‘SEBMo06204 KOMATSU Loaber WA420:3 MACHINE MODEL SERIAL NUMBER wWaAdz0-3 50001 and up01 10 20 30 40 00-2 CONTENTS GENERAL .. Ont STRUCTURE AND FUNCTION TESTING AND ADJUSTING 04 DISASSEMBLY AND ASSEMBLY ... 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The ‘service and repair techniques recommended by Komatsu and described in this manual ‘te both effective an safe. Some ofthese techniques requir the uso of tools specially ‘designed by Komatsu forthe specific purpose. ‘To prevent injury to workors, the symbol ls used to mark safety precautions inthis manval. The cautions accompanying these cymbols should always be followed care fully. any dangerous situation arses or may possibly arse, rst consider safety, and take the necessary sctons to deal with the situation, (GENERAL PRECAUTIONS Mistakes in operation are extremely dangerous Read the Operation and Maintenance Manual ‘arofully BEFORE operating the machine, 4. Before carying out any greasing oF repair, read al the precautions given on the decals ‘which are fixed tothe machine. When carrying out any operation, always wear safety shoes and helmet. Do not wear Toose work lathes, or clothes wth Buttons missing Always woar efety glasses when hiting parts witha hammer. + Always wear safety glasses when grind ing parts with grinder, ete 23. welding repels are neaded, always have a trained, experonced welder carry out the ‘work. When carrying out welding work, a ways wear welding gloves, apron, hand {hislcap and othr clothes suited for wala ing work 4. When carrying out any operation with two cor more workors,ehways agre on the oper sting procedure before sterting. Always In form your fellow worker before stating sry ‘top of the operation. Before starting work hang UNDER REPAIR signs onthe controls In the operator's compartment ‘5. Keop all toot in good condition and learn the corract way to use them. 6. Decide Place in the repair workshop to keep tools and removed pars. Always keop the tools and parts in their correct paces. [Always Keep the work tea cleen and make ture that there is no dit of ail onthe flo. ‘Smoke only in the areas provided for smok Ing. Never smoke wile working, PREPARATIONS FOR WORK Betore adding ol or making any repairs, park the machine on hard, ov! ground, and block the wheels or tracks to prevent the ‘machine from moving, Before starting work, lower blade, ripper, bcket or any other work equipment to the ‘round, f this is not posse, insert the {Safety pin or use blocks to prevent the work ‘equipment trom fling. In adtion, bo sure to lock ll the control fevers and hang war ing signe on ther, When disassembling or assembling, support the machine with blocks, jecks or stands before stating work Remove all mud and oil fom the steps oF ‘other places used to get on and off the me chine. Always use the handall, ladders oF ‘ope when getting on of of the machine. Never jump on of off the machine. Ii Is Impossile to use the handrails, ladders or stops, ue a stand to provide safe footing, 00-3PRECAUTIONS DURING WORK. 11. When removing the ol llr cap, dean plug for hydraulic pressure measuring plugs, Joosen them slowly to prvent the el from Betore disconnecting or removing compo: nents of the ol, water or alr cleus, fst remove the pressure completly from the 12, The water and oil in the circuits are hot wien the engine is stopped, so be careful not to get burned, Wait for the ll and water to cool before earring out any work of the oll oF water cireuits 18. Bafore starting work, remove the leads trom the battary. Always remove the lead trom ‘the negative (+ terminal fet "4. when rasing heavy components, use shoist Check that the sie ro 1 free from damage. ‘Always use lifting equipment which hat ‘ample capacty. Install the iting equipment atthe correct places. Use a hoist or crane and operate Slowly to prevent the component fram hit ting any ether par. Do not work with any ort stl ated by the hot or rane. nan and hooks 18. When removing covers wich are under in temal pressure or under pressure fom & spring, slays leave two bolts in position (on opposite sides, Slowly release the pros. sure, then siowly losen the bolts to remove, 16. When removing componerts, be careful not to break or damage the wiring. Damaged wiring may cause oloctrica fires. 17, When removing piping, stop the fuel or oll {rom sping out any Tus or ol dips onto ‘the tloor, wipe it up immediately. Fuel oo ‘on the flor can eause yeu to slp, or can ‘ven start free. 18. As @ general rule, do not use gasoline to wath pant. particular, ute nly the mini: ‘mum of gasoline when washing electrical 2. 23. SAFETY NoTICE Be sure to assemble all parts agaln in their origina paces. «+ Wren instaling hoses and wires, bo sure that thy will not be damaged by contact With other parts when tha machine is be Ing operated when insaling high pressure hoses, make ‘sure that they are not twisted. Damaged tubes are dangerous, so be extremely care- ful when installing tubes for high pressure circus. Also, check that connecting parts ate correctly installed. tse the specified tightening toques. When Instaling protective parts such as guards, for pate which vibrate violently or rotate at high speed, be particulary caefl to check ‘that they are installed correct fingers oF hand. Be careful not to get your fingers caught in a hoe. when measuring hydraulic pressure, check that the measuring tool i correctly assem bled before taking any measurements ‘Tako care when removing or instaling the tracks of tracketype machines. When removing the ack, the track sep ‘tos suddenly, 20 never lt anyone stand st citer end of the trackFOREWORD GENERAL FOREWORD GENERAL This shop manual has been prepared as an aid to improve the quality of repairs by giving the serviceman an accurate understanding ofthe product and by showing im the correct way to perform repairs and make judgements. Make sure you understand the contents of this manual and use It full offect 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 dvidad into the folowing shaptos: these Chapters are further divided into the each main group of components, ‘STRUCTURE AND FUNCTION This section explains tho structure and function of each component. It serves not only to give {an understaning ofthe structure, but also serves as reference material for teubleshooting, TESTING AND ADJUSTING ‘This section explains checks to be made before snd after performing cepts, as well as aciustmentst0 be made at completion ofthe cheeks and repairs. Troubleshooting charts correlating "Problems" to "Causes" aro also included inthis section. DISASSEMBLY AND ASSEMBLY ‘This section expiaine the order to be folowed when removing, insaling, disassembling or assembling each component, a8 well as precautions to be taken fr these operations MAINTENANCE STANDARD ‘This section gives the judgement standards when Inspecting dsassembled ports NoTICE ‘The specifications contained in this shop manual aro subject to change st any time and without any advance notice, Use the specifications given In the book withthe latest date.FOREWORD HOW TO READ THE SHOP MANUAL re issued as aguide to carrying ‘Thay are divided 8 follows: ‘Chassie volume: esued for avery machine model Engine volume: Issued for each engine ser Ca "ech faued a one ‘Attachments volume: | Yelume to cover all models ‘These various volumes are designed to avoid plieting the same informaton. Therefore, to Seal wth all repairs for any rode, iis neces- ‘ment volumes be available ~ DISTRIBUTION AND UPDATING Any adaitions, amendments or ether changes wil be sont to KOMATSU dlstrbutors. Get the ‘ott up-to-date Information before you stat any work. FLING METHOD 1. See the page number on the bottom of the ‘page. Fle the pages in corect order 2, Following examples show how to read the ‘page number. Example 1 (chassis volume! 19- tom nurmbe (10, Structure ‘and Function) |___aneeeutive page number for tach fem. Example 2 (Engine volum et Unit number (1. Engine) em numbe! (2. Testing and ‘Adjusting? |____ Consecutive page number for ‘ach tom. 2. Additional pages: Adstionl pages re ind fated by a hyphen () and number after the age number. File os in tho example. Example 104 s2.200 wo 12.208-1 30.42} Adsed paves I 22032 308 e206 00-6 HOW To READ THE SHOP MANUAL REVISED EDITION MARK When» manual is revised, en edition mark (@19..) fe recorded on the bottom of the eaes REVISIONS. Revieed pages are shown in the LIST OF FE VISED PAGES next tothe CONTENTS page. Se thatthe shop manual can be of ample prac tical uso, important safety snd quality portions fave marked with the fllowing symbos ‘Symbol |_ em Remarts al Spada oley precutone are oceesry when poring Special chr precautions rotor precuton for pre Steving tandoras ora notes ESry"nen performing the te | caution (Cs)) wom only who voning pases, ‘meni fnion or the aering [rahening Pacer fo be costed with a = Os wl aces war ol wt ol ‘oi water) tbo aed a he i — pai. Places whore ol or water Disin | must be aries ane Suan yt be anedFOREWORD HOISTING INSTRUCTIONS HoIsTING Hoavy parts (25 kg or mors) must be lites with 2 Rost ot. SEMBLY AND ASSEMBLY section, ‘very part weighing 25 4g or more is Indlested clery withthe symbol Ca in the DISAS: ‘should be made 4) Check for removal of all bolts fetening the part to the relative part. 2) Check for existence of another part caus- ing interference with the part to be re moved, Wore ROPES 1) Use edequste ropes depending on the \woight of parts to be host the table below Wire ropes (Standard °Z" or "5" twist ropes ‘without galvanizing) part cannot be smoothly removed from ‘the machine by hoisting, the following checks refering to ope diameter | Allowable oad om | tone 10 oe | 10 na a7 | ow as 17 | 16 u as | 22 6 ms | 28 8 asa | a6 2 ar | ou 24 seo | 58. 2 ver | 100 © ves | 180 50 zs | 280 a so2_| «oo 4 The allowable load valve is estimated to be onosith or one-soventh ofthe break. ing stongth ofthe rope used 2) Sling wice ropes from the mide portion ofthe hook. a HOISTING msstRUCTIONS Singing near the edge of the hook may fause the rope to slp off the hook during hoisting, and a serious accident can re fut Hooks have maximum strength the middle portion 64944 100% 88% 79H TIAN Do not sling a heavy load with one rope alone, but sling with two ar more ropes Eymmetialy wound onto the las, |B Sivsina win ene rope moy cause fuming of the load during helsing, Luntwstng ofthe rope or slipping af the rope from its orginal winding potion on the load, which can r0 Sutin dangerous szidont Do not sling a heavy load wth ropes form ing a wide hanging ange from the hook. When hoisting Toad with two or mor ropes, the force subjected to ach rope twiinerese with te hanging angles. The {able below shows the variation of allow ‘ble Toad KN (kg) when hastings made With two rapes, each of which is allowed. to sling up fo 9.8 KN (1000 kg) vertealy, at various hanging angles. \Wnen two ropes sling 8 Toad vertically, up {o 191 KN (2000 kg} of total weight can be suspended. This weight becomes 9: KN {1000 ka} when two ropes make 2 120° hanging angle. On the eter hand, two subjected to an excessive ores 29.2 EN (4000 Ig) if they sling £8196. (2000 ka) lsd at ling angleFOREWORD COATING MATERIALS COATING MATERIALS ++ The recommended costing materiale such as adhesives, gasket sealants end greases used for lsessembly and assembly ar Iistod below. ++ For coating materials not sted below, use the equivalent of products shown inthis lie Cctenory [Hemawucode] Peano. | ay | Container Main aplication, features Lr-1a _[yeozs-oso] 180.9 | Tube |" ishions, and cock plug tom coming ov [Uses in paces requiing an imeditey 200. lponetnyene|_ sisive, tong dhosv. Used for ple jrs-ize-oco| 200, |Poh {es ence pelatvane,peaertvens Features: Resietonce to heat and chor v2 | ona 00020 Peyeone al 80.0 | Caner |+ Used for attaosaring and sealant pu 790-129-0060 |Anesive: Used ar adhesveor snlat or metal glass (Serot aahe | Sra plate urs |Sheand’ [Hawering] con nadening "ogo, ‘eon | Bog oietnene|- Used as salnt for machined holes. iow : Vand we astreaining saint for psn whet, |reo-ia6sr20] 759 | Tube |* ed eb Quick nedoning yp aahesive “Tne bond Iraytnene|* Cure time winin 3 se, 3 min a6" |790-12-940) S00 PCr | Used mai for adhesion of metals, rb | Quick haraening pe aahoslve | Gickeure type imax song sor 30min |- Used min or adhesion of uber Aronaiohe |yop-129-9130] 29 os Lost SE frmranann| an [mn Chaicsonne bee han om Used at aahasve or sealant for gaskets Ler [peotzs-soro) 200¢ | Tube |” packing of power an ass te Usese eal Yor ange surfaces ana bois thigh temperature tocatona, used tos |rao-rancora) tha | Can | ed ar selnt for heb resistance gasket foc high temperature oeatons such sanFOREWORD CComTING MATERIALS como [eormmneoa] ronne [ey [one | wan apicion tres |+ Used as sealant for flange surtace, thread. vos fsa] sone | som | Sesame atria es Sates mang srs o ‘ait tan arama ce [Used a er vr al be es e-reson| 14g [eine ae tanee | oe lr prs pp ove iit int om [Fear Sion wd rine fot Stem] so fessor] 2505 | oe | Sean ett age wee f Seas tote at [rns Bon ted it Rann tee or |ovemoonn| og | rte |. BS onan rhe! owing se tt ig, Tors vond fer-gpsonl wow} aw Ula tego psing ae | ° ES | |+ Used as lubricant for sliding portion (to pre- Molyode- \M-G | c9940.00081 | 60.9 Can vent from squeaking). Senin F Usa prvr sino siig oie SEN | une [omosono | 200 | rave |! sisedanren in dteang tearing at reams [ere prone oe Eres cou eziatia| vaous | veto Eve eo be | die coma npr, Ro bad crete sropsucn Scare sa ea as aca [Berane veiw | vous eer yea vedo per th ‘disuiphide | SYG2-400M | (10 per [Belows type teres ‘enw ions ‘moe m5FOREWORD STANDARD TIGHTE ‘STANDARD TIGHTENING TORQUE ‘STANDARD TIGHTENING TORQUES OF BOLTS AND NUTS Use these torques for mete bolts and nuts (Aways use torque wrench) ta~'| tt. | © © @ © G... nm mm Nm kom ‘ x ae 3 3 ge g 3 Be z z ES, oft, wogee| ath ‘of bolt cron fa Don : 3 ee ‘mba Toma ornese wars ‘ray ort See me aatea Wa oa | Tana z . = TS ats : BORE ge "ene Tora Fs race srs ans sparen wo 00-10FOREWORD ‘TIGHTENING TORQUE OF O-nING BOSS CONNECTOR ‘Use these torques for O-ing boss connector ‘STANDARD TIGHTENING TORQUE "Thread damater With cross fat Tighionng torus Nominal No mm am Nm 1g e rm Hag Beso 08 a fire cteomacut.”| 121118 nei ‘TIGHTENING TORQUE Uso these torques for O-ring boss con OF O-RING BOSS CONNECTOR nestor Tone” Tc a | Tia oe es = i ia i i | He | ORS : 3 S| eg | ES i 3 =| BEE | RE yre TonouEs OF ane wt Mr toes wc Ta te] Wa a Toa = 3% 7652234 1833 3 : me 3h 3 3 ad BuFOREWORD [STANDARD TIGHTENING TORQUE TIGHTENING TORQUE FOR 182 SERIES ENGINE (BOLT AND NUTS) Use these torques for metic bolts and nuts of 102 Series Engine. Thvesd damoter Tightening toraue TIGHTENING TORQUE FOR 142 SERIEG ENGINE (EYE JOINTS} Use these torques for metic ey jolnts of 102 Series Engine ameter Tightening toraue — mn kgm ei? oa 8 eis 13 F020 mek 2 tot 335 ie tosh TIGHTENING TORQUE FOR 112 SERIES ENGINE (TAPERED SCREWS) ‘Uso these torques for inches tapered screws of 102 Series Engine. Tightening trav, am Oa +000 Bian fa9 133 $023 180. 2s to ie tosFOREWORD ELECTRC WIRE CODE ELECTRIC WIRE CODE employed to indicate the thiiness of wices. “Tis wire code table wil help you understand WIRING DIAGRAMS. Example: SWB indicstes cable having a nominal number 5 and white coating with back stripe. CLASSIFICATION BY THICKNESS ooo vente! [igagrpe aeration MRS [AMS] Potente 2 26 a2 200 | 20 Lighting, signal ete. es 65 032 “523 7 | Chorging ard signal ce @ [eae [ems | na | a | ss [oe | em [am | oe |_| se vor [ ven [eon |e | ef rs etassicanon av coLon AND cooe im foal Ww [ef [| vf ef * [P= [cotor] write Black ‘Black fed Yellow Green Blue ss a [color] white & fea] —_isck& wit Red & whit [Yalow & Ras freon & vine bue & White a ec coisa] —— aa ven rar | es Tune eae] wef CJ Y Ye ow wy “ FF [color|whe & Biv) — | aack a Rea fed & Vevowftow& Gerfrom & Yale A Yalow T] feoel ve [=] - | | « | @ | cain cae] —— | = tor reve lea T) few) = a co [color] = = = [Red & 8ive fretow & wiitefGreen & Biusl 00-13FOREWORD ‘CONVERSION TABLE CONVERSION TABLE [METHOD OF USING THE COIWVERSION TABLE "The Conversion Table inthis section is provided to enable simple conversion of figures. For etala ofthe method of using the Conversion Table, see the example given below. EXAMPLE + Method of using the Conversion Table to convert fom millimeters to inches 4. Convert 55 mm into inches. (3) Locate te number 60 tha vertical column atthe left sie, tke this as thon draw a horzontal lia fom (2) Locate the number 5 inthe row across the top ake this as @, then draw a perpendicular ine down tram ®. (2) Take the point where the two lines cross as ©. This point © gives the value when converting from milmeters to Inet, ‘Therefore, $6 mm = 2.165 inches 2 Convert 850 mm nto inches. (G1 The number 580 dove vot sppear inthe table, so divide by 10 (move the dacimal point one place to the left to convert ito 88 mm. (2) Carryout the same precedute as above 1 convort 55mm to 2.165 inches. (3) The origina value (850 mm) wae divided by 10, so multiply 2.165 inches by 10 (move the decimal point one place tothe “ight o return to the orignal value. This gives 50 mmm = 21.85 Inches. ® Mitimeters to inches 1 mm = 093857 in ol[t+,2,[2,/+*[s [e«[7][ slo 0 fo (0.079 | oxte | 0357 | ors7| 0296 | o276| 0315 | 0354 wo | 0204 0.472 | a8t2 | 0851 | 0581 | 0.620 | 0689 | 0.709 | 0.740 20 | 0767 (0.86 | os06 | 0.945 | 0984 | 1.028 | 1.063 | 1.102 | 1-142 so | 1st 41200 | 3.298 | 4390 | ae | tar7 | 1457 | 1496 | 1536 i | 157 ase / 603] vse | 4772 | 1211) aso] 1800 | raze and -50_[ 999 2087, 2087 | 2.126 |'27@5)| 2205 | 2244 | 2.263 | 2325, eo” 2362 PEA] Zaas'| 2820] 2969 | 2596 | 2038 | 2677 | 2717 m | 2756 2eas | 2074 | 2912 | 2953 | 2992 | 3022] 3071 | 3110 ao | 3150 3226 | 3260 | 3307 | 3346 | 3306 | 3.425) 3.405 | 3500 9 | 3503 3622 34st | 3701 | 3740 | 3760| a819| 3858| 308 00-14FOREWORD Mitioneters to Inches (CONVERSION TABLE zat [708 [zee 21a.26 oj): ]2z][af«{[s]e]fz]alfe © }o | o0a8 | a07e | 0.218 | 187 | a97 | 0236 | 0276 | o218 | 0256 so | os | o4ae | 072 | ore | 0551 | 0591 | o630 | 0669 | a709 | 0.748 20 | 0767 | 0827 | oss | as0s | 0945 | oes | 102e | 1063 | 102 | 1.142 ao | rset | 1.220 | 1260 | 1200 | 1339 | 178 | 1er7 | 1487 | 496 | 1538 ao | 1575 | 1614 | 1658 | 1603 | 1732 | 1772 | rar | 1880 | 890 | 1929 50 | 1969 | 2008 | 2047 | 2087 | 2.126 | 26s | 2205 | 2244 | 2209 | 2323 eo | 2962 | 24oz | 2481 | 2490 | 2520 | 2559 | 2508 | 2638 | 2677 | 2717 70 | 2758 | 2795 | 2935 | 2074 | 2813 | 2953 | 2992 | soxz | a0 | s110 20 | 2150 | 2.169 | 2220 | 3260 | ss07 | aes | asus | 3.425 | 2405 | a500 90 | aes | ase | 2622 | 3601 | 3.701 | a740 | 2700 | aste | aase | 2090 Kilogram to Pound ea tig = 22006 ofr f2fs}e4}si6]7]a| os 0 | o | 220] 441] sor) az] rr02| 1323] 1543] 75e] r9.98 ro | 2205| 2425] 2646] 2566] 3086/ s307| 3527| s748| co00| 4109 20 | 4409! 4620) «950/ s0.71| 5191] 55:12] 5732) s9sa| 6173| 6399 0 | 6514] 6224) 7055/ 7275| 7496] 77:16) 7937) e157] «78| 05.90 40 | eae| 9039/ s259| 94a0| 97.00] 9921| 101.41 | 19.62 | 10522 | 10808 50 rr24e| 11466 | 11605 | 11908 | 121.25 | 123.46 | 125.66 | 12787 | 13007 0 344g | 13669 | 1989 | 141-10 | 43:30 | 145.51 | 147.71 | 9.90 | 152.12 70 15653 | 150.73 | 160.98 | 163.14 | 165.35 | 167.55 | 160.78 | 171.96 | 174.17 ” 757 | 19078] 18298 | 165.19 | 1979 | 199.60 | 191.90 | 16401 | 196.21 % 200.2 | 20283 | 206.09 | 207.24 | 209.44 00-15FOREWORD CONVERSION TABLE ofaf}2}a]a«}s}oejri]eles 0 [© | 266] 0526] ors] 1057 | 1321] 1505 | x24 | 2.113 2370 wo | 2042 | 2905] 3170] 3434 | s698 | 2963 | 4227) 4491 | 4755 | 5.019 20 | 5253 | sea] serz| 6076 | 6340 | 604 | easo | 7.132 | 7297 | 7661 30 | 7925) 6169 | 945 | e718 | e902 | 9.246 | os10 | 9:74 | 10.039 | 10202 40 | 10567 | 10.831 | 13.095 | 11.299 | 11.624 | 11.988 | 12.152 | 12.416 | 1.600 | 12.948 50 | 13.200 | r2.473 | xa.2797 | 14.001 | 14268 | 14509 | 14.795 | 15.050 | 16.222 | 15.586 co | 15.350 | 16.115 | 16.379 | 16.643 | 16.907 | 7.171 | 17.495 | 17700 | 17968 | 16.228 70 | 18.492 | 18.756 | 19.020 | 1.285 | 18.549 | 19.813 | 20.077 | 20:31 | 20.05 | 20870 ao | 21.134 {21.396 | 21.962 | 21.926 | 22.190 | 72.488 | 22.719 | 22969 | 79.207 | 23511 90 | 23.778 | 24.040 | 24.204 | 24.508 | 24.822 | 25.096 | 25.261 | 25.625 | 26.009 | 6.159 Liter to UX. Gallon 16+ 0.21907 UX. Gal ofar}2]afals|el7 lel] s © | 0 | 0220) asso | 660 | o2e0| 1.100| 1220| 1540) 760] 1900 10 | 2200| 2420| 2640 2860 | s080| 3300] s520/ a740| 3950) 4179 20 | 4300| s619| 4539| 5.059 | 5279] 5499 | 5719) 5929| 6.159 | 6279 20 | 6599 | ser9| 7039 | 7.259 | 7.470 | 79¢9| 7919 | 139 | e269 | e579 0 8.793 8.019 9239| 9.489 | 9.679 | 9899 | 10.119 | 10.339 | 10.859 | 10.778 snes | rae | 14 |e | nar | 208 | rat | rss | re | rare dean |snen| vam [son [eae [team | tre | eae || ae tare | nor |aoze | zou [aner| ana || aa | am | air egzas 00-16FOREWORD CONVERSION TABLE kam to fb 1 hom = 7298. ofrf2]}s)4}s]foelrisalo ° o | 72] us| 27] 29| 262| a4) so6| sro] os wo | 73] 796| s68| s40| 1013) 1065 | 1157 | x230| 1902) 1374 zo | var] 1519] 159.1 | 1664 | 1736) 1908 | 108.1 | 1952 | 225 | 2008 30 | avo] zza2| za1s | 2087 | zas9| asaz | 2604 | 2676 | 249 | 202.1 | 28903 2966 | sos | a1r0| ate | 2255 | 2927 | auo0 | a172| asea so | ser7 | seas | s761| sos | 3906] 2978 | 405.1 | «129 | s108 | 4200 eo | asco | aar2 | esas | 4557 | a529| a702 | a774| anes | unre | 490.1 70 | sos | sts | sz08| 5260 | 5952 | 42s | s197 | sseo | sez | sri a0 | sre | sass | ss31| 003 | oo76| cree | e720 | e202 | ees | 6497 90 | esto | 6582 | 688.4 | 6727 | 6799| 6x71 | e944 | 7016 | mee | 7161 ro | 733 7308) 7378 | 7450 | 7522 | 1595 | 7667 | 7729 | 72 | 7004 110 | 7956 | 029 | stor | e179 | 246 | core | e200 | es | ass | 9607 120 | a6a0| 2752) 024 | 9997 | aves | c041| ora | ora | gee | oaa1 130 | 9403 | 9475 | 9548 | 9620| 9692 | e765 | 9827 | 2009 | o902 | 1005.4 140 [0126 | 10139 | 1027.1 | r0983 | 1041 | 10483 | 10560 | 1069.2 | 005 | 10777 150 | 10849 | 10822 | 1099.4 | 11066 | 11199 | 2121 |r1283 | 1956 | 1128 | 11500 seo | 11573 | nee | 11717 | 11790 | 11062 | 11994 | 12002 | 2079 | ras | 1272.8 vro | 11296 | 1236 | 1248.1 | 12513 | 12585 | 1265.9 | 12720 | 1290.1 | 1297 | 12047 00 | 12018 | 19082 | 13164 | 1323.6 | 19909 | 1298.1 | 1948.2 | 1982.6 | 192 | 1967.0 190 |13743 | 13615 | 19887 | 13980 | 14032 | sero. | rar7.7 | r4249 | 122. | r94 00-17FOREWORD eglom? to tie? alot = 14.28 Ie T ofs}2fs}«a}s]efr]efo ° o | 2] aa] 427] 69] m1 53) 906 | 1138) 1280 ro | 422] 1565| 1707 | 1249 | 1991 | 2124 | 2278 | 2418 | 2560] 2702 zo | 2a45| 2007| 2129 | 3271| aura | 2566 2608 | 2040 | 290 | 4125 a0 | 4267) 409] 455.1 | s60.4| asze | a978| s1z0 | s263| saos | 5547 wo | 5009) s032| save | errs | 6250 | c1o1| 6543 | e885 | 6527 | 6969 so | 7112} 7254| 7996 | 7538 | 7601 | 7023 7965 | 8107 | s250 | 8392 eo | 0534 | 9678| sors | e061 | o103 | szes| osa7 | 9530 | 9672 | 9614 70 | a56| 1010 |024 | 102 |1059 | 1057 | 1081 | 1095 | 1109 | 324 0 ara | ais2 |rs0s |rser [1195 | 1209 |1223 | r2a7 | 1252 | 1206 90 1260 | 1298 [300 | 1328 [537 | rast | 1365 | 1350 | 1394 | 1408 soo raze | usr [1451 | 140s [479 | 1403 | 1508 | 1522 [1598 | 1580 ro [1505 [1579 | 1599 |1607 |re2x | 636 | r650 [166 | s678 | 1693, ro |r7or |vr2x fara |a749 | r764 |a778 [1792 | 806 | 1g21 | 135, a0 freee | 86 [1077 {1092 | 1906 |1920 [1996 | 1949 | 1963 | 1977 suo 1901 | 2005 | 2020 | 2036 2048 | 2062 | 2077 | 2001 | 2105 | 2118 yo fais |2ue |are2 | 2176 | 2190 | 2205 | 2219 | 2235 | 2267 | 2200 60 | 2276 | 2290 | 2006 | 2010 2533 |zs47 | 2561 | 2375 | 2380 | 2204 vo |zare | 2432 | 2405 | 2460 2475 | 2489 | 2503 | asi | 25a | 2546 rao | 2500 | 2574 | 2569 | 2603/2617 | 2631 | 2648 | 2650 |267¢ | 2088 190 [2702 |zrv7 |2rax |2re5 |2759 [2773 | 2768 | 802 | 016 | 2830 200 | 2aus | 2080 | 2072 | 2907 | 2901 | 2016 210 | 2aa7 | 001 |a018 |2020 | 2046 | 2058 aoa [ator | aris 229 aia jaa [arse |av72 | a105 | 200 so29|s2es | 257 2x0 [aa | 286 | 900 | 2014 | 028 | 343 aan [aes | 299 zu acre | 2028 | 2442 | 2456 | 3470 | 3405 seis [sar | sea 00-18FOREWORD CONVERSION TABLE Temperature enti Contarte Convio ine wy fo one Fale tempers rang io 8 Ceara {wre singer ve erento act he nsmpanyig able ner ole ft. ‘ets rater tte tempore alr Faber Caras veemer “ + [i of | cc + | F Ss | ka 2 | 86] 63) @ | nes | a0 | ae | ime So | 0 ua | see] ao | a | ime | aaa | a | tare Ss | Tae uw | sa | sa) t | woo | zea | ae | ten Se |e ws | 50 | woo | so | v0 | tea | as | toso -ma]-2 | 22] 29 | 1 | os] ws] s1 | 128 | 00 | s6 | soe cna| we | ca] 3) | es] mr | 2 | vase | sos | a | iene cna| oy | Sa] Ge] ie | cee] 3 | ssa] ate | ae | joe ter | 46 | 32 | 92 | ae | oz | a2 | se | ane | any | mo | ame car | Ts | so] “7 | 2 | cao] wee | se | tao | m2 | o | ion 286 se] sr | 2 | ce | ta | so sme | ae | or | rose So se] se) 2 | me] m9) & | tae | sa ae | tore Sue wa} so] 2 | ra | tee | so | tzce | sas) sa | tone aa waa | 44) a | 52 | so | so | taee | ane | oe | done aa wo | 35| 2 | m0 | ise | o | woo | aso | se | ama cas | 2 | ree | ror | sx | wre | ase | oo | aos ss| 7 | os | ir) & | was] 61 | gr | tose G2 | me | aa] we | es | tase | any | oo | dose “7 | a | a2 | are | ce | tea | are | se | 202 =r | 30 | aco | tas | os | sas | are | seo | 220 -os| av | aa] so | 66 | rsa | wos | 10s | 2210 0 | a2 | sos | we | o | ae | wos | wo | 200 oe | a | ore | 200 | oe | tsee | ast | is | 200 ur} a | a2] 206 | oo | tse2 | aa | too | dao sa | as | 50] arr | m0 | aseo | sty | te | aro -na| 1 | ssa] 22] a6 | o58| 27 | m | roe | sea | wo | ano cer | 2 | ase | 28 | a7 | san | 222 | te | tere | m2 | us | 0 cer | 3 | sa | 33] ae | roa | dan | 73 | tsa | soo | wo | zoeo wise | 4 | 392] 38 | 30 | too2 | 23) 7 | to52 | 27 | we | amo sso} $ | ao] 4a] a | too} aaa | as | toro | ase | eo | Sneo cus] 6 | as] so} a | rosa] 20 | 26 | re08 |] 02 | ws | anno Sag | 7 | a6 | 55) a | tors | aso | a | s08 | a1 | x | 200 saa | a | tea} sr | a | toe | 266 | re | toe | a9 | we | aeno saa | 3 | a2 | or | a jamz | 26r| m | rez | 67 | no | aero S22 | w | so | 52] a | 130 | 67 | | tre0 | a4 | te | sero 00-19vvezeoa O11 GENERAL assembly drawing libresnt and water o1-1GENERAL, GENERAL ASSEMBLY DRAWING Serial No. 50001 - 52099 [GENERAL ASSEMBLY DRAWING vezsoaGENERAL GENERAL ASSEMBLY DRAWING Serial No. 53001 and up mcdGeNenaL SPECINCATIONS SPECIFICATIONS ocr ose waza Seva somo 52009 9001 on vp ] ninemsn we Tas oy B} orton trom a so sas0 | cxston rent a a0 a0 Bucket cpecy Dowpe me |v oaen 800 |= wn B00 fate os woo) | 805520) 5.06.20 FonwaRo 2nd | mt 1 nw Fomwano ad | am ns ns fomwano an | sm ns ne : reverse t | a oo os E reverse nd | umn m2 wa i feverse a8 | mm a2 m reverse an | am x9 ne Max tit s ci oe raeaty ea 250 150 win tung [oe tea] mm 0 se con | gasp, | mm 505 eos vera oath vom | 8 win 860) 1245 wn 800) vera wi (eas xm 280 20 Bua wth th 806: xm 08 300 Overall Hit top of a) om 000 a0 908078 anop|_ mm sues 400 evens | mm 70 sas 3] wneonsse vm 3000 a0 | te om 2200 220 3) tn. oun cera om wo 1 Hight of bucket Ning 9 om aaa Pre Dumping clewance ipof806) | mm 200 ays Dumping rnc edge often | mm us a0 Buca dump ange eg * ® cas angle travel on) | eg * ” oping cot 0" dump wth 8063] 2 2 ezsoauses cenenat srecncaTions Sera Ne somos S001 aw a Tora SOT ™ yan mre rn yn age cornet sto | mm nm Paton dence ta zs Pes Komen 0 | Terseram 48) serum wre hen omen 7.500 “| Fut consumption ratio |akvn giHPn 738 (17.5) eo aged ea 240 Low ting see a 1 String meter ay stomner av 3A sonay wv won Trg omen omen Tape le phe Rona TEAST §] roenin Spcarmarematare sabes Ses 4) poten ow otal bv ge ah etn 2) sateen Stal bo gear toe propoieing amt runany gr ng np sh enn Dive pe Tween! re tom rt te tengo | mre Catan spon aoatng nee ye 2576108 4 on] | eet cm tas 2578 Inaton peste Frontte |e tot 3888 hawt _|taoaem sun Seniesa rom, cuits neat A sia aati i ina eae #) nin tote ve sht wet ped tae Hyaroucafy eased Spring b>Genera SPecINCATIONS ech mode wae swt Na 0001-9 2001 a vp iz "aed weaing sce ype omer sang Mrdaue pmb We Geo pump trsaaiepume ea Date | Sa erm, " ' [pecs . § [F] Seren or wou eupent Reel - He hes iol SEruae EL | St meee or see {MPa koe Beat a rd a aa Eset evince, Reprogating ston 5 No. bere x stroke mm Peo 8 Stora eigen an pete go ‘Sige kate pe Ft ee wih 800 01-6 ® szsoevvezdoa WEIGHT TABLE WEIGHT TABLE Br This weight tabi {§ 9 guide for use when mnspating or handling companen ‘era No sa00r- 52669 | 5200 and up Engine 750 720 “Tranemisin Gnlasing toque converte 1.000 1.00 center eve she 38 es Front dive shat a2 na oar dive ena 1 oar ae 16 136 Front atari 2 a Panstary ena each) 6 06 ‘pot rear ae) 1 wo Tea ese 5 a Storing wave ns ns Stecng onder seh) na m7 sae tan 165 5 Hydrate, PPC pump tandem pump) ms 208 Staring, awiten pump (ander pur ns no Main contra vive ” 7 tevin fosen) 183 8 Bucket ringer 3 20 ose fame 1296 rat Suet tk 6 6 LU am intaing Bushing) 1370 1281 Bucket ith BOC 1670 1670Unit ig Machine node! were ‘Seva No soot -s2se0 | 52001 and wp uot tank am 23 Baty (ech) “6 6 Air condone unit ns ns Operators seat = 3% OPS canopy : 8 OPS cab : ws 01-8 ® vezeoaus2coa GENERAL LST OF LUBRICANT AND WATER LIST OF LUBRICANT AND WATER "AMBIENT TEMPERATURE ewraay reservorn | OF |g gu am mo wet [Sb FR SS BE] soeatea | ner Engine oil pan | ae ee tine ot || we | we rote wate awe | wee Crm od ma | fei See Note woe | we ea Poe ( wernec2 : = re Fin waa : > reming sytem) f woe | - ron |S | de aa Coating sytem | Wat | Ad ations se |} ASTM DOTS No 11) Saat Nov BOOT ond op #2 NUGI No. 2 ‘When operating a machine withthe auto-reasing system at temperatures below -20°, set the ‘roating ume to 20 minutos. See the Operation & Maintenance Manual. Note 1: For axe cl, use only recommend SHELL: DONAX TT or TD CALTEX: RPM TRACTOR HYDRAULIC FLUID ‘CHEVRON: TRACTOR HYDRAULIC FLUID ExXACO: TOH OL MOBIL: MOBILAND SUPER UNIVERSAL ‘tle poetble to subattote engine oll CLASS. CO SAE90 for axle ol, noise comes from the brake, It is no problem of durabilty oil a follows, 01-9 @(GENERAL, LUST OF LUBRICANT AND WATER REMARK ‘© Whon fuel sulphur contant is less than 0.8%, change oll in the oll pan every periodic maintenance hours desribed in this mana. {Change oil secording tothe folowing tab fel sulphur content is above 05%. ‘Change interval of ola ‘ongin ll pan| 05 t0 10% 12 of regular Interval Fuel sulphur content ‘Above 1.0% | V4 of regular Interval ‘© When starting the engira in an atmospheric temperature of lower than 0°, be sure to use engine oll of SAETOW. SAETO30 and SAETSW. 40, evan though an atmosphere temperature gone $0 more or lees In the day tine, ‘© Use API classification CD as engine oll and if AP classifi Interval to hal 2” C6, reduce the engine il change '¢ There is no problom if single grade ol is mixed with multigrad ol (SAEIOW-20, 161-40), but be sie to add single grads all that matches the temperature inthe table ‘© We commend Komatsu gonuine ol which has been specially formulated end approved for use In engine and hydraulic work equipment applications, Specified capecty: Total amount of oil nclading ol for components and olin piping. Fefl capacity: Amount of el needed to ffl system during normal inspection and maintenance ASTM: American Society of Testing and Materia SAE! Society of Astomotive Engineers Pt Aenrican Petzoleum Institute 1-10 @ szsoe10 STRUCTURE AND FUNCTION us2soa Powertrain system Torque converter, transmission piping ‘Transmission hydrate system ‘diagram. .. Transmission hyaraute cut ‘iagram Torque converter ‘Torque converter ai ite ‘Tranemission| ‘Tranemigsion control valve ‘Tranemiasion solenoid valve Pilot often essrsvscnnnne Drive shat, ale iterenial Final deve ‘Axle mount, con Steering piping. Stoorng column Stoerng valve : Orpitvol valve ” ‘Stop valve Emergency Diverter valve Brake piping Brake circ lagrom. Brake vale nn (Charge valve ‘Accumulator ifr brake) Sack agjuster Brake. Parking brake cote. : Parking beak Parking brake slencid valve Parking brake valve hinge Bin ring pump 10 © 0 1. wo. 10. 1. 10. w 0 1° 1 10 10 0. 1. 1». wo. 0 0 © 1 10. wo. 0. 3 a 6 ” 8 u 6 o 2 50 5 55 sr 2 % @ ro ee %0 3 10.100 so0 so. ro.103 Parking brake emergency ea solenoid valve sce 10-108 Hydraulic piping ns = 10-108, Work equipment hydraul systom diagram sn 0-106 Work equipment hyarauis Scul| ‘diagram 10-07 Work equipment iver linkage 10-108 Hydroute tan x0.109 PPC valve some PPC rai waive = wo? ‘Accumulator (or PPC val) nn 10118 Main contol valve 10120 Work equipment linkage ro138 Bucket oS 10138 ‘Bucket postiner and boom Wekout - vow 10497 cab. 10.108 OPS cab I gotas.2 ‘ir conditioner Comet Electrical ereuit diagram wos Machina monitor syste. 10355 Main monitor. oT 10.86 Maintenance monitor 10.61 Werk equipment contol systam 10-168 ECs. 17 Sensors I eis Engin staring croult * s0180 Engine stop creut oS tose Proheating circuit aos Electric tranamision contol. 10.188 Kkedowm site 10-186 Kickown electric circuit diagram ns 10.187 Transmission eut of seh 10.192 Transmission cutoff function 10-189 Electric parking brake contol 10198 10-1ve24oa STRUCTURE AND FUNCTION. POWER TRAIN POWER TRAIN 1. Transmission (mutiple shat 4. Rear axle Outing othe motive force from engine (3) passes {through the engine flywheel and is vans ted to torque converter (2, which Is con ‘ected 10 the Input shat of tansmission (1 ‘The transmission has si hydraulically atu ad clutches, and these provide Tour speod anges for both FORWARD and REVERSE. ‘Tho tansmission speed ranges are selected manvaly 5. Rear drive shaft 8. Contor drive shat 1. Front drive shat 8. Front axle ‘Tne motive force from the outbut shaft of the wansmission passes thvoughoentar ive ‘shaft (6), ont dive shaft (7) and rear dive ‘Shaft (6), and Is then transmited to front ‘axle (8) and rear ale () to divetho whee 10-3‘STRUCTURE AND FUNCTION POWER TRAIN SYSTEM. 10-4 POWER TRAIN SYSTEM us240sus24os STRUCTURE AND FUNCTION 1 2 6 6 2 8 10 "1 % 3 16 Mu. 18. 1. 20. a 2. a Front axle Ditton Front drive shaft Center driveshaft Parking brako (wot type multiple die) Rear drive shaft Diferemia Rear ti Final deve Wit type muttipe dse brake Rear axl Engine (SA6D108) Hydraulic pump PRC pump Steering pump, Swatch pump | “Transmission, torque converter charging pomp Transmission (multiple shst type) Flange bearing Front tie Final deve Wot type multiple dis brake POWER TRAIN SYSTEM ousting othe motive force from engine (12) ps through the flywheel and is transmitted to torque converter (3) ‘The torque converter uses oil as & medium, Ie converts the transmitted tage in accord ‘ance withthe change inthe los, and tans mite the motive Tore to the irput shaft of In dation, the mative force of the engine passes through the pump drive gear of the forque converter, and is transmiteato ster ing pump (16), switch pump (1), hyéraulic ‘pump (él and PPC pump (15 drive each pump. + Transmission (19) operates the diroetionsl spool and speed spool of the transmission valve through the solenoid valves, and ect at the six hydraulically actuated clutches to select one of the four FORWARD or RE: VERSE speeds, The transmission speed range is selected manual + Parking brako (6) installed to the font out put shaft and acts To stop tie machine through the solenoid valve and hydraulically Ssetuatd clutehos when the parking broke Switch is operated +The output shat of wensmission (19) rane mits the powor tothe front and rear axes. ‘Actho font, the power is ransmited to front ‘lo trough conor drive shat), flange bearing (20), ane font drive shat (3h [A the tear, the power is transmitted to rear ‘axle (11 theough sear drive shat) + The motive force tranamittad front axle (11 and rear ate (11) has its sped reduced by the bovel gear and pinion gear of eitfer fentats(2) and (7, an fe then transite the sun gaar shaft through the eiferontal ‘mechani. +The metive Torco of the sun gear is tauced further by the planetary mechanism and is transmitted to the wheels trough the axle 10-5STRUCTURE AND FUNCTION ‘TORQUE CONVERTER, TRANSMISSION PIPING TORQUE CONVERTER, TRANSMISSION PIPING Reclator Ott cooler 5. & a Pilot oi iter Transmission conta valve ‘Transmission onrfer vve24oaSTRUCTURE AND FUNCTION “TRANSMISSION HYDRAULIC SYSTEM DIAGRAM TRANSMISSION HYDRAULIC SYSTEM DIAGRAM (Conditions: Engine at low idling, transmission shift lever at neutral) Leela Hill} 10-8 vszsoaSTRUCTURE AND FUNCTION TRANSMISSION HYDRAULIC CIRCUTT OGRAM TRANSMISSION HYDRAULIC CIRCUIT DIAGRAM an 24, Solenoid valve range selec: 25 13. Torque conver tion) 3. Torque converter cherging valve 25. Range selector valve pump 14, Oi cooler 28. Solenoid. valve (parking 4. Plow valve 15. Transmission lubrication brake) 5 olfiter ‘gency manual spool 27. Parking brake valve 6. Plot reducing valve 1, Solenoid valve (FORWARD) 28. Parking brake 7. Plo it tor 18, Directional selector valve. 29. ath clutch 8. Priory valve 18, Solonoid valve (REVERSE) 30. 3rd elton 8, Modulation valve 20, REVERSE cuter 31. 2nd euteh 10. Quick 21, FORWARD eluch 2. 11 Main rele 22 Solenoid valve (HL selec 53 tion) 23, HL elector valve 10-9‘STRUCTURE AND FUNCTION “TORQUE CONVERTER TORQUE CONVERTER 1. Broathor ‘Specifications 2 Model: Tea? 22 3 sm pump mount “Type: 3 eloment. 1 stage, 1 phase 4 vdem pump mount ‘Stal torque vaio: 327 10-10sza02 STRUCTURE AND FUNCTION ‘TORQUE CONVERTER 5. Flywhee! 9, Stator A Inlet port © Dre case 10. Transmission input shaft B._Outlet port 2. Turbine 11: Housing Pump 10-11‘STRUCTURE AND FUNCTION Path of motive force +The torque converter ie installed between ‘the engine and the transmission. ‘The mative force from the engine antars rive case (6) fom flywheel (5). Drivo caso (6, pump Band PTO gear crive) 112) aro each socured by bolts and are ro: {ated directly by the roation of the engine, ‘The motive foree of pump (8 uses il as 9 ‘medium to rotate turbine (7) and transmit the motive force to tarsmision input shaft (0), + The motivo forc of drive case (6) is used as the motive force to dive the geer puma through PTO gear tariv) (12 Flow of ot + "Tha oil supplied trom the torque converter charg ump enters inlet port A, passes through tho oil passage of stator shat (19, and lows fo pump (8 ‘The oll given contifygal force by pump (8), enters turbine (7, and ranemits the anergy of the oll to the turbine, Turbine (7) is fixed 10 ‘wansmission input shat 70), so the mative ores is wansmitts tothe warsmission input shat ‘Tho oll rom turbine [711s sent to stator (8), and centers the pump again However part ofthe oi |e'eent fom the stator fvough outlet port B to 10-12 “TORQUE CONVERTER seanvszaoe ‘STRUCTURE AND FUNCTION TORQUE CONVERTER OIL FILTER 2 a Operation 2ST ol rom the torque converter charging pump enters fiter inlet por A tis fered from the outside of lament (2) t0 the In temperature i low init por A the al from inlet ort A Valve (1) and flows sirety 10 ‘tet port Bin order to prevent damage to ‘he pump or element (2). € ‘TORQUE CONVERTER OIL FILTER Reliot valve Element Center bot Drain plug Speetcations ter mesh sie Fitoring area Foliot pressure 10 microns 2800 orn 0.3 MPa (3.25 kale’) coun 10-13STRUCTURE AND FUNCTION TRANSMISSION 1. Torque convertr charging pump 2. Transmission input shat 3. Torque converter housing 4 Accumulator a 6. Rear output coupling ranamision 8 Parking brake (wet type multiple disc) 4, Front output coupling 10. Oi ker 11, Transmission control valve 2. Pro 13. Transmission ol filler 10-14 saae2aos [STRUCTURE AND FUNCTION 6 6. m. 1. 8. a 2 2 2s “TRANSMISSION PTO gear (No. of tooth: 85) PTO gear (No.of teeth: 76) PTO gear (No.of teeth: 74) at luteh (No. of teeth: 26) FORWARD suteh Input gear (No. of tooth: 281 Torque convertor PTO drive gear No. of tooth: 74) FORWARD gear (No.of tath: 48) REVERSE gear INo. of tooth 47) 4th goar (No.of teth: 53) 26. Output shat 2 (Output gear (No.of teth: 43) 28: 3rd goat (No.of toth: 48) a Besseeee . 31a gear (No.of toath: 43), 2rd elutes itn euten REVERSE, 2nd shott 2nd oar (No.of teeth: 26) 2nd gear (No.of tsth: 50) REVERSE goor FORWARD, Tst shaft {et goor (No, of oath: 25) 3rd goa (No.of teth: 37) CCountershatt 4h gear {No.of tooth; 27) 10-15STRUCTURE AND FUNCTION torque converter. The mative fore from the Torque converter passes through the trans ‘mission inpt sft and enters the vans. son CLUTCH FORWARD, 1ST CLUTCH the for speed clutches to shit to FI or BI ~ fd transmits the motive force from the in pt shaft tothe output shaft, 1 5. FORWARD, 1st eylinder a. tat clutch ol port 2 5. FORWARD clutch FORWARD cute oi! port, 3 7. FORWARD gear © Lubrication ei! port, i 8 Ast luten 10-16 FORWARD, st shaft vus24oauseage [STRUCTURE AND FUNCTION ‘TRawsmission REVERSE, 2ND CLUTCH 1. Spacer 5. 2nd clutch 9. Thrust washer 2. 2nd dutch ol port 2. Thrust washer 6. 2nd, REVERSE cylin. 10. Spacer B. REVERSE clutch 3. 2nd goat er 18. 2nd, REVERSE shat ol port 4 2nd gear 7. REVERSE clutch e Lubreation oll 8. REVERSE goor por 1. Spacer 5. 31d clutch 8. Thrust washor a, Sr clutch oil port, 2 Trust washer 8. 3rd, ath cylinder 10. Spacer Bath elten ol port, 3. sed gear 1. ath gear 11. rd, Ath shaft 6 Lubrestion oi por 4 Sed gear 8. ath elteh 10-17STRUCTURE AND FUNCTION Operation of clutch When operated + "Tho all seat from the transmission valve passes through the oll passage inside shaft {Mi anid goes tothe roa face of piston (5) t0 {sctuate the piston, + When piston 15) 'sactsted, separator pate (2) pressed agoinst clutch dice (3) and forms shat (1) and clutch gear (4) ito one Unit to tranemi the meive fowce, When not actuated + the ol rom the transmission valve is shut ‘of the pressure of tho oll acting on the rear {ace of piston (8! drops The piston is returned tits original position bby wave spring (8, s0 shat (1) and cluten tar (8) are separated 10-18 TRANSMISSION szsoauses STRUCTURE AND FUNCTION FORWARD 1ST “TRansmission Operation ir the case of FORWARD st, FORWARD cluteh (18) and 1st clutch (17) re engaged ‘The motive force transmitted fram the trae converter to input shat (2) is vansmited to (ar (19), which is installed to he Input shat. Een cluteh cise of FORWARD clic (18) and Yst clutch (17) is ongaged by the oi pressure applied tothe piston {The motive force fromm the oraue converter passes from input shat 2 through gear (18) find is transmitted to FORWARO gear (22 ‘Wan FORWARD clutch (18) ls engaged, the ‘motive fore is transmitted ta the FORWARD 1st ylinder ‘Tho Ist clutch is engaged, 20 the motive force transmitted 9 the FORWAAD ts yn er pasees through Tet clutch (171 and Is snsmited from Tet gear (38) to 2nd clutch (eats (35.33). then pastes “hrough ra flutch gear (28) and output goo (27h and is transmitted 10 output shat (26 10-19[STRUCTURE AND FUNCTION FORWARD 2ND Operation vin the caso of FORWARD 2nd. FORWARD clutch (18) and 2nd eluteh (24 are engaged ‘The motive force transite from te forgue converter to input shaft 2) i wansiitted to (ear (19), which is installed to the input shat. +The cluten discs of FORWARD clten (18) and 2nd cltch (34) are engaged by the oil Dressure applied to tho piston +The motive free from the torque convertor passes from input shat 2) through gear (18) tnd is transmitted to FORWARD gear (22), FORWARD clutch (18) is engeged, 40 the ‘motivo force is vansmited to FORWARD Tat Minder gear (42) 10-20 ‘The motive force is transmited to REVERSE 2nd cylinder goar (63) and REVERSE 2nd shaft (82), which are mashed with the FOR- WARO st eyindor gear. 2nd clutch (34) is ‘engaged, so the motive forco transmitted to the REVERSE 2nd shatt passes through the 2nd clutch and goes trom 2nd gear (23) trough Sed gear {28} and output gear (27), and is transmitted to output shat (28) szaoeuszao2 ‘STRUCTURE AND FUNCTION Trawsmission. FORWARD 3RD Operation ‘in the esse of FORWARD 3rd, FORWARD + The motive force is transmitted through RE luton (18) and 3rd clutch (30) aro engage. \VERSE 2nd cylinder gear (9) ad REVERSE ‘The motive force transmites from the trae 2nd. shaft (92), whieh ie meshed with the converte to input shaft 2) is ansmite to FORWARD "et cylinder gear, end Is trans. ‘ear (9), which Is nstalled to the input shat rite t0 3d, ath evinder gear Ws) and 3, +The cluten aises of FORWARD catch (18) {th shat (24. 3d lute (30 is angaged, so tnd ed uch 2 wo angze by ie the motive foree passes through the 3 ure applied tothe piston Clutch and goes from 3rd goat 28) through «+The motve force frm the torque converter ‘utp gear 127), and is wanted to out passes from input shat 2 through gear (18) put shat (2). fnd is tranemited to FORWARD esr (22) FORWARD clutch (18) is engaged, s0 the ‘mative force Is transmitted to FORWARD Ist fyinder gear (2, 10-21[STRUCTURE AND FUNCTION FORWARD 4TH Operation othe case of FORWARD Ah, FORWARD futon (18) and ath clutch (31) are engaged ‘The motive fore tranamitae om th torque converter to input shat 2s transmit to {oa (19), which ie inetal ed to the input shat. +The clutch dace of FORWARD clutch (18) fand th eluteh (31) are engaged by the ol pressure applied tothe piston +The motive force trom he torque converter passes from Input shaft 2 through gear 19) fnd ie tranemited to FORWARD gear (22), FORWARD clutch (18) is engaged, so the ‘motive frca is ransmited to FORWARD Tet Eylinder gear 22, 10-22 “TRANSMISSION ‘The motive fore ie transmitted trough RE VERSE 2nd cylinder goar (43), which is meshed with the FORWARD st cylinder for, and i transmitted to 3d, th eylnder Sear (4) and 3rd, th sett (2 th clutch (G1) is engeged, so the mative forca tans ited to the 2d, ith shaft passes through the fh clutch and goes from 4th gear (25), through 4th counter gear (41, countershatt (40), and 316 counter gear (98), is transmit 10 3rd. gears 129) and (28), and then passes trough output gear (27), and is ran fitted to output shat (28.szs03 ‘STRUCTURE AND FUNCTION REVERSE 1ST ‘Transmission Operation “inthe casa of REVERSE tat, REVERSE clutch (96) and 15t clutch (17) are engaged. The ‘mative force transmitted from the toraue Converter to input sat 2) tranemite to {oar (9), hin installed to the input shat. With reverse clutch (38) and tat clutch (17, teach clutch disc is engaged by te ol pres: Ste aplied tothe piston. ‘The motive fore from the torque converter passes from input shat (2 through gear (18) fnd is transmitted to. REVERSE gear (25) ‘When REVERSE clutch (30) is engaged, the motive force is transmitted tothe REVERSE “The mative fore is transmitted te FORWARD 1st cylinder gear (42) and FORWARD ist shaft (37), whieh are meshed with REVERSE 2nd eylindor gear (43.18 lucy (17) is on ‘3908, so the motive fore transmited to the FORWARD ‘st shot passes trough Tet ‘dutch (17) and Is wansmited fom Ist goat (38) to 2nd gears (35, 33) ‘31a gear (28) and output ‘of ‘wansmited t0 output shaft (28) 10-23STRUCTURE AND FUNCTION TRANSMISSION CONTROL VALVE TRANSMISSION CONTROL VALVE 1. Mechsnical modulation a, Torque converter inlet port. Patking brake oil pressure valve cl pressure measurement messuremeat port ioioriy 2. Upper valve poet ‘measurement port 2. Lower valve b. Torque converter outlet port f. From pump 4 Solenoid valve cil pressure measurement 9g. Main oll pressure measure 5. Emergency manval spo! por iment port Clute ol prossure measure: h. Pilot it pressure measure ment por ‘ment pot 4. Toll cooler Outing +The ell from the pump passes through the +The quik return valve end modulation valve flow valve and torque converter ol tite, are imerconnected whan shifting gear Ths lente the transmission valve, and edged Sllows tho clutch pressure to ree smoothly Into tho pilot circuit and clutch atuation cir and reduces the shock when shiting goat ut Imaddtion, when the machine is traveling, The priority valve adjusts the detvery pres the clutch proseure is Kept constant. The sure ofthe pump and ensures the plot pros pressure ofthe ol lowing to the plot valve Sure and ol pressure used to felease the |S regulate by the plot reducing valve, and parking brake ‘sctuaas the directional and range spools 05 + The prassure ofthe ol owing tothe elutch the solenoid valves are switched ON or OFF actuation ccuit ie regilated by the main + When the directional and range spools are Folie valve, and actuates the cute ‘The ol rlieved by the main v supplied to the torque convertor speed range. 10-24 switched, tho ol, whoso pressure i regu: ‘valve is Iated by the modulation valve, is soppieg to the selected clutch to provide the necessary us240avezeoa ‘STRUCTURE AND FUNCTION “TRANSMISSION CONTROL VALVE UPPER VALVE 10-25STRUCTURE AND FUNCTION TRANSMISSION CONTROL VALVE LOWER VALVE i 1. Upper vaive body 8, Lowor valve body 2. Emergency manual spo! 10! Directional selector valve 3. Quick return valve " 4 Torque converter outlet port valve 2 5. Main elie valve 15. Prionty val © Plot reducing valve 14. Parking brake valve 1. Accumulstor 18. Parking brake solenoid valve 8 Filvave 16. HL elector valve 10-26 vszsoaszaoa ‘STRUCTURE AND FUNCTION TRANSMISSION SOLENOID VALVE (9) for FORWARD selector [21 for REVERSE solectr Wve (61 for parking brake Structure 7 The transmission solonoid valve i install’ to the lower valve ofthe transmission valve nen tha speed levers operated, the move ‘ment i converted to eletiety, and this {pens or ciosos each solenoid valve to move the spoo inside the transmission valve “The parking or valve i inetalod to the tonsmision lower valve. When the parking brake switch is operated the sole hold valve is opened or caved by en electric Signal to move the parking brake spoo). TRANSMISSION CONTROL VALVE or range selector 21 Tor HL selector 5. Solenoid vale Actuation table for solenoid valve end clutch Ree Parking brake operated Parking rake released 10-27‘STRUCTURE AND FUNCTION Function nen the speed tver nthe operator's com Valve ate switched ON or OFF to actuate the ‘iroctonal selector sped HA selector spool land range selector spon Operation 1 Solenoid valve OFF ‘Tho al fom pile reducng valve bore @ and b of HL slactr spo! (2) and ange selector spool 3} The ail a and bs blocked by solenoid valves (4) and (8), 50 Selector spools (2) and'3) are moved tthe fight Inthe direction of arrow. ‘Asa result the oll from the pump flows to fhe 2nd elute, 2. Solenoid valve ON ‘When the speed lavar is operated, the dain ports of solenoid valves (4) and (5) open ‘The oi at ports a and bof selector spoots (2) and (3) lowe from porte and dt the drain Geuit, Therefore, the pressure in the cit uls at ports @ and b dops, andthe spools ‘te moved to te left inthe direction ofthe ‘arrow by return springs (6) and (7) [AS a result, the ol a pert @ ows to the &th ‘teh and swrtchee from 2nd to th 10-28 TRANSMISSION CONTROL VALVE Fremeune > Veep sza0ee240 STRUCTURE AND FUNCTION FLOW VALVE 1 Valve body 2. Vas spo0! Bump Rows fhe wanes Tubriestion TRANSMISSION CONTROL VALVE 2. To transmission clutch circuit . From pump ©. Totranemission lubrication circuit 10-29STRUCTURE AND FUNCTION TRANSMISSION CONTROL VALVE ACCUMULATOR VALVE 0 b fo B | 9 oJ , tof we o- a . nie es : 1 Paton FORWARD cat oxtine 2 Peston ist ute) 2th acsmultor sae itd int FOR 3: Pon ae em ano aa ten rau nen the £ Boar socmultor Wanemisnon anit ger te acasmaor 5 Sena na tem vate sony oaues theo presi he &: Sooper an sun) that want engages in rr ore 1 Stoppers cat) Sent lomo trqe nt rest hoa 8: Stopper ConWAA® cash ison sock wan shin es. empo 5: Sorno FORWARD cu rai tors este ot rss n oder 10. Song ist ue {2'thow gsr =niting tobe cares out “emoothly witout any tine Ing {To make it possible to reduce the ail pros ‘ure othe clutenelowy, thre are theatas installed inthe directional spool and selec tor spoel of ho ansmission contol valve.) 10-30 usz4oaszsoe ‘STRUCTURE AND FUNCTION Operation 1 Shiting down when digging kick down F2 Tr ites the transmission is in F2, ol pressure is stored inthe 2nd clutch secumlaor When the klek-down is operated, the FY Clutch is engaged, but the al prassure Inthe ‘Secumulatr ts maintained forthe 2nd clutch Unt tho torque fs transmitted to the st lute In this way ts possible to shit gear “rmoothty without losing the torque Moving out after digging (F1 > Ra) When the transmissions in Fo prossu | stored in the accumulator for the FOR: WARD clutch and tet clutch, When shiting to R2 after completing di ging operations the AZ clutch is engaged, Butthe oi pressure forthe FORWARD clutch fad st elton is maintained in te accu Istor. This motes it possible to reduce the lose of torque due to the resction free to the product being handled, and to move Back smoothly without shock TRANSMISSION CONTROL VALVE i “ 10-31‘STRUCTURE AND FUNCTION ‘TRANSMISSION OIL PRESSURE SYSTEM DIAGRAM Operation of FORWARD 1s TRANSMISSION CONTROL VALVE 10-32 vsasogvszsoa STRUCTURE AND FUNCTION +The oll rom the pump passes through the {iter then passes through the plot circu nd prot valve, and is vided fo the clutch Setation crelt and the torque converter + When the speed lever is operated oF, FOR: [WARO solenoid valve (1 is setusted. The ot which was filing porta ls drained, dra tional poo! (8) Is moved to the lat, and ‘utch oll pressure port b and FORWARD tut ol pressure port b’ aro connectod ‘atthe same time, of file the cet and push the HL oloctor spool) uly othe Fight to prevent H-L selector solenoid valve (2) from being actuated. In adition, tho ol Is deained and range selector spool (6) is pushed fully tothe loft to actuatorango so Tector solenoid vave (2) Inthis condition, Ta cliteh ol pressure port is connected to ol pressure port eof he HAL selector valve and the range selector valve. + Ab the same time, the oil fowing through pron valve 71 tothe clutch actuation ei uit passes through the modulation valve fnd thon flows to the FORWARD cten ond {at cluteh through directional spool a), HL selector spool (5), and range selector pool ©. + When th oil completo fills the clutch ev Inder, the pressure rises gradually because ofthe action of accumulator (8) and mod Tation vaive (9) When i resches the set pres sure, the FORWARD end 1st clutches aro ompletly engage. “TRANSMISSION CONTROL VALVE 10-33STRUCTURE AND FUNCTION ‘TRANSMISSION CONTROL VALVE DIRECTIONAL SELECTOR VALVE Operation Ten at neutral + Solenoid valves (4) and (6 are OFF andthe From petro pecan ‘rain por fe closed. The ol from the pilot Creut passes through the oll hele in the ‘emergency menual speol end ils ports & Sind bof the dvectiona p00. + Inthiscondtion, P+ spring forco(1)= Pe + spring fore 2), cathe bance is maintained ‘Thoreore, the ol st pert e does not go 10 the FORWARD or REVERSE clutch 2. When at FORWARD "When the directional lever is placod at the FORWARD position, solanoid valve (8) Is ‘switched ON and erain port opens. The oil, ‘which is fling port als drained, 50 Ph + pring fore (1) «Pa spring Tovce (2). hon this happens, the directional spool moves to the let, and the oll at porte flows to port @ land Is Supplied to the FORIWARD clteh 10-34 uszaosszao ‘STRUCTURE AND FUNCTION EMERGENCY MANUAL SPOOL, Funetion rp there shouldbe a failure in the electrical system and the directional solenoid velve angot be actuated, is possible to actus the FORWAAD or REVERSE clutch manually Operation 1. When emergency manual spool is at neutral + The oil rom upper valve (pilot reducing sues around emergency manual Spoat {1} and ls blocked by solenoid valves 2) ana (3 + During normal operations, the emergency ‘manval poo is atthe neutral postion. 2. When emergeney manual spool is actuate (Forwaroy When emergency menus! spool {1 is pushed In, pot a is connected tothe a the ail in chamber b ls happens. ciectonal spos! (8) moves to the Toft in the direction of the arrow Oi then flows tothe FORWARD clotch ana the clit Is engaged. TRANSMISSION CONTROL VALVE 10-35‘STRUCTURE AND FUNCTION TRANSMISSION CONTROL VALVE MODULATION VALVE Function The modulation valve regulates the pressure ofthe ail entering the aecumlator and con. trol the ol flow fo raise the lutzh pressure, Operation 1 Clute fully engaged (pint Ad 12. Tranamission switched from FORWARD to the quik return valve, and accumulator pis ton 1) moves tothe right in the direction of, the straw When this happens, the proscu In-chamber ¢ and charrbor d ops, and fil Valve (3 is moved to tha oft in the direction ‘of the arcw by spring [2 0 open porta 10-36 Serngest™ za eae ora Fane ft Iieonsgs y tit szaoevs240s ‘STRUCTURE AND FUNCTION 3. Clutch pressure starts tise point C-polat BD ‘Tho ol from the pump fils the clutch piston fand the pressure inthe eluteh eicut stars to rise: For this reason, the arain circut of the quick return valve Is closed ‘When the quick return valve drain elect is «losed, the ol passing through port a enters thamber d and pressure Pein chamber d ‘When this happens, and the relationship b tween Brand Ps becomes Pa > Pr Pte Son of spring free 2), the modulation valve ‘moves to the ight In the dvection of the arrow, shuts off port a, and provents the {utc pressure from rising suddenly ‘Tho oil at port a flows to the dirsctional spool, and atthe came time, Pa > Py 50 it Passos through orifice (8 nthe quick return Valve and flows into chamber e. When pres Sure Ps rises, pressure Pr aso iss. The ro- lationship of Pr = Prs Ps tension of spring (2) maintained, and thie action fe rapeates 10 allow tho clutch pressure tose, ‘Tho ol from the crcut a the toraue con vorer ouat port becomes the plot pres Sure tothe modulation valve end flows to pote ‘The pressure at porte var the engine spoed, ‘Thoreforo, ifthe relationship is takon as Pz Pris Pa + Pe {change according to engine Speed), pressure Pr changes by the same famount that pressure Pe changes. ‘Theretore, pressure P rises simultaneously by the amaunt that Pa changes, sts pos Sibi to produce oll pressure charactrstics that mat the engine speed. according to TRANSMISSION CONTROL VALVE 10-37STRUCTURE AND FUNCTION QUICK RETURN VALVE tapatageent Function 23408 TRANSMISSION CONTROL VALVE “To allow the modulation valve to else the fa32h tlutch pressure smoothly, the quick return Valve sends the pressure in the accumulator acting on the modulaton valve spool ma: ‘mentary othe drain ckcut when the tans mission te shifted, ee Operation 1 After engine is started, clutch completely ‘engaged (clutch pressure at point A (FORWARD 130) apt — 10-38 a vve240gsean STRUCTURE AND FUNCTION 2 When switehing trom FORWARD to RE: VERSE (clutch pressure at point B) TRANSMISSION CONTROL VALVE 2 alee Whoo the directional lever is shifted trom FORWARD to REVERSE, FORWARD solenoid [) cosas and REVERSE solenotd (2) opens Diroctonal spool (3) is moved tothe right in the direction ofthe arrow andthe ol at FOR. WARD eluteh {al is drained from the drain + Atthe same time, the oil fom the pump ‘ows REVERSE clutch (5), but while the fli filing the inside ofthe clutch, the clutch fil pressure ops, Hy Maas ‘As a result, tho oll pressure zt port @ of ‘uick return valve (6) tops, check valve (7) ‘pens, and the ol at port lows t port a [A the same time, quick return valve (6 is ‘moved tothe let inthe directcn ofthe ae ow by the eccumulator ol prssure, and the oi in accumulator (8) is @ained su: Genly from porte Aecurutator (8) ie returned tothe left end by the fore of spring 10-39‘STRUCTURE AND FUNCTION 3. Clutch pressure begining to rise (cltch pressure at point C) ‘The oll kom the pump fils the REVERSE lth and the clutch eeu pressure starts ‘Rela result the pressure at porta rises and ‘quick return valve (6) fe moved to the right In the direction of the arow to clase drain porte 10-40 TRANSMISSION CONTROL VALVE sews‘STRUCTURE AND FUNCTION 4 Start of accumulator operation, clutch com- letoly engaged (clutch pressure at polnt D) al oh TRANSMISSION CONTROL VALVE + Because ofthe siferential pressure crested by modulation valve (1 essing ‘rough efi (10) of the quek return valve flows asa constant amount into accumula tor (8). When this el flows in tho accumula tor moves tothe left inthe rection of the arrow and compresses spring (9) 0 the 20 Cumalator pressure rises. The clutch of pres fre algo rises because of this rise in the ocumlator pressure ‘when the piston in accumulate (8) moves to the end ofits stoke, the iso in the ol pressure at por dis completed avd the spect fied pressure is maintained to completly ‘engage the REVERSE clutch, 10-41STRUCTURE AND FUNCTION PRIORITY VALVE Function +The priority valve rogues the datvery pros: sure ofthe pump, and ensures the pilot pros Ste andl oll pressure fer releasing the park ing brake. In dation, if he pressure in the cireut goes above tho’ specified pressure, it acts a8 Feliot valve t protect the hydrauli circuit, Operation +The ail from the pump is divided into two valve, and flows to the pilot creult of tho Tower valve, white te ether circu owes to poaty valve ( + The oil owing to prioity valve (1) passes through orifice (2) and Tows to port b. In this way, it overcomes the tension of re turn spring (4, pushes priorty valve (1) to the right in the civection ofthe arto, and flows to porte + Whon the pressure at port b goes above the sot prossute,pronty valve (1) Is moved fur ‘hor to the right m the cirsction ofthe arrow, land the ol is drained from port do protect, 10-42 TRANSMISSION CONTROL VALVE 2 vepervave ch ae Z| \ ‘=p ocr — tte 5 7 o/ 4b eeFrom pump bisin see vvs240asees STRUCTURE AND FUNCTION ‘TORQUE CONVERTER OUTLET PORT VALVE Function 2h torque converter outlet port valve i in stale in the outlet line ofthe torque eon \orter and adjusts the maximum pressure of the torque converter. Operation + "The oll at porta passes through the orice in spool (1) and flows to porte When the pressure at port a rises, the pros: suto at porte also rises. This overcomes the of spring 2) and moves spoot (1) to in the direction ofthe arow to allow fo flow trom port ato port B +I the pressure at port a becomes even higher, spool (1) is maved further to the left In the drection of the arrow, and the oi lows trom port ato port and dain port (Cola reer TRANSMISSION CONTROL VALVE ee eS 10-43STRUCTURE AND FUNCTION TRANSMISSION CONTROL VALVE PILOT REDUCING VALVE Function The pilot reducing vale controls the pres: sure used to dette ths directional eolctor Spool, Hi selector spool, range selector pool, and parking brale spool. Operation +The ol from the pump antors por a, passos tivough por b of pilot reducing spool (1, fnters spools (2) and 2) nthe lower valve, Bnd fils the pilot eet ‘The oll at port b passes though the ortice {and lows to porte + hen he pase inept et es, rm pone the poste pore sos. Tle ove ¢ ‘ores the fron of ting tana moves Plot roduing spool (tte ight ne Seton of he arom forthe estn por toe rea a pr port bare shut off, {5 maintained. 10-44 seanuszeoa ‘STRUCTURE AND FUNCTION TRANSMISSION SOLENOID VALVE TRANSMISSION SOLENOID VALVE 6. Pia ©. Spring 8 Valve seat 8. Body 10, Connector 2 a ‘ 5 10-45PILOT OWL FILTER ‘STRUCTURE AND FUNCTION PILOT OIL FILTER eovern Specifications : Filter mesh size: 108 10-46e240 [STRUCTURE AND FUNCTION DRIVE SHAFT DaIVE SHAFT outing The motive force trom the engine passes Lvough the torque converter and the tans Imission. Same off trananited torn rear drive shaft (4 10 the rear axle, while the rest ‘goes from conter drive shaft (3) through Mange bearing (2) and front drive shat (1) to the front aso ‘The driv shat has the following purpose in ation to simply transiting "Re power. ‘The drive shatt hag a univorsl joint and sliding Joint to enable it to respond to changes inthe angle and lens. This ens bls the dive shaft to tango fr shock from the road ‘machine i traveling 10-47STRUCTURE AND FUNCTION AXLE FRONT AXLE 1. itferontat 2. oilfiler 3 Brake. 10-48 4. Final ve 5. Breather 6. Level plog AXLE vs240avs240s ‘STRUCTURE AND FUNCTION REAR AXLE 1. Final erive 5. Breather 2. Brake 8. Level pug 2. Diferentiat 7 Drein plug 2 ont 10-49STRUCTURE AND FUNCTION DIFFERENTIAL FRONT DIFFERENTIAL, DIFFERENTIAL ‘Shatt Bevel gear INo. of eet: 41) Bevel pnion INO. of teeth: 10) Side gear (No. of teeth: 12) Pinion INo. of tooth: 10-50 Specications ‘ype: Spicl bevel gar, splash ub Reduction rato: 410 Differential typ: Torque proportioning, splash Iubrieston szaoesza0e [STRUCTURE AND FUNCTION DEFERENTIAL REAR DIFFERENTIAL —— — ‘Specifications Type: Spiral bevel gear, spiash ub Sido goar (No.of teeth: 12) Reduction ratio: 8.10 Pinion (No, of teth: 3) Diferential type: Torque proportioning, splash lubriestion 10-51[STRUCTURE AND FUNCTION DIFFERENTIAL outing 7 Te motive fore from te driveshaft passes ‘through bevel pinion {and Is transmito Bevel goar (8). The baval gear changes “rection of tho mative force by 80" atthe samo time roducrs the speed. I then mit the motive fore though ilferen” (a) to sun goar shat 2 When driving straight forward rnen the machine i even stesight forward, ‘he rotaing speed of hele and ight wheels ually left and right sun gear shaft (2. f> Wen tuning , Pinan ning, the rotsing speed ofthe oft {and nght wheels ren 0 piston gear it) and side gear (2) ade to cern ‘esa stn crane win the Ge | ference between the reating speed of the a TT tem and ight wheels. The motive force of to ll Wo) (than tramied to son gest Ue ise ak \ 10-52 us240susz403 [STRUCTURE AND FUNCTION TORQUE PROPORTIONING DIFFEREN- TIAL Funetion re Bocaus ofthe nature of thelr work, whee: ‘ive loaders have to workin places where the ‘oad surface a bad. In uh paces, te tres Sip the ability to work as a loader is rduced, Gnd aleo the Ife ofthe re is reduced. The Torque proportioning sifferenta is nstalled to ‘overcome this problem, + Instrvcture ft esambles the aiterenal of an Sulomobil, but ferent plnion goat 3) has fn edd umber of tet, Satause of the citer. nce inthe recetance fom the road sre, the positon of mesting of pinion gear 3) and Side goor (0) changes, and tis changes the trston of th let snd ight es Operation ‘When traveling straight equal resitane from road surface to left and right tre] cenit the resstanca from the road surfoce to the Tot and right whe between pinion na" of le ide ‘stance Between pinion gear (2) and meshing point b" of aft sido gear (3). + Therefore the lf side tation TL. and he right ‘ide taction TR are balanced, ‘When traveling on soft ground (esstance fom ‘road surface to lft and eight tes Is diferent) On soft ground, ithe tre on one side sips, the side goer ofthe tre onthe side sien has leas eetance frm the road surface ties 10 rotate forward. Bacau of thi rotation, the meshing of pinion gear (2) and side gear hanges +I atside gear (1) rotates slighty forward th distance between the pinion gear and the meshing point "a" ofthe of side goar be ‘omee longer than the distance between the pinion goer and the meshing port "b” of the Fight side gear. The postion is balanced os folows aeThebx TR ‘The ratio betwoon the dstances to “a” and "bean change 0 121.38, + Therefore hon th ratio of the distances to a" and "bis lose than 1: 138 (hat the ronting bat srinoe 2. Parking brake released When th parking brake swith is turned OFF, solenoid valve (1) 8 tuned ON, and tho dai cults closed + When the oil pressure at port rises, it ‘bushes egainst spring (3) and moves spool {2} to the right inthe direction ofthe arto. This ‘shuts otf the eran eruitof the brake ‘ylinde, so the ol from the main rei ows ftom port to porte to actuate the broke ‘ylinder ane release the parking brake, 10-103STRUCTURE AND FUNCTION PARKING BRAKE EMERGENCY RELEASE SOLENOID VALVE PARKING BRAKE EMERGENCY RELEASE SOLENOID VALVE smergeney release solenoid vave is in stalled between the breaks down and no. from the transmission pump, i is possible {o acwate the solenoid ‘or # 1 brake felease switen in the operator's compart ‘ant This sllows the accumulator charge cre 10 low to the 3 fom por. The circuit is Switchod by the pilot pressure, to the oll flows from port A to the parking brake to release the parking beak 10-104 Valve ase'y Solenoid vaive To parking brake From parking brake From plat clout Drain From brake (accumulator evel) paper Fromolctcest open fom pag | Eo vvezsoasso STRUCTURE AND FUNCTION. HYDRAULIC PIPING HYDRAULIC PIPING Outing "The hydraulic system consists of the work sauipment cireut and the steering elu. ‘The work aquipmont eircurt controls the ac of the bucket and atachments by yell pump (12). t ‘the spools for the bucket an boom in the ‘main contra valve aa atthe HOLD position, the main control valve are actuated by by ‘raulle pressure to send the oil fom the ‘main contrel valve to boom eylinda 15} oF ‘Bucket cylinder (2) to operate the boom oF bucket. + Contoi of the maximum prossure in the hy: ‘ral eu is cried out bythe Insido the maln control valve, A ‘i has stopped + Hyrule tank (4) is 2 pressurized sealed evipped with @ possibo to pres: i ana sls to pre. ‘ent any nogative pressure, thereby prevent Ing any cavitation ofthe pump, Main contol vale 9. Check valve 2 Bucket ovinder 10, Accumulator 5. Steering valve 11. Radiator 4 Hydraulc tank 412 Hydraulic pump 5. PPC val 18. PPC, brake pump © Solonaid vaie 14. Staring eyiinger 7. Switch pump 15. Boom eyinder @ Steering pump. 10-105STRUCTURE AND FUNCTION WORK EQUIPMENT HYDRAULIC SYSTEM DIAGRAM WORK EQUIPMENT HYDRAULIC SYSTEM DIAGRAM (Conditions: Engine at low idling, work equipment control levers at HOLD) 10-106 sz40aezaoe STRUCTURE ANO FUNCTION HYDRAULIC PIPING. WORK EQUIPMENT HYDRAULIC CIRCUIT DIAGRAM Serial No. 50001 - 50041 1. Hydrate tank Ott titer 2 Fiter 9, Accumulator charge valve 10, Pitt rolit valve E11 Accumulator 12, PPC valve 13. Steering valve assembly 14 Flow contol valve i Hl iE = 15. Rolf valve a 16. Steering spoo! 17, Overload rele valve with suction 18, Stooring eyinder ive 1l ese I ae Ba 38, Remote positioner shuttle valve 237, Auto lovaling shuttle valve 10-107 ®‘STRUCTURE AND FUNCTION. HYDRAUUC PIPING Seri No. 0042 and up Hydraulic tank oilfiter or Hyarauie pump PPC, brake pump Steering pump. ‘Switch pump Fier ‘Accumulator Pit rele valve PPC valve ‘Steering valve assembly Flow contra valve Rel valve Steering spoo! Overload reliet valve with suction Stooring cin Orbital vaio Catt valve Attachment spoo! Safety valve with suction Reliet ‘Bucket spoo! Sataty valve with suction Boom spool Suction vate Slow return vaive Boom oylindr ‘Buckat eyinder Attachment eylinr Oitcooter Stop valve 238 Emergency steering pump 235, Divider vale 38. Remote postoner shuttle valve 37. Aut leveling shuttle valve ge valve Tr are rif 2hSTRUCTURE AND FUNCTION WORK EQUIPMENT LEVER LINKAGE WORK EQUIPMENT LEVER LINKAGE 4. Boom lever 5 2. Kick down swteh é 3. Bucket lover 1 4 Attachment lover 8 10-108 Solenoid valve for bucket lover Solenoid valve for Boom lever Sa PPC valve ue2eoaszsoe ‘STRUCTURE AND FUNCTION HYDRAULIC TANK HYDRAULIC TANK 1 3 \ / AA 1. fer suction valve 4 oi iter 2 One 5 Sant mae 3 Seater &. fda one 10-109STRUCTURE AND FUNCTION BREATHER + Preventing negative pressure inside tank Th the oll the yaraule tank goes wil be negative pressure in the happens, 8 poppet Is opened by ‘iforonce betwsen the pressure insige tank and the atmospherle pressure, and ‘iris lt nto prevent napative pressure rom Torming inside the tank 10-110 HYDRAULIC TANK ody Filter element Poppet Sloove Preventing rise in pressure inside tank Ifthe pressure in the crcl aes above the Dressure during operations because of fhe change in the evel inthe hydraule Cylinders or the rise in the temperature, the Sleeve is actuated to rolease the pressure Inside the hydraulic tank szaoe[STRUCTURE AND FUNCTION PPC VALVE PC VALVE. APRRP 10-112 vs240aszsoa STRUCTURE AND FUNCTION PPC VALVE. Bort Coltse Retainer Centering spring ‘Metering spring Valve Body Function 1THe FPC valve is instalod tho work equipment contro! nected by a linkage to the co + Theil ftom the PPC pump is supped to the end af each spoo! of the rain contol valve in secordane withthe movoment of the contol over and his actuate the sp For this reason, the operating force of the conta! lever ix small and thi haps to re ‘duce operator fatigue 10-113STRUCTURE AND FUNCTION OPERATION OF PPC VALVE [at neutral Tootingae Tounk Tostnde + The ol from the pump entors por P. The rcut is ‘elosed by spool (8, the oll is ‘rained tom rll valve (1). [tthe same time, the ot at post main contol valve fs dsined from port # of p00. In addition, the cil at port PB Is drained trom port g of speo! (10 wrsnate one 7 10-114 VALVE vvezeoavsza [STRUCTURE AND FUNCTION FUNCTION OF PPC VALVE ‘The PPC valve supplies pressure oil from the harging pump tothe side face ofthe sp00! of ‘sech contol valve according to the amount of ttaval ofthe contro aver. ‘This prossure oll actuates the spool. Operation 1. Control tver at “hold” (Fg. 1) Ports PAs, Ps, PB: end Pr are connected to Grain chamber D tough fine control hole (tin valve a. 2, Control lever operated slightly fine contol (Fig 2 ‘hen piston 2 starts to be pushed by plate 10), retainer (5) pushed Vive (8) i350 pushed by sping 7) and moves down. When this happens fine contol hole i) i ‘hut off from grain chamber D. At sloost the same time itis connected to pump prs ‘sure chamber Pr, and the pilot prossure of ‘the contol valve fe sont through fine control hole fo port Pe. When the presse st port Fat seve rises, valve (8) pushed back. Fine con ‘wot hole If Is shut ft from pump pressure Chamber Ps. At almost the same time Its connected to drain chamber D, so the pros: Sure at port Pa escapes to drain chamoer D. Valve (8h moves up and down unt the fore of spring {7 Is balanced with the pressure of port Pe ‘The position of valve (8) and body (9 fwhen Fine control ola (is midway between drain ‘chamber D and pump pressure chamber Pr) foes not change unt the head of valve (8) comacts the bottom of piston (2, ‘Thateore, spring (7) is comprossod in pro portion to the travel ofthe control "where the pressure of port PAY (same ‘as pressure at port Pa) and the force ofthe Feuuen spring of the contro! valve are Bal tend, 10-115STRUCTURE AND FUNCTION Pc ave 3. Convo ever moved bak rom slighty oper sated position to hold (Fne control Fi. When plate (10) stars to be pushed back, piston (2) ia pushed vp by a force core ‘Sonding tothe foes of centering spring (8) ‘athe procture at pot Pa A the samme time, fa» contol hole (of valve (8) i connacted to dain chamber B, 50 the ol at port Pe escapes, the pressure at port Props too far, valve {80's pushed down by spring (7. Fine con two! hole fis shut off from drain chamber , and at almost the same time itis con nected to pump pressure chamber P. The Bump pressure fs supplied unt the pres ‘Sure at port Pas retunato a pressure eve lent tothe position of he lever. Wien the spool a the contra valve returns, the olin drain chamber flows ia fom fine control hole {fof the valve which has not ‘moved. The extra ol then flows thraugh port Pr to chamber PB, 4. Control ever operate to en of travel Fig. Plate (10) pushes pistor (2) down, and pia ton (2) frebly pushes valve (8 Fine contrl Role is shut ff from drain ibe D, and is connect to pump pros. ing ump passes through fne contol hole tf ‘nd flaws from port Bush the spoa! ofthe centro val ‘he oil returning from {rom port Pt tvough fin control hole (to ‘rain chamber D. 10-116 uszea‘STRUCTURE AND FUNCTION PPC RELIEF VALVE PPC pump ts not being actuated, o when Say aoa presure genres he sent fom the pump le relieved ‘ale to prevent any damage tthe pump Overaton “The relief valve is installed to the charge. valve Port Ais connected to the pump er Cult and port © connected to the drain ‘The cl passes through the cfice in main valve (1 and fils por B. In adaltion pilot poppet (is soated in valve seat (3. + When the pressure at port A and port B aches the set pressure, pilot poppet (4) ‘opens and the ol pressure at por B escapes ‘tom port B to port Cto lower the pressure atporB ‘Wien the pressure a port B goss down, 2 iteence in prestute Is gonorated at ports ‘A and B by the orice of main valve (1. Main valve (1) 8 opened by the prossure st rt A and the oat part Ais drained to port Gro relieve the cc PPC RELIEF VALVE Main valve Spring Valve seat Pilot poppet Spring Serow 2 a 5 6 a Bite cL oo 10-117‘STRUCTURE AND FUNCTION ACCUMULATOR (FOR PPC VALVE!) ACCUMULATOR (FOR PPC VALVE) Funetion 2th accumulator it insaiodbetwoont dhs ds > de abnormal pressure is ereated at port A suction valve (1) fs not actuated because of Felationship de > dh >, but relationship be- twaan port A and port Cis ds > de 80 main valve (2h receives ail pressure equivalent 9 the ctfernce betwoen the areas of de and ‘de the ol pressure reaches tho fore (set, prossuel of main valve spring (3), main valve (2hisaetusted, ane the el rom por & flows to por 8 Eeeeee MAIN CONTROL VALVE Suetion veve Main vale Main va Pilot piston Suetion vlve spring Valve bods sob de 10-123[STRUCTURE AND FUNCTION seis gonorated at which land di because of the “ank prassure st port E Thorefore, ol pressure movos the valve in the direction of opening, nd ol prssure ‘ats to mova suction valve 1) nthe dire tion ofelosing When the pressure at port A drops tan comes close to negative prossure), i be comes ower than hydraulic pressure @. The Felationship becomes a pressure e > ol Pressure a + force of valve spring (S), and Suction valve (1) opens to lat the ol rom or Bow into port A ard prevent any nega tive pressure from forming at por SUCTION VALVE , 73 Y , | 1, LIPS ae g as, LEP Function “This valve acts to prevent any negative pes: sure fom forming in te eeu Operation + "ifany negative pressure is generated at por ‘A boom cylinder rod era (when 9 pressure lower than tank ccut port Bis generated, main poppet (1) is apaned Because of the ditference in area betwesn dh and dy and lt, flows from port B atthe tank end 9 por A atthe evlinder port end 10-124 1. Main poppet 2 Sleeve 3 Spring [MAIN CONTROL VALVE vs240aus24oa STRUCTURE AND FUNCTION ‘OPERATION OF CUT-OFF VALVE Funetion “The cutoff valve Is mounted between the witch pump and work equipment val. It ‘itches the oil flow from the swich purmp between the working equipment valve and the desi, according to operating conditions land contols the speed of the work equip- Cutoff operation conditions Cuvof rain Not seated ito main control valve) 960 gtr 80 gem Operation . 2 ‘When the work equipment valve is held ‘Theol atthe such pump (the el from the steering valve) prossos up check valve (3), merges with the ol from the work feuipment pump and flows tothe work ‘equipment valve ‘When the work equipment valveis activated 1)" When the work equipment pump pres- sure is lower than the cut-off pressure As wen the work equipment valve is neste pur tthe oi steering valve presses up check ‘wath te ol fom the jump and flows to the ‘work eavipment valve. MAIN CONTROL VALVE Sm 10-125‘STRUCTURE AND FUNCTION 2), When the work equipment pump pres: sure is higher than th cut-off pressure Winen the cutoff presbure is reached, the pressure ofthe oll in chamber a opens {Eutoff valve (2), and the ol In unload ‘Valve (3}chambork pasces through cu of valve (2) chamter e and is drained. ‘The oi in unload valve (3) chambor passes through orfeese and f, into chamber b causing the ol pressure in ‘chamber d decrease, and unload valve {ito open. Thus, fe ol fom the switch pump is drained 10-126 MAIN CONTROL VALVE fe ve2s0auseage STRUCTURE AND FUNCTION MAIN CONTROL VALVE BOOM AND BUCKET SPOOL HOLD POSITION u © Sait ou + t + Tonyenuicank Frompune Toh tank somo enters port A from the pump, and + The ol rom the PPC pump passes through the maximum prossute i et by rele valve chook valve (13), and entre port of the am, PC valve. However the boom and Bucket + Bucket spool (1 i at the HOLD postion, 20 vers re at the HOLD pesitor,s0 the ol ‘the bypass cicutie open and the ol at port, ‘turns to the hydraulic tank from PCC rll ‘Apactes around the spool and flows to port, vate (12 '.'Boom spool (2 is also at HOLD, so bypass circuit is open and the oil at por B passes around the spool, enters por © of, the drain eel, passes trough the filter, fad returas to the ten, 10-127[STRUCTURE AND FUNCTION BOOM SPOOL AT RAISE POSITION 1 Tonystionne ron Operation + "When boom lever (3) is pulled, the il lows from port Lof the PPC valve to port Nand ort 8. In addition, the oat por T pass {through port Mand flows to the drain cit- “Tho ol pressure at por § pushes boom spoo! (2) and moves ft the AAISE position, + Theil from the pump passes through the bypass crcut of the bucket spool and flows 10-128 MAIN CONTROL VALVE ‘Siro Snr 8 4A t to the bypass circuit of boom spool 21. The Dypaue circuit i losed by the spool, o th fl pushes open check valve (10). The oll ‘ows fom por H to port, and flows to the ‘eyliner bottom, + Bethe same timo, the ol at he cylinder rod ‘ond enters. drain port € from port K and Fotuens to the tank: Therefore, the boom vs2403vsesoe ‘STRUCTURE AND FUNCTION BOOM SPOOL AT LOWER POSITION t t Operation + "When boom Iever (8) is pushed, the ol ows {rom port Lof the PPC valve to port M and por T In addition, the oa port § flaws fhe drain ceut ol pressure at port T pushes boom spoo! 1d moves Ito the LOWER position +The all fom the pump passes through the Dbypaes circu of the bucket spool and flows {0 the bypass crcult of boom spoa! 12). The [MAIN CONTROL VALVE ig ese ft Sanat ume t 4 Taya tnt bypass circuit is closod by the spool, o the fll pushes open check valve (0). The oll flows trom part. to port K, and flows to the cinder tod ends + AL tho seme time, the oll at the eylindor 10-129STRUCTURE AND FUNCTION (MAIN CONTROL VALVE BOOM SPOOL AT FLOAT POSITION 1 + + + Tonydrusictnk From pump Toya tk el Operation +" When boom lever (is pushod to the FLOAT + Therefore, the oil at the cylinder rod ond position, the PPC valve spool moves beyond ‘lows from port J to port €, and flows tothe the LOWER position to the FLOAT position, dain circuit. The oil at the cylinder bottom ‘ll at port L flows to port Mt, flows from port Ito port C, and then flows sme ime, It also flows to port T. to the drain circuit. Therefore, the boom is Inaddition, the pressurizsd oll at port $ flows set to the FLOAT condition. 10 port ‘+ Tho pressurize oil at ort T pushes boom poo! (2) to the LOWER position 10-130 x20vve24oa [STRUCTURE AND FUNCTION BUCKET SPOOL AT DUMP POSITION MAIN CONTROL VALVE ene # i + i} & A \\ vio abies rk t Tohysic tink Frompume —— Tohnatan — Operation + When buckst lover (is pushed, the pros- ‘sure oil at port L of the PPC valve flows, {rom port @'to por V. In aéitin, the oil a por R flows othe drain ecu The pros {ure ol t port V moves bucket 89001 (1 t0 the DUMP pesition +The bypate coulis closed by bucket spool (1),50"he ol rom port A pushes open check value (9). The ll fom check vave (8) os ftom port Fio port G, and then lows tthe linda rod ond. [At tho same tim, the oll at the eyindor bottom flows from por to crain por, and returns to the tank, so the bucket is ‘umpc! 10-131STRUCTURE AND FUNCTION MAIN CONTROL VALVE BUCKET SPOOL AT TILT POSITION S \ ¥ vie gw t Operation + PW buckot lever ()ispulled, the pressure cil at port ofthe PPC valve flows trom por P to part R In addition, the oll st port V flows tothe drain circuit The pressure ot at ort R moves bucket spoo! {1} to the TILT Postion 10-132 Taya tnt Shas + ‘The bypass criti closed by bucket spool {11,s0'he al fom por A pushes open check valve (5). The ol fom check valve (9) flows {tom port Dto port and then flows tothe elinder botr ‘A the same time, the ol at the cylinder rod fend flows trom port to drain por C, and Fetuens 1 the tank, £0 the bucket ested usewea‘STRUCTURE AND FUNCTION WORK EQUIPMENT LINKAGE 41. Bucket 2. Bollerank 5. Bucket evinder 10-134 ae Boom eylinder Boom Bucket link WORK EQUIPMENT LINKAGE veza0ae240 [STRUCTURE AND FUNCTION, WORK EQUIPMENT LINKAGE 10-135STRUCTURE AND FUNCTION ucKeT BUCKET 1. Bucket 2. Bolton euting edge 3 Bucket tooth 10-136 vve24oasean [STRUCTURE AND FUNCTION ‘BUCKET POSITIONER AND 800M KICK-OUT BUCKET POSITIONER AND BOOM KICK-OUT Proximity switch a ein rod 10-137STRUCTURE AND FUNCTION BUCKET POSITIONER “The bucket positioner ean electrically act ated system which is used to eet the buckst to the desired angle when the bucket is ‘moved from the DUMP postion tothe TILT Position, When the bucket reaches the de ‘Sted position, the buctst lever is returned {rom the TILT poston tothe HOLD position, {and the bucket is autamaticaly set to tho Sultable digging anal. + Lever (ais secured to bucket cylinder roa {31 by bolts In ation, proximity swten (1, fixed 10 the cylinder by bolts. position tothe TILT postion, the bucket cy ide rad maves tothe ef ang atthe same ime, lever (alsa moves tothe left. Prox Imity switch (1) seperate from lover (4) at the desired postion, andthe bucket lever is ‘returned to neutral 800M KicK-OUT ‘The boom kik-out ie anelectrially actuated system. It acts to move the boom lever tO ‘the HOLD postion and stop the boom atthe desired position betore the boom reaches the maximum height. + Plato (8) Is xed 10 the boom. in adaltion, proximity switch 2 is xed to tho Frame ‘When the boom is moved from the LOWER position to the RAISE poston, the boom fises, and when i rescies the dosred pos! {onthe proximity swish end lever come together and the system is sctusted 10 e- tum the boom lever to he HOLD position 10-138 WUCKET POSITIONER AND BOOM KICK-OUT sewsvvezaoa ‘STRUCTURE AND FUNCTION Operation of proximity switch Boom RAISE. ‘When the boom is lowor than the sat posi tlon forthe kik-ou, the detector ate! pate) ie nat above the detection surface of the Proximity switen, s0 the. proximity slich ot \Whan the boom levers moved tothe RAISE positon, the boom spoo! felt atthe RAISE positon by the cam follower and eam on {he lever, and the baom rises. [BUCKET POSITIONER AND BOOM KICK-OUT q ie eS A i: ial iE |: 10-139[STRUCTURE AND FUNCTION ‘+ Whon the boom rises and reaches the set position forthe kck-our, In other words, the Setector (tos! plate) isin postion on the Setection surface ofthe Pr proximity switch, an flecuic currents sont the solenoid by the faction of the proximity uit As a result, the fnd the cam ie plea Getent so the lit spoe is fetuned to. the HOLD position bythe turn spring. uiten and roay ci. olenald ts Settod, Keou sid ‘wey trom the cam er 50m gen ° < a me) Fee TR eS esteem ames inane ea ‘st detection surface of proximity site from detection surface of proximity switch ‘ctution display Lah up Goes out Proximity switch (rola suite eeu Curren ows CCurrnt is shut of eouen aoc aaa Current ows Current is shutoff (solenoid circuit) 10-140 vve240aue24oa STRUCTURE AND FUNCTION JOKET POSITIONER AND BOOM KICK-OUT Operation of proximity switch Bucket TLT Pane buckets lve hn the st pos spas reset ace ea vo sia ex sve eon soe st Retusha peninhy suche tee rer fows he pony seo stan cer te! ee oe ram 7 Sarath wana whe ot re — st eo SS cs \ + When the bucket lever fe moved tothe TILT position, the DUMP spool is held at the TILT position by the cam follower and cam on fh lever, ana tho bucket fits Posner stnle Proximty Sten 10-141STRUCTURE AND FUNCTION BUCKET POSITIONER AND BOOM KICK-OUT + When the bucket tits and reeches the set position for the bucket love words, the detector (ste! plate) separates Of the proximity ‘wtch, electnie current is sent to tho sole hold by tho action of the proximity switch tom the detection surf ‘and relay cut. [AS a result the solenoid is actuated, 1 away from the cam detent the DUMP spool Is veumed to the HOLD postion by the retum spring cam isp ‘Action of proximity siteh in other peat T Postion ‘When detector isin position is detection surface of proximity switch ‘When detector ie soparated ‘rom detection surface of roximity ston Proximity switch sctuation display Lights up Govs out Proximity witch load cut (rolay swith excut) Curent tows Curent fs shutoff Relay switch load circuit [solenoid circu) 10-142 Curent fs shutoff Curent flows a sesoe[STRUCTURE AND FUNCTIONSTRUCTURE AND FUNCTION AIR CONDITIONER AIR CONDITIONER PIPING {AIR CONDITIONER vent Window defroster 10-144 Air conditioner condenser Compressor Arcondlioner condenser Air conditioner unt vs2s0gELECTRIC CIRCUIT DIAGRAM (1/2) Serial No. 50001 ~ 52909 a REESE ET a = E s eT 10-146 @szaoa Fae a Le. TEE cr ETE TEES EEE 10-147(2/2) Serial No. 50001 ~ 52899 aE EEE EE Tevue2eoa x EEE REET 10-149ELECTRIC CIRCUIT DIAGRAM (1/2) ‘Seria No. $2001 and upsoveen v ev FEE. EES Pe RE o Ea EE On 10-149-2(os (= ES (2/2) Serial No. $3001 and up ae z HEA cee 10-149-3, ®usados W eo aa Pe ao z ES r EL v ESE EL x Ey z 10-149-4 ®vezaoa ELECTRIC CIRCUIT DIAGRAM WORK EQUIPMENT CONTROLLERELECTRIC CIRCUIT DIAGRAM 10-152Sf) inane ELECTRIC CIRCUIT DIAGRAM AUTO-GREASING 10-153,sean ‘STRUCTURE AND FUNCTION MACHINE MONITOR SYSTEM ee [MACHINE MONITOR SYSTEM ‘casera war / | \\ machine monitor system uses the sen sors and other devioes installed To various parts ofthe machine to obsewve the conch tion ofthe machine processes this infor. ‘mation sity and clepiays ton the mont. = {or panel to inform the operator ofthe con- tition ofthe machine, system consists ofthe is, lar buzzer, and fore, smitehes, power soutes. ‘The deplays can be broadly divided into the following: Cautions displayed on the mon: tore (abnormalities inthe machine whore 99 Slat is given) and normal conditions whieh fre lvaysipieyed onthe instument panel [plot lamps and readings for the geuges, Speedometer, and sevice meter. There are algo various switches built into the monitor panel which function operate the machine. ‘when the optional controller se installed, the main monitor communicates with the contaller though the network witlng and functions 10 display the contalerfelure 10-155‘STRUCTURE AND FUNCTION MAIN MoNTTOR MAIN MONITOR 4G wD Mac wy 2 VT PP? 1. CHECK Lamp SC. Hi beam Switch 2. CAUTION tam 4. Shit incestor A. Auto greasing suitch 3. Caution tam 4€. Spoedomet 5B. ECSS. ewtcn SA.Emorgency steering af. Parking brake 5C. Working lamp font) actuated 4G. Emergency steering normal swten 4 Pilot tom 42H. reheating 5. Working lamp rear), 4A Turn signal (eh) 4 Falure action code ‘teh 48. Turn signal ight Se, Teams ‘teh outine 1 THe main motor hes 2 daplay function for signals trom the sensors and outputs the the speedometer and ether gauges and Sipiay. ‘itching function te contol theeletriccom: +A iguld crystl dgplay snd LEDS are used ponents and controllers, + There is one CPU (Cantal Processing Unit) lad internally, ad this processes the ‘The siitches are embossed vrza0ae240 STRUCTURE AND FUNCTION MAIN MONITOR DISPLAY FUNCTION ‘main MONITOR Day Barley | symbot | Delay tom Dispay tongs Diray metog| ‘ipiay Tasos dor din ooo eck cnet MialnfeNance MONTOR ° ImSitonandemonfor” | OSPLAY FUNCTION Enaraarey womeg | yen scruaed Dispiy snes orhing brake Stadia fabs nd aor caston ie sin 9) | contin we Diely testes taser ney ta fb dun or eae tes rary apy on | ROSTER gua maintenance monitor” | Bigmay FUNCTION) BD) | Hvean Won operated Dispay ahs op = {Taras ‘When operated Dispay oh Bienen atin ZW |renina ote | man oper Seer rganse ear SL |Saggrrerssrrm Rowe ttle | oan toe ue tas Rng pe charges bcorcng engine ate Prabetiog nes poening | femprntre wen ern 8 bo Serre ten Se'eneueatine ourrur Foneion ‘ia oly apy aetcen seems | FEAIED | met eneet 0-993 Eeben tenon an Shae | AP | svi dean Digital say Wan canola detec {stun scton by | Digital disatey con Jon code | EAL datyed | (ror dents ofthe ve ota ES” | SES [Fete ccton code | eNcaii ans 210 | apy mode one TROUBLE (Gcton cog) are Baa bISALAY Moe 10-157STRUCTURE AND FUNCTION. MAIN MONITOR SWITCH FUNCTION MAIN MONITOR Tom Funston Display ‘atunon ate up goes out | Ato greasing conto! actuated momentary when | (utomatic gresing cried urogessing | Forced anasing is cared out | Fashes stowy) | Grease emery Sen Biya aneapamy | AERA nana ‘Goes out ‘Auto rensing contol not ross. CSS. tunation ie actuated or | Ugh up CSS. funtion acne pressed “Gone out CSS. function topoed wwoning amp | remrtinaame take its up Front working amp hts UP "ron Sonaug mmeree Front working lam goes out Rear worting tmp thts oF | Lites up oar working lamp ahs up ‘wering temp | goas out sacn time swen ie | 4 a (ean Pressed when sel ae fgred op ‘Gone out ear werkng lamp goes out ‘ronamnsion | Tasemiaion cut funeon a | Ugh up ‘Cato function aeuted cot sch i esse8 “Gove oxt Cutoff fonction topped 10-158 us2woauses ‘STRUCTURE AND FUNCTION MAN MONITOR PREHEATING OUTPUT FUNCTION Elctrial intake sirheater ‘Actstion Powwe — % Staring oN signal ermal) opp Display output Relationship between engine water temperature and alspley ane output time Dispay time } Tee! ! Ouiput tine ' Taba) ' Engine water temperature (C) 10-159 @STRUCTURE AND FUNCTION MAIN MONITOR ‘TROUBLE DATA DISPLAY MODE (when optional controller are installed) trouble dor slay ‘mode sto of sensing sth tured ON. press 2nd sch from top oni side of main rmentor (wich below emergency ering pay) end working lamp Ura switeh smataneousty torat teas 8 seconds ross wortng la tron eh = \ 2 ‘Al etch aeploys (LEDS) go out and {ature coves cepayes on speedometer ‘lepay and ie lpaad ance fire is finpayed on fare action code ape {1) ral cde = two-tign apey ie display forthe fre now Decurting hes sna the elo fr Pst flcas phe up FFtherei'm ure, CC i pte [000 eeplyed for time sapeed leaves a8 vonage number to show how long ago the fre Drcurred te eldest lure Se it {00H apoyo ae 00H, In tmamory for he fare code Faure code and time eapsed since aes) ‘lorng tire code Pre working lam ea switch forateat 2 seconds (= {209 for prebiom now ocerting sehing deplay| cannot be lard fide of main monitor (eth blow fmegency steering spay ens ‘wowing lamp thon seh Sirutaneousy frat east Changes 0 normal ply 10-160, szsoeszaoe ‘STRUCTURE AND FUNCTION [MAINTENANCE MONITOR STRUCTURE AND FUNCTION _____ MAINTENANCE MONITOR MAINTENANCE MONITOR 04 SA 9B IC aA aac aD 3 Gauge items 4c. Remote bocm ‘3A. Ful level positioner RAISE 438. Engine water tempera: Postion set sith 1B. Engine ol level wr 40. Remote boot Caution items (vering 36. Torque converte ot positionor RAISE/ tems! temperature LOWER selesorswiteh 2A.Engine ol pressure 4, Work equipment contol 8, Service meter 28. Batey charge switches 5A. Service mater numaric 2C. Brake oil pressure 4A. Bucket auto loveor set 20. Air cleaner ‘witch (1A. Engine water level) 48, Bucket auo-oveier pilot lamp automode sultch 8. Monitor module 7. Switch module tine ‘The maintenance monitor has a display fune- +The monitor module hes bir CPU (Cen tion fr the caution toma and gavges, and tral Processing Unit processes the signal ‘swtchTunetions to control the work equip from the sensors, and caries cit the dle ‘mont controle. play and output The maintenance monitor consists of the + A liguid crystal display and LEDS are used monitor module, switey module, service for tho display portions. The avitches oro meter, case, and other mechanism. embossed sheet switches, 10-161STRUCTURE AND FUNCTION (MAINTENANCE MONITOR MAINTENANCE MONITOR DISPLAY FUNCTION Bipley | symbot | dipey tom Disoly range Display method 1 | Frawarient [Bow wt | ip wen agi woop ond aning ouch ON neck ‘Binty hen norma: OFF 1G | Eeseestowe Bet tw tat | Bei men Str Fn HB Paneer eae ee | Biplay wen ermal OFF Dipay amen sonormal Fischer WG | Fost pve | Ble peng EURO shew @ | Proteome | Boon once GI | Froese toms] ato roe ‘Torque converter il | Above 120° ‘Buzzer sounds i ebove 130° cawion | | nent Footie ‘cio ow lve! | Dapova when engine is rnning ry ‘ply when norma OFF ile when normal: Fshes ERUTION lop Hoahoe| coc gis whe eran ro ® hore eos aod “Bic lamp fester QR [er = 98809% ‘aie when are arora onsen — isseen cer ee ° anna Foal ial ‘Al lamps Wht up below epocabe Engine water temperate] ________| One pace Nght unt show couges uae” | Semeabie evr 2 a\B Ons eae ow show shes won lve is 6 or 10-162 seane202 ‘STRUCTURE AND FUNCTION [MAINTENANCE MONITOR MAINTENANCE MONITOR SWITCH FUNCTION ern Function Bispley Actuation Bucket auto: | Sting avtomais stopping | eiahes (2 topping ara Iowier eating | angle for bucket o fork bucket 20) | See w Bucket auto” | Swtchos ato mode bowen | gts up Bucket atolovle wo mode Towle auto | ON and OFF each me swtch oN Remote woom | Sete stopping poston i AISE | Fssnes 5.90) | Som stopping poniton postoner RAISE | rection for rote oom eee postion seting_ | positone ibeom postion when ‘wtoh = presad in vecordea) | GOS out - remote oom | instopping direction (switches | COM OM function OFF planer RAISE) funtion each time switch toweR rested) RAGE lights up | Rema BOOM positoner RAISE ‘op function ON raise, owen | Remoto boom postioner ane up AISELOWER sto ‘clon ON 10-163SYSTEM STRUCTURE AND FUNCTION WORK EQUIPMENT CONTROL SYSTEM ‘SYSTEM STRUCTURE DIAGRAM Peles [ott bee] a PL pg ta ect ofecmmseasee fo fo fe] [Le brea > [eter ea =| 3 peter a3 2 erg ped z 2 2 Peis 3 [| evel wet 2 ° > ens = ° Sepia [ares sw —[ > + 2 [min | Pe Pue sigal ‘CONTROL FUNCTIONS [— Aut leveling funtion [— Bucket angle compensation contro 1 Bucket automatic stop contrat |X Remote postionar function |-— Boom LOWERIRAISE position stop | Boom RAISE stop position st [— Remote & leveling function [— Sensor adjustment function [— Mode selection function L__ Troubleshooting funetion outing ‘Because of the structure of the Zar link work equipment the ange ofthe work equ ‘ent to the ground changes according to the height. “The autolveling contrat keeps the angle to ‘the ground constant regaaess af the Height of tho work equipment This makes i easy to control oporations such as removing the lose trom the bucket, 10-164 withthe remote positioner control the op trator can set the boom stopping [lever Kick fut) postion tothe desrad position, This ‘makes the moverant smaath when starting fr stopping the boom, and makes It safer land easier 10 operate the machine when ‘moving back, carrying out digging opera tions, or sporoaching dump tusk, vusz403us24oa ‘STRUCTURE AND FUNCTION WORK EQUIPMENT CONTROL SYSTE EM, ‘STRUCTURE OF WORK EQUIPMENT CONTROL CIRCUITSTRUCTURE AND FUNCTION WORK EQUIPMENT CONTROL ‘SYSTEM FUNCTION. ‘Autoeveing function 11 Bucket angle compensition control +The controler aways caleuates the an also the work equipment othe ground ftom the value of the voltage of the potentometor (angle sensor) installed to {he rotating part a he bucket and boom. +The range forth control is imite, and tthe work equipment i within the range, this contol is earind out by setting to the auto mode. The control range is do. termined by the peaiton of the bucket and boom, and if thay are outside the ange, the contr snot eared out +The control is eared out to keep the angle constant by astomaticaly contro Ting the bucket vik and dump solenoigs ‘according to the angle to the ground {which changes in comparison withthe angle (position ofthe boom. + Control range irom horzontl 0°) + Manual (ever contol) priority: Ifthe bucket lever is operated during this can- tol and the bucket set tothe desires angle the angle to the ground when the Tevor is returned to neutel wil become the now contra target angle, (Howey thes only ifthe work equipment lwthin the contol range) 2. Bucket automatic stop sontrol "Set the bucket to the maximum dump {and place the bucka over the detent. the Bucket reaches the horizontal Stops. The sot poston is retained even Ifthe kay is turned OFF 1), Seting desived stop position IN" Oporate the buckt lever to de termine the postion (-30°— {F157 thon set the lever to HOLD. ly Proge the auto levelar st suite li) When the auo-evelar lamp goes fut, the actoleveler set lamp will Mash 25 ses) 10-166 2 WORK EQUIPMENT CONTROL SYSTEM |v) When the autodeveler sat lamp ove out and the auto-leveler amp tights up, the stop postion {is written to memory Setting horizontal postion stop i)" Operate the bucket lover to de termine the postion (20° — 115%, then set the lever to HOLD. 1) Pross the autoloveler sot sitch wy ro-eveler lamp goes to leveleraet lamp wil while the lamp fs lasting. w) The auto-leveler set lamp goes cout immediatly, the ato. lover amp lights up, snd the horizon tal angle Is se. (This horontal langle ls the standard forthe ma 60 the work equipment ‘may not necessarily be herzo- {alto the ground for reasons such 135 the weight of the work equip ment oF the angle of the ms chine e240sza03 STRUCTURE AND FUNCTION REMOTE POSITIONER FUNCTION 1. Boom RAISE/LOWER postion stop +The conllr sways detects the cloc- tion of operation of the lever from the pressure switch installed to the boom PC valve andthe angle (position) ofthe boom from the boom angle 4) RAISE kikeout (RAISE lamp ON) ‘When the boom lever Is placed in the RAISE detent andthe boom rises te the set poston, it slows down ‘and then stop, and at tho same tir the dotent i rolased. ithe boom st any postion other thon the RAISE ‘tent it wil ise as normal 21 LOWER boom stop (LOWER lamp on) TF the boom lever is placed at the FLOAT or LOWER position and the boom goes down tthe sat poston, itil stoe down and stop. Hf the wil stay stopped. Ifthe lever Is ‘moved back slightly, the boom will {90 down again, ‘Tho RAISE postion (which the op trator can set to the desired pos tion) 'and the LOWER stop poston fifr according to the model. For Sap Eottion! aise | Lowen Mode! wasoa ease] 2 wase0.3 [0 0s-| 27 wawzo-a | 0-20 | -26 wasro-a | 0° ae | 26" The setting of the control can be changed in the order given below by pressing the mode positioner RAISEILOWER selector sultch. Won the lamp is lighted up, the boom ‘ail sutomatialy stop st that pos WORK EQUIPMENT CONTROL SYSTEM Setting remote positioner (setting RAISE stop position) ‘When the RAISE lamp is ON, set the stop position as desited. The setting poston is fetained even when the key ls urned OFF 1 Sating stop postion 1)" "Operate the boom lever to decide the position (above horzontall, then Fotuen the lover tothe reat. ly Prose the remote positioner set li) The RAISE lamp will go out and the amote positioner set lamp wil fas, (25 sec) ‘Whar the remote positioner st lamp ‘go0e out and the RAISE lomp lights Up, the stop position ix writen to 2) Setting horizontal stop postion IN" Operatathe boom ever to move the boom to postion above horizontal, thon return the lever to the neva. res the remote positioner set li) The RAISE lamp wit go out and the remote positioner sot lamp wail flash, Iv) While tho amp is flashing, pross the remote positioner set swith, MI The remote positioner set lamp goes out immedissly end the RAISE lamp lights 2p, and the horaontal angles sc (Ths hor zontal angle Is tho standard for ‘the machine so the work eauip ment may not necessarily be horontal to the ground for ree fone such a8 the woight of the ‘Work equipment or ne angle of the machine) 10-167STRUCTURE AND FUNCTION REMOTE LEVELING FUNCTION When using the auto mode with the remote positioner LOWER lamp ON the following bucket ontrl can be eared out bv operating the boom 1) Boom lever LOWER detent \Whan the boom is lower than the horiontat position, the bucket itis controlled and the ‘bucket stops atthe LOWER postion withthe ‘bucket horizontal tothe ground 2) Boom lever FLOAT detent + "The boom wl fl under its own weight 0 the work equipment moves quickly ‘The bucket tt contol is started regards less ofthe position, the boom is stopped at the LOWER sto> position, and the Bucket is sot horizontal to tho groune. + For bath lems 1) and 2,9 damping so lenoid ie used to rece the Boom speed ftom lust before the set stopping point im order to reduce the shock when tho work equipment sts. SENSOR ADJUSTMENT FUNCTION + This function offsets any error caused by the Installation of the poterdiometer and makes Itpossie to detect he correct postion data for the work equipment ‘Always carry out the bijustment when the Controller, potenomete; or work equipment ae replaced (For deals, see TESTING AND ADJUSTING.) 10-168 [WORK EQUIPMENT CONTROL SYSTEM MODEL SELECTION FUNCTION + This contller has data tables forfour mod. ls, and can handle these by means of the foliowing selection signale when the key ie turned ON. (See Table 2) + Who the kay is turned ON, the selected ‘models sisplayed fr 2 seconds onthe con- ler LED. + Ifthe te any error in the model seletion, (8) is displayed Table 2 ‘TROUBLESHOOTING FUNCTION + The controler always observes if the elec: teonie devices the potentiometers which ro feive the input signals, and the solenoid lahich receive the output signals) re func Soning normaly + Hany abnormalty should occur in hese de vices, the controlar judges that there an Abnormality, displays the abnormality as 8 failure code on the main monitor and warns the operotor of the abnormality. {For detalis, see TROUBLESHOOTING OF WORK EQUIPMENT CONTROLLER SYS- Tem)vs24og STRUCTURE AND FUNCTION CONTROLLER WORK EQUIPMENT CONTROL SYSTEM 1. Modal selection depay portion 2. Connector ent ‘eN2 cna — CONNECTOR SIGNALS cn cna. cons, 10-169[STRUCTURE AND FUNCTION POTENTIOMETER a WORK EQUIPMENT CONTROL SYSTEM 1. Connector 5. Boating 2 Case 5 Contact 3. Shar 1 Mold 4 Eloment §. Est Be 32) i po é é Funetion “Tho boom angle potentiometer is installed to the front frame boom mount and the Bucket angle potontometer Is Insalled to the boom belerank mount. They att detect the angle of the work equipment. Inside the potentiometer the SV power source voltage trom the angle is canverted to signal Voltage by the resistance valve of the variable str, and this is sent to ‘he controle. 10-170 In the diageams sbeve, the hatched area ie the abnormal detection aro, and Ht the con toler caves this signa, judges that there is. eisconnection, short creult or other ab normality in the potentiometer system. In ac dition, ifthe correct position cannot bo de tected, the controler shuts off the contro! ‘utput and alplays flute code on the main vuez403szaoa STRUCTURE AND FUNCTION E.C.S.S, (Electronic Controlled Suspension System) 1. ESS. (Electronic Controlled Suspension Systom) + This system uses a combination of oioving the hydraulic ll from the work equipment land switching ONIOFF an accumulator which is charged with high pressure gas. The con troller aries out tomatic contol of these in accordance with the tovel condition of the machine to give rsilance tothe up and down movement ofthe work equipment nd te suppress the vibeation ofthe chassis when tavaling at igh speed. In this way, it iw proves tho ride forthe operator, prevents {plage of the load, and improves the ope ‘tng afioncy. + Special solonold vlves (ON-OFF valves) are Used to contol the ON-OFF aitching of he Becumulatar thigh pressure, low pressure) ‘ana the opening and closing of the relict ‘valves + With this syst, itis possible to handle four models (A220, WA3EO, WAA2, and WAG7O) with the same system simply by ‘changing the connections of the model so lection wiing harness. 2. Structure of syste ‘The ECSS, consists of the following ele tronie viens 1)ECSS controler IM type contol) 2} Input deviees: ECS.S switch Iaystom site), pressure switch (boom evinde Bottom pressure), wavel speed sonsor, ‘adel selection wiring hammoss, speed ange selection wiring harness 2) Output devices: solonand valves (clot valve, high pressure accumulator, low pressure acumolotor Ecss. ‘wag Set conminaton Siew — 10-171STRUCTURE AND FUNCTION ecss. 3. Content of contro 1 InTesponse to te input on the loft side of the table Below, the controller caries out th ston the nh cone Se on : nor Tat Ow ECS awich | Spondon ate 21 | Tel pars | Sour [Soin Salant evar ON Foon [Presa | Sno |g | tow iWon” | mt [ sorea | weress | SH | vatan prune [ras =| _oFr : E : ee or | oF 2 oF | ON | min simn | ow o | x ox | en 3| ow or [ov |mnsinn | or | o | o | o ou | ow FI ~ | BiB] Reed Note 1: TeECS.S sysomis switched ONOFF — Note 3: Input pulse frequency when travel by operating the EC'S saith on tho speed ft kn main mentor ar Be TaquaNEY FA When the sytem is ON, the CSS a LED dieplay on the main montr Hoh & wase0 a7 ‘The ON OFF condion of he sytem i= waa2o 2036 ‘eteines ven afta the engine stops oF WAa7O. 8 the starting swter is turned OFF, The ext time that the starting switch 's Noto 4: Ifthe travel speed exceed 5 kmh winen {ured ‘ON, the ststom is sotto the the output OFF, the output is turned Same condition as before was turned oN. OFF. ‘When the output is ON, the output stays {Main monitor funtion) (ON unt the travel spe reaches 3 kmh Switch OFF Machine stops land when the travel spoed goos below 3 1 sitch ON ken, the outputs tuned OFF. [iter system i 01 sytem ON \Wnen system is OFF > Systom OFF Note 2: Relationship between speed range sg- nal and shift postion oN it postion Speed range ore cn ‘Speed Bao Senet iat ‘OFF ON. 2nd OFF ‘OFF tre enns aed ON. OFF — cc ON. ‘ON. ‘ON: +24, _ OFF? OPEN 10-172 vse4oa