow, ice, etc., taking care
dryer body, causing the temperature to not to damage the dryer body and the
lower excessivelv. heater wirina.
52-25
TESTING AND ADJUSTING TROUBLESHOOTING TABLES
Symptom Probable cause Possible remedy
The heater does not work, because the Securely connect the wiring between the
connection between the heater and heater and thermostat.
thermostat is loosened off.
Air leaks through The valve is not completely seated be- Disassemble and inspect the valve. If
the purge valve. cause of the foreign matter caught in the necessary, replace with a valve kit. If the
valve. valve body is damaged on its sliding
surface, replace the valve body complete-
ly.
The wet tank pres- In the unloading cycle of the compres- Disassemble and inspect the check valve
sure drops ab- sor, the dry air in the wet tank leaks out between the wet tank and purge cham-
normally. by flowing in the reverse direction, as ber. If necessary, replace the valve.
the check valve on the wet tank side
1 does not function as a non-return valve. 1
52-26
E
AIR GOVERNOR . . ................................................................... 3

DISASSEMBLY ................................................................... 3
ASSEMBLY . . ................................................................... 4
AIR DRYER . . . . . ................................................................... 5

REMOVAL . . . ................................................................... 5
INSTALLATION ................................................................... 5
DISASSEMBLY ................................................................... 7
ASSEMBLY . . ................................................................... 9
BRAKE VALVE . . . .................................................................. 11

REMOVAL . . . .................................................................. 11
INSTALLATION .................................................................. 12
DISASSEMBLY .................................................................. 13
ASSEMBLY . . .................................................................. 15
BRAKE CHAMBER .................................................................. 17

REMOVAL . . . .................................................................. 17
INSTALLATION .................................................................. 19
DISASSEMBLY .................................................................. 20
ASSEMBLY . . .................................................................. 23
SLACK ADJUSTER .................................................................. 27

REMOVAL . . . .................................................................. 27
INSTALLATION .................................................................. 27
DISASSEMBLY .................................................................. 28
ASSEMBLY . . .................................................................. 29
BRAKE . . . . . . . . . .................................................................. 30
DISASSEMBLY .................................................................. 30
ASSEMBLY . . .................................................................. 36
SPRING CYLINDER . . . . . . . . ........................................ ....... 44

REMOVAL . . . . . . . . . . . . ........................................ ....... 44
INSTALLATION . . . . . . . . . ........................................ ....... 45
DISASSEMBLY . . . . . . . . . ........................................ ....... 46
ASSEMBLY . . . . . . . . . . . ........................................ ....... 48
PARKING BRAKE . . . . . . .. ........................................ ....... 50

REMOVAL . . . . . . . . .. .. ........................................ ....... 50
INSTALLATION . . . . ..... ........................................ ....... 52
PARKING BRAKE PAD . ..... ........................................ ....... 54

REMOVAL . ... . . ........................................ ....... 54
53-1
INSTALLATION ..... .. ...................... .... ........... ...... .... ..... ....... 55
* Take the following method for air bleeding when you start to operate hydraulic cylinders after reassembling
53-2
DISASSEMBLY AND ASSEMBLY AIR GOVERNOR
AIR GOVERNOR
DISASSEMBLY
1. Cover
Remove cover (15) then remove retaining ring (14).
2. Spring seat
1) Remove spring seat assemblies (10, 11, 12, 13,
16 and 17).
t Remove lock nut (16) inside the spring seat
assembly before removing the assembly.
2) Remove exhaust stem (9) and spring (8) from
top of piston (3).
3. Piston
1) Turn body (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 a
423F442A
53-3
DISASSEMBLY AND ASSEMBLY AIR GOVERNOR
ASSEMBLY
& Inside surface of body, outside surface of

piston, O-ring groove, spring guide, ad-
justment screw: Grease (G2-Ll).
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 (5) in bottom of piston (3), insert
spring (4), fit in groove, then install on O-ring
(18) and assemble piston assembly in body (1).
Spring seat assembly

Assemble lower spring seat (llA), spring guide
(lo), lower spring seat (11) spring (12) and upper
spring seat (13) in order on adjustment screw (17).
Tighten lock nut (16) so that distance from bottom
face of adjustment screw to top face of upper
spring seat (13) is 47.6 mm.
t Check that exhaust stem (9) and spring (8) are
correctly fitted on piston (3), then insert the
adjustment screw assembly in the body.
3. Cover
Stop cover (15) with retaining ring (14), then install.
423F443
4. Filter
Insert filter (2).
* Install the governor on the machine and con-
nect the air piping. Check the air pressure when
the air compressor is increasing and decreasing
pressure. If the pressure is outside the specified
value, adjust it.
1 2 423F444A
53-4
DISASSEMBLY AND ASSEMBLY AIR DRYER
AIR DRYER
REMOVAL
A Apply the parking brake and block the wheels.
1. Bleed the air from the brake piping.
+ When the air is bled out, the parking brake

remains ON.
2. Remove the thermostat wiring.
3. Remove all tubes (IN, OUT and CONTROL lines)

from the air dryer.
4. Remove the 4 mounting bolts; remove the air dryer.
INSTALLATION
1. Install the 4 mount bolts.
2. Install all tubes (IN, OUT and CONTROL lines).
3. For operational check out procedure, see Section

52, Testing and Adjusting, page 52-9, Air Dryer.
+ See the next page for explosion view.
53-5
AIR DRYER
AIR DRYER
14
17
19
18
w
20 29
e-l1
& 24
25 a-34
30 8
31
5
e-
G 26
i.
-27 7
‘6
L03BR003
53-6
DISASSEMBLY OF AIR DRYER
Refer to exploded view of air dryer on previous

page.
Secure the air dryer body (1) vertically in a vice.
Remove 4 of the 6 bolts (16) on the body, then

loosen the remaining 2 bolts.
Remove set spring (11) and filter plate (10). Further,

remove case (5). case guide (9) oil filter (2) and
gasket rings (3 & 4) in this order.
Remove filter (7) from the upper side of case (5)

and take the desiccant (8) out of place. Then the
filter plate (6).
DISASSEMBLY OF THE VALVE BODY AS-

SEMBLY (20)
1. Remove the retaining ring (27) with the C-type snap

ring pliers (for hole) with the body on the flange
side kept down, and take the valve body (20)
completely out of place.
2. Remove exhaust cover (26) from valve body assem-

bly (20).
3. Fit the piston (28) with a 10 mm hexagon socket

wrench, loosen the bolt (31) tightening valve (25)
and remove piston (28), valve spring (21), O-rings
(23 & 24) and valve (25).
53-7
AIR DRYER
82
20
a-10
a-34
e-25
b=
@-
30
31
26
8
5
7
e-27
L03BR003
53-8
ASSEMBLY OF AIR DRYER
t Refer to exploded view of air dryer on previous

page.
+ All removed parts except for the rubber parts and

desiccant should be washed thoroughly in clean
washing oil, wipe off foreign matter from the surfac-
es and dry them up. Replace the desiccant with a
new one.
Grease must be silicone based or equiva-

lent.
1. Face the opening of case (5) upward and push filter

plate (6) and filter (7) into case; then, add the
desiccant (8).
+ The standard weight of the desiccant is 480 g.

When one bag of a repair kit has been opened,
add all contents of the bag.
2. Tap the external surface of the case (5) with a

plastic hammer for the satisfactory seating of the
desiccant and set the second filter. The filter should
be set in place with the thick and soft layer kept
down.
3. Place the body (1) of the air dryer vertically into a

vice. (large open end - up).
4. Put the filter gasket (3) into the body together with
the oil filter (2) and gasket (4).
5. Set case (5) and case guide (9) in place.
6. Coat sealing ring (12) and O-ring (13) for the body
with grease and set them in place.
7. Place filter plate (34), set spring (11) and seal ring
(12) on case (5).
8. Coat O-ring (15) for the purge chamber with grease

and set the cover (33) with the check valve (32) in-
stalled, into place.
9. As the final step, rest cover (33) and purge chamber

(14) on the body (1) and push in 6 bolts (16) from
the under-side. Install washer (18), lock washer (19)
and nuts (17).
Tightening torque range: .9 - 1.4 kgm
53-9
ASSEMBLY OF THE VALVE BODY ASSEM-

BLY (20)
Grease must be silicone based or equiva-

lent.
Coat O-ring (22) with silicone base grease and set

on piston (28).
Coat the sliding portion of the valve body (29) and

the piston shaft.
Set the valve spring (21) in the valve body and

install the piston.
Secure the piston in place with a 20 mm hexagon
socket wrench and tighten valve (25) lock ring (30)
with bolt (31).
Tightening torque range: .4 - .7 kgm
After coating O-rings (22) and (24) for the valve

body (20) with grease, put them onto the valve
body.
Set exhaust cover (26) on the valve body (20). At

this time, apply light hammer blows on the exhaust
cover (26) end surface.
E3 26
After coating the O-ring portion on the body (1) side
with grease, set the valve body assembly (20) into @-
place. a-27
L03BR004
Set retaining ring (27) in place with the C-type snap
ring pliers.
53-10
DISASSEMBLY AND ASSEMBLY BRAKE VALVE
BRAKE VALVE
REMOVAL
Stop the machine on level ground and install

A the safety bar on the frame. Lower the bucket
1. Draining air
Drain air from air tank, then remove cover of pedal.
2. Air piping, wiring

Disconnect air pipings (1, 2, 3, 4, 5 and 6) con-
nector (7) and wire (8).
3. Pedal
Pull out cotter pin (10) of pin (9) remove pin, then
remove pedal (11).
4. Brake valve
Remove mounting bolt (12) disconnect valve body
(13) and mounting flange (14), then remove plunger
(16).
423F445
12
INSTALLATION i”/
1. Brake valve
Assemble plunger (15) on mount flange (14), then
install in valve body (13). II
a Plunger: Engine oil (SAE low)
‘13
423F445
2. Pedal
Set pedal (11) in mounting position, insert pin (9),
align stopper hole on left side of pin and assemble
on right side with cotter pin.
+ Bend the cotter pin securely.
3. Air piping, wiring

Connect air pipings (1, 2, 3, 4, 5 and 6), wiring (7)
and connector (8).
4. Air leakage check

Stand engine, check for leakage of air, and check
operation of brakes.
53-12
1. Body assembly
1) Make match mark “a” on upper body and lower
body.
I” 56OBP372
2) Loosen mounting bolts (1) remove upper body

(2) and lower body (3), then disconnect them.
2. Upper valve assembly

1) Hold slot-head screwdriver @in vise 0, and fii in ,, “.
- ,,
slot in stem inside exhaust passage of relay

piston.
5600P374
2) Loosen nut (4), then remove washer (5) plain

washer (6), spring seat (7), rubber spring (8)
upper piston (9), return spring (IO), relay piston
spring (1 l), relay piston (12), and stem assem-
bly (13).
a
s
4
&
When loosening the nut, the piston may fly
out under the force of the return spring, so
hold the piston by hand when loosening
the nut.
3) Remove snap ring (14), then remove primary

valve (15) from upper body.
4) Remove snap ring (16), then disassemble

primary valve into washer (17), O-ring retainer
(18), O-rings (19 and 20), upper valve spring
(21), valve retainer (22), and upper valve (23).
3. Lower valve assembly

1) Remove exhaust cover (24), then remove
secondary valve assembly (25).
2) Remove O-ring from lower body.
3) Remove snap ring (27), then disassemble

secondary valve assembly into washer (28)
O-ring retainer (29), O-rings (30 and 31) lower
valve spring (32), valve retainer (33), and lower
valve (34).
53-l 4
ASSEMBLY
1. Lower valve assembly

1) Set lower valve (34) with valve seat at bottom,
assemble valve retainer (33), lower valve spring
(32), O-ring retainer (29) and washer (28), then
secure with snap ring (27).
t Assemble O-rings (30 and 31) on the O-ring
retainer first.
,., ‘... ,, ,,,,,, ,,,,,

56OBP3-19
2) Assemble secondary valve assembly (25) in

lower body, then install exhaust cover (24).
2. Upper valve assembly

1) Set upper valve (23) with valve seat at bottom,
assemble valve retainer (22), upper valve spring
(21), O-ring retainer (18) and washer (17), then
t Assemble O-rings (19 and 20) on the O-ring
retainer first.
2) Assemble primary valve assembly (15) in upper

body, then secure with snap ring (14).
5608P37.5
53-15
3) Hold slot-head screwdriver @ in vice 0, as-

semble relay piston spring (1 l), relay piston
(12) and stem assembly (13) in bottom of upper
body, then set with screwdriver.
* Do not forget to fit an O-ring on the relay
piston.
4) Assemble return spring (lo), upper piston (9),

rubber spring (8), spring seat (7), 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.
*
A& The piston may fly out under the force of
4 the return spring, so hold the piston by
hand when assembling.
D Nut: OS&O.15 kgm 5608P375
3. Body assembly
1) Install O-ring (35) on lower body (3).
560BP380
2) Align match marks on upper body (2) and lower

body (3), assemble and tighten mounting bolts
(1).
53-16
DISASSEMBLY AND ASSEMBLY BRAKE CHAMBER
BRAKE CHAMBER
REMOVAL

Disconnect the cable from the negative (-)

A terminal of the battery.
1. Draining air
Loosen drain valve (1) and drain air from air tank.
2. Hydraulic piping, wiring (rear)

1) Remove washer tank (2A), then disconnect
wiring connector (2).
I I LljDV007
2) Disconnect hose (3) between slack adjuster and

brake chamber at brake chamber end.
PU4.2302018
3) Disconnect hose (4) between brake oil tank and

3. Air piping (rear)

Disconnect tube (5) between brake valve and brake
chamber at brake chamber end.
4. Brake chamber (rear)

Sling brake chamber (S), remove mounting bolts
(7) then lift off brake chamber.
t 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)

+ The front brake chamber is behind the rear
brake chamber, so remove the rear brake
chamber first, then repeat the same procedure
as in Steps 2 - 4 to remove the front brake
chamber.
A
423P990
53-18
1. Brake chamber (rear)

Set brake chamber (6) in mounting position, then
tighten mounting bolts (7).
+ 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. Air piping (rear)

Connect tube (5) between brake valve and brake
chamber at brake chamber end.
3. Hydraulic piping, wiring (rear)

1) Connect hose (4) between brake oil tank and
t Install front brake chamber hose without
bending and twisting, then install strap
securely.
2) Connect hose (3) between slack adjuster and

PU42302018
3) Connect wiring connector (2) then install

washer tank (2A).
4. Air check
1) Check for leakage of air from piping
connections.
2) Bleed air from brakes and check operation.
t For details of bleeding air, see SECTION
52, TESTING AND ADJUSTING.
5. Brake chamber (front)

Use the same procedure as for installing the front
brake chamber.
53-19
DISASSEMBLY
1. Accessories
Remove breather (I), bleeder (2) and sensor (3).
2. Cylinder
Loosen lock nut (4) then remove cylinder (5).
+ There is an O-ring fitted on the thread of the
cylinder, so remove it.
3. Piston assembly
1) Move retainer (6) to right, remove pin (7), then
remove piston assembly (8).
+ Use a guide pin (Thread dia. 2.5 mm,
length 50 mm) to remove pin.
423F446
2) Remove rod (9) then remove O-ring.
4. Disassembly of piston assembly

1) Remove snap ring (lo), then remove seat (ll),
spring (12) and valve (13).
1
+ Spring (12) is small, so be careful not to
lose it.
2) Remove packing (15) from piston (14).
423F447
4-
53-20
5. Body
Hold body (16) with hand, remove mounting bolt,
then remove body.
* The tension of the spring on the body is 25 kg,
so be careful when removing it.
* Remove the O-ring from the contact surfaces of
the body and air cylinder.
6. Disassembly of body
1) Remove snap ring (17) then remove ring (18),
packing (19), seat (20) and packing (21).
423F448
423P39S
2) Remove snap ring (22), then remove ring (23)

and seal (24).
7. Air piston
1) Remove spring (27) and piston assembly (26)
from air cylinder (25).
53-21
2) Remove nut, then remove piston (28) and rod

(2%.
3) Remove packing (30) and ring (31) from piston.
4) Remove O-ring (32) and washer (33) from rod.
53-22
ASSEMBLY
1. Assembly of piston assembly

1) Install washer (33) and O-ring (32) on rod (29).
+ When fitting the O-ring, wind tape around
the threads of the rod to prevent damage
to the O-ring.
& O-ring: Engine oil (SAE 1OW)
2) Assemble packing (30) and ring (31) on piston

(28).
& Packing: Grease (G2-Ll)
3) Insert rod (29) in mount of piston (28) then

secure with nut.
+ After tightening the nut, check that there is
no clearance between the stepped part of
the rod and the piston.
& Piston mounting hole: Grease (G2-Ll)
D Nut: 1422 kgm
53-23
2. Assembly of body
1) Install seal (24) and ring (23) in body (16), then
+ Install the seal with the lip facing the out-
side.
‘:
t Check that the snap ring is fitted securely :@
*3$:,@
in the groove. &,&
;@&<*>
Q Seal: Engine oil (SAE low)
2) Turn over body, assemble packing (21), seat

(20) and packing (19), inset-t ring (18), then
+ Install the seal with the lip facing the out-
side.
+ Check that the snap ring is fitted securely
in the groove.
& Packing: Engine oil (SAE low)
423F450
53-24
3. Piston assembly
Insert piston assembly (27) in air cylinder (25).
+ Coat inside of air cylinder with grease.
* When inserting the piston assembly, tilt at an
angle of about 30”, insert about l/3, then lay
the air cylinder on its side and insert the piston
fully.
t 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 (16) then install in air cylin-
der.
* Push in the body by hand, install 2 mounting
bolts in diametrically opposite positions, then
tighten together with bracket (35).
B Mounting bolt: 4.420.6 kgm
423P i 009
5. Assembly of piston
1) Insert valve (13) spring (12) and seat (11) in
piston (14), then secure with snap ring (10).
+ Be careful to insert the spring facing in the
correct direction.
+ Check that the snap ring fitted securely in
the groove.
__,_,, ,,,,,,
,,,,,,,,, ,,
2) Assemble packing (15) on piston.
+ Install the packing with the lip facing the
outside.
e Packing: Grease (G2-Ll)
53-25
6. Piston assembly
Blow air into air cylinder and blow out rod. Set
piston assembly (8) in mounting position, then
connect with pin (7).
t The pin hole is hidden by the retainer, so move
the retainer to the right and insert the pin.
t After inserting the pin, check that the retainer
has moved back to its original place and the
pin is hidden.
7. Cylinder
Install nut (4) and O-ring (36) on cylinder (5), screw
into mount, then secure with nut.
+ Screw the cylinder in fully, then turn back until
the breather and bleeder are in a straight line.
& ;;I surface of cylinder: Engine oil (SAE
a Nut: 14-3 kgm
8. Sensor
Fit O-rings on rod (9) and sensor (3) then install in
mounting position.
+ Insert the rod until it is level with the body.
D Sensor: 5620.6 kgm
9. Accessories
Install breather (1) and bleeder (2).
D Bleeder: 0.95?0.25 kgm
53-26
DISASSEMBLY AND ASSEMBLY SLACK ADJUSTER
SLACK ADJUSTER
REMOVAL

Brake piping
1) Disconnect tube (1) between slack adjuster and
brake chamber at slack adjuster end.
+ Hose (2) at rear.
2) Disconnect tube (3) between slack adjuster and
left and right brake pistons at slack adjuster
end.
Slack adjuster
Remove mounting bolts, then remove slack adjuster
(4).
+ There is little space, so be careful when work-
ing.
Front
INSTALLATION
1. Slack adjuster
Set slack adjuster (4) in mounting position, then
en fully after connecting the piping.
2. Brake piping
1) Connect tube (3) between slack adjuster and
left and right brake pistons at slack adjuster
end.
2) Connect tube (1) between slack adjuster and
brake chamber at slack adjuster end. Rear
* Hose (2) at rear.
3. Bleeding air
Bleed the air from brake system, then check that
there is no leakage of oil from connections.
+ For details of bleeding air, see SECTION 52,
t Bleed the air at the brake end and slack adjust-
er end.
53-27
DISASSEMBLY
1. Bleeder
Remove bleeder (2) from body (1).
2. Cylinder
Remove mounting bolts, then disconnect body (1)
and cylinder (4) together with bracket (3).
Y
AY There is spring tension inside the cylinder, so
hold the contact surfaces and be careful when
4
removing.
3. Piston
1) Remove spring (5) and O-ring (6).
2) Remove piston (7), then remove O-ring.
t 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 cover (8) from cylinder (4), then re-
move plug (9), spring (10) and poppet (11).
+ When removing the poppet, 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.
t Do not to change the combination of pop-
pet (11) and cylinder (4). If replacing the
poppet or the cylinder, replace the poppet
and cylinder as a set.
2) Remove O-ring (12) from poppet.
53-28
ASSEMBLY
1. Poppet
1) Fit O-ring (12) on poppet (11).
2) Install poppet (ll), spring (lo), plug (9) and
cover (8), then assemble cylinder (4).
2. Piston
1) Install O-ring (13) on piston (7).
2) Insert piston (7) in cylinder (4).
t Check that the piston moves smoothly.
3. Cylinder
1) Install O-ring (6) and spring (5) in cylinder.
* Installed load of spring: 4.4 kg
2) Install body (1) and cylinder (4) together with
bracket (3).
4. Bleeder
Install bleeder (2).
DISASSEMBLY AND ASSEMBLY BRAKE
BRAKE
DISASSEMBLY
Soecial tools
I Part number I Part name Q’ty
A I 790-425-l 620 I Fixture I 3
* I 790-425-l 630 I Fixture I 3
c 1 790-570-1010 I Push plate I 1
D I 790-425-l 640 I Eyebolt 1
a Stop the machine on level ground and install

Y
AY Loosen oil filler cap (1) slowly to release the
4 pressure inside the hydraulic tank, then operate
1. Brake chamber
Disconnect hose (2) between hydraulic tank and
brake chamber from brake chamber.
+ Remove the clamp and the band.
t The oil inside the hydraulic tank will flow out, so
catch the oil in an old oil container, and fit a
blind plug in the tip of the hose.
+ Inside diameter of hose: 4 14.3 mm
2. Tire, wheel
Jack up axle, put stand under axle, then lift off tire
and wheel (3).
Tire, wheel: 459 kg
53-30
3. Draining oil
assembly.
* Set with the drain plug at the bottom.
Axle assembly: 55 4
4. Cover
Remove cover (5), then remove O-ring (6).

Remove axle shaft assembly (7) from axle.
t Attach a hook to the gear when removing the
shaft.
6. Planetary carrier assembly

Remove 3 mounting bolts (8), then lift off planetary
carrier (9).
t Make match marks to act as a guide when
assembling.
t Be careful of the center of gravity, and remove
slowly.
Planetary carrier: 69 kg
Bolt (M20X2.51 Nut for wheel

1) Using tools A and B, hold wheel hub (10) and
brake (11) in position.
t Using washers, install tools A and B at
three equidistant points around the circum-
ference.
423FO1122
2) Remove mounting bolts of retainer (12), then

remove ring gear assembly (13).
+ There are shims between the retainer and
axle housing, so check the number and
thickness of the shims, and use for refer-
ence when installing.
Ring gear assembly: 36 kg
8. Brake, wheel hub assembly

1) Remove brake tube (14).
2) Sling brake and wheel hub assembly (15)
remove mounting bolts, then lift off assembly.
Brake and wheel hub assembly: 196 kg

(Width across flats of mounting bolt:
36 mm)
9. Axle housing
Remove bearing (17) and retainer (18) from axle
housing (16).
423P1032A
53-32
10. Piston
1) Set with wheel hub (20) at bottom, then remove
tools A and B.
2) Using forcing screw, lift off piston assembly
(21).
3) Remove O-ring (22) from piston assembly.
4) Using tool C, pull out pin (23) and remove rod

(24) and piston return spring (25) from piston
assembly. 423807112
+ Be careful not to lose the pin.
w F42101145
F42101146
5) Pump in air through brake oil filler (26) and

push out piston (27).
+ Hold one end of the piston by hand and
pump in the air slowly to prevent the piston
from flying out.
t Be careful not to damage the piston.
421PO1103
6) Remove oil seals (28 and 29) from piston (27).
27
421POt 104
11. Discs, plates

1) Remove O-ring (31) from outer gear (30).
2) Remove plates (32) and discs (33) from outer
gear in order, then remove spacer (34).
+ When removing the disc, make match
marks on the inner gear and disc, outer
gear and plate and spacer.
+ The plates are made of a soft material, so
be careful not to damage them when re-
moving.
421Po1:05
12. Outer gear

Using tool D, lift off outer gear (30) from wheel hub
(37), and remove seal ring (35) and O-ring (36).
Outer gear: 36 kg
_
42lFOO3
42 I FO05
3/5 421FOO4
53-34
13. inner gear

Remove mounting bolts, then remove inner gear
(38) from wheel hub (37).
14. Wheel hub

1) Remove seal ring (39) and O-ring (40) from
wheel hub (37).
42TPO1107
2) Remove bearing caps (41 and 42) from wheel

hub (37).
53-35
ASSEMBLY
Soecial tools
I Part number I Part name I Q’W
A I 793-520-2680 I Installer I 1
B 790-425-l 640 Eyebolt 1
C 793-570-l 010 Push plate 1
D 790-425-l 620 Fixture 3
E 790-425-l 630 Fixture 3
1. Wheel hub
1) Press fit bearing cups (41 and 42) on wheel
hub (37).
2) Install O-ring (40) to seal ring (39), then using
tool A, assemble to wheel hub.
t Remove all the white powder bloom from
the surface of the O-ring with alcohol.
t Remove all the grease from the O-ring
mating surface of the wheel hub and seal ‘423P7549A‘
ring.
+ Push tool A in uniformly to prevent the

O-ring of the seal ring from twisting, mea-
sure height “t” at four places around the
circumference after press fitting, and check
that the difference in dimensions is within 1
mm.
42
2. Inner gear
Install inner gear (38) on wheel hub (37).
& Mounting bolt: 28.523.0 kgm
53-36
3. Outer gear
1) Install O-ring (36) to seal ring (35) then using
tool A, assemble to outer gear (30).
* Remove all the white powder bloom from
the surface of the O-ring with alcohol.
t Remove all the grease from the O-ring
meeting surface of the outer gear and seal
ring.
* Push tool A in uniformly to prevent the
O-ring of the seal ring from twisting, mea-
sure height ‘4” at four places around the ‘,
circumference after press fitting, and check ‘423P10498
that the difference in dimensions is within 1

mm.
1 I 423F455
2) Using tool B, assemble outer gear (30) to wheel

hub (37).
t When assembling, check that there are no
scratches or other damage on the seal ring
mating surface.
+ Check that the seal ring is not assembled
at an angle.
Q Seal ring mating surface: Axle oil
421PO1111
42 I FO07
42 I FOO9
4. Discs, plates
1) Align match marks of outer gear (30) and
spacer (34) and plate (32), and disc (33) and
inner gear, then assemble the plates and discs
in turn.
+ Set with the chamfered side of the spacer
facing down.
* The final plate must be fitted securely on
the spline of the outer gear.
t Soak the discs in brake oil for at least 30
minutes before assembling.
t Align the match marks of the discs and
inner gear when assembling.
‘34 42 I FO03
2) Fit O-ring (31) on outer gear (30). -32
-33
-30
421PC 11105
5. Piston, cylinder
1) Assemble seals (28 and 29) on piston (27).
+ Fit the seal securely in the groove.
& Seal: Brake oil
421PO1104
2) Press fit piston (27) in cylinder (43).

+ When press fitting the piston, hit it with a
plastic hammer. Do not use a steel or
copper hammer.
* Coat the press fitting portion of the piston
assembly and the outside circumference of
the piston with brake oil.
& Sliding surface of piston: Brake oil
421PO1102
53-38
3) Using tool C, insert return spring (25) and rod

(24) in cylinder assembly, and lock with pin
(23).
F42101145 F42101146
4) Fit O-ring (22) on cylinder assembly.
5) Using eyebolts, install cylinder assembly (21).
w Mounting bolt: 18+2 kgm
6) Set wheel hub (20) facing down, then using

tools D and E, tighten uniformly until dimension
is clearance “a”.
Clearance “a”: Approx. 2.4 - 8.6 mm
+ Install tools D and E at three equidistant

points around the circumference.
Bolt (M20X2.5)
Nut for wheel
421FOO8 asher for wheel 423FO1122
53-39
DISIASSEMBLY AND ASSEMBLY BRAKE
6. Axle housing
Press fit retainer (18) and bearing (17) on axle
housing (16).
+ After press fitting the retainer, and bearing onto
housing, check that there is no clearance at
any point.
7. Brake, wheel hub

1) Raise brake and wheel hub (15), set in position
on axle housing mount, then tighten mounting
bolts.
+ Be careful of the center of gravity, and raise
horizontally.
t Do not force into position because the
O-ring will be twisted. Align the centers and
install slowly.
6 Mounting bolt: Thread tightener (LT-2)
D Mounting bolt: 94.5 + 10.0 kgm

(Width across flats of mounting bolt:
36 mm)
2) install brake tube (14).

1) Raise ring gear assembly (13) set in mounting
position, and insert in axle housing.
+ Align the spline groove and insert the as-
sembly slowly.
53-40
2) Tighten retainer (12) temporarily with 3 bolts,

then remove tools D and E.
+ Remove all grease and oil from the bolt
hole of the retainer mount.
+ Do not insert shims in the retainer when
tightening temporarily.
+ Rotate the wheel hub to settle the bearing,
then tighten to a uniform torque.
D Mounting bolt of retainer: 3.0 kgm
3) Insert a depth micrometer through measuring

hole of retainer (12), and measure clearance “a”
between end face of housing and end face of
retainer.
t Measure at 2 places and take the average.
* Shim thickness is clearance “a” + 0.3 mm.
t Use the smallest number of shims which
gives the required thickness.
t Be careful that the total shim thickness is
no more than “a” + 0.3 mm.
t Shim thickness: 1.0, 0.3, 0.2, 0.05 mm.
423F456
4) Install tools D and E to brake assembly and

wheel hub, and remove retainer. Install required
thickness of shims, then install retainer again.
+ Always install tools D and E before assem-
bling the shims.
+ Rotate the wheel hub and tighten the
mounting bolts uniformly to the specified
tightening torque.
D Mounting bolt: 18?2 kgm
9. Planet carrier assembly

Fit O-ring (1OA) to wheel hub (IO), raise planet
carrier assembly (9), set in mounting position, then
install.
+ Align mounting holes and install carefully so
that the O-ring does not slip out of place.

Install axle shaft assembly (7).
t If the position of the sun gear does not match,
rotate the wheel hub to align.
11. Cover
Fit O-ring (6) in groove in cover, then install cover
(6).
D Mounting bolt: 11.5+ 1.O kgm

1) Tighten drain plug and add oil through level
plug (44) to the specified level.
t Set the machine so that the level plug of
the final drive is at the bottom when refilling
with oil.
Q Axle assembly: 55 P
2) Connect hose between hydraulic tank and

brake chamber, then add hydraulic oil through
oil filler (1) to the specified level.
53-42
13. Tire, wheel

Install tire and wheel (3), then remove stand.
1 Mounting nut: 48-r-5 kgm

5
(Width across flats: 30 mm)
14. Checking for leakage of brake oil

After completing all operations, check for leakage of
brake oil.
t For details, see SECTION 52, TESTING AND
ADJUSTING.
53-43
DISASSEMBLY AND ASSEMBLY SPRING CYLINDER
SPRING CYLINDER
REMOVAL

t Check again that the wheels have been blocked

properly, then turn the starting switch to ON,
and release the parking brake.
1. Cover
1) Raise lift arm, then place a support under the
lift arm.
2) Remove cover (1) at front of front frame.
2. Linkage
Disconnect ball joint (2) of parking brake linkage.
+ The ball joint can not be disconnected if the
parking brake is applied.
3. Air piping
Disconnect air piping (3) of spring cylinder.
t Drain the air.
* After removing, cover to prevent dust or dirt
from entering.
4. Spring cylinder
Remove mounting nut, then remove spring cylinder
(4).
53-44
INSTALLATION
1. Spring cylinder
Set spring cylinder (4) in mounting position, and
install.
D Mounting nut: 28.5-1-3.0 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 of adjusting the linkage, see SEC-
TION 52, TESTING AND ADJUSTING.
* Check the operation of the parking brake.
D Mounting nut: 11.5?1.0 kgm
4. Cover
1) Install cover (1) at front of front frame.
2) Remove support.
53-45
DISASSEMBLY
2
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.
,423P FO73:
4. Rod
Remove lock nut (5) and mounting nut (6) of boot,
then remove rod (7).
53-46
5. Spring and support

Using a press, remove mounting bolt of support (8),
then remove spring (9).
ti
AIt When the pressure of the press is released,
4 there is danger that the spring may fly out, so
release the press slowly.
6. Piston
1) Remove piston (11) from cylinder (10).
2) Remove wiper ring (12) and seal (13) from

piston.
7. Cylinder
Remove bushing (14) and seal (15) from cylinder.
ASSEMBLY
1. Cylinder
install bushing (14) and seal (15) in cylinder (10).
2. Piston
1) Install wiper ring (12) and seal (13) on piston
(11).
+ Use a new part for the wiper ring and seal,
and soak in oil before installing.
e Wiper ring: Engine oil (SAE low)
2) Assemble piston (11) in cylinder (10).
a Piston seal, inside of seal and bushing,

sliding surface of piston and cylinder:
Silicon grease
3. Spring, support
Using a press, assemble spring (9) and support (8)
then tighten mounting bolt.
+ Align the mounting bolt holes correctly.
* Installed load of spring: 310 kg
YII& Tighten the mounting bolt fully before removing

4 the press.
53-48
4. Rod
1) Install flange nuts (16 and 17) and lock nuts (18
and 19).
+ Tighten the flange nut partially.
t Installed distance LJ of lock nut: 55 mm
w Lock nut: 5+ 1 kgm
2) Install flange nuts (16 and 17) to give installed

distance L2.
* Installed distance Ls of flange nut: 100 mm
D Flange nut: 5+1 kgm
3) install boot to rod, then install nut (6) and lock

nut (5) to give specified clearance “a”.
Clearance “a”: 1.6-2.6 mm
t After installing, check that clearance “a” is

correct.
D Mounting nut of boot, lock nut: 5? 1 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 (2) and boot (1).
DISASSEMBLY AND ASSEMBLY PARKING BRAKE
PARKING BRAKE
REMOVAL

t Turn the starting switch ON and release the parking

brake.
I. Linkage
Disconnect parking brake lever (1) and linkage (2).
424P793
2. Drive shaft
Disconnect front drive shaft (3) from differential.
3. Caliper assembly
Remove mounting bolts (4) then remove caliper
assembly (5).
53-50
4. Disc
1) Drain axle oil.
Axle oil: 55 P
2) Remove mounting bolt (6) of coupling, then

remove coupling and disc assembly (7), retain-
er (8) and O-ring (9).
Coupling and disc assembly: 25 kg
3) Remove disc (11) from coupling (10).
424F133
5. Disassembly of caliper
1) Remove pad pin clips (12 and 13).
2) Remove pad pins (14 and 15).
3) Remove pads (16 and 17) from caliper.
INSTALLATION
1. Assembly of caliper
1) Set pads (16 and 17) on caliper mount.
2) Align holes of pads (16 and 17) with caliper,

then install pad pins (14 and 15).
3) Assemble pad pin clips (12 and 13).
+ Assemble the clips securely in the pin
holes.
2. Disc
1) Install disc (11) to coupling (10).
+ Clean the mounting surface, align correctly
with pilot and then assemble so that there
is no gap at the join.
D Mounting bolt: 1822 kgm
2) Align differential pinion shaft with spline, then

assemble coupling and disc assembly (7). Fit
O-ring (9) in groove, then install retainer (8) and
mounting bolts (6).
+ Install so that it faces in the same direction
as the coupling of the. drive shaft.
a Mounting bolt: 94.5k10.5 kgm
53-52
3. Caliper assembly
Set caliper assembly (5) in mounting position, then
tighten mounting bolt (4).
z Mounting bolt: 2823 kgm

5
4. Drive shaft
Connect front drive shaft (3) at differential end.
D Mounting bolt: 11.5? 1.O kgm
5. Linkage
Connect parking brake lever (1) and linkage (2).
a Mounting bolt: 5.5+0.5 kgm
4 24P805

Tighten drain plug and add oil through plugs (18
and 19) to the specified level.
+ Stop with the drain plug at the bottom when
adding oil.
Q Axle assembly: 55 0
t For details of adjusting the clearance between

the disc and pad, see TESTING AND ADJUST-
ING.
DISASSEMBLY AND ASSEMBLY PARKING BRAKE PAD
PARKING BRAKE PAD

REMOVAL

t Check that the blocks are set properly

under the wheels.
1. Cover
1) Raise lift arm, then place support under the lift
arm.
2) Remove cover (1) at front of frame.
2. Linkage
Remove lock nut (2) then disconnect parking brake
lever (3) and linkage (4).
+ Before disconnecting the linkage, turn the
starting switch to ON and release the parking
brake.
3. Pads
1) Remove pad pin clips (5 and 6).
2) Remove pad pins (7 and 8).
3) Remove pads (IO and 11) from caliper (9).
DISASSEMBLY AND ASSEMBLY PARKING BRAKE PAD
INSTALLATION
1. Pads
1) Set pads (IO and 11) on mount of caliper (9).
2) Align holes of caliper and pads (10 and 1I),
then install pad pins (7 and 8).
3) Assemble pad pin clips (5 and 6).

t Assemble the clips securely in the pin
holes.
2. Linkage
1) Connect parking brake lever (3) and linkage (4).
2) Remove support, then install cover (1) at front
of front frame.
3. Adjusting linkage
+ For details of adjusting the disc and pad clear-
ance, see SECTION 52, TESTING AND
ADJUSTING.
+ After adjusting, tighten lock nut (12).
BRAKE VALVE . . . . ..... ....................... ....... ..... ..... ....... 2
BRAKE CHAMBER . ........................ ...... ...... .... ....... 4
SLACK ADJUSTER . .. .................... ...... .. .... .... ......... 5
BRAKE ......... .............. ............ ...... ...... ...... ... 6
PARKING BRAKE . . .............. ............ ...... .... ....... .... 8
SPRING CYLINDER .... ........... ..... ........... ..... ...... ...... .. 10
54-I
MAINTENANCE STANDARD BRAKE VALVE
BRAKE VALVE
423F222
54-2
MAINTENANCE STANDARD BRAKE VALVE
BRAKE VALVE
Unit: mm
1 Clearance between pedal

mounting pin and mount plate
2 Clearance between roller and

pin
3 Clearance between mount

plate and plunger
4 Clearance between primary

piston and upper body
Clearance between relay piston

and lower body
Outside diameter of roller
Free height of rubber spring
Piston return spring
Primary valve spring
10 Inner stem spring 35.6 16.8 2.8 30
11 Outer stem spring 41 .o 16.0 4.0 34
12 Relay piston spring 39.5 12.1 4.7 33
13 Secondary valve spring 16.5 10.2 3.0 14
14 Tightening torque of nut .55?.15 kgm Retighten
54-3
MAINTENANCE STANDARD BRAKE CHAMBER
BRAKE CHAMBER
L04AM003
Ilnit. mm
Clearance between cylinder
Clearance diameter of oil
69.2-75.2 (Normal pressure: Max. 9.5 kn/cm2)
4 Tightening torque of nut 14t-2 kgm

I I Retiahten
5 1 Tightening torque of nut 4.4k.6 kgm
54-4
MAINTENANCE STANDARD SLACK ADJUSTER
SLACK ADJUSTER
5
\
423F224
Unit: mm
4 Tightening torque of bolt 6.7k.7 kgm Retighten
5 Tightening torque of plug 5.7k.7 kgm
54-5
BRAKE
BRAKE
m 28 5+3 Okqm
m 18+2kgm 1
1 \ /
\
\ !I
-94 5k10 5kgm
424F3 I4
54-6
MAINTENANCE STANDARD BRAKE
BRAKE
Unit: mm
Free installation Installation Free Installation

length length load length load
Return spring
75.6 66.2 58 kg 74.7 52.2 kg

Thickness of plate
2.3k.08 2
3 Thickness of disc 3.8k.l 3.5 Replace
4 Total thickness of plate and disc 32.82.98 24.3
+ .097
Wear of surface in contact with piston seal 420
0
+ .089
Wear of surface in contact with piston seal 383
0
7 Backlash between outer gear and plate .21 - .65
8 Backlash between inner gear and disc .31 - .74
54-7
MAINTENANCE STANDARD BRAKE
PARKING BRAKE
Unit: mm
I I I
Wear of pad Standard size Repair limit

(remaining thickness of friction material)
10 2 Replace
1
(including backing plate) 16 a
2 Face runout of disc .25 .5

Rebuild
Thickness of plate must be
Wear of disc iak.2 under 17 mm
3
(thickness of disc plate)
Less than 17 mm Replace
4 Clearance between pad and disc .33 - .66 Adjust
5 1 Tightening torque of nut I 5.5k.5 kgm

I Retighten
6&7 1 Tightening torque of bolt 45?5 kgm I
54-8
This page is blank.
54-9
MAINTENANCE STANDARD SPRING CYLINDER
SPRING CYLINDER
I
II 6
423F2278
54-10
MAINTENANCE STANDARD SPRING CYLINDER
SPRING CYLINDER
- Unit: mm
Tolerance
Standard L Standard Clearance
size Shaft Hole size limit
1 Clearance between cylinder and

Hole: 159
piston
Shaft
156.65
Replace
0.8
2 Clearance between piston insert Hole: 38.8
and center boss Shaft: 38
Standard size Reoair limit
3 Piston spring
4 Play of rod in axial direction 1.6-2.6

Adjust
5 Installed dimension of rod 225
6 Tightening torque of rod, lock nut 5+1 kgm Retighten
7 Setting dimension of lock nut 55-58 Adjust
8 Tightening torque of mounting bolt 1.42.4 kam Retiahten

B -
54-11
This page is blank.
54-12
WORK EQUIPMENT SYSTEM
HYDRAULICPIPING .. .................. ...... .. ............ .... ...... ... ... .......... 2
HYDRAULIC CIRCUIT DIAGRAM ......................................................... 3

FORP-SPOOL ................................................................... 3
FOR3-SPOOL ................................................................... 4
FOR 3-SPOOL, WITH GROUND DRIVEN STEERING AND SECURITY VALVE ..................... 5
BUCKET LINKAGE ...... ............................. ........ ...... .... .... ...... .... 6
BUCKET POSITIONER AND

BOOM KICK-OUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
HYDRAULICTANK.. ...................
OIL FILTER BYPASS VALVE ...........
BREATHER ....................... .............. ....... ...... .... .... ...... ... 12
HYDRAULICPUMP ..... .............................. ....... ....... .... ... ...... .... 13
MAIN CONTROL VALVE ............... ................... 14

FOR 2-SPOOL ................... ................... 14
FOR 3-SPOOL ................... ................... 16
RELIEFVALVE ................... ................... 24
SAFETY VALVE (WITH SUCTION VALVE) ................... 25
SUCTION VALVE ................. ................... 26
HYDRAULIC CYLINDER ............... ............................................ 27

LIFT CYLINDER .................. ............................................ 27
DUMP CYLINDER ................. ............................................ 28
61-l
STRUCTURE AND FUNCTION HYDRAULIC PIPING
HYDRAULIC PIPING
Outline
The work equipment system consists of the hydrau-
lic circuit and steering circuit. The hydraulic circuit
controls the operation of the bucket and attach-
ment.
The oil in the hydraulic tank (3) is sent by hydraulic
and switch and steering pump (4) to main control
valve (5). When the dump and lift spools of the
main control valve are at neutral, the oil passes
through the drain circuit of the main control valve.
It is then filtered by the filter in the hydraulic tank,
and returns to the tank.
When the levers are operated, the dump spool or lift
spool in the main control valve moves, and oil flows
from the main control valve to lift cylinder (6) or
dump cylinder (1). The lift arm or bucket then
moves.
The maximum pressure of the hydraulic circuit is
regulated by the relief valve inside the main control
valve. There is a safety valve (with suction valve) in
the dump cylinder circuit to protect the circuit.
Hydraulic tank (3) is a pressurized, sealed type and
has a breather with a relief valve. This acts to
pressurize the tank and at the same time prevents
negative pressure. This protects the pump from
cavitation.
61-2
STRUCTURE AND FUNCTION HYDRAULIC CIRCUIT DIAGRAM
HYDRA LlLlC CIRCUIT DIAGRAM

FOR 2-S ‘OOL
F42301108B
1. Hydraulic tank 5C. Relief valve

2. Gear pump 5D. Safety valve (With suction)
(SAR(3)-80+63+50+(l)-12) 6. Lift cylinder
3. Steering valve 7. Dump cylinder
3A. Steering spool 8. Oil cooler
3B. Flow control spool 9. Oil filter
3C. Safety valve (With suction) 10. Breather
3D. Relief valve 11. Relief valve
4. Steering cylinder 12. Orbit-roll valve
5. Main control valve 13. Stop valve
5A. Lift spool
58. Dump spool
61-3
FOR &SPOOL
Pa
8
. <
F423011128
1. Hydraulic tank 5D. Relief valve

2. Gear pump 5E. Safety valve (With suction)
(SAR(3)-80+63+50+(l)-12) 5F. Safety valve (With suction)
3. Steering valve 6. Lift cylinder
3A. Steering spool 7. Dump cylinder
38. Flow control spool 8. Oil cooler
3C. Safety valve (With suction) 9. Oil filter
3D. Relief valve 10. Breather
4. Steering cylinder 11. Relief valve
5. Main control valve 12. Orbit-roll valve
5A. Lift spool 13. Stop valve
58. Dump spool 14. Attachment spool
5C. Attachment spool
61-4
FOR 3-SPOOL, WITH GROUND DRIVEN STEERING AND SECURITY VALVE
Pa
14
f
1 I I ‘i
F42301113B
1. Hydraulic tank 5E. Safety valve (With suction)

2. Gear pump 5F. Safety valve (With suction)
(SAR(3)-80+63+50+(l)-12) 6. Lift cylinder
3. Steering valve 7. Dump cylinder
3A. Steering spool 8. Oil cooler
3B. Flow control spool 9. Oil filter
3C. Safety valve (With suction) 10. Breather
3D. Relief valve 11. Relief valve
4. Steering cylinder 12. Orbit-roll valve
5. Main control valve 13. Stop valve
5A. Lift spool 14. Attachment spool
58. Dump spool 15. Ground driven steering pump
5C. Attachment spool 16. Diverter valve
5D. Relief valve 17. Security valve
61-5
BUCKET LINKAGE
BUCKET LINKAGE
1. Tilt lever
2. Dump cylinder
3. Lift cylinder
4. Lift arm
5. Bucket link
6. Bucket
424F311A
61-6
STRUCTURE AND FUNCTION BUCKET LINKAGE
Section D-D Section E-E Section F-F
Section G-G Section H-H Section J-J
424F3 I2
61-7
STRUCTURE AND FUNCTION BUCKET POSITIONER AND BOOM KICK-OUT
BUCKET POSITIONER AND

BOOM KICK-OUT
1. Proximity switch
2. Plate
3. Lever
4. Cylinder
5. Proximity switch
Section A-A
423F627
61-8
STRUCTURE AND FUNCTION BUCKET POSITIONER AND BOOM KICK-OUT
Bucket positioner
The bucket positioner is electrically actuated and is
used to automatically obtain the optimum digging
angle for the bucket.
When the bucket is moved from the DUMP position
to the TILT position, and it reaches the desired
angle, the dump lever is automatically moved from
the TILT position to the neutral.
Lever (3) is secured by bolts to dump cylinder rod.
A contact switch is fixed by bolts to the cylinder.
When the bucket is moved from the DUMP position
to the TILT position, the dump cylinder rod moves
to the left. At the same time, lever (3) also moves to
the left. When it reaches the desired position, lever
(3) separates from proximity switch (5), and the
bucket lever returns to neutral.
Boom kick-out
l The boom kick-out is electrically operated and acts
to stop the lift arm. When the lift arm reaches the
desired position before the maximum height, the lift
arm lever is returned to neutral.
l Plate (2) is secured to the lift arm. A contact switch
(1) is fixed to the frame. When the lift arm is moved
from the LOWER position to the RAISE position, the
lift arm rises. When it reaches the desired position,
the contact switch and lever come into contact and
the lift arm lever is returned to neutral.
61-9
STRUCTURE AND FUNCTION HYDRAULIC TANK
HYDRAULIC TANK
Outline
l The oil from the hydraulic tank is sent from the l The oil filter (2) filters all the oil in the circuit. If the
pump through the control valve to the cylinders. In oil filter (2) becomes clogged, a bypass valve (1)
the return circuit, the oil from various parts merges. acts to allow the oil to return directly to the tank (4).
Some of the oil is cooled in the oil cooler, passes This prevents damage to the filter (2). The bypass
through the oil filter (2) and returns to the tank (4). valve (1) is also actuated when negative pressure is
generated in the circuit.
Section A-A
423F6 IS
1. Bypass valve
2. Oil filter
3. Breather
4. Hydraulic tank
5. Oil level sight gauge
6. Drain valve
61-10
OIL FILTER BYPASS VALVE
When the filter is clogged

Bypass valve (1) opens and the oil returns directly to
the tank without passing through the filter.
Bypass valve set pressure: 1.27 kg/cm2
423F131
When negative pressure is formed in the return

circuit
Valve (2) moves up and acts as a check valve.
Check valve set pressure: 0.26 kg/cm2
_ To ma,"
Controlvalve
/)
423F132
61-11
BREATHER 1
Preventing negative pressure inside the tank

The tank is a pressurized, sealed type, so negative
pressure is formed inside the hydraulic tank when the oil
level drops during operations. When this happens, the
difference in pressure between the tank and the outside
atmospheric pressure opens the poppet (3), and air
from the outside is let into the tank to prevent negative
pressure.
(Set pressure: 0.03 kg/cm* max.)
Preventing rise in pressure inside the tank

When the hydraulic cylinders are being used, the oil
level in the hydraulic circuit changes and the tempera-
ture rises. If the hydraulic pressure rises above the set
pressure, the breather is actuated to release the hydrau-
lic pressure inside the tank.
(Set pressure: 1.4 kg/cm2)
1. Body
2. Filter element
3. Poppet
4. Sleeve
61-12
STRUCTURE AND FUNCTION HYDRAULIC PUMP
HYDRAULIC PUMP
HYDRAULIC, SWITCH, STEERING AND STEERING PILOT PUMP
(SAR(3)-80+63+50+(l)-12)
Section A-A
F42301109
Specifications
1. Hydraulic pump drive gear (Teeth 12) Hydraulic pump
2. Front cover Model SAR(3)-80
3. Gear case Theoretical discharge 80 cc/rev
4. Switch pump drive gear (Teeth 12) Max. pressure 210 kg/cm2
5. Gear case Max. pump speed 2,500 rpm
6. Steering pump drive gear (Teeth 12)
7. Gear case Switch pump
8. Pilot pump drive gear (Teeth 12) Model SAR(3)-63
9. Gear case Theoretical discharge 63.1 cc/rev
10. Rear cover Max. pressure 210 kg/cm2
11. Driven gear (Teeth 12) Max. pump speed 2,500 rpm
12. Driven gear (Teeth 12)
13. Driven gear (Teeth 12) Steering pump
14. Driven gear (Teeth 12) Model SAR(3)-50
Theoretical discharge 49.8 cc/rev
Max. pressure 210 kg/cm2
Max. pump speed 2,500 rpm
Steering pilot pump

Model SAR(l)-12
Theoretical discharge 12.5 cc/rev
Max. pressure 30 kg/cm’
Max. pump speed 2,500 rpm
61-13
STRUCTURE AND FUNCTION MAIN CONTROL VALVE
MAIN CONTROL VALVE

FOR P-SPOOL
Section X-X
Section Y-Y
423F135
1. Dump spool A. Pump port

2. Main relief valve B. To dump cylinder rod side
3. Body C. To lift cylinder rod side
4. Lift spool D. Drain port
5. Safety valve (With suction) E. To lift cylinder bottom side
6. Safety valve (With suction) F. To dump cylinder bottom side
7. Check valve G. Drain port
H. Drain port
61-14
Section U-U
Section W-W
Section Z-Z
Section V-V
423F136
Outline
l The main control valve controls the actuation of the However, the circuit gives priority to the bucket, so
attachments and the bucket in the hydraulic system. when the dump spool is being operated, even if the
It has a tandem circuit which gives priority to the lift spool is operated, the lift arm will not move.
bucket circuit. l There are two safety valves (with suction valves) (5
l The oil from the pump enters port A. The maximum and 6) to protect the circuit if abnormal pressure is
pressure is set by the relief valve. The oil passes generated in the bucket circuit. If one of the two
through the bypass circuit of dump spool (1) and lift safety valves is acting as a relief valve, the other
spool (4). It then flows from port D to the drain valve acts as a suction valve to make up for any
circuit, passes through the filter and returns to the lack of oil.
tank. If the dump and lift spools are actuated, the oil
flows to the dump and lift cylinders.
61-15
FOR 3-SPOOL
Section F-F
Section D-D
F424CO119
1. Check valve 6. Spool a. From steering valve

2. Suction valve 7. Spool return spring b. To attachment cylinder
3. Main relief valve 8. Valve body c. To dump cylinder
4. Spool 9. Safety valve (With suction) d. To lift cylinder
5. Spool e. To hydraulic tank
f. To lift cylinder
g. To dump cylinder
h. To attachment cylinder
61-16
1
Section C-C
5-
4-
Section A-A
Section E-E Section B-B F424CO120
Outline
l The main control valve controls the actuation of the However, the circuit gives priority to the attachment
attachments and the buckets in the hydraulic and the bucket, so when the dump spools are
system. It has a tandem circuit which gives priority being operated, even if the lift spool is operated, the
to the attachment and the bucket circuit. lift arm will not move. The attachment and the dump
l The oil from the pump enters port “a”. The maxi- spools can be operated at the same time.
mum pressure is set by the relief valve. the oil There are two safety valves (with suction valves) (9)
passes through the bypass circuit of attachment to protect the circuit if abnormal pressure is gener-
spool (4) and dump spool (5) and lift spool (6). It ated in the attachment and the bucket circuit. If one
then flows from port “e” to the drain circuit, passes of the two safety valves is acting as a relief valve,
through the filter and returns to the tank. If the the other valve acts as a suction valve to make up
attachment, dump and lift spools are actuated, the any lack of oil.
oil flows to the dump and lift cylinders.
61-17
LIFT AND DUMP SPOOLS AT “NEUTRAL POSITION”
@I Hydraulic tank
Ll OAT!024
Operation
l The oil flows from pump (1) through the steering The lift spool (3) is also at neutral, so the bypass
valve and enters port A. circuit is open. The oil from port B passes around
l Dump spool (2) is at neutral, so the bypass circuit the spool, flows from the drain circuit through the
is open and the oil from port A passes around the filter, and goes back to the tank.
spool and flows to port B.
61-18
LIFT SPOOL AT “RAISE POSITION”
LlOAZ025
Operation
l When lift control lever (4) is pulled, lift spool (3) is l At the same time, the oil from the cylinder rod end
pushed into the RAISE position. flows from port E to drain port F and returns
l The oil flows from pump (1) through the steering through the filter to the tank. When this happens,
valve and enters port A. It then passes through the the lift arm goes up.
bypass circuit of dump spool (2) and flows to the
bypass circuit of lift spool (3). The bypass circuit is
closed by dump spool (2) so the oil pushes open
check valve (5). The oil from check valve (5) flows
to port D and enters the cylinder bottom.
61-19
STRUCTUREANDFUNCTION MAIN CONTROL VALVE
LIFT SPOOL AT “LOWER POSITION”
Ll OAZ026
Operation
l When lift control lever (4) is pushed, lift spool (3) is The oil then flows from check valve (5) to port E
pulled out to the LOWER position. and enters the rod end of cylinder.
l The oil flows from pump (1) through the steering l At the same time, the oil from the cylinder bottom
valve and enters port A. It then passes through the flows from port D and enters drain port F. It then
bypass circuit of dump spool (2) and flows to the passes through the filter and returns to the tank.
bypass circuit of lift spool (3). The bypass circuit is When this happens, the lift arm goes down.
closed by lift spool (3) so the oil pushes open
check valve (5).
61-20
LIFT SPOOL AT “FLOAT POSITION”
Float
4 -
Ll OAZ027
Operation
l When lift control lever (4) is pushed down further In addition, RAISE circuit D and LOWER circuit E of
from the LOWER position, lift spool (3) is pulled into the lift cylinder are connected to the drain circuit, so
the FLOAT position. the lift arm goes down under its own weight.
l The oil flows from pump (1) through the steering l When the bucket is in contact with the ground, it
valve and enters port A. It then flows around the can move up and down in accordance with the
bypass circuit of dump spool (2) to the lift spool shape of the ground.
bypass circuit. The oil in the bypass circuit flows to
the drain circuit because of the spool, but it cannot
push open check valve (5).
61-21
DUMP SPOOL AT “TILT BACK POSITION”
Ll OAZ028
Operation
l When dump lever (6) is pulled, dump spool (2) is 0 At the same time, the oil at the cylinder rod end
pushed into the TILT position. flows from port H to drain port F. It then passes
l The bypass circuit is closed by dump spool (2) so through the filter, and flows back to the tank. When
oil from port A pushes open check valve (7). The oil this happens, the bucket tilts.
from port A flows from check valve (7) through port
G to the cylinder bottom.
61-22
DUMP SPOOL AT “DUMP”
I Hydraulic tank
Ll OAZ029
Operation
l When the dump lever (6) is pushed, dump spool (2) 0 At the same time, the oil at the cylinder bottom end
is pushed into the DUMP position. flows from port G to drain port F and then returns
l The bypass circuit is closed by the dump spool (6), to the tank. As a result, the bucket is dumped.
so the oil front oar-t A oushes LID check valve (7).
The oil from port’ A flows from pok D into the spddl.
It then flows from port H to the cylinder rod end.
61-23
RELIEF VALVE
1. Main valve
2. Valve seat
3. Pilot poppet
4. Pilot poppet spring
5. Adjustment screw
423F137
Function
o The relief valve is installed at the inlet of the main
control valve. When the oil goes above the set
pressure, the relief valve drains the oil to the tank.
In this way, it sets the maximum pressure in the
hydraulic circuit and protects the circuit.
56OBFO70
Operation
Port A is connected to the pump circuit and port C
is connected to the drain circuit. The oil passes
through the orifice of main valve (1) and flows to
port B. Pilot poppet (3) is in close contact with
valve seat (2).
When the hydraulic pressure in the circuit inside
port A and port B reaches the set pressure of the
pilot poppet spring (4) pilot poppet (3) opens, and
the pressurized oil from port B flows from port D to
port C, so the pressure at port B drops.
56OBFO71
1
When the pressure at port B drops, the orifice effect
of main valve (1) generates a difference in pressure
between port A and port B. The main valve is
pushed open and the oil from port A passes
through port C and flows to the drain circuit to
release the abnormal pressure.
The set pressure can be varied by changing the
tension of pilot poppet spring (4). To change the set
pressure, remove cap nut, loosen lock nut and turn
adjustment screw (5) as follows.
5606FO72
61-24
SAFETY VALVE (WITH SUCTION VALVE)
1. Valve body
2. Suction valve
3. Main valve
4. Main valve spring
5. Pilot piston
6. Suction valve spring
423F138
Function
l The safety valve (with suction valve) is in the dump
cylinder circuit in the main valve. If shock causes
any abnormally high pressure in the cylinder when
the main valve is at neutral, the safety valve (with
suction valve) releases the abnormal pressure and
protects the cylinder from damage.
Operation
As a safety valve
Port A is the cylinder circuit and port B is the drain
circuit.
The oil pressure in port A flows to port D through a
hole in the pilot piston. It also flows to port C
through an orifice consisting of the main valve (3)
and the pilot piston (5).
The pilot piston is secured to the safety valve by a
lock nut. The diameter of the cross section (cross-
sectional area) gives a relationship of d, > d, > d,
> d,.
If abnormally high oil pressure occurs in port A, the
suction valve (2) is not actuated because of the
relationship d, > d,.
However, because of the relationship d, > d, in
ports A and C, the hydraulic pressure on the main
valve (3) is equivalent to the area difference be-
tween d, and d,. If this pressure goes up to the
poppet spring force (set pressure), the poppet is
actuated, and the oil in port A flows into port 8.
423F139
61-25
As a suction valve
l If negative pressure is generated in port A, port D
also has negative pressure, because ports D and A
are connected with each other. The tank pressure
in port B is applied to port E.
Hydraulic pressure “a” equivalent to the area differ-
ence between d, and d, is applied to the safety
valve because of the tank pressure in port E.
Therefore, hydraulic pressure “e” acts to open the
valve and hydraulic pressure “a” acts to close the
suction valve (2).
l If the pressure in port A drops, (approaching nega-
tive pressure) hydraulic pressure “a” becomes
smaller than oil pressure “e”.
When oil pressure “e” becomes larger than oil
pressure “a” + valve spring (6) force, the suction
valve (2) opens, causing the oil to flow from port B
into port A. This prevents negative pressure from
building up in port A.
SUCTION VALVE
1. Main poppet
2. Sleeve
3. Spring
423F142
Operation
l If negative pressure is generated in port A (lift
cylinder rod end) (if the pressure is lower than in
port B in the tank circuit), the main poppet (1)
opens because of the difference in area between d,
and d,. Oil then flows from port C at the tank end
to port A at the cylinder port end.
,,,,,,,,, 423F143
61-26
STRUCTURE AND FUNCTION HYDRAULIC CYLINDER
HYDRAULIC CYLINDER
LIFT CYLINDER
Unit: mm
Item
Cylinder bore I 160

1. Head
2. Rod Rod dia. I 90
3. Cylinder
4. Piston Cylinder max. length I 2167
5. Lock ring
Cylinder min. length I 1398
Stroke I 769
61-27
STRUCTURE AND FUNCTION HYDRAULIC CYLINDER
DUMP CYLINDER
Ll OBR057
Unit: mm
1. Head Item
2. Rod
3. Cylinder Cylinder bore 200
4. Piston
Rod dia. 100
5. Lock ring
Cylinder max. length 1568
Cylinder min. length 1083
Stroke 485
61-28
STANDARD VALUE TABLE ......... .. ... ... ......... ...... ......... ...... ... 3
TOOL LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . ......... ...... ........ ....... ... 4
DUMP AND LIFT CONTROL LEVERS ...... ....... ........ ...... ...... 5
HYDRAULICPRESSURE .. ............... .... ......... ...... ..... .. ....... 7
LIFT ARM AND BUCKET . . . . .......... .. ........ ......... ..... ......... 9
HYDRAULIC DRIFT OF LIFT ARM AND BUCKET .. .. ........ ....... ..... .. ...... 10
BUCKET POSITIONER ... . . ..... .. ......... .......... ..... ...... .. 11
BOOM KICK-OUT . .. .... ... ...... ....... ......... ..... ..... ...... 12
TROUBLESHOOTING ................... ... ................................ 13

TROUBLESHOOTING TABLES ......... .................. 14
1. Liftarmdoesnotrise.....................:::...:::::::::::::: .................. 14
2. Lift arm moves slowly or does not have sufficient lifting power. ............................ 15
3. Lift arm movement becomes slow after it reaches a certain height. ......................... 16
4. Bucket cannot be held down with lift arm cylinder. ..................................... 16
5. Lift arm has large hydraulic drift. .................................................. 16
6. Lift arm movement is unsteady during work. ......................................... 16
7. Lift arm descends momentarily when control lever is shifted from “Hold” to “Raise”. ............. 16
8. Bucket does not tilt back. ....................................................... 17
9. Bucket moves slowly or has insufficient tilt back power. ................................. 18
10. Bucket movement becomes slow during tilt back. ..................................... 19
11. Bucket cannot be held down by the bucket cylinder. ................................... 19
12. Bucket has large hydraulic drift. .................................................. 19
13. Bucket moves unsteadily when machine travels under load. (Main control valve in “Hold”). ....... 19
14. Bucket dumps momentarily when control lever is shifted from “Hold” to “Tilt back”. ............. 19
15. Control levers of lift arm and dump move stiffly and sluggishly. ............................ 20
t The following precautions are necessary when using Standard Value Tables to make judgements during
62-1
judgements.
* Before carrying out the troubleshooting in this section, read “PRECAUTIONS WHEN TROUBLESHOOTING”,
“METHOD OF READING TROUBLESHOOTING TABLES” and “PREVENTING RECURRENCE OF TROUBLE” in
SECTION 22.
62-2
value value
Dump and lift levers

0 Lift lever operating force
Hold - Raise Max. 2.3 Max. 5.5
Raise - Hold Max. 2.3 Max. 5.5
Hold - Lower l Hydraulic temperature: 45-55°C Max. 3.2 Max. 5.2
Lower - Hold Max. 3.2 Max. 5.2
Lower - Float kg Max. 3.6 Max. 7.2
Float - Hold Max. 3.2 Max. 5.5
l Dump lever operating force l Engine speed: Low idling

Hold - Dump Max. 3.5 Max. 4.5
Hold - Tilt Max. 2.5 Max. 4.5
Tilt - Hold Max. 2.5 Max. 4.5
0 Lift lever travel

Hold - Raise 60-90 50-l 10
Hold - Lower 60-90 50-l 10
Hold - Float 80-l 10 88-l 48
mm
l Dump lever travel
Hold - Dump 60-90 50-l 10
Hold - Tilt 60-90 50-l 10
Main valve l Hydraulic temperature: 45-55°C

kg/cm* 210+;
o Main relief oil pressure l Enoine speed: Hiah idling
Lift arm and bucket operating l Hydraulic temperature: 45-55” C

speed l Engine speed: High idling
Lift arm lifting time l Steering position: Neutral 6.1-6.7 Max. 8.0
Lift arm lowering time l Coolant temperature: Inside 3.6-4.2 Max. 5.0
Bucket dumping time operating range 1.2-l .8 Max. 2.2
l
sec.
Bucket tilt back time (Full Bucket: unloaded 2.8-3.4 Max. 4.1
stroke)
Bucket tilt back time 1.1-1.7 Max. 2.1
(Horizontal position of
bucket)
Hydraulic drift of lift arm l Hydraulic temperature: 45-55°C

and bucket l Coolant temperature: Inside
l Retraction of lift cylinder rod operating range Max. 14 Max. 17
l Retraction of dump cylinder l Stop engine, leave for 5 minutes, Max. 36 Max. 43
rod then measure for next 15 mm
minutes.
l Lift arm horizontal
l Bucket horizontal
l Unloaded
Bucket positioner 0 Hydraulic temperature: 45-55°C

l Clearance of switch 3-5
mm
Boom kick-out 3-5
l Clearance of switch
62-3
TESTING AND ADJUSTING TOOL LIST
TOOL LIST
No. Testing and measuring item I Tool name I Part number I Remark
1 Hydraulic pressure Hydraulic tester 799-l 01-5000 O-300 kg/cm2
2 Oil temperature Thermistor kit 799-l 01-6000 o-1,000” c
3 Engine speed Tachometer 799-203-8000 60-19999 rpm
Dump lever and lift lever operating

4 Push-pull scale 7AO-262-0020 O-25 kg
force
5 Measuring travel Convex scale Commercially available O-2 mm
When carrying out testing, adjusting or troubleshooting, stop the machine on level ground, install the safety
A bar on the frame, lower the bucket to the ground, and stop the engine.
A Do not allow unauthorized persons near the machine.
A When measuring the engine speed, one worker should measure the engine speed while the other sits in the
operator’s seat to operate the controls. Always check that the operation is safe, and use agreed signals.
Be careful to not get caught in rotating parts.

A
62-4
TESTING AND ADJUSTING DUMP AND LIFT CONTROL LEVERS
DUMP AND LIFT CONTROL LEVERS

Special tool
Part number Part name I Q’ty
A 1 7AO-262-0020 1 Push-pull scale 1
A Install the safety bar on the frame.
Measuring procedure
1. Operating force of dump and lift control levers

l Fit push-pull scale A on dump and lift control
levers and measure operating force.
+ Hook the push-pull scale A on the center of
the knob.
t Operate at the same speed as normal and
measure the minimum force needed to
operate the knob.
2. Travel of dump and lift control levers

l Measure the travel X of the dump and lift
control levers at each position.
+ Mark the knob of the lever and use a scale
to measure.
62-5
TESTING AND ADJUSTING DUMP AND LIFT CONTROL LEVERS
Adjusting procedure
1. Adjusting front-rear position of solenoid

Disconnect cable (4).
:; Set the lift arm lever and bucket lever at the
hold position.
3) Push the shaft of the solenoid down fully.
4) Adjust the position of the solenoid so that plate
(1) and pin (2) at the lever end contact the end
of the oblong hole. (Clearance: 0 mm)
5) Operate the lever backwards and forwards,
adjust the length of cable (4) so that the roller
enters the notched portion of the cam properly,
then connect the cable.
2. Left-right adjustment of solenoid position

1) Set the lift arm lever and bucket lever at the
hold position.
2) Move plate (1) backwards and forwards by
hand, and check that the plate and lever (2)
move freely.
+ When there is no electricity flowing, the
solenoid valve shaft can move freely.
3) If the movement is not smooth, shake the
solenoid to the left and right and adjust so that
the plate moves smoothly.
3. Adjusting stopper position of work equipment

control levers
1) Operate the work equipment control levers to 423FO1218-1
the end of the RAISE, FLOAT, TILT, and DUMP
strokes and adjust the position of the bolts so
that plate (6) and stopper bolts (7 and 8)
contact.
2) Turn back stopper bolts (7 and 8) one turn, and
lock in position.
4. Check the hold position of the dump lever and

lift lever.
t Use the diagram to check the hold position of
the dump and lift levers.
+ Check that the main control valve is in the hold
position.
5. If the levers are heavy, adjust the mounting

position of spring (5).
it After carrying out the above adjustment, 423F0 I2 I9
measure again to check that it is within the
standard value.
62-6
TESTING AND ADJUSTING HYDRAULIC PRESSURE
HYDRAULIC PRESSURE
Special tool
A 799-l 01-5000 Hydraulic tester 1
1. Measuring procedure (Main relief valve)
Loosen the oil filler cap slowly to release the

a pressure inside the hydraulic tank. Then operate ‘\ ,,,,
1) Remove plug (1) for measuring pressure of

dump cylinder circuit.
2) Install hydraulic tester A to measuring port.
t Check that there is no oil leakage from any
connection.
+ Use a hose 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 pres-
sure to the pressure gauge.
A When removing the hydraulic pressure gauge,

release the pressure inside the circuit in the
same way as when installing the gauge.
62-7
TESTING AND ADJUSTING HYDRAULIC PRESSURE
Adjusting procedure
Always stop the engine before adjusting the

A hydraulic pressure.
1. Remove inspection cover of front cover.

l Stop the engine, remove front cover (4) of front
frame.
2. Remove cap nut (1) of the relief valve.
3. Loosen lock nut (2), then turn adjustment screw (3)

to adjust.
t Amount of adjustment for 1 turn of screw:
1 turn: Approx. 35.7 kg/cm*
t Turn the adjustment screw to adjust as follows:
To INCREASE pressure, TIGHTEN screw.
To DECREASE pressure, LOOSEN screw.
+ If the relief pressure cannot be measured
accurately, do not try to adjust the pressure.
3 2
423F3 I5A
62-8
TESTING AND ADJUSTING LIFT ARM AND BUCKET
LIFT ARM AND BUCKET 433 Lifting time of lift arm
l Steering position: Neutral
o Hydraulic temperature: 45 - 55°C
l Bucket: Unloaded
Special tool
Part number Part name Q?y
A 7AO-262-0550 Stop watch 1 423F327
Lowering time of lift arm
Measuring procedure
1. Lifting time of lift arm

Set the bucket near the maximum tilt back position
and at the lowest position on the ground. Raise the
bucket and measure the time taken for bucket to
reach the maximum height of the lift arm.
2. Lowering time of lift arm

Set the bucket horizontal with the lift arm at the
maximum height, lower the bucket and measure the
time taken for the bucket to reach the lowest 423F328
position on the ground.
Dumping time of bucket
3. Dumping time of bucket
Raise the lift arm to the maximum height and
measure the time taken for the bucket to move from
the maximum tilt back position to the maximum
dump position.
423F329
4. Tilt back time of bucket Tilt back time of bucket

1) Raise the lift arm to the maximum height and
measure the time taken for the bucket to reach
the maximum tilt back position.
2) Set the bucket horizontal and measure the time
taken for the bucket to move from the horizon-
tal position to the maximum tilt back position.
423F330
62-9
TESTING AND ADJUSTING HYDRAULIC DRIFT OF LIFT ARM AND BUCKET
HYDRAULIC DRIFT OF
LIFT ARM AND BUCKET
e Stop engine, leave for 5 minutes, then measure for
next 15 minutes.
l Lift arm horizontal
o Bucket horizontal
o Unloaded
Unit: mm
Retraction of lift
1 Max. 14 1 Max. 17
cylinder rod
Retraction of dump
1 Max. 36 1 Max. 43
cylinder rod
Special tool
Commercially available Convex scale 1
A Fit the safety locks on the control levers.
A Do not go under the work equipment.
Measuring procedure
1) Set the lift arm and bucket horizontal, then stop the
engine.
2) Stop the engine, wait for 5 minutes, then start 423F33 I
measuring.
3) Measure the amount that the lift and dump cylinder
rods retract during 15 minutes.
+ Use the same procedure to measure when the
bucket is unloaded and loaded.
t When measuring with bucket loaded, the load
may spill, so be careful.
A. Retraction of dump cylinder rod
B. Retraction of lift cylinder rod
423F332
62-10
TESTING AND ADJUSTING BUCKET POSITIONER
BUCKET POSITIONER
l Engine water temperature:
Within green range on engine water temperature
gauge
o Hydraulic oil temperature: 45 - 55°C
Testing
1. With the engine stopped, check that the clearance
between switch (1) and angle (2) is within the
standard value.
2. Start the engine, run at high idling, and check the

actuation position.
(Check three times and take the average value.)
3-5mm
Adjusting procedure
1. Lower the bucket to the ground, set the bucket to
423F333
the desired digging angle, return the control lever to
the HOLD position, and stop the engine.
2. Secure support (3) to the bucket cylinder bracket

so that the clearance between the center of the
switch and rear end of angle (2) is 0 - 5 mm.
3. Fix the switch in position so that the clearance

between the angle and the detector surface of the
switch is 3 - 5 mm.
t Adjust the angle with shims and fix the support
so that the clearance between the angle and
the detector surface of the switch is within the
423F334
standard value for the whole stroke of the
angle.
D Switch mounting nut: 1.8kO.2 kgm
* Set the detector surface of the switch 0.5 - 1.0

mm below the tip of the protector and fix in
position.
t After adjusting, operate the bucket lever and
check that the bucket positioner is actuated at
the desired position.
62-11
TESTING AND ADJUSTING BOOM KICK-OUT
BOOM KICK-OUT
Testing procedure
1. With the engine stopped, check that the clearance
between switch (1) and plate (2) is within the
standard value.
2. Start the engine, run at high idling, and check the

actuation position.
(Check three times and take the average value.)
Adjusting procedure
1. Raise the bucket to the desired height, return the
control lever to the HOLD position, and stop the
engine.
Always apply the safety lock to the work equip-

A ment control levers.
2. Adjust the position of the plate so that the clearance

between the center of switch (1) and the top end of
plate (2) is 0 - 5 mm then fix in position.
3. Fix the switch in position so that the clearance

between plate (2) and the detector surface of the
switch is 3 - 5 mm.
a Switch mounting nut: 1.8kO.2 kgm
\
423FOl218
* After adjusting, operate the lift lever and check
that the boom kick-out is actuated at the
desired position.
62-12
TROUBLESHOOTING
62-13
1. Lift arm does not rise.

l Did the boom suddenly fail to raise? - Seizure
or damage to various units.
l Was an unusual noise produced? (Where did it
emanate from?)
l Were there previous signs of the boom slowing
down? - Wear of parts or flattening of spring.

l Is oil level in hydraulic tank correct?
l Is stroke of lift control lever and spool correct?
LO2zZO41
The following symbols are used to indicate the action to

be taken when a cause of failure is located.
X: Replace A: bpair
A: Adjust C: Clean
62-14
2. Lift arm moves slowly or does not have sufficient

lifting power.

l Is the amount and type of oil in the hydraulic
tank correct?
l Is the stroke of the lift control lever and also the
spool of the main control valve correct?
l Seizure of bucket linkage bushing.
(Emits unusual noise)
Fault check.
There is a strong relationship between faults involv-
ing lifting force and lifting speed. Such faults appear
initially in the form of insufficient lifting speed.
Measure the lifting speed of the lift arm when
loaded and refer to the judgement criterion table to
determine whether or not there is a fault.
NO
Problems
Bucket tilt back and speed are abnormal and lift arm
1
,,,y
lifti__ ^..^^A
3pcsu
.e
ID
In,.,
I”...
lolol
I I I
0 lolol
2
ELM:ket tilt back and speed are normal but hft arm I I I A A
lift)
LO222042

X: Replace A: kpair
A: Adjust C: Clean
62-15
3. Lift arm movement becomes slow after it reaches 6. Lift arm movement is unsteady during work.
a certain height. During excavation or ground leveling when the lift
arm control lever is in the “Hold” position, the
Check before troubleshooting. bucket and lift arm move up and down in accor-
l Visible deformation of lift cylinder. dance with the terrain.
Cause Problem and cause

l Swollen or internally damaged lift cylinder tube. Check the amount of hydraulic drift and whether or
* Regarding other faults occurring during lift arm not the machine body can be lifted up by the lift
ascent, refer to item “2. Lift arm moves slowly cylinder.
or does not have sufficient lifting power”. 1) If the amount of hydraulic drift is greater than
the standard value, refer to item “5. Lift arm has
4. Bucket cannot be held down with lift arm cylin- large hydraulic drift”.
der. 2) If the machine body can be lifted up by the lift
If the relief pressure in the circuit at the bottom of cylinder, refer to item “4. Bucket cannot be held
the lift cylinder is insufficient, refer to item “2. Lift down with lift arm cylinder”.
arm moves slowly or does not have sufficient lifting 3) If the amount of hydraulic drift is normal and
power”. the machine body can be lifted up by the lift
cylinder after the lift arm is moved several times
Checks before troubleshooting. to cause the lift cylinder to move through its
l Is level of oil in the hydraulic tank correct? entire stroke - the trouble is due to the genera-
l Is stroke of main control valve and lift spool tion of a vacuum in the cylinder.
correct? t If a vacuum is generated frequently, - faulty
suction valve on lift cylinder rod side.
Cause
l Faulty main control valve or suction valve seat 7. Lift arm descends momentarily when control
on lift cylinder rod side. lever is shifted from “Hold” to “Raise”.
l Oil leakage from lift cylinder piston seal. The lift arm descends momentarily under its own
weight when the lift arm control lever is gradually
5. Lift arm has large hydraulic drift. shifted from the “Hold” position to the “Raise”
position while the engine is at low idling. When the
Ask the operator the following questions. control lever is put completely into the “Raise”
l Did the hydraulic drift suddenly become large? position, the lift arm behaves normally.
- Dirt lodged in valve or damaged parts.
l Did the hydraulic drift gradually become large? Cause
- Worn parts. l Faulty seating of main control valve or lift arm
load check valve.
l Is the type and temperature of the oil in the
hydraulic tank correct?
l Is the lift arm spool in the neutral position? -
Seized link bushing, faulty spool detent.
Problem and cause

l When measuring hydraulic drift, internal of lift
cylinder produces oil leak noise - Damaged
piston packing.
62-16
8. Bucket does not tilt back.

l Did the bucket suddenly cease to move? -
Seized or damaged equipment.
Was any unusual noise emitted? Where did it
emanate from?
l Were there previous signs of the bucket slowing
down? - Worn parts or flattened spring.

l Is amount of oil in hydraulic tank satisfactory?
l Is the stroke of the bucket control lever and
spool correct?

A: Adjust C: Clean
62-17
9. Bucket moves slowly or has insufficient tilt back

power.

l Is the quantity and type of oil in the hydraulic
tank satisfactory?
l Is the stroke of the bucket control lever and the
main control valve spool correct?
l Seizure of bushing in bucket linkage.
(Emits unusual noise)
Fault checks.
l Check the amount of deficient tilt force by per-
forming actual work.
l Measure the operating speed of the bucket and
check it against the judgement criterion table to
determine whether or not it is normal.
c d e f g h
NO
Remedy CA A AAA
x x
Problems Ax x xn x
1 Lift arm llftmg force and llftmg speed are abnormal and also 0 o
bucket tilt back force and tilt back speed are abnormal. 0 0
2 Lift arm llftmg force and llftmg speed are normal but
bucket tilt back force and ttlt back speed are abnormal. 000
Phenomena of Item 1 become particularly bad when the
3
011temperature wreases 0
4 The hydraulic pump emIts an unusual noise. n 0
LO222044

A: Adjust C: Clean
62-18
10. Bucket movement becomes slow during tilt back. 13. Bucket moves unsteadily when machine travels
under load. (Main control valve in “Hold”).
Check before troubleshooting.
l External deformation of dump cylinder. Checks before troubleshooting.
Cause correct?
l Swollen or internally damaged dump cylinder l Excessive play in pin and bushing of work
tube. equipment linkage.
l Regarding other faults which occur when the l Was an unusual noise produced?
bucket operates, refer to item “9. Bucket moves
slowly or has insufficient tilt back power”. Cause
l Faulty piston seal of dump cylinder.
11. Bucket cannot be held down by the bucket l Faulty safety valve with suction valve for the
cylinder. bottom side of dump cylinder.
Refer to item “9. Bucket moves slowly or has insuffi- If the above symptoms occur together with
cient tilt back power”. other symptoms, refer to the problem items
corresponding to each fault.
l Is oil level in the hydraulic tank satisfactory? 14. Bucket dumps momentarily when control lever is
l Is the stroke of the main control valve dump shifted from “Hold” to “Tilt back”.
spool correct? The bucket dumps momentarily under its own
weight when the dump control lever is gradually
Cause shifted from the “Hold” position to the ‘Tilt bacK
l Faulty seat of safety valve with suction valve of position while the engine is at low idling. When the
control valve for the bottom side of dump control lever is put completely into the ‘Tilt back’
cylinder. position, the bucket behaves normally.
l Oil leakage from seal of dump cylinder piston.
Cause
12. Bucket has large hydraulic drift. l Faulty seating of main control valve dump spool
check valve.
l Did the hydraulic drift suddenly become large?
- Dirt lodged in valve or damaged parts.
l Did the hydraulic drift gradually become large?
- Worn parts.

l Is the type and temperature of the oil in the
hydraulic tank correct?
l Is the dump spool in the hold position? -
Seized link bushing, faulty spool detent.
Fault checks.
l Use the judgement criterion table to check
whether or not the hydraulic drift of the bucket
is actually large.
l If hydraulic drift is large,
Cause: Oil leakage in dump cylinder.
l If hydraulic drift returns to normal,
Cause: Faulty seating of overload relief valve
or suction valve on bottom side. Faulty
oil sealing on spool of dump control
valve.
62-19
15. Control levers of lift arm and dump move stiffly

and sluggishly.
Fault check.
Using the judgement criterion table, check whether
or not the operating force of the lever is large.
Maln control valve
No
I ’
Movement of ltft arm and bucket becomes sluggish
when load IS aoolled and 011oressure Increases I I
21 Movement of lift arm and bucket becomes

a Iona with chanoe I” 011temnerature
sluggish
lol II01 I I
Movement of lift arm and bucket becomes partially
3 0
sluggish lrrespectlve of 011pressure and temperature
Movement of lift arm and bucket becomes generally
4 0 0 0
sluggish lrrcspectlve of 011pressure and temoerature
5 Cable IS heavy even when operated after disconnectmg 0

-r cable at connection between lever and valve.
LO222045

A: Adjust C: Clean
62-20
HYDRAULIC TANK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
HYDRAULIC FILTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
INSTALLATION .... ............ .. ... ...... ... .. .......... ...... ....... ....... .... 9
STEERING PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
REMOVAL . . . .
INSTALLATION .
MAINCONTROLVALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
DUMP CYLINDER .
REMOVAL . . .
INSTALLATION
LIFT CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
HYDRAULIC CYLINDER
DISASSEMBLY . . .
ASSEMBLY . . .
WORK EQUIPMENT . . .................................................. 30

REMOVAL . .... .................................................. 30
INSTALLATION . . . .................................................. 33
COUNTERWEIGHT . . .................................................. 36
REMOVAL . . . . .................................................. 36
INSTALLATION . . . .................................................. 36
63-1
* For details of disassembly and assembly of the gear pump, see SECTION 97.
+ Take the following method for air bleeding when you start to operate hydraulic cylinders after reassembling
63-2
HYDFUWLIC TANK
REMOVAL

the parking brake and put blocks under the \
Loosen the oil filler cap slowly to release .u

% Y
A the pressure inside the hydraulic tank. Then
+ operate the control levers several times to iw . -_ m . ..A
release the remaining pressure in the hy- L L1062002
draulic piping.
* Disconnect the cable from the negative

(-) terminal of the battery.

1. Draining air
Pull drain valve (5) and drain air from air tank.
2. Hydraulic piping
and hydraulic pump.
and main control valve from hydraulic tank.

and work equipment circuit from hydraulic tank.
3. Brake chamber
1) Disconnect hose (9) between slack adjuster and
brake chamber from brake chamber.
+ Before disconnecting hose (9), disconnect
hose (lo), and take action to prevent the oil
inside the hydraulic tank from flowing out.
2) Disconnect wiring connector (11).
423POl224
I
63-4
4. Window washer, radiator sub-tank hose

1) Disconnect vinyl tubes (12), then remove win-
dow washer.
2) Disconnect hose (13) between radiator sub-tank
and radiator from radiator sub-tank.
5. Air conditioner hose

1) Disconnect hose (16) between air condenser
and air conditioner from hydraulic tank.
2) Disconnect hose (17) between receiver tank
and air conditioner unit from hydraulic tank.
6. Hydraulic tank
Sling hydraulic tank, remove mounting bolts, then
lift off.
* Be careful not to hit the rear window of the cab
when lifting off the hydraulic tank.
Hydraulic tank: 380 kg

(incl. brake chamber, hydraulic oil and etc.)
63-5
INSTALLATION
1. Hydraulic tank
Sling hydraulic tank, set in mounting position, then
t The rear window of the cab is close, so be
careful when lifting the hydraulic tank.
* Align the connections of the hoses when setting
in mounting position.
* Fit the tip of the oil drain hose in the clamp on
the rear frame.
2. Air conditioner hose

1) Connect hose (17) between receiver tank and
air conditioner unit to hydraulic tank.
2) Connect hose (16) between air condenser and
air conditioner to hydraulic tank.
3. Window washer, radiator sub-tank hose

1) Connect hose (13) between radiator sub-tank
and radiator to radiator sub-tank.
2) Install window washer, then connect vinyl tubes
(12).
4. Brake chamber
1) Connect wiring connector (11).
2) Connect hose (9) between slack adjuster and
brake chamber.
63-6
5. Hydraulic piping
work equipment circuit at hydraulic tank end.
ing.
+ Install the hose without twisting or interfer-
ence.

main control valve at hydraulic tank end.
hydraulic pump at the tube of hydraulic tank.
63-7

the system.
Then check the oil level again.
%b Transmission oil: 53 P
* Run the engine to circulate the transmission

wait for 15 minutes, then check the oil level
again.

For details of bleeding air, see SECTION 52,
Close hood, then lock with catch.

A
DISASSEMBLY AND ASSEMBLY HYDRAULIC FILTER
HYDRAULIC FILTER
REMOVAL
Y Y Loosen the oil filler cap slowly to release

A the pressure inside the hydraulic tank.
+
\
1. Cover
Remove mounting bolts, then remove covers (1 and
2).
The tension of the spring is pushing the c L10Bz002

% &
A cover, so be careful when removing.
4
t Be careful not to damage the O-ring on the

contact faces of the cover and tank.
2. Filter
Remove spring (3) and bypass valve (4), then
remove filter (5).
t Repeat the same procedure for the cover (2).
INSTALLATION
1. Filter
Install filter (5), then install bypass valve (4) and
spring (3).
2. Cover
Fit O-ring (6) in groove of cover, then install cover
(1) to tank.
t Replace the O-ring with a new part.
* Fit the O-ring securely in the groove, and make
63-9
DISASSEMBLY AND ASSEMBLY STEERING PUMP
STEERING PUMP
REMOVAL
t. Remove hydraulic tank

For details, see SECTION 63, REMOVAL OF HY-
DRAULIC TANK.
2. Hydraulic. steerina ourno

1) Disconnect hose’ (12) between steering pump
and steering valve from hydraulic, steering
pump.
pump.
3) Disconnect hose (13A) between hydraulic pump
and hydraulic control valve from hydraulic,
steering pump.
4) Disconnect tube (13B) between steering pump
and orbit-roll from hydraulic, steering pump.
5) Disconnect tube (14) between hydraulic pump
and hydraulic tank from hydraulic, steering
pump.
6) Fit sling around hydraulic, steering (15), and
raise. Remove mounting bolts, then lift off.
Hydraulic, steering pump: 45 kg
63-l 0
DISASSEMBLY AND ASSEMBLY STEERING PUMP
INSTALLATION
1. Hydraulic, steering pump

1) Fit sling around hydraulic, steering (15), and
raise. Remove mounting bolts, then lift off.
el kg Hydraulic, steering pump: 45 kg
2) Disconnect tube (14) between hydraulic pump

and hydraulic tank from hydraulic, steering
pump.
3) Disconnect tube (138) between steering pump
and orbit-roll from hydraulic, steering pump.
4) Disconnect hose (13A) between hydraulic pump
and hydraulic control valve from hydraulic,
steering pump.
pump.
6) Disconnect hose (12) between steering pump
pump.
2. Hydraulic tank
HYDRAULIC TANK.
63-l 1
DISASSEMBLY AND ASSEMBLY MAIN CONTROL VALVE
MAIN CONTROL VALVE

REMOVAL

Loosen the oil filler cap slowly to release

Y
AY the pressure inside the hydraulic tank. Then
4 operate the control levers several times to
release the remaining pressure in the hy-
draulic piping.

1. Cover
Remove cover (2A) at front of front frame.
2. Drive shaft
1) Disconnect front drive shaft (3) from differential
end and center end.
2) Remove flange bearing (4), and move front
drive shaft towards rear frame.
63-l 2
3. Hydraulic piping
1) Remove lift cylinder tube (10) from left and right
front frame brackets (11).
valve and steering valve from main control
valve.

valve and hydraulic pump from main control
valve.
valve and dump cylinder from main control
valve.
5) Disconnect tube (15) between main control
valve and lift cylinder from main control valve.
valve and hydraulic tank from main control
valve.
4. Main control valve

1) Disconnect control cable (17) from main control
valve.
2) Sling main control valve (18) then remove
mounting bolts, and remove from below.
el kg Main control valve: 57 kg

INSTALLATION

1) Raise main control valve (18) and set in mount-
ing position, then tighten mounting bolts.
2) Connect control cable (17) to main control
valve.
D Nut: 0.7kO.l kgm
3) Adjusting control cable

For details of adjusting the control cable, see
SECTION 62, TESTING AND ADJUSTING.
2. Hydraulic piping
and hydraulic tank to main control valve.
2) Connect tube (15) between main control valve
and lift cylinder to main control valve.
and dump cylinder to main control valve.
and hydraulic pump to main control valve.
and steering valve to main control valve.
6) Install lift cylinder tube (10) to left and right

front frame brackets (11).
t Fit the O-ring in the groove securely and be
careful that it is not caught when assem-
bling.
+ Install the hoses without twisting or intetfer-
ence.
63-14
3. Drive shaft
1) Install flange bearing (4) temporarily.
2) Connect front drive shaft (3) to differential end
and center end.
3) Tighten flange bearing fully.
+ When connecting the drive shaft, clean the
mating surface of the spider and the cou-
pling, then align the pilot securely and
install.
D Flange bearing mounting bolt: 28.5 23 kgm
4. Cover
Install cover (2A) at front of front frame.

Tighten plug (1) at the top of the hydraulic tank filter
and pump piping plug (2), then add hydraulic oil
through oil filler to the specified level.
t Run the engine to circulate the oil through the
system. Then check the oil level again.
DISASSEMBLY
1. Case assembly
1) Remove case assembly (2).
2) Remove plate (3), then loosen bolt (5) of lever
(4).
3) Remove shaft (6) from lever (4).
4) Remove oil seal (7) and bearings (8 and 9).
2. Spool assembly
1) Remove case (lo), then remove spool assembly
(11). 25
2) Remove bolt (12), then remove retainer (13),
spring (14), and retainer (13) from spool (15).
+ Remove bolt (12) with the spool still assem-
bled in the valve body.
Main relief valve assembly (with suction)

1) Remove main relief valve assembly (17).
2) Loosen nut (18), then remove holder (19).
3) Remove poppet (20), spring (21) and retainer 224
(22).
4) Remove seat (23) from sleeve (25), then re-
0
move spring (24).
+ If there is any abnormality in sleeve (25),
valve (26) or plug (27), replace the whole
assembly. These parts are not available
individually.
Safety valve with suction valve assembly

Remove safety valve assembly (28).
Suction valve assembly

Remove suction valve assembly (29). 423F460
Check valve
Remove plug (30), then remove spring (31) and
valve (32) in body (33).
63-l 6
MAIN CONTROL VALVE
423F459
a
63-17
ASSEMBLY
1. Check valve
Assemble valve (32) and spring (31) in body (33) fit
O-ring, then tighten plug (30).
D Plug: 47.5k2.5 kgm
2. Suction valve assembly

Fit O-ring and back-up ring, then install suction
valve assembly (29).
z
0
D Suction valve: 142 1 kgm 274

26----+
3. Safety valve with suction valve assembly
Fit O-ring and back-up ring, then install safety valve
assembly (28). 25
D Safety valve: 142 1 kgm
4. Main relief valve assembly

1) Assemble spring (24) in sleeve (25), then install
seat (23).
2) Assemble poppet (20) spring (21) and retainer 23---@
(23) in sleeve (25).
3) Screw nut into holder (19) fit O-ring, install 20
--+I
sleeve (25) then tighten nut (18). @,
4) Fit O-ring and back-up ring, then install main
relief valve (17). E
21-z
0
D Main relief valve: 15.522.5 kgm 22d
0
5. Spool assembly
1) Assemble retainer (13), spring (14) and retainer
w--a
(13) in spool (15), then tighten bolt (12).
19
D Bolt: 7.OkO.5 kgm -+! 0
* When tightening bolt (12), tighten with the

spool assembled in the valve body.
2) Assemble spool assembly (11) in body, fit
O-ring, then install case (10).
6. Case assembly
1) Install bearings (9 and 8) and oil seal (7) in case 423F460
assembly (2).
2) Assemble lever (4) inside case, fit key, then
install shaft (6) to lever (4) inside case.
3) Tighten bolt (5).
4) Fit O-ring, align lever (4) with spool, then install
case assembly (2).
63-18
423F459
63-19
DISASSEMBLY AND ASSEMBLY DUMP CYLINDER
DUMP CYLINDER
REMOVAL

Y
1. Bucket positioner
Disconnect connector (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.
424P837
3. Hydraulic piping
1) Disconnect hose (3) at rod end from cylinder.
424P838
63-20
2) Disconnect tube (4) and hose (5) at bottom end

from connector.
4. Dump cylinder
1) Remove lock bolt, then remove pin (6) at bot-
tom end.
t There are shims installed, so check the
424PW.O~
2) Remove dump cylinder (7).

t Be careful not to damage the cylinder rod.
Dump cylinder: 220 kg
63-21
INSTALLATION
1. Dump cylinder
1) Raise dump cylinder (7) and set in mounting
position.
2) Align pin hole at bottom end, assemble shim so
that clearance “a” between cylinder and frame
on left and right is within specified range, then
install pin (6) and lock with bolt.
Clearance “a”: Max. 3 mm
424F 134
2. Hydraulic piping
1) Connect tube (4) and hose (5) at bottom end.
2) Connect hose (3) at rod end.
* Fit the O-rings securely in the grooves.
ence.
3. Pin (rod end)

Align pin hole at rod end, then install pin (2) and
lock with bolt.

fingers.
4. Bucket positioner
Connect connector (1).
t For details of adjusting bucket positioner, see
SECTION 62, TESTING AND ADJUSTING.
63-22
DISASSEMBLY AND ASSEMBLY LIFT CYLINDER
LIFT CYLINDER
REMOVAL

i
pressure inside the hydraulic tank. Then operate
4
t Place a support under the lift arm.
1. Rod pin
1) Sling lift cylinder (I), remove lock bolt, then
remove pin (2).
* If shims are inserted, check numbers of
shims.
2) Start engine, and operate control levers to
retract cylinder rod on side where pin has been
removed.
2. Hydraulic piping
1) Disconnect tube (3) and hose (4) at rod end
from connector.
2) Disconnect tube (5) and hose (6) at bottom end
from connector.
3. Lift cylinder
1) Remove lock bolt, then remove pin (7) at bot-
tom end.
2) Remove lift cylinder (1).
* Be careful of the center of gravity, and
remove slowly.
+ Be careful not to damage the cylinder rod.
Lift cylinder: 180 kg
63-23
DISASSEMBLY AND ASSEMBLY LIFT CYLINDER
INSTALLATION
1. Lift cylinder
1) Raise lift cylinder (1) and set in mounting posi-
tion.
2) Align pin hole at bottom end, assemble shim so

that clearance “a” between cylinder and frame
on left and right is within specified range, then
install pin (7) and lock with bolt.
Use bar to align the pin holes. Never use your

A fingers.
Clearance “a”: Max. 3 mm
424F 135
2. Hydraulic piping
1) Connect tube (5) and hose (6) at bottom end.
2) Connect tube (3) and hose (4) at rod end.
+ Fit the O-rings securely in the grooves.
+ Install the hoses without twisting or interfer-
ence.
3. Rod pin
Start engine, operate control levers to extend rod.
Align pin holes, insert shims so that clearances “b”
are even. Then install pin (2), lock with bolt.
+ Remove the support.
* Clearance “b”: Max. 2 mm.
63-24
DISASSEMBLY AND ASSEMBLY HYDRAULIC CYLINDER
HYDRAULIC CYLINDER
DISASSEMBLY
Special tool
1. Set cylinder assembly (1) on tool A.
2. Remove mounting bolts (2) of cylinder head.
3. Pull cylinder head and piston rod assembly (3)

about 900 mm out of cylinder (4) and lift off.
t Oil will come out when the piston rod assembly
is removed from the cylinder, so place a con-
tainer in position to catch the oil.
4. Remove piston bolt (5), then remove spacer (6),

piston assembly (7) and cylinder head assembly (8).
5. Remove O-ring (10) and back-up ring (11) from

piston rod (9).
423F484
53-25
6. Disassemble piston assembly as follows:

Remove wear ring (12) and piston ring (13) from
piston (14).
7. Disassemble cylinder head assembly as follows:

1) Remove O-ring (15) and back-up ring (16).
2) Remove snap ring, then remove dust seal (17).
3) Remove rod packing (18).

4) Remove bushing (19).
63-26
ASSEMBLY
Special tools
A 790-502-1001 Cylinder 1
repair stand
B 790-702-l 000 Expander 1
C 796-720-l 680 Ring 1
796-720-l 690 Ring 1
t Clean all parts, and check for dirt or damage. Coat

the sliding surfaces of all parts with engine oil
before installing. Be careful not to damage the
packings, dust seals or O-rings when installing.
1. Assemble cylinder head assembly as follows:

1) Using push tool 0, press fit bushing (19) on
cylinder head (20).
+ Be careful not to deform the bushing when
press fitting.
2) Assemble rod packing (18).
+ Be careful to install the rod packing facing
in the correct direction.
208F240A
3) Install back-up ring (16) and O-ring (15).

t 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 0, install dust seal (17) on
head, then secure with snap ring.
63-27
2. Assemble piston assembly as follows:

1) Using tool B, expand piston ring (13).
* Set the piston ring on the tool C and turn
the handle 8 to 11 times to expand the ring.
2) Remove piston ring (13) from tool B and as-
semble on piston (14).
3) Fit tool C on piston ring and compress piston
ring with clamp 0.
-c Part No. of clamp 0.

07281-01919 (Lift cylinder)
07281-02169 (Bucket cylinder)
4) Assemble wear ring (12) on piston.
3. Assemble O-ring (10) and back-up ring (11) on

piston rod (9).
4. Assemble cylinder head assembly (8) and piston

assembly (7) on piston rod.
t Apply the grease to rod to prevent back-up ring
423F484
(11) from sticking out.
5. Assemble spacer (6) then tighten piston bolt (5).

* Width across flats of socket: 19 mm
D Piston bolt: 10-12.5 kgm
63-28
6. Set cylinder (4) in tool A, then raise cylinder assem-

bly and piston rod assembly (3) and install in
cylinder.
7. Tighten mounting bolt (2) of cylinder head.
B Mounting bolt of cylinder head:

85? 10 kgm (Tilt cylinder)
8. Remove cylinder assembly (1) from tool A.
63-29
DISASSEMBLY AND ASSEMBLY WORK EQUIPMENT
WORK EQUIPMENT
REMOVAL

1. Bucket link
1) Remove mounting pin (1) of bucket link.
t Tie the bucket link to the tilt lever with wire.
2) Remove left and right mounting pins (2) of

bucket hinge.
a Do not put your fingers in the pin hole.
3) Drive machine in reverse to disconnect bucket.
Bucket (with teeth): 1540 kg

r5 kg
2. Dump cylinder pin

Sling dump cylinder (3), remove pin (4), then
disconnect cylinder rod and tilt lever.
t Inset-t a block between the cylinder bottom and
frame.
Dump cylinder: 200 kg
3. Lift cylinder pin

Sling lift cylinder (5), remove pin (6), then remove
lift cylinder.
t If shims are inserted, check numbers of shims.
* Place a support under the tip of the lift arm.
* Place a block on top of the axle, and lower the
cylinder onto it.
Lift cylinder: 170 kg
63-30
4. Lift arm, tilt lever, bucket link assembly

Sling lift arm, tilt lever and bucket link assembly (7),
remove mounting pin (8) of lift arm, then lift off lift
arm.
Lift arm, tilt lever, bucket link assembly:

b kg
1530 kg
a If there are any shims, check the number and

place.
5. Tilt lever, bucket link assembly

1) Remove pin (10) from tilt lever (11) and bucket
link assembly (9), and disconnect tilt lever (11)
and bucket link assembly (12).
2) Sling tilt lever (ll), remove mounting pin (13),

then lift off from lift arm (14).
Tilt lever: 333 kg
Bucket link: 56 kg
6. Dust seal, bushing

1) Remove dust seal (15) and bushing (16) from
lift arm (14).
423P12t6 &?3P12:?
423F475
63-31

tilt lever (11).
423F476

bucket link (12).
12
19
20
423F477
63-32
llNSTALlATlON

fingers.
1. Dust seal, bushing

Using a press, press fit bushing (16) in bucket link,
tilt lever, and lift arm, then assemble dust seal (15).
6 Bushing: Grease (G2-Ll)
423F478
2. Tilt lever, bucket link

1) Align holes of tilt lever (11) and lift arm (14)
assemble shim so that clearance “a” on left and
right is equal, then install mounting pin (13) and
lock with bolt.
+ Clearance “a”: Max. 1.5 mm
F42301009
2) Assemble cord ring on bucket link (12), align

holes of tilt lever (ll), then install pin (10) and
lock with bolt.
+ Tie the bucket link to the tilt lever with wire.
* Make sure that the cord ring is not caught.
63-33
3. Lift arm, tilt lever, bucket link assembly

1) Raise lift arm, tilt lever, and bucket link assem-
bly, and set in mounting position. Align holes at
mount of front frame and lift arm, assemble
shim so that clearance “b” on left and right is
equal, then install mounting pin and lock with
bolt.
* When installing the lift arm, be careful not
to damage the boom kick-out switch, and
+ Clearance “lo”: Max. 1.5 mm
+ After installing the pin, set a support under
the tip of the boom.
b
423F479
4. Lift cylinder
Sling lift cylinder (5), start engine and align cylinder
rod with boom mounting hole. Install pin (6), then
lock with bolt.
Before starting the engine, check that the gear

gi 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 installing the pin, remove the block.
63-34
6. Bucket
1) Operate control lever align hole of bucket
mounting pin (2). Assemble shim so that clear-
ance “c” on left and right is equal, then install
mounting pin (2) and lock with bolt.
* Clearance “c”: Max. 1.5 mm
423 F480
2) Install cord ring (20).
7. Bucket link
1) Raise bucket link (12), align hole of mounting
pin (10). Assemble shim so that clearance “d”
on left and right is equal, then install mounting
pin (lo), and lock with bolt.
+ Clearance “d”: Max. 1.5 mm
423F481
2) Install cord ring.
8. Greasing
Grease all pins.
63-36
DISASSEMBLY AND ASSEMBLY COUNTERWEIGHT
COUNTERWEIGHT
REMOVAL

1. Grille
Remove grille.
2. Counterweight
el kg Counterweight: 885 kg
INSTALLATION
1. Counterweight
D Mounting bolt: 94.5 2 10.5 kgm
2. Grille
Install grille.
63-36
WORK EQUIPMENT
SYSTEM
MAINCONTROLVALVE ............................................................ 2
(2 -Spool valve) ................................................................ 2
(3 -Spool valve) ................................................................ 4
DUMP CYLINDER ................................................................ 6
LIFTCYLINDER .................................................................. 7
BUCKET LINKAGE.. .............................................................. 8
BUCKET POSITIONER AND BOOM KICK-OUT .......................................... 11
BUCKET ...................................................................... 12
HYDRAULIC PUMP ._............................................................ 13
64-1
MAINTENANCE STANDARD MAIN CONTROL VALVE
MAIN CONTROL VALVE

(2 - Spool valve)
15
6
16
10
\
2
18 17 3
Section A-A
423F229
64-2
(2 - Spool valve)
Unit: mm

I
Poppet spring of relief valve 49.3 41.9 1 26.4 kg 47.8 1 21.2 kg Replace
I I I
6 Tightening torque of plug at end of 6.8k.7 kgm
spool (DUMP, LIFT)
7 Tightening torque of joint at end of 6.82.7 kgm

spool
8 Tightening torque of adjustment lever 3.2 f .3 kgm

lock bolt
Tightening torque of cover mounting 3.2 2.3 kgm

bolt I
10 Tightening torque of main relief valve 15.522.5 kgm
11 Tightening torque of adjustment screw 3.2k.3 kgm Retighten

lock nut
12 Tightening torque of safety valve with 14+1 kgm

suction valve
13 Tightening torque of suction valve 14+1 kgm
14 Tightening torque of plug 15.522.5 kgm
15 Tightening torque of plug 7kl kam
16 Tightening torque of case mounting 3.2t.3 kgm

bolt
17 Tightening torque of plug I 47.5 +2.5 kgm I
18 Tightening torque of plug 37.5 22.5 kgm
64-3
. -.
MAIN CONTROL VALVE

(3 - Spool valve)
15
16
ia
F424CO126
64-4
(3 Spool valve)
Unit: mm
ring (for DUMP, LIFT,
Poppet spring of relief valve
6 Tightening torque of plug at end of 6.8k.7 kgm

spool (DUMP, LIFT, ATTACHMENT)
7 Tightening torque of joint at end of 6.8k.7 kgm

spool
8 Tightening torque of adjustment lever 3.22.3 kgm

lock bolt
9 Tightening torque of cover mounting 3.2 2.3 kgm

bolt
10 Tightening torque of main relief valve 15.5+2.5 kgm
11 Tightening torque of adjustment screw 3.22.3 kgm Ftetighten

lock nut
12 Tightening torque of safety valve with 1421 kgm

suction valve
13 Tightening torque of suction valve 1421 kgm
14 Tightening torque of plug 15.5+2.5 kgm
15 Tightening torque of plug 7+l kgm
16 Tightening torque of case mounting 3.2k.3 kgm

bolt
64-5
MAINTENANCE STANDARD DUMP CYLINDER
DUMP CYLINDER
i 1 h 6 3
Ll OBR025
Unit: mm
1 Clearance between dump

cylinder rod and bushing
3 Clearance between cylinder

bottom mounting pin and
4 Cylinder bore 200 + .3 +.3

0 0
5 Tightening torque of cylinder 5025 kgm

head mounting bolt
Tightening torque of piston Retighten

6 11.5+1 kgm
mounting bolt
64-6
MAINTENANCE STANDARD LIFT CYLINDER
LIFT CYLINDER
Ll OBR059
Unit: mm
No Check item Criteria Remedv
1 Clearance between rod and

bushing
Clearance between piston rod 95 Replace

mounting pin and diameter of
hole
Clearance between cylinder

bottom mounting pin and
bushing
Cylinder bore I Standard size I Tolerance I Repair limit
160 +.40
0
5 Tightening torque of cylinder 12Ok30 kgm

head mounting bolt
Retighten
6 Tightening torque of piston 11.5&l kgm
mounting bolt
64-7
MAINTENANCE STANDARD BUCKET LINKAGE
BUCKET LINKAGE
a b a b i
Section A-A Section B-B Section C-C
a a b
Section D-D Section E-E Section F-F
17
-8
a b a b a b
424F3 I6
Section G-G Section H-H Section J-J
64-8
MAINTENANCESTANDARD BUCKETLINKAGE
- Unit:mm
i=
No Check item
1 Criteria
- Remedy
Clearance between pin and bushing at

boss ends of bucket link
Standard Tolerance 1 Standard
clearance
Clearance
limit
Hole

joint of lift arm and bucket
3 Clearance between pin and bushing at

joint of lift arm and frame

joint of bucket cylinder bottom and Replace also if oth-
frame -.036 + .207 .156- 1 er parts are biting
-.OQO +.120 .297 into pin
joint of bucket cylinder rod and lever
Clearance between pin and bushing at 120

joint of tilt lever and lift arm I
I
7 Clearance between pin and bushing at 95
8
joint of lift cylinder bottom and lift arm

ioint of lift cvlinder rod and lift arm -I 95
Width between
- L
Width of hinge
L 1
Standard clearance
bosses (clearance a + b)
9 Joint of bucket cylinder and frame
+.8 1.7-5.5
110
0
Joint of lift arm and frame 122t1.5 +3

129 Insert shims on
0 both sides to make
clearance on both
left and right sides
Joint of lift arm and bucket 106k1.5 t1.5
less than 1.5 mm
108
0
Joint of bucket link and bucket t2.8 t1.5

112.5 116
-.5 0
Joint of lift cylinder and frame +.8 +3 2.7-6.5

90 93.5
0 0
Joint of tilt lever and bucket link t2.8 117k1.5 .2-6.5

112.5
-.5
Replace
Joint of tilt lever and lift arm 223k.5
64-9
MAINTENANCE STANDARD BUCKET LINKAGE
1 fj Joint of tilt lever and bucket cylinder +.8 117r1.5 4.7-8.5 Insert shims on
both sides to make
110
clearance on both
0 left and right sides
less than 1.5 mm
17 Joint of lift cylinder and lift arm 10321.5 106+1.5 O-6 Insert shims on
both sides to make
clearance on both
left and right sides
less than 2.5 mm
64-10
MAINTENANCE STANDARD BUCKET POSITIONER 81 BOOM KICK-OUT
BUCKET POSITIONER AND BOOM KICK-OUT
5.5 f 2 kgm
m 1 8 % 0.2 kgm
1 423F645
Section A-A
Unit: mm
1 Clearance of bucket positioner switch

3-5 Adjust
2 Clearance of boom kick-out switch
64-11
MAINTENANCE STANDARD BUCKET
BUCKET
Section A-A
U42401013
Unit: mm
NO Check item Criteria Remedy
1 Wear of cutting edge (thickness) 32 14 Replace
2 Wear of cutting edge (length) 76+11 kgm Retighten
64-12
MAINTENANCE STANDARD HYDRAULIC PUMP
HYDRAULIC PUMP
0 SAR(3)-80+63+50+(l)-12
7.2 kgm
25 - 31.5 kgm 25 - 31.5 kgm 16.0 - 20.0 kgm

16.0 - 20.0 kgm
16.0 - 20.0 kgm F42301 IlOA
Unit: mm
Model Standard clearance Clearance limit
Clearance between gear case and side

SAR(3)-63
plate, gear
SAR(3)-80 .l-.15
SAR(3)-50
SARHL12
Replace
Clearance between inside diameter of .20

plain bearing and outside
SAR(l)-12 .06-. 119
I I
Model Revolution Discharge Standard Repair limit
(rpm) pressure discharge discharge
(kg/cm* 1 (elmin) (elmin)
SAR(3)-80 2500 210 184 170

(Front)
SAR(3)-63 2500 210 145 134

(Middle,
Front) -
Discharge
Oil: EOl O-CD
Temperature: 45-55°C SAR(3)-50 2500 210 112 102
(Middle,
Rear)
SAR(l)-12 2500 30 40 37
(Rear)
64-13
MAINTENANCE STANDARD HYDRAULIC PUMP
4 insertion depth of pin Model Standard Tolerance Repair Replace

size limit
SAR(3)-80
SAR(3)-63 14
SAR(3)-50 0
SAR(l)-12 10 -5
5 Rotating torque of spline shaft 2.3-4.1 kgm
64-14
ELECTRIC AND
ELECTRONIC SYSTEM
ELECTRICAL WIRING DIAGRAM ...................................................... 2
ELECTRICAL WIRING 3D CIRCUIT DIAGRAM ............................................ 2
ELECTRICAL WIRING CONNECTORS (CN) DIAGRAM ...................................... 2
ENGINE STARTING CIRCUIT ........................................................ 3
ENGINE STOP CIRCUIT ............................................................ 5
ELECTRICAL TRANSMISSION CONTROL ............................................... 6

COMBINATION SWITCH.. ........................................................ 7
TRANSMISSION CUT-OFF SWITCH ................................................. 8
TRANSMISSION CUT-OFF SELECTOR SWITCH ........................................ 9
NEUTRALIZER RELAY ........................................ 10
KICK-DOWN SWITCH .......................................... 11
KICK-DOWN ELECTRIC CIRCUIT .................................. 12
ELECTRICAL PARKING BRAKE CONTROL ........................... 18
ELECTRONIC VEHICLE MONITORING SYSTEM (EVMS) ................. 27

INDICATION ON MONITOR PANEL. .............................. ..... ...... .... 29
SENSORS ................................................. 31
ENGINE OIL LEVEL SENSOR ................................. ... ..... ....... 32
COOLANTLEVELSENSOR ................................... 32
COOLANT TEMPERATURE SENSOR ............................ 33
TORQUE CONVERTER OIL TEMPERATURE SENSOR ............... . ..... ..... .... 33
PARKING BRAKE SENSOR ................................... 34
ENGINE OIL PRESSURE SENSOR ............................. ..... .... ...... 34
BRAKE CHAMBER STROKE SENSOR ........................... 35
AIR PRESSURE SENSOR .................................... ..... .... ...... 35
ROTATIONALSPEED SENSOR ................................ 36
FUEL GAUGE SENSOR ..................................... 37
WIRING HARNESS.. ......................................... 38
BUCKET POSITIONER AND BOOM KICK-OUT ... .. . ........ .. ..... ....... 39
81-l
STRUCTURE AND FUNCTION ELECTRIC AND 3D FOLDOUT
ELECTRICAL WIRING DIAGRAM
See Foldout #‘s 5, 6 & 7 at end of book.
ELECTRICAL WIRING 3D CIRCUIT DIAGRAM
ELECTRICAL WIRING CONNECTORS (CN) DIAGRAM
See Foldout #lO at end of book.
81-2
STRUCTURE AND FUNCTION ENGINE STARTING CIRCUIT
ENGINE STARTING CIRCUIT
BATTERY
L08AD039
Function @ Battery (t) - starting switch terminal B 4 starting

l To ensure safety when starting the engine, the switch terminal C - safety relay terminal S - safety
system is equipped with a neutral safety circuit. relay terminal B - directional lever switch terminal N
This makes it impossible for the engine to start if - ground, so the safety relay switch is closed.
the directional lever is not at the N (Neutral) posi- In addition, current flows from starting switch
tion. terminal BR - battery relay coil - ground, so the
battery relay switch is closed. This forms the follow-
Operation ing circuit.
l When the directional lever is placed at the N (Neu- @ Battery (t) - battery relay - starting motor termi-
tral) position, the neutral contacts of the directional nal B 4 safety relay terminal B 4 safety relay termi-
lever switch are closed. In this condition, if the nal C - starting motor terminal C, and the engine
starting switch is turned to the START position, starts.
current flows in the following circuit. If the directional lever is at any position other than
N (Neutral), circuit @ is not formed, and the engine
does not start.
81-3
STRUCTURE AND FUNCTION ENGINE STARTING CIRCUIT
a) Safety relay
TERMINAL 6 n
TERMINAL C
CONNECTOR 1
iI 2
TERMINAL B
TERMINAL C
SAFETY REIAY CONNECTION CHART
L08CD007
81-4
STRUCTURE AND FUNCTION ENGINE STOP CIRCUIT
ENGINE STOP CIRCUIT

Operation
l When the starting is turned ON, electric current l When the starting switch is turned OFF, circuit @ is
flows in the following circuit. shut off, but the engine is rotating, so there is still
@ Battery (+) - starting switch terminal B - starting voltage at terminal R of the alternator. For this
switch terminal BR - fuel cut solenoid - ground reason, the following circuit is formed.
connection. @Alternator terminal R - battery relay terminal BR
When electric current flows to the fuel cut solenoid, - ground connection.
the fuel governor is put in the FREE position by the The battery relay is maintained, but because of the
fuel control linkage. diode inserted into the circuit, no electric current
Fuel flows to the fuel injection pump and the engine flows to the fuel cut solenoid, so the engine stops.
starts.
t To safety relay
(terminal C)
Startmg switch Alternator
To safety relay
(terminal R)
To starting motor
“-- IJ.. Y
Battery relay 1 H
L08AD075
81-5
STRUCTURE AND FUNCTION ELECTRICAL TRANSMISSION CONTROL
ELECTRICAL TRANSMISSION CONTROL
Kick-down switch
Transmission cut-off (Lift control lever)
console)
Combination switch
FORWARD-REVERSE leve
Transmission cut-off switch
421FO1049
Function
Selection of FORWARD,
FORWARD-REVERSE lever
REVERSE and NEUTRAL
Selection of travel speed range Speed control lever
When traveling in F2 it is possible to use this switch to shift down to

Fl regardless of the position of the speed control lever.
Kick-down switch
If the directional lever is placed in R or N, the transmission
automatically returns to 2nd.
Transmission cut-off function Transmission returned to neutral when left brake is operated.
Selects if transmission cut-off function is used or not used.

Transmission cut-off selection With this function, the left brake pedal can be used to get even better
function performance than conventional loaders in digging operations or ease
of steering when loading on to trailers.
To prevent the operator from driving off when the parking brake is
Neutralizer function still applied and causing seizure of the parking brake, the transmis-
sion is returned to neutral when the parking brake is applied.
The engine can only be started if the FORWARD-REVERSE lever is in

neutral. In any other position the engine will not start.
7 Neutral safety function
This prevents-the machine from star&g suddenly. (For details, see
STARTING CIRCUIT.)
When the machine is driven in reverse, a back-up lamp lights up and

8 Warning function
a back-up horn sounds to warn people standing near the machine.
81-6
COMBINATION SWITCH
9
1
.F
\ ‘N
\
OR
---_ :2
:31
‘I
2
3
\
(
[ 7 _-___-_______--_---_-_____-.
423F188A
Outline
l The FORWARD-REVERSE lever has three contacts; When the lever is moved to the desired position, the
the speed control lever switch has four contacts. switch, which is connected by a shaft, moves and
The switch alone has no detent mechanism. The electric current flows in only that circuit to move the
detent mechanism is in the combination switch machine.
itself. Each switch is held at two places by pins. In
addition, each switch is secured to the base by
three screws.
Function
1 FORWARD-REVERSE lever switch Selecting FORWARD, REVERSE or NEUTRAL
2 Speed control lever switch Selecting machine speed range
Prevents speed control lever from going into 3rd or 4th speed
3 Speed control lever stopper
during operations
4 1 Direction indicator lamp I Indicates direction when turning left or right

Returns direction indicator lamp lever to neutral
5 Self cancel
automatically after turning left or right
6 Lamp switch Selects clearance lamps, headlamps, parking lamps
7 Dimmer switch Selects travel beam, low beam
8 Emergency flasher switch Makes left and right turn signal lamps operate at the same time
9 Emergency flasher pilot lamp Flashes when emergency flasher lamp is ON
81-7
TRANSMISSION CUT-OFF SWITCH
l 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 trans-
mission to neutral.
- From rear au tank
Two-way check valve
Stop-lamp swtch
-- From front brake tank
wo-way check valv
- To front brake
ra”SrrIssIo”
- From rear brake tank
ut-off switch
- To rear brake
- From front aw tank
421F123
Diaphragm
\
421 FO1050
81-8
TRANSMISSION CUT-OFF SELECTOR SWITCH
Outline 2. Transmission cut-off selector switch at ON

l This is a waterproof toggle switch for two circuits l The points of the cut-off selector switch are
installed in parallel with the transmission cut-off separated, and current flows to the directional
switch at the power source end of the transmission clutch solenoid valves only from the cut-off
directional circuit. switch.
0 When the left brake pedal is depressed, the
Operation points of the cut-off switch are separated by air
pressure, and the electric current to the direc-
1. Transmission cut-off selector switch at OFF tional solenoid valve is shut off.
l The points of the cut-off selector switch are in As a result, the brake acts as a normal brake,
contact, and current always flows to the direc- and, at the same time, places the transmission
tional clutch solenoid valves from the cut-off in neutral.
selector switch and cut-off switch.
l When the left brake pedal is depressed, the
points of the cut-off switch are separated by air
pressure, and the electric current is shut off.
However, electric current still flows to the direc-
tional solenoid valve from the cut-off selector
switch, so the brake acts normally in the same
way as the right brake.
81-9
NEUTRALIZER RELAY
Back-up lamp &stop lamp
terminal R
To machine
monitor *
Transmission
Kick-down
switch
switch (manual)
cut-off switch
(actuated by
air pressure)
th
Machine monitor SyStem

neutral terminal
Back-up horn Back-up lamp L08CDDD8
Operation
1. When the parking brake is applied (ON), electric 3. When the parking brake switch is turned OFF
current flows from battery relay - parking brake (brake released), and the engine is started, the
switch terminal (3) - terminal (2) - parking brake circuit in Section 1 is not formed, so the parking
safety relay terminal (2) - ground. As a result, the brake switch must be turned ON before the engine
coil of the safety relay is actuated, and terminal (3) will start.
and terminal (5) of the safety relay are joined to
form this circuit.
2. When the parking brake is applied, no electric

current flows to the coil of the neutralizer relay, so
terminal (3) and terminal (5) of the neutralizer relay
are separated. As a result, no electric current flows
to the transmission directional circuit, so the trans-
mission is kept in neutral while the parking brake is
applied.
81-10
STRUCTURE AND FUNCTION KICK-DOWN SWITCH
KICK-DOWN SWITCH
1. Switch
2. Washer
3. Screw
4. Cover
5. Body
6. Cable
Circuit structure
6Y----II
Q
421FO1053
Operation The kick-down is canceled (or will not operate)

l The kick-down (shift down from 2nd to 1st) oper- under the following conditions.
ates only when the transmission is in FORWARD 2. l When the directional lever is at N.
l When traveling in FORWARD 2, if it is desired to l When the directional lever is at R.
shift down to 1st without operating the speed l When the speed control lever is at any position
control lever, it is possible to shift down to 1st by other than 2.
pushing the kick-down switch at the top of the left l When the parking brake is applied.
lever. l When the starting switch is at OFF.
l After this, even if the kick-down switch is pressed,
the transmission remains in FORWARD 1.
81-11
STRUCTURE AND FUNCTION KICK-DOWN ELECTRIC CIRCUIT
KICK-DOWN ELECTRIC CIRCUIT

Normally ON
When directional lever is in FORWARD When weed control lever is Dlaced in 2nd
l If the directional lever is placed at F, current flows When the speed control iever is placed in 2nd,
from battery (+) - neutralizer relay terminal (3) - current flows from battery (+) - 2nd solenoid relay
terminal (5) - FORWARD solenoid relay terminal (6) terminal (2) - terminal (1) - speed control lever
- terminal (5) - directional switch terminal F - switch 2nd terminal - ground, and the 2nd solenoid
ground. relay is actuated.
As a result, the FORWARD solenoid relay is actuat- When the 2nd solenoid relay is actuated, the circuit
ed, and the circuits between terminals (1 and 2) between terminals (3 and 5) is closed, and current
and terminals (3 and 4) are closed. flows from battery (t) - 2nd solenoid - 2nd sole-
e Next, current flows from battery (+) - neutralizer noid relay terminal (5) - terminal (3) - 2nd-1st
relay terminal (3) - terminal (5) - transmission cut- selector relay terminal (6) - terminal (3) - ground,
off switch - FORWARD solenoid - FORWARD and the 2nd solenoid is actuated to shift the trans-
solenoid relay terminal (2) - terminal (1) - ground. mission to 2nd.
The FORWARD solenoid is actuated, and the When the kick-down switch is actuated, the circuit
FORWARD clutches are joined. between terminals (3 and 6) of the 2nd-1st selector
relay contacts is opened, and the circuit between
contact terminals (3 and 5) is closed, so current
passes through the 1st solenoid, and the transmis-
sion is shifted to 1st.
81-12
When kick-down switch is operated

(When operating or traveling with speed control lever ar F2)
When kick-down switch is pushed ON

l When the kick-down switch is pressed, current terminals (2 and 1) - ground. The coil of the 2nd-
flows from battery (+) - neutralizer relay terminals 1st selector relay is actuated, the circuit between
(3 and 5) - kick-down switch - FORWARD solenoid terminals (3 and 6) is opened, and the circuit be-
relay terminals (4 and 3) - kick-down relay terminals tween terminals (3 and 5) is closed.
(6 and 5) - speed control lever switch 2nd terminal l When the circuit between 2nd-1st selector relay
- ground. As a result, the kick-down relay coil is terminals (3 and 6) is opened, electric current stops
actuated, and the circuits between terminals (1 and flowing to the 2nd solenoid.
2), and terminals (3 and 4) of the kick-down relay l When the circuit between the 2nd-1st selector relay
are closed. terminals (3 - 5) is closed, the electric current is
l A circuit is then formed from kick-down relay termi- switched to a circuit from battery (+) - 1st solenoid
nals (2 and 1) - FORWARD solenoid relay terminals - 2nd-1st selector relay terminals (5 and 3) -
(4 and 3) - kick-down relay terminals (6 and 5) 4 ground, and flows from the 2nd solenoid to the 1st
speed control lever switch 2nd terminal - ground. solenoid, so the transmission is shifted down from
Following this, even if the kick-down switch is 2nd to 1st.
canceled, the kick-down relay continues to be After the transmission is shifted down, even if the
actuated. (Self-hold circuit of kick-down relay). kick-down switch is pressed again, the circuit
l When the kick-down relay is actuated, in the 2nd- between kick-down relay terminals (1 and 2) (con-
1st selector relay coil, current flows from battery (+) nected in parallel to both ends of the switch) is
- neutralizer relay terminals (3 and 5) - kick-down closed, so there is no effect on the operation of the
relay terminals (4 and 3) - 2nd-1st selector relay kick-down switch when it is being operated.
81-13
Cancellation of kick-down switch I

(When directional lever is placed at N or R)
I I I
L08ADO43
If the directional lever is placed at any position is reset, so the circuit between terminals (3 and 5)
except F, the F terminal contacts are OFF, so is opened, and the circuit between terminals (3 and
electric current stops flowing in the circuit from 6) is closed.
battery (+) - neutralizer relays terminals (3 and 5) The electric current stops flowing in the circuit from
- FORWARD solenoid relays terminals (6 and 5) - battery (+) - 1st solenoid - 2nd-1st selector relay
directional switch terminal F - ground, and the terminals (5 and 3) - ground, so the kick-down to
FORWARD solenoid is reset. 1st is canceled.
When this happens, the circuit between FORWARD Next, the circuit between terminals (3 and 6) of the
solenoid relay terminals (3 and 4) is opened, so Pnd-1st selector relay is closed, so electric current
electric current stops flowing to the circuit between flows to the 2nd solenoid, and the transmission is
kick-down relay coil terminals (6 and 5). The kick- shifted back to 2nd, the position of the speed
down relay is then reset, and the self-hold circuit is control lever.
canceled. In this way, the operation of the kick-down switch is
When the kick-down relay is reset, the circuit canceled, and the machine travels at the position
between terminals (3 and 4) of the kick-down relay indicated by the speed control lever. If the direction-
is opened, so the current stops flowing in the circuit al lever is shifted to R, the machine will travel in
from neutralizer relay terminal (5) - kick-down relay REVERSE 2.
terminals (4 and 3) 4 2nd-1st selector relay termi-
nals (2 and 1) - ground. The 2nd-1st selector relay
81-14
Cancellation of kick-down switch II

(When speed control lever is at position other than 2nd)
4th
If the speed control lever is placed at any position terminals (4 and 3) - 2nd-1st selector relay termi-
except 2, the circuit between the speed control nals (2 and 1) - ground.
lever 2nd terminal and ground is opened, so electric As a result, the 2nd-1st selector relay is reset, so
current stops flowing in the circuit from battery (+) the circuit between terminals (3 and 5) is opened.
- neutralizer relay terminals (3 and 5) - kick-down The current then stops flowing to the 1st solenoid,
relay terminals (2 and 1) - FORWARD solenoid so the kick-down to 1st is canceled, and the trans-
relay terminals (4 and 3) kick-down relay terminals mission is shifted back to the position of the speed
(6 and 5) - speed control lever switch 2nd terminal control lever.
- ground, and the kick-down relay is reset. The circuit between speed control lever 2nd termi-
When this happens, the circuit between kick-down nals and ground is opened, so the 2nd solenoid is
relay terminals (1 and 2) is opened, and the self- reset. As a result, even if the circuit between termi-
hold circuit is canceled. Therefore, even if the speed nals (3 and 6) of the 2nd-1st selector relay is
control lever is again placed in 2nd, the system will closed, the circuit between 2nd solenoid terminals
not be returned to the condition where the kick- (3 and 5) is open, so the 2nd solenoid circuit is also
down switch is actuated. canceled.
At the same time, the circuit between terminals (3 In this way, the operation of the kickdown switch is
and 4) of the kick-down relay is opened, so the canceled, and the machine travels at the position
electric current does not flow in the circuit from indicated by the speed control lever.
neutralizer relay terminal (5) - kick-down relay
81-15
Cancellation of kick-down switch Ill

(When parking brake is applied)
&k-up horn -L-Up bmp

L08AD045
l If the parking brake switch is turned ON (brake l When the end-1st selector relay is reset, the circuit
applied), electric current stops flowing to the park- between terminals (3 and 5) of the 2nd-1st selector
ing brake valve and the parking brake is applied. relay is opened, electric current stops flowing to the
When this happens, the neutralizer relay is also 1st solenoid, and the circuit between terminals (3
reset at the same time, so the circuit between and 6) is closed, so a circuit is formed from battery
neutralizer relay terminals (3 and 5) is opened, and (+) - 2nd solenoid - 2nd solenoid relay terminals (5
electric current stops flowing to the directional and 3) 4 2nd-1st selector relay terminals (6 and 3)
circuit of the transmission. The transmission is set - ground. Current flows to the 2nd solenoid, and
in neutral, the kick-down relay and 2nd-1st selector the transmission is shifted to 2nd, the position of
relay are reset, and the actuation of the kick-down the speed control lever.
is canceled. l In this way, the kick-down operation is canceled
when the parking brake is applied. In addition, the
directional lever switch is set at neutral, the trans-
mission gear is set to 2nd, and the machine stops.
81-16
Cancellation of kick-down switch IV

(When starting switch is turned OFF)
l When the starting switch is turned OFF, the battery

relay is opened, so electric current stops flowing to
the directional circuit and speed circuit of the trans-
mission, so the kick-down action is canceled.
l When the starting switch is at OFF, the kick-down
switch cannot be actuated even if the kick-down
switch is turned ON (actuated).
81-17
STRUCTURE AND FUNCTION ELECTRICAL PARKING BRAKE CONTROL
ELECTRICAL PARKING BRAKE CONTROL

Outline
l When electrical current flows to the parking brake l When the electric current is stopped, the air pres-
valve (solenoid valve), air pressure from the air tank sure from the air tank is cut off. The air pressure
(wet tank) is applied to the spring cylinder and the inside the spring cylinder passes through the
parking brake is released. parking brake valve and is released. The parking
brake is then actuated by the force of the spring.
L08CDOlO
1. Parking brake switch 5. Parking brake valve

2. Parking safety relay 6. Air tank (Wet)
3. Not used 7. Emergency brake switch
4. Neutralizer relay 8. Spring cylinder
81-18
Function
Actuation and release
Parking brake switch used
of parking brake
Parking brake is automatically applied when engine is stopped (starting switch

Automatic parking
is turned to OFF). This prevents the machine from running away when the
brake
operator leaves his seat.
The parking brake is automatically applied when it is impossible to maintain

braking power because of a drop in the air pressure inside the tank caused by
3 Emergency brake
damage to the air circuit. In this way, the parking brake acts as an emergency
brake.
It is dangerous if the parking brake can be canceled simply by turning the

starting switch on after the automatic parking brake has been applied. There-
4 Parking brake safety fore, to ensure safety, the system is designed so that the brake cannot be
canceled unless the parking brake switch is turned ON (brake applied) after the
starting switch is turned to the ON position.
If the machine is driven with the parking brake still applied, the parking brake
will seize up.
Therefore, the caution lamp lights up and the caution buzzer sounds to warn
the operator of this mistake in operation. At the same time, when the parking
brake is applied, the transmission is moved to neutral, so it is impossible for
5 Neutralizer the machine to move. However, when the parking brake is used as an
emergency brake, if the transmission is returned to neutral, the braking
distance will increase and the machine may stop in a dangerous place (for
example, on a railroad crossing). For this reason, the circuit is designed so that
the transmission is not returned to neutral when the emergency brake is
applied.
Parking brake switch
Connection table
Large size multi-pin connector

(3 pole blue1 with lock
I OFF (released)
View Z Water proof O-ring 423F195
for panel face
81-19
PARKING BRAKE VALVE
Valve actuation table

To parking brake chamber
From air tank
PortNo 3 Port No. 1
423F196
423F196A
PARKING SAFETY RELAY

NEUTRALIZER RELAY
Relav connection chart
Termnal No 1
Relay actuation table
TerminalNo 2 Terminal No.5
m\
unal
423F197A
/ Terminal NO 6
Black
EMERGENCY BRAKE SWITCH
423F198
81-20
1. STARTING SWITCH OFF

l When the starting switch is turned OFF, the
battery relay is opened, so no electricity flows
to the parking brake circuit. For this reason, if
the starting switch is OFF, no electricity flows to
the parking brake valve regardless of whether
the parking brake switch is ON (actuated) or
OFF (released). As a result, the parking brake
is actuated. (Automatic parking brake).
Parking brake Parking brake

switch Imanual) safety relay Neutralizer relay
Cd
OFF
Startxitch 1
I!1
!* Alternator
BR terminal R
To transmission
FORWARD-REVERSE
circuit
To transmission Emergency brake
spaed circuit switch L08ADW7
(with wet tank)
81-21
2. STARTING SWITCH ON
2-1A. When parking brake switch is turned ON

before starting switch is turned ON
0 Electric current is flowing in circuit @ battery (+) l In this condition, electric current does not flow
- starting switch 4 battery relay coil - ground, to the parking brake valve, so the parking brake
so the battery relay is closed. For this reason, is applied.
the current flows in circuit @ battery (+) - 0 Furthermore, in this condition, the circuit be-
battery relay - parking brake switch terminals (3 tween terminals (3 and 5) of the neutralizer
and 2) - parking safety relay terminals (2 and 1) relay is opened, so electric current does not
- ground. Because of this, the parking safety flow to the directional circuit of the transmis-
relay is actuated, and the circuit between sion, and the transmission is olaced in neutral.
terminals (5 and 3) of the safety relay is closed.
When this happens, the following circuit @ is
formed: battery (+) - battery relay - parking
safety relay terminals (3 and 5) - parking safety
terminals (2 and 1) - ground, and the parking
safety relay remains as circuit @ until the start-
ing switch is turned OFF.

switch (manual) safety relay Neutralizer relay
Battery rleay
Battery
Startina switch IT

speed circuit switch
(with wet tank)
L08ADW8
81-22
2-2. Parking brake switch turned OFF (released)

before starting switch is turned ON
l Electric current flows as follows. flows to the parking brake valve. Therefore,
(1) Battery (+) - starting switch - battery relay after the automatic parking brake is actuated,
coil - ground connection, so the battery relay even if the starting switch is turned to ON, the
is CLOSED. parking brake is not automatically released.
However, in this case, the parking brake switch l In addition, no electric current flows to the
is OFF (released), so the parking safety relay is FORWARD-REVERSE circuit of the transmis-
not actuated. For this reason, no electricity sion, so the machine does not move.
Patlung brake Parking brake

switch (manual) safety relay Neutralizer relav

L08ADO49
(with wet tank)
81-23
3. PARKING BRAKE SWITCH TURNED OFF

(RELEASED) AFTER STARTING SWITCH IS
TURNED ON.
l If the parking brake switch is moved from ON Circuit @ is formed from emergency brake
(applied) to OFF (released), a circuit is formed switch - parking brake valve - ground, and the
between terminals (1 and 2) of the parking parking brake is released.
brake switch. In addition, the parking brake Circuit @ is formed from battery (+) - battery
safety relay is actuated, so electric current flows relay - neutralizer relay terminals (3 and 5) -
from circuit @ battery (+) - battery relay - Transmission directional circuit, so the machine
parking brake safety relay - arking brake moves according to the operation of the direc-
switch to the following circuits 8 and 0. tional lever.

___ -
I-- 1
Battery rleay
Battery
Starting switch
._ _._.._ ___
FORWARD-REVERSE
cxcut
To transmission. Emergency brake
(with wet tank)
8-l -24
4. PARKING BRAKE SWITCH ON (OPERATED)

o After operating with the parking brake switch at l At the same time, the neutralizer relay is also
OFF (released), if the parking brake switch is restored, so the circuit between terminals “3”
turned to ON (operated), the circuit becomes and “5” is OPEN. No electric current flows to
as shown below. the FORWARD-REVERSE circuit of the trans-
l No electric current flows to the parking brake mission, so the transmission is placed in neu-
valve, so the air pressure from the air tank tral. In this way, when the parking brake is
acting on the spring cylinder is shut off. At the operated, the neutralizer relay shuts off the
same time, the air pressure inside the spring electric current to the transmission solenoid
cylinder passes through the parking brake valve valve and puts the transmission in neutral. As a
and is released, so the parking brake is actuat- result, there will be no seizing of the parking
ed by the force of the spring. brake caused by the machine being driven with
the parking brake still applied.

e-
OFF
Battery dew
r---
I
Starting switch
I’ ‘i-i’ ’ 1
._ Alternator
_ terminal R

s-d circuit switch
L08AD051
(with wet tank)
81-25
5. WHEN AIR PRESSURE DROPS.

(EMERGENCY BRAKE ACTUATED)
Operation
l If the air pressure drops, the emergency brake l For this reason, electric current flows to the
switch installed to the dry tank is opened. FORWARD-REVERSE circuit of the transmis-
For this reason, the electric current stops flowing to sion, and it is possible to connect the trans-
the parking valve, so the air pressure inside the mission clutch. Therefore, when the emergency
spring cylinder is released, and the parking brake is brake is actuated, the engine also acts as a
applied. brake. This makes the braking distance shorter,
However, this case is different from when the and at the same time, if the emergency brake is
parking brake switch is turned ON (brake applied), actuated, and it is necessary to move the
because electric current is flowing to the neutralizer machine (for example, if the emergency brake
relay coil. was actuated on a railroad crossing), the ma-
chine can be driven by operating the transmis-
sion lever.
Parking brake
Parking brake
switch (manual)
satety relay Neutralizer relay
--
OFF n ON rr
----
rjIIn6
--- -
Battery rleay
Starting switch
TO transmission,
(with wet tank)
L08AD052
81-26
STRUCTURE AND FUNCTION ELECTRONIC VEHICLE MONITORING SYSTEM
ELECTRONIC VEHICLE MONITORING SYSTEM (EVMS)

Outline
l The electronic vehicle monitoring system is a o The displays can be broadly divided into CHECK
system to inform the operator of the condition of items (1) and CAUTION items (2 and 3) which
the machine. It consists of sensors installed in display warnings if any abnormality arises in the
various parts of the machine, which observe the machine, and gauges (5) speedometer (7), and
condition of the machine and process the informa- service meter (9), which always display the condi-
tion speedily, and display the situation on the tion of the machine.
monitor panel.
l The electronic vehicle monitoring system consists of
the monitor panel, sensors, warning buzzer, warning
lamp and power source.
Warning lamp Warning buzzer
Sensor
421FO1039
81-27
4A \ \ \
View Z
L08CHOO2 ~
1. Check 4. Pilot indicator

1A. 4A. Transmission cut-off
1B. Engine oil level 48. Parking brake
IC. Coolant level 4C. Work lamp
2. Caution (Warning) 4D. Preheat monitor
2A. Battery charge 5. Gauge
2B. Fuel level 5A. Air pressure
3. Caution (Emergency warning) 58. Coolant temperature
3A. Brake line failure 5C. Torque converter oil temperature
3B. Engine oil pressure 5D. Fuel level
3C. Coolant level 6. Turn signal pilot lamps
3D. Air pressure 7. Speedometer
3E. Coolant temperature 8. Head lamp (High beam)
3F. Torque converter oil temperature 9. Service meter
10. Service meter indicator
81-28
INDICATION ON MONITOR PANEL

Category indication item Indication range Description
Engine oil level Below low mark Displayed when starting switch is turned to
Checks
ON with engine stopped.
before
Display goes out when normal
starting
Below low mark Display flashes when abnormal
Coolant level
When charging Emergency steering actuated when operat-

Battery charge ed.
is defective
Displays when engine is running
Caution 1
Fuel level Below low mark Display flashes when abnormal and
lamps flash at the same time
Brake chamber When stroke is

stroke over
Engine oil Below specified

pressure pressure
Coolant level Below low mark Display when engine is running.

Caution 2
Display flashes when abnormal; buzzer
Below specified and lamp actuated
Air pressure
pressure
Coolant
Above 105” C
temperature
Torque converter
Above 105” C
oil temperature
Parking brake When operated
Display when starting switch is turned ON;

Pilot Work lamp When operated Lights up when operated
Transmission
When operated
cut-off
81-29
Category Symbol Indication item Indication range Description
Travel speed O-100 MPH Digital display
---
Speed-
-- 0 High beam When operated
Displays when starting switch is turned ON;
ometer Lights up when operated
CID Signal lamps
When operated
(right, left)
QD Hazard When operated Lights up when operated
Actuated when engine oil pressure is

0-99999/h
Service meter normal.
displayed
Advances 1 for every hour of operation
Service
meter
Service meter
Flashes when service meter is operating
indicator
Red
G rem
Air pressure One lamp lights up to indicate level
Red
N
Red 115Oc
102t3"1
$
97Oc
Coolant Green
90” c One lamp lights up to indicate level
temperature
80°C
67°C
White
Gauge
H
Red 130°c
120°C
Torque converter 110°C
One lamp lights up to indicate level
oil temperature Green
90°C
7o”c
50°C
C
FULL
617
Green 517
p3 Fuel level 417

317
All lamps light up below indicated level
217
Red EMPTY
81-30
SENSORS
Function
l The signals from the sensors are directly input to
the monitor panel. With contact type sensors, one
side is always grounded to the chassis. When the
contacts are closed, the panel recognizes that the
sensor signal for the engine oil pressure is reversed
by the relay.
Sensor actuation table

Check item Sensor type When normal When abnormal
Engine oil level Contact ON OFF
Coolant level Contact ON OFF
Fuel level Resistor
Engine oil pressure Contact ON OFF
Coolant temperature Resistor
Torque converter oil temperature Resistor
Travel speed Solenoid
81-31
ENGINE OIL LEVEL SENSOR
Terminal A
Black
(Terminal C)
(Terminal B)
(Terminal D)
L08CDOll
Function
e The engine oil level sensor is installed on the engine
oil pan. When the engine oil goes below the speci- 1. Connector
fied level, the switch is turned OFF. The machine 2. Wire
monitor lamp then lights up to indicate the abnor- 3. Plug
mal ity.
COOLANT LEVEL SENSOR
(zJ+E
Circuit structure
Function
l The coolant level sensor is installed on the radiator. 1. Switch
When the coolant level goes down, the float goes 2. Float
down and the electric current is shut off. The 3. Plug
machine monitor lamp then lights up to indicate the 4. Wire
abnormality. 5. Connector
81-32
COOLANT TEMPERATURE SENSOR
Q!izlf
I
I
0
f4?2
Circuit structure
L08CD012
Function
l These sensors are installed on the engine cylinder
block. They use a thermistor to detect the tempera- 1. Thermistor
ture, and when the temperature goes above the 2. Plug
specified temperature, the machine monitor lamp 3. Connector
lights up to indicate the abnormality.
Circuit structure
421FO1043
Function 1. Thermistor
l These sensors are installed on the transmission 2. Plug
case. They use a thermistor to detect the tempera- 3. Tube
ture, and when the temperature goes above the (Black: Torque converter
specified temperature, the machine monitor lamp oil temperature)
lights up to indicate the abnormality. 4. Wire
5. Connector
81-33
PARKING BRAKE SENSOR
Oil (Engine)
- Air (Parking)
Circuit structure
423F177
Function
l This is installed to the engine block and parking 1. Connector
brake solenoid valve. A diaphragm detects the oil 2. Wire
and air pressure, and when it drops below the 3. Switch
specified pressure, the contacts separate. The ma- 4. Diaphragm
chine monitor lamp flashes to warn of the abnor- 5. Plug
mality.
ENGINE OIL PRESSURE SENSOR
C B A 1 2 3
Function
l The engine oil pressure sensor is installed to the
engine block. The button detects the oil pressure, 1. Connector
Circuit structure
and when it drops below the set pressure, the 2. Button
switch turns OFF and the machine monitor lamp 3. Plug
flashes to warn of the abnormality.
81-34
BRAKE CHAMBER STROKE SENSOR
Circuit structure
423F180
Function
l The brake line failure sensor is installed to the brake
chamber. When the stroke of the air piston in the 1. Ball
brake chamber goes above the specified stroke 2. Shaft
(over-stroke), the rod installed to the brake chamber 3. Switch
pushes the ball and shuts off the electric current. 4. Wire
This turns the switch OFF and the machine monitor 5. Connector
lamp lights up to indicate the abnormality.
AIR PRESSURE SENSOR
m
Circuit structure
423F181
Function
l The air pressure sensor is installed to the wet air
tank. It acts through a diaphragm to actuate a 1. Connector
sliding resistor according to changes in the air 2. Ventilation tube
pressure. This sends signals to the machine monitor 3. Wire
to indicate the air pressure. If the air pressure drops 4. Resistor
below the specified level, it generates a signal to the 5. Resistor selector contact
module inside the machine monitor, and the warn-
ing lamp flashes.
81-35
ROTATIONAL SPEED SENSOR
Section A-A
Circuit structure
421FO1045
Function
o The rotational speed sensor is installed on the
transmission output gear. A pulse voltage is gener- 1. Connector
ated by the rotation of the gear teeth, a signal is 2. Magnet
then sent to the machine monitor, and this displays 3. Case
the travel speed.
81-36
FUEL GAUGE SENSOR
5
@
6
Section A -A
Circuit structure
421FO1046
Function
l The fuel gauge is installed to the fuel tank, and the
float moves up and down according to the fuel 1. Connector
level. The movement of the float actuates a variable 2. Float
resistor through an arm, and sends a signal to the 3. Spring
machine monitor to indicate the fuel level. If the 4. Contact
display on the fuel monitor drops to a specified 5. Spacer
level, a signal is generated between the modules 6. Variable resistor
inside the machine monitor, and the warning lamp
flashes.
81-37
WIRING HARNESS
o CNPZ
(8P,
Buzzer
Lamp
U41901066
Operation of monitor panel

If the monitor panel is working normally, the lamps on c) The CHECK item lamps will go out when the
the monitor panel will work as follows: engine is started. (Judge whether the engine is
1) When the starting switch is turned to ON. running by the rise in the engine oil pressure, or
a) All monitor lamps will light up for 3 seconds. see if there is a voltage of over 1OV from the
b) The warning buzzer will sound for 2 seconds. alternator.)
2) CHECK MONITOR GROUP 3) CAUTION MONITOR GROUPS
a) All monitor lamps will light up for 3 seconds, a) All monitors are working from the time the
then if there is any abnormality in any check engine starts to the time the engine stops and
item, that item will flash. (About 0.8 seconds the starting switch is turned to OFF.
ON, then 0.8 seconds OFF repeated.) If there is any abnormality in the machine, the
b) If the outside air temperature is low (below lamp for that item will start to flash (0.8 seconds
about -lO’C), the flashing interval will change ON, 0.8 seconds OFF).
slightly, but this is not an abnormality.
81-38
STRUCTURE AND FUNCTION BUCKET POSITIONER & BOOM KICK-OUT
BUCKET POSITIONER AND BOOM KICK-OUT

OPERATION OF PROXIMITY SWITCH
Lift arm RAISE

l When the lift arm is lower than the set position for
the boom kick-out, the detection unit (steel plate) is
on the sensing surface of the proximity switch.
Electricity flows through the proximity switch. The
relay switch is at OFF and the electric current of the
magnet switch coil is shut off.
Proximity switch for

boom kick-out
To battery relay
Lift lever AFL
Proximity switch
Lift a
Detect/on unit
LO8BVOOl
I”\ Main control valve
81-39
l When the lift control lever is moved to the RAISE

position, the lever cam and the cam follower keep
the lift spool in the RAISE position, so the lift arm
goes up.

boom kick-out
Solenoid for
kick-out
Lift lever
\
Lift “,‘” Proximity switch
\
Detection unit
81-40
l When the lift arm goes up and reaches the set

position for the kick-out (that is, the detection unit
[steel plate] is separated from the sensing surface
of the proximity switch), the proximity switch and
relay circuit act to send electric current to the
magnet coil. This actuates the magnet, the cam is
pulled out of the cam detent, and the lift spool is
returned to the neutral position by the return spring.

boom kick-out
To battery relay
Solenoid for Kick-out relay

Lift lever
\<
Lift arm
Solenoid
Detection unit \ \
/ \
i\ Main control valve
7
LO8BVOO3
Movement of Droximitv switch

Sensing surface of magnet switch is Sensing surface of proximity switch
Position
in contact with detection unit is separated from detection unit
Proximity switch display ON OFF
Proximity switch load circuit Current flows Current shut off

(Relay switch circuit)
Relay switch load circuit Current flows Current shuts off

(Solenoid circuit)
81-41
Bucket TILT
l When the bucket is lower than the set position for
the bucket positioner, the detection unit (steel plate)
is on the sensing surface of the proximity switch.
No electricity flows through the proximity switch.
The relay switch is at ON and the electric current
from the battery flows through the magnet switch
coil.

bucket positioner
To battery relay
Solenoid for Positioner relay

!I
bucket positioner
Detection unit Proximity switch
? Main control valve

LO8BVOO4
81-42
l When the bucket control lever is moved to the TILT

position, the lever cam and the cam follower keep
the dump spool in the TILT position, so the bucket
tilts.

bucket positioner
To battery relay
Dump lever
\ Solenoid for
bucket positioner
II Positioner relay
Detection init Proximity switch

‘-i-A Main cOntrOl valve
L08BV005
81-43
l When the bucket tilts and reaches the set position

for the bucket positioner (that is, the detection unit
[steel plate] is separated from the sensing surface
of the proximity switch), the proximity switch and
relay circuit act to send electric current to the
magnet coil. This actuates the magnet, the cam is
pulled out of the cam detent, and the dump spool
is returned to the neutral position by the return
spring.

bucket positioner
To battery relay
Solenoid for Positioner relay
Dump lever
,.,_,.,
Solenoid
Detection unit Proximity switch
L08BV006
Movement of Droximitv switch

Sensing surface of magnet switch is Sensing surface of proximity switch
Position
in contact with detection unit is separated from detection unit
Proximity switch display ON OFF
Proximity switch load circuit Current flows Current shut off

(Relay switch circuit)
Relay switch load circuit Current shuts off Current flows

(Solenoid circuit)
81-44
ELECTRIC AND
ELECTRONIC SYSTEM
STANDARDVALUETABLE ....... ..... .. .. ................ ....... .... ... ..... .... .. .... 4
ADJUSTING SPEEDOMETER MODULE IN THE VEHICLE MONITOR . . . . . . . . . . . . . . .. .... ...... ... 7
TROUBLESHOOTING .................................... ... ..... ... ...... ... .. .... 9

CHECKS BEFORE TROUBLESHOOTING ................... . .. ..... .... .... .... ..... 10
METHOD OF USING YES-NO TROUBLESHOOTING FLOW CHART
CONNECTOR TERMINAL NUMBERS ......................
PRECAUTION WHEN HANDLING CONNECTOR ............. ...... ... .... ..... ....... 20
ELECTRICAL WIRING (3D) DIAGRAM .....................
ELECTRICAL CONNECTOR (CN) WIRING DIAGRAM ..........
ELECTRICAL CIRCUIT SYSTEM .........................
ENGINE STARTING AND STOP CIRCUIT SYSTEM ......... ..... .... ... ..... ...... .. 23
TRANSMISSION CONTROL, PARKING BRAKE CIRCUIT SYSTEM ......................... 24
ETHER INJECTION CIRCUIT SYSTEM .................... ......................... 25
KICK-DOWN CIRCUIT SYSTEM ................................................... 26
TROUBLESHOOTING CHARTS FOR ELECTRIC SYSTEM ................................... 27
POSITION OF CONNECTORS FOR TROUBLESHOOTING ............................... 28
E-l ENGINE DOES NOT START. 32
E-2 ENGINEDOESNOTSTOP. .:::::::::::::::::::::::::::::::::::::::::::::::: 34
E-3 ENGINE STOPS WHEN TRAVELING. .......................................... 34
E-4 PARKING BRAKE DOES NOT WORK. .......................................... 35
E-5 PARKING BRAKE IS APPLIED WHEN TRAVELING. ................................ 36
E-6 PARKING BRAKE IS RELEASED WHEN STARTING SWITCH IS TURNED ON. ............ 38
E-7 WHEN PARKING BRAKE IS APPLIED, SHIFT LEVER DOES NOT ENTER NEUTRAL. ........ 38
E-8 TRANSMISSION DOES NOT WORK NORMALLY. ................................. 39
E-9 KICK-DOWN SWITCH DOES NOT WORK. ....................................... 60
E-10 KICK-DOWN ONLY WORKS WHEN KICK-DOWN SWITCH IS ON. ..................... 63
E-l 1 KICK-DOWN OPERATION IS NOT CANCELED. ................................... 64
E-12 KICK-DOWN WORKS BY MISTAKE WHEN TRAVELING IN F2. ........................ 66
E-13 MACHINE DOES NOT TRAVEL WHEN KICK-DOWN SWITCH IS PRESSED. .............. 66
TROUBLESHOOTING CHARTS FOR ELECTRONIC VEHICLE MONITORING SYSTEM .............. 69
POSITION OF CONNECTORS FOR TROUBLESHOOTING ............................... 70
M-l WHEN STARTING SWITCH IS TURNED TO ON POSITION, MONITOR PANEL DOES NOT LIGHT
UPFOR3SECONDS. ..................................................... 75
a) None of monitor panel lights up. ........................................... 75
b) Except for speedometer module, none of monitor panel lights up. .................. 75
c) None of CAUTION items light up. .......................................... 75
d) Some other parts do not light up. .......................................... 75
M-Z WHEN STARTING SWITCH IS TURNED TO ON POSITION, ALL MONITOR PANEL LIGHTS UP
AND DOES NOT GO OUT. .................................................. 76
82-1
M-3 WHEN STARTING SWITCH IS TURNED TO ON POSITION (ENGINE STOPPED), CHECK ITEM
FLASHES, (LEVELS OF CHECK ITEMS ARE CORRECT). ............................ 77
a) (Engine oil level) flashes. ................................................ 77
b) (Radiator water level) flashes. ............................................. 78
M-4 NO OPERATION IS BEING CARRIED OUT, BUT PILOT DISPLAY LIGHTS UP ABNORMALLY. . 80
a) (Transmission cut-off) lights up ............................................ 80
b) (Parking brake) lights up. ................................................ 81
c) (Working lamp) lights up. ................................................ 81
M-5 WHEN STARTING SWITCH IS TURNED TO ON POSITION (ENGINE STARTED), CHECK ITEM
FLASHES. .............................................................. 83
a) Engine oil pressure system. .............................................. 83
b) Alternator system. ...................................................... 83
M-6 WHEN STARTING SWITCH IS TURNED TO ON POSITION (ENGINE STOPPED), CAUTION ITEM
FLASHES. .............................................................. 84
a) Engine oil pressure system. .............................................. 84
b) Alternator system. ...................................................... 84
M-7 WHEN STARTING SWITCH IS TURNED TO ON POSITION (ENGINE STARTED), CAUTION ITEM
FLASHES .............................................................. 86
a) (Charge level) flashes ................................................... 86
b) (Fuel level) flashes ..................................................... 86
c) (Brake line failure) flashes. ............................................... 86
d) (Engine oil pressure) flashes. ............................................. 86
e) (Radiator water level) flashes. ............................................. 86
f) (Air pressure) flashes. ................................................... 87
g) (Engine water temperature) flashes. ......................................... 87
h) (Torque converter oil temperature) flashes .................................... 87
M-8 SPEED SENSOR DISPLAY STAYS AT “0”. ....................................... 90
M-9 HIGH BEAM DOES NOT LIGHT UP, OR LIGHTS UP ABNORMALLY. ................... 91
a) If high beam does not light up. ............................................ 91
b) If high beam lights up when head lamp switch is OFF. ........................... 91
c) If high beam display lights up when head lamp dimmer switch is at Lo beam position. 92
M-10 TURN SIGNAL LAMP DOES NOT FLASH. TURN SIGNAL LAMP STAYS ON OR DOES NOT ST&
FLASHING. ............................................................. 93
a) If turn signal lamp does not flash .......................................... 93
b) If turn signal lamp stays ON or does not stop flashing. ........................... 93
M-l 1 WHEN STARTING SWITCH IS TURNED TO ON POSITION (ENGINE STOPPED), BUZZER DOES
NOT SOUND FOR 1 SEC. CAUTION ITEM IS FLASHING BUT BUZZER DOES NOT SOUND. . 94
M-12 NO ABNORMALITY IS SHOWN ON MONITOR DISPLAY, BUT ALARM BUZZER SOUNDS. ... 95
M-13 WHEN STARTING SWITCH IS TURNED TO ON POSITION (ENGINE STOPPED), WARNING LAMP
DOES NOT LIGHT UP FOR 2 SEC. CAUTION ITEM IS FLASHING BUT WARNING LAMP DOES
NOTFLASH. ............................................................ 96
M-14 NO ABNORMALITY IS SHOWN ON MONITOR DISPLAY, BUT WARNING IAMP LIGHTS UP. . 96
M-15 WHEN STARTING SWITCH IS TURNED TO ON POSITION, LAMPS DO NOT LIGHT UP FOR 4
SEC. WHEN LAMP SWITCH IS ON, LAMPS DO NOT LIGHT UP. ...................... 97
a) None of panel lights up. ................................................. 97
b) Some of panel lamps do not light up. ....................................... 97
M-16 IAMP SWITCH IS NOT BEING OPERATED, BUT NIGHT LIGHTING LIGHTS UP. NIGHT LIGHTING
STAYS ON. ............................................................. 98
M-17 SERVICE METER DOES NOT WORK. .......................................... 99
M-18 SERVICE METER MOVES WHEN ENGINE IS STOPPED. ............................ 99
M-19 ABNORMALITY IN AIR PRESSURE GAUGE. ..................................... 100
a) If nothing is displayed in display area. ....................................... 100
b) If indicator remains at maximum level. ....................................... 100
M-20 ABNORMALITY IN ENGINE WATER TEMPERATURE GAUGE. ........................ 101
b) If indicator remains at minimum level. ....................................... 101
M-21 ABNORMALITY IN TORQUE CONVERTER OIL TEMPERATURE GAUGE. ................ 102
b) If indicator remains at minimum level. ....................................... 102
M-22 ABNORMALITY IN FUEL GAUGE. ............................................. 103
b) If indicator remains at FULL. .............................................. 103
82-2
t The following precautions are necessary when using the Standard Value Tables to make judgements during
judgements.
use these values alone to make simple judgement calls.
* Before carrying out the troubleshooting in this section, read “PRECAUTIONS WHEN TROUBLESHOOTING”,
“METHOD OF READING TROUBLESHOOTING TABLES” and “PREVENTING RECURRENCE OF TROUBLE” -all
in SECTION 22.
t When carrying out troubleshooting of the power train, it is necessary to distinguish if the breakdown is in the
power train itself or in the electrical system. See “JUDGEMENT ON POWER TRAIN” in SECTION 22.
* 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 ( ))
+ When disconnecting connectors or connecting T-adapters, return them to the original condition immediately after
checking, then go to the next check.
82-3

Name of Connector Inspection Measurement
Judgement table
component number method conditions
If the condition is as shown in the table

below, the sensor is defective.
Short Short connector connected - Starting

connector Monitor OFF switch ON
Radiator water
CN107
;yiJf%i’[“,I.,,~ 1
level sensor If the condition is as shown in the table
Continuity Water level normal - Starting

check Continuity switch OFF
Short
connector
Engine oil level

CN96
sensor
)I
If the condition is as shown in table be-
Continuity %.h”goFF
check
Engine oil level abnormal -

No continuity

below, the sensor is normal.
Air pressure Measure Air pressure 1 kg/cm2 - Starting

CN92
sensor resistance Approx. 1 kQ switch OFF
Air pressure 5 kg/cm2 -

Approx. 600 Cl

Torque convert- below, the sensor is normal.
er oil tempera-
ture sensor, CN84 Measure Normal temperature (2PC) - Starting
engine water CN101 resistance Approx. 37 - 50 kQ switch OFF
temperature
sensor 100°C -
Approx. 3.5 - 4.0 kQ
82-4

Judgement table

Fuel level Measure Full tank - Starting

CN105 switch OFF
sensor resistance Approx. 12 n or less
Empty -
Approx. 85 - 110 !2
When engine is running (l/2 throttle or

above): 27.5-29.5 V
Measure Start
Alternator engine
voltage
t If the battery is old or after starting
in cold areas, the voltage may rise.

Short Short connector connected - Starting

connector Monitor OFF switch ON
CN87, 88 disconnected -
Monitor ON
Brake stroke CN87
limit switch CN88 If the condition is as shown in the table
Continuity Brake normal - Starting

check Continuity switch OFF
Brake abnormal -
No continuity

Connection
Terminal wiring harness disconnected - Starting
with chassis
Monitor OFF switch ON
ground
Terminal wiring harness grounded -
Monitor ON
Engine oil pres-
sure sensor If the condition is as shown in the table
Continuity Oil pressure above 0.7 kg/cm* - Starting

check No continuity engine
Oil pressure below 0.3 kg/cm* -

Continuity
82-5

Judgement table
11
Shot-t izzh”goN
connector
Parking brake
CN36
;~~yE,,,,~ 1
switch If the condition is as shown in the table
Continuity
check
82-6
TESTING AND ADJUSTING ADJUSTING SPEEDOMETER MODULE
ADJUSTING SPEEDOMETER
MODULE IN THE
VEHICLE MONITOR
Adjustment procedure
0 Remove the machine monitor, and adjust at the
adjustment portion at the back of the speedometer.
+ Measurement condition: Starting switch OFF
1) Remove rubber caps 1 and 2 at the rear of the
speedometer.
2) When the rubber caps are removed, rotary
switches can be seen inside. Using a flat-head-
ed screwdriver, turn the switch to adjust as
shown in the figure on the right.
+ Switch 3 has no connection with adjust-
ment of the speedometer, so do not touch
Rotary switch
it under any circumstances.
/
Tire size Switch 2
20.525 STD I 2 1 A 1 7 (or 8)
23.5-25 OP I 2 IAl 3
3) After completing adjustment, fit the rubber caps

back on securely and install the machine moni- F41E01113
tor.
Reference
Amount of comoensation for switch (2)
tswitch
position 0 1 2 3 4 5 6 7
Correction
factor (%) 1 +14 1 +12 1 +lO 1 +8 1 +6 1 +4 1 +2 1 0
89ABC D E F
CmectiO” 0 -2 _4 _6 _8 -10 -12 -14

fackx (%)
82-7
82-8
TROUBLESHOOTING
82-9
TROUBLESHOOTING CHECKS BEFORE TROUBLESHOOTING
CHECKS BEFORE TROUBLESHOOTING

Standard
Item Remedy
value
Checks Lubricating 1. Check fuel level Add fuel

before oil, cooling 2. Check for dirt or water in fuel Clean, drain
starting water 3. Check hydraulic oil level Add oil
4. Check hydraulic oil strainer Clean, drain
5. Check brake oil level Add oil
6. Check engine oil level (Level of oil Add oil
in oil pan)
7. Check cooling water level Add water
8. Check condition of dust indicator Clean or replace
Item Electrical 9. Check for loose or corroded Tighten or replace

Equipment battery terminals
10. Check for loose or corroded alter- Tighten or replace
nator terminals
11. Check for loose or corroded start- Tighten or replace
ing motor terminals
Other Hydraulic, 12. Check for abnormal noise or smell Repair

check mechanical 13. Check for oil leakage Repair
items components 14. Bleed air from system Bleed air
Electrical 15. Check battery voltage (engine 20 - 30 V Replace

components stopped)
16. Check level of battery electrolyte Add or replace
17. Check for discolored, burnt, or Replace
bare wires
18. Check for missing wiring clamps, Repair
hanging wires
19. Checks for water leaking onto wir- Disconnect con-
ing (check carefully water leakage nector and dry
at connectors and terminals) connection
20. Check for broken or corroded Replace
fuses
21. Check alternator voltage (engine 27.5 - 29.5 V Replace
running at over half throttle)
22. Noise when battery relay is operat- Replace
ed (switch starting switch from on
to off)
82-10
TROUBLESHOOTING METHOD, TROUBLESHOOTING FLOW CHART
METHOD OF USING YES-NO TROUBLESHOOTING FLOW CHART
The electrical system can be broadly divided into the following two parts.
1. Starting system, transmission electrical control system, and brake system.

2. ELECTRONIC VEHICLE MONITORING SYSTEM.
The charts for these systems are marked as E-xx, and M-xx respectively.
Troubleshooting Item
chart No.
Troubleshooting of starting system, transmission electrical control system, and brake

E-xx
system.
M-xx Troubleshooting of electronic vehicle monitoring system.
1. Method for troubleshooting YES
Check or measure the items inside the rectanale m

-NO
According to the result, follow the YES arrow or the NO arrow and proceed to the next rectangle. (Note:
The number given at the top right of the rectangle is a reference number. It does not indicate the order for
troubleshooting.)
If the result of the check or measurement leads directly to the CAUSE column, note the cause and take the
action given in the REMEDY column.
The value for the check and the measurement method is given inside the rectangle. If the value is correct,
or the answer is yes, follow the YES arrow; if the value is not correct or the answer is no, follow the NO
arrow.
Below the rectangle, there is a list given preparatory work, methods of operating and handling, and
judgement values needed for checking and measuring. If the preparatory work is ignored, or the wrong
method of operating or handling is used, or the judgement is wrong, this could result in damage to the
equipment. Therefore, always read the procedure carefully before starting the check or measurement, and
carry out the operation in the order given.
2. Precautions when carrying out troubleshooting

The precautions to be followed when carrying out troubleshooting for each failure is marked * under the
description of the failure. Always follow these precautions when making measurements.
3. Tools needed for troubleshooting

The tools needed for troubleshooting for each problem are listed as follows.
Tool A Tool B
Troubleshooting
tools Item Item
Prepare these tools before starting troubleshooting.
4. Place to install connectors, connector pin numbers

When troubleshooting some problems, measurements have to be made of continuity, voltage and resistance
at each step during the troubleshooting procedures. The location for measurement at each step (location of
connector, connector pin number) is shown in a photograph or diagram. For this reason, use these photographs
together with the YES-NO type troubleshooting flow charts to carry out troubleshooting quickly and accurately.
82-11
TROUBLESHOOTING METHOD, TROUBLESHOOTING FLOW CHART
Example
* When disconnecting or connecting the T-adapter (or socket adapter) or short socket adapter, or when
+ 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
Cause Remedy
a) lights up.
Defectwe transmlsslon cut-off

++X?
switch
Defectwe CHECKS BEFORE Replace

STARTING module
Is there contmuty
YES between CNP4
- (femaleI and
chassas ground?
I I Dlsconnecbon I” wwnng After w.pectlon.
harness. or defectw contact
1 I Short-clrcut CNl 8 1) Trallsmlssnn cut-off No *
between CN18 ~femalel(31 and
repar (clean1 or
switch ON &Xt?
(female)(3) and (4)
2) Connect T-adapter to CNP4 (fernale)
2) Turn start,rrg switch
ON CNP4 (female)
31 Turn starting switch
2 OFF
Is there contlruty
between CN18
NO
(male)141 and chaws
ground,
Dlscollnection ,,I wlr,ng After ,nspect,on.
Turn starting swtch

NO harness. or defectwe contact repaIr
(clean) or
m between CN18 (fern&l (41 and replace
OFF
chassis ground
Tester
Troubleshooting
tools T-adapter or socket adapter
T-adapter (for DLI)
(for Econoseall
LO822098
CN18
82-12
TROUBLESHOOTING CONNECTOR TERMINAL NUMBERS
CONNECTOR _TERMINAL
._ - -- NUMBERS
ECONOSEAL CONNECTOR
No. of Pins
Female terminal (Socket) Male terminal (Pin)
I-
1
2
1
1
J
142F401A 142F400A
1'
142F403A 142F402A
142F405A 142F404A
3
142F407A 142F406A
12
142F408A
LO8ZZOO9
82-13
DLI CONNECTOR (For monitor panel)

No of Pins
(Connector)
5 0
‘\
1 4 5’
8
142F418 142F419
1 6
1 6 7 ‘12
12
142F420 142F421
,8
/ 16
16
16
\
8
142F422 142F423
LO822007
82-14
No. of Pins
T N-SLC CONNECTOR
1
423F349 423F350
3 2 423F352
2 1
423F353 423F354
423F355 4
j
423F357 423F358
LO8ZZO18
82-15
MIC CONNECTOR
No. of Pins
142F410
142F411
7 1
13
13
142F412 I J 142F413
10
17
142F414 : 142F415
1 11
21
12’r--‘2’
142F416
423F417
LO82701 1
82-16
BENDIX CONNECTOR
No.of Pins
10
421FO1132 421FO1133
No.of Pins RELAY CONNECTOR
c
1
423F348
LO8ZZO12
82-17
NO. METRI-PACK CONNECTOR

OF PINS
FEMALE TERMINAL (SOCKET)
I
A
LO8ZZO 13
82-18
NO. METRI-PACK CONNECTOR

OF PINS
MALE TERMINAL (PIN)
3Q El
0
;/-Jo I
4
B
A
118
LO8ZZO13
82-19
TROUBLESHOOTING PRECAUTION WHEN HANDLING CONNECTOR
PRECAUTION WHEN HANDLING CONNECTOR
1. If the connector has a lock, always release the lock

before disconnecting the connector.
When connecting, align

this arrow and push in.
Be sure to fit rubber When remowng, press When connecting. align
cover tightly. this part in and pull the guide lnslde the
n the connector out. connector and push in. /
When remowng, press in

on both sides and pull
the connector out. F 142A093
F 142A092
2. Never pull the cord to disconnect the connector.
F 142A094 F 142A095
3. If the connector is difficult to disconnect, do not try

to pull it out.
(If it is difficult to reach by hand, remove the clamp
and move the wiring harness.)
This must be removed. ,
F 142A096
82-20
TROUBLESHOOTING PRECAUTION WHEN HANDLING CONNECTOR
4. After pulling out the connector, cover with a vinyl

bag to protect the contacts from dirt or oil.
F 142AQ97
5. When cleaning the connector, never use cleaning

agents such as trichloroethane or trichloroethylene.
If the connector is very dirty, use a neutral cleaning
agent. After cleaning, wash well and dry completely
immediately. (Do not use any connector which has
deposits left on it after drying.)
Coat with contact restorer.
(When drying, 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 with locks, it should be possible to
hear the locks click as they fit completely into posi-
tion.)
F142AlOO
F 142A099
0 Correct any protrusion of the boots.
82-21
TROUBLESHOOTING ELECTRICAL WIRING DIAGRAM
ELECTRICAL WIRING (3D) DIAGRAM
See Foldout #9 in back of this book.
ELECTRICAL CONNECTOR (CN) WIRING

DIAGRAM
See Foldout #lO in back of this book.
82-22
TROUBLESHOOTING ELECTRICAL CIRCUIT SYSTEM
ELECTRICAL CIRCUIT SYSTEM
ENGINE STARTING AND STOP CIRCUIT SYSTEM
Starting switch
Transmlsslon
control swtch
I I
Battery
To transmlsslon
solenoid relay
CN58 I
I Alternator
Main
20A
fuse
02 cl---. I, ‘I CN64
r
To monitor panel c--- Safety Startmg
CN102 relay motor
CN63
Solenoid
CN223
CN97
L08AD076
82-23
TRANSMISSION CONTROL, PARKING BRAKE CIRCUIT SYSTEM
Parking brake valve

CN35
CN39
Parking brake safety relay
I I I
Morutor panel
Neutralizer relay
Emergency
brake switch
Transmisslon
cut-off switch
CN60
Parking brake switch
Main breaker
Transmission control &7l
‘IM control F-R

witch switch ‘p-e p To buttery relay
n n
R
F
4th
3rd
2nd
1 St
L08AD054
82-24
ETHER INJECTION CIRCUIT SYSTEM
ETHER INJECTION CIRCUIT SYSTEM
EIher l”,eCtlOn
SWltCh CN13
I
I
CN232
16:3 CN116 S”lenoIc

r
9
7
CN97
5 m
2 _
L08AD077
82-25
TROUBLESHOOTING CHARTS FOR ELECTRIC SYSTEM
82-27
TROUBLESHOOTING POSITION OF CONNECTORS
POSITION OF CONNECTORS FOR

TROUBLESHOOTING
Engine stop motor
CN11 (Parking brake switch)

N-SLC connector 3 pins
CN14 (Main switch)

Econoseal4 pins
CNl6 (Transmission speed lever, F-R lever)
Econoseal9 pins
CN21 (Transmission cut-off switch)

Econoseal 2 pins
82-28
CN35 (Parking brake solenoid)

ECONOSEAL connector 2 pins
CN52 (Parking brake safety relay)

CN53 (Neutralizer relay)
CN233 (Engine stop relay)
CN237 (2nd solenoid relay)
CN239 (2nd - 1st selector relay)
CN247 (Back-up lamp relay)
Relay connector 5 pins
CN236 (Reverse solenoid relay)

CN242 (Kick-down switch relay)
CN246 (Forward solenoid relay)
Relay connector 6 pins
CN75
82-29
CN85 (Transmission control valve inlet)

BENDIX connector 8 pins
CN85
*-_-I i
P42101038A
,..
CNI 16 (Engine stop motor inlet)

METRI-PACK connector 3 pins
CN204 (Emergency brake switch)

CN243 (Kick-down switch inlet)

82-30
CN102 (Safety relay)

LlZBD006
CNI 04 (Battery relay)

82-31
TROUBLESHOOTING E-l
TROUBLESHOOTING CHART No. E-l

Failure mode: E-l ENGINE DOES NOT START.
* 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.
a When connecting the T-adapter (or socket adapter), connect to the connector specified. (CN 0 A( ))
Inspection of starting circuit.
Isthem conhnu~ty
YES ketween CNlO2 (31
- (female) and YES
chassts) . 3
1
11 DlsconnscC
Is them conhnuty
CN102 Wrtmg
- betwwnCN16W -
motor inbt).
ND (nub) andchassa,
2) Place F-R bver at
N
1 3) Turnstarting 1) connect
-I switch OFF. T-adapter NO
IS voltage batween (socket adapter)
’ CNlO2 IO (femab) _ to CN16 (F-R
and chassn 20 - lever inlet).
3ov7 2) Pbce F-R bwr at
N
11 Disconnect 3) Tumstarbng
CN102 lstart~ng switch OFF.
motor ass’yl
YES
21 Turn start,ng
1
switch ON
f
IS Volta@ between
CN14 (31 (fornab _
Nz sndchsssus 20 -
3DV7
11 connect
T-adapter
I
NO
(socket adapter)
to CN 14 lfemabl
2) Turn starttng
swtch to START
4 Inspection of battery - battery relay - starting switch.
Is vdtage between
YE two thrk termwmls
of battev relay and
chassts each 20 -
?f-l”7
1 I Turn startng I
swtch ON NO
2) Measure voltage
ISthere sound of oteach
battery relay being connecting
termnal of thwzk
cable
1) Turn stamng
swtch ON - ES
OFF
r----G
Is voltage between
YES
YES 5
CN104 (31 (temabl
and chassts 20 -
3ov7 Is vdtage between
4 CN14 (21 Wemale) _
and chassos 20 -
1) Dtsconnect Is vdtage betwwn 3ovp
CN104
2) Tumstartmg
. CN14!0 lfemabl _ .
and chassn 20 - 11 connect
swtch ON. 3ov7 T-adapter 1 NO
bockat adaptsrl
11 connect to CN14 Ifemabl
T-adapter 21 Tumstartmg
(socket adapterI , swtch ON
toCNl4 Wnabl NO
LO82203 1
82-32
TROUBLESHOOTING E-l
* If the lights and other electrical equipment are not working properly, go first to 2) inspection of battery - starting
Cause Remedy
Defective start,“9 motor Replace

ass’y or safety r&y
Defectwecontact. or
dlScO”nectlO” I” wlrlng hanles.!
between CNlO2 131 lfemakl -
CN97 I71 - CN64 191 - CNll
191 (female)
Defectwe F-R swtch. or

defectwe contact. or
ds.connectlon I” w,rtn9
harness between F-R
SWI,Ch - chasse. ground
Defecuve ccmtact. or
d,xo”nectw,n I” ww”9 hares:
/
between CN 102 I1 (female1 -
CN97 141 - CN63 (51 - CNI,
(31
c Defectwe startq switch Rephx
Detectwe contact or After Inspectlo”

drxonnectlo” I” thh‘k cable
repall Ic)eanl or
between stanI” motor -
redace
battev relay
After inspection
c repaN kkanl or
redace
Dsconnection I” w,r,n9 hames

between CNlO4 131 - batter,
r&y - chas,s g,o”“d. or Replace
ckfectwe banery reiay
Defectwe contact or
dsconnecton I” wwng harnes
between CN104 131 ltemakl
CN95 Ill - Idaode - CN95
121 - CN63 (21 - CNl 4 121
Replace
harness between battery rsla,

- CN104 121 - CN63 I71 -
CN59 I1 /- fuse - CN58 (21
-CN14lllima!-ai
LO822032
82-33
TROUBLESHOOTING E-2, E-3
TROUBLESHOOTING CHART No. E-2

Failure mode: E-2 ENGINE DOES NOT STOP.
+ When disconnecting or connecting the T-adapter (or socket adapter) or short socket adapter, or when
+ When connecting the T-adapter (or socket adapter), connect to the connector specified. (CN o A())
t When disconnecting connectors or connecting’T-adapters, return them to the original condition immediately after
Cause Remedy
Defective adjustment of llnkage

between fuel cut solenoid and Adjust
governor
DefecWe fuel cut solenoid ReplaCe
1) Turn starting
swtch ON -
OFF and check
L
NO
Contact or dlsconnected w,r,“g
between +24V and wiring
harness between CN14 (male) (2) After InspectIon.
visually. - CN232 (1) - CN232 (2) - repaIr or replace
CN63 (9) - CN97 (11) -
CNIlG(A)
Defective start,ng swtch

Defectlve safely relay
Contact or dlsconnected wring

harness between CN14 (3) ~ After mspect,on,
CN63 (5) - CN97 (4) - CN222 - repall or replace
1) Turn start,ng
CN102 (1). safety relay (6) -
switch OFF.
CN116 (5)
Failure mode: E-3 ENGINE STOPS WHEN TRAVELING.
YES Defective adjustment of linkage
between fuel cut solenoid and Adjust
governor
Dlsconnectlon I” w,r,ng harness

or defective contact between
startlng switch termmal BR -
CN14 (2) chaws ground CN232
- CN63 (9) - CN97 (11) -
CN116 (A), CN14 (13) - CN63 (5)
- CN97 (A) ~ CN222 - CNIOZ
Does spool of
(1) -safety relay (Cl ~
fuel cut solenoid terminals of fuel CN116 (B)
work?
t
Isvoltage between cut-off solenoid
start,ng switch CN116 (A) - (C),
lerm~nal C and Defective fuel cut solenoid Repl.Xe
r
1) Turn starting CNl16 (B) - (C)
swtch ON ~ YES chassis ground 20
OFF and check - 3ov
VlSUally -OR- 1) Disconnect w,ring
Is voltage between Of fuel cut-Ofl
start,ng switch
termmal BR and
chaws ground 20
- 3ov7
termfnal Band Rt?plXe
NO
chassis ground 20 l) Turn starting
switch ON
switch OFF After ~“spect,on.

replace
NO
Tester
TroubleshootIng
tools
LO822083
82-34
TROUBLESHOOTING E-4

Failure mode: E-4 PARKING BRAKE DOES NOT WORK.
* When carrying out troubleshooting of the brake system, stop the machine on level ground.
t When disconnecting or connecting the T-adapter (or socket adapter) or short connector, or when disconnecting
+ When connecting the T-adapter (or socket adapter), connect to the connector specified. (CN 0 A( ))
(a) If parking brake does not work when parking brake switch is ON (applied)
Cause Remedy
YES
defective pwtdng brakeswitcl Repbce
Is pmbbrn rsmovsd
when CNl 1 8s YES :ontact of wiring hamess at After mspectii
dwonmcted~ 2 :Nl 1 (1) Wemabl and (21 repair
w mpkxe
A
1) Disconnect Is then, continuity
CNll. L be-CNll
2) Startengme NO (fornab) (1 I and (2) 7 3 YES )efectwe parking brake
_ (Chegesu mIenad
prsssurel - bvdteqe tatween
31 Tumpsdung 1) Dlrconnect CN35 (fsmb) (1 I
brake switch ON, CNll. NO andchasM ,tpprox -
21 Turn starting ow
switch OFF. :ontact of wiring hsmess at Afterinspactnn
3) Dizcaltmct 1) connect NO :Nll (11 (female) and (31 repair of npbcs
CN53. T-adapter
41 Dtsconmct (socket adapterI
CN52 to CN35.
21 Start engine
lcha,ye$
31 Turn parking
twke mitch ON
(b) If parking brake does not work when air pressure has dropped.
(Does not work as emergency brake)
1 YES
bfectii. emergency brake
Rspbce
wtch
Is pmbbm removsd
when CN204 1s -
darconnected~
Replace
1) Turn stwtu-q NO
switch ON
21 Tumparkmg
brake swtch ON
-OFF
LO8ZZO34
82-35
TROUBLESHOOTING E-5

Failure mode: E-5 PARKING BRAKE IS APPLIED WHEN TRAVELING.
t When carrying out troubleshooting of the brake system, stop the machine on level ground.
+ When disconnecting or connecting the T-adapter (or socket adapter) or short connector, or when disconnecting
-or When connecting the T-adapter (or socket adapter), connect to the connector specified. (CN 0 A( ))
t When disconnecting connectors or connecting T-adapters, return them to the original condition immediately after
2 YES
Is there contanuty
YlES
between CN35 (21 -
Imale andshassls’
II Dlscollnect
1 NO
i CN35
2) Turn start~r~~
switch OFF.
I---+
II connect 1 I Interchange
T-adapter parking brake
Isocket adapter) *atety relay
to CN35 (CN52) with
2) start engtne
(TrWZl)
(Charge aar
pl.ZsSlNfA
11 Connect short
cclnnector to 7
CN204 lfsmalel
I
Is contmutv of CNl 1 21 start engsne IS voltage between
I1 ), (2). (31 as shown (Charge a1r YES CNl 1 12) (female)
I” Table 1) pressure1 and chassis 20 - -!
3ov7
6
1 I Disconnect 11 Turn startong
CNll IS voltage between watch ON
21 Turn startng CN52 131 ifemale) _
2) Turn parkong
swatch OFF N I a3ngdhasss 20 -
brake switch ON
NO
31 Turn pahlng
brake switch -OFF
ON/OFF.
1) Dlscmlnect
CN52
21 Turn startbng NO
swtch ON
T-adapter or socket adapter

a
dZr lfor Econoseall
28,s
;r, Short co”“eCtOr
LO822035
82-36
TROUBLESHOOTING E-5
Table 1
Remedy
Defectwe parkong brake

Replace
sobnold
Defectwe contact. or
d,sconnectlon I” wrong harms After anspectlon.
_ between CN35 12) (male) and repal, or replace
chassts
Defective parking brake safeh

l%bV
Defectwe emergency brake

swtch
10 YES d,sconnectlon I” wring harms After mspectoon.
between CNZ04 12) Ifemale) repa,r or replace
Is voltage between CN35 (11 Imabl.
YES CNZD4 11) Ifemabl _
9 - and chassos 20 -
- 3ov7
disconnectan I” wring harmr After ,“spectoo”.
YES
Is there conbnuoty
betwwnCN52 (11 _
1
11 Dtsconnect NO
I
between CN204 (1 (female) repau or replace
CNl 1 (11 ffemabl
,- (female) and CN204
8 chassts~ 2) Turn stxong
swttch ON Defectwe contact. or
-
IS voltage between 1 I Disconnect 31 Turn parkng brake swtch ON-OFF d,sconnect,o” I” wrong ham! After ,nsPeCtlOn.
_ CN52 (21 (female) _ CN52 between CN52 II) Ifemale). - repa,r or laplace
NO
a3ngdVc:asss20 - 2) Turn startq ChaSSlS
swtch OFF
I I
1 I
Dasconnect
d,sconnsctDn I” w”Wq hsr”W After mspectwm.
CN52
21 Turn startong NO
’ between
CN52 (2) (female1 - repeN or replace
CNl 1 (2) (female)
swatch ON
31 Turn ~ark~na
brake swrc~ ON
I Defectwe contact. or After ,ns,,ectlOn.
repaIr or replace
d,sco”W,ctlon I” wW”L, hBr”eS After Inspectlo”.
between CN52 131 Ifemale) - repal, or repbce
CN60 (41 - fuse
. Defectwe parfang brake swltcl
82-37

Failure mode: E-6 PARKING BRAKE IS RELEASED WHEN STARTING SWITCH IS TURNED ON.
a When disconnecting or connecting the T-adapter (or socket adapter) or short connector, or when disconnecting
* When connecting the T-adapter (or socket adapter), connect to the connector specified. (CN 0 A( ))
Cause Remedy
cl
1
k problem removed
when rday IS
replaced’
I
Interchange
pahl”g safety
relay ICN52) ’
>sfsctna psrk~ng brake swtch
:ontact of v.w”g harness

,twee” CN52 (3) and 151.12)
SePlaCe
After ,nspectlon.
repaor or replace
wtth back-up
female)
lamp relay
ICN2471.
2) Start engine
ICharge 81, Contact of wirtng harness
After Inspection.
prW.sll*) I
aetwec” CNl 1 I1 and 131
repaw or replace
31 Turn starhng Ifsmale)
swlfch ON 3) ium starting CN52
swtch ON 21 Turn starbng
swtch OFF

Failure mode: E-7 WHEN PARKING BRAKE IS APPLIED, SHIFT LEVER DOES NOT ENTER NEUTRAL.
(PARKING BRAKE IS WORKING NORMALLY.)
Lunormal contact between

kfter
1 YES + 24V and w,rw~ harness
Inspectlo”,
-t ,etween CN53 151 - CN18 I1
repar or replace
Is there cont,“u,n, (21 - CN75 18) - CN85 IA1
between “eutrakzer
relay CN53 lmakl 13) -
and 1517
- [,efectw neutra11zer relay ReDlace
11 Dtsconnect NO
mUtra11zer relay
CN53
2) Turn starttng
rwtch OFF
LO822037
82-38
TROUBLESHOOTING E-8

Failure mode: E-8 TRANSMISSION DOES NOT WORK NORMALLY.
t When carrying out troubleshooting of the brake system, stop the machine on level ground.
+ When disconnecting or connecting the T-adapter (or socket adapter) or short connector, or when disconnecting
+ When connecting the T-adapter (or socket adapter), connect to the connector specified. (CN 0 A( ))
Testing and inspection of transmission solenoid control circuit
A Stop the machine on level ground and put blocks under the tires.
1. Install a T-adapter (or socket adapter) to connector CN75, and check the voltage between the connector pin
and the chassis ground.
2. Turn the starting switch ON. Do not start the engine.
3. Turn the parking brake switch ON -- OFF (release).
4. When depressing the foot brake, depress the R.H. brake so that the transmission is not cut off.
5. Check the normal actuation table shown below. If there is any abnormality, go to the troubleshooting table on
the right according to the results of the check below.
CN75 pins - Pin No.

Lever position 1 2 3 4 5 6 7 8
1st 2nd 3rd 4th F R power source
Normal actuation table

0 : 0 - 0.5V (continuous)
l : 20 - 30V (battery voltage)
Result of inspection (abnormality) Cause Troubleshooting
l No battery voltage at all Problem in transmission cut-off switch, E-8 (a)

parking brake, neutralizer relay circuit
o No continuous (F) I Problem in F circuit I E-8 (b)

o No continuous (R) I Problem in R circuit I E-8 (c)
0 Continuous at two places Contact in F and R circuits E-8 (d)

l No battery voltage at all Problem in power circuit E-8 (e)
o No continuous Problem in speed circuit E-8 (e)

0 Continuous at two places or more Contact in speed circuit E-8 (9
82-39
TROUBLESHOOTING E-8
(a) Problem in parking brake, transmission cut-off, neutralizer relay circuit.
1) Connect shdh
CO”“eckx to
1 CN21 (femsb)
2) Turn
l-t
Is problem removed tra”smlsslo”
when tra”smlSSD” cut-off switch
cut-off swlch 1s ON
turned OFF, 3) Startengine
1) stsrten!qne
3
Is pabbm removed
YI IS there cont,nuty
1) Interchange
betweenCN53 (1)
“eutrallzer relay
(female) and chaws?
(CN53) with
back-up lamp
relay KIN247) 1) Disconnect
2) start anglne Is problem removed CN53
2) Turn starting
switch OFF
1) Interchange
parking brake
safety relay
lCN52) with
back-up lamp
relay (CN247)
2) Start engine.
1) Dlscmnect
CN52
2) Turn startma
1) Disconnect sw#tchON ”
CNll. 3) Turn parking
21 Turn starhng brake swttch ON
switch OFF bpplad)
3) Turn parkmg
brake swtch
ON/OFF
T-adapt‘” or socket adapter

(for Econoseal)
Short connector
LO822038
82-40
TROUBLESHOOTING E-8
Tsbb 1
I I
Between terminals Bstween terHunals Cause Remedy
Opelat~
1
I1 and (2) (3) and (7-l I
Oefect1vs t,anSmlsslOn cut-off

Replace
switch
Defective contact. or
dimonnectbn in wiring hrrmrs After InSpeCtIon.
between CN21 (female) Ill. (21 mpmr 0, replace
- CN18 (femabl I1 I, (21.
Defectwe psrkmg barke safety Replace

mbv
Defective contact or
disconractbn tinwnmg harness
After mspction,
between CN53 (51 (femsbl -
repmr or replace
CN21 (11 Ifemab). CN21 121
(femsbl - CN65 IA) (female)
Defectwe contact, or
dwxonnectwn in winng harness After mspsctmn.
between CN53 Ill (female) ant mpmr or replace
NO
chassis
Defectwe contact. of
9 YES d,sco”“ectD” I” ww”g harness
between CNl 1 (1) (female) -
CN53 (21 (female)
YES Is there contmwtv
- between CN52 (1) -
Ifemabl and chasas Defective contact. or
d,sconnectnn ,n wwng harness
1) Disconnect NO I
between CN52 I1 (femabl
CN52
- 21 Tumstsmng
sw,tch OFF if encorrect voltage for (3)
Dsfectwo contact. or
dtsconmctmn I” wm”~
harness between CN52 (31
Ifemsb) - CN60 - fuse
If Incorrect voltage for 121. (51.
NO Defectwe contact. or
dwxmnectlon I” wwmg
harness between CN52 (2).
(51 (female) - CNl 1 (21.
CNl 1 I31 lfemabl - CN60
- fuse
Defectwe padung brake swtch
LO8ZZO39
82-46
TROUBLESHOOTING E-8
(b) Defective continuity in FORWARD solenoid circuit.
YE
YI Is them continum,
between CN85 01
(female) and chassa?
I
j Dacumect CN85.
!I Turn starimg
switch OFF
3) Place F-R hver I”
3
I I
FORWARD.
k pmbbm removed
I when rnby n
NO rsplaced~
1 1 I I
1) Intorehangs
1) Disconnect
1 FORWARD
CN246.
r , sobnoid mby 2) Turn startmg
(CN246) with
k voltage bstween watch OFF
REVERSE
CN85 (A) (female) and chassts 20 - 3) Place F-R lever I”
sobnod relay
FORWARD
ICN2361.
1
2) stall enfww
!
3) Tump&ng
1 b Dlscollnect rwtch ON - Is thorn contmulty
CN85
OFF between CN16
2) Turn startng
4) Pbce F-R bver I” p10 (mob) (1) and (2) 7
switch ON
FORWARD switch ON -
3) Turn parkIng
OFF.
sg;:ch ON -
1 ) Dwxnrwcl
CN16.
2) Turn startmg
switch OFF.
3) Pbce F-R bver in
FORWARD.
T-adapter 01 wcket adapter

(for Econosesl)
LO8ZZO40
82-42
TROUBLESHOOTING E-8
Cause Remedy
Defective FORWARD robnod

mbV
7 YES diionmcticln 1” wiring harness 4ftsr I”spectlo”.
I between CN246 (2) (Cmabt - speir or mpbce
CN85 (D)
Is there contmuitv
. between
CN246 (1) -
(female1 and chasL)sI Defective contact. or
dnconnactmn m wonng harmss
11 Dnconnect NO I
betweaan CN246 (1 (female)
- ct?arsir
CN246.
21 Tumstartmg
swatch OFF Defectwe contact. or
8 YES dbconmctan m wiring hsrmss
between CN16 (21 (farnab) -
CN246 (51
Is there continuity
. bLltwea,CN16 (11 -
’ Ifemab~ and chassis? Defective cOntact. or
daconnectoon 8” wnng hames~
11 Dtsconnect NO
I
bstwwn CN16 (1 (female) -
chassis
CN16
2) Turn stwt~ng
swtch OFF Defecttve contact, or
dsconnectwn m wvlng harntss 4fter mspectiw.
between CN246 (61 lfemsbl - apsn or repbce
CN53 15)
Defective F-R lever swtch 3epi.m
Dsfsctwe ccotact. or
dsconmction anwnng harness
between CN65 (Al (femab) -
tmnsmnsion cut-off switch -
CN53 (5)
82-43
TROUBLESHOOTING E-8
(c) Defective continuity in REVERSE solenoid circuit.
YES
Y ES
7
Yl ES IS there co”t,nuty
between CN85 IC)
(female) and chaws
1) olsconnect
CN85
21 Turn starting
swtch OFF 6
3) Place F-R lever ,n
REVERSE
I I
1) Interchange 5 ’1 I Dwmlnect
1 REVERSE relay 7 CN236
ICN236) wth
Is voltage between 21 Turn startang
IS voltage between FORWARD relay
YES CN236 16) lfemalel swatch OFF
CN85 (A) Ifemale) lCN246)
ygdVc,h,hassls20 - 3) Place F-R lever,”
and chassis 20 - 2) start eng,ne
REVERSE
3ov7 3) TurnQarklng
switch ON - 4 *
1
1) Disconnect
_
L
OFF
1) Disconnect CN236
4) Place F-R lever I” Is there continuity
2)
CN85
Turn starting
switch ON
REVERSE between CN16
1
hIO ~ (male) I1 and (3) 7
2)
3)
Turn starting
swtch ON
Turn park,ng
INO
3) Turn parktng switch ON -
swtch ON - OFF
1) Disconnect
OFF CN16.
2) Turn stamng
swtch OFF L
3) Place F-R lever I” NO
REVERSE
Nl

be) ifor Econoseal)
z=r
288
;c-
LO822042
82-44
TROUBLESHOOTING E-8
Cause Remedy
1 Defectwe REVERSE solenad
Defectwe REVERSE solenad

relay
Defective contect. or
7 YES d#sconnectwn onwirmg hemes After ,nspectlon.
between CN236 (2) (female) repear or replace
CN65 (CI
YES
Isthere conttnu,ty
between CN236 11) _
lfemakl and
chaws) daconnectton in wring harnes After ~ns.~eCt~on.
I Disconnect NO
between b
CN236 (1 (female) repa, or replace
CN236 CheSSIS
!I Turn starhng
swtch OFF Defectwe contact. or
fl YES d,sconnectlon I” wrmg harnes After tnspecbon.
between CN236 (5) Ifemale) repaw or repkce
ISmere
co”tl”“lty CN16 (3)
_ betweenCNlGI11 _
NO lfemakl and Defectwe contact, or
chews7 d,sconnectlon m wrq harnes After mspecbon.
1
1) D~sconnec: NO
I
’ between CN16 (1 Ifemale) - repan or replace
ChaSSlS
CN16
2) Turn starbng
swtch OFF Defectwe contact. or
d,sconnectmn I” w,r,ng hames After InsPeCtIon.
between CN236 (6) (female) reparr or replace
CN60 (fuse)
Replace
After nnspecbon,
repax or replace
LO822043
82-45
TROUBLESHOOTING E-8
(d) Contact in F-R circuit.
YES
3
11 D~sccnnect
CN85
21 Turn stanmg
swy~~tchOFF IO
h
1 between CN85 (01 ES
CO”rnctM body’ 4
1 I
1) D~sccmnect
2)
CN85
Disconnect
h
J YES
CN75
31 Turn stann~
swatch OFF
1) D~sconn.act
CN85 Is there contmuty
YES
21 Dtsconnect between CN75 151
P
CN75
31 Turn stamng
1 swtch OFF
1
1) Disconnect
CN75 between CN 16 (21
21 D~scarnect (mabl and (11. (3).
CN16 (41. (5). 161. 171. (81’
3) D~~connecf
FORWARD
sobnod relay
1) Connect CN16
(CN2461 NO
l-adapter to 21 F-R lever a, N or
41 Turn startnq
CN85 R prxmon
swtch OFF
21 Turn stanr~ 3) Turn stamng
swtch ON swtch OFF
31 Turn oark~na
swch ON L
OFF
Is them cmhnunty
between CN85 (Cl
imabl and chaws
Corltlnuous locatla ISL 15there contrnwty
when there IS between chassis and
problem w,th (01. (El. (Fl. (Gl. and
REVERSE
1 I Disconnect
21 Turn stanr~g
swtch OFF
1) Disconnect NO
CN85
21 Disconnect
CN75
31 Turn startng
lw!tch OFF
LO822044
82-46
TROUBLESHOOTING
E-8
Cause Remedy
l Defsctlve lnsubtlon between

CN85 (01 lmakl and
ccmnector body. OTabnormal
contact between chasws After mspectlon.
ground and wnng harness of mpalr or mPkCe
CN85 IDI uwde control valve
l Defectwe wwnng between
pns of CN85
Defectwe ,nsubtlon tetwnn

After ,nspect~on.
CN85 (0) Ifemsk) and
repaw or replace
c0nmct0r body
(femsk) - CN246 (2) (female) reps’r Or rsplace

and chassis or ground
I CO”nect*” wlr,ng
Dafectwe trans.nvssK)” contrDl

I
Replace
swdch
YES Defecttvs transrnoss~)” control I

7 I swtch
II I
Is there contorwty Abnormal contact wth wnng
_ betweenCN16(21 - harness between CNl6(2J
Imakl and chassts’ 8 YES
(female) - CN246 (5) (female1 After mspectrcm.
repair or replace
I an chnssts or ground
- Is them confvwity connectIon v.wng
1) Dtrconnect _ between CN16 (21 -
CN16 NO (femakl and chessus)
21 Turn starting Short c,rm,t between t.rm,n.ls
swtch OFF 11) and 12) of FORWARD
1 I
Dwxmnect NO sobnad relay CN246 (male)
CN16
21 De.connect
CN246 I
31 Turn starmg ’ Defectwe lnsuletoon batween
switch OFF CN85 IC) (male1 and
conrmctw body, or abnormal
contact between chassn After Inspectvan.
ground and wnng harness of rePM Or mPkce
CN85 (01 UIS& control valve
. Defectwe wrmg between
pins of CN85
Defectwe ww4atton between

After ~nspectlon.
CN85 (C) ifemabl and
repel, or replace
conrmctor body
T-adapter or socket adaPtOr

(for Ecomsaall
LO822045
82-47
TROUBLESHOOTING E-8
11
between CN75 (61

A-
Imabl and I1 ), 12); YES
(3). (41.1517
1 1
1 I
Disconnect 12
CN65
21 Disconnect Is there coWnutty
CN75 _ betweenCN75 (61 - YES
31 Turn starting NO (female1 and chassis)
swtch OFF 13
1 I
Disconnect Is there continuity
CN75 between CN16 131
YES
7.1 Dosconnect ,.,$ imab) and it ), (21. -
CN16 (41.15l. 161. (71. 16)’
31 Disconnect
47
REVERSE 1 I
Dwonnecl Is there contnutv
solenod relay CN16 - between CN16 I31 -
CN236 21 F-R bver at N or NO Imabl andchassis ~ 15 _YES
4) Turn startmg R posotlon
swtch OFF 31 Turn starttng - b th.,,e co”tmu~ty
swtch OFF 1) Disconnect _ betweenCN16 13) -
CN16 NO Ifsmabl and chassns’
2) Turn stamng
swatch OFF
II Dwzonnect NO
CN16
21 Disconnect
CN236
31 Turn startnng
switch OFF
LO8zzo46
82-48
TROUBLESHOOTING E-8
I Remedy
1 Abnrxmal contact wth wwmg

harness between CN75 161
Imale) - CN85 (Cl (female) an,
wrung harness between CN75
01. (2). 131. (4). (51 (male) -
CN85 ID). IEI. IF). It). (HI
(female)
I Abnormal contact w,th ww,ng

harness beween CN75 161
__. _ .-__ .-. .._..._._
COnrmctlo” wlrlng
Defective tra”smlSslO” Control

RePlaCe
switch
Abnormal contact wth wtnng

harness between CN 16 (3)
J lfemalel- CN236 (5) lfemalel
CO”reCba” wnng
Shorl corcuntbetween terminal!

- I1 I and (21 of REVERSE Replace
so,ew.,,d relay CN236 Imalel
LO872047
82-49
TROUBLESHOOTING E-8
(e) Problem in speed solenoid circuit.
YES
B r
1st
- Is them connc~nuty
1 I
Disconnect
L between CN16 141 -
CNB5 NO (makl and CN16 181)
21 Place speed k’ier
I” 1 s1
31 Turn star-h”9 1) Disconnect NO
swatch OFF CN16
21 Turn starbn9
swttch OFF
YES
YES
YES
-
CNB5
21 Place speed kver Is problem removed
on 2nd
31 Turn startwva
nwtch ON
41 Turn parknng
swtch ON - 1I Interchange 2nd
OFF sokmd relw
ICN2371 with
I
To A
backup kmP
reky lCN2471
21 start angtne
31 Turn parking
swatch ON -
I1
4
NO
IS probkm
when r&y
rech3d’
removed
IS
I
OFF
11 Interchange
Znd-1st sekctor
r&y lCN2391
w,th back-up
lamp relay
ICN247)
21 Stan engne
11 Connect 31 Turn parkqz
T-adapter swefch ON -
(socket adapter1
to CNl6 lfemaki
OFF
uo
21 Turn stantn9
swtch OFF
I
IS voltage tatween
CNB5 (B) Ifemaki
;ngdVc:assn* 20 -
I 1
1, Disconnect
CNB5
21 Turn starttng
swtch ON
31 Turn parlang
swtch ON -
OFF
LO822048
82-50
TROUBLESHOOTING E-8
Cause Remedy
Defectwe 1 st sdenad ileplace
. Defectwe speed lever swtch
Defectwe 2nd sdenad Replace
Defectwe 2nd sdenad relay
Defectwe 2nd-1st sekctor

relay
10 YES d,sconnectlo” I” wnng harm! After ms~ctoo”.
between CN237 (51 lfsmakl repar or replace
IS voltage between CN65 it)
YE CN237 (21 Ifemakl
ygdV:hhassls 20 -
deconnectnn onwmng harne! After mspectaon.
between CN237 (21 Ifemak) repa,r or replace
9 11 Disconnect NO
power source
CN237
21 Turn startfing
YI IS there contl”“lty swtch ON
between CN237 13) 31 Turn parklng
(fern&l andchaws~ swtch ON -
OFF Defectwe ccafact. or
After ~nspecteo”.
1 I Dasconnect 11 YES d,scon,wctlon I” w,r,ng hame
between CN237 131 lfemakl repan or replace
CN237
2) Turn starting CN239 I61
Is there cont,nu,ty
switch OFF . betweenCN239 13) -
h (female1 and chaws) Defectwe contact. or
d,sco”“ect,o” I” wlnng harW! After ~nspectvw
between CN239 131 (female) repav or replace
1 I Disconnect NO
ChaSSlS
CN239
I 1
2) Turn starbng
11Disconnect
CN237
21 Turn starbng
sw,tch OFF
31 Place speed lever
L I I Detectwe
speed lever switch RePLaCe
11 D,sconnect NO
CN16
2) Turn start,ng
sw,tch OFF Defective contact. or
3) Place speed lever I” 2nd dwxmnecto” I” wmng hamel After ,nspectm”.
- between CN16 (6) lfemakl - repa,r or replace
chasss ground
DefectNe contact. or
d,sconnect,o” I” wnng hame
After ,nspectn”.
between CN85 I61 lfemakl -
,epa,r br replace
CN75 171 - CN56 (61 - fuss
- CN59 (71 - maon breaker
82-51
TROUBLESHOOTING E-8
Cause Remedy
YES
Defectwe 3rd solenad
1s I
YES disconnectwon In wring t?WfWs
between CN65 IF) (female) -
CN16 (61
Defective spead lever swrtch Rsplace

31 Turn starbng 1 I Disconnect NO
swtch OFF CN16
2) Turn startang
swtch OFF
3) Place spead lever
,n 3rd
YES
Defectwe 4th sdanoid
15
15there contlnuty
4th
. between
CN85 (El -
16 .YES
lfemakl and chass~s~ disconnectwn in wrung harWS
between CN65 IE) Ifemale) ar
- IS there cont~“uW CN16 (7)
1) De.connect L betwwnCN16(71 -
CN65 NO sndCN16(6),
on4th Defectwe speed lever swtch
31 Turn startng 1) Disconnect NO
swtch OFF CN16
21 Turn startn(l
swtch OFF”
,n 4th
LO822050
82-52
TROUBLESHOOTING
82-53
TROUBLESHOOTING
E-8
(f) Contact in speed circuit.
CNa5
2) Turn slrtn&?
,wtch OFF
c*nnector W’
11 Dlsconr?Kt
CNBS.
21 Dnconnect
CN75
h there contlnuw
31 Turn ,tdrten9 YES
bsweanCN75 111
swwh OFF
r
21 Disconnect
CN75 1s there ccmt~nuty
31 Turn st~rtung bstween CN75 11)
swatch OFF
CN75
21 Dtsconnect
CN16
31 Turn starfun
swxh OFF
I
Ii Disconnect
CN75
21 D,sconnect
CN16
31 Disconnect
NO
CN239
41 Turn rtsrt,n9
swnch OFF
V
To P
LO822051
82-54
TROUBLESHOOTING E-8
Cause Remedy
. Detectwe ~nsullltan between

CN85 WI) and conmctor
body. or abnormal ccmtact
betwan chassis ground and
wiring harness of CN85 &I)
r&da control vabe
l Defectrve w,r,ng betwssn
pans of CN85
Abnormal contact with wrong

harrmss between CN75 11)
(mab) - CN85 WI (female)
and w,nng harp1)SS betwWn
CN75 (21 - 161 Imale) -
CN85 (Cl - (G) Ifemab)
Abnormal contxxct witi wiring

harness betwwn CN75 (1)
. (fernok) - CN16 141 (female)
- CN239 (51 (femabl and
chass,s wnng harness
Abnormal contact wth wlrlng

harness between CN75 (1)
Ifsmale) - CN16 14) lfemsbl
- CN239 (5) (female) and
winng harness of lww botWWr
CN75 (21 - (6)
Abnormal contact wth wlnng

harness of CN 16 14) (fernebb
and wnng harness of CN 16
(5) (fsmabl
7
Is them cont~nultv
_ betweenCN16141 _
Ifemabl and CNI 6
YES Defectwe tiansm~sso” COntrOl
15) (femaleI’
swtch
1
II Disconnect
CN85
Is there contruty
21 Disconnect
_ tatweenCN16~41 _
CN75 YES Defectwe transm~ss~o” control
NO (male) and (1). (21.
3) Doscomwct
(31. (51.16). (7). (8)’ 9 swtch
CN16
4) Turn startong
swtch OFF 1) Dtsconnect Is there conttnuW
CN16 _ betwbenCN16l4l -
2! F’J;~peed bver NO lmabl and chassis) 10 YES Defective 2nd.1st S&C~W
rl3laV
31 Turn startong p 15them contwuty
swtch OFF 1 I
Dwxnnect between 13) and (51
CN16 f.,c Of 2nd. 1 St sebctor
21 Turn startng mlay CN239 hnab)~ Abnwrnal contact with wwmg
swtch OFF harness of CN239 (5) ifemale)
NO and wnng harness of CN239
11 Disconnect (3) lfsmabl
Znd-1 st sebctor
relay CN239
I
82-55
E-8
TROUBLESHOOTING
YES
r
2nd 11
Isthsrecontl""lty
betweenCN85V.J
Imale) and chaws YES
IS there contlnu~~
between ICI. (D). (E).
(FI. IH) andchsss~s~
122
II D~sccnnect
CN65
2) Turn startrq
switch OFF YES
1 I
D,sconnect
CN65
21 Disconnect
Is there continuity
CN75
between CN75 (21
31 Tumstartmg
Imale and 11). (31. YES
switch OFF
I I
11 01rconl-ect
CN85 1(I
2) D~sccnnect Is there cont,nu~ty
CN75 YES
between CN75 (21 _
31 Tumstartq 1QO lfemalel and chassvs7
t sw,tch OFF
15
- -
1 I
Dtsconnect Is there cont~nu~tv
CN75 between CN75 (21
21 D~scommct NC ~fe”Mi-8) and 11). 131.
CN16 141, (51. 161’
31 Turn stannng
swtch OFF
11 D~sccnnect
CN75
2) D~scomwct
NO
CN16
31 Dtsconnect
CN237
4J Turn stxbng
watch OFF
LO822053
82-56
TROUBLESHOOTING E-8
Cause Remedy
1 Defective msubtwx batweef

CN65 (Gl and connector
body. or sbnwmal contact
between chassis ground and After mspectian.
wiring harness of CN85 (G) repan or replsce
inside contml valve
) Defectwe wiring between
Dins of CN65 (male)
Defectwe n-tsubtlon betwm

After mspectm.
CN65 IGI (fsmabl and
connector body repair or replace
Abnormal contact wth wirtng

harness betwesn CN75 12)
(msbl - CN85 (G) (female) After mspection.
an* winng harness between rspw or replace
CN75 11). 131, 14). (5). (61
hnsbl - CN65 (CL KJ). (El.
IF). WI
Abnormal contact with wrung

harmss k~~~een CN75 (21
lfemabl - CN237 15) (femsb
and ChaSSlS or ground
connectan wmng
Abnormal contact with wnng

harmss of lme between CN75
(2) (female) and wnng hsmesr
of line between CN75 (1). (3).
14). (5). (61 ifemabl
Defective 2nd sobnad relay Repbce
Abnormal cwatact with wrmg

betwwn(3l - WOf harmss of CN237 131 lmabl After mspectton,
2nd sobnad relay and wiring harness of CN237 repaar or repbce
(51 (male)
1) Dosconrwct IS them calhnulw

CN237 between 131 - Dsfectws transm~son control ReDlace
P 2nd sobnaid relay swatch
CN237 (male)’
11 D~sconmct
CN237
21 Disconnect Defective transm,ss~n control
CN75.. swtch
3) turn starting
-U
switch OFF
Is them continuity
between CN16 151 t
2) Placew-3 lever b-nab) and chassts)
I” 1 St
Abnomwl ~ontmztwth winng
3) Turns
harness between CN237 I1 I
switct > OFF 1 I
Disconnect
lmabl - CN242 (51 lmabl -
CN16. NI
21 Turn starhnc. CN16 (51 (male) and chassis or
swtch OFF.-
LO822054
82-57
TROUBLESHOOTING E-8
YES
3rd 20
h them continuity
between CN85 (Fl I
(mabl and chassis?
‘ES
Isthere
co”ti”dy
bdtww”chsssk ant
i 1~1;‘DJ. (U. IGI, and
2
1) D~occrmect I
4
CN85. k them ccmtmuity
2) Turn start,ng between CN85 IF)
swatch OFF NO lfemabi and YES
co”“ectM body’
11 DiiCo”“ect
CN85 I
21 Diico”nect k them continutty
CN75. between CN75 (31
3) Turn start,ng NO hnsb) and (1). (21. -
switch OFF. (41. (51, IS)? YES
23
11 Dscmnect
CN85. k there continuity
21 Dlsco”“ect bHwe@n CN16 (61
CN75. NO k”ab) and(l). (21. - 24 YES
3) Tumstartin~ (3). (41. (5). (7). ISI? r
switch OFF
k thers contlnulty
1 I Disconnect
- bstweenCN1616l -
CN16.
NO lmab) andchassis,
2) Pbce speed bvsr
in 2nd w4th
31 Turn statt~ng 11 Dnconnsct NO
watch OFF CN16.
21 Turn starting
switch OFF
YES
Is them co”tw~“~
between CN85 (E)
(male) and chassis)
IS there CO”ti”ulty YES
between chassis and
ICI. IDI. (FL (G). and
L-
Is there continwty
between CN85 IE) _
NO (fornab) and YES
CO”“e&M body?
1) Dasconnect 27
CN85.
2) Disconnect k there contunuity
CN75. _ betwesn CN75 (41
3) Turn starting ND hnabl and (1). (21. -
owtch OFF. (3). (51. 161) YES
28
1) Dtsconnect
CN85 Is them conhnulty
21 Disconnect _ betweenCN16 17) _
CN75 NO (nub) and (II. 121. 29 YES
31 Turnstating 13). 14). 151. (6). 181’ y -
switch OFF
- k them co”t~“ulW
- betweenCNl6l71 -
NO (male) and chaws?
NO
LO8ZZO55
82-58
TROUBLESHOOTING E-8
Cause Remedy
- Defective lnsubtica betwea

CN85 (Fl (male) and
connector body. or abnorma
caltact batwaen charsa
g’cund and wvmng ha-ness a
CN85 IFI inside control valw
l Defective winng between
pins of CN85 Imabl
Abnormal contact with wiring

harmss between CN75 (3)
lmabl - CN85 IF) Ifemabl sn
wiring hermrs between CN75
I1 I. (2). (41. 15). 16) Imale) -
~;~NSl~L ID). (Fl. (G). OfI
Defective transmission ~OIWO Fbpbce

switch
Redace
Abnormal contact wth wiring

harness between CN16 16)
(femsbl - CN75 13) Ifemab)
cOnmctl0” wnng
’ Dsfectlve lnsubtlon betwetu

CN85 (El Itnab) and
ConnectOr body, or ablorma After inspectmn.
contact tmtween CheSSIS mpa,r 0, mpbce
ground and wnng harness o
CN85 (E) insode control vale
After ms,mct~~“,
mpaor or replace
LO822056
82-59
TROUBLESHOOTING E-9

Failure mode: E-9 KICK-DOWN SWITCH DOES NOT WORK.
(NORMAL Fl - F4 SWITCHES CORRECTLY)
* When connecting the T-adapter (or socket adapter), connect to the connector specified. (CN o A( ))
t When disconnecting connectors or connecting T-adapters, return them to the original condition immediately after
ES
I-
ES
1) Interchange
3
4
kick-down mlq
ICN2421 with
REVERSE Is problem removed
odenad relay when day is
(CN236). NO mplaced~
21 Startengme
FORWARD
Solenad relay
(CN2461 wth
REVERSE
solenood relay
1 (CN2361
2) Stanenglne N
Is there contmu,ly
between CN243 (1)
I I YES
(male) and (2)
1) Interchange
Znd- 1 st s&actor
Imale) 7 6
relay ICN2391
I I with back-up
11 Dwmlmt lamp relay
CN243 YES Is there contanuity
(CN247l
2) Press krk-down - between CN239 I51 -
2) start engine (female) and chaws)
swtch
31 Tumstamng 5
swtch OFF
Is there contmuty
1 I Drxonnect
CN239.
- between CN239 (1 b - 2) Turn stan~ng
h ) (female) and chassts) NO
swtch OFF.
. 3) Placespeed lever
I” 1 st
11 Disconnect
CN239
21 Turn start~19
switch OFF NO
L08ZZ057
82-60
TROUBLESHOOTING E-9
Cause Remedy
Defectwe back-down relay Sepka
Defectwe FORWARD sdenold Replace

rekv
Defectwe 2nd.151 Selector

Redace
relay
9 YES
c To A
*,scrJn”et,lOn an w*rlrnng harness
t,e,ween CN242 I51 ifemakl
YE!
r and CNl 6 151 lfemalei
d,%x,“wx,lo” I” w,r,ng harrIeSI
between CN239 (21 CN242 and between CN242 I21. 141
(female1 and CN242 CN53 ,femaki - CN53 151 (female!
2) Turn stamng
swtch OFF
Defecwe co”tact or
CN239 and d,sconnectlon I” wnng harness
1
bewteen CN239 121 lfemakl -
CN242 NO
CN242 (31 lfemalei
21 Turn starhng
swnch OFF
Defectwe contact or
*,SCO”“eCtiO” I” wmng harness
between CF1239 151 lfemakl -
CNl 6 141 lfemakl
Defectwe k,ci-dew” swtch Replace
LO8ZZO58
82-61
TROUBLESHOOTING E-9
Cause Remedy
Dsfectwecontact. or
YES disconnection m wiring harms! /
12 7 b&wean CN243 (2) ffsmsbl -
CN53 (51 ffemab)
Is there contiruty
YES b&wear-~ CN242 (1 I
- (femsbl - CN243 -
11 11) Ifemale)’
_ Defective contact, or
Is there continuity 1) Daconnact dw.conmction ,n wnvlng harnt~s!
YI between CN246 (4) CN242 and Nr I
betwwr~ CN242 (1 Ifemabl -
(female) - CN242 - CN246 CN243 (1) (female).
10 IO (fernab)~ 21 Turn starting
switch OFF
1) Disconnect Defective contact, or
CN242 and dbconmction m wmr?~ harms! After anspsctwn.
CN246 NO between CN246 (4) (female) - rapan or replace
21 Tumstartq CN242 (1) Wemale).
switch OFF.
1) Dnconnect Defective contact, or
CN7.42 and dwaxvmction in wvlng harmsr After mpectc.“,
CN246 0 - f~~ear CN242 16) (fornab) - mpmr 0, rspbcs
2) Turn stamng CN246 (31 ~fernab)
swtch OFF
LO8ZZO59
82-62
TROUBLESHOOTING E-10
TROUBLESHOOTING CHART No. E-IO

Failure mode: E-10 KICK-DOWN ONLY WORKS WHEN KICK-DOWN SWITCH IS ON.
(KICK-DOWN SWITCH RELAY DOES NOT CARRY OUT SELF-HOLD OPERATION.)
* When connecting the T-adapter (or socket adapter), connect to the connector specified. (CN 0 A( ))
Cause Remedy
YES
Defective kxzk-down relay Replace
1 I
IS problem removed
when day IS Dsfectwe contact, or
repbced~ 2 YES disconnectmn anwnng harness After mspecmn,
between CN242 I21 (female) - repmr or replace
- Is there conb”“,ty CN53 (5)
lb Interchange tatwwn CN242 (2)
kck-down NO $ybl andCN53 -
swtch relay Defectwe contact, or
lCN242) wth dwonmctwn I” wrmg harness After mspectlo”.
REVERSE 1 I Disconnect NO h
between CN242 (1 lfemab) - *pm or replace
sobrad reby CN242 and
I
CN243 (1 (female)
lCN2361. CN53.
21 start sng,ne 2) Turn stamng
watch OFF
82-63
TROUBLESHOOTING E-l 1
TROUBLESHOOTING CHART No. E-l 1

Failure mode: E-11 KICK-DOWN OPERATION IS NOT CANCELED.
+ When connecting the T-adapter (or socket adapter), connect to the connector specified. (CN o A( ))
Krk-down IS not 3 YES

canceled even when
1 I
11 Interchange F-R bver IS moved
Znd- 1 st selector tromFtoNorR
relay (CN2391
wth back-up
1 b Interchange NO
FORWARD
sobnad relay
lCN2461 wth
1) Drxonnect REVERSE 5 YES
CN239 sobmd relay
21 Turn stat-w9 ICN236)
watch OFF
;o to problem baton
3 (CN53) wrth back-up
lamp relay (CN247)
1 J
21 start e”9l”e
YES
Krk-down is not
canceled eve” when
speec_bver IS moved I----G
/
2)
sdenold relay
lCN236)
start enggne
I
1 I Disconnect
CN242
‘L
NO
2) Turn startong
swtch OFF
3) Place F-R lever n
NEUTRAL

(for Econoseall
LO8ZZO61
62-64
TROUBLESHOOTING E-l 1
Cause Remedy
Defectw 2nd.1 st sdector

RClplKZe
r&lv
Contact w,tt? w,r,ng h.s”BSS

between CN239 ltemabl 13)
and 15). or contact wfh wmn(
hanwss between CN239 (51
lfemsbl and chessIs
Dsfectwe FORWARD sdenar Replace

mslv
Contact wth wnng harness

After I”S~B.X~IO”.
between CN246 ttamabl (31
mpw or replace
and 14)
oetectlve
neutralizer relay Replace
Contact with w~nng harness

between CN33 Ifemale) (3)
and (5)
For detalts. see Troubleshootor

“Padung brake does not work’
Detectwe krk-down swtch

Replace
mlw
Contact wth wwng harness

between CN242 (female1 131
and (41
8 YES Contact with vnng hw”ess

batwesn CN242 tfsmsbl Ill
and 121
Is there cont~nuty
- betwsanCN242 -
ltemalei (11and 7I21
Contact w,th w,r,“9 harnass
batwexm CN242 ltamabl I1 1
1 I
Disconnect NO and 141
CN242
21 Turn s,sr(,ng
swtch OFF
LO8ZZO84
82-65

Failure mode: E-12 KICK-DOWN WORKS BY MISTAKE WHEN TRAVELING IN F2.
a When connecting the T-adapter (or socket adapter), connect to the connector specified. (CN 0 A( ))
YES
1
h the-0 ccnbnuify
beaCeenl1~and~Z~
YES
of Ylck-down relay -
CN242 kne.b). end
between (31 and 14)’ 2
1) olsconn.3ct
kiik-down mlay 1s pro&m rsmoved
L whenrelsyls YES
CN242.
21 turnstartIng NO repbwd?
3
swttch OFF.
1) Interchange Is then caltinulty
Znd-1 st sebctor
nby (CN2391
between CN243 (11 _ YES
NO- (nwbl e.nd CN243
wth back-up (21? 4
Lsmp mlw
(CN247) Is then, ccmtinu~ty
1) Dnconnect
21 start sngmne CN243. between CN243 (1 b
21 Tumstamng N< Lyy” and CN243 - 5 YES
rwtch OFF
3) Donotprsss 1 Is there caMnutty
kick-down 1) Dtsconnect _ betweenCN242 (1) _
switch. CN243 NO $&a’ and CN242
2) Tumstarhng
switch OFF.
1) Dwonnect NO
CN242
21 Turn stsrtung
swtrh OFF.
31 Place F-R lever in
TROUBLESHOOTING CHART No. E-13 NEUTRAL.
Failure mode: E-13 MACHINE DOES NOT TRAVEL WHEN KICK-DOWN SWITCH IS PRESSED.
1 YES
1s probbrn removed
when relay IS
WpbCed?
2nd-1st &ctor
relay (CN239)
wth bsck-up
Kp2~?
start eng,ne
Pbce speed bvet
in 2nd
Pbce F-R lever ,n
FORWARD.
62-66 LO8ZZO63
Cause Remedy
k/
k
Defectwe krk-dow” reby Cpbce
Contact with wiring harness

between CN242 Ifemsbl(3)
Snd’(41
Defective 2nd-1 st sebctor

Replace
relay
Defectwecultsct, or
dwxwmchon I” WWQ harries!
tetween CNBS Oil - CN239
15) Ifemab)
82-67
TROUBLESHOOTING
82-68
TROUBLESHOOTING CHARTS
FOR ELECTRONIC VEHICLE MONITORING SYSTEM
82-69
POSITION OF CONNECTORS FOR

TROUBLESHOOTING
CNPI (Monitor module)

DLI connector 16 pins
CNP2 (Monitor module)



CN12 (Working lamp switch)

82-70
POSITION OF CONNECTORS
TROUBLESHOOTING
CN14 (Inlet of starting switch)

CN15 (Lamp switch)

CN17 (Warning lamp)

CN18 (Transmission cut-off selector switch)

CN36 (Parking brake detection sensor)

82-71
CN38
CN55 (Turn signal unit)

2 1
4 ‘3
421FOI 134
CN60 (Fuse)
CN83 (Speed sensor)

423P425
82-72
CN84 (Torque converter oil temperature sensor)

CN87 (Brake stroke sensor)

CN88 (Brake stroke sensor)

CN92 (Air pressure sensor)

CN96 (Engine oil level sensor)

82-73
CNI 01 (Engine water temperature sensor)

CN10.5 (Fuel level sensor)

CNI 07 (Radiator level sensor)

CN130 (Warning buzzer)

Plug
82-74
TROUBLESHOOTING M-l
TROUBLESHOOTING CHART No. M-l

Failure mode: M-l WHEN STARTING SWITCH IS TURNED TO ON POSITION, MONITOR PANEL DOES NOT
LIGHT UP FOR 3 SECONDS.
Cause Remedy
a) None of monitor panel lights up.
2 YES
Defective monitor pane,
YES IS voltage between

- CNPl lfemalei 11) -
and (2) 20 - 3OV7 Defectwe contact. or
1 dlsconnecuon I” w,r,ng hamess
NO
between CN60 (61 - CNP 1II I
Is voltage between
11 Connect orbetween CNPl 121 - chass,:
CN60 (male1 151and _
T-adapter to
CNPl
ground (See Fug 1 I
chassts ground 20 -
2) Turn starbng
3OV’
swWh ON
1) connect Abnormalrty in wwng harness

T-adapter to between battery terminal (+i -
CN6b (male) battery relay - ma,” breaker - After ~nspecbon.
2) Turn starting NO CN146 - CN60 (male) 151 repav or replace
swttch ON (See Fig 11
b) Except for speedometer module, none of monitor panel lights up.
1 YES
Defectwe monitor panel Gpl.Xe
Is voltage between
CNP5 (female) (1)
and (71 10 - 2OV7
IS voltage between
(21 and 171approx
5V7 H kfectwe contact. 0,
jwxnnxtwm I” wnng harness
I I I wtween CNP2 (1 I-
CNP5 I1 1,
:lean (defectwe
11 Connect NO ontactl or rep,ac
3NP2 (2) - CNP5 (21. CNP2 17
T-adapter to - CNPS (71. or defectwe
CNP5 (female1 Tlonltor panel
21 Turn start,ng
switch ON
None of CAUTION items light up.
d,sconnect,on in w,r,ng harness
between CNP2 lfemalel and
CNPS ifemalel
Defective mon,tor panel

II Connect NO
T-adapter to
CNP2 and CNP5
Ifemale
21 Turn stamng
swtch OFF
d) Some other parts do not light up.

I
Tester T-adapter
LO8ZZO67
82-75
TROUBLESHOOTING M-l, M-2
M-l Related electrical circuit drawing (Fig. 1).
Fuse box
I I
Llain breaker
Battely relay
CN60
CNPI
CN 148
I
Monitor panel
CN64 7J7
421FO1139
TROUBLESHOOTING CHART No. M-2

Failure mode: M-2 WHEN STARTING SWITCH IS TURNED TO ON POSITION, ALL MONITOR PANEL
LIGHTS UP AND DOES NOT GO OUT.
Cause Remedy
hfective monitor Panel leplace
LO8ZZO14
82-76
TROUBLESHOOTING M-3

Failure mode: M-3 WHEN STARTING SWITCH IS TURNED TO ON POSITION (ENGINE STOPPED), CHECK
ITEM FLASHES, (LEVELS OF CHECK ITEMS ARE CORRECT).
Cause Remedy
a) (Engine oil level) flashes.
YES Defective engine 011level

s?“SOI
CN96 (1) and (4)
1) Turn start,“9 switch

oh Do not start
en9,ne
Defeci~ve contact. or
deconnection I” w,r,ng
Connect between L harness between fuse box _
CN96 (female) (2) NO CN63 (9) - CN97 ,I 1) -
and chassis CN96 (1) or CN96 (4) -
ground CN97 (121 and chaws
Does display ground
disappear?
1) Connect CN96
(female) (2) to
chasse ground
2) Turn start1n9 YES
switch ON Do no, r
start enSIne 3
I
conllnulry
IS there
between CNP3
1) ConnectT
adapter 10 CNP3
2) Turn stanlng
switch ON Do not
stan engine
YES Defecllve engine oil level

. sens0i relav
1) Interchange
enylne Oil lee
*e”soI relay
(CN233) wllh
bucke, poslllone~
relay (CN49)
harness between CNP> (2)

sw.tch ON DO not - CN233 151- CN233 131
s,ait engine NO
harness between CN96

(female) (2) - CN97 (5) ;
CN62 (1) - CN233 (1)
LO8ZZO85
82-77
TROUBLESHOOTING M-3
b) (Radiator water level) flashes.
Cause Remedy
lefectwe radaator water level IePlXe

e”SCX
connector to CN 107 Y
befectlve mclnltor panel teplace
display daoappear,
1I Connect short
CpnnectOr to
CN107 Ifsmalel h bfectlve contact, or
21 Turn starbng and chassis ground’ Ikconnactmn 8nwirmg brnesr
watch ON Do atwean CNP3 (female1 (3) -
not start sng,ne 1) Connect short :lesn (defectwe
i :N62 (21 - CNllO 12) -
Connector tcl hIO :N107 Ill,orbetwwnCN107
:ontactl or nplac :*
CN107 Ifemale) 21 - CNl 10 (41 - chassis
21 Connect Iround (See Fog 4)
T-adapter to
CNP3
3) Turn starting
switch OFF
LO8ZZOJ7
82-78
TROUBLESHOOTING M-3
M-3 Related electrical circuit drawing
a) Engine oil level (Fig. 3).
Engine oil level

sensor relay
CN233
+24V
4 Engine oil
CN97 CN96 level sensor
CNP3
c24V
LO8ZZO69
b) Radiator water level (Fig. 4).
CNP3 CN 62 CNI IO CN 107
Monitor panel
Radmtor water
level sensor
421FO1142
82-79
TROUBLESHOOTING M-4
TROUBLESHOOTING CHART NO. M-4

Failure mode: M-4 NO OPERATION IS BEING CARRIED OUT, BUT PILOT DISPLAY LIGHTS UP ABNOR-
MALLY.
(SWITCH POSITIONS ARE NORMAL)
a) (Transmission cut-off) lights up.
Cause Remedy
YES Defectwe transmossoon cut-off

RePlace
swatch
1
I
Connect CNl8
II
(female1 131and 141 _
YES
Does dq?aly Defectwe monitor panel Replace
disappear? 2
11 Connect CNl8 Is there contmuotv
(female) 131and _ betweenCNP3 _
14) NO (female1 (11) and
21 Turn starhng chassis ground, Defectwe contact, or
swfch ON Do dlsconnectan I” wrmg harness
not sta” engme 11 connect between CNl8 (3) - CNP3 Cban (defectwe
T-adapter to (female) (1 1). or between CNl E contact) or rep,ac
NO
CNP3 Ifemale) 14) - chassts ground
2) ConnectCN18 (SeeFug 71
ifsmale~ (3) and
141
31 Turn startmg
swtch OFF
Tester T-adapter
LO8ZZO70
82-80
TROUBLESHOOTING
M-4
b) (Parking brake) lights up.
Cause Remedy
1
Connect
short
connector to CN36
(female1 Does YES
Defectwe monitor pand REPkXX
dtsplay disappear’ 2
1) Connect Short Is there conhnutty

conrmctpr to L bstwwnCNP3
CN36 Ifemale NO (female1 15) and
21 Turn starbng chassis ground? Defective contact. or
watch ON Do dusconnechon m winng harms
not starteng!“e 1) connect between CN36 (1) - CN36 (4 Clean (defectwe
T-adapter to - CNP3 Ifsmale) 151. or contact) or replac
NO
CNP3 (female) betwesn CN36 (21 - chass!S
7.1 Connect short ground (SW FQ. 6)
cp”nxtpr tp
CN36 (femaleI
31 Turn stnrbng
sw Itch OFF
(Working lamp) lights up.
YES
Defective worktng lamp swttch
1 I
Does d@ay light “P

Contact betwser, +24V and
when CNl2
removed’
IZ
2 YES ww,ng harress betwee” CN12 \fter mspactlorl.
12) - CN40 (1) -CN40 (4) - span or replace
- Is voltage between CNP3 (female1 (141 (See FQ 9
,) Re,,,oveCN,2 _ CNP3 (hmale) (141 _
2) Turn stattang NO and chassis ground
swtch ON Do 20 - 3OV’
not star? engine Defectws rnon~tpr panel leplace
1) connect NO
T-adapter to
CNP3 Ifsmale)
2) Turn startng
swtch ON Do
not start engine
LO82207 1
82-81
TROUBLESHOOTING M-4
M-4 Related electrical circuit drawing.
a) Transmission cut-off (Fig. 7).
CNP3 CNl8
421FO1145
b) Parking brake (Fig. 8).
CNP3 CN38 CN36
I I
ParkIng brake
display switch
421FO1146
c) Working lamp, head lamp (Fig. 9).
Momtor panel Lamp Lamp Lamp Service meter Momtor panel
421FO1147
82-82
TROUBLESHOOTING M-5

Failure mode: M-5 WHEN STARTING SWITCH IS TURNED TO ON POSITION (ENGINE STARTED),
CHECK ITEM FLASHES.
t Check both the engine oil pressure system and alternator system. Cause Remedy
a) Engine oil pressure system.
Defective engine oil Replace

pressuresensor.
engine 011pressure
sem.or crJnnec,or
female) terminals A
YES
1) COnnect engine 011 Defective monitor panel. Replace
pressure sensor
1) Connect T -
adapter to CNPB.
Defective contact, or
2) Turn staning
swlfch ON. Start disconnection in wiring
engine. harness between CNP3 Clean (defective
(female) (9) - CN64 (6) - contact) or
NO CN97 (8) - engine oil replace
pressure Se”*“, connector
terminal B - engine 011
pressure sensor connector
terminal A - CN97 (12). (See
Flg. 10)
b) Alternator system.
2 YES
Defective monitor panel. Fi+Xe
Is voltage between
YES CNP4 (female) (5)
and chassis
ground 20-3OV? Defective contact, or
disconnectlo” In wlrlng Clean (defective
1
harness between CNP4 contact) or
1) Connect T - NO replace
Is vo!tage between adapter to CNP4 (female) (5) - alternator
alternator terminal _ (female). terminal R. (See Fig 11)
R and chassis 2) Turn slanlng
ground 20-3OV? switch ON. Start
engine
1) start engine. Run
at half throttle or
above. Defective alternator, Replace
NO
T&t?, T-adapter
Wiring harness with

croccdlle CIIP LOB22072
82-83
M-6
TROUBLESHOOTING

Failure mode: M-6 WHEN STARTING SWITCH IS TURNED TO ON POSITION (ENGINE STOPPED),
CAUTION ITEM FLASHES.
* Check both the engine oil pressure system and alternator system.
a) Engine oil pressure system. Cause Remedy
between CNP3
(female1 (91 and
chassis ground’
lkiectlve
contact, or
~lsconnectlon I” w,r,ng
Wrness between CNP3
1 j Connect T-
female/ (9) - CN64 (6) -
adapter to CNP3
S ZN97 (8) - engine 011pressure
2) Turn stamng
ensor COnneCtOr terminal B -
sw,tch ON Do
:ng,ne 011pressure sensclr
not start eng,ne
:OnneCtor termlnai A - CN97
12). (See Fig. 10)
b) Alternator system.
YES
:ontact between +24V and

wnng harness bntwwn
lltemator termmal R - CNP4
female) 15) ISee Fg 11)
11 Connect NO
T-adapter to
CNP4 (female)
21 Turn stanq
swatch ON Do
not start eng,ne
T.¶SlW T-adapter lfor DLIJ
LO8ZZO86
82-84
TROUBLESHOOTING M-5, M-6
M-5, M-6 Related electrical circuit drawing.
a) Engine oil pressure (Fig. 10).
CNP3
1
+24v
CN64 Engine 011 pressure

CN97 CN96A
tX”SOT
b) Charge level (Fig. 11)
CNP4 CN64 CN97
0 Alternator terminal R
LO822087
82-85
TROUBLESHOOTING M-7
TROUBLESHOOT ING CHART No. M-7

Failure mode: M-7 Wt EN STARTING SWITCH IS TURNED TO ON POSITION (ENGINE STARTED),
CAUTION ITEM FLASHES. (FLASHING ITEMS ARE SPECIFIED VALUE)
Cause Remedy
a) (Charge level) flashes.
See M-5 (b)
b) (Fuel level) flashes.
YES
- Defectwe fuel se”sor ReplaCe
CN105 Imak) (1)

and (2) approx. 80 -
oerectwe contact. or
11 Connect dlsconnectwn I” w,r!ng harries:
T-adapter to between CNP4 lfemakl 14) -
CN64 13) - CN105 Ili.or 3kan (defectwe
CNI 05 (male) :ontact) or repkc
2) Turn starting between CN105 12) - CN64
swttch OFF 14) - chassis ground
Bee Fm 12)
1) Turn stamng
swtch ON
2) Stanenglne
0
c) (Brake line failure) flashes.

YES
Defectwe brake stroke se”sor
1
connector to CN87
and CN88 Ifemale)
Is there cont,nu,ty
COnnectcJr to between CNPJ
(femak) (4) and Defectwe contact. or
(female) dtsconnectlon I” wnng harness
21 Turn startq between CNP3 Ifemale) 14) -
sw,tch ON 1) Connect CN64(121 - CN221 11) -
T-adapter to :kan ldefectwe
31 start eng,ne CN87 I1 1, CN87 (21 - CN88
CNP3 (female) NO ontact) or repkc<
(1)~ CN88 121 - CN221 13) -
2) Turn stanng chassts ground Benal NO
swtch OFF 1 1296 - 20000 do not have
CN2211 (SeeFg 131
d) (Engine oil pressure) flashes.
I SeeM-5 Ial
e) (Radiator water level) flashes.
d- See M-3 (bl
I m Tester T-adapter
2s”
$”
e? Short cc.-a”ector
82-86
TROUBLESHOOTING M-7
Cause Remedy
f) (Air pressure) flashes.
Contact between chasws

ground and wwng harness After ~nspect,on.
between CN92 111 - CN63 repan or replace
11) - CNP4 (1) (See FQ 141
Clean ldefectlve
- CNP4 (1). or between CN92 contactl or replacl e
21 - CN62 (101 - chassas
qund (See FQ 1 AI
Defective mon,tor panel
(Engine water temperature) flashes.
YES )efect,ve eng,ne water

2 temperature se”sor
IS leslstance
YES between CNl 01
- (female] (A) and (6) -
below approx.
3.8kQ, Contactbetween chassis
I-
ground and wmng harness
F 11 Connect 4fter !“spe‘t!o”.
T-adapter to between CNlOl (A) CN97
IS eng,ne water NO repas cl1 replace
CN: 01 (female1 (3) - CN62 (9) - CNP4
temperature gauge _
wtthln red range? 2) Turn stannng (female) (2) (See Fig 15)
switch ON
31 start engone
1 I Turn starang
sw,tch ON
21 start eng,ne
NO
h) (Torque converter oil temperature) flashes.
YES
2 -
15resstance between
YES CN84 (female1 11 I
and I21 below
appmx 2 4 kil?
I- 11 Connect
T-adapter to xW.‘=n CN64 121 - CN22
NO
Is torque con”wtel CM CN64 Ifemalel 21 - CNP4 lfemalel 131
temperature gauge - 2) Turn staRl”g See Fig 161
wlthtn red range’ sw,tch ON
31 stsn erQne
1 / Turn stertnng
swrtch ON
21 Stan eng,ne 1 )efect,ve mO”ItOr pane, Replace
NO
T-adapter
I
LO822088
82-87
TROUBLESHOOTING M-7
M-7 Related electrical circuit drawing.
a) Fuel level (Fig. 12).
CNP4 CN64 CN 105
Fuellevel 5ms0,
4,
m
b) Brake line failure (Fig. 13).
CN87
CNP3 CN64 CN221
Brakestrokesensor
421FOl 151
c) Air pressure (Fig. 14).
CNP4 CN63
82-88
TROUBLESHOOTING M-7
d) Engine water temperature (Fig. 15).
Engmewater
CNP4 CN 62 CN97 CN 101 temperature
se”SOl
421FO1153
e) Torque converter oil temperature (Fig. 16).
421FO1154
82-89
TROUBLESHOOTING M-8

Failure mode: M-8 SPEED SENSOR DISPLAY STAYS AT “0”.
I Cause Remedy
YE.s
I
\/ES CNPl Ifemale) (9)

speedsensor
and I1 01300 fI - 1
clockwse. If at
contacts the gear
within one turn, the Defective contact, or
11 connect dtstance 1swlthln 1 .5 disconnectvan I” wring harness
T-adapter to mm. between CN83 (21 - CN22 (4)
:lean IdefectIve
CNPl Ifemale). - CNPl (female) (9). or
Is resistance between :ontactl or replact
i
CN83 (male) (1 and
2) Turn starting 3 between CN83 (1 i- CN22 (3)
swtch OFF - CNPl (female) I1 0).
(2) 300 fI - 1 kfl,
(See Fig 17)
11 connect
T-adapter to
CN83 (male)
2) Turn start,ng : Replace
switch OFF h
LO6ZZO16
M-8 Related electrical circuit drawing (Fig. 17).
CNPI CN 22 CN 83
Monitor panel
Speed sensor
421FO1155
82-90
TROUBLESHOOTING M-9

Failure mode: M-9 HIGH BEAM DOES NOT LIGHT UP, OR LIGHTS UP ABNORMALLY.
a) If high beam does not light up. Cause Remedy
efectlve momtor pane1 spkxe
2 I
Turn head lamp
dmmer swtch ON -
OFF Is conbnuty pntact between chass6
YES ound and wur@ hameSS
between CNPl u
~femalel 15) and ,tween left and rtght head
fter !“spectIo”,
chassis ground as mps - CNPl (female) (5).
pal, 0, replace
shown I” iaYe, between CNPl (female) (51
CN15 (female) (3)
dimmer switch ON -
11 Connect ;eeFlg 181
OFF Is cont~nu,tY
.I
CNPl (female1
21 Turn starbng ground as shown I”
3) Turn head lamp sfectwe haad lamp dummer

Does head lamp light eplace
dimmer switch NO wtch
up’ 11 connect
T-adapter to
CN15 (female1
1 I Turn stanmg 2) Turn stanmg
swatch OFF
swtch ON
31 Turn head lamp dmvner switch ON/OFF
21 turn head lamp
swtch ON efectlve contact. or
YES *co”nectD” I” wlrlng harries! lean (defectwe
f head lamp (See Fig 18)
3ntactI or replac :*
When head lamp
1
switch IS ON, IS there
efectlve head lamp watch epklce

1) connect NO
T-adapter to
CN15 (female)
21 Turn stamng Table
swtch OFF
31 ium head lamp Head lamp
watch ON dommer swtch
I
HI beam NO
Lo beam Ye5
b) If high beam lights up when head lamp switch is OFF.

(Dimmer switch at Lo position)
li YES
When head lamp

swtch IS OFF, IS
there conbnulty -I
betweenCN15 htact
INO
between +24V and
,mng harness between head
wnp watch - head lamp (Se
g 18)
T-adapter to
CNl5 (male1
21 Turn starbng
IS head lamp ON’ - switch OFF
31 Turn head lamp
watch OFF :ontact between +24V and
1) Turn starttng
3 YES ,irmg harnsss between bft an
ght head lamps - CNPl
watch ON
Is voltage between female1 I51 (See Fog 18)
2) Turn head lamp
swtch OFF CNPl (femalel (51 _
NO a;dJch;ws;,ground
II Connect NO
T-adapter to
CNPl (female)
2) Turn starbng
swtch ON
3) Turn head lamp
swtch OFF
LO8zzO17
82-91
TROUBLESHOOTING M-9
c) If high beam display lights up when head lamp dimmer switch is at Lo beam position.
Cause Remedy
2 YES Defective head lamp dimmer

watch
Is voltage between
YE CNPl (female) (5) _
and chassis ground
20 - 3OV’
Defectlve monitor panel
1) Connect NO
r-adapter to
CNPl (female)
Is head lamp ON7 21 Turn starting switch ON
31 Turn head lamp swtch ON
4) Turn head lamp dimmer switch to LO
lefectwe contact. or
1) Turn start,ng 3 YES jnsconnectlon I” wwng harness :lean (defectwe
switch ON oetween CN15 I1 2) and chassl s ontactl or replace
When head lamp
21 Turn head lamp around (See Fig. 181
dimmer switch IS at
switch ON
3) Turn headlamp F
: LO. IS there cont,nu,ty -
between CN15
dimmer watch to
(female) (9) and (217
LO Defective head lamp dimmer
11 Connect NO switch
T-adapter to
CNl 5 (femalei
21 Turn starting
swttch OFF
3! Turn head lamp
dimmer switch to
LO
Tester T-adapter (for DLli

iP
u+_
0 og
;= VI T-adapter lfor Econoseali
LO8ZZO18
CN 15 CN201 CN28
Head lamp watch L.H. head lamp Lo
Head lamp dimmer

swtch
R.H. head lamp LO
CN29 CN27
Monitor panel )&--
CNP I 421FO1156
82-92
TROUBLESHOOTING M-10
TROUBLESHOOTING CHART No. M-l 0

Failure mode: M-10 TURN SIGNAL LAMP DOES NOT FLASH.
TURN SIGNAL LAMP STAYS ON OR DOES NOT STOP FLASHING.
a) If turn signal lamp does not flash.

Cause Remedy
afectlve turn sgnal swatch splace

2
HConnect CN 15
(male) (51 and (31. (51
and (61 Does turn
sqial fbsh
YI
efective monttor Panel Isplace
11 connect
T-adapter to
2)
31
i-adapterto
CNt 5 (male)
Connect CN15
;;;“-“1;6:’ - (3).
Turn starts””
swtchON e
NC
I
1)
2)
3)
IS turn sgnatbang
,nput to CNPl
lfemaleb (61. 17)’
Connect
T-adapter to
CNPl Ifemale)
Turn startang
swrtch ON
Turn turn signal
I
Ni0
afsctive contact. or
sawectwn in wiring harms
,tween CN15 (5) - turn sign,
wtch - CN15 (6). 131 - CNP
I, 17) ISee Fig 19)
lean ldetectlve
ontact) or I-ePbC’
CN 15 Imale) watch ON
2) Turn starang
swatch ON 4 YES
mefectiveturn signal unat teplace
31 Measure voltage
between CNl5
(male1 (51 and Is voltage between
chassis ground , CN55 (31 and (1) 20 -
- 3OV? ‘efectlve contact. or
1sco”nBctlo” I” W”“g harnes :lean (detectwe
.&.,cB” + 24V - turn qnal ontactl or replac
1) connect NO
“,t. (See Fig 19)
T-adapter to
CN55 lfamalel
21 Turn stsrtlng
swtch ON
b) If turn signal lamp stays ON or does not stop flashing.

:ontact between +24V and
2 YES “l”“g harness between turn :leen (defectwe
.g”al swtch - CNPl lfemak :0ntd
IS voltage between
61. I71 (See Fag 19)
YES CNPl tfemaU 161.
- (71 and chasss
1 ground normally 20
- - 3ow
Remove CN 15 1) connect NO
(female) Does turn - T+,&p,er
to
SIgnal go out’ CNPl Ifemalel
21 Turn starbng
watch ON
11 RemoveCN15. x3fectNa monitor panel
2) Turn starting NO
swttch ON
Tester T-adapter
LO822019
82-93

+24V
421FO1157

BUZZER DOES NOT SOUND FOR 1 SEC. CAUTION ITEM IS FLASHING BUT
BUZZER DOES NOT SOUND.
Cause Remedy
* The buzzer does not sound for charge level and fuel
level of CAUTION items.
YES
Defect,ve monitor panel ReDlace
I
Connect CNP4
(female) (8) and Defective contact. or
chasse ground Does 2 YES d,sconnect,on I” wnng harness Clean (defectwe
alram buzzer sound? between CN147 - CNP4 contact) or repiacr
- Connect CN130 and (female) (8) (See Fig 201
1) connect
- chasse ground Does -
T-adapter to NO alarm buzzer sound,
CNP4 lfemalei
2) Connect CNP4 Defectw alarm buzzer
(81 to chassis 1) ConnectCN130 NO
ground to chive.6
31 Turn starting
ground
watch ON 2) Turn start,ng
watch ON
T-adapter
Wmgharness wth
crocodale clip
82-94
LO8ZZO21

Failure mode: M-12 NO ABNORMALITY IS SHOWN ON MONITOR DISPLAY, BUT ALARM BUZZER SOUNDS.
+ The alarm buzzer sounds when the parking brake is applied and the transmission is in any position except
NEUTRAL.
Cause Remedy
YES
Defectwe alarm buzzer
After ,nspect,on,
repar cl1 replace
1) RemoveCNP4 1
(female). Defective monitor panel RC?hW
NO
2) Turn starting
switch ON
LO8ZZO20
M-l 1, M-l 2 Related electrical circuit drawing (Fig. 20).
buzzer
Monator mnel
CN 130
421FO1158
82-95

WARNING LAMP DOES NOT LIGHT UP FOR 2 SEC. CAUTION ITEM IS FLASHING
BUT WARNING LAMP DOES NOT FLASH.
Cause Remedy
YES
Defective mO”lrOr panel Repl%X
1
Connect CNP4
ifemalel (7) and
chassis ground Does -
2 YES
warnmg lamp light Defective warmng lamp Replace
UP’
- IS voltage between
1) connect
- CNl 7 (female) Ill -
T-adapter to NO and (2) 20 - 3OV,
CNP4 (female1 Defectwe contact. or
2) Connect CNP4 dwonnectlon in winng harness Zlean (defective
(71 to chassis 11 Connect NO of warning lamp. (See Fig. 211 ,:ontact)or replace
ground T-adapter to
3) Turn startnng CNl 7 (female)
switch ON 21 Turn startnng
switch ON

Failure mode: M-14 NO ABNORMALITY IS SHOWN ON MONITOR DISPLAY, BUT WARNING LAMP LIGHTS
UP.
Contact between chassis
2 YES ground and wmng harness After Inspectnon.
between lamp relay - CNP4 repaIr or replace
Is there contmuty (female) 171 ISee Fag 2 1)
YES between CNP4 _
(female) (71 and contact between +24V and
chassis ground’ w,r,ng harness between Iamp
After Inspecton.
- r&y - warnmg lamp. or
Remove CNP4 repar or replace
1 connect NO defectwe lamp relay
(femalei Does
warning lamp go out’
T-adapter to (See F!g 2 1)
CNP4 (female)
21 Turn start!ng
swtch ON
I Defectwe monitor panel RepbCe
NO
M-13, M-14 Related electrical circuit drawing (Fig. 21).

LO822022
caution lamp relay

I
Warning lamp
82-96 d7 LO822023

Failure mode: M-15 WHEN STARTING SWITCH IS TURNED TO ON POSITION, LAMPS DO NOT LIGHT
UP FOR 4 SEC. WHEN LAMP SWITCH IS ON, LAMPS DO NOT LIGHT UP.
a) None of panel lights up.

Cause Remedy
YES
kfectlve “wnltor panal PeDbce
3
YE
Turn wtiing bmp )efectNe ccntact. cn
1
YES :ban uefecllve
swatch. bad lamp kccmnsctw” n-lw*“g herne*s
:ontact) or reprace
swatch ON - OFF h d right laghth-q ISee Fg 91
conhnuity between
1
I
11 ccNmect L CNl 2 Imabl(1I and
T-adapter to NO
1 CNPl lfemabl
(21. and between
CN15 ItsmaW 141 Iefectlva wu-km”g lamp swtfch
2) Turn ttarhng
;$I$, as shwon ,”
When stmtmg switch
switch ON NO x head lamp swvltch
31 Turn working -r
IS ON. do Imps Ight I
Connect
lamp swech or
head bmp swoch T-adapter to
ON CN12 Imsb) or
1) Turn starting CN15 Mernabl
switch ON 21 Turn stsnmg swatch OFF
1 YFS
Connsct CNPl
(femabl I1 61 to
N +24V Do bmpr - )efeIxlve ccmtact. OI
liiht up) ~lsco”nectlc.” anwnng hsrness
)otww” CNPl (farnab) I1 6) - :ban ldefectlve
Bach lamp - cMss~s grwnd :ontactl OTmpbce
II connect NO
TatA
T-sdaptar to ISee Fg 9)
CNPl Ifemabl
2) Connect CNPl
Ifemabl (161 to
+ 24V
31 Turn startong
swttch ON
b) Some of panel lamps do not light up.
1 YES
D~sconnectlon a” bmp
Is them any broke” _

bmp?
Dekctlve ccmtact. M Clean Idefecteve
dlscon”ectDn m wuuq h~nesl :ontact) M rnPbC#
1 I Remove
Iamp NO of each lamp ISee Fg 9)
and check
VISU.IIV
LO82ZO24
82-97

Failure mode: M-16 LAMP SWITCH IS NOT BEING OPERATED, BUT NIGHT LIGHTING LIGHTS UP.
NIGHT LIGHTING STAYS ON.
Cause Remedy
C :ontact between +24V and

,fter ,nspectwn.
. ” vwmg harness of nght loghtq
?paU or replace
I SeeFeg 91
YI
1 Cjefectwe worknng lamp swtch

medace
0)r head lamp swatch
Do both panel and
1) Connect
servnce meter lught
T-adapter to
UP’ CNl2 (male1 01
CN15 ffemalel
II Turn starttng 2) Turn stannng
swtch ON swtch OFF c:ontact between +24’.‘and
21 Turn worktng ” v,nng harness between CNPl
lamp swtch and IO I female) (161 and lamp
head lamp swtch I SeeFq 91
OFF
Table
LO822025
82-98

Failure mode: M-17 SERVICE METER DOES NOT WORK.
Defectwe engme 011pressure
harness termml of
engnne 011pressure YES
Defectwe swwce meter
sensor Does selwce
1IRemove wmng
harness termn-al
of engine 011
pressure sensor
21 Turn stanmg
c 1
:,_;;;_ff!iiJ D,sconnectlon in wnmg harness
between CNP6 Ifemakl (4) and
swltc h ON Do engme oil pressure relay. or
I, Connect
not start eng,ne contact Lx?tween ChaSSlS grounl
T-a&mtar tn After inspection.
and wrq harness between
NO npa,r or replace
2) Turn starmg engme 011pmssure relay -
switch ON. Start engone MI pressurn sensor. or
engme defectwe engine 011pressure
relay. (See Fug 10)

Failure mode: M-18 SERVICE METER MOVES WHEN ENGINE IS STOPPED.
ontact between chassis gro”” d

and wr,nQ harness between
CNP6 Ifemale) (41 - engone 011
YES pressure relay. or dlsconnecto”
41ter Inspectlo”.
I” w,r,n~ harness between
2 . engtne &I pess”re relay -
apaw or replace
I
engme 011 pressure sensor. or
Is voltage between jefectwe engme 011pressure
YES
- CNP6 Ifemalel (11 - relay ISee Fog 10)
1 and I41 20 - 30V’
connect wmng
harness ,ermlMl of 1) connect
engne 011pressure _ T-adapter to NO
sensor and ChaSSIS CNP6 (female1
ground Does service 21 Turn stamng
meter move) sw,tch ON
Defectwe eng,ne 011pressure 3eplace

NO S*“sOr
LO8ZZO26
Tester T-adapter
Wntng harness wth

crocodile ckp 82-99

Failure mode: M-19 ABNORMALITY IN AIR PRESSURE GAUGE.
a) If nothing is displayed in display area.

Cause Remedy
YES
Defectwe wr pressure sensor R*plaCT
II
Defectwe monitor panel Replace
,
11 Connect short
connector to IS there cont~nu~n,
CN92 Lw
pressure sensor1
2) Turn startong
Defective contact. 01
swatch ON
11 Connect dnconnechon in winng harries:
T-adapter to between aK pressure *enso, -
:bsn (defectwe
CNP4 (female1 4 CN92 11) - CN63 (11 - CNPd
:ontaci! M repbc,
2) Connect shwt (fornab) (1). or between 8~
connector to pressure sensor - CN92 (2) -
CN92 (female) CN52 (101. (See Fi9 14)
31 Turn starton9
swtch OFF
b) If indicator remains at maximum level.
YES
Defectwe aorpressure sensor S*pkC*
1
Doeswhde display
area of aar pressure - /Contactbetween chaws
9aqe 90 out’ 2 YES ground and w,r,ng harness 4tter Inspectlo”.
between ar pres*“re sensor - FpaW or replace
’ Is there cont,nu,ty ,
CNP4 (female) I1 I (See Fg 14
1 I Dtsconnect
- between CNP4
CN92 la,r
pressure sensor, NO (female1 (1) and (1 117
2) Turn startnng
IDefectwe mpn,tor panel Seolace
swtch ON 1) Connect NO
T-adapter to
CNP4 (female)
2) Remove CN92
3) Turn startmg
swtch OFF
T-adapter (for DLII Tester
Short connector
LO822027
82-100

Failure mode: M-20 ABNORMALITY IN ENGINE WATER TEMPERATURE GAUGE.
Cause Remedy
YES Ietecwe eng,ne wafer

,mpera,ure Sensor
1
ontact between chas-sa
round and wmg harrwss
YES 4tter Inspectlo”.
8twee” eng3n.zwater
‘epalr or replace
2 ,mpera,ure wns~ - CNP4
emakl 121 ISeeFq 151
I I Dlsccmnec! Isthere con,~nuw
CN, 01 ~engl~ 3 befween CNP4
bvater NO ~fema~ei 121 snd II I I 7
temperature)
21 Turn stamng
sw*,ch ON 11 Connect
Ietectwe mO”l,Or paw
T-adapter ,o NO
CNP4 liemalel
21 D~sconnec,
CNlOl
31 Turn starbng
sw,,ch OFF
b) If indicator remains at minimum level.

YES Ietec,I”e engine water
3eplXe
!mc.xa,“re sensor
1
,
Does whde cltsplav
area of erglne water _ YES
temperature gauge
go out’ 2 ’
L
1 I Connec1 Short Isthere cca,,nu,,y
cO”nK,cJr 10 - between CNP4
CNl01 lfemalel NO (ma~ei 121 and (1 I 1)
21 Turn stamng fJetect1ve
contac,. or
sw,ch ON dlsconnewon ,n w,r,nq
11 Connect
harness between CNl61 (A)
T-adapter 10 NO - CNP4 (female) (4) or
CNP4 (female1
between CNlOl (8) and
2) Connect short
cclnnecror 10 chassis ground.
CNIO 1 Ifemalel :See Fig. 15)
31 Turn startnng
switch OFF
LO8ZZO89
82-101
TROUBLESHOOT ING CHART No. M-21

Failure mode: M-21 AB UORMALITY IN TORQUE CONVERTER OIL TEMPERATURE GAUGE.
Cause Remedy
YES >efectwe torque convetteroil

I temperature sensor
Lmtact between chassn

ground snd winng harness
YES between torque converter 011
+fyiijgl
temperature sensor - CNP4
Ifamak) 13). (See Fg. 16)
1I Disconnect
CN64 (torque
convwter 011
temperature)
2) Turn stamng
watch ON Defectwe monltcn panel
NO
CNP4 Ifemak)
2) Remove CN64
3) Turn stsn~ng
swatch OFF
b) If indicator remains at minimum level.
YES Defectwe torque conveRero~l

ReplaCe
temperature sensor
1
Does whde dtsplay
area Of torque
YES
converter WI Redace
temperature gauge 2
go out7
1I Connect
short Is there continuity
COnnectOr to - betweenCNP4
CN64 (female1 No Imak) (31 and I1 1 I’
21 Turn stsrt,ng Defectwe contact. or
swdch ON dtsconrmctwn in wiriw horns!
1) Connect 1 :kan ktefeCtWe
T-adapter to NO :ontactl or replac
CNP4 (female)
ISeeFg 16)
21 Connect short
COnnectOr to
CN84 (female)
31 Turn startong
swtch OFF
T-adapter IforbLlj Tester
LO8ZZO29
82-102

Failure mode: M-22 ABNORMALITY IN FUEL GAUGE.
Cause Remedy
YES
Mectlve fuel sensor
Does fuel gauge J YES

ShW FULL’ 3etsctlvs
mcl”ltOr panel
2
1I Connect short Is there ccntnwlty
COnneCtor to _ between CNP4
CN 105 ltemalel NO (female1 141 and I1 117
bel sensor)
21 Turn starung k?fectlve contact, or
switch ON 11 connect :kan (detectwe
IsconnectIon I” wlrlng harIles!
T-adapter to NO ontact) or replac
>t fuel sensor. (See Fg 12)
CNP4 (female)
2) Connect Short
COnneCtOr to
CN105 Itemale)
3) Turn startq~
swtch OFF
b) If indicator remains at FULL.

YES
,etectwe fuel sew,or Isplace
1 I
:ontact between chassts
YES Iround and ww,ng harness 4f,er Inspectlo”.
atween fuel sensor - CNP4 epar or replace
2
ternale) (41 ISee Fq 121
1 I Dsconnect IS there cont~n~,,y

CN105 ltwl - between CNP4
5elWX) NO Imale 141 and II 11,
21 Turn start,ng
sw!tCh ON I
11 connect 1 )etectlve mclnltclr pane1 XeplaCe
T-adamer to wn
CNPd’ltemale) ‘Vu
2) Remove CNlO5
3) Turn sta”,ng
swtch OFF
LO8ZZO30
82-103
ELECTRIC AND
ELECTRONIC SYSTEM
MACHINE MONITOR .............................................................. 2

REMOVAL .................................................................... 2
INSTALLATION ................................................................. 2
83-1
DISASSEMBLY AND ASSEMBLY MACHINE MONITOR
MACHINE MONITOR
REMOVAL OF

moving.

(-)
+ After disconnecting the connectors, mark

with a tag to distinguish when installing.
t When removing the machine monitor, be

careful not to give it any sudden shock.
MACHINE MONITOR
INSTALLATION OF
* After inserting the connectors, apply the con-
nector lock securely. Assemble so that there is
no strain on the wiring.
83-2
OTHER
CAB .......................................................................... 2
REMOVAL .................................................................... 2
INSTALLATION ................................................................ 2
93-1
DISASSEMBLY AND ASSEMBLY CAB
CAB
REMOVAL

* Remove mounting bolts on rear side of cab (4

bolts).
* Disconnect wiring for cab.
* Lii off the cab evenly.
Cab: 310 kg
CAB
INSTALIATION
* Coat the seal evenly with adhesive compound.
& Seal: Adhesive compound (Cemedine

366E)
93-2
GEAR PUMP
97 SA SERIES
GENERAL ...................................................................... 2
PRINCIPLE OFOPERATION ....................................................... 3
PRESSURELOADEDTYPEGEAR PUMP ............................................. 6
FIXEDSIDEPLATETYPEGEARPUMP.. ............................................. 8
SASERIES ..................................................................... 9
STRUCTURE .................................................................. 9
TESTINGANDADJUSTING ...................................................... 13
DISASSEMBLY ................................................................ 16
ASSEMBLY .................................................................. 20
MAINTENANCESTANDARD ...................................................... 25
97-1
GEAR. PUMP GENERAL
GENERAL
The hydraulic pump is a device which receives me- The hydraulic pumps used in construction machinery
chanical energy from a prime mover such as an engine, are external gear pumps and are classified as fixed
converts the energy into fluid energy, and functions as displacement rotary pumps.
the source of energy in a hydraulic system.
External gear pumps employ involute spur gears, and
The fluid energy can be divided into the energy of can be structurally classified into the following types.
velocity, pressure, and potential. Almost all of the fluid
0 Type of side plate adjustment
energy used for hydraulic pressure is pressure energy.
Fiied side plate type
The hydraulic pump receives and transmits the energy (FAL, FAR, GAL, GAR)
through the static pressure of a fluid, and easily produc-
es a high pressure since its delivery is determined by Pressure loaded type
the transfer of volumetric displacement enclosed by the (PAL, PAR, KAL, KAR)
fixed walls. Therefore, the pump delivery is not changed
significantly with variations in the load. Pressure plate type
It follows that the pump itself is a device which makes

l Type of bearing
the oil flow, rather than a device to produce pressure.
The pump pressure is generated by the resistance (the Ball or roller bearing type
load) against the oil flow. Therefore, when there is no
resistance, no pressure is produced. Plain bearing type
Structurally, hydraulic pumps can be broadly classified

into rotary pumps and reciprocating pumps. Function- Gear pumps installed on installed on the machines are
ally, They can be classified into fiied displacement called standard pumps. They are designed as follows:
pumps and variable displacement pumps.
“PAL 160”
r PAL 160 I
P= A= L= 160=
s: For high pres- A: Flange type mount L: Counter-clockwise Theoretical pump deliv-
sure: 210 kg/cm- section rotation ery at 1,000 rpm
2, pressure load- (liters/min)
ed type
K: For high pres- B: Foot type mount R: Clockwise rotation
sure: 175 kg/cm- section
*, (210 kg/cm*
for some pumps)
pressure loaded
type
P: For medium pres-
sure: 140 kg/c-
m* (155 kg/cm*
for some pumps)
pressure loaded
type
c: For medium pres-
sure: 125 kg/-
cm*, fixed side
plate type
F: For low pressure:

30 kg/cm*, fixed
side plate type
97-2
GEAR PUMP GENERAL
l MECHANISM FOR DELIVERING OIL
The drawing at right shows the operational principle

of an external gear pump in which two gears are
rotating in mesh. Suction Discharge
The oil entering through the suction port is trapped

in the space between two gear teeth, and is deliv-
ered to the discharge port as the gear rotates.
Except for the oil at the bottom of the gear teeth, 23OFl 37
the oil trapped between the gear teeth is prevented
from returning to the suction side with the gears in
mesh.
Since the gears are constantly delivering oil, the oil

delivered to the discharge 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 oil flows, the oil merely flows 23OF138
through the passage, producing no increase in
pressure.
If, however, the oil passage is blocked with some

thing like a hydraulic cylinder, there will be no other
place for the oil to flow, so the oil pressure will rise.
But the pressure which rises in this way will never
go higher, once the hydraulic cylinder piston starts
moving because of the oil pressure.
As described earlier, the pump produces the oil

flow, but not the oil pressure. We can therefore 23OF139
conclude that pressure is a consequence of load. In
other words, the pressure depends on a counter-
part
23OF140
97-3
GEAR PUMP PRINCIPLE OF OPERATION
placing an overload on the bearings, and resulting in a

l INTERNAL OIL LEAKAGE shortened service life of the bearing or interference of
the gear with the case.
Oil 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 at right shows how the leaked oil

flows in the pump. As such, there is always oil
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, the delivery of the pump will also de-

crease as the amount of oil leakage increases
because of expanded radial clearance resulting
23OF141
from the wear of pump parts, the lower oil viscosity
resulting from increases in the oil temperature, and
the initial use of low viscosity oil.
l FORCES ACTING ON THE GEAR
The gear, whose outer surface is subjected to oil

pressure, receives forces pointing 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 section, the pressure will
gradually lower as the position moves from the
delivery 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

side are received by the bearings. Since the gears ‘Pmsure dirtributian
are pressed toward the suction side by theses
forces, the radial clearance becomes smaller on the
suction side in the case. In some pumps (PAL, PAR, 23OF142
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 deliv-

ery pressure must be avoided, since it will produce
a large force which will act on the gears,
97-4
GEAR PUMP PRINCIPLE OF OPERATION
l “TRAPPING” PHENOMENON OF THE OIL
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. D&very si
When two sets of the teeth are in mesh simulta-

neously, the oil in the space between the meshed
gear teeth will be trapped inside - the front and rear
exits will be completely shut.
Trapping starts
This is called the “trapping” phenomenon of oil.
The space in which the oil is trapped moves from

the suction side to the delivery side as the gears The rpwa reehea
rotate. The volume of the space gradually decreas- the minimum
es from the start of trapping until the space reach-

es the center section, and then gradually increases
after leaving the center section until the end of
trapping.
Since the oil itself is non-shrinkable, a reduction of

the volume of space will greatly increase the oil
pressure, unless some provision is made to relieve
oil 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 tot he delivery side
when the volume of the space is reduced.
Relief notches are also provided on the suction side

to prevent the formation of a vacuum in the space
by allowing the oil to enter the space from the
suction side when the space is expanded.
Eushing
23OF144 23OF145
97-5
GEAR PUMP PRESSURE LOADED TYPE GEAR PUMP
PRESSURE LOADED TYPE GEAR PUMP
‘9
23OF146
GENERAL
DESCRIPTION 1. Drive gear
2. Bracket
Hydraulic pumps used for the work equipment hydraulic 3. Bushing
units on construction machinery are pressure loaded 4. Gear case
type gear pumps. Some gear pumps of this type have 5. Cover
a maximum delivery pressure of 210 6. Seal plate
kg/cm* or higher. 7. Collar
8. Bach-up ring
The pressure loaded type gear pump is designed so 9. Driven gear
that the clearance between the gear and the side plate
can be automatically adjusted according to the delivery
pressure. Therefore, the oil leakage from the side plate
is less than in the case of the fixed side plate type
under a high discharge pressure. Consequently, no
significant reduction of the pump delivery occurs, even
when the pump is operated under high pressure.
97-6
GEAR PUMP PRESSURE LOADED TYPE GEAR PUMP
STRUCTURE AND 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
on 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 has leaked out
from the clearance between 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, the area of the bushing on the dis-

charge side is made larger than that on the suction side
by partitioning the area of the bushing subjected to
pressure on the cover side, with a back-up 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 provided on the with balance gwove
\ without balance groow
bushings to keep the balance of the force on the cover Discharge
side against the pressure acting on the bushing from withoutbeiemegroove
the gear side that varies with the pump rotation and the \ (high speed)
pressure distribution. Thus the delivery pressure is led

as shown in the drawing and the pressure distribution is
stabilized at any rotational speed. -140
97-7
GEAR PUMP PRESSURELOADEDTYPEGEARPUMP
FIXED SIDE PLATE TYPE GEAR PUMP
1. Driie gear
GENERAL DESCRIPTION 2. Bracket
Hydraulic pumps used for the main clutch, transmission, 3. Gear case
and steering system on bulldozers are fixed side plate 4. Cover
type gear pumps which can be classified as follows: 5. Driven gear
pumps generally called FAL or FAR pumps having a
maximum delivery pressure of 30 kg/cm2 and pumps
generally called GAL or GAR pumps having a maximum
delivery pressure of 125 kg/cm2.
Since the bracket and the case cover serve as the side
plates and the gear teeth bottom land is closer to the
outer race of the bearing in the case of the fixed side
plate type gear pump, oil leakage is liable to occur at
the clearance between the gear and the side plate.
However, this is only a small problem, as the pump is
used for steering control which is operated at a low
service pressure.
97-8
SA SERIES STRUCTURE
SA SERIES yida plate
STRUCTURE
FEATURES
The gear pump is a high quality, reliable product that is

specially designed for use in construction equipment
which works under severe conditions.
l The side plate, given surfaces treatment to improve
its matching characteristics with the special copper
alloy, ensures minimum torque loss and excellent
wear resistance.
l Wiih the improved hydraulic balance mechanism,
the pump offers stable performance and high
durability.
2WF132
STRUCTURE
1. Drive gear
5 9 10 8
2. Driven gear
3. Snap ring
4. Oil seal
5. Plate
6. Bracket
7. O-ring
8. Side plate
9. Back-up ring
10. Seal ring
11. Gear case
12. Side plate
13. Back-up ring
14. Seal ring
15. Cover
8 16. O-ring
17. Bolt
18. Dowel pin
21FO23
97-9
SA SERIES STRUCTURE
SA-1 Series single pump
+ycL. . . H
Delivery port
LloAvol9
(The drawing above shows a pump of the counter-clock-

wise rotation type. In a clockwise rotation pump, the
positions of the suction and delivery ports are reversed.)
l Side’ port type

97-10
SA SERIES STRUCTURE
l Rear port type


l Side port type
Ddivwy port

97-11
SA SERIES STRUCTURE
l Rear port type
110iW023

Dmlivmry port
Dmpth:
-F

NOTE: Dimensions A through H in the drawings vary with pump capacity.
97-12
SA SERIES STRUCTURE

Measure the pump delivery with a bench or flow meter kii (790-303-1001).
For SA pumps operating at a service pressure of 50 kg/cm2 or less, see the standard and the repair limit in Table
No. 2. (Examples: Pumps for power trains and servo-hydraulic pumps for excavators)
* See Notes on pa!le followir table 1 &. .. The capacity codes marked + are for triple pumps.
No Check item Series

No
Delivery
pressure
T Standard Repair limit
Rotation Delivery Rotation Delivery

(kglcm2) (rpm) (liters/min) (rpm) (ktme;!
1 Performance 008 25 23
Hydraulic 010 29
oil: 012 x; 34
EOlO- 1 014 210 3500 47 43
CD 016 52 48
020 66 61
Oil temper- 025 83 76
ture:
50” c &I16 40
420 zz 50
+025 67 62
028 77 71
032 210 3000 88 82
036 100 92
040 111 103
045 121 111
050 138 128
420 45 42
+025 55 51
M40 90 82
450 112 102
056 210 2500 129 2500 119
063 145 134
071 158 146
080 184 170
100 231 214
112 140 2000 212 2000 192

125 236 213
112 233 215

125 2200 253 2200 234
140 287 266
160 210 328 303
____________
_______________ I____________
180 336 310
200 2000 373 2000 345
224 411 385
250 460 425
97-13
SA SERIES STRUCTURE
Repair limit
No Check item Series Delivery
No pressure Rotation Delivery Rotation Delivery
(kg/cm? (rpm) (liters/min) (rpm)
U:?
2 Performance 008 27
010 33 ::
Hydraulic 012 40 37
oil: 014 30 3500 48 3500 44
EOlO- 016 54 50
CD 020 68 63
025 86 79
Oil Tempera
-ture: MO8 23 21
50°C MI16 47 43
420 59 53
425 72 66
028 30 3000 80 3000 74
032 92
036 104 z
040 115 106
045 126 115
050 144 132
420 49 44
MI25 60 55
+040 96 88
+050 119 109
056 30 2500 134 2500 123
063 151 138
071 164 150
080 192 176
100 241 221
112 30 2000 217 2000 198

125 240 220
112 242 222

125 2200 264 242
140 300 2200 275
160 342 314
4 30
180 350 321
200 389 2000 257
224 434 398
250 480 440
For SA pumps operating at a service pressure of 50 kg/cm2 or less, see the standard and the repair limit in table,
No. 2. (Examples: Pumps for power trains and servo-hydraulic pumps for excavators).
97-14
SA SERIES STRUCTURE
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 follow-
ing formula:
Q = Qo-(No-N)Qth
1000
N2 1000 rpm
where, . RPM of test bench
;: Repair limit for delivery at N rpm
(liters/min)
No: RPM in the table
Qo: Repair limit for delivery in the table
(liters/min)
Qth: Capacity code
Note 2.) If the test bench allows the pump to raise

its delivery pressure above 140 kg/cm2 but
not above 210 kg/cmz, use the repair limit
for delivery given in Table, No 1
Note 3.) For pumps whose service pressure ex-

ceeds 50 kg/cm* in operation, use Table,
No 1. (do not use Table, No 2)
Note 4.) The volumetric efficiency of a pump de-

creases after the pump is reassembled.
After reassembly, therefore, perform the
following tests with a test bench or flow-
meter kii (790-303-1001).
(1) Shock test

20 times
iii LlOAVO25
(2) Performance test (measure the delivery)
97-15
SA SERIES DISASSEMBLY
1. Single pump
t Cautions before disassembly
To avoid confusion in the reassembly, stamp
match marks on connecting sections of bracket
(6) to gear case (11) and gear case (11) to
cover (15).
6
UOAV031
1) Put the pump assembly on a work bench with

the bracket side facing down, and loosen
mounting bolts (17) for cover (15).
t Use the bracket mounting bolt holes to secure

the pump assembly.
LlOAVO32
2) Remove cover assembly (15).

+ Place the internal parts in line in the order of
removal, taking care not to damage the con-
tacting 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.
LlOAVO33
3) Remove O-ring (16) from the cover.
LlOAVO34
97-16
4) Pull out side plate (12) on the cover side.
LlOAVO36
5) Remove backup ring (13) and seal ring (14).
23OF221
6) Remove drive gear (1) and driven gear (2).

t Pull out the gears by hand. Do not use a ham-
mer.
it If the oil seal is not replaced, tape the drive
gear and the spline section to protect the oil
seal from damage.
7) Remove bracket (6) from gear case (11).

+ When removing bracket (6) from gear case
(ll), 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 hii the side plate surface.
LlOAVO38
97-17
8) Pull outside side plate (8) from gear case (11).
UOAVO39
9) Remove backup ring (13) and seal ring (14).
10) Remove O-ring (7) from bracket.
LlOAVO41
97-18
2. Tandem pump
1) Stamp match marks.
2) 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.
Yatch
3) Disconnect the front pump from the rear pump.
4) For the disassembly of single pumps, see the

section on single pumps.
3. Triple pump
Follow the same procedure for tandem pumps. LlOAVO55
LlOAVO56
97-19
SA SERIES ASSEMBLY
1. Single pump
t When a used gear case is assembled, remove
the burrs from the case and make sure that the
side plate can be sided smoothly.
+ Make sure that the dowel pin on the case has
specified length (P).
LlOAVO42
P + Lenoth of dowel Din
2
1) Put cover (15) on a work bench.
2) Install side plate (12) into gear case (11) 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.
t Do not damage the periphery of the side plate,
especially around the seal section. Discharge port
LlOAVO44
Measurement of side clearance

Temporarily assemble bracket (6) and gear case (11)
as shown in the drawing at right. Place the assembly on
a work bench and measure the difference between the
stack height including drive gear (1), side plates (8) and
(12) and the height of gear case (11).
Measure with a depth dial gauge or depth micrometer.
Judgement criteria
Confirm that the measurements conform to the standard
clearance given in the Maintenance Standard Table.
230F222
97-20
SA SERIES ASSEMBLY
3) Install gear case (11) to cover (15) with the

match marks aligned.
LlOAVO45
4) Install drive gear (1) and driven gear (2).
LlOAVO46
5) Install side plate (8) with the backup and seal

ring grooves facing upward.
LlOAVO47
6) Install backup ring (9) and seal ring (10).

l Install them with care to prevent gaps between 10 DiFcharge port
the ring and the gear case.
* If it is impossible to eliminate the gap, replace
the seal ring and the backup ring.
Gap
23OF223
97-21
SA SERIES ASSEMBLY
7) Apply some hydraulic oil to the shafts of gears

(1 and 2) and also to the sliding section of the
side plate.
t Take care to keep gear case free from oil.
LiOAVO48
8) Install O-ring (7) to bracket (6).
L10AV049
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 fii 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.
t 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.
LlOAVO51
97-22
SA SERIES ASSEMBLY
11)Remove the cover (15)and install O-ring (16).

12)Install backup ring and seal ring to side plate
(12) in the manner described in item 6.
13) Install cover (15).
* Align the match marks when installing the
cover.
* Before installing the cover, make sure backup
ring and seal ring are properly installed ac-
cording to the precautions given in item 6.
* Make sure O-ring (16) is fii properly.
LlOAVO36
14) Tighten mounting bolts (17).

* Use a torque wrench and tighten the bolts to
the specified torque in the order shown in the
drawing.
For the tightening torque, see the Mainte-
nance Standard Table, this section.
sa1
4
3
2
Tightening order
LlOAVO26
Series
LlOAVO32
Rotational torque
1 0.2 - 0.5 kgm

15) After assembly, check the rotational torque of
the pump shaft to see if it conforms to the value 2 0.3 - 0.7 kam
given in the table.
* After the pump is assembled, carry out the 3 0.7 - 1.2 kgm
performance test (measure the pump delivery)
with a test bench or flow meter kii (790-303- 4 1.0 - 1.5 kgm
1001). Confirm that the performance is with the
repair limits.
2. Tandem Dump
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.
97-23
SA SERIES ASSEMBLY
3) Install the coupling to the front pump.
4) Fit the O-ring to the rear pump bracket.

5) Put the rear pump on top of the front pump.
t Take care not to let the O-ring come off.
t Align the match marks.
lightening order
L10AV052
UOAVO27
6) Tighten four mounting bolts.

+ Tighten the bolts with a torque wrench to the
specified torque in the order shown in the
drawing below.
Match m
LlOAVO57
t After the pump is assembled, carry out the

performance test (measure the pump delivery)
with a test bench or flow-meter kit (790-303-
1001). Confirm that the performance is within
the repair limits.
3. Triple pump
Follow the same assembly procedure as for the
tandem pump.
MOAV056
97-24
SA SERIES MAINTENANCE STANDARD
MAINTENANCESTANDARD
LlOAVO28
Unit: mm
Criteria
No Check item Series Remedy
No Standard clearance Clearance
limit
1
0.10 - 0.15 0.19
2
SAL & SAR

0.10 - 0.15 0.19
Clearance between o;o - 060
the gear case and 3
SAL & SAR
the gear plus the Replace the side
0.13 - 0.18 0.20
side plate plate or the
Too-125
pump assembly
SAL & SAR
0.11 - 0.16 0.19
712 - 160
SAL & SAR

0.14 - 0.19 0.22
2=00- 250
SAL & SAR

0.06 - 0.144
o=os-014
Clearance between
the I.D. of the plain SAL & SAR
bearing and the 0.06 - 0.119
O.D. of the gear o;s-025
shaft Replace
4 0.06 - 0.140 I
97-25
SA SERIES MAINTENANCE STANDARD
Criteria
No Check item Series Remedy
No Standard clearance Clearance
limit
1 10 - 12.5 kgm
3 Tightening torque 2 10 - 12.5 kgm

for the case mount-
ing bolts 3 23.5 - 27 kgm
4 15 - 18 kgm
97-26
OTHER
99 METRIC CONVERSIONS
99-1
METRIC CONVERSIONS
UNIT MULTIPLY BY TO GET MULTIPLY BY TO GET
AREA
I 645.16 square millimeter (mm2) 0.001550003 square inch

I
square inch (in2) 6.4516 square centimeter (cm2) 0.1550003 square inch
0.00064516 square meter (m2) 1550.003 square inch
square foot (ft2) 0.09290304 square meter (m2) 10.76391 square foot
square yard (yd2) 0.8361274 square meter (m2) 1.195990 square yard
25.29285 square meter (m2) 0.03953686 square rod

square rod (rod2)
0.002529285 square hectometer (hm2) 395.3686 square rod
4046.856 square meter (m2) 0.0002471054 acre

acre
0.4046856 square hectometer (hm2) 2.471054 acre
2589988.0 square meter (m2) 0.OOOwO3%1022 square mile

square mile (mile2)
2.589988 square kilometer (km2) 0.386102175 square mile
DENSITY (Mass Density)
pound per cubic yard kilogram per cubic meter

0.5932763 1.685555 0b/yd3)
(lb/yd3) (kg/m3)
pound per cubic foot kilogram per cubic meter 0.06242797

16.01846 (lb/ft3)
(lb/ft3) (kg/m3)
pound per cubic inch gram per cubic centimeter 0.03612730 (lb/in 3 )
27.67990
(lb/in3) (g/cm3)
pound per US gallon k$l;j;,, per liter

0.1198264 8.345406 (lb/US gal)
(lb/US gal)
pound per UK gallon k&l;,;,, per liter 10.02242

0.09977633 (lb/UK gal)
(lb/UK gal)
4.448222 0.2248089 pound-force

pound, pound-force
(lbf)
0.004448222 kilonewton (kN) 224.8089 pound-force
ounce-ounce-force (07f) 0.2780139 newton (N) 3.596942 ounce force
99-2
METRIC CONVERSIONS
FORCE PER LENGTH
0.1751268 newton per millimeter (N/mm) 5.710148 pound-force per inch

;;;;’ force per inch
175.1268 newton per meter (N/m) 0.005710148 pound-force per inch
pound-force per foot) newton per meter (N/m) 0.06852178 pound-force per foot
14.5939
@f/n)
I UNIT
I
MULTIPLY BY
I
TO GET
I
MULTIPLY BY
I
TO GET
1.055056 kilojoule (kj) 0.9478170 (Btu)

British thermal unit
(Btu)
1055.056 joule (J) 0.0009478170 (Btu)
Btu per hour* @u/h) 0.2930711 watt (W) 3.412141 (Btu/h)
Btu per minute* 17.58427 watt (w) 0.06686902 (Btu/min)

(Btu/min)
Btu per gallon @u/gal) 0.2787163 kilojoule per liter (kJ/I) 3.6878777 (Btu/gaj)
*Heat flow rate. Also see POWER.
LENGTH
25.4 millimeter (mm) 0.03937008 (in)
inch (in) 2.54 centimeter (cm) 0.3937908 (in)
0.0254 meter (m) 39.37008 (in)
microinch @in) 0.0254 micrometer (rtm) 39.37008 (rtm)

I
mil 25.4 micrometer (rtm) 0.03937008 mil
I
micron @) (same as micrometer one for one)
f00t (ft)
I 0.3048 meter (m) 3.280840 (ft)
I
yard W)
I 0.9144 meter (m)
I
1.093613 (Yd)
I
1.609344 kilometer (km) 0.6213712 mile
mile
1609.344 meter (m) 0.0006213712 mile
rod 5.0292 meter (m) 0.1988388 rod
99-3
METRIC CONVERSIONS
MASS (WEIGHT)
ounce
short ton (2ooo lb)
long ton
POWER
0.7456999 kilowatt (kW) 1.341022 (hp)

horsepower (hp)
745.6999 watt (W) 0.001341022 (hp)
Btu per hour* (Btu/h) 0.2930711 watt (W) 3.412141 (Btu/h)
Btu per minute* 17.53427 watt (W) 0.05666902 (Btu/min)

(Btu/min)
*Also heat flow rate. Bee HEAT.
PRESSURE
6.694757 kilopascal (kPa) 0.1450377 (psi)

pound force per square
inch (psi)
o.!x6694757 megapascal (Mpa) 145.9377 @si)
inch of mercury (in Hg) 3.37636 kilopascal (kPa) 0.296134 (in Hg)
inch of water (in H20) 0.24664 kilopascal (kPa) 4.0166 (in H20)
bar 100.0 kilopascal (kPa) 0.01 bar
99-4
METRIC CONVERSIONS
TEMPERATURE
degree Fahrenheit (“F) (“F-32) + 1.8 degree Celsius (“C) (1.8x%) + 32 (‘F)
TEMPERATURE INTERVAL OR TOLERANCE
degree Fahrenheit (OF) divide by 1.8 degree Celsius (“C) 1.8 (“F)
US fluid ounce
UK fluid ounce
METRIC CONVERSIONS
TORQUE
pound-force foot 1.355818 newton meter (Nom) 0.7375621

(Ibf ft) (ft lb) (ft lb)
pound-force inch newton meter (Nom) a.650746 (in lb)

0.1129846
(Ibf in) (in lb)
ounce force inch (ozf in) 0.007061552 newton meter (Nom) 141.6119 (ozf in)
I UNIT
I
MULTIPLY BY
I
TO GET
I
MULTIPLY BY
I
TO GET
mile per hour (mph) 1.609344 kilometer per hour (km/h) 0.6213712 (mph)
0.3046 meter per minute (m/min) 3.260840 (ft/min)

foot per minute (ft/min)
0.0606 meter per second (m/s) 196.6504 (ft/min)
foot per second (ft/s) 0.3046 meter per second (m/s) 3.260640 @Is)
25.4 millimeter per second 0.03937006 (in/s)

(mm/s)
inch per second (in/s)
0.0254 meter per second (m/s) 39.37006 (in/s)
99-6
FOLDOUTS
FOLDOUTS #‘S:
1. Transmission
2. Hydraulic Circuit Diagram - Steering
3. Hydraulic Circuit Diagram - WITH Ground Driven Steering
4. Air Piping
5. Electrical Wiring Diagram, pg. 1
8. Air Circuit Diagram
9. Electrical Wiring Diagram (3D) Circuit
10. Electrical Wiring Diagram Connectors (CN)
11. Hydraulic Piping

FOLDOUT # 1
TRANSMISSION
9. No. 1 sun gear (Teeth 25)

10. No. 1 planet gear (Teeth 23)
II. No. 1 ring gear (Teeth 76)
12. No. 1 clutch
13. No. 1 idler ring gear (Teeth 7 1)
16. No. 2 ring gear (Teeth 75)
17. No. 2 clutch
18. No. 3 clutch
2 I. No. 3 sun gear (Teeth 17)
22. No. 5 clutch
25. No. 6 clutch
26. No. 6 gear (Teeth 75)
28. Output shaft
29. No. 5 carrier
30. No. 4 clutch
34. No. 2,3,4 carrier
35. No. 1 carrier
L07CR029
Section A-A
FOLDOUT #2
HYDRAULIC CIRCUIT DIAGRAM FOR NORMAL STEERING
STEERING
CYLINDER
I- r
r
I 1STOP VALVE
r
1
-- MAIN CONTROL VALVE 1
--- --- c c
I I I
16! I
I I
I
BOOM CYLINDER
1
BOOM
BUCKET CYLINDER
ATT. CYLINDER
t I
L10zz015
VALVE FOLDOUT #3
HYDRAULIC CIRCUIT DIAGRAM WITH GROUND DRIVEN STEERING
I I
I I
TRANSMISSION 57T I
I
STEERING
CYLINDER
? CAUTION
#
i_. i LIGHT
(OPT)
ORBI -
VALV
-- -- MAIN CONTROL
-_ VALVE
165 1 1 I, l-y+-
HYDRAULIC
PUMP
BOOM CYLINDER
I,
-
I --
HYDRAULIC
t
--- =I TANK
ATT. 1 ATT. CYLINDER
I
L1022016
FOLDOUT # 4
AIR PIPING
‘11
1. Front brake
2. Slack adjuster
3. Spring cylinder
4. R.H. brake valve
5. Rear brake
6. Front brake chamber
7. Rear brake chamber
a. Air compressor
9. Air governor
10. Slack adjuster
11. Air tank (dry)
12. Safety valve
13. Air pressure sensor
14. Air tank (wet)
16. L.H. brake valve
17. Transmission cut-off switch
ia. Horn
19. Solenoid valve
21. Air dryer (optional)
20 LO3zzOO4
FOLDOUT # 8
AIR CIRCUIT DIAGRAM
1. Air compressor
2. Air governor
3. Check valve
4. Air tank (wet)
26 5. Air pressure sensor
7. Safety valve
8. Drain valve
9: Air tank (dry)
IO. Tire inflation
11. Solenoid valve
13. Spring chamber
14. Horn
15. L.H. brake valve
17. R.H. brake valve
p’
18. Double check valve
23 I 9. Stop lamp switch
20. Front brake chamber
21. Rear brake chamber
22. Overstroke sensor
23. Stack adjuster
24. Rear brake
26. Front brake
26. Hydraulic tank
27. Air dryer
L0322005
FOLDOUT # 9
ELECTRICAL WIRING DIAGRAM CIRCUIT
1. Air compressor relay

2. Front wiper switch
3. Rear wiper switch
4. Car radio
5. Caution lame
7. Glow switch
8. Working lamp switch
9. Parkmg brake switch
10. Main switch
11. Cigarette lighter
12. Caution buzzer
13. Fuses
14. Electronic monitor panel
15. Work equipment magnet switch
16. Head lamp
17. Front combination lamp
18. Front wiper
19. Brake line failure sensor
20. Brake line failure sensor
21. Brake oil level sensor
22. Washer tank motor
23. Front window washer
24. Rear window washer
25. Rear wiper
26. Engine oil pressure sensor
27. Fuel cut solenoid valve
28. Engine oil level sensor
29. Fuel level sensor
30. Coolant level sensor
31. Rear combination lamp
32. Air compressor
33. License plate lamp
View X 34. Air governor
35. Battery
36. Alternator
37. Coolant temperature sensor
38. Battery relay
39. Main breaker
40. Safety switch relay
41. Starter motor
42. Torque converter oil temperature sensor
44. Brake chamber
45. Rotate speed sensor
46. Brake pedal assembly
47. Parking brake valve
LO8DDO41
CN233
CN53 \
FOLDOUT # 10
ELECTRICAL CONNECTORS (CN) WIRING DIAGRAM
CNl
CN107
CN CN105
CN85 CN96 I \ -\
\, CN116
CN CN96A
,_\\ I
View 2
CNPP CN250 CNPl CNP4 CNP5
/ /
CNP6 CN249
View X
II ’
CN35
LO8DDO42
FOLDOUT #ll
HYDRAULIC PIPING
1. Dump cylinder
2. Steering valve
3. Hydraulic tank
4. Hydraulic pump
6. Lift cylinder
LlOZZO24
Komatsu America international Company
440 North Fairwav Drive I 1
Vernon Hills, IL 66061-8112 U.S.A.
Attn: Technical Publications PROPOSAL FOR MANUAL REVlslON
Fax No. (847) 970-4186
FOR INTERNAL USE ONLY -- No. PMR
2 NAME OF COMPANY: LOCATION:
: PHONE NO:
:
S DEPARTMENT: DATE:
E
R NAME:
MANUAL NAME:
MANUAL NO:
MACHINE MODEL:
S/N IF APPLICABLE:
PAGE NO:
PROBLEM:
Attach photo or sketch.

If more space is needed, use another sheet.
1 FOR INTERNAL USE ONLY

CORRECTIVE ACTION:
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CEBMW24020

MACHINE MODEL SERIAL NUMBERS

WA420-1 LC A25001 and up

PHONE NO. FAX NO. SHIPPING METHOD DISTR/BRANCH CODE

PARTS BooK PUBLICATION

KDC91 D 081696 CURRENT PRICES WILL BE CHARGED

12 TESTING AND ADJUSTING .................................................. 12-1

21 STRUCTURE AND FUNCTION ................................................ 21-1

41 STRUCTURE AND FUNCTION ................................................ 41-1

50 BRAKE AND AIR SYSTEM

51 STRUCTURE AND FUNCTION ................................................ 51-l

60 WORK EQUIPMENT SYSTEM

61 STRUCTURE AND FUNCTION ................................................ 61-1

80 ELECTRIC AND ELECTRONIC SYSTEM

81 STRUCTURE AND FUNCTION ................................................ 81-1

93 DISASSEMBLY AND ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93-l

A WARNING! IMPORTANT SAFETY NOTICE

PREPARATIONS FOR WORK

STRUCTURE AND FUNCTION

TESTING AND ADJUSTING

DISASSEMBLY AND ASSEMBLY

HOW TO READ THE SERVICE MANUAL

These volumes are designed to avoid duplication

Consecutive page number Weight of parts or systems.

When a manual is revised, an edition mark is

Hooks have maximum strength at the middle

103% 88% 79% 71% 41%

1. If a part cannot be smoothly removed from the

The allowable load value is estimated to be

Slinging near the edge of the hook may

STANDARD TIGHTENING TORQUE

1. STANDARD TIGHTENING TORQUE OF BOLTS AND NUTS

Thread diameter Width

t Nm (newton meter): 1Nm & 0.1 kgm

2. TIGHTENING TORQUE OF SPLIT FLANGE BOLTS

Use these torques for split flange bolts.

Thread diameter Width Tightening torque

3. TIGHTENING TORQUE FOR NUTS OF FLARED FllTlNGS

Use these torques for nut part of flared.

Thread diameter Width across flats Tightening torque

Nomenclature Code Applications

LT3 Provides an airtight, electrically insulating seal.

LG-1 Used with gaskets and packings to increase sealing effect.

LG-3 Heat-resistant gasket for precombustion chambers and exhaust

*LT-2 is also called LOCTITE in the shop manuals.

ELECTRIC WIRE CODE

CLASSIFICATION BY COLOR AND CODE

Prioritv Classification Circuits Starting Charging Lighting Signal Instrument Other

Engine assembly 655

LUBRICANTS, FUEL AND COOLANT

AMBIENT TEMPERATURE CAPACITY

Drive axles - Axle oil See NOTE 3 55 e 55 e

All lubrication Grease See NOTE 4 Fill as in- --

Fuel tank Diesel fuel See NOTE 5 305 e --

Cooling system Coolant See NOTE 6 50 e -_

API: American Petroleum Institute

Normal Operation A sulfated ash limit of 1.O mass percent is suggest-