Shop Manual Wa500 PDF

CEBM001202
SHOP
MANUAL
WA500-3
WHEEL LOADER
MACHINE MODEL SERIAL NUMBERS
WA500-3LE A70001 and up
This material is proprietary to Komatsu America International Company and is not to be reproduced, used, or disclosed
except in accordance with written authorization from Komatsu America International Company.
It is our policy to improve our products whenever it is possible and practical to do so. We reserve the right to make
changes or add improvements at any time without incurring any obligation to install such changes on products sold
previously.
Due to this continuous program of research and development, periodic revisions may be made to this publication. It is
recommended that customers contact their distributor for information on the latest revision.
CONTENTS
01 GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-1
10 STRUCTURE AND FUNCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-1
20 TESTING, ADJUSTING, AND TROUBLESHOOTING . . . . . . . . . . . 20-1
30 DISASSEMBLY AND ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . 30-1
40 MAINTENANCE STANDARD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-1

90 OTHER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-1
00-2
PRODUCT PUBLICATIONS INFORMATION
VARIOUS PRODUCT PARTS & SERVICE PUBLICATIONS ARE AVAILABLE TO ALL KOMATSU CONSTRUCTION
EQUIPMENT OWNERS, INCLUDING OPERATION & MAINTENANCE MANUALS, PARTS BOOKS AND SHOP
MANUALS.
SPECIAL PUBLICATIONS SUCH AS SERVICE TOOL, AIR CONDITIONING, AND TURBOCHARGER SHOP
MANUALS ARE ALSO AVAILABLE AS WELL AS SELECTED OPERATION & MAINTENANCE AND SHOP MANUALS
IN FOREIGN LANGUAGES.
THE PUBLICATIONS LISTED BELOW ARE AVAILABLE FOR THIS PARTICULAR MACHINE(S).
DESCRIPTION FORM NUMBER
PARTS BOOK - PAPER:
Engine and Chassis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BEPB002201
PARTS BOOK - MICROFICHE:
Engine and Chassis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BEPM002201
OPERATION & MAINTENANCE MANUAL:
Chassis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CEAM001400
Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3666095
SHOP MANUAL:
Chassis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CEBM001202
Engine:
Shop Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3810487
Troubleshooting & Repair Manual - Base Engine . . . . . . . . . . . . . . . . . . . . . . . 3666142
Specifications Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3666090
Standard Repair Times . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3666031
Performation Degradation Troubleshooting Procedure . . . . . . . . . . . . . . . . . . . 3666006
Outer Base Circle Overhead Set Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3666007
Overhead Set Specifications Service Bulletin . . . . . . . . . . . . . . . . . . . . . . . . . . . 3666089
SAFETY MANUAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WLT70-1
PARTS AND SERVICE PUBLICATIONS CAN ONLY BE ACQUIRED BY AUTHORIZED KOMATSU DISTRIBUTORS,
USING THE KOMATSU AMERICA INTERNATIONAL COMPANY PARTS INFORMATION PROCESSING SYSTEM
(PIPS).
IF THE PIPS SYSTEM IS NOT AVAILABLE AT THE DISTRIBUTOR LOCATION, THEN THE FOLLOWING
REQUISITION FOR TECHNICAL SERVICE PUBLICATIONS AND SERVICE FORMS CAN BE USED. FORM KDC91D
IS SHOWN ON THE REVERSE SIDE OF THIS PAGE.
REQUISITION FOR TECHNICAL SERVICE PUBLICATIONS AND SERVICE FORMS
COMPLETE FORM
AND RETURN TO Komatsu America International Company
440 North Fairway Drive
Vernon Hills, IL 60061-8112 U.S.A.
Attn: Technical Publications
Fax No. (847) 970-4186
Tel No. (847) 970-5887
COMPANY NAME
PURCHASE ORDER NO.
SHIP TO
ATTN.
STREET ADDRESS ORDER DATE

TYPE or PRINT
CITY, STATE, ZIP CODE
ONLY
COUNTRY
PHONE NO. FAX NO. SHIPPING METHOD DISTR/BRANCH CODE
IMPORTANT - TO ASSURE SHIPMENT OF THE CORRECT PUBLICATION(S), THE MODEL NUMBER AND MACHINE
SERIAL NUMBER MUST BE SHOWN.
PARTS BOOK
PUBLICATION
QTY. PUBLICATION FORM NO. P-Paper MODEL NUMBER SERIAL NUMBER
DESCRIPTION
M-Microfiche
KDC91D 081696 CURRENT PRICES WILL BE CHARGED

The affected pages are indicated with the
Symbol Indication Action
following marks. Please update the manual by
deleting, replacing and/or adding pages O New pages to be added Add
according to information in the table below.
Ž Pages to be replaced Replace
( ) Pages to be deleted Discard

Pages without symbols are not revised at this
time.
LIST OF ORIGINAL, NEW AND REVISED PAGES

MARK PAGE REV MARK PAGE REV MARK PAGE REV MARK PAGE REV
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SAFETY SAFETY NOTICE
SAFETY
SAFETY NOTICE
IMPORTANT SAFETY NOTICE
Proper service and repair is extremely important for the safe operation of your machine. The service and repair techniques
recommended and described in this manual are both effective and safe methods of operation. Some of these operations
require the use of tools specially designed for the purpose.
To prevent injury to workers, the symbols and are used to mark safety precautions in this manual. The cautions
accompanying these symbols should always be followed carefully. If any dangerous situation arises or may possibly arise,
first consider safety, and take the necessary actions to deal with the situation.
GENERAL PRECAUTIONS
Mistakes in operation are extremely dangerous. Read the 7. Before adding oil or making repairs, park the machine on
OPERATION & MAINTENANCE MANUAL carefully BEFORE hard, level ground, and block the wheels or tracks to
operating the machine. prevent the machine from moving.
1. Before carrying out any greasing or repairs, read all the 8. Before starting work, lower blade, ripper, bucket or any
precautions given on the decals which are fixed to the other work equipment to the ground. If this is not
machine. possible, insert the safety pin or use blocks to prevent the
work equipment from falling. In addition, be sure to lock
2. When carrying out any operation, always wear safety all the control levers and hang warning signs on them.
shoes and helmet. Do not wear loose work clothes, or
clothes with buttons missing. 9. When disassembling or assembling, support the machine
with blocks, jacks or stands before starting work.
Always wear safety glasses when hitting parts with a
hammer.
10. Remove all mud and oil from the steps or other places
Always wear safety glasses when grinding parts with a used to get on and off the machine. Always use the
grinder, etc. handrails, ladders or steps when getting on or off the
machine. Never jump on or off the machine. If it is
3. If welding repairs are needed, always have a trained, impossible to use the handrails, ladders or steps, use a
experienced welder carry out the work. When carrying stand to provide safe footing.
out welding work, always wear welding gloves, apron,
glasses, cap and other clothes suited for welding work. PRECAUTIONS DURING WORK
4. When carrying out any operation with two or more 11. When removing the oil filler cap, drain plug or hydraulic
workers, always agree on the operating procedure before pressure measuring plugs, loosen them slowly to prevent
starting. Always inform your fellow workers before starting the oil from spurting out. Before disconnecting or
any step of the operation. Before starting work, hang removing components of the oil, water or air circuits, first
UNDER REPAIR signs on the controls in the operator's remove the pressure completely from the circuit.
compartment.
12. The water and oil in the circuits are hot when the engine
5. Keep all tools in good condition and learn the correct way is stopped, so be careful not to get burned. Wait for the
to use them. oil and water to cool before carrying out any work on the
oil or water circuits.
6. Decide a place in the repair workshop to keep tools and
removed parts. Always keep the tools and parts in their
correct places. Always keep the work area clean and
make sure that there is no dirt or oil on the floor. Smoke
only in the areas provided for smoking. Never smoke
while working.
PREPARATIONS FOR WORK
00-3
SAFETY SAFETY NOTICE
13. Before starting work, remove the leads from the battery. 19. Be sure to assemble all parts again in their original places.
ALWAYS remove the lead from the negative (-) terminal Replace any damaged part with new parts.
first.
When installing hoses and wires, be sure that they
will not be damaged by contact with other parts
14. When raising heavy components, use a hoist or crane.
when the machine is being operated.
Check that the wire rope, chains and hooks are free from
damage. Always use lifting equipment which has ample
20. When installing high pressure hoses, make sure that they
capacity. Install the lifting equipment at the correct places.
are not twisted. Damaged tubes are dangerous, so be
Use a hoist or crane and operate slowly to prevent the
extremely careful when installing tubes for high pressure
component from hitting any other part. Do not work with
circuits. Also check that connecting parts are correctly
any part still raised by the hoist or crane.
installed.
15. When removing covers which are under internal pressure
21. When assembling or installing parts, always use the
or under pressure from a spring, always leave two bolts
specified tightening torques. When installing protective
in position on opposite sides. Slowly release the pressure,
parts such as guards, or parts which vibrate violently or
then slowly loosen the bolts to remove.
rotate at high speed, be particularly careful to check that
they are installed correctly.
16. When removing components, be careful not to break or
damage the wiring, Damaged wiring may cause electrical
22. When aligning two holes, never insert your fingers or
fires.
hand. Be careful not to get your fingers caught in a hole.
17. When removing piping, stop the fuel or oil from spilling
23. When measuring hydraulic pressure, check that the
out. If any fuel or oil drips on to the floor, wipe it up
measuring tool is correctly assembled before taking any
immediately. Fuel or oil on the floor can cause you to slip,
measurements.
or can even start fires.
24. Take care when removing or installing the tracks of track-
18. As a general rule, do not use gasoline to wash parts. In
type machines. When removing the track, the track
particular, use only the minimum of gasoline when
separates suddenly, so never let anyone stand at either
washing electrical parts.
end of the track.
00-4
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
of the product and by showing him the correct way to perform repairs and make judgements. Make sure you understand the contents
of this manual and use it to full effect at every opportunity.
This shop manual mainly contains the necessary technical information for operations performed in a service workshop. For ease of
understanding, the manual is divided into the following sections. These sections are further divided into each main group of compo-
nents.
GENERAL
This section lists the general machine dimensions, performance specifications, component weights, and fuel, coolant and lubricant
specification charts.
STRUCTURE AND FUNCTION
This section explains the structure and function of each component. It serves not only to give an understanding of the structure,
but also serves as reference material for troubleshooting.
TESTING AND ADJUSTING
This section explains checks to be made before and after performing repairs, as well as adjustments to be made at completion
of the checks and repairs. Troubleshooting charts correlating "Problems" to "Causes" are also included in this section.
DISASSEMBLY AND ASSEMBLY
This section explains the order to be followed when removing, installing, disassembling or assembling each component, as well
as precautions to be taken for these operations.
MAINTENANCE STANDARD
This section gives the judgement standards when inspecting disassembled parts.
NOTICE
The specifications contained in this shop manual are subject to change at any time and without any advance notice. Contact
your distributor for the latest information.
00-5
FOREWORD HOW TO READ THE SHOP MANUAL
HOW TO READ THE SHOP MANUAL

VOLUMES REVISED EDITION MARK
Shop manuals are issued as a guide to carrying out repairs. When a manual is revised, an edition mark ( ....) is
They are divided as follows: recorded on the bottom outside corner of the pages.
Chassis volume: Issued for every machine model
Engine volume: Issued for each engine series REVISIONS
Electrical volume: Each issued as one to cover all models
Attachment volume: Each issued as one to cover all models Revised pages are shown at the LIST OF REVISED PAGES
between the title page and SAFETY page.
These various volumes are designed to avoid duplication of
information. Therefore to deal with all repairs for any model, it is SYMBOLS
necessary that chassis, engine electrical and attachment be
available. So that the shop manual can be of ample practical use,
important places for safety and quality are marked with the
DISTRIBUTION AND UPDATING following symbols.
Any additions, amendments or other changes will be sent to your

distributors. Get the most up-to-date information before you start Symbol Item Remarks
any work. Special safety precautions are
Safety necessary when performing the
FILING METHOD work.
1. See the page number on the bottom of the page. File the Special technical precautions or
pages in correct order. other precautions for preserving
Caution
2. Following examples show how to read the page number: standards are necessary when
Example 1 (Chassis volume): performing the work.
10 - 3 Weight of parts or systems.

Caution necessary when selecting
Weight
Item number (10. Structure and Func- hoisting wire or when working
tion) posture is important, etc.
Consecutive page number for each Places that require special
item Tighten-
attention for tightening torque
ing torque
during assembly.
Example 2 (Engine volume):
Refer to the pertinent engine manual. Places to be coated with adhesives
Coat
and lubricants etc.
3. Additional pages: Additional pages are indicated by a
Places where oil, water or fuel
hyphen (-) and numbered after the page number. File as in Oil, water
must be added, and the capacity.
the example.
Example: Places where oil or water must be
10-4 Drain drained, and quantity to be
10-4-1 drained.
10-4-2 Added pages
10-5
00-6
FOREWORD HOISTING INSTRUCTIONS
HOISTING INSTRUCTIONS
HOISTING
Heavy parts (25 kg or more) must be lifted with a

hoist etc. In the DISASSEMBLY AND ASSEMBLY
section, every part weighing 25 kg or more is indicated
clearly with the symbol
If a part cannot be smoothly removed from the machine by 3) Do not sling a heavy load with one rope alone, but sling
hoisting, the following checks should be made: with two or more ropes symmetrically wound on to the
1) Check for removal of all bolts fastening the part to the load.
relative parts.
2) Check for existence of another part causing interface
with the part to be removed. Slinging with one rope may cause turning of the
load during hoisting, untwisting of the rope, or
WIRE ROPES slipping of the rope from its original winding position on the
1) Use adequate ropes depending on the weight of parts to load, which can result in a dangerous accident.
be hoisted, referring to the table below:
4) Do not sling a heavy load with ropes forming a wide
Wire ropes hanging angle from the hook. When hoisting a load with
(Standard "Z" or "S" twist ropes without galvanizing two or more ropes, the force subjected to each rope will
increase with the hanging angles. The table below shows
Rope diameter (mm) Allowable load (tons) the variation of allowable load (kg) when hoisting is made
with two ropes, each of which is allowed to sling up to
10.0 1.0 1000 kg vertically, at various hanging angles. When two
11.2 1.4 ropes sling a load vertically, up to 2000 kg of total weight
12.5 1.6 can be suspended. This weight becomes 1000 kg when
14.0 2.2 two ropes make a 120 r
16.0 2.8 hand, two ropes are subject to an excessive force as
18.0 3.6 large as 4000 kg if they sling a 2000 kg load at a lifting
20.0 4.4 angle of 150
22.4 5.6
30.0 10.0
40.0 18.0
50.0 28.0
60.0 40.0
The allowable load value is estimated to be 1/6 or 1/7 of

the breaking strength of the rope used.
2) Sling wire ropes from the middle portion of the hook.

Slinging near the edge of the hook may cause the rope
to slip off the hook during hoisting, and a serious accident
can result. Hooks have maximum strength at the middle
portion.
00-7
FOREWORD COATING MATERIALS
COATING MATERIALS
The recommended coating materials prescribed in the shop manuals are listed below.
Category Code Part No. Qty Container Main applications, features

Used to prevent rubber gaskets, rubber cushions and cork plugs from
LT-1A 790-129-9030 150 g Tube
coming out
Used in places requiring an immediately effective, strong adhesive.
Plastic
LT-1B 790-129-9050 20 g (x2) Used for plastics (except polyethylene, polypropylene,
container
tetrafluoroethylene, and vinyl chloride), rubber, metal and non-metal.
Plastic Features: Resistance to heat, chemicals
LT-2 09940-00030 50 g
container Used for anti-loosening and sealant purposes for bolts and plugs.
Adhesive 790-129-9060
Adh 1 kg
Set of adhesive
LT-3 Hard agt Can Used as adhesive or sealant for metal, glass or plastic.
and hardening
500 kg
agent
Plastic
LT-4 790-129-9040 250 g Used as sealant for machined holes.
container
Loctite Features: Resistance to heat, chemicals
79A-129-9110 50 cc ---
648-50 Used at joint portions subject to high temperature.
Used as adhesive or sealant for gaskets and packing of power train
LG-1 790-129-9010 200 g Tube
case, etc.
Features: Resistance to heat
Used as sealant for flange surfaces and bolts at high temperature
LG-3 790-129-9070 1 kg Can locations; used to prevent seizure.
Used as sealant for heat resistant gasket for at high temperature
locations such as engine pre-combustion chamber, exhaust pipe.
Features: Resistance to water, oil
Used as sealant for flange surface, thread.
LG-4 790-129-9020 200 g Tube Also possible to use as sealant for flanges with large clearance.
Gasket sealant Used as sealant for mating surfaces of final drive case, transmission
case.
Used as sealant for various threads, pipe joints, flanges.
Plastic
LG-5 790-129-9080 1 kg Used as sealant for tapered plugs, elbows, nipples of hydraulic
container
piping.
Features: Silicon based, resistant to heat, cold.
LG-6 09940-00011 250 g Tube Used as sealant for flange surface, thread.
Used as sealant for oil pan, final drive case, etc.
Features: Silicon based, quick hardening type.
LG-7 09920-00150 150 g Tube Used as sealant for flywheel housing, intake manifold, oil pan,
thermostat housing, etc.
Rust prevention
--- 09940-00051 60 g Can Used as lubricant for sliding parts (to prevent squeaking).
lubricant
Used to prevent seizure or scuffing of the thread when press fitting or
Molybdenum
--- 09940-00040 200 g Tube shrink fitting.
disulfide lubricant
Used as lubricant for linkage, bearings, etc.
SYG-350Ll
SYG-400Ll
Lithium grease G2-L1 SYG-400Ll-A Various Various General purpose type
SYG-160Ll
SYGA-160CNLl
SSG2-400CA
SYG2-350CA
Used for normal temperature, light load bearing at places in contact
Calcium grease G2-CA SYG2-400CA-A Various Various
with water or steam.
SYG2-160CA
SYGA-16CNCA
Molybdenum 400 g
--- SYG2-400M Bellows type Used for places with heavy load.
disulfide grease (10/case)
00-8
FOREWORD STANDARD TORQUE REQUIREMENTS
STANDARD TORQUE REQUIREMENTS

STANDARD TORQUE REQUIREMENTS OF BOLTS AND NUTS
The following charts give the standard torques values of bolts and nuts. Exceptions are given in sections of
DISASSEMBLY AND ASSEMBLY.
1 kgm = 9.806 Nm
Thread diameter of bolt Width across flat
mm mm kgm Nm
6 10 1.35 ±0.15 13.2 ±1.4

8 13 3.20 ±0.3 31.4 ±2.9
10 17 6.70 ±0.7 65.7 ±6.8
12 19 11.5 ±1.0 112 ±9.8
14 22 18 ±2.0 177 ±19
16 24 28.5 ±3 279 ±29
18 27 39 ±4 383 ±39
20 30 56 ±6 549 ±58
22 32 76 ±8 745 ±78
24 36 94.5 ±10 927 ±98
27 41 135 ±15 1320 ±140
30 46 175 ±20 1720 ±190
33 50 225 ±25 2210 ±240
36 55 280 ±30 2750 ±290
39 60 335 ±35 3280 ±340
This torque table does not apply to the bolts with which nylon packing or other non-ferrous metal washers are to
be used, or which require torquing to otherwise specified values.
00-9
FOREWORD STANDARD TORQUE REQUIREMENTS
TORQUE REQUIREMENTS OF SPLIT FLANGE BOLTS

Use these torques values for split flange bolts.
Thread diameter of bolt Width across flat torque requirement values
mm mm kgm Nm
10 14 6.70 ±0.7 65.7 ±6.8

12 17 11.5 ±1.0 112 ±9.8
16 22 28.5 ±3 279 ±29
TORQUE REQUIREMENTS FOR FLARED NUTS
Use these torque values for flared part of nut.
Thread diameter of bolt Width across flat torque requirement values
mm mm kgm Nm
14 19 2.5 ±0.5 24.5 ±4.9

18 24 5 ±2 49 ±19.6
22 27 8 ±2 78.5 ±19.6
24 32 14 ±3 137.3 ±29.4
30 36 18 ±3 176.5 ±29.4
33 41 20 ±5 196.1 ±49
36 46 25 ±5 245.2 ±49
42 55 30 ±5 294.2 ±49
00-10
FOREWORD ELECTRIC WIRE CODE
ELECTRIC WIRE CODE

In the wiring diagrams, various colors and symbols are employed to indicate the thickness of wires. This wire code
table will help you understand WIRING DIAGRAMS.
Example: 05WB indicates a cable having a nominal number 05 and white coating with black stripe.
CLASSIFICATION BY THICKNESS
Copper wire
Nominal Cable Current rating
Number of Dia. Of strand Cross sec- Applicable circuit
number O.D. (mm) (A)
strands (mm) tion (mm²)
0.85 11 0.32 0.88 2.4 12 Starting, lighting, signal etc.
2 26 0.32 2.09 3.1 20 Lighting, signal etc.
5 65 0.32 5.23 4.6 37 Charging and signal
15 84 0.45 13.36 7.0 59 Starting (Glow plug)
40 85 0.80 42.73 11.4 135 Starting
60 127 0.80 63.84 13.6 178 Starting
100 217 0.80 109.1 17.6 230 Starting
CLASSIFICATION BY COLOR AND CODE
Priority Classification Circuits Charging Ground Starting Lighting Instruments Signal Other
Code W B B R Y G L
1 Primary
Color White Black Black Red Yellow Green Blue
Code WR --- BW RW YR GW LW
2
Color White/Red --- Black/White Red/White Yellow/Red Green/White Blue/White
Code WB --- BY RB YB GR LR
3
Color White/Black --- Black/Yellow Red/Black Yellow/Black Green/Red Blue/Red
Code WL --- BR RY YG GY LY
4 Auxiliary
Color White/Blue --- Black/Red Red/Yellow Yellow/Green Green/Yellow Blue/Yellow
Code WG --- --- RG YL GB LB

5
Color White/Green --- --- Red/Green Yellow/Blue Green/Black Blue/Black
Code --- --- --- RL YW GL ---

6
Color --- --- --- Red/Blue Yellow/White Green/Blue ---
00-11
FOREWORD CONVERSION TABLES
CONVERSION TABLES
METHOD OF USING THE CONVERSION TABLE
The Conversion Table in this section is provided to enable simple conversion of figures. For details of the method of
using the Conversion Table, see the example given below.
EXAMPLE
Method of using the Conversion Table to convert from millimeters to inches.
1. Convert 55 mm into inches.
(1) Locate the number 50 in the vertical column at the left side, take this as , then draw a horizontal line from
.
(2) Locate the number 5 in the row across the top, take this as , then draw a perpendicular line down from .
(3) Take the point where the two lines cross as . This point gives the value when converting from millimeters
to inches. Therefore, 55 millimeters = 2.165 inches.
2. Convert 550 mm into inches.

(1) The number 550 does not appear in the table, so divide by 10 (move the decimal one place to the left) to
convert it to 55 mm.
(2) Carry out the same procedure as above to convert 55 mm to 2.165 inches.
(3) The original value (550 mm) was divided by 10, so multiply 2.165 inches by 10 (move the decimal one place
to the right) to return to the original value. This gives 550 mm = 21.65 inches.
Millimeters to Inches
1 mm = 0.03937 in
mm 0 1 2 3 4 5 6 7 8 9
0 0 0.039 0.079 0.118 0.157 0.197 0.236 0.276 0.315 0.354

10 0.394 0.433 0.472 0.512 0.551 0.591 0.630 0.669 0.709 0.748
20 0.787 0.827 0.866 0.906 0.945 0.984 1.024 1.063 1.102 1.142
30 1.181 1.220 1.260 1.299 1.339 1.378 1.417 1.457 1.496 1.536
40 1.575 1.614 1.654 1.693 1.732 1.772 1.811 1.850 1.890 1.929
50 1.969 2.008 2.047 2.087 2.126 2.165 2.205 2.244 2.283 2.323
60 2.362 2.402 2.441 2.480 2.520 2.559 2.598 2.638 2.677 2.717
70 2.756 2.795 2.835 2.874 2.913 2.953 2.992 3.032 3.071 3.110
80 3.150 3.189 3.228 3.268 3.307 3.346 3.386 3.425 3.465 3.504
90 3.543 3.583 3.622 3.661 3.701 3.740 3.780 3.819 3.858 3.898
00-12
Millimeters to Inches
1 mm = 0.03937 in
mm 0 1 2 3 4 5 6 7 8 9
0 0 0.039 0.079 0.118 0.157 0.197 0.236 0.276 0.315 0.354

10 0.394 0.433 0.472 0.512 0.551 0.591 0.630 0.669 0.709 0.748
20 0.787 0.827 0.866 0.906 0.945 0.984 1.024 1.063 1.102 1.142
30 1.181 1.220 1.260 1.299 1.339 1.378 1.417 1.457 1.496 1.536
40 1.575 1.614 1.654 1.693 1.732 1.772 1.811 1.850 1.890 1.929
50 1.969 2.008 2.047 2.087 2.126 2.165 2.205 2.244 2.283 2.323
60 2.362 2.402 2.441 2.480 2.520 2.559 2.598 2.638 2.677 2.717
70 2.756 2.795 2.835 2.874 2.913 2.953 2.992 3.032 3.071 3.110
80 3.150 3.189 3.228 3.268 3.307 3.346 3.386 3.425 3.465 3.504
90 3.543 3.583 3.622 3.661 3.701 3.740 3.780 3.819 3.858 3.898
Kilogram to Pound
1 kg = 2.2046 lb
kg 0 1 2 3 4 5 6 7 8 9
0 0 2.20 4.41 6.61 8.82 11.02 13.23 15.43 17.64 19.84

10 22.05 24.25 26.46 28.66 30.86 33.07 35.27 37.48 39.68 41.89
20 44.09 46.30 48.50 50.71 51.91 55.12 57.32 59.53 61.73 63.93
30 66.14 68.34 70.55 72.75 74.96 77.16 79.37 81.57 83.78 85.98
40 88.18 90.39 92.59 94.80 97.00 99.21 101.41 103.62 105.82 108.03
50 110.23 112.44 114.64 116.85 119.05 121.25 123.46 125.66 127.87 130.07
60 132.28 134.48 136.69 138.89 141.10 143.30 145.51 147.71 149.91 152.12
70 154.32 156.53 158.73 160.94 163.14 165.35 167.55 169.76 171.96 174.17
80 176.37 178.57 180.78 182.98 185.19 187.39 189.60 191.80 194.01 196.21
90 198.42 200.62 202.83 205.03 207.24 209.44 211.64 213.85 216.05 218.26
00-13
Liter to U.S. Gallon

1
0 1 2 3 4 5 6 7 8 9
0 0 0.264 0.528 0.793 1.057 1.321 1.585 1.849 2.113 2.378

10 2.642 2.906 3.170 3.434 3.698 3.963 4.227 4.491 4.755 5.019
20 5.283 5.548 5.812 6.076 6.340 6.604 6.869 7.133 7.397 7.661
30 7.925 8.189 8.454 8.718 8.982 9.246 9.510 9.774 10.039 10.303
40 10.567 10.831 11.095 11.359 11.624 11.888 12.152 12.416 12.680 12.944
50 13.209 13.473 13.737 14.001 14.265 14.529 14.795 15.058 15.322 15.586
60 15.850 16.115 16.379 16.643 16.907 17.171 17.435 17.700 17.964 18.228
70 18.492 18.756 19.020 19.285 19.549 19.813 20.077 20.341 20.605 20.870
80 21.134 21.398 21.662 21.926 22.190 22.455 22.719 22.983 23.247 23.511
90 23.775 24.040 24.304 24.568 24.832 25.096 25.361 25.625 25.889 26.153
Liter to U.K. Gallon

1
0 1 2 3 4 5 6 7 8 9
0 0 0.220 0.440 0.660 0.880 1.100 1.320 1.540 1.760 1.980

10 2.200 2.420 2.640 2.860 3.080 3.300 3.520 3.740 3.950 4.179
20 4.399 4.619 4.839 5.059 5.279 5.499 5.719 5.939 6.159 6.379
30 6.599 6.819 7.039 7.259 7.479 7.699 7.919 8.139 8.359 8.579
40 8.799 9.019 9.239 9.459 9.679 9.899 10.119 10.339 10.559 10.778
50 10.998 11.281 11.438 11.658 11.878 12.098 12.318 12.528 12.758 12.978
60 13.198 13.418 13.638 13.858 14.078 14.298 14.518 14.738 14.958 15.178
70 15.398 15.618 15.838 16.058 16.278 16.498 16.718 16.938 17.158 17.378
80 17.598 17.818 18.037 18.257 18.477 18.697 18.917 19.137 19.357 19.577
90 19.797 20.017 20.237 20.457 20.677 20.897 21.117 21.337 21.557 21.777
00-14
kgm to ft. lb
1 kgm = 7.233 ft. lb
kgm 0 1 2 3 4 5 6 7 8 9
0 0 7.2 14.5 21.7 28.9 36.2 43.4 50.6 57.9 65.1

10 72.3 79.6 86.8 94.0 101.3 108.5 115.7 123.0 130.2 137.4
20 144.7 151.9 159.1 166.4 173.6 180.8 188.1 195.3 202.5 209.8
30 217.0 224.2 231.5 238.7 245.9 253.2 260.4 267.6 274.9 282.1
40 289.3 296.6 303.8 311.0 318.3 325.5 332.7 340.0 347.2 354.4
50 361.7 368.9 376.1 383.4 390.6 397.8 405.1 412.3 419.5 426.8
60 434.0 441.2 448.5 455.7 462.9 470.2 477.4 484.6 491.8 499.1
70 506.3 513.5 520.8 528.0 535.2 542.5 549.7 556.9 564.2 571.4
80 578.6 585.9 593.1 600.3 607.6 614.8 622.0 629.3 636.5 643.7
90 651.0 658.2 665.4 672.7 679.9 687.1 694.4 701.6 708.8 716.1
100 723.3 730.5 737.8 745.0 752.2 759.5 766.7 773.9 781.2 788.4
110 795.6 802.9 810.1 817.3 824.6 831.8 839.0 846.3 853.5 860.7
120 868.0 875.2 882.4 889.7 896.9 904.1 911.4 918.6 925.8 933.1
130 940.3 947.5 954.8 962.0 969.2 976.5 983.7 990.9 998.2 1005.4
140 1012.6 1019.9 1027.1 1034.3 1041.5 1048.8 1056.0 1063.2 1070.5 1077.7
150 1084.9 1092.2 1099.4 1106.6 1113.9 1121.1 1128.3 1135.6 1142.8 1150.0
160 1157.3 1164.5 1171.7 1179.0 1186.2 1193.4 1200.7 1207.9 1215.1 1222.4
170 1129.6 1236.8 1244.1 1251.3 1258.5 1265.8 1273.0 1280.1 1287.5 1294.7
180 1301.9 1309.2 1316.4 1323.6 1330.9 1338.1 1345.3 1352.6 1359.8 1367.0
190 1374.3 1381.5 1388.7 1396.0 1403.2 1410.4 1417.7 1424.9 1432.1 1439.4
00-15
kg/cm² to lb/in²
1kg/cm² = 14.2233 lb/in²
kg/cm² 0 1 2 3 4 5 6 7 8 9
0 0 14.2 28.4 42.7 56.9 71.1 85.3 99.6 113.8 128.0

10 142.2 156.5 170.7 184.9 199.1 213.4 227.6 241.8 256.0 270.2
20 284.5 298.7 312.9 327.1 341.4 355.6 369.8 384.0 398.3 412.5
30 426.7 440.9 455.1 469.4 483.6 497.8 512.0 526.3 540.5 554.7
40 568.9 583.2 597.4 611.6 625.8 640.1 654.3 668.5 682.7 696.9
50 711.2 725.4 739.6 753.8 768.1 782.3 796.5 810.7 825.0 839.2
60 853.4 867.6 881.8 896.1 910.3 924.5 938.7 953.0 967.2 981.4
70 995.6 1010 1024 1038 1053 1067 1081 1095 1109 1124
80 1138 1152 1166 1181 1195 1209 1223 1237 1252 1266
90 1280 1294 1309 1323 1337 1351 1365 1380 1394 1408
100 1422 1437 1451 1465 1479 1493 1508 1522 1536 1550
110 1565 1579 1593 1607 1621 1636 1650 1664 1678 1693
120 1707 1721 1735 1749 1764 1778 1792 1806 1821 1835
130 1849 1863 1877 1892 1906 1920 1934 1949 1963 1977
140 1991 2005 2020 2034 2048 2062 2077 2091 2105 2119
150 2134 2148 2162 2176 2190 2205 2219 2233 2247 2262
160 2276 2290 2304 2318 2333 2347 2361 2375 2389 2404
170 2418 2432 2446 2460 2475 2489 2503 2518 2532 2546
180 2560 2574 2589 2603 2617 2631 2646 2660 2674 2688
190 2702 2717 2731 2745 2759 2773 2788 2802 2816 2830
200 2845 2859 2873 2887 2901 2916 2930 2944 2958 2973
210 2987 3001 3015 3030 3044 3058 3072 3086 3101 3115
220 3129 3143 3158 3172 3186 3200 3214 3229 3243 3257
230 3271 3286 3300 3314 3328 3343 3357 3371 3385 3399
240 3414 3428 3442 3456 3470 3485 3499 3513 3527 3542
00-16
Temperature
Fahrenheit Centigrade Conversion; a simple way to convert a Fahrenheit temperature reading into a Centigrade temperature reading or vise versa is
to enter the accompanying table in the center or boldface column of figures. These figures refer to the temperature in either Fahrenheit or Centigrade
degrees. If it is desired to convert from Fahrenheit to Centigrade degrees, consider the center column as a table of Fahrenheit temperatures and read
the corresponding Centigrade temperature in the column at the left. If it is desired to convert from Centigrade to Fahrenheit degrees, consider the
center column as a table of Centigrade values, and read the corresponding Fahrenheit temperature on the right.
1
-40.4 -40 -40.0 -11.7 11 51.8 7.8 46 114.8 27.2 81 117.8

-37.2 -35 -31.0 -11.1 12 53.6 8.3 47 116.6 27.8 82 179.6
-34.4 -30 -22.0 -10.6 13 55.4 8.9 48 118.4 28.3 83 181.4
-31.7 -25 -13.0 -10.0 14 57.2 9.4 49 120.2 28.9 84 183.2
-28.9 -20 -4.0 -9.4 15 59.0 10.0 50 122.0 29.4 85 185.0
-28.3 -19 -2.2 -8.9 16 60.8 10.6 51 123.8 30.0 86 186.8

-27.8 -18 -0.4 -8.3 17 62.6 11.1 52 125.6 30.6 87 188.6
-27.2 -17 1.4 -7.8 18 64.4 11.7 53 127.4 31.1 88 190.4
-26.7 -16 3.2 -7.2 19 66.2 12.2 54 129.2 31.7 89 192.2
26.1 -15 5.0 -6.7 20 68.0 12.8 55 131.0 32.2 90 194.0
-25.6 -14 6.8 -6.1 21 69.8 13.3 56 132.8 32.8 91 195.8

-25.0 -13 8.6 -5.6 22 71.6 13.9 57 134.6 33.3 92 197.6
-24.4 -12 10.4 -5.0 23 73.4 14.4 58 136.4 33.9 93 199.4
-23.9 -11 12.2 -4.4 24 75.2 15.0 59 138.2 34.4 94 201.2
-23.3 -10 14.0 -3.9 25 77.0 15.6 60 140.0 35.0 95 203.0
-22.8 -9 15.8 -3.3 26 78.8 16.1 61 141.8 35.6 96 204.8

-22.2 -8 17.6 -2.8 27 80.6 16.7 62 143.6 36.1 97 206.6
-21.7 -7 19.4 -2.2 28 82.4 17.2 63 145.4 36.7 98 208.4
-21.1 -6 21.2 -1.7 29 84.2 17.8 64 147.2 37.2 99 210.2
-20.6 -5 23.0 -1.1 30 86.0 18.3 65 149.0 37.8 100 212.0
-20.0 -4 24.8 -0.6 31 87.8 18.9 66 150.8 40.6 105 221.0

-19.4 -3 26.6 0 32 89.6 19.4 67 152.6 43.3 110 230.0
-18.9 -2 28.4 0.6 33 91.4 20.0 68 154.4 46.1 115 239.0
-18.3 -1 30.2 1.1 34 93.2 20.6 69 156.2 48.9 120 248.0
-17.8 0 32.0 1.7 35 95.0 21.1 70 158.0 51.7 125 257.0
-17.2 1 33.8 2.2 36 96.8 21.7 71 159.8 54.4 130 266.0

-16.7 2 35.6 2.8 37 98.6 22.2 72 161.6 57.2 135 275.0
-16.1 3 37.4 3.3 38 100.4 22.8 73 163.4 60.0 140 284.0
-15.6 4 39.2 3.9 39 102.2 23.3 74 165.2 62.7 145 293.0
-15.0 5 41.0 4.4 40 104.0 23.9 75 167.0 65.6 150 302.0
-14.4 6 42.8 5.0 41 105.8 24.4 76 168.8 68.3 155 311.0

-13.9 7 44.6 5.6 42 107.6 25.0 77 170.6 71.1 160 320.0
-13.3 8 46.4 6.1 43 109.4 25.6 78 172.4 73.9 165 329.0
-12.8 9 48.2 6.7 44 111.2 26.1 79 174.2 76.7 170 338.0
-12.2 10 50.0 7.2 45 113.0 26.7 80 176.0 79.4 175 347.0
00-17
FOREWORD MEMORANDA
00-18
01 GENERAL
DIMENSIONS ............................. . . . . . . 01-2
SPECIFICATIONS ......................... ..... 01-4
WEIGHT TABLE ........................... ..... 01-7
FUEL, COOLANT AND LUBRICANTS ......... ..... 01-8
ENGINE OIL SPECIFICATIONS .............. . . . . . . 01-9
TRANSMISSION, HYDRAULIC, AND BRAKE OIL . . . . 01-10
AXLE OIL SPECIFICATIONS ................ . . . . . 01-10
GREASE SPECIFICATIONS ................. . . . . . 01-10
DIESEL FUEL SPECIFICATIONS ............. . . . . 01-10
COOLANT SPECIFICATIONS ................ . . . . . 01-10
01-I
GENERAL DIMENSIONS
With General Purpose Bucket With Excavating Bucket With Spade Nose Rock
4.3 m3 (5.6 yd3) 4.0 m3 (5.2 yd3) Bucket 4.0 m3 (5.2 yd3)
26.5 x 25 Tires 29.5 x 25 Tires 26.5 x 25 Tires 29.5 x 25 Tires 26.5 x 25 Tires 29.5 x 25
Tread 2.4 m 2.4 m 2.4 m 2.4 m 2.4 m 2.4 m

(7 ft 10 in) (7 ft 10 in) (7ft 10 in) (7 ft 10 in) (7ft 10 in) (7 ft IO in)
Width over tires 3.1 m 3.2 m 3.1 m 3.2 m 3.1 m 3.2 m

(10 ft 2 in) (lOft6in) (IO ft 2 in) (lOft6in) (lOft2in) (lOft6in)
A Wheelbase 3.5 m 3.5 m 3.5 m

(11 ft8 in) (11 ft 8 in) (11 ft 8 in) (113.5
ft 8m in) I iiiixz
B Hinge pin height 4.3 m 4.4 m 4.3 m 4.4 m 4.3 m 4.4 m

- maximum (14 ft 5 in) (14 ft 7 in) (14 ft 5 in) (14 ft 7 in) (14 ft 5 in) (14 ft 7 in)
C Hinge pin height 0.54 m 0.59 m 0.54 m 0.59 m 0.54 m 0.59 m

- carry position (1 ft 9 in) (1 ft 11 in) (1 ft 9 in) (1 ft 11 in) (1 ft 9 in) (1 ft 11 in)
D Ground 0.44 m 0.49 m 0.44 m 0.49 m 0.44 m 0.49 m

clearance (1 ft 5 in) (1 ft 7 in) (1 ft 5 in) (1 R 7 in) (1 ft 5 in) (1 ft 7 in)
E Hitch height 1.13 m 1.18 m 1.13m 1.18 m 1.13 m 1.18 m

(3 ft 9 in) (3ft 11 in) (3 ft 9 in) (3 ft 11 in) (3 ft 9 in) (3ft 11 in)
01-2
GENERAL DIMENSIONS
With General Purpose Bucket With Excavating Bucket With Spade Nose Rock
4.3 m3 (5.6 yd3) 4.0 m3 (5.2 yd3) Bucket 4.0 m3 (5.2 yd3)
26.5 x 25 Tires 29.5 x 25 Tires 26.5 x 25 Tires 29.5 x 25 Tires 26.5 x 25 Tires 29.5 x 25
Tires
F Overall height to 3.63 m 3.68 m 3.63 m 3.68 m 3.63 m 3.68 m

top of exhaust (11 ft 11 in) (12 ft 1 in) (11 ftll in) (12 ft 1 in) (11 ft 11 in) (12 ft 1 in)
pipe
G Overall height to 3.89 m 3.94 m 3.89 m 3.94 m 3.89 m 3.94 m

top of ROPS (12 ft 9 in) (12ft 11 in) (12 ft 9 in) (12ft 11 in) (12 ft 9 in) (12 ft 11 in)
canopy
H Dumping 3.21 m 3.27 m 3.27 m 3.32 m 3.11 m 3.16 m

clearance at (lOft7in) (lOftgin) (loftgin) (lot? 11 in) (lOft2in) (10 ft 4 in)
maximum height
& 45” dump
angle
Reach @ 2.13 m 2.03 m 1.98m 1.99 m 1.94m 2.08 m 2.03 m

(7 ft) cutting (6 ft 8 in) (6 ft 6 in) (6 ft 7 in) (6 ft 5 in) (6 ft 10 in) (6 ft 8 in)
edge clearance
8 45” dump
angle
J Reach @ 1.37 m 1.32 m 1.32 m 1.27 m 1.46 m 1.41 m

maximum height (4 ft 6 in) (4 ft 4 in) (4 ft 4 in) (4 ft 2 in) (4 ft 10 in) (4 ft 8 in)
& 45”dump
angle
Reach with lift 2.81 m 2.76 m 2.73 m 2.68 m 2.95 m 2.90 m

arm horizontal & (9 ft 3 in) (9 ft 1 in) (8 ft 11 in) (8 ft 10 in) (9 ft 8 in) (9 ft 6 in)
bucket level
K Operating height 6.02 m 6.07 m 6.13 m 6.18 m 6.21 m 6.26 m

- fully raised (19ft9in) (19ft 11 in) (20 ft 2 in) (20 ft 4 in) (20 ft 5 in) (20 ft 7 in)
L Overall length 8.97 m 8.93 m 8.89 m 8.85 m 9.12 m 9.08 m

(29 ft 5 in) (29 ft 4 in) (29 ft 2 in) (29 rT 1 in) (29 ft 11 in) (29 ft 10 in)
Loader clearance 14.39 m 14.39 m 14.35 m 14.35 m 14.35 m 14.35 m

circle at outside (47 ft 3 in) (47 ft 3 in) (47 ft 1 in) (47 ft 1 in) (47 ft 1 in) (47 ft 1 in)
corner of bucket
& bucket in carry
position
Digging depth at 0.175 m 0.125 m 0.115 m 0.065 m 0.125 m 0.075 m

0” (6.9 in) (4.9 in) (4.5 in) (2.6 in) (4.9 in) (3.0 in)
Digging depth at 0.460 m 0.410 m 0.330 m 0.290 m 0.385 m 0.330 m

IO” (1 ft 6 in) (1 ft 4 in) (1 ft 1 in) (11.4 in) (1 ft 3 in) (1 ft 1 in)
NOTICE: All specifications are subject to change without notice.
01-3
GENERAL SPECIFICATIONS
SPECIFICATIONS
Machine model WA500-3L
Serial number f A70001 and up
E Operating weight 28,430 kg (63,711 lb)

.o, Distribution (front) 13,120 kg
3 Distribution (rear) 15,310 kg
Bucket capacity (piled) 4.3 m3 (5.6 yd3)

Rated load 75.9 kN (7,740 kg)
Travel speed:
FORWARD 1st 7.1 km/h (4.4 mph)
FORWARD 2nd 12.6 km/h (7.8 mph)
FORWARD 3rd 21.2 km/h (13.2 mph)
FORWARD 4th 34.8 km/h (21.6 mph)
REVERSE 1st 7.9 km/h (4.9 mph)
REVERSE 2nd 14.1 km/h (8.8 mph)
REVERSE 3rd 23.5 km/h (14.6 mph)
REVERSE 4th 38.1 km/h (23.7 mph)
Grade-ability 25 deg
Turning radius (bucket at carry - outside corner of

7390 mm (24 ft 3 in)
bucket)
Overall length 9320 mm (30 ft 6 in)
Overall width (Chassis) 3,190mm(10ft5in)
Bucket width (with bolt on cutting edge) 3460 mm (11 ft 4 in)
Overall height (top of cab) 3860 mm (12 ft 7 in)
Overall height (bucket raised) 6115 mm (20 ft 1 in)
Wheelbase 3600mm(11ft10in)
Tread 2400 mm (7 ft 10 in)
Minimum ground clearance 450 mm (1 ft 5 in)
Height of bucket hinge pin 4500 mm (14 ft 8 in)
Dumping clearance (tip of cutting edge) 3335 mm (10 ft 9 in)
Dumping reach (tip of cutting edge) 1255mm4ftl in)
Bucket dump angle 45 deg
Bucket tilt angle (SAE carrying position) 48 deg
Digging depth (10” dump angle) 425 mm (1.4 in)
01-4
Serial number A70001 and up
Model Cummins NTA14C diesel engine
Type 4-cycle, water cooled, direct injection, turbocharged
No. of cylinders - bore x stroke 6 - 140 mm (5.5”) x 152 mm (5.9”)
Piston displacement 14 Q(855 ins) (14,000 cc)
Gross power @ 2100 rpm 235kW (315 HP)
Maximum torque (gross) @ 1500 rpm 908 N*m (670 Ibf ft)
High idle 2300 rpm

Low idle 760 rpm
Fuel consumption ratio 220 g/kW lh (164 g/HP*h)
Starting motor 24V, 25 kW

Alternator 24V, 70A
Battery 12V, 170Ahx2
Torque converter 3-element, single-stage, single-phase

(TCA40-1 C)
Transmission Planetary gear, constant-mesh multiple-disc,

hydraulic actuated, modulation type
Reduction gear Spiral bevel gear, splash lubrication
Differential Straight bevel gear
Final drive planetary gear, single stage, splash lubrication
Drive type Front I rear wheel drive
Front axle Fixed frame full-floating type
Rear axle Center pin support full-floating type
Tire 29.525-22pr tubeless (L3)
Wheel rim 25.00 x 25 WTB
Inflation pressure Front tire 4.5 kg/cm2 (64.0 psi) (440 kPa)
Inflation pressure Rear tire 3.5 kg/cm* (49.8 psi) (340 kPa)
Front I rear wheel braking, separate front/rear wheel, wet disc,

Service brakes
9E Parking brake
hydraulically actuated
m Drive shaft, wet type disc brake

Hydraulically released spring type
01-5
Serial number A70001 and UD
Type Articulated steering
Structure Fully hydraulic power steering
Work equipment pump 348 P (Gear type: SAR(4) - 160)

Hydraulic
Switch pump 135 P (Gear type: SAR(3) - 63)
Pump
Delivery
Steering pump 172e (Gear type: SAR(3) - 80)
PPC pump 6OP (Gear type: SAR(1) - 28)
Set pressure for work equipment Spool type 20.58 Mpa (210 kg/cm*)
Set pressure for steering Orbit-roll valve type 20.58 Mpa 210 kg/cm2)
Boom cylinder qty. - bore x stroke

Reciprocating piston 2-200 x 839 (mm)
Bucket cylinder qty. - bore x stroke
Reciprocating piston l-225 x 613 (mm)
Steering cylinder qty. - bore x
Reciprocating piston 2 - 110 x 486 (mm)
stroke
Linkage type Single link (Z-bar linkage)
Bucket edge type Flat edge with bolt on cutting edge
01-6
GENERAL WEIGHT TABLE
WEIGHT TABLE
This weight table is a guide for use when transporting or handling components.
Machine model I WA500-3LE Machine model I WA500-3L
Serial No. I A70001 and UQ Serial No. A70001 and up

I
Engine 3,038 lb (1,378 kg) Hydraulic tank 1 507 lb (230 kg)
Radiator 723 lb (328 kg) Hydraulic pump 45 lb (20.3 kg)
Transmission with torque Switch and PPC pump 42 lb (19 kg)

2,524 lb (1,145 kg)
converter
Steering pump 1 27 lb (12.2 kg)
PPC valve I 8 lb (3.5 kg)
Main control valve I 199 lb (90 kg)
Steering cylinder (each) I 104 lb (47 kg)

Upper drive shaft I 40 lb (18 kg)
Boom cylinder (each) 1 600 lb (272 kg)
Center drive shaft I 73 lb (33 kg)
Front drive shaft 99 lb (45 kg)
Rear drive shaft 86 lb (41 kg)
Center support 93 lb (42 kg)

Rear frame 1 4.817 lb (2,185 kg)
Front axle assembly 4,277 lb (1,940 kg)
Bucket link 1 234 lb (106 kg)
Rear axle assembly I 4,138 lb (1,877kg)
Bellcran k I 1,151 lb (522 kg)
Axle pivot (Rear axle) 114 lb (251 kg)
Boom including bushings 4,449 lb (2,018 kg)
Tire and wheel (each) 1,740 lb (789 kg) I
Bucket with bolt on cutting
5,997 lb (2,720 kg)
Wheel (each) 591 lb (268 kg) edge I
Tire (each) 1,149 lb (521 kg) Counterweight 1 4,954 lb (2,247 kg)
Front differential assembly I 591 lb (268 kg) Fuel tank 1 670 Ib(213 kg)
Rear differential assembly I 612 lb (278 kg) Battery (each) I 117 lb (53 kg)
Planetary carrier (each) I 137 lb (62 kg) Floor, dash, console 1 472 lb (214 kg)
Planetary hub (each) 227 lb (103 kg) Cab (ROPS) I 661 lb (300 kg)
I
Steering valve I 52 lb (23.5 kg) Air conditioner unit I 117 lb (53 kg)
Orbit-roll valve I 12 lb (5.3 kg) Operator’s seat 88 lb (40 kg)
Brake valve (Tandem) I 19 lb (8.5 kg)
Brake valve (Single) I 12 lb (5.3 kg)
01-7
GENERAL FUEL, COOLANT AND LUBRICANTS
COOLANT, AND LUBRICANTS

RESERVOIR FLUID AMBIENT TEMPERATURE CAPACITY
TYPE -22 -4 14 32 50 68 86 104 122°F
-30 -20 -10 0 10 20 30 40 59°C Specified Refill
SAE 15W-40
I I
Engine oil
Engine with filter See SAE low-30 42 e 36 P
NOTE 1 I I
11.1 gal 9.5 gal
Synthetic SAE 5W-30
1
Torque convert- SAE 30W

I
er, Transmission, 70 P 62 e
Transfer case SAE 1ow 18.5 gal 16.4 ga
I I
& Oil cooler
Engine oil
See SAE tOW 284P 1751
Hydraulic system NOTE 2 I 1 75.0 gal 46.2 ga
SAE 5W-20 1
Drive axles - Axle oil 78 P 78 e

Front & rear See NOTE 3 20.6 gal 20.6 ga
each each
411lubrication Grease See NOTE 4 Fill as --

%tings instructed
=uel tank Diesel fuel See NOTE 5 465 e --

122.8 gal
Cooling system Coolant See NOTE 6 83~ --

21.9 gal
API: American Petroleum Institute

ASTM: American Society of Testing and Material
SAE: Society of Automotive Engineers
Specified capacity: Total amount of oil including oil for components and oil in piping.
Refill capacity: Amount of oil needed to refill system during normal inspection and maintenance.
01-8
NOTES:
1. ENGINE OIL
Normal Operation
Oil performance recommendations are as follows:
The use of a high quality engine lubricating oil combined with appropriate oil and filter change intervals are critical
factors in maintaining engine performance and durability.
SAE 15W-40 multi-viscosity heavy duty engine oil meeting the American Petroleum Institute (API) performance
classification of CF-4 or CG-4 is recommended.
NOTE: CE oil may be used in areas where CF-4 or CG-4 oil is not yet available.
A sulfated ash content of 1.O mass percent is suggested for optimum valve and piston deposit and oil consumption
control. The sulfated ash must not exceed 1.85 mass percent. The sulfated ash limit of 1.85 mass percent has
been placed on all engine lubricating oils recommended for use in the engine. Higher ash oils can cause valve
and/or piston damage and lead to excessive oil consumption.
The API service symbol displays the following information. The upper half of the symbol displays the appropriate
oil categories; the lower half may contain words to describe oil energy conserving features. The center section
identifies the SAE oil viscosity grade.
Oil viscosity recommendations are as follows:
The use of a multi-graded lubricating oil has been found to improve oil consumption control and improve engine
cranking in cold temperatures while maintaining lubrication at high operating temperatures.
While SAE 15W-40 multi-viscosity oil is recommended for most operating climates, refer to the previous table for
oil viscosity recommendations for extreme climates.
Limited use of low viscosity oils, such as SAE 1OW-30 may be used for easier starting and providing sufficient oil
flow at ambient temperatures below -5°C (+23”F). However, continuous use of low viscosity oils can decrease
engine life due to wear.
Special “break-in” lubricating oils are not recommended for a new or rebuilt engine. Use the same type of oil
during the “break-in” as specified for normal operation.
Additional information regarding lubricating oil availability throughout the world is available in the “E.M.A.
Lubricating Oils Data Book for Heavy Duty Automotive and Industrial Engines.” The data book may be ordered
from the Engine Manufacturers Association, One Illinois Center, 111 East Wacker Drive, Chicago, IL U.S.A.
60601. The telephone number is (312) 644-6610.
Arctic Operation
If an engine is operated in ambient temperatures consistently below -23°C (-10°F) and there are no provisions to keep
the engine warm when it is not in operation, use a synthetic API performance classification CE/SF engine oil with
adequate low temperature properties such as SAE 5W-20 or 5W-30.
The oil supplier must be responsible for meeting the performance service specifications.
IMPORTANT: The use of a synthetic base oil does not justify extended oil change intervals. Extended oil change
intervals can decrease engine life due to factors such as; corrosion, deposits and wear.
01-9
2. TRANSMISSION, HYDRAULIC SYSTEM AND BRAKE SYSTEM OIL
Use API performance classification CE engine oil.
When using SAE 5W-20 engine oil in the work equipment hydraulic system in cold areas, return to SAE 1OW when
the cold season ends.
3. AXLE OIL
For axle oil, use only the recommended oil as follows:
SHELL: DONAX lT or TD
CALTEX: RPM TRACTOR HYDRAULIC FLUID
CHEVRON: TRACTOR HYDRAULIC FLUID
TEXACO: TDH OIL
MOBIL: MOBIL AND SUPER UNIVERSAL
j, It is possible to substitute engine oil SAE 30W API classification CD for axle oil. Although increased brake noise
may result, durability should not be affected.
4. GREASE
The recommended lubricating grease is No. 2 multi-purpose lithium grease with 3% molybdenum disulfide.
5. DIESEL FUEL
A
WARNING! Do not mix gasoline or alcohol with diesel fuel. This mixture can cause an explosion.
IMPORTANT: Due to the precise tolerances of diesel injection systems, it is extremely important that the fuel be kept
clean and free of dirt or water. Dirt or water in the system can cause severe damage to both the injection pump and
nozzles.
For normal service above -12°C (+lO”F), the use of ASTM Grade No. 2-D diesel fuel with a minimum Cetane number
of 40 is recommended. The use of No. 2-D diesel fuel will result in optimum engine performance under most operating
conditions. Fuels with Cetane numbers higher than 40 may be needed in high altitudes or extremely low ambient
temperatures to prevent misfires and excessive smoke.
At operating temperatures below -12°C (+lO”F), use ASTM Grade No. I-D diesel fuel. The use of lighter fuels can
reduce fuel economy.
Where a winterized blend of Grade No. 2-D and No. I-D fuels is available, it may be substituted for Grade No. I-D
fuel. However, it is the supplier’s responsibility to provide the fuel for the anticipated ambient temperature.
Use a low sulfur content fuel having a cloud point that is at least 10 degrees below the lowest expected fuel
temperature. Cloud point is the temperature at which crystals begin to form in the fuel.
The viscosity of the fuel must be kept above 1.3 cSt at 100°C (212°F) to provide adequate fuel system lubrication.
6. COOLANT
General
Selection and maintenance of the engine coolant is important to long engine life. The following information provides
recommendations for selecting the engine coolant and maintaining the supplemental coolant additive (SCA).
01-10
Heavy duty diesel engines require a balanced coolant mixture of water, antifreeze, and supplemental coolant additive.
Supplemental coolant additive recommendations are included in the section entitled “Supplemental Coolant Additive”.
The coolant mixture must be drained and replaced at the specified service interval shown in the “SCHEDULED
MAINTENANCE GUIDE” or every two years of operation, whichever comes first.
Water
Use water which has a low mineral content. Water used in conjunction with antifreeze, coolant filters and inhibited
water must meet the following standards:
Total Hardness - Not to exceed 170 parts per million (10 grains/gallon maximum) to prevent scale deposits. Water
containing dissolved magnesium and calcium (the usual reason for water hardness) above the specified amount
will cause scale deposits to develop in the engine.
Chlorides - Not to exceed 40 parts per million (2.5 grains/gallon maximum) to prevent corrosion.
Sulfites - Not to exceed 100 parts per million (5.8 grains/gallon maximum) to prevent corrosion
Dissolved Solids - Not to exceed 340 parts per million (20 grains/gallon maximum) to minimize sludge deposits,
scale deposits, corrosion or a combination of these.
If any of the above requirements cannot be met, use distilled, de-ionized, or de-mineralized water. To determine if local
water supplies meet these standards, water samples can be tested by water treatment laboratories. “Softened” water
that is prepared using common salt (sodium chloride) contains excessive amounts of chlorides and should not be
used.
NOTE: Never use water alone in the cooling system because corrosion will occur
Antifreeze
In climates where the temperature is above -37°C (-34°F) use a coolant mixture that contains 50 percent antifreeze.
Antifreeze is essential in any climate. It broadens the operating temperature range by lowering the coolant freezing
point and by raising its boiling point. Do not use more than 50 percent antifreeze in the mixture unless additional freeze
protection is required. Never use more than 68 percent antifreeze under any condition.
An antifreeze concentration greater than 68% will adversely affect freeze protection and heat transfer rates. Antifreeze
concentrations between 68% and 100% actually have a higher freezing point than a 68% antifreeze concentration and
should not be used due to reduced heat transfer rates.
Low silicate ethylene glycol antifreeze is recommended. The antifreeze should contain no more than 0.1% anhydrous
alkali metasilicate. Low silicate antifreeze is recommended to avoid the formation of silica-gel (hydro-gel). This gel
formation can occur when the cooling system contains an over concentration of high silicate antifreeze and/or
supplemental coolant additive. DO NOT use methanol or alcohol as an antifreeze because of its low boiling point.
Antifreeze may retain its freeze protection for more than one season but coolant conditioners must be added to
maintain corrosion protection.
Antifreeze formulated with methoxy propanol, or propylene glycol, is not recommended for this system.
NOTE: Do not mix types of antifreeze solutions. Mixed solutions make it impossible to determine the protection
against freezing, Antifreeze containing sealer or anti-leak additives should NOT be used in this system. Sealer
or anti-leak additives will cause plugging problems in the cooling system. ,
Check the solution periodically and at normal operating temperature, to be sure the cooling system has sufficient
protection against freezing.
01-I 1
The following table shows the approximate percentage of antifreeze solution required for various temperatures.
Percentage of
Approximate Antifreeze Specific
Freezing Concentration Gravity at
Point by Volume 60°F (16°C)
+32”F (O°C) 0 1 .ooo

+2O”F (-7°C) 15 1.025
+lO”F (-12°C) 25 1.040
0°F (-18°C) 33 1.053
-10°F (-23°C) 40 1.062
-20°F (-29°C) 45 1.070
-30°F (-34°C) 48 1.074
-40°F (-40°C) 53 1.080
-50°F (-46°C) 56 1.083
-60°F (-51 “C) 59 1.088
-70°F (-57°C) 62 1.092
-80°F (-62°C) 65 1.095
-90°F (-68°C) 67 1.097
-92°F (-96°C) 68 1.098
In tropical climates where antifreeze availability may be limited, use a corrosion inhibitor SCA, to protect the engine
cooling system.
Supplemental Coolant Additives

1. All supplemental cooling system additives, including those in antifreeze solutions, become depleted through
normal operation. If the coolant additive in antifreeze are allowed to become depleted, the antifreeze becomes
corrosive and attacks and coats the metallic surfaces of the cooling system which reduces heat transfer. Cooling
system conditioners which contain these additives must be added to maintain corrosion protection.
2. SOLUBLE OIL IS NOT RECOMMENDED for use in this engine as its use will reduce heat transfer and allow
internal engine damage.
3. There are no miracle additives that will increase heat transfer or prevent overheating. Conditioned water is still
the best coolant.
4. SCA is recommended to inhibit corrosion in the cooling system for the following reasons:
l Improved compatibility with high silicate antifreezes to minimize hydro-gel formation if over concentration
occurs.
l Provides engine protection in the following areas:
- Solder corrosion/bloom - Copper corrosion/erosion/stress cracking
- Oil fouling - Cylinder liner cavitation corrosion
-Aluminum cavitation corrosion - Seal and gasket degradation
MAINTENANCE OF SUPPLEMENTAL COOLANT ADDITIVES
Keeping the engine coolant properly inhibited will keep the engine and radiator free of rust, scale deposits and
corrosion.
New machines are delivered with antifreeze protection. Service at regular scheduled interval specified in the
“SCHEDULED MAINTENANCE GUIDE” with a service DCA4 filter.
01-12
Each time the coolant is drained and replaced, the coolant must be recharged with SCA. New coolant can be correctly
charged with supplemental coolant additives by using a DCA4 service filter or SCA concentrate listed in the table
entitled. “DCA4 Unit Guide”.
If coolant is added between drain intervals, additional SCA will be required.
COOLANT TESTING FOR CONDITIONER CONCENTRATION
When the cooling system is maintained as recommended, the conditioner concentration should be satisfactory. The
SCA concentration must not fall below 1 .O unit per 3.8 P (1 US gal) or exceed 2 units per 3.8 e (1 US gal) of coolant.
The only accurate method for testing chemical concentrations in coolant with mixed chemical compounds is a
laboratory analysis. For this reason, the coolant inhibitor should be maintained as shown in the “SCHEDULED
MAINTENANCE GUIDE”.
NOTE: Inadequate concentration of the supplemental coolant additive can result in major corrosive damage to cooling
system components. Over concentration can cause formation of “gel” that can cause restriction, plugging of
passages and overheating.
REPLENISHING COOLANT CONDITIONER
Install a “precharge” DCA4 filter when the coolant is changed or a significant (more than 50%) coolant loss occurs.
Install a service DCA4 filter as specified in the “SCHEDULED MAINTENANCE GUIDE”. When antifreeze is added,
add coolant conditioner equal to 1 .O unit per 3.8 e (1 US gal) of antifreeze.
NOTE: Mixing of DCA4 and other supplemental coolant additives is not recommended because there is currently no
test kit available to measure concentration levels with mixed chemical solutions.
SCA UNIT MAINTENANCE GUIDE
Use supplemental coolant additives (corrosion inhibitors) to protect the engine cooling system from corrosion.
Antifreeze alone does not provide enough corrosion protection for a heavy duty diesel engine. Supplemental corrosion
protection must be supplied through periodic additions of supplemental coolant additives to the coolant.
To protect against corrosion, a new coolant charge must be brought up to 0.26 SCA unit per liter [one unit per U.S.
gallon] of coolant (initial charge). Maintain the correct SCA concentration by changing the service coolant filter at each
engine oil and filter change interval.
Each time the coolant is drained and replace, the coolant must be recharged with supplemental coolant additives. Use
the appropriate DCA4 spin-on filter listed in following table. The coolant mixture must be drained and replaced as
defined under “General”.
The amount of replacement inhibitor is determined by the length of the service interval and the cooling system
capacity. Refer to the DCA4 Unit Guide for the selection of the correct filter to replenish the SCA.
If coolant is added between drain intervals, additional SCA will be required. Check the coolant DCA concentration level
anytime make-up coolant is added to the system. The SCA concentration must not fall below 0.13 units per liter or
exceed 0.5 units per liter [0.5 units per U.S. gallon or exceed 2 units per U.S. gallon].
01-13
DCA4 Unit Guide
Fleetguard DCA4
Part No. Units
DCA4 Coolant Filter

WF-2070 2
WF-2071 4
WF-2072 6
WF-2073 8
WF-2074 12
WF-2075 15
WF-2076 23
WF-2077 0
DCA4 Liquid
DCAGOL 4 (1 Pint)
DCA80L 1760 (55 US gal)
DCA4 Powder
DCA95 20
DCA4 Precharge and Service Filters
System Capacity Precharge Filter Service Filter

(See NOTE 1) (See NOTE 3)
Gallons
5-7 WF-2072 WF-2070

8-l 0 WF-2073 WF-2071
11-15 WF-2074 WF-2071
16-20 WF-2075 WF-2071
21-30 WF-2076 WF-2072
31-50 (See NOTE 2) WF-2073
NOTE l- After draining and replacing coolant, always precharge the cooling system to maintain the SCA
concentration between 1 .O and 2.0 units per 3.8 P (1 US gal).
NOTE: When performing service which requires draining the cooling system, discard the coolant.
Reusing coolant can introduce contaminates or over concentrated chemicals, resulting in
premature failure of cooling system components.
NOTE 2 - To precharge cooling systems larger than 114 r?(30 gal) do the following:
l Install appropriate service filter listed in the above table based on cooling system capacity.
Example: 95 gal (360 Q)cooling system capacity

-15 Units (1) WF-2075 Filter
80 Units
l The answer represents the additional units required to precharge the cooling system. Four bottles of
powder, part number DCA95, will provide a sufficient amount of SCA units (80) to precharge the example
cooling system.
l Install the appropriate service filter at the next and subsequent maintenance intervals.
NOTE 3 - Change the coolant filter at every engine oil and filter change interval to protect the cooling system.
01-14
Maintain a nominal SCA concentration of 1 .O unit per 3.8 Q(1 US gal) of coolant in the system. Less than 0.5 unit per
3.8 P (1 US gal) indicates an under-concentrated coolant solution. More than 2.0 units per 3.8 e (1 US gal) indicates
an over-concentrated coolant solution.
To check the SCA concentration level, use coolant test kit, CC-2606. Instructions are included with the test kit.
SCA Unit Concentration Guide
Number of Solution A Drops to Coolant Condition Action Required

Cause Color Change
0- 10 Drops Extremely under-concentrated - Initially charge the system to a

less than 0.4 SCA units per 3.8 P (1 minimum of 1 .O SCA unit per 3.8 e
US gal) (1 US gal).
11 - 16 Drops Marginally under-concentrated - i Add SCA liquid units to maintain

0.45 to 0.8 SCA units per 3.8 e (1 ~ 1.0 SCA unit per 3.8 e (1 US gal)
US gal) minimum or change the DCA 4
coolant filter.
17 - 25 Drops Acceptable - 0.85 to 1.3 SCA units None.

per 3.8 e (1 US gal)
26 - 35 Drops Highly acceptable - 1.35 to 2.0 None.

SCA units per 3.8 P (1 US gal)
36 - 55 Drops Marginally over-concentrated - 2.1 Review maintenance practice.

to 3.3 SCA units per 3.8 P (1 US
gal)
Over 55 Drops Extremely over-concentrated Drain 50% of the coolant and
replace with water antifreeze
mixture. Retest the system for
correct SCA unit concentration.
01-15
GENERAL MEMORANDA
01-16
10 STRUCTURE AND FUNCTION
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-2 Accumulator (for PPC valve) . . . . . . . . . . . . . 10-108
Radiator and oil cooler . . . . . . . . . . . . . . . . . . . . 10-4 PPC valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-110
Damper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-5 PPC relief valve . . . . . . . . . . . . . . . . . . . . . . . . 10-117
Torque converter and transmission piping . . . . . 10-7 Cut-off valve . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-118
Hydraulic circuit for power train . . . . . . . . . . . . . . 10-8 Main control valve . . . . . . . . . . . . . . . . . . . . . . 10-122
Hydraulic circuit diagram for power train . . . . . . 10-9 Work equipment linkage . . . . . . . . . . . . . . . . . 10-138
Torque converter and PTO . . . . . . . . . . . . . . . . 10-10 Bucket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-140
Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-12 Bucket positioner and boom kick-out . . . . . . . 10-142
Transmission control valve . . . . . . . . . . . . . . . . 10-22 Proximity switch . . . . . . . . . . . . . . . . . . . . . . . . 10-144
ECMV (electronic control modulation valve) . . 10-24 Cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-150
Main relief, torque converter relief valve . . . . . . 10-30 ROPS canopy . . . . . . . . . . . . . . . . . . . . . . . . . 10-151
Lubricating relief valve . . . . . . . . . . . . . . . . . . . . 10-32 Air conditioner . . . . . . . . . . . . . . . . . . . . . . . . . 10-152
Torque converter oil filter . . . . . . . . . . . . . . . . . 10-33 Air conditioner piping . . . . . . . . . . . . . . . . 10-152
Pilot filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-34 Basic information on air conditioners . . . . 10-153
Transfer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-35 Units related to refrigeration . . . . . . . . . . . 10-153
Drive shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-36 Principle of cooling . . . . . . . . . . . . . . . . 10-155-2
Center support . . . . . . . . . . . . . . . . . . . . . . . . . . 10-37 Refrigerants . . . . . . . . . . . . . . . . . . . . . 10-155-7
Axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-38 Safety precautions . . . . . . . . . . . . . . . . 10-155-7
Differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-40 Refrigerator oil (lube oil) . . . . . . . . . . . . 10-155-8
Final drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-44 Air conditioning condenser . . . . . . . . . . . . 10-155-10
Axle mount . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-46 Function . . . . . . . . . . . . . . . . . . . . . . . 10-155-10
Center hinge pin . . . . . . . . . . . . . . . . . . . . . . . . 10-48 General description . . . . . . . . . . . . . . 10-155-10
Tire and wheel . . . . . . . . . . . . . . . . . . . . . . . . . . 10-49 Air conditioner compressor . . . . . . . . . . . . 10-155-13
Steering piping . . . . . . . . . . . . . . . . . . . . . . . . . . 10-50 Receiver with sight glass . . . . . . . . . . . . . . 10-155-14
Steering column . . . . . . . . . . . . . . . . . . . . . . . . 10-51 Air conditioner unit . . . . . . . . . . . . . . . . . . . 10-155-16
Steering valve . . . . . . . . . . . . . . . . . . . . . . . . . . 10-52 Outline . . . . . . . . . . . . . . . . . . . . . . . . . 10-155-16
Orbit-roll valve . . . . . . . . . . . . . . . . . . . . . . . . . . 10-66 Electric circuit diagrams . . . . . . . . . . . . . . . . . 10-156
Stop valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-70 Machine monitor system . . . . . . . . . . . . . . . . . 10-166
Diverter valve . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-71 Main monitor . . . . . . . . . . . . . . . . . . . . . . . . . . 10-167
Brake circuit diagram . . . . . . . . . . . . . . . . . . . . 10-75 Maintenance monitor . . . . . . . . . . . . . . . . . . . . 10-171
Brake valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-76 All-range electronic control automatic
Charge valve . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-82 transmission system . . . . . . . . . . . . . . . . . 10-174
Accumulator (for brake) . . . . . . . . . . . . . . . . . . 10-86 Transmission controller . . . . . . . . . . . . . . . . . . 10-186
Slack adjuster . . . . . . . . . . . . . . . . . . . . . . . . . . 10-87 Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-188
Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-90 Engine starting circuit . . . . . . . . . . . . . . . . . . . 10-194
Parking brake control . . . . . . . . . . . . . . . . . . . . 10-92 Engine stop circuit . . . . . . . . . . . . . . . . . . . . . . 10-196
Parking brake . . . . . . . . . . . . . . . . . . . . . . . . . . 10-93 Ether start circuit . . . . . . . . . . . . . . . . . . . . . . . 10-197
Parking brake solenoid valve . . . . . . . . . . . . . . 10-94 Electric transmission control . . . . . . . . . . . . . . 10-198
Parking brake emergency Combination switch . . . . . . . . . . . . . . . . . . . . . 10-199
release solenoid valve . . . . . . . . . . . . . . . . 10-95 Kick-down hold switch . . . . . . . . . . . . . . . . . . . 10-201
Hydraulic circuit system . . . . . . . . . . . . . . . . . . 10-102 Kick-down electric circuit . . . . . . . . . . . . . . . . . 10-202
Work equipment lever linkage . . . . . . . . . . . . 10-104 Electric parking brake control . . . . . . . . . . . . . 10-205
Hydraulic tank . . . . . . . . . . . . . . . . . . . . . . . . . 10-105
10-1
STRUCTURE AND FUNCTION GENERAL
GENERAL
OUTLINE
The power from the engine (1) is transmitted from A multiple disc parking brake is installed to the
the flywheel to damper (2) through the ring gear. output shaft of transmission (10). At the front end,
The damper alleviates the torsional vibration the power from the output shaft passes through
caused by the variation of the engine torque and center drive shaft (12) and front drive shaft (14) and
transmits the power to torque converter (4) through is transmitted to front differential (15), at the rear
drive shaft (3). The torque converter converts the end it is transmitted to rear differential (20) by rear
delivered torque according to the variation in the drive shaft (19).
load on the oil used as the medium, and transmits
the power to the input shaft of transmission (10). The power transmitted to front differential (15) and
The engine power then is transmitted to PPC pump rear differential (20) is transmitted to the axle
(7), steering pump (9), hydraulic pump (8), switch shafts.
pump (6), and torque converter charging pump (5)
through the pump driving gear in torque converter The power from the axle shafts has its speed
(4). reduced by final drives (16) and (21), and it is then
transmitted to tires (18) and (23) through the
In transmission (10), the six hydraulic clutches are planetary carrier.
operated by the forward-reverse spool and the
speed change spools in the transmission valves,
which are themselves activated by solenoid valves.
Thus, the desired travel speed can be selected
from among the 4 forward and 4 reverse gear
speeds.
10-2
STRUCTURE AND FUNCTION GENERAL
1. Engine 9. Steering pump 17. Front brake

2. Damper 10. Transmission 18. Front tire
3. Upper drive shaft 11. Parking brake 19. Rear drive shaft
4. Torque converter 12. Center drive shaft 20. Rear differential
5. Torque converter charging pump 13. Center support 21. Rear final drive
6. Switch pump 14. Front drive shaft 22. Rear brake
7. PPC pump 15. Front differential 23. Rear tire
8. Hydraulic pump 16. Front final drive
10-3
STRUCTURE AND FUNCTION RADIATOR AND OIL COOLER
RADIATOR AND OIL COOLER
1. Radiator Specifications:
2. Coolant level sensor Radiator
3. Fan guard Radiator core type: G7 type
4. Torque converter oil cooler Total heat dissipation area: 98.44 m2
5. Hydraulic oil cooler Cross-sectional area of water flow: 193.8 cm2
Torque converter oil cooler
A. Coolant inlet port Type: PTO-OL (multiple disc type)
B. Coolant outlet port Heat dissipation area: 1, 829 m2
C. Hydraulic oil outlet port Type: SF-2 (Air to Air)
D. Hydraulic oil inlet port Heat dissipation area: 14.04 m2
E. Torque converter oil outlet port Hydraulic oil cooler
F. Torque converter oil inlet port Type: PTO-LS (multiple disc type)
Heat dissipation area: 1.147 m2
10-4
STRUCTURE AND FUNCTION DAMPER
DAMPER
FUNCTION
1. Coupling The damper reduces the twisting and vibration
2. Output shaft caused by the variations in the engine torque, and
3. Cover acts to protect the engine and other parts from
4. Bearing such twisting and vibration.
5. Bearing
6. Outer body
7. Rubber cushion
8. Inner body
10-5
STRUCTURE AND FUNCTION DAMPER
OPERATION
The engine power is transmitted to the flywheel and

outer body (6) and rubber cushion (7) absorbs the
twist and vibration of the engine. The engine power
is then transmitted through the inner body (8) to
output shaft (2). From here, the engine power is
transmitted through the coupling to the torque
converter and drive shaft.
10-6
STRUCTURE AND FUNCTION TORQUE CONVERTER AND TRANSMISSION PIPING
TORQUE CONVERTER AND TRANSMISSION PIPING
1. Transmission 7b. Oil cooler (air-cooled type)

2. Transmission valve 8. Torque converter charging pump
3. Torque converter 9. Parking brake solenoid valve
4. Accumulator 10. Oil filter
5. Parking brake emergency release valve 11. Parking brake
6. Radiator 12. Torque converter oil cooler (air to air)
7a. Oil cooler (water-cooled type)
10-7
STRUCTURE AND FUNCTION HYDRAULIC CIRCUIT FOR POWER TRAIN
HYDRAULIC CIRCUIT FOR POWER TRAIN
10-8
STRUCTURE AND FUNCTION HYDRAULIC CIRCUIT DIAGRAM FOR POWER TRAIN
HYDRAULIC CIRCUIT DIAGRAM FOR POWER TRAIN
1. Transmission case 11. Pilot oil filter 21. 1st ECMV

2. Strainer 12. Parking brake solenoid valve 22. Flow detector valve
3. Torque converter charging pump 13. Parking brake emergency 23. Pressure control valve
4. Torque converter oil filter release valve 24. FORWARD clutch
5. Main relief valve 14. Accumulator 25. REVERSE clutch
6. Torque converter relief valve 15. Parking brake 26. 3rd clutch
7. Torque converter 16. FORWARD ECMV 27. 4th clutch
8a. Oil cooler (water-cooled type) 17. REVERSE ECMV 28. 2nd clutch
8b. Oil cooler (air-cooled type) 18. 3rd ECMV 29. 1st clutch
9. Transmission lubrication 19. 4th ECMV
10. Lubrication relief valve 20. 2nd ECMV
10-9
STRUCTURE AND FUNCTION TORQUE CONVERTER AND PTO
TORQUE CONVERTER AND PTO
10-10
STRUCTURE AND FUNCTION TORQUE CONVERTER AND PTO
Flow of motive force
The torque converter is installed between the damper and

transmission. The motive force from the damper passes
through the drive shaft and enters drive case (7). Drive case
(7), pump (10) and PTO gear (drive) (13) are fixed with bolts.
They are rotated directly by the rotation of the engine.
The motive force of pump (10) uses oil to rotate turbine

(8). This transmits motive force to transmission input
shaft (12).
The motive force of drive case (7) passes through PTO gear
(drive) (13) and is also used as the motive force to drive the
gear pump.
Flow of oil
The oil pressure is adjusted by the torque converter relief

valve and then enters inlet port A, passes through the oil
passage in housing (9) and flows to pump (10). In pump (10)
centrifugal force is applied. The oil enters turbine (8) and the
energy of the oil is transmitted to the turbine.
Turbine (8) is fixed to transmission input shaft (12), so the

motive force is transmitted to the transmission input shaft
(12).
The oil from turbine (8) is sent to stator (11) and again
enters the pump. However, part of the oil passes from the
stator through outlet port B and is sent to the cooler.
10-11
STRUCTURE AND FUNCTION TRANSMISSION
TRANSMISSION
1. Main relief, torque converter relief valve 6. Parking brake

2. Transmission valve 7. Output coupling (front)
3. Transmission input shaft 8. Output coupling (rear)
4. Transmission 9. Oil filler port
5. Transfer 10. Strainer
10-12
A. To torque converter I. Mounting port for parking brake actuation pilot lamp
B. From torque converter case J. To torque converter charging pump
C. Breather mount port K. To REVERSE clutch
D. From oil filter L. To 3rd clutch
E. Transmission main oil pressure port M. To 1st clutch
F. To parking brake emergency release valve N. To 2nd clutch
G. Lubricating oil pressure port O. To 4th clutch
H. From oil cooler P. To FORWARD clutch
10-13
1. Input shaft
2. No. 1 sun gear (22 teeth)
3. No. 1 planet gear (24 teeth)
4. No. 1 ring gear (90 teeth)
5. No. 1 clutch
6. No. 1 idler gear (70 teeth)
7. Lubrication relief valve
8. No. 2 clutch
(Output shaft)
11. No. 3 clutch
16. No. 4 clutch
20. No. 5 clutch
21. No. 6 gear (90 teeth)
22. No. 6 clutch
23. Output shaft
24. No. 5 carrier
25. No. 3, 4 carrier
28. No. 2 carrier
29. No. 1 carrier
10-14
OUTLINE
Speed range Clutch combination
The transmission consists of a 4-FORWARD, 4-
REVERSE speed planetary gear transmission, F1 No.2, No.6
transfer, and transmission control valve.
In the transmission, the motive force of the input F2 No.2, No.5
shaft is changed by the combination of No.1 or
No.2 clutch with No.3,4,5, or 6 clutch to give F3 No.2, No.4
FORWARD 1 - 4 or REVERSE 1 - 4 speed, and is
transmitted to the output shaft F4 No.2, No.3
R1 No.1, No.6
R2 No.1, No.5
R3 No.1, No.4
R4 No.1, No.3
OPERATION OF CLUTCH
Engaged
The oil sent from the transmission control valve
passes through the oil passage inside the
transmission. When it reaches the rear piston (1),
it moves the piston (1).
When the piston (1) moves, disc (2) and plate (3)
are pressed together. Ring gear (4) is meshed with
disc (2), so the rotation is stopped.
Disengaged
When the supply of oil from the transmission
control valve is shut off, the pressure of the oil is
acting on the rear of piston (1) is reduced. The
piston is then pushed back to the right by return
spring (5), and disc (2) and plate (3) are separated.
Ring gear (4) then rotates freely, and no motive
force is transmitted.
10-15
FORWARD 1st
In 1st FORWARD, No. 2 clutch and No. 6 clutch are The motive force from the torque converter is
engaged. The motive force transmitted from the transmitted to the input shaft (2). The rotation of the
torque converter by input shaft (2) is transmitted to input shaft (2) is transmitted to planetary gear (14)
output shaft (31). through sun gear (13).
No. 2 clutch is actuated by the hydraulic pressure Ring gear (15) is held in position by No. 2 clutch so
applied to the clutch piston, and it locks ring gear (15) the rotation of planetary gear (14) rotates carriers
in position. No. 6 clutch is actuated by the hydraulic (33) and (34), which is on the inside ring gear (15).
oil pressure applied to the clutch piston and holds This carrier is connected to No. 5 carrier (32)
gear (29) to carrier (32). through No. 4 ring gear (23, so when No. 6 clutch
is actuated, the rotation of carrier (32) is transmitted
to gear (29) and rotate output shaft (31).
10-16
FORWARD 2nd
In 2nd FORWARD, No. 2 clutch and No. 5 clutch are Ring gear (15) is held in position by No. 2 clutch so
engaged. The motive force transmitted from the the rotation of planetary gear (14) rotates carriers
torque converter by input shaft (2) is transmitted to (33) and (34), which is on the inside ring gear (15).
output shaft (31). The rotation of carrier (33) is transmitted through
No. 2 clutch is actuated by the hydraulic pressure ring gear (23) to carrier (32).
applied to the clutch piston, and it locks ring gears Ring gear (27) is held in position by No. 5 clutch, so
(15) and (27) in position. the rotation of carrier (32) rotates planetary gear
The motive force from the torque converter is (26). The planetary gear rotates on the inside of
transmitted to the input shaft (2). The rotation of the ring gear (27), and rotates sun gear (25). The sun
input shaft (2) is transmitted to planetary gear (14) gear rotates output shaft (31).
through sun gear (13).
10-17
FORWARD 3rd
In 3rd FORWARD, No. 2 clutch and No. 4 clutch are Ring gear (15) is held in position by No. 2 clutch, so
output shaft (31). Ring gear (23) is held in position by No. 4 clutch, so
No. 2 clutch and No. 4 clutch are actuated by the the rotation of carrier (33) is transmitted to
hydraulic pressure applied to the clutch piston, and it planetary gear (22) rotates on the inside of ring
locks ring gears (15) and (23) in position. gear (23), and rotates sun gear (21). The sun gear
The motive force from the torque converter is rotates output shaft (31).
transmitted to the input shaft (2). The rotation of the
input shaft is transmitted to planetary gear (14)
10-18
FORWARD 4th
In 4th FORWARD, No. 2 clutch and No. 3 clutch are Ring gear (15) is held in position by No. 2 clutch so
output shaft (31). Ring gear (19) is held in position by No. 3 clutch, so
No. 2 clutch and No. 3 clutch are actuated by the the rotation of carrier (33) is transmitted to
hydraulic pressure applied to the clutch piston, and it planetary gear (18). The planetary (18) rotates on
locks ring gears (15) and (19) in position. the inside of ring gear (19), and rotates sun gear
The motive force from the torque converter is (17), which forms one unit with output shaft (31).
10-19
REVERSE 1st
In 1st REVERSE, No. 1 clutch and No. 6 clutch are Carrier (35) is held in position by No. 1 clutch, so
engaged. The motive force transmitted from the the rotation of planetary gear rotates the ring gear.
torque converter by input shaft (2) is transmitted to Ring gear (15) rotates in the opposite direction from
output shaft (31). the input shaft. Ring gear (15) rotates carrier (34),
No. 1 clutch is actuated by the hydraulic pressure and the rotation of carrier (34) rotates ring gear
applied to the clutch piston, and it locks carrier (35) in (23), which then rotates carrier (32). Carrier (32)
position. No. 6 clutch is actuated by the hydraulic rotates No. 6 clutch (30). When No. 6 clutch is
pressure applied to the clutch piston and hold ring actuated, the rotation of carrier (32) is transmitted
gear (29) in position. to gear (29) and rotates output shaft (31).
The motive force from the torque converter is
10-20
- MEMORANDA -
10-21
STRUCTURE AND FUNCTION TRANSMISSION CONTROL VALVE
TRANSMISSION CONTROL VALVE
10-22
STRUCTURE AND FUNCTION TRANSMISSION CONTROL VALVE
1. ECMV (for FORWARD clutch)

2. ECMV (for REVERSE clutch)
3. ECMV (for 3rd clutch)
4. ECMV (for 4th clutch)
5. ECMV (for 2nd clutch)
6. Parking brake solenoid valve
7. ECMV (for 1st clutch)
8. Pilot filter
A, A’: FORWARD clutch oil pressure measurement port.

B, B’: REVERSE clutch oil pressure measurement port.
C, C’: 3rd clutch oil pressure measurement port.
D, D’: 4th clutch oil pressure measurement port.
E, E’: 2nd clutch oil pressure measurement port.
F, F’: 1st clutch oil pressure measurement port.
G’: To parking brake emergency release valve.
H’: To parking brake emergency release valve (Pilot pressure).
ECMV actuation table

Speed Clutch
range
FORWARD REVERSE 3rd 4th 2nd 1st
Auto O O
N
Manual O O O O
F1 O O
F2 O O
F3 O O
F4 O O
R1 O O
R2 O O
R3 O O
R4 O O
When at manual N, the clutch of the speed range where the

gear shift lever is placed, is ON.
10-23
STRUCTURE AND FUNCTION ECMV
ECMV (ELECTRONIC CONTROL MODULATION VALVE)
A. To clutch
D. Drain port
P. From pump
T. Clutch drain port
10-24
1. Connector
2. Connector
3. Spring
4. Pressure control valve spool
5. Proportional solenoid
6. Fill switch
7. Pin
8. Spring
9. Flow detector valve spool
10-25
OUTLINE OF ECMV
The ECMV (Electronic Control Modulation Valve) consist of
two valves: The pressure control valve and the flow detection
valve.
Pressure control valve
The proportional solenoid receives the flow of electricity sent
from the transmission controller, and the pressure control
valve converts this into hydraulic pressure.
Flow detection valve
This valve is actuated by a trigger from the pressure control
valve and has the following functions:
1) When the clutch is filled with oil, it sends a signal (fill
signal) to the controller to inform the controller that the
filling is completed.
2) While oil pressure is applied to the clutch, it outputs a
signal (fill signal) to the controller to inform the controller
of the existence of the oil pressure.
ECMV AND PROPORTIONAL SOLENOID

There is one proportional solenoid installed to each ECMV.
It generates propulsion as shown in the diagram on the right
according to the command current from the transmission
controller.
The propulsion generated by the proportional solenoid acts
on the pressure control valve spool and generates oil
pressure as shown in the diagram on the right. In this way,
the command current is controlled and the propulsion force
varies to actuate the pressure control valve and control the oil
flow and oil pressure.
ECMV AND FILL SWITCH

There is one fill switch installed to each ECMV.
When the filling of the clutch is completed, the fill switch is
turned on by the action of the flow detection valve. With this
signal, the oil pressure starts the build-up.
10-26
ACTUATION OF ECMV
The ECMV is controlled by the command current from the
transmission controller to the proportional solenoid and the
fill switch output signal. The relationship between ECMV
proportional solenoid command current and the clutch input
pressure and fill switch output signal is as shown in the
diagram on the right.
Range A: Before shifting gear (when draining)

Range B: Fill starts (during trigger)
Range C: Fill completed
Range D: Pressure adjustment
Range E: During filling
1. Before gear shifting (during draining) - Range A in

graph.
When no current is flowing to proportional solenoid (5),
proportional solenoid (5) is pushed back by the reaction of
pressure control valve spring (3) through pressure control
valve spool (4), so pressure control valve (4) drains the oil
at clutch port A through drain port T.
When this happens, there is no hydraulic force acting on

flow detection valve spool (9), so flow detection valve spool
(9) is separated from fill switch (6) by the reaction force of
fill switch spring (8).
10-27
2. Start of fill (when trigger command is input to pressure

control valve) - Range B in graph .
When there is no oil inside the clutch, if the trigger current is
applied to proportional solenoid (5) (if the maximum current
is applied), the proportional solenoid moves and pressure
control valve spool (4) moves to the left. As a result, the
circuit between pump port P and the pressure control valve
output port B opens, and oil passage through orifice “a” of
flow direction valve spool (9) and starts to fill the clutch.
3. Filling completed (pressure control valve set to default

pressure)
1) To reduce the transmission shock, action must be
taken to prevent peak pressure from being generated
at clutch port A when the filling is completed. In order
to do this, the electric current in proportional solenoid
(5) is lowered to the default pressure before the filling
is completed and pressure control valve spool (4) is
moved to the right. This allows a small amount of oil to
leak from pressure control valve output port B to drain
port T. In this way, the generation of peak pressure at
clutch port A can be prevented when the filling is
completed.
10-28
2) When the clutch is filled with oil, the oil stops flowing
from pressure control valve output port B to clutch port
A. The area receiving the pressure on the left and right
sides of orifice a of flow detection valve spool (9) is
different. The left side is larger, so when the oil pressure
on both sides of orifice a becomes equal, fill switch
spring (8) is compressed, and as a result, pin (7)
contacts fill switch (6) and sends the clutch fill
completion signal to the shift controller. At this point, the
default pressure current is flowing to proportional
solenoid (5), and the oil pressure is set to the default
pressure setting by pressure control valve spool (4).
4. Adjusting pressure (Range D in graph)

When electric current flows to proportional solenoid (5), the
solenoid generates a force proportional to the current. The
total of this propulsion force of the solenoid and the propulsion
force of the oil pressure at the clutch port and the reaction
force of pressure control valve spring (3) is balanced. Flow
detection valve spool (9) is pushed to the right by the
difference in the force of the oil pressure applied to both sides
of orifice a, and it continues to send the fill signal to the shift
controller.
10-29
STRUCTURE AND FUNCTION MAIN RELIEF, T.C. RELIEF VALVE
MAIN RELIEF, TORQUE CONVERTER RELIEF VALVE
1. Body OUTLINE
2. Torque converter relief valve 1. Main relief valve.
3. Valve spring Main relief valve (6) sets the pressure of the
4. Piston transmission oil.
5. Piston spring
6. Main relief valve 2. Torque converter relief valve.
7. Valve spring Torque converter relief valve (2) acts to protect the
8. Piston spring torque converter from abnormally high pressure. It
9. Piston relieves the pressure when the pressure at the inlet
port of the torque converter goes above the
A. Drain port (torque converter relief) specified pressure.
B. Drain port
C. From pump
Specified pressure
D. Drain port
E. To torque converter Main relief pressure 3.52 MPa (35.9 kg/cm2)
P1 Main relief oil pressure detection port (engine at rated speed
Torque converter inlet 0.84 MPa (8.5 kg/cm2)

port pressure (cracking pressure)
10-30
STRUCTURE AND FUNCTION MAIN RELIEF, T.C. RELIEF VALVE
OPERATION OF MAIN RELIEF VALVE

The oil from the torque converter charging pump passes
through the filter, enters port A of the main relief valve, and
then passes through orifice a and enters port B. When the oil
from the pump fills the circuit, the pressure starts to raise.
When the oil pressure in the circuit rises, the oil entering port
B pushes piston (4). The reaction compresses spring (7) and
moves main relief valve (6) to the left to open the passage
between port A and port C. When this happens, the oil from
the pump is relieved from port A to port C, and flows from
port C, into the torque converter. The oil pressure at port A at
this point is 3.52 MPa (35.9 kg/cm2) engine at rated speed.
OPERATION OF TORQUE CONVERTER RELIEF VALVE

The oil relieved from the main relief valve flows from port
C
into the torque converter, and at the same time, passes
through orifice b and enters port D. When the oil fills the
circuit to the torque converter, the oil pressure starts to
raise.
When the oil pressure in the circuit to the torque converter

rises, the oil entering port D pushes piston (9). The reaction
compresses spring (3), and moves relief valve (2) to the right
to open the passage between port C and port E. When this
happens, the oil from port C is relieved to port E and flows to
the transmission lubrication circuit. The oil pressure at port C
at this point is 0.84 MPa (8.5 kg/cm2) cranking pressure.
10-31
STRUCTURE AND FUNCTION LUBRICATING RELIEF VALVE
LUBRICATING RELIEF VALVE
1. Piston A. From oil cooler

2. Spring B. Drain
3. REVERSE clutch housing C. Drain
OUTLINE
The lubricating relief valve is assembled to the left Unit: MPa (kg/cm2)
face of the REVERSE clutch housing, and protects
Specified value
the lubricating circuit and oil cooler
Pressure when normal 0.15 - 0.23 (1.5 - 2.3)
Cracking pressure 0.3 (3.0)
10-32
STRUCTURE AND FUNCTION TORQUE CONVERTER OIL FILTER
TORQUE CONVERTER OIL FILTER
OPERATION
The oil from the torque converter charging pump enters the
filter inlet port A and passes from the outside of element (2)
to the inside. It then flows to the outlet port B.
If the element (2) is clogged with dirt, or the oil temperature

is low, the pressure at the inlet port A rises. When this
happens, the oil from the inlet port A opens relief valve (1)
and flows directly to the outlet port B. This prevents damage
to the pump or element (2).
10-33
STRUCTURE AND FUNCTION PILOT FILTER
PILOT FILTER
OUTLINE Specifications
The oil flows from the transmission case to pump Filter mesh size: 10
to torque converter oil filter, and is then divided and Filtering area: 0.063 m2 (630 cm2)
flows to the torque converter and transmission Element pressure resistance: 4.9 MPa (50 kg/cm2)
control valve.
There is a pilot filter installed at the inlet port of the
transmission control valve, and this filters the dirt
out of the oil flowing to the control valve.
10-34
STRUCTURE AND FUNCTION TRANSFER
TRANSFER
Outline
The transfer is installed at the power output end of 1. Transmission output shaft
the transmission and is secured to the transmission 2. Transfer input gear (teeth 48)
case by bolts. 3. Transfer idler gear (teeth 45)
4. Output gear (teeth 43)
Transmission path 5. Output shaft
Output shaft (1) of the transmission is coupled to 6. Front coupling
transfer input gear (2) by a spline. The motive force 7. Rear coupling
is transmitted to output gear (4) through idler gear 8. Parking brake
(3) and output shaft (5).
Part of the power transmitted to the output shaft is

transmitted to the front axle through the center
drive shaft and front drive shaft. The rest of the
power is transmitted to the rear axle through the
rear drive shaft.
10-35
STRUCTURE AND FUNCTION DRIVE SHAFT
DRIVE SHAFT
1. Front drive shaft 4. Rear drive shaft

2. Center support 5. Upper drive shaft
3. Center drive shaft
Outline
The motive force from the engine passes through When the body is articulated, or when there is
the damper, upper drive shaft (5), torque converter, shock from the road surface during traveling, or
transmission and transfer. Part of this motive force when there is shock during operations, the axle in
passes through rear drive shaft (4) and goes to the front and behind the engine and transmission
rear axle: the rest of the motive force passes change position.
through center drive shaft (3), center support (2) To allow the motive force to be transmitted without
and front drive shaft (1) and is sent to the front axle. damage to parts of the machine when there is
In addition to transmitting the motive force, the drive shock or when the components move position, the
shafts have the following purposes. drive shafts have a universal joint and a sliding
joint. This allows them to handle changes in angle
and length.
10-36
STRUCTURE AND FUNCTION CENTER SUPPORT
CENTER SUPPORT
Function
The center support is installed to the front frame

1. Front coupling between the center drive shaft and the front drive
2. Case shaft.
3. Grease fitting
4. Rear coupling With the articulating frame, this part is constantly
twisting from side to side, so there is liable to be a
large amount of stress on the drive shafts. There-
fore, the center support is used to transmit the
power smoothly, to reduce the stress on the drive
shafts, and improve the durability of the drive
shafts.
10-37
STRUCTURE AND FUNCTION AXLE
AXLE
FRONT
10-38
STRUCTURE AND FUNCTION AXLE
Rear
10-39
STRUCTURE AND FUNCTION DIFFERENTIAL
DIFFERENTIAL
Front
1. Slide gear (18 teeth)

2. Bevel pinion (9 teeth)
3. Bevel gear (37 teeth)
4. Pinion (10 teeth)
5. Shaft
10-40
Rear
1. Bevel gear (37 teeth)

2. Shaft
3. Slide gear (18 teeth)
4. Pinion (10 teeth)
5. Bevel pinion (9 teeth)
10-41
OUTLINE
The motive force from the drive shaft passes through bevel
pinion (1) and is transmitted to the bevel gear (5). The bevel
gear changes the direction of the motive force by 90
the same time reduces the speed. It then transmits the
motive force through the differential (4) to the sun gear shaft
(2).
When driving straight forward
When the machine is driven straight forward, the rotating

speed of the left and right wheels is the same, so the pinion
gear (4) inside the differential assembly (6) is sent through
the pinion gear (4) and the side gear (3) and is transmitted
equally to the left and right sun gear shafts (2).
When turning
When turning, the rotating speed of the left and right wheels
is different, so the pinion gear (4) and side gear (3) inside the
differential assembly rotate in accordance with difference
between the rotating speed of the left and right wheels. The
motive force of the carrier (6) is then transmitted to the sun
gear shafts (2).
10-42
TORQUE PROPORTIONING DIFFERENTIAL "b" is less than 1 : 1.38 (that is, the difference
between the resistance from the road surface to
FUNCTION the left and right tires is less than 38%), the pinion
gear will not rotate freely, so drive force will be
Because of the nature of their work, 4-wheel-drive given to both side gears, and the tires will not slip.
loaders have to work in places where the road Because of this effect, the tire life can be increased
surface is bad. In such places, if the tires slip, the by 20 - 30%, and at the same time the operating
ability to work as a loader is reduced, and also the efficiency is also increased.
life of the tire is reduced. The torque proportioning
differential is installed to overcome this problem.
In structure it resembles the differential of an auto-

mobile, but the differential pinion gear (4) has an
odd number of teeth. Because of the difference in
the resistance from the road surface, the position of
meshing of the pinion gear (4) and side gear (3A),
(3B) changes, and this changes the traction of the
left and right tires.
OPERATION
When traveling straight (equal resistance from road

surface to left and right tires)
If the resistance from the road surfaces to the left

and right wheels is the same, the distance between
the pinion gear and the meshing point "a" of the left
side gear is the same as the distance between the
pinion gear and meshing point "b" of right side gear
(3B).
Therefore the left side traction TL and the right side

traction TR are balanced.
When traveling on soft ground (resistance from

road surface to left and right tires is different)
On soft ground, if the tire on one side slips, the side

gear of the tire on the side which has least resis-
tance from the road surface tires to rotate forward.
Because of this rotation, the meshing of the pinion
gear and side gear changes.
If left side gear (A) rotates slightly forward, the

distance between the pinion gear and the meshing
point "a" of the left side gear becomes longer than
the distance between the pinion gear and the
meshing port "b" of the right side gear. The position
is balanced as follows:
a x TL = b x TR
The ratio between the distances to "a" and "b" can

change to 1 : 1.38.
Therefore when the ratio of the distances to "a" and
10-43
STRUCTURE AND FUNCTION FINAL DRIVE
FINAL DRIVE
1. Axle shaft Outline

2. Planetary gear (29 Teeth)
3. Ring gear (78 Teeth) To gain a large drive force, the final drive uses a
4. Planetary carrier planetary gear system to reduce speed and send
5. Sun Gear (18 Teeth) drive force to the tires.
6. Wheel
10-44
STRUCTURE AND FUNCTION FINAL DRIVE
Operation
The motive force transmitted from the differential through

axle shaft (1) to sun gear (5) is transmitted to planetary gear
(2). The planetary gear rotates around the inside of a fixed
ring gear (3) and in this way transmits rotation at a reduced
speed to the planetary carrier (4). This motive force is then
sent to the wheels (6) which are installed to the planetary
carriers (4).
10-45
STRUCTURE AND FUNCTION AXLE MOUNT
AXLE MOUNT
10-46
STRUCTURE AND FUNCTION AXLE MOUNT
1. Front axle Front axle

2. Rear axle The front axle (1) receives the force directly during
3. Front frame operations, so it is fixed directly to the front frame
4. Rear frame (3) by axle mounting bolts (5).
5. Axle mounting bolts
Rear axle
The rear axle (2) has a structure which allows the
center of the rear axle to float, so that all tires can
be in contact with the ground when traveling over
soft ground.
10-47
STRUCTURE AND FUNCTION CENTER HINGE PIN
CENTER HINGE PIN
1. Front axle OUTLINE

2. Rear axle The front frame (3) and rear frame (4) are connect-
3. Front frame ed through a bearing by the center hinge pin (5)
4. Rear frame and (6). The steering cylinders are connected to
5. Upper hinge pin the left and right front and rear frames, so when the
6. Lower hinge pin cylinders are operated, the frame bends at the
middle to give the desired angle, that is the desired
turning radius.
10-48
STRUCTURE AND FUNCTION TIRE AND WHEEL
TIRE AND WHEEL

The tire acts to absorb the shock from the ground Specifications
surface to the machine, and at the same time they
must rotate in contact with the ground to gain the Tire type: 26.5 x 25, 20PR
power which drives the machine TRA code: L3
Nominal size of wheel: 22.00 x 25WTB
Various types of tires are available to suit the Nominal inflation pressure:
purpose. Therefore it is very important to select the FRONT tire: 441.3 kPa (4.5 kg/cm², 63.9
correct tires for the type of work and bucket capaci- psi)
ty. REAR tire: 343.2 kPa (3.5 kg/cm², 49.7
psi)
1. Tire
2. Rim
3. Air valve
4. Lock ring
5. Side ring
10-49
STRUCTURE AND FUNCTION STEERING PIPING
STEERING PIPING
1. Steering cylinder (R.H.) 7. Switch pump and PPC pump

2. Orbit-roll valve 8. Steering pump
3. Stop valve (R.H.) 9. Stop valve (L.H.)
4. Hydraulic tank 10. Steering valve
5. Hydraulic pump 11. Steering cylinder (L.H.)
6. Oil cooler
10-50
STRUCTURE AND FUNCTION STEERING COLUMN
STEERING COLUMN
1. Steering wheel
2. Steering column
3. Joint
4. Orbit-roll valve
10-51
STRUCTURE AND FUNCTION STEERING VALVE
STEERING VALVE
1. Safety valve (with suction) A: To steering cylinder

2. Check valve B: To steering cylinder
3. Steering spool Pa: From orbit-roll valve
4. Relief valve Pb: From orbit-roll valve
5. Demand spool P1: From steering pump
P2: From steering pump
PB: To main control valve
T: Drain (to oil cooler)
10-52
OPERATION OF DEMAND VALVE
Steering spool at neutral
The oil from the steering pump enters port A, and When the pressure at pressure-receiving camber
the oil from the switch pump enters port B. (I) reaches a certain value (set by spring {5}), notch
When steering spool (2) is at neutral, pressure- (f) opens, and the oil from the steering pump flows
receiving chamber (II) is connected to the drain to the drain circuit. At the same time, notch (g)
circuit through orifice (b), and notch (c) is closed. closes, and the oil from the switch pump all flows
Notch (c) is closed, so the pressure of the oil at port to the main control valve.
A and port B rises. This pressure passes through
orifice (a), goes to pressure-receiving chamber (I),
and moves demand spool (1) to the left in the
direction of the arrow.
10-53
Steering spool operated

Engine at low speed
When steering spool (2) is pressed (operated), The merged oil passes through notch (c) and notch
pressure-receiving chamber (III) and the drain (d), pushes up load check valve (4), and flows to
circuit are shut off, ans at the same time notch (c) the cylinder. The oil returning from the cylinder
opens. passes through notch (e) and enters the drain
When this happens, the pressure in pressure- circuit.
receiving chamber (III) rises, and demand spool (1) In this condition, the pressure before passing
moves to the right in the direction of the arrow until through notch (c) goes to pressure-receiving
notch (h) closes. chamber (I), and the pressure after passing notch
The passage from port B to the main control valve (c) goes to pressure-receiving chamber (II).
is shut off, so the oil from switch pump pushes up Demand spool (1) moves to maintain the pressure
merge check valve (3), and merges with the oil at difference on the two sides of notch (c) at a
port A from the steering pump. constant value. Therefore, a flow corresponding to
the amount of opening notch (c) is discharged from
the cylinder port. These pressure differences
(control pressure are set by spring (5).
10-54
Engine at high speed
The extra oil from the switch pump is not needed, The oil from steering passes through notch (c) and
so the steering pump pressure rises until notch (g) notch (d), pushes up load check valve (4), and
closes, and shuts off the merge passage at port B. flows to the cylinder. The oil returning from the
The pressure difference on the two sides of notch cylinder passes through notch (e) and flows to the
(c) is controlled only by notch (f), so the excess oil drain circuit.
from the steering pump is drained from notch (f) to Notch (g) is closed, so the oil from the switch pump
drain the circuit (when this happens, notch (g) is is sent from port B to the main control valve.
completely closes.
10-55
FLOW AMP
1. Steering spool 5. Cap A: From orbit-roll valve

2. Valve housing (body) 6. Capscrew B: From orbit-roll valve
3. Spring seat 7. Orifice C: Passage (inside housing)
4. Return spring
Operation of flow amp

1. Spool at neutral (Orbit-roll valve not actuated)
When the Orbit-roll valve is not actuated, both pilot spool (1) is kept at neutral by return spring (4).
port PiA and pilot port PiB are connected through
the Orbit-roll to the drain (return) circuit, so steering
10-56
2. Spool actuated (oil flows to port PiA)
When oil flows to port PiA, the pressure inside the Port PiB is connected to the drain circuit through
cap end A rises and moves steering spool (1) in the the Orbit-roll valve, so the oil flowing to end B is
direction of the arrow. drained.
The oil entering from port PiA passes through the The pressure generated at port PiA is proportional
hole in spring seat (3), through orifice (7) in steering to the amount of oil flowing in, so steering spool (1)
spool (1), and then flows to the opposite end (B moves to a position where the opening of the flow
end). amp notch balances the pressure generated with
the force of return spring (4).
10-57
3. Spool returning (steering wheel stopped, flow of oil to port PiA cut)
When steering wheel (Orbit-roll valve) is stopped,

ports PiA and PiB are both connected to the drain
circuit through the Orbit-roll valve. For this reason,
steering spool (1) is returned to neutral position by
return spring (4).
10-58
OPERATION OF STEERING VALVE
Neutral
The steering wheel is not being operated, so When the pressure at ports A and B rises, demand
steering spool (1) does not move. spool (4) moves to the left in the direction of the
The oil from the steering pump enters port A, the arrow. The oil from the steering pump passes
oil from the switch pump enters port B. through port C of the spool and is drained. The oil
from the switch pump passes through port D and
flows to the main control valve.
10-59
Turning right
When the steering wheel is turned to the right, the The oil from the left and right cylinders passes
pressure oil from the Orbit-roll valve acts on through load check valve (3) of the steering spool,
steering spool (1), and steering spool (1) moves to and is drained.
the left in the direction of the arrow. The oil from the switch pump enters port B, flows
The oil from the steering pump enters port A, through demand spool (2), pushes open check
passes through demand spool (2), and flows to valve (5), and merges with the oil from the steering
steering spool (1). It pushes open load check valve pump.
(4) of the spool, and the oil flows to the bottom end
of the left cylinder and the rod end of the right
cylinder to turn the machine to the right.
10-60
Turning left
When the steering wheel is turned to the left, the The oil from the left and right cylinders passes
pressure oil from the Orbit-roll valve acts on through load check valve (4) of the steering spool,
steering spool (1), and steering spool (1) moves to and is drained.
the right in the direction of the arrow. The oil from the switch pump enters port B, flows
The oil from the steering pump enters port A, through demand spool (2), pushes open check
passes through demand spool (2), and flows to valve (5), and merges with the oil from the steering
steering spool (1). It pushes open load check valve pump.
(3) of the spool, and the oil flows to the bottom end
of the right cylinder and the rod end of the left
cylinder to turn the machine to the left.
10-61
STEERING RELIEF VALVE
1. Adjustment screw
2. Spring
3. Plug
4. Pilot popper
5. Valve seat
Function
The steering relief valve is inside the steering valve,
and sets the maximum circuit pressure of the
steering circuit when the steering valve is actuated.
When the steering valve is being actuated, if the
steering circuit goes above the set pressure of this
valve, oil is relieved from this valve. When the oil is
relieved, the flow control spool of the demand valve
is actuated, and the oil is drained to the steering
circuit.
10-62
Operation of relief valve
When the pressure in the circuit rises, and it When demand spool (6) moves, the oil from the
reaches the pressure set by adjustment screw (1) steering pump is drained, and the oil from the
and spring (2), pilot poppet (4) opens, and the oil is switch pump is released to the main control valve.
drained. This prevents the pressure in the steering circuit
When this happens, the balance in pressure from going above the set value.
between pressure-receiving chamber (I) and
pressure-receiving chamber (II) is lost, so demand
spool (6) moves to the left in the direction of the
arrow.
10-63
SAFETY VALVE (WITH SUCTION)

1. Poppet
2. Relief valve poppet
3. Check valve poppet
4. Pilot poppet
5. Spring
Function
The safety valve is installed to the steering valve. It has the
following two functions:
1) When the steering valve is at neutral, if any shock is
applied to the cylinder, and an abnormal pressure is
generated, the oil is relieved from the valve. In this way,
it functions as a safety valve to prevent damage to the
cylinder or hydraulic piping.
2) If negative pressure is generated at cylinder end, it
functions as a suction valve to prevent a vacuum from
forming.
Operation
Acting as relief valve
Port A is connected to the cylinder circuit and port B is
connected to the drain circuit. Oil passes through the hole in
poppet (1) and acts on the different areas of diameters d1
and d2, so check valve poppet (3) and relief valve poppet (2)
are firmly seated in position.
When the pressure at port A reaches the set pressure of the

relief valve, pilot poppet (4) opens. The oil flows around pilot
poppet (4), passes through the drill hole, and flows to port B.
10-64
When pilot poppet (4) opens, the pressure at the back of

poppet (1) drops, so poppet (1) moves and is seated with
pilot poppet (4).
Compared with the pressure at port A, the internal pressure

is low, so relief valve poppet (2) opens. When this happens,
the oil flows from port A to port B, and prevents any
abnormal pressure from forming.
Acting as suction valve

When negative pressure is formed at port A, the difference in
area of diameters d3 and d4 causes check valve poppet (3) to
open. When this happens, the oil from port B flows to port A,
and prevents any vacuum from forming.
10-65
STRUCTURE AND FUNCTION ORBIT-ROLL VALVE
ORBIT-ROLL VALVE
1. Needle bearing 5. Rotor 9. Spool

2. Center spring 6. Cover 10. Stator
3. Drive shaft 7. Center pin 11. Lower cover
4. Valve body 8. Sleeve 12. Check valve
10-66
Outline
The steering valve is connected directly to the shaft of the
steering wheel. It switches the flow of oil from the steering
pump to the left and right steering cylinders to determine the
direction of travel of the machine.
The orbit-roll valve, broadly speaking, consists of the
following components: Rotary type spool (9) and sleeve (8),
which have the function of selecting the direction, and the
Girotor set (a combination of rotor (5) and stator (10)), which
acts as a hydraulic motor during normal steering operations,
and as a hand pump (in fact, the operating force of the
steering wheel is too high, so it cannot be operated) when the
steering pump or engine have failed and the supply of oil has
stopped.
Structure
Spool (9) is directly connected to the drive shaft of the
steering wheel, and is connected to sleeve (8) by center pin
(7) (it does not contact the spool when steering wheel is at
neutral) and centering spring (2).
The top of drive shaft (3) is meshed with center pin (7), and
forms one unit with sleeve (8), while the bottom of the drive
shaft is meshed with the spline of rotor (5) of the Girotor.
There are four ports in valve body (4), and they are connected
to the pump circuit, tank circuit, and the circuits at
the head end and bottom end of the steering cylinders. The
pump port and tank port are connected by the check valve
inside the body. If the pump or engine fail, the oil can be
sucked in directly from the tank by the check valve.
10-67
CONNECTION BETWEEN HAND PUMP AND SLEEVE
The diagrams above show the connections with the

sleeve ports used to connect the suction and
discharge ports of the Girotor.
If the steering wheel has been turned to the right,

ports a, c, e, g, I, and k are connected by the
vertical grooves in the spool to the pump side. At
the same time, ports b, d, f, h, j, and l are
connected to the head end of the left steering
cylinder in the same way.
In the condition in Fig. 1, ports 1, 2, and 3 are the

discharge ports of the Girotor set. They are
connected to ports l, b, and d, so oil is sent to the
cylinder. Ports 5, 6, and 7 are connected and the oil
flows in from the pump.
If the steering wheel is turned 90 n

changes to the condition shown in Fig. 2. In this
case ports 1, 2, and 3 are the suction ports, and
are connected to ports I, k, and c. Ports 5, 6, and 7
are the discharge ports, and are connected to ports
d, f, and h.
10-68
In this way the ports of the Girotor acting as delivery ports are
connected to ports which are connected to the end of the
steering valve spool. The ports acting as suction ports are
connected to the pump circuit
Adjusting delivery in accordance with angle of the steering
wheel:
For every 1/7 turn of the steering wheel, the inner teeth
of the Girotor gear advances one position so the oil flow
from the pump is adjusted by this movement. In this way,
the oil delivered from the pump is directly proportional to
the amount the steering wheel is turned.
FUNCTION OF CENTER SPRING

Centering spring (2) consists of four layers of leaf springs
crossed to form an X shape. The springs are assembled in
spool (9) and sleeve (8) as shown in the diagram on the right.
When the steering wheel is turned, the spring is compressed
and a difference in rotation (angle variation) arises between
the spool and the sleeve. Because of this, the ports in the
spool and sleeve are connected and oil is sent to the cylinder.
When the turning of the steering wheel is stopped, the Girotor
also stops turning, so no more oil is sent to the cylinder and
the oil pressure rises.
To prevent this, when the turning of the steering wheel is

stopped, the action of the centering spring only allows it to
turn by an amount equal to the difference in angle of rotation
(angle variation) of the sleeve and spool, so the steering
wheel returns to the NEUTRAL position.
10-69
STRUCTURE AND FUNCTION STOP VALVE
STOP VALVE
1. Boot A: From orbit-roll

2. Wiper B: To steering valve
3. Seal DR: To drain
4. Poppet
5. Spring
6. Spool
7. Spring
10-70
STRUCTURE AND FUNCTION DIVERTER VALVE
DIVERTER VALVE
1. Spool A. From steering pump

2. Valve body B. To steering valve
3. Check valve C. To hydraulic tank
4. Check valve D. Sensor mounting port
E. Ground driven steering pump port
F. Ground driven steering pump port
G. From hydraulic tank
FUNCTION
If the engine stops or the pump seizes while the
machine is traveling, it becomes impossible to
steer, the rotation of the transmission is used to
turn the ground driven steering pump to make
steering possible
10-71
OPERATION
Pump and engine are working normally.
When the steering pump and engine are working normally,

the hydraulic pump, steering pump, and switch pump are
rotated by the engine. Therefore, oil is sent to the steering
valve, and the machine can be steered. In addition, the
ground driven steering pump is rotated by the transmission,
so oil from port A of the diverter valve (1) pushes open check
valve (2) and enters port B.
Pressure oil from steering pump is flowing to port D, so it
pushes spool (3) in the direction of the arrow. As a result, the
oil from port B flows to port C and is drained to the hydraulic
tank.
10-72
Failure in pump or engine when machine is traveling.
If there is a failure in the pump or engine when the

machine is traveling, the rotation of the wheels is trans-
mitted through the transfer to rotate the ground driven
steering pump. The steering pump is not rotating, so no
oil pressure is formed at port D. As a result, spool (3) is
pushed in the direction of the arrow by spring (4).
The oil from the ground driven steering pump passes
from port A through port B and flows to the steering valve
to make steering possible.
The ground driven steering pump is designed so that
it can rotate both directions.
10-73
STRUCTURE AND FUNCTION BRAKE PIPING
1. Brake valve (right)

2. Hydraulic tank
3. Parking brake switch
4. Emergency release parking
brake switch
5. Rear brake (right)
6. Charge valve
7. Filter
8. Accumulator
9. Parking brake valve
10. Slack adjuster (rear)
11. Rear brake (left)
12. PPC pump (also for brake)
13. Transmission control valve
14. Parking brake (built into
transmission)
15. Brake valve (left)
16. Front brake (left)
17. Slack adjuster (front)
18. Front brake (right)
10-74
STRUCTURE AND FUNCTION BRAKE CIRCUIT DIAGRAM
BRAKE CIRCUIT DIAGRAM
1. Hydraulic tank 11. Check valve

2. Brake, PPC pump 12. Accumulator
3. Charge valve (Front brake, emergency parking brake)
4. Check valve 13. Brake valve (left)
5. Accumulator (rear brake) 14. Transmission (case)
6. Brake valve (right) 15. Torque converter charging pump
7. Rear slack adjuster 16. Transmission control valve
8. Rear brake cylinder (Parking brake valve)
9. Front slack adjuster 17. Emergency parking brake
10. Front brake cylinder 18. Parking brake
10-75
STRUCTURE AND FUNCTION BRAKE VALVE
BRAKE VALVE
BRAKE VALVE (RIGHT)
1. Brake pedal (left, right brake) A. Pilot port (right brake)

2. Rod (right brake) B. To rear brake (right brake)
3. Pilot piston (right brake) C. To front brake (right brake)
4. Spool (right brake) D. Drain (left, right brake)
5. Upper cylinder (right brake) E. To pilot port (left brake)
6. Spool (right brake)
7. Lower cylinder (right brake)
8. Rod (left brake)
9. Spool (left brake)
10. Cylinder (left brake)
10-76
BRAKE VALVE (LEFT)
Outline
There are two brake valves installed in parallel In addition, the left brake pedal operates the
under the front of the operator’s cab, and these are transmission cut-off switch to actuate the
actuated by depressing the pedal. transmission solenoid valve electrically and set the
When the right pedal is depressed, oil is sent to the transmission to neutral.
brake cylinders to apply the brakes.
When the left pedal is depressed, oil is sent to the
right pedal to apply the brakes in the same way as
when the right pedal is depressed.
10-77
Operation
Brake applied (right brake valve)
Upper portion
When brake pedal (1) is depressed, the operating force is
transmitted to spool (3) through rod (2) and spring (4). When
spool (3) goes down, drain port a is closed, and the oil from
the pump and accumulator flows from port A to port C and
actuates the rear brake cylinder.
Lower portion
When brake pedal (1) is depressed, the operating force is
transmitted to spool (3) through rod (2) and spring (4). When
spool (3) goes down, spool (5) is also pushed by plunger (6).
When this happens, drain port b is closed, and the oil from
the pump and accumulator flows from port B to port B and
actuates the rear brake cylinder.
Brake applied (left brake pedal)

When pedal (7) is depressed, spool (10) is pushed up by rod
(8) and spring (9), and drain port c is closed. The oil
from the pump and the accumulator flows from port E to port
F.
Port F of the left brake valve and port Pp of the right brake
valve are connected by a hose, so the oil flowing to port F
flows to pilot port Pp of the right brake valve.
The oil entering pilot Pp enters port G from orifice d, and

pushes pilot piston (11). The spring pushes spool (3) down,
so the operation is the same as when the right brake valve is
depressed.
10-78
Applying brake when upper valve fails (right brake valve)

Even if there is leakage of oil in the upper piping, spool (5) is
moved down mechanically when pedal (1) is depressed, and
the lower portion is actuated normally. The upper brake is not
actuated.
Applying brake when lower valve fails (right brake valve)

Even if there is leakage of oil in the lower piping, the upper
portion is actuated normally.
When actuation is balanced

Upper portion
When oil fills the rear brake cylinder and the pressure
between port A and port C becomes high, the oil entering
port H from orifice e of spool (3) pushes against spring (4). It
pushes up spool (3) and shuts off the circuit between port A
and port C. When this happens, drain port a stays closed, so
the oil entering the brake cylinder is held and the brake
remains applied.
Lower portion
When spool (3) in the upper portion moves up and the circuit
between port A and port C is shut off, oil also fills the front
brake cylinder at the same time, so the pressure in the circuit
between port B and port D rises. The oil entering port J from
orifice f of spool (5) pushes up spool (5) by the same amount
that spool (3) moves, and shuts off port B and port D. Drain
port b is closed, so the oil entering the brake cylinder is held,
and the brake is applied.
The pressure in the space in the upper portion is balanced
with the operating force of the pedal, and the pressure in the
space in the lower portion is balanced with the pressure in the
space in the upper portion. When spools (3) and (5) move to
the end of their stroke, the circuits between ports A and C and
between ports B and D are fully opened, so the pressure in
the space in the upper and lower portions and the pressure in
the left and right brake cylinders is the same as the pressure
from the pump. Therefore, up to the point where the piston
moves to the end of its stroke, the effect of the brake can be
adjusted by the amount that the pedal is depressed.
10-79
Brake released (right brake valve)

Upper portion
When brake pedal (1) is released and the operating force is
removed from the top of the spool, the back pressure from
the brake cylinder and the force of the spool return spring
move spool (3) up. Drain port a is opened and the oil from
the brake cylinder flows to the hydraulic tank return circuit to
release the rear brake.
Lower portion
When the pedal is released, spool (3) in the upper portion
moves up. At the same time, the back pressure from the
brake cylinder and the force of the spool return spring move
spool (5) up. Drain port b is opened and the oil from the
brake cylinder flows to the hydraulic tank return circuit to
release the front brake.
10-80
STRUCTURE AND FUNCTION MEMORANDA
10-81
STRUCTURE AND FUNCTION CHARGE VALVE
CHARGE VALVE
A. To PPC valve Function

ACC. To brake valve The charge valve is actuated to maintain the oil
PP. To brake valve pressure from the pump at the specified pressure
P. From pump and store it in the accumulator.
T. Drain When the oil pressure reaches the specified
pressure, the oil from the pump is connected to the
drain circuit to reduce the load on the pump.
10-82
1. Valve body
2. Main relief valve (R3)
3. Relief valve (R1)
4. PPC relief valve (R2)
5. Relief valve (H1)
10-83
Operation
1. When no oil is being supplied to accumulator (cut-out
condition)
The pressure at port B is higher than the set pressure of
the relief valve (R1), so piston (8) is forcibly pushed up by
the oil pressure at port B. Poppet (6) is opened, so port
C and port T are short circuited.
The spring chamber at the right end of spool (15) is
connected to port C of the relief valve (R1), so the
pressure becomes the tank pressure. The oil from the
pump enters port P, pushes spool (15) to the right at a
low pressure equivalent to the load on spring (14), and
flows from port A to the PPC valve. At the same time, it
also passes through orifices (17), (18), and (16), and
flows to the tank.
2. When oil is supplied to accumulator

1) Cut-in condition
When the pressure at port B is lower than the set
pressure of the relief valve (R1), piston (8) is pushed
back down by spring (5). Valve seat (7) and poppet
(6) are brought into tight contact, and port C and port
T are shut off.
also shut off from port T, so the pressure rises, and
the pressure at port P also rises in the same way.
When the pressure at port P goes the pressure at
port B (accumulator pressure), the supply of oil to
the accumulator starts immediately. In this case, it is
decided by the size (area) of orifice (17) and the
pressure difference (equivalent to the load on spring
(14)) generated on both sides of the orifice. A fixed
amount is supplied regardless of the engine speed,
and the remaining oil flows to port A.
10-84
2) When cut-out pressure is reached

When the pressure at port B (accumulator pressure)
reaches the set pressure of the relief valve (R1),
poppet (6) separates from valve seat (7), so an oil
flow is generated and the circuit is relieved.
When the circuit is relieved, a pressure difference is
generated above and below piston (8), so piston (8)
moves up, poppet (6) is forcibly opened, and port C
and port T are short circuited.
connected to port C of the relief valve (R1), so the
pressure becomes the tank pressure.
The pressure at port P drops in the same way to a
pressure equivalent to the load on spring (14), so the
supply of oil to port B is stopped.
3. Safety
relief
valve (R3)
If the pressure at port P (pump pressure) goes
above the set pressure of the relief valve (R3),
the oil from the pump pushes spring (3). Ball
(11) is pushed up and the oil flows to the tank
circuit, so this sets the maximum pressure in
the brake circuit and protects the circuit.
10-85
STRUCTURE AND FUNCTION ACCUMULATOR (FOR BRAKE)
ACCUMULATOR (FOR BRAKE)
1. Valve
2. Top cover
3. Cylinder
4. Piston
Specifications
Function Gas used: Nitrogen gas
The accumulator is installed between the charge Charge amount: 4,000 cc
valve and the brake valve. It is charge with nitrogen Charging
gas between cylinder (3) and free piston (4), and pressure: 3.4 ±0.15 MPa
uses the compressibility of the gas to absorb the {35 ±1.5 kg/cm2} (at 50
pulse of the hydraulic pump or to maintain the
braking force and to make it possible to operate the
machine if the engine should stop.
10-86
STRUCTURE AND FUNCTION SLACK ADJUSTER
SLACK ADJUSTER
1. Bleeder
2. Cylinder
3. Check valve
4. Piston
5. Spring
A. Inlet port
B. Outlet port
Function Specifications
The slack adjuster is installed in the brake oil line Piston actuation pressure:
from the brake valve to the brake piston. It acts to 0.01 +0.01 MPa {0.1 +0.1 kg/cm2}
provide a fixed time lag when the brake is applied. Check valve cracking pressure:
0.93 ±0.05 MPa {9.5 ±0.5 kg/cm2}
Check valve closing pressure:
0.6 ±0.05 MPa {6.0 ±0.5 kg/cm2}
10-87
Operation
1. When brake pedal is depressed
Before the brake is depressed, piston (4) is returned by the
distance of stroke S (full stroke). When the brake pedal is
depressed, the oil discharged from the brake valve flows
from port P of the slack adjuster and is divided to the left and
right cylinders (2), where it moves piston (4) by stroke S to
the left and right.
When this is done, brake piston (7) moves by a distance of

stroke S. In this condition, the closer the clearance between
the brake piston and disc is to 0, the greater the braking force
becomes.
If the brake pedal is depressed further, and the oil pressure

discharged from the brake valve goes above the set
pressure, check valve (3) opens and the pressure is applied
to port C to act as the braking force. Therefore, when the
brake is applied, the time lag is a fixed value.
10-88
2. When brake pedal is released

When the brake is released, piston (4) is returned by brake
return spring (8) by an amount equivalent to the oil for stroke
S, and the brake is released. In other words, return stroke T
of brake piston (7) is determined by the amount of oil for
stroke S of the slack adjuster. The time lag of the brake is
always kept constant regardless of the wear of the brake
disc.
10-89
STRUCTURE AND FUNCTION BRAKE
BRAKE
1. Guide pin Function

2. Return spring The brakes are wet-type multiple disc brakes, and
3. Cylinder are fitted to all four wheels.
4. Brake piston
5. Outer gear (138 Teeth)
6. Inner gear (105 Teeth)
7. Plate
8. Disc
10-90
STRUCTURE AND FUNCTION BRAKE
Operation
When the brake pedal is depressed, the pressure oil from the
brake valve moves brake piston (4) to the right in the direction
of the arrow. This brings disc (8) and plate (7) into contact,
and friction is generated between the disc and plate. The
wheel is rotating together with the disc, so the machine speed
is reduced, and the machine is stopped by this friction.
When the brake pedal is released, the pressure at the back

face of brake piston (4) is released, so the piston is moved to
the left in the direction of the arrow by the force of return
spring (2), and the brake is released.
10-91
STRUCTURE AND FUNCTION PARKING BRAKE CONTROL
PARKING BRAKE CONTROL
1. Parking brake switch 4. Parking brake solenoid valve

2. Parking brake emergency release switch 5. Transmission (built-in parking brake)
Outline relay shuts off the electric current to the

The parking brake is a wet-type multiple-disc brake transmission solenoid valve and keeps the
built into the transmission. It is installed to the transmission at neutral.
output shaft bearing, and uses the pushing force of Emergency release switch (2) for the parking brake
a spring to apply the brake mechanically and is installed for use when moving the machine, if the
hydraulic power to release the brake. machine has stopped (the parking brake is
When parking brake switch (1) installed in the automatically applied) because of trouble in the
operator’s compartment is switched ON, parking engine or drive system.
brake solenoid valve (4) installed to the
transmission control valve (3) shuts off the oil
pressure and applies the parking brake. When the
parking brake switch is turned OFF, the oil pressure
in the cylinder releases the parking brake.
When the parking brake is applied, the neutralizer
10-92
STRUCTURE AND FUNCTION PARKING BRAKE
PARKING BRAKE
Outline
The parking brake is a wet-type multiple-disc brake. 1. Output shaft
It is actuated mechanically by a spring and applies 2. Piston
the braking force to output shaft (1) of the 3. Disc
transmission. 4. Plate
The pushing force of spring (5) pushes piston (2), 5. Spring
Plate (4), and disc (3) into contact and applies the
braking force to stop output shaft (1).
10-93
STRUCTURE AND FUNCTION PARKING BRAKE SOLENOID VALVE
PARKING BRAKE SOLENOID VALVE
Operation
Parking brake applied (solenoid deactivated)

When the parking brake switch in the operator’s
compartment is turned ON, the solenoid is turned OFF and
spool (6) is pushed to the left by spring (5). When this
happens, the passage between pump port P and parking
brake port A is closed, and the pressure oil from the pump
does not flow to the parking brake.
At the same time, the pressure oil from the parking brake
flows from port A to port T and is drained. As a result, the
disc inside the parking brake is pushed by the spring and the
parking brake is applied.
When the parking brake switch is turned OFF, the solenoid is

turned ON and spool (6) is moved to the right. As a result, the
pressure oil from the pump passes from port P through the
inside of spool (6), flows to port A and then flows to the
parking brake. At the same time, port To is closed, so the oil
is not drained. As a result, the spring inside the parking brake
is pushed back by the oil pressure and the parking brake is
released.
10-94
STRUCTURE AND FUNCTION PARKING BRAKE SOLENOID VALVE
PARKING BRAKE EMERGENCY RELEASE SOLENOID VALVE
1. Valve assembly
2. Solenoid valve
A: To parking brake
B: From parking brake valve
C: From pilot circuit
T: Drain
P: From brake (accumulator circuit)
Function
The emergency release solenoid valve is installed
between the transmission and the transmission
control valve. If the engine breaks down and no oil
pressure is supplied from the transmission pump,
it is possible to actuate the solenoid for the parking
brake release switch in the operator’s
compartment. This allows the accumulator charge
pressure in the brake circuit to flow to the parking
brake cylinder.
Operation
When the parking brake is emergency release
turned ON, solenoid valve e
pressure stored in the accumulator
port P. The circuit is switched by pilot pressure, so
the oil flows from port A to the parking brake, to
release the parking brake.
10-95
10-96
STRUCTURE AND FUNCTION HYDRAULIC PIPING
HYDRAULIC PIPING
OUTLINE
The hydraulic system consists of the work
equipment circuit and the steering circuit. The
work equipment circuit controls the movement of
the bucket and attachment.
The oil in hydraulic tank (5) is sent to the main
control valve (1) by hydraulic pump (13). When
the bucket and boom spools of the main control
valve are at HOLD, the oil passes through the
drain circuit of the main control valve, is filtered
by the filter inside the hydraulic tank, and then
returns to the tank.
When the work equipment control levers are
operated, the bucket or boom spool of the PPC
valve (6) moves, and the spools of the main
control valve are actuated by hydraulic pressure,
so oil flows from the main control valve to boom
cylinder (17) or bucket cylinder (2) to move the
boom or bucket.
Control of the maximum pressure in the hydraulic
circuit is carried out by the relief valve inside the
main control valve. A safety-suction valve si
installed to the bucket cylinder circuit to protect
the circuit.
Accumulator (10) is installed in the PPC pilot
circuit, so this makes it possible to lower the
boom to the ground even when the engine si
stopped.
Hydraulic tank (5) is a pressurized sealed type
and is equipped with a breather with relief valve.
This compresses the inside of the tank and also
prevents negative pressure, so this prevents
cavitation of the pump.
1. Main control valve 10. Accumulator

2. Bucket cylinder 11. Radiator
3. Steering valve 12. Oil cooler
4. Orbit-Roll 13. Hydraulic pump
5. Hydraulic tank 14. Steering pump
6. PPC valve 15. Cut-off valve
7. Solenoid valve 16. Steering cylinder
8. Switch, PPC pump 17. Boom cylinder
9. Check
10-97
STRUCTURE AND FUNCTION WORK EQUIPMENT HYDRAULIC CIRCUIT DIAGRAM
WORK EQUIPMENT HYDRAULIC

CIRCUIT DIAGRAM
(MACHINES WITH STANDARD SPECIFICATIONS)
1. Hydraulic tank
2. Oil filter
3. Breather
4. Switch, PPC pump
5. Torque converter charging pump
6. Hydraulic pump
7. Steering pump
8. Strainer
9. Accumulator charge valve
10. Check valve
11. Accumulator
12. PPC valve
13. Main control valve
13A. Main relief valve
13B. Bucket spool
13C. Safety valve with suction
13D. Unloader valve
13E. Float selector valve
13F. Boom spool
13G. Suction valve
13H. Slow return valve
14. Boom cylinder
15. Bucket cylinder
16. Orbit-roll valve
17. Stop valve
18. Steering valve
18A. Demand spool
18B. Steering spool
18C. Steering relief valve
18D. Safety valve with suction
19. Steering cylinder
20. Cut-off valve
21. Oil cooler
10-98
STRUCTURE AND FUNCTION HYDRAULIC PIPING
REPLACE THIS PAGE WITH
FOLDOUT 10-99
WORK EQUIPMENT HYDRAULIC CIRCUIT DIAGRAM

(MACHINE WITH OPTIONAL SPECIFICATIONS)
10-99
10-100
10-101
STRUCTURE AND FUNCTION HYDRAULIC CIRCUIT SYSTEM
HYDRAULIC CIRCUIT SYSTEM
10-102
STRUCTURE AND FUNCTION HYDRAULIC CIRCUIT SYSTEM
1. Hydraulic tank
2. Oil filter
3. Breather
4. Switch, PPC (brake) pump
5. Torque converter charging pump
6. Hydraulic pump
7. Steering pump
8. Filter
9. Accumulator charge valve
10. Check valve
11. Accumulator
12. PPC valve
13. Main control valve
13A. Main relief valve
13B. Bucket spool
13C. Safety valve with suction
13D. Unloader valve
13E. Float selector valve
13F. Boom spool
13G. Suction valve
13H. Slow return valve
14. Boom cylinder
15. Bucket cylinder
16. Orbit-roll valve
17. Stop valve
18. Steering valve
18A. Demand spool
18B. Steering spool
18C. Steering relief valve
18D. Safety valve with suction
19. Steering cylinder
20. Cut-off valve
21. Oil cooler
10-103
STRUCTURE AND FUNCTION WORK EQUIPMENT LEVER LINKAGE
WORK EQUIPMENT LEVER LINKAGE
1. Boom lever 6. Solenoid valve for bucket lever

2. Kick-down switch 7. Solenoid valve for boom lever
3. Hold switch 8. Safety lever lock
4. Bucket lever 9. PPC valve
5. Attachment lever
10-104
STRUCTURE AND FUNCTION HYDRAULIC TANK
HYDRAULIC TANK
10-105
OPERATION OF OIL FILTER BY-PASS VALVE

When the filter is clogged
By-pass valve (1) opens and the oil returns directly to the
tank without passing through the filter.
By-pass valve set pressure: 125 kPa (1.27 kg/cm2)
When negative pressure is formed in the return circuit

Valve (2) moves up and acts as a check valve.
By-pass valve set pressure: 25.5 kPa (0.26 kg/cm2)
10-106
BREATHER
1. Body
2. Filter element
3. Poppet
4. Sleeve
Function
Preventing negative pressure inside the tank

The tank is a pressurized, sealed type, so negative
pressure is formed inside the hydraulic tank when
the oil level drops during operations. When this
happens, the difference in pressure between the
tank and the outside atmospheric pressure opens
the poppet (3), and air from the outside is let into
the tank to prevent negative pressure.
Preventing rise in pressure inside the tank

When the hydraulic cylinders are being used, the
oil level in the hydraulic circuit changes and the
temperature rises. If the hydraulic pressure rises
above set pressure, sleeve (4) is actuated to
release the hydraulic pressure inside the tank.
10-107
STRUCTURE AND FUNCTION ACCUMULATOR (FOR PPC VALVE)
ACCUMULATOR (FOR PPC VALVE)
1. Gas plug
2. Shell
3. Poppet
4. Holder
5. Bladder
6. Oil port
Specifications:
Type of gas: Nitrogen gas
Gas amount: 500 cc
Actuation Pressure:
Maximum: 3.4 MPa (35 kg/cm2)
Minimum: 1.2 MPa (12 kg/cm2)
Function
The accumulator is installed between the
accumulator charge valve and the PPC valve. Even
if the engine stops when the boom is raised, it is
possible to lower the boom and bucket under their
own weight by using the pressure of the nitrogen
gas compressed inside the accumulator to send
the pilot oil pressure to the main control valve to
actuate it.
Operation
After the engine stops, if the PPC valve is at hold,
chamber A inside the bladder is compressed by the
oil pressure in chamber B.
When the PPC valve is operated, the oil pressure
in chamber B goes below 2.9 MPa (30 kg/cm2).
When this happens, the bladder is expanded by the
pressure of the nitrogen gas in chamber A, and the
oil inside chamber B is used as the pilot pressure
to actuate the main control valve.
10-108
10-109
STRUCTURE AND FUNCTION PPC VALVE
PPC VALVE
FOR BUCKET / BOOM
P. From PPC pump. P3. To RAISE end of main control valve boom spool.
P1. To TILT end of main control valve bucket spool. P4. To DUMP end of main control valve bucket.
P2. To LOWER end of main control valve boom spool. T. Drain.
10-110
1. Bolt 6. Centering spring

2. Piston 7. Metering spring
3. Plate 8. Valve
4. Collar 9. Body
5. Retainer
10-111
FOR OPTION
P. From PPC pump.

P2. To main control valve attachment spool.
P3. To main control valve attachment spool.
T. Drain.
10-112
1. Bolt 6. Centering spring

2. Piston 7. Metering spring
3. Plate 8. Valve
4. Collar 9. Body
5. Retainer
10-113
OPERATION OF PPC VALVE

(At neutral)
The oil from the PPC pump enters port P of the

PPC valve, but the circuit is closed by spool (8), so
the oil is drained from the relief valve (1). At the
same time, the oil at port PA1 of the main control
valve is drained from port f of spool (8). In addition,
the oil at port PB1 is drained from port g of spool
(10).
10-114
FUNCTION OF PPC VALVE

The ppc valve supplies pressure oil from the charging
pump to the side face of the spool of each control valve
according to the amount of travel of the control lever.
This pressure oil actuates the spool.
Operation
1. Control lever at "hold". (Fig. 1)

Ports PA1, PA4, PB1, and P1 are connected to drain
chamber D through fine control hole (f) in valve (8).
2. Control lever operated slightly (fine control)

(Fig. 2)
When piston (2) starts to be pushed by plate (10),
retainer (5) is pushed. Valve (8) is also pushed by
spring (7) and moves down. When this happens,
fine control hole (f) is shut off from drain chamber
D. At almost the same time it is connected to pump
pressure chamber PP, and the pilot pressure of the
control valve is sent through fine control hole (f) to
port P4. When the pressure at port P4 rises, Valve
(8) is pushed back. Fine control hole (f) is shut off
from pump pressure chamber PP. At almost the
same time it is connected to drain chamber D, so
the pressure at port P4 escapes to drain chamber
D. Valve (8) moves up and down until the force of
spring (7) is balanced with the pressure of port P4.
The position of valve (8) and body (9) (when fine
control hole (f) is midway between drain chamber
D and pump pressure chamber PP) does not
change until the head of valve (8) contacts the
bottom of piston (2).
Therefore, spring (7) is compressed in proportion
to the travel of the control lever, so the pressure at
port P4 also rises in proportion to the travel of the
control lever. The spool of the control valve moves
to a position where the pressure of port PA1 (same
as pressure at port P4) and the force of the return
spring of the control valve are balanced.
10-115
3. Control lever moved back from slightly

operated position to hold (Fine control) (Fig. 3)
When plate (10) starts to be pushed back, piston
(2) is pushed up by a force corresponding to the
force of centering spring (6) and the pressure at
port P4. At the same time, fine control hole (f) of
valve (8) is connected to drain chamber D, so the
oil at port P4 escapes. If the pressure at port 4P
drops too far, valve (8) is pushed down by spring
(7). Fine control hole (f) is shut off from drain
chamber D, and at almost the same time it is
connected to pump pressure chamber PP. The
pump pressure is supplied until the pressure at port
PA1 returns to a pressure equivalent to the position
of the lever. When the spool of the control valve
returns, the oil in drain camber D flows in from fine
control hole (f1) of the valve which has not moved.
The extra oil then flows through port P1 to chamber
PB1.
4. Control lever operated to end of travel (Fig. 4)

Plate (10) pushes piston (2) down, and piston (2)
forcibly pushes in valve (8). Fine control hole (f) is
shut off from drain chamber D, and is connected to
pump pressure chamber PP. Therefore, pressure
oil from the charging pump passes through fine
control hole (f), and flows from port P4 to chamber
PA1 to push the spool of the control valve. The oil
returning from chamber PB1 flows from port 1P
through fine hole (f1) to drain chamber D.
10-116
STRUCTURE AND FUNCTION PPC RELIEF VALVE
PPC RELIEF VALVE
1. Main valve
2. Spring
3. Valve seat
4. Pilot poppet
5. Spring
6. Screw
Function
The PPC relief valve is between the PPC brake
pump and the PPC valve. When the PPC pump is
not being actuated, or when abnormal pressure is
generated, the oil sent from the pump is relieved
through this valve to protect the pump and circuit
from damage.
Operation
The relief valve is installed to the charge valve. Port
A is connected to the pump circuit, and port C is
connected to the drain circuit.
The oil passes through the orifice of main valve (1)
and fills port B. In addition, pilot poppet (4) is
seated in valve seat (3).
When the pressure at port A and B reaches the set

pressure, pilot poppet (4) opens and the oil
pressure at port B escapes from port D to port C to
lower the pressure at port B.
When the pressure at port B goes down, a

difference in pressure is generated at ports A and
B by the orifice in main valve (1). Main valve (1) is
opened by the pressure at port A, and the oil at
port A is drained to port C to relieve the circuit.
10-117
STRUCTURE AND FUNCTION CUT-OFF VALVE
CUT-OFF VALVE
1. Unload valve Function

2. Check valve The cut-off valve is installed between the switch
3. Cut-off valve pump and the main control valve. Depending on
4. Screen the operating condition, it switches the oil from the
switch pump to the main control valve or to the
drain circuit.
C. Port C (from hydraulic pump) The cut-off valve is operated by hydraulic pressure.
P. Port P (From steering valve)
T1. Port T1 (to tank)
T2. Port T2 (to tank)
10-118
OPERATION OF CUT-OFF VALVE

Cut-off operation conditions
O: Cut-off (drain)
X: Not actuated (to main control valve)
More than Less than Kick-down

17.2 MPa 17.2 MPa switch
(175 kg/cm2) (175 kg/cm2) “ON”
O X X
OPERATION
1. When the work equipment valve is held.
The oil at the switch pump (the oil from the steering
valve) presses up check valve (1), merges with the
oil from the work equipment pump and flows to the
work equipment valve.
2. When the work equipment valve is activated.

1) When the work equipment pump pressure
is lower than the cut-off pressure.
As when the work equipment valve is held, the
oil at the switch pump (the oil from the steering
valve) pushes up check valve (1), merges with
the oil from the work equipment pump and
flows to the work equipment valve.
10-119
1) When the work equipment pump pressure

is higher than the cut-off pressure.
When the cut-off pressure is reached, the
pressure of the oil in chamber a opens cut-off
valve (2), and the oil in unload valve (3)
chamber b passes through cut-off valve (2)
chamber c and is drained. The oil in unload
valve (3) chamber d passes through orifices e
and f, and into chamber b causing the oil
pressure in chamber d decrease, and unload
valve (3) to open. Thus, the oil from the switch
pump is drained.
10-120
10-121
STRUCTURE AND FUNCTION MAIN CONTROL VALVE
MAIN CONTROL VALVE
PA1. From PPC valve P4 A2. To boom cylinder bottom end

PA2. From PPC valve P2 B1. To bucket cylinder head end
PB1. From PPC valve P1 B2. To boom cylinder head end
PB2. From PPC valve P3 D1. Drain port
P. From pump D2. Drain port
P1. From PPC valve P2 T. Drain port
P2. From PPC valve P3
A1. To bucket cylinder bottom end
10-122
1. Main relief valve 6. Body

2. Bucket spool return spring 7. Suction valve
3. Boom spool return spring 8. Unloader valve
4. Boom spool 9. Safety valve (with suction)
5. Bucket spool 10. Float selector valve
10-123
A1. To attachment cylinder D1. Drain port PA2. From PPC valve P4
A2. To bucket cylinder bottom D2. Drain port PA3. From PPC valve P2
A3. To boom cylinder bottom P. From pump PB1. From option PPC valve
B1. To attachment cylinder P1. From PPC valve P2 PB2. From PPC valve P1
A2. To bucket cylinder head P2. From PPC valve P3 PB3. From PPC valve P3
A3. To boom cylinder head PA1. From option PPC valve T. Drain port
10-124
1. Main relief valve 7. Attachment spool

2. Attachment spool return spring 8. Body
3. Bucket spool return spring 9. Unloader valve
4. Boom spool return spring 10. Suction valve
5. Boom spool 11. Safety valve (with suction)
6. Bucket spool 12. Float selector valve
10-125
Outline
The main control valve controls the actuation of the However, the circuit gives priority to the bucket, so
attachments and the bucket in the hydraulic sys- when the dump spool is being operated, even if the
tem. It has a tandem circuit which gives priority to lift spool is operated, the lift arm will not move.
the bucket circuit.
There are two safety valves (with suction valves)
The oil from the pump enters port P. The maximum (10) to protect the circuit if abnormal pressure is
pressure is set by the main relief valve. The oil generated in the bucket circuit. If one of the two
passes through the by-pass circuit of dump spool safety valves is acting as a relief valve, the other
(5) and lift spool (4). It then flows from port T to the valve acts as a suction valve to make up for any
drain circuit, passes through the filter and returns to lack of oil.
the tank. If the dump and lift spools are actuated,
the oil flows to the dump and lift cylinders.
10-126
10-127
RELIEF VALVE
1. Main valve
2. Valve seat
3. Pilot poppet
4. Pilot poppet spring
5. Adjustment screw
6. Lock nut
Set pressure: 20.6 MPa (210 kg/cm2)
Function
The relief valve is installed to the inlet portion of the
main control valve. If the oil goes above the set
pressure, the relief valve drains the oil to the tank to set
the maximum pressure for the work equipment circuit,
and to protect the circuit.
Operation
Port A is connected to the pump circuit and port B
is connected to the drain circuit. The oil passes
through the orifice of the main valve (1) and fills
port B. Pilot poppet (3) is seated in valve seat (2).
If the pressure port A and port B reaches the set

pressure of pilot poppet spring (4), pilot poppet (3)
opens, and the oil pressure at port B escapes from
port D to port C, so the pressure at port B drops.
When the pressure at port B drops, a difference in

pressure between port A and port B is created by
the orifice of main valve (1). The main valve is
pushed open and the oil at port A passes through
port C, and flows to the drain circuit to release the
abnormal pressure.
The set pressure can be varied by changing the

tension of pilot poppet spring (4). To change the set
pressure, remove cap nut, loosen lock nut (6) and
turn adjustment screw (5), to adjust the set
pressure as follows:
Tighten to increase pressure

Loosen to decrease pressure
10-128
SAFETY VALVE (WITH SUCTION)
1. Suction valve
2. Main valve
3. Main valve spring
4. Pilot piston
5. Suction valve spring
6. Valve body
Set pressure: 22.6 MPa (230 kg/cm2)
Function
The safety valve is in the bucket cylinder circuit
inside the main control valve. If any abnormal
pressure is generated by any shock to the cylinder
when the main control valve is at the neutral
position, this valve relieves the abnormal pressure
to prevent damage to the cylinder.
Operation
1. Operation as safety valve.
Port A is connected to the cylinder circuit and
port B is connected to the drain circuit. The oil
pressure at port A is sent to port D from the
hole in pilot piston (4). It is also sent to port C
by the orifice formed from main valve (2) and
pilot piston (4). Pilot piston (4) is secured to the
safety valve, and the size of the cross-sectional
surface (cross-sectional area) has the
following relationship: d2 > d1 > d3 > d4.
If abnormal pressure is created at port A,
suction valve (1) is not actuated because of
relationship d2 > d1 >, but relationship between
port A and port C is d3 > d4 , so main valve (2)
receives oil pressure equivalent to the
difference between the areas of d3 and d4 . If
the oil pressure reaches the force (set
pressure) of main valve spring (3), main valve
(2) is actuated, and the oil from port A flows to
port B.
10-129
2. Operation as suction valve

If any negative pressure is generated at port A,
port D is connected with port A, so there is also
a negative pressure at port D. The tank
pressure of port B is applied to port E, so the
safety valve receives oil pressure a, which is
equal to the difference in the area of d2 and d1
because of the tank pressure at port E.
Therefore, oil pressure e moves the valve in
the direction of opening, and oil pressure a
acts to move suction valve (1) in the direction
of closing.
When the pressure at port A drops (and comes
close to negative pressure), it becomes lower
than hydraulic pressure e. The relationship
becomes oil pressure e > oil pressure a + force
of valve spring (5), and suction valve (1) opens
to let the oil from port B flow into port A and
prevent any negative pressure from forming at
port A.
SUCTION VALVE
1. Main poppet
2. Sleeve
3. Spring
Function
This valve acts to prevent any negative pressure
from forming in the circuit.
Operation
If any negative pressure is generated at port A
(boom cylinder rod end) (when a pressure lower
than tank circuit port B is generated), main poppet
(1) is opened because of the difference in area
between d1 and d2, and oil flows from port B at the
tank end to port A at the cylinder port end.
10-130
FLOAT SELECTOR VALVE AND

UNLOADER VALVE
Function
The float selector valve and unload valve are inside
the main control valve. When the boom lever is
operated to the FLOAT position, the float selector
valve detects this, and it is actuated to actuate the
unload valve and set the boom to the FLOAT
position.
Operation
If the boom lever is pushed further from the
LOWER position, it is set to the FLOAT position and
the PPC valve is set to the same condition as for
the LOWER position. The pressure at port A
becomes high pressure and the pressure at port B
becomes low pressure.
The oil from the setting valve fills chamber F and
chamber E.
If the difference in pressure between port A and

port B becomes greater than the specified
pressure, float selector valve (2) is moved to the
right, and port C and port D open.
When port C opened, the oil pressure in chamber
E drops, unload valve (4) is moved up in the
direction of the arrow, and the oil from the pump
flows to the drain circuit, and also flows to the rod
end of the boom cylinders.
The oil at the bottom end of the boom cylinders is
connected to the drain circuit and forms the FLOAT
position.
10-131
BOOM SPOOL AT RAISE POSITION
Operation
The oil from the pump enters port A and the maxi- The oil from the PPC pump passes through check
mum pressure is set by the relief valve (11). valve (13) and enters port L of the PPC valve.
Bucket spool (1) is at HOLD, so the by-pass circuit is However, the boom and bucket levers are at the
open. The oil at port A passes around the spool and HOLD position, so the oil returns from PPC relief
flows to port B. Boom spool (2) is also at HOLD, so valve (12) to the hydraulic tank.
the by-pass circuit is open. The oil at port B passes
around the spool and flows to port C in the drain
circuit. From here it passes through the filter and
returns to the tank.
10-132
BOOM SPOOL AT RAISE POSITION
Operation
When boom lever (3) is pulled, pressure oil from open check valve (10). The oil then flows from port
port L of the PPC valve flows to port N and port S. H to port I, and goes to the bottom end of the
The oil in port T passes through port M and flows to cylinder.
the drain circuit. The pressure oil in port S pushes
the push piston against the force of the spring and At the same time, the oil at the rod end of the
moves boom spool (2) to the RAISE position. cylinder flows from port K to drain port C, and
returns to the tank. Therefore, the boom rises.
The oil flows from the pump through the by-pass
circuit of the bucket spool, and then flows to the by-
pass circuit of boom spool (2). The by-pass circuit
is closed by the spool, so the oil pushes
10-133
BOOM SPOOL AT LOWER POSITION
Operation
When boom lever (3) is pushed, pressure oil from valve (10). The oil then flows from port J to port K,
port L of the PPC valve flows to port M and port T. In and goes to the rod end of the cylinder.
addition the oil at port S is connected to the drain At the same time, the oil at the bottom end of the
circuit. The pressure oil at port T pushes the push cylinder flows from port I to drain port C, and
piston against the force of the spring and moves returns to the tank. Therefore, the boom goes
boom spool (2) to the LOWER position down.
The oil from the pump passes through the by-pass
circuit of the bucket spool and flows to the by-pass
circuit of boom spool (2). The by-pass circuit is
closed by the spool, so the oil pushes open check
10-134
BOOM SPOOL AT FLOAT POSITION
Operation
When boom lever (3) is pushed to the FLOAT to the drain circuit. When port C1 1 is connected to
position, the spool of the PPC valve moves further the drain circuit, unload valve (8) moves up, and
from the LOWER position to the FLOAT position. the oil from the pump flows to the drain circuit.
Pressure oil at port L flows to port M, and at the same Therefore, the oil at the rod end of the cylinder
time, it also flows to port T and port W. In addition, flows from port K, and then flows from unload
the pressurized oil at port S flows to port N. valves (8) to the drain circuit. At the same time, the
The pressure oil at port T pushes the push piston oil at the bottom end of the cylinder flows from port
against the force of the spring and moves boom I to port C, and then flows to the drain circuit.
spool (2) to the LOWER position. Therefore, the boom is set to the FLOAT condition.
If the pressure difference between port W and port X
goes above the specified level, valve (7) moves to the
right and opens ports C1 and C to connect them
10-135
BUCKET SPOOL AT DUMP POSITION
Operation
When bucket lever (4) is pushed, pressure oil from At the same time, the oil at the bottom end of the
port L of the PPC valve flows to port V via port Q. In cylinder flows from port D to drain port C, and
addition, the oil at port R is connected to the drain returns to the tank. Therefore, the bucket is
circuit. The pressure oil at port V pushes the push dumped.
piston against the force of the spring and moves
bucket spool (1) to the DUMP position.
The by-pass circuit is closed by bucket spool (1), so
the oil from port A pushes open check valve (9).
The oil from check valve (9) then flows from port F
and enters port G, and goes to the rod end of the
cylinder.
10-136
BUCKET SPOOL AT TILT POSITION
Operation
When bucket lever (4) is pulled, the pressure oil at oil from check valve (9) flows from port D to port E,
port L of the PPC valve flows to port R via port P. The and goes to the bottom end of the cylinder.
oil in port V is connected to the drain circuit. The At the same time, the oil at the rod end of the
pressure oil at port R pushes the push piston against cylinder flows from port G to drain port C, and
the force of the spring and moves bucket spool (1) to returns to the tank. Therefore, the bucket is tilted.
the TILT position.
The by-pass circuit is closed by bucket spool (1), so
the oil from port A pushes open check valve (9). The
10-137
STRUCTURE AND FUNCTION WORK EQUIPMENT LINKAGE
WORK EQUIPMENT LINKAGE
1. Bucket 6. Bucket link

2. Bellcrank 7. Bucket hinge pin
3. Bucket cylinder 8. Cord ring
4. Boom cylinder 9. Cord ring
5. Boom
10-138
STRUCTURE AND FUNCTION WORK EQUIPMENT LINKAGE
10-139
STRUCTURE AND FUNCTION BUCKET
BUCKET
1. Bucket
2. Tooth
3. Corner tooth
10-140
10-141
STRUCTURE AND FUNCTION BUCKET POSITIONER / BOOM KICK-OUT
BUCKET POSITIONER AND BOOM KICK-OUT
10-142
STRUCTURE AND FUNCTION BUCKET POSITIONER / BOOM KICK-OUT
Bucket positioner
The bucket positioner is electrically actuated and is
used to automatically obtain the optimum digging
angle for the bucket.
When the bucket is moved from the DUMP position
to the TILT position, and it reaches the desired
angle, the dump lever is automatically moved from
the TILT position to the neutral.
Lever (4) is secured by bolts to dump cylinder rod
(3). A proximity switch (1) is fixed by bolts to the
cylinder.
When the bucket is moved from the DUMP position
to the TILT position, the dump cylinder rod moves
to the left. At the same time, lever (4) also moves
to the left. When it reaches the desired position,
lever (4) separates from proximity switch, and the
bucket lever returns to neutral.
Boom kick-out
The boom kick-out is electrically operated and acts
to stop the lift arm. When the lift arm reaches the
desired position before the maximum height, the lift
arm lever is returned to neutral.
Plate (5) is secured to the lift arm. A proximity
switch (2) is fixed to the frame. When the lift arm is
moved from the LOWER position to the RAISE
position, the lift arm rises. When it reaches the
desired position, the proximity switch and plate
come into contact and the lift arm lever is returned
to neutral.
10-143
STRUCTURE AND FUNCTION PROXIMITY SWITCH
PROXIMITY SWITCH
Function
Proximity switches are installed by a support to the switch, the electric current flows to a magnet and the lift
boom and bucket cylinders. The lift arm RAISE or dump lever is returned to the hold position. When
position and the TILT BACK position can be this happens, the main control valve is also returned to
selected to match the operating conditions. When hold and the movement of the lift arm or bucket stops.
these positions are reached, a pulse is generated
from the
Operation of Proximity Switch

BOOM RAISE
When the boom is lower than the set position for the
boom kick-out, the detection unit (steel plate) is on
the sensing surface of the proximity switch. Electricity
flows through the proximity switch. The relay switch is
at OFF and the electric current of the magnet switch
coil is shut off.
10-144
When the boom lever is moved to the RAISE

position, the lever cam and the cam follower keep
the lift spool in the RAISE position, so the boom
arm goes up.
10-145
Kick-out
When the boom goes up and reaches the set relay circuit act to send electric current to the magnet
position for the kick-out (that is, the detection unit coil. This actuates the magnet, the cam is pulled out of
(steel plate) is separated from the sensing surface the cam detent, and the lift spool is returned to the
of the proximity switch), the proximity switch and neutral position by the return spring.
Action of proximity switch
Position When detector is in position at When detector is separated from

detection surface of proximity switch detection surface of proximity
switch
Proximity switch actuation Lights up Goes out

display
Proximity switch load circuit Current flows Current shut off

(relay switch circuit)
Relay switch load circuit Current flows Current shut off

(Solenoid circuit)
10-146
BUCKET "TILT"
Hold
When the bucket is dumped beyond the set
position for the bucket leveler, the sensor (steel
plate) is above the detection surface of the bucket
proximity switch, so electric current flows in the
proximity switch load circuit. The positioner relay is
turned ON and the current for the solenoid is shut
off.
10-147
Tilt
When the bucket lever is moved to the TILT
position, the bucket spool is held at the TILT
position by the cam follower and cam on the lever,
and the bucket tilts.
10-148
Positioned
When the bucket tilts and reaches the set position
for the bucket leveler (that is, the detection unit
(steel plate) is separated from the sensing surface
of the proximity switch), the proximity switch and
relay circuit act to send electric current to the
magnet coil. This actuates the magnet, the cam is
pulled out of the cam detent, and the dump spool
is returned to the neutral position by the return
spring.
Action of proximity switch

Position When sensor is in position at When sensor is separated from
detection surface of proximity switch detection surface of proximity
switch
Proximity switch actuation Lights up Goes out
display
Positioner relay Current flows Current shut off
Solenoid (for bucket) Current shut off Current flows
10-149
STRUCTURE AND FUNCTION CAB
CAB
1. Front glass
2. Front wiper
3. Rear wiper
4. Door
10-150
STRUCTURE AND FUNCTION ROPS CANOPY
ROPS CANOPY
1. ROPS guard
2. Cab
10-151
STRUCTURE AND FUNCTION AIR CONDITIONER
AIR CONDITIONER
AIR CONDITIONER PIPING
1. Vent 6. Compressor
2. Window defroster 7. Hot water inlet port
3. Vent 8. Hot water outlet port
4. Dry receiver 9. Air conditioner unit
5. Air conditioner condenser
10-152
AIR CONDITIONING (GENERAL)

BASIC INFORMATION ON AIR CONDITIONERS
UNITS RELATED TO REFRIGERATION
Heat
The kinetic energy of the molecular activity of a
substance takes the form of heat. If a substance is
given heat by any other substance, its temperature
will rise. If heat is taken away by another body, the
temperature will decrease.
1. Quantity of heat.
If the heat is transferred from one substance to
another, the temperatures of both substances will
change. The amount of change in temperature will
depend on the quantity of heat transferred. The
quantity of heat is indicated in units of calories (cal)
or kilocalories (Kcal). One cal denotes the quantity
of heat required to raise the temperature of 1g of
water by 1 degree. One Kcal denotes the quantity
of heat required to raise the temperature of 1 kg of
water by 1 degree.
2. Specific heat.
The quantity of heat required to raise or lower the
temperature of substance varies depending on the
type, weight, and amount of change in temperature
of the substance. The quantity of heat required to
raise the temperature of one unit weight of a
substance by 1 degree is called the "specific heat"
of the substance. The unit of the specific heat is
"kcal/kg C”. The specific heat is often indicated with
a numerical value without the unit.
The larger the specific heat of a substance, the
more difficult it is for the substance to warm up and
cool down. The specific heat of water is 1, the
largest value of any solid or liquid.
Substance Specific heat (Kcal/kg
Water 1.0
Alcohol 0.57
Ice 0.49
Iron 0.11
Copper 0.09
Aluminum 0.21
10-153
Temperature
When cooling or warming a substance, the units of
warmth or coolness measurement are expressed as
degrees C (Centigrade) or F (Fahrenheit).
1. Scales of temperature.
The temperature at which water freezes at the
standard barometric pressure (1 barometric
pressure) (the "freezing point"):
Centigrade . . . . . . . . . . . . . . . . 0 degree ( C)
Fahrenheit . . . . . . . . . . . . . . . 32 degrees ( F)
Temperature at which water boils at the standard
barometric pressure (the "boiling point"):
Centigrade . . . . . . . . . . . . . . . 100 degrees ( C)
Fahrenheit . . . . . . . . . . . . . . . 212 degrees ( F)
On the Centigrade scale, the scale is equally
divided into 100 graduations ranging from 0 to 100
degrees. One graduation is 1 e
below the freezing point (a sub-zero temperature)
is indicated by a negative number, such as -a
On the Fahrenheit scale, the scale is divided into
180 graduations ranging from 32 to 212 degrees.
One graduation is 1
F is called sub-zero temperature and indicated by
a negative number, such as -B F.
Relationship between the Centigrade and the

Fahrenheit scales:
Centigrade and Fahrenheit temperatures can be
converted according to the following formulas:
Centigrade temperature (
Fahrenheit temperature (
10-154
2. Absolute temperature (Kelvin scale)

At zero degrees on the absolute scale ("absolute
zero"), the molecular activity of all substances
ceases. Absolute temperature, lowest temperature
in the natural world, often is for theoretical studies.
Relationships between the absolute temperature
scale and the Centigrade and Fahrenheit
temperature scales:
0 C is 273 e
absolute temperature system. One degree in the
Kelvin scale equals one degree in the Centigrade
scale.
On the Fahrenheit temperature scale, 0 s
equivalent to 460
degree in the Rankine scale is equivalent to one
degree on the Fahrenheit scale.
Thus, their relationships are as follows:
Absolute temperature (
0
Absolute temperature (
0
Pressure
The force acting on a unit area is called "pressure".
Normally, the force acting on a unit area of 1 cm² is
indicated in unit of kg.
Unit of pressure: kg/cm².
1. Absolute pressure.
The pressure actually imposed on the wall of a
vessel by the gas inside is called “absolute
pressure”. The “complete vacuum pressure”, in
which no molecular activity occurs, is defined as
the zero pressure. The absolute pressure is used
in the same manner as the absolute temperature
when treating problems theoretically. The unit of
absolute pressure is kg/cm² abs.
2. Gauge pressure.
The pressure measured with a pressure gauge at
zero barometric pressure is called the gauge
pressure. This pressure indicates the difference
between the absolute pressure and the
atmospheric pressure. For a theoretical calculation,
the gauge pressure must be converted into the
absolute pressure. In most cases, pressure refers
to the gauge pressure. The unit gauge pressure is
kg/cm² g, which distinguishes it from ordinary
pressure.
3. Atmospheric pressure.
This is the pressure of the air. The standard
atmospheric pressure is 1.03 kg/cm² abs. at sea
level, equivalent to a mercury column of 760 mm
(Hg) or to a water column of 10.3 m. The
relationship between the absolute pressure and the
gauge pressure is simple:Absolute pressure =
Gauge pressure + Atmospheric pressure.
Even if the gauge pressure of a gas in a container
is zero, the gas is actually subject to a pressure of
1.03 kg/cm² abs.
10-155
4. Vacuum and the degree of the vacuum.

Normally, a pressure gauge has a red zone on its
scale to indicate the pressure below 0 kg/cm². Any
gas pressure indicated in the red zone is below the
atmospheric pressure.
The term "vacuum" refers to a given space filled
with gas at a pressure below the atmospheric
pressure. A “perfect vacuum” refers to a space
completely empty of gas pressure (an absolute
pressure of 0 kg/cm² abs).
The degree of vacuum applies to the static
pressure below the atmospheric pressure and is
indicated in terms of absolute pressure in units of
cm Hg. On the gauge scale, the atmospheric
pressure is set at zero and the perfect vacuum is
set at 76 cm Hg. To convert the reading, h cm Hg,
of the vacuum gauge into the absolute pressure P
kg/cm² abs., the following formula is used:
P = 1.03 x (1 - h/76)
In this case, the degree of vacuum is (76-h) cm Hg.
Humidity
The amount of water contained in the air is called
the humidity. Humidity is generally classified into
absolute humidity and relative humidity.
1. Absolute humidity.
The absolute humidity is the weight of moisture per
kg of dry air contained in the wet air, expressed in
units of x kg/kg. Practically, an air diagram is used
to indicate the weight of moisture contained in 1 kg
of wet air. For example, if 30 g of moisture is
contained in 1 kg of wet air, the absolute humidity
on the air diagram is indicated as follows:
Absolute humidity = 0.03 (kg)/1 (kg) = 0.03 kg/kg.
2. Relative humidity.
The ratio between the water partial pressure P
(kg/cm²) of the wet air and the max. partial
pressure Ps contained in the water at that humidity
(the water partial pressure of the saturated air) is
called the "relative humidity".
That is, Relative humidity = P/Ps x 100 (%).
Generally, when we speak of humidity, we mean

relative humidity. This is the humidity obtained from
a home hygrometer or a weather forecast.
10-155-1
PRINCIPLE OF COOLING
1. Why do coolers cool?

We have all experienced the cold feeling when we
are sweating and the wind blows, or when we put a
liquid like alcohol on our skin. This feeling occurs
because water and alcohol draw heat from the
surrounding area when evaporating and turning
into gas. If we express this another way, if we apply
heat to a liquid it turns into gas. This is called
evaporation latent heat.
In a cooler, freon (R134a) is used instead of
alcohol. When the liquid freon (R134a) turns into
gas, it takes latent heat from its surroundings.
However, if it is allowed to disperse as a gas, this is
uneconomical. We need a device which can collect
this gas and turn it back into liquid before
evaporating it again, and then repeat this cycle
continuously. A cooler is such a device. The fluid
which turns into a liquid and then becomes a gas to
cool the surroundings is called the refrigerant.
2. Refrigerator using evaporation latent heat

The liquid refrigerant freon (R134a) is sent under
high pressure through a valve where it is allowed to
expand and is sent to the heat exchanger. The
refrigerant takes heat from the air in the room (or
cab) sucked in by low pressure vapor (moist
vapor), turns into gas (super heated vapor) and is
discharged. The air which has lost its heat is blown
into the cooled room. This is the basic principle of
the cooler, but using only this device to cool is
uneconomical and not very practical.
3. Refrigeration method (Vapor compression)

The refrigerant gas is compressed by a
compressor (adiabatic compression) and changes
to high temperature and high compression. It is
then sent to the condenser and undergoes forced
cooling in the condenser to be turned to liquid. If
this liquefied refrigerant is expanded suddenly at
the expansion valve, it changes into a low
temperature and low pressure mist and flows inside
the evaporator.
The refrigerant, which enters the evaporator as a
mist, passes through the fins of the evaporator and
takes latent evaporation heat from the surrounding
air. This causes it to evaporate and turn to its
original gaseous condition. In this way it acts to cool
the surrounding air.
10-155-2
4. Refrigerating cycle
The refrigerating cycle of an air conditioner consists
of the compressor, condenser, expansion valve,
and evaporator as shown in the diagram.
Refrigerant is circulated in this sealed circuit
(refrigeration cycle), and heat is transferred from
the low temperature source (air inside the
operator's compartment) to the high temperature
source (outside air) to give the cooling. This is
called the evaporation compression refrigeration
system, the most widely used form of cooling used
for bus coolers, room air conditioners, and small
refrigerators.
A) Flow of refrigerant
1) The liquid refrigerant which leaves the receiver
is expanded suddenly at the expansion valve.
It becomes a low temperature, low pressure
mist and flows to the evaporator.
2) The refrigerant mist which flows into the
evaporator takes heat from the air (air inside
the operator's compartment) at the surface of
the evaporator. It evaporates and is further
heated, and is then sucked into the
compressor as a gaseous refrigerant.
The air inside the operator's compartment is
sucked into the cooling unit by a fan, is cooled
on the evaporator surface, and is then sent out
into the operator's compartment again.
3) The gaseous refrigerant evaporated in the
evaporator is sucked into the compressor.
4) The gaseous refrigerant is compressed in the
compressor, and is then sent to the condenser
at high temperature and high pressure.
5) In the condenser, the gaseous refrigerant is
cooled. It becomes a liquid refrigerant again
and flows to the receiver.
By repeating the above steps (1) to (5), the
heat is taken from the air at the surface of the
evaporator, and heat is dissipated to the air at
the surface of the condenser to produce
cooling inside the operator's compartment.
Note: The temperature and pressure of the

refrigerant vary according to the air flow
and temperature of the front surface of the
condenser.
In this way, the refrigerant circulates during the

refrigeration cycle to carry out the refrigeration
action.
In refrigerators using the evaporation latent
heat of the refrigerant at present used, if the
gaseous refrigerant is not liquefied at near
normal temperature, it cannot take evaporation
latent heat from the surrounding material to
carry out refrigeration (cooling).
10-155-3
Generally speaking, for a gas to be liquefied, it must be

pressurized. However, if it is cooled at the same time as
being pressurized, it can be liquefied easily.
For this reason, compressors and condensers are

needed in the present refrigerating systems.
B) Properties of R-134a
Using R-134a as an example, let us explain
how the refrigerant can be liquefied.
High temperature (70 5
kg/cm²) gaseous refrigerant is compressed in
the compressor. It then enters the condenser
where it is cooled and liquefied.
R-134a starts to liquefy at about 62 5
kg/cm², so the temperature of the refrigerant
need only be brought below 62
10-155-4
C) Temperature and pressure in the refrigeration cycle
1. Receiver 4. Compressor
2. Evaporator 5. Blower
3. Condenser 6. Expansion valve
In the refrigeration cycle, the refrigerant transforms

from a liquid to a gas (evaporation) and from a gas to
a liquid (condensation). Both the temperature and
pressure of the refrigerant vary throughout the
refrigeration cycle.
The figure above indicates variations of the temperature
and pressure in the refrigeration cycle. (The numbers
in the diagram are taken from the design values of a
standard air conditioner, and are given only for
reference. These values vary depending on the
conditions for the actual cycle).
10-155-5
5. Heating cycle
The heating cycle uses cooling water taken from
the engine cooling system.
A) The cooling water absorbs the heat from the
engine, and its flow is controlled by the water
valve to enter the heater core.
B) In the heater core, the heat of the cooling
water is transferred to the air at the surface of
the core.
C) The heat is sent by the blower to the operator's
compartment.
D) The cooling water which has given up its heat
in the heater core returns to the engine.
By repeating the above steps (A) to (B), the inside

of the operator's compartment is heated.
10-155-6
REFRIGERANTS
The refrigerant plays the most important role in the

refrigeration cycle. Various kinds of refrigerants are
available for various types of applications. The most
critical characteristic of a refrigerant is the ease with it
liquefies and vaporizes at normal or low temperatures.
However, only a few kinds of refrigerants are used in air
conditioners, depending on various conditions, such as
the type of compressor, evaporation temperature
(pressure), and condensation temperature (pressure).
Ammonia and freon type gases, which satisfy the
requirements, are widely used. Air conditioners usually
use "freon type" gases because of their safety and the
small size required for a refrigeration system.
Freon-type gases
Components in this system are compatible with
Refrigerant 134a (CCL2F2 -
Dichlorodifluoromethane). Use of other refrigerants
would not achieve performance characteristics,
and more importantly, would, in most cases,
chemically deteriorate components.
SAFETY PRECAUTIONS
WARNING! The refrigerant R-134a can be a

fire and health hazard if handled incorrectly.
Avoid contact with the substance and never
expose it to extreme heat, sparks or open
flame.
The substance used in the air conditioning system,

called R-134a is basically a safe, non-toxic refrigerant.
However, when it is exposed to an open flame, it
changes to a very highly poisonous and deadly
phosgene gas. This phosgene gas will tarnish bright
metal surfaces.
The liquid refrigerant will boil (or vaporize at -29.8

(-21.7 F) at atmospheric pressure (or when it is
exposed to the air). It also evaporates so rapidly that the
gas may displace the oxygen in the area, if it happens
to be a small enclosed area. Therefore, whenever the
system is worked on, a safe practice would be to work
on it in a well ventilated area.
The refrigerant, when exposed to the air, is

approximately -29 C (-21 F). Upon contact with the skin,
the effect is just like frostbite. Treat the same as you
would for frostbite.
If the refrigerant contacts the eyes, immediately flush

the eyes with water and continue to do so until the
temperature is above the freezing point. Consult an eye
specialist immediately. Blindness could result from an
injury of this sort and it is highly recommended that
safety goggles be worn whenever servicing the system
10-155-7
If the air conditioning system must be discharged, do it

out of doors or in a well ventilated area where no
extreme heat or open flame is present. Release the
refrigerant slowly as it will suck the oil from the
compressor if the system is opened too fast.
Always use the correct type of hoses for the air

conditioning system. Do not use any hose which is not
specified for refrigeration use. Never apply heat of any
sort on any of the air conditioning hoses or components
of the system while it is charged. The extra heat could
cause the pressure of the refrigerant in the system to
become excessive and cause a dangerous rupture.
Be sure the pressurized refrigerant containers are

never exposed to or stored in an area where the
temperature could exceed 52
Do not discard empty refrigerant containers where they

might be subjected to a temperature of 52
or higher.
Do not add alcohol or other liquid driers to the system

to prevent freeze-up. The desiccant in the dryer prefers
alcohol to water and will discharge moisture to absorb
alcohol.
Refrigerant oil is the exception to the rule that water and

oil do not mix. If left in an open container it will absorb
moisture and may cause freeze-ups at the expansion
valve or sludge build up.
Use only refrigerant oil in the compressor.
Remember:
1. Wear safety goggles.

2. Keep refrigerant away from heat, flame or sparks.
3. Do not smoke or have an open flame near when
discharging refrigerant.
4. Work in a well ventilated area.
5. Avoid physical contact with refrigerant.
REFRIGERATOR OIL (LUBE OIL)
The lubricant used in air conditioners is generally called

refrigerator oil. Its purpose in the compressor is to
minimize wear of the piston, cylinder walls, and other
frictional parts like bearings, and to prevent them from
seizing by removing the heat created by friction. In
addition, the substance helps prevent leakage of
refrigerant by maintaining a uniform thin oil film on the
contact surface of parts.
10-155-8
Freon type refrigerant dissolves in oil better than

ammonia does. When the freon is dissolved in oil, the
freezing point of the oil goes down, which causes no
hindrance to the use of the oil at low temperatures. The
flash point and the ignition point of the refrigerant oil are
ordinarily 160 ,
respectively.
The lube oil for air conditioners will contact refrigerant.

Thus, the viscosity of the oil when mixed with refrigerant
is an important factor in the selection of the refrigerant
oil. The lube oil used in air conditioners is a mineral oil
refined from petroleum, and various types are
available. The refrigerant has a large effect on the
durability of the compressor and therefore, the oil must
conform to that specified for each compressor.
Characteristics of SUNISO (SUNISO is a U.S.

specification) refrigerator oil:.
1. Chemical stability
The oil is resistant to chemical reactions with the
refrigerant or any other substance in the system.
2. Thermal stability
No carbon deposits are formed at high
temperatures in the valve and delivery (discharge)
portion of the compressor.
3. Low wax content
The flocculent material does not separate from the
oil-refrigerant mixture in the low-temperature
portion of the refrigeration system.
4. Low pour point
The oil in the refrigeration system does not freeze
because the pour point is lower than the lowest
temperature in the system.
5. High insulation resistance
6. Proper viscosity
Excessive wear of the compressor is prevented
because the proper viscosity is maintained even at
high temperatures. Sufficient fluidity of the oil is
maintained at low temperatures and a satisfactory
oil film is formed at all times.
7. Cleanliness of oil
No dust, or foreign matter that accelerate the
deterioration of oil are mixed in the oil. Thus, the
cylinder liners and bearings will not get flawed and
oil grooves will not get clogged.
10-155-9
STRUCTURE AND FUNCTION AIR CONDITIONING CONDENSER
AIR CONDITIONING CONDENSER

FUNCTION
In a refrigeration system, the job of the condenser is to

convert the heated, high pressure gaseous refrigerant
compressed in the compressor back into a liquid
refrigerant. Heat at the same time dissipates into the
atmosphere. An auxiliary fan helps force the heat
exchange.
GENERAL DESCRIPTION
In the condenser, the quantity of heat to be emitted

from the gaseous refrigerant depends on the quantity of
heat absorbed from the room air in the evaporator and
the work to be done to compress the gas in the
compressor. Accordingly, the effect of the heat
radiation on the cooling effect is so large that the forced
cooling is performed by two special cooling fans, in
addition to the cooling fan for the engine radiator. This
independent condenser helps prevent overheating of
the engine and does not effect engine performance.
1. 2-Stage control of condenser fan motor

The electric fan of the condenser is controlled to
two speeds by the pressure of the refrigerant on
the pressure side.
If the pressure of the refrigerant on the high
pressure side rises above 18 kg/cm², the pressure
switch is turned ON and the fan motor runs at high
speed.
When the pressure of the refrigerant on the high
pressure side drops below 14 kg/cm², the pressure
switch is turned OFF and a resistor reduces the
voltage to make the fan motor run at low speed.
This extends the life of the fan motor, and also
avoids the unnecessary use of electricity.
10-155-10
2. Pressure switch
This switches ON and OFF according to the
pressure of the refrigerant.
ON: 14 kg/cm² (199 psi)
OFF: 18 kg/cm² (266 psi)
1) Pressure switch
3. Defrosting device
Frost can build up on the evaporator fins if their

temperature drops below freezing. Efficiency will
suffer, so a thermistor has been provided, attached
to the evaporator fins, to signal when the fins are
too cold. If so, the controller will turn off the
magnetic clutch, stopping the compressor.
10-155-11
4. Magnetic clutch
The compressor pulley incorporates a magnetic

clutch to connect and disconnect from the engine.
The clutch engages whenever current is supplied
to its magnet stator coil (air conditioning is switched
on). The drive belt then can power the compressor.
5. Electric fan motor

This turns the electric fan and carries out the forced
cooling of the condenser.
1) Fan
2) Fan motor
10-155-12
AIR CONDITIONER
COMPRESSOR
The compressor is a pump to raise the pressure of the
refrigerant. As the refrigerant pressure increases, so
does its temperature, and the high temperature
refrigerant gas then will condense rapidly in the
condenser by releasing heat to the surroundings.
The compressor illustrated here, a swash plate type,

operates paired pistons on the swash plate. Rotation of
the shaft and attached swash plate operates the pistons
in their bores. The swash plate and shoes convert
rotary motion of the shaft to reciprocating motion of the
pistons.
Intake stroke: When the piston moves to the left, the

right side of the piston draws the refrigerant through the
suction valve while the discharge valve is held closed
against the valve plate.
Discharge stroke: When the piston moves to the left,

the left side of the piston forces out the refrigerant
through the discharge valve while the suction valve is
held closed against the valve plate.
A shaft seal and seal plate seal the compressor shaft.

The cutaway drawing illustrates a typical arrangement.
10-155-13
STRUCTURE AND FUNCTION RECEIVER
RECEIVER WITH SIGHT GLASS (LIQUID TANK)

The refrigerant liquified in the condenser is temporarily stored in this tank so that the refrigerant can be supplied to the
evaporator according to the cooling load.
A strainer is provided in the tank and the silica-gel is sealed on the external surface of the strainer. A sight glass and
a fusible plug are provided in the top. The purpose of the strainer and silica-gel is to remove dust and water content from
inside the refrigeration cycle.
If water gets into the refrigeration cycle, functional parts will corrode and/or water can freeze in the small port of the
expansion valve, and obstruct refrigerant flow.
1. Body
2. Sight glass
3. Drier
4. Drier
10-155-14
STRUCTURE AND FUNCTION RECEIVER
1. Fusible plug
A fusible plug, also called a melt bolt, has a hole
through its center which is filled with special solder
that melts at 103 r
cannot ventilate properly, and thoroughly dissipate
the heat, the special solder in the fusible plug will
melt. The refrigerant escapes to the open air
before the pressure in the condenser and receiver
can increase enough to damage them.
When the special solder melts at 103
the pressure of the refrigerant is approx. 30 kg/cm².
2. Sight glass
This small window allows observation of the
refrigerant flowing through the refrigeration cycle.
Generally, if air bubbles appear, the refrigeration
system is lacking refrigerant. When no air bubbles
are observed, the proper quantity of refrigerant is in
the system.
When there is no refrigerant in the system, no
air bubbles will be seen.
10-155-15
STRUCTURE AND FUNCTION AIR CONDITIONER UNIT
AIR CONDITIONER UNIT

OUTLINE
In this all-season-type air conditioner unit, the air is
cooled and dehumidified through the evaporator and
reheated to the proper temperature through the heater
for a comfortable cab atmosphere. In hot weather, only
the evaporator operates and in cold weather, mainly the
heater operates. In other seasons, particularly rainy
and humid weather, the heater and evaporator operate
to dehumidify and heat the air.
1. BLOWER SWITCH
Acts as the main switch and is used for controlling
the air flow when cooling or heating.
This switch controls the air flow to three levels:
Low Medium High
If the knob is turned to the OFF position, the air

conditioner will stop.
2. AIR CONDITIONER SWITCH

Switching when cooling (power for compressor)
When the button is pressed, the switch is
turned on and the pilot lamp lights up.
When the button is pressed again, the switch is
turned off and the pilot lamp goes out.
If the air conditioner switch is turned on but the
blower switch is still off, the air conditioner will
not work (the pilot lamp does not light up).
Turn the air conditioner switch on after turning
the blower switch on.
3. TEMPERATURE CONTROL
This lever controls the temperature during cooling
or heating.
Move the lever towards (left) the Cool position
to lower the temperature; move the lever
towards (right) the WARM position to raise the
temperature.
If the air conditioner switch and blower switch
are turned on, and the lever is moved to the
WARM position, the air conditioner will give
dehumidifying and heating.
4. AIR SOURCE SELECTOR

This lever switches the source of air during cooling
or heating.
FRESH (right - outside air is brought in) This is
used for normal cooling and heating. Fresh air
from the outside is used in addition to the air
inside the operator's compartment.
RECIRC (left - inside air is recirculated) This is
used for quick cooling and heating.
In this position, only the air inside the operator's
compartment is used.
10-155-16
STRUCTURE AND FUNCTION ELECTRIC CIRCUIT DIAGRAM
AUTO-GREASING
10-161
ELECTRONIC CONTROLLED SUSPENSION SYSTEM (E.C.S.S.)
10-162
10-163
JOYSTICK STEERING REMOTE POSITIONER
10-164
10-165
STRUCTURE AND FUNCTION MACHINE MONITOR SYSTEM
MACHINE MONITOR SYSTEM
1. Fuel level 5. Engine oil level

2. Engine water temperature 6. Brake oil pressure
3. Torque converter oil temperature 7. Engine oil pressure
4. Engine water temperature 8. Air cleaner clogging
OUTLINE
The machine monitor system uses the sensors and There are also various switches built into the
other devices installed to various parts of the monitor panel which function to operate the
machine to observe the condition of the machine. machine.
It processes this information swiftly and displays it The main monitor uses the network wiring to send
on the monitor panel to inform the operator of the signals to the controller, and functions to display
condition of the machine. the following information:
The machine monitor system consists of the main Shift indicator: 1st - 4th, N, F, R (F and R are
monitor, maintenance monitor, sensors, switches, optional).
relays, alarm buzzer, and power source. HOLD
The displays can be broadly divided into the Failure action code, failure code, time elapsed
following: Cautions displayed on the monitors since failure (failure data display mode).
(abnormalities in the machine where an alarm is
given), and normal conditions which are always
displayed on the instrument panel (pilot lamps,
readings for the gauges, speedometer, and service
meter).
10-166
STRUCTURE AND FUNCTION MAIN MONITOR
MAIN MONITOR
1. Check lamp 4F. Shift hold 5C. Working lamp (front) switch
2. Caution lamp 4G. Parking brake 5D. Working lamp (rear) switch
3. Caution items 4H. Ground driven steering 5E. Transmission cut-off switch
3A. Ground driven steering normal (option) 5F. Auto shift, manual selector
actuated (option) 4I. Not used switch
4. Pilot items 4J. Failure action code
4A. Turn signal (left) 5. Switches
4B. Turn signal (right) 5A. Auto grease switch
4C. High beam (option)
4D. Shift indicator 5B. Travel damper switch
4E. Speedometer (option)
OUTLINE
The main monitor has a display function for the A liquid crystal display and LEDs are used for the
speedometer and other gauges, and a switching display. The switches are embossed sheet
function to control the electric components and switches.
controllers.
There is one CPU (Central Processing Unit)
installed internally, and this processes the signals
from the sensors and outputs the display.
10-167
MAIN MONITOR DISPLAY FUNCTION
10-168
MAIN MONITOR SWITCH FUNCTION

Item Function Display Actuation
Auto-greasing Forced greasing is carried Lights up (goes out momentarily Auto-greasing control
out while switch is being when switch is turned ON) actuated (automatic greasing
pressed when display is carried out at fixed interval)
lighted up.
Flashes (slowly) Grease empty
Flashes (rapidly) Abnormality in auto-greasing

controller system
Goes out Auto-greasing controller not

installed
E.C.S.S. E.C.S.S. function is Lights up E.C.S.S. function actuated

actuated or stopped each
time switch is pressed Goes out E.C.S.S. function stopped
Working lamp Front working lamp lights Lights up Front working lamp lights up
(front) up or goes out each time
switch is pressed when Goes out Front working lamp goes out
side lamps are lighted up
Working lamp Rear working lamp lights Lights up Rear working lamp lights up
(rear) up or goes out each time
switch is pressed when Goes out Rear working lamp goes out
side lamps are lighted up.
Transmission Transmission cut-off Lights up Cut-off function actuated

cut-off function is actuated or
stopped each time switch Goes out Cut-off function stopped
is pressed
Manual Auto shift mode switches Lights up Manual mode

to manual mode when
switch is pressed Goes out Auto shift mode
10-169
TROUBLE DATA DISPLAY MODE (When optional controller is installed)

Item Switch operation Actuation
Method of switching to With engine stopped and starting switch turned All switch displays (LEDs) go out, and
trouble data display ON, press 2nd switch from top on left side of failure code is displayed on speedometer
mode main monitor (switch below ground driven display and time elapsed since failure is
steering display) and work lamp (front switch displayed on failure action code display.
simultaneously for at least 5 seconds 1) Failure code is two-digit display
given in numbers or letters. The
display for the failure now occurring
flashes and the display for past
failures lights up.
2) The time elapsed since failure is
displayed as a three-digit number to
show how long ago the failure
occurred (the oldest failure time is
displayed. Any time greater than
999H is displayed as 999H).
3) A maximum of 9 times are stored in
memory for the failure codes.
Method of sending Press working lamp (front) switch Failure code and time elapsed since
failure code failure change to next item
Clearing failure code Press working lamp (rear) switch Failure code and time lapsed since
for at least 2 seconds failure being displayed are cleared.
Failure code for problem now occurring
(flashing display cannot be cleared.
Resetting from travel Press 2nd switch from top on left side of main Changes to normal display
data display mode monitor (switch below ground driven steering
display) and front working lamp switch
simultaneously for at least 5 seconds, or start
the engine.
10-170
STRUCTURE AND FUNCTION MAINTENANCE MONITOR
MAINTENANCE MONITOR
Outline
The maintenance monitor has a display function for The monitor module has a built-in CPU (Central
the caution items and gauges, and switch functions Processing Unit). It processes the signal from the
to control the work equipment controller. sensors, and carries out the display and output.
The m aintenance monitor consists of the monitor A liquid crystal display and LEDs are used for the
module, switch module, service meter, case, and display portions. The switches are embossed sheet
other mechanisms. switches.
10-171
MAINTENANCE MONITOR DISPLAY FUNCTION
10-172
MAINTENANCE MONITOR SWITCH FUNCTION
Item Function Display Actuation
Remote boom Sets stopping position in LOWER Flashes (2.5 sec) Sets stopping position
positioner LOWER direction for remote boom
position setting positioner (boom position when Goes out -
switch is pressed is recorded)
Remote boom Sets stopping position in RAISE Flashes (2.5 sec) Sets stopping position
positioner RAISE direction for remote boom
position setting positioner (boom position when Goes out -
switch is pressed is recorded)
Selection of remote Sets remote boom positioner in Goes out Remote boom positioner
boom positioner stopping direction (Switches function Off
RAISE/LOWER function each time switch is
pressed) RAISE lights up Remote boom positioner
RAISE stop function ON
LOWER lights up Remote boom positioner

LOWER stop function ON
RAISE, LOWER light Remote boom positioner

up RAISE/LOWER stop
function ON
10-173
STRUCTURE AND FUNCTION AUTOMATIC TRANSMISSION SYSTEM
ALL-RANGE ELECTRONIC CONTROL AUTOMATIC

TRANSMISSION SYSTEM
OUTLINE OF SYSTEM
the all-range electronic control automatic The self-diagnostic function always observes the
transmission system consist of the transmission input and output condition, and displays the output
controller, directional and speed levers, engine condition on the two 7-segment LED displays on
speed sensor, speed sensor, and all-speed-range the transmission controller. There is also a failure
ECMV (transmission clutch modulation valve). detection function, and if any abnormality occurs, it
The transmission controller controls the shifting to displays a failure code. Depending on the
the appropriate speed range according to the lever condition, it also displays a failure action code on
position and travel speed signal. the main monitor and flashes the caution lamp to
To reduce shock when shifting gear (engaging the improve safety.
clutch), all-speed-range ECMV carries out The transmission controller has a communications
modulation control. function, and it sends the speed range (N, 1st-4th)
A travel damper function and joystick steering data to the main monitor, which displays the speed
control function are available as options, and these range. (If the joystick mode is used, it also displays
controls are possible if the function is installed to F and R.)
the machine.
To improve durability, there is a safety function
which prevents the machine from moving suddenly
when the engine is started, and a transmission
protection function which protects the clutch when
the direction of travel is changed.
10-174
SYSTEM STRUCTURE DIAGRAM
10-175
FUNCTION
1. Auto-shift function. rpm, the gear is shifted to a range that
Shifting the transmission up or down is carried out matches the travel speed.
when the engine speed is above 1450 rpm. Shifting 6) Gear shift prevention interval.
is decided by signals from the directional lever, To prevent shift hunting after shifting gear, a
speed lever, and travel speed sensor according to time interval is set to maintain the speed range.
(Table 1 Automatic gear shift change point table) The gear shift prevention interval differs
recorded in the memory of the transmission according to the shift pattern. For details, see
controller. [Table 1 Automatic gear shift change point
1) Speed lever (1st - 4th). table].
This controls the maximum speed range
(available speed range) for automatic gear
shifting. 2. Modulation control.
Example: Speed lever at 4th: 2nd - 4th The modulation control acts to reduce the shock
Speed lever at 2nd: 2nd only when shifting gear (when engaging the clutch). It
2) Directional lever N position. uses the data for the engine speed, transmission oil
To prevent the vehicle from moving temperature, and gear shift pattern to control the
accidentally, when the lever is at neutral clutch oil pressure (including the characteristics
position, only the 2nd clutch is engaged. when starting) to match the condition of the
3) Directional lever F position. hydraulic circuit to control all speed ranges to the
When the directional lever is operated from N optimum according to the data in the transmission
to F, the transmission turns ON the F and 2nd modulation table stored in the transmission
ECMVs (F2). (Automatic start in 2nd) controller memory. In addition, to reduce the torque
a) Shift up (when speed lever is at 4th) When cut, it carries out modulation control of the ECMV
the accelerator pedal is depressed to at the side which switches OFF also.
increase the engine speed and the travel The transmission modulation data table is set for
speed rises, when the travel speed each transmission oil temperature. In addition, it
reaches approx. 9.3 km/h, the ECMV 3rd has a learning function (transmission clutch piston
is turned ON, and at the same time, 2nd is data) to prevent any abnormal time lag when
turned OFF. (Shifting to F3) shifting gear.
When the travel speed rises further to
approx. 17.6 km/h, the ECMV 4th is turned
ON, and at the same time, 3rd is turned 3. HOLD function.
OFF. (Shift to F4) When the HOLD switch is pressed, the speed
b) Shift down (speed lever at 4th). range is held at the optimum speed range, and
When traveling in 4th, if the accelerator even if the travel speed goes down, the
pedal is let back, and the travel speed transmission does not shift down. However, when
comes down to approx. 15.6 km/h, the switching between forward and reverse, the
ECMV 3rd is turned ON, and 4th is turned transmission normally shifts down to 2nd according
OFF. (Shift to F3) to the travel speed, and then shifts up to the HOLD
When the travel speed goes down to shift range according to the travel speed and gear
approx. 9.8 km/h, the ECMV 2nd is turned shifting conditions. (This prevents any unnecessary
ON, and 3rd is turned OFF. (Switches to shift down when leveling ground, or when traveling
F2) downhill.)
4) Directional lever R position.
Automatic gear shifting is carried out according
to the travel speed between 2nd and 4th
speeds (when the speed lever is at 4th) in the
same way as when the speed lever is at the F
position.
5) Skip shift.
When coasting (in engine speed OFF mode) in
3rd or 4th speed with the accelerator pedal
depressed, if the travel speed is less than 8
km/h, the gear shifts down to 2nd to make it
easier to accelerate. If the travel speed is more
than 8 km/h, the speed range is maintained,
and when the engine speed goes above 1450
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4. Kickdown function. transmission shifts down to 2nd according

When operator turns the kickdown switch ON, it to the deceleration.
overrides the auto shift and switches down forcibly (For details, see Fig. 1 F-R selection gear
to 1st if the conditions (speed range, travel speed) shift pattern, table 1 Automatic gear shift
in [Table 1 Automatic gear shift change point table, change point table, 7. F-R selection.)
5. Kickdown] are fulfilled. b). Alarm buzzer.
When the speed range control and travel
fulfill the conditions for range III, the alarm
5. Travel mode. buzzer sounds to warn the operator. (If the
1). Manual mode (option). engine speed is above 1700 rpm and the
It is possible to switch between auto and travel speed is above 13 km/h, or the
manual shift. When using the manual mode, travel speed is above 14 km/h).
the gear is shifted according to the operation of (See Fig. 2 F-R selection alarm buzzer
the speed lever. When traveling in F2, it is also range.)
possible to use the kickdown function. 4). Manual shift.
2). Joystick steering control function (option). If the travel speed sensor is abnormal and it is
a). If the machine is equipped with the joystick impossible to detect the travel speed data, the
steering function, the operator can switch transmission is set to manual (shift) mode.
between steering wheel and joystick
steering mode as desired.
b). The transmission controller controls the
signals from the travel system. (The
steering system is controlled by the work
equipment controller.)
c). When switching the steering between
steering wheel and joystick steering,
always stop the machine first, return the
speed lever to the N position, then switch
the steering. When this is done, the
transmission controller is set to the neutral
safety condition to prevent the machine
from suddenly moving.
6. Safety function.
1). Neutral safety.
When the engine is started, if the directional
lever is at any position other than N, the
transmission controller keeps the transmission
in neutral and prevents the machine from
moving. If the N signal is input after the engine
is started, the neutral safety is canceled.
2). Speed lever priority.
It is possible to shift down immediately by
operating the speed lever, so the engine can
be used as a brake when traveling downhill.
3). Transmission protection.
When traveling in 3rd or 4th speed, the travel
speed is controlled and a warning buzzer
sounds to protect the transmission when
shifting between forward and reverse.
a). Speed range control.
speed fulfill the conditions for range I, the
transmission shifts down to 2nd.
speed fulfill the conditions for range II, the
speed range is maintained and the
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Table 1: Automatic gear shift change point table.
Item Speed Travel speed Gear shift

range (Km/h) prevention interval
1. Basic shift change. 1 5.1 (5.3) or above 2
2 8.7 (9.2) or above 2
3 16.5 or above 1
4 Less than 14.5 1
3 Less than 9.2 (8.7) 2
2. Engine speed. 4 Less than 1.0 o

(less than 1450
rpm) 3 Less than 1.0 0
3. Engine speed. 4 Less than 8.0 2

(less than 1450
rpm 3 Less than 8.0 2
1450 rpm)
4. Shift when HOLD is 1 5.1 0

ON.
2 8.7 0
3 16.5 0
5. Shift down when 2 Whole range 5

kickdown is ON.
3 Less than 12.0 5
4 Less than 12.0 5
6. FR selection (range I) 4 (Note 1)

(F 3 2
(R 1
7. FR selection (range II) (Note 2)

(F 16.5 or above 2
(R Less than 14.5 - 16.5
86. FR selection 16.5 or above

(F Less than 8.7 - 16.5 0
(R Less than 8.7
Note 1: When the engine speed is less than 1900 rpm and the travel speed is less than 16 km/h, or the travel
speed is less than 13 km/h.
Note 2: When the travel speed is 1900 rpm or above and the travel speed is 13 km/h or above, or the travel speed
is 16 km/h or above, the speed range maintained and the transmission shifts down to 2nd according to
deceleration.
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10-179
7. Self-diagnostic function 1) Normal display:

The transmission controller always observes the Transmission controller LEDs display output range.
input and output signals of the automatic gear 2) Failure code display:
shifting system. It carries out self diagnosis and If an abnormality is detected, the nature of the
displays the results on the LEDs of the failure is displayed as a code. For details of failure
transmission controller. In addition, it sends the code, see Table 2 Failure code table.
following data to the main monitor.
Table 2: Failure code table.

Code Item System Main Monitor
Short Circuit Disconnection Action Code
10 Back-up alarm relay O O None
11 None - - -
12 F ECMV solenoid O O Call
13 R ECMV solenoid O O Call
14 1st ECMV solenoid O O Call
15 2nd ECMV solenoid O O Call
16 3rd ECMV solenoid O O Call
17 4th ECMV solenoid O O Call
18 None - - -
19 Joystick direction switch O O E00
20 Directional switch signal O O Call
21 Range switch signal O O None
22 Travel speed sensor X O E00
23 Engine speed sensor O O E00
24 Abnormality in memory (EEPROM) - - None
25 Transmission oil temperature sensor O X E01
26 F ECMV fill switch O X Call
27 R ECMV fill switch O X Call
28 1st ECMV fill switch O X Call
29 2nd ECMV fill switch O X Call
30 3rd ECMV fill switch O X Call
31 4th ECMV fill switch O X Call
32 F or R ECMV fill switch X O E00
33 1st, 2nd, 3rd, or 4th ECMV fill switch X O E00
10-180
8. Communications function 4. FORWARD switch

The transmission controller is equipped with a This signal is a +24V/OPEN digital signal and +24V
communications function using S-NET. It always is input when the HOLD switch on the work
maintains communications with the main monitor, equipment control lever is pressed. The switch
and when the engine is started, it receives model, operation is judged from the +24V starting signal
travel damper availability, and tire compensation from the OPEN condition at that point.
data. 5. Neutralizer relay signal
When any abnormality occurs, it displays an action This signal is a +24V/OPEN digital signal and +24V
code on the main monitor according to the is input when the parking brake switch is pressed.
condition of the problem to warn the operator in When signal is OPEN, the transmission controller
order to increase safety. maintains the neutral condition.
The failure code can recognize the codes recorded 6. Transmission cut-off signal
in the main monitor memory using the main This signal is a GND/OPEN digital signal, and when
monitor problem history mode. For details of the transmission cut-off switch is operated (using
operating the main monitor, see the section on the the left brake), it changes to GND. When it is
main monitor. actuated, the transmission controller changes to
9. Travel damper (option) the neutral output condition, and when it is
If the machine is equipped with a travel damper restored, it sets to a suitable speed range for the
function, the operator can use this function by travel speed at that point.
operating a switch. 7. Manual mode signal
When the engine is started, the availability of the This signal is a GND/OPEN digital signal, and when
travel damper function is transmitted from the main the manual mode switch is ON, GND is input.
monitor, and the troubleshooting function can also 8. Fill switch (F, R, 1st - 4th signals)
be actuated for the travel damper system. This signal is a GND/OPEN digital signal, and is
installed to each ECMV. The switch is operated by
oil pressure.
When the ECMV is on, GND is input.
TRANSMISSION CONTROLLER POWER 9. Engine selection signal
SOURCE This signal is a GND/OPEN digital signal, and when
When the starting switch is turned ON and the the engine is started, the type of engine mounted is
supply voltage is more than 2OV, and +20V or judged from this signal. (The speed conversion
more is supplied to the transmission controller data is different.)
solenoid power source input, it is possible to drive
each solenoid valve. Table 3 Engine selection signal table
If the supply voltage is less than 19V, all outputs Input signal Engine Speed conversion
are turned OFF and the solenoids cannot carry out data
control (travel is impossible).
GND Cummins 118
10. Memory clear signal

INPUT SIGNALS This signal is a GND/OPEN digital signal. It is
1. Directional lever (F,N,R) signal normally OPEN. When clearing the memory, start
This signal is a +24V/OPEN digital signal, and the engine, then input OPEN N
when it is normal, one of F, N, or R signals (+24V) signals.
is input.
2. Speed lever (lst - 4th) signal
This signal is a +24V/OPEN digital signal and +24V
is input for the signal for the lever position.
3. Kickdown switch
This signal is a +24V/OPEN digital signal and +24V
is input when the kickdown switch on the work
equipment control lever is pressed. The switch
operation is judged from the +24V starting signal
from the OPEN condition at that point.
10-181
11. Engine speed sensor signal OUTPUT SIGNALS

This signal is a pulse signal, and it converts the 1. Transmission modulation valve (ECMV
pulses from the electromagnetic pickup sensor to command current)
rotation speed for control. When the engine speed This signal is an electrical output (O - 1A). There
is 1450 rpm or above, it is called the engine speed are six types of ECMV: R and F for direction, and
ON mode, and when the speed is less than 1450 lst, 2nd, 3rd, and 4th for each speed range. This
rpm, it is called the engine speed OFF mode. valve is a pressure control valve and converts to a
Komatsu engine: Speed P (rpm) pressure matching the value of the current flowing
= Input frequency (Hz) x 60/6 to the solenoid. Therefore, it controls the oil
Cummins engine: Speed P (rpm) pressure for the clutch selected for each speed
= Input frequency (Hz) x 60/118 range and controls the engagement of each
12. Travel speed sensor signal independent clutch. In addition, only the 2nd clutch
This signal is a pulse signal, and it converts the is actuated when the transmission is at neutral.
pulses from the electromagnetic pickup sensor to
rotation speed for control. Table 4: Combination of speed ranges and ECMV
To convert to the travel speed, the tire
compensation data (communications data from the ECMV/ F R 1st 2nd 3rd 4th
main monitor) are added. In addition, the Speed range
acceleration is also calculated to judge the travel
F1 O O
speed for gear shifting.
Speed P (rpm) = Input frequency (Hz) x 60/ 59 F2 O O
Travel speed V (km/h) = Speed P (rpm)/
(101.6 x tire compensation value k) or Travel F3 O O
speed V (km/h) = Input frequency (Hz)/(99.9 x
tire compensation value k) F4 O
13. Transmission oil temperature sensor signal
This signal is an analog signal and converts 0 - 5 V N
inside the controller to temperature. This is used R1 O O
for selecting the modulation table when shifting
gear. R2 O O
14. Communications signal (S-NET)
This receives the following data set in the main R3 O O
monitor and is used for control.
1) Model selection R4 O O
It selects the automatic gear shift change point
data table for each model to use for shifting O = ON
gear.
2) Tire compensation data 2. Backup lamp relay signal
This adds the compensation value (covering a This signal is a +24V digital (ON/OFF) output. It is
range from 0.86 to 1.14) to the speed data actuated when the directional lever is placed at R
from the travel speed sensor to obtain an and lights up the backup lamp and caution lamp.
accurate travel speed. 3. F1 (cut-off) signal
3) Travel damper function selection This is a This signal is a +24V digital (ON/OFF) output. This
function selection signal and judges if the signal is output when the kickdown is operated and
travel damper function exists. lt controls the sets the machine to Fl.
travel damper system, including 4. Engine speed signal
troubleshooting. This outputs a signal at the same cycle as the
engine speed sensor signal input to the
transmission controller.
10-182
5. Communications signal (main monitor display

data)
For details of the display position and operation of
the main monitor, see the section on the main
monitor.
1) Speed range
1st speed range output: [1]
2nd speed range output: [2]
3rd speed range output: [3]
4th speed range output: [4]
Neutral: [N]
2) F / R display
F / R are displayed in the joystick steering
mode (option).
3) HOLD display
The pilot display is given on the main monitor
when the HOLD function is ON.
LED DISPLAY
When the engine is started, the display goes first to
1. “Program quality display mode”, and next to 2.
“Output speed range display mode”. However, if
any abnormality is detected, it goes immediately to
the troubleshooting mode.
1. Program quality display mode.
When the power source is on, it switches once
every second.
2. Output speed range display mode.

LED display X. Y. (Both dots are out)
X: Direction ECMV drive condition
FORWARD [F]: F, REVERSE [R]: A, Neutral: O
Y: Speed range ECMV drive condition 1 - 4.
10-183
3. Troubleshooting display mode (currently

existing failure)
A cycle of [E-(2 sec)], [Code (2 sec)] is repeated.
1) When there is one abnormal item.
2) When there are two abnormal items.
10-184
10-185
STRUCTURE AND FUNCTION TRANSMISSION CONTROLLER
TRANSMISSION CONTROLLER
10-186
STRUCTURE AND FUNCTION TRANSMISSION CONTROLLER
CONNECTOR SIGNALS
CNC1 CNC3A 13 Direction N
1 Joystick N output 1 NC 14 Neutralizer relay
2 Buzzer signal 2 NC 15 Range SW 2
3 Relief solenoid 3 NC 16 Range SW 4
4 Engine speed output 4 NC CNC4
5 Low pressure solenoid 5 NC 1 NC
6 GND 6 Pressure sensor power supply 2 Engine speed

(+24v)
7 Power supply (+24V) 3 NC
7 potentio power supply
8 F1 output 4 NC
8 NC
9 Damper solenoid 5 5 NC
9 NC
10 High pressure solenoid 6 NC
10 ENC select
11 Back lamp relay 7 NC
11 T/M oil temp. Sensor
12 GND 8 NC
12 NC
13 Power supply (+24V) 9 GND (for rotate sensor)
13 NC
CNC2 10 NC
14 NC
1 Sol. power supply (+24V) 11 Network (-)
15 NC
2 ECMV 3 (+) 12 Network (-)
16 GND (for pressure sensor)
3 NC CNC5
17 GND (for potentio)
4 ECMV 4 (+) 1 GND (for plus)
18 NC
5 NC 2 Speed
19 Jotstick ON/OFF SW
6 NC 3 GND
20 Pressure SW
7 ECMV F (+) 4 GND
CNC3B
8 ECMV R (+) 5 Kick down SW
1 Pressure SW B
9 ECMV 1 (+) 6 T/M cut-off SW
2 Fill SW F
10 ECMV 2 (+) 7 Joystick N (NC)
3 Fill SW 1
11 P GND 8 Joystick F (NC)
4 NC
12 Sol. power supply (+24V) 9 Joystick R (NC)
5 Direction F
13 ECMV 3 (-) 10 GND (for plus)
6 Direction R
14 NC 11 Fill SW 3
7 Range SW 1
15 ECMV 4 (-) 12 Fill SW 4
8 Range SW 3
16 NC 13 Hold SW
9 Damper SW
17 ECMV F (-) 14 Manual SW
10 Fill SW R
18 ECMV R (-) 15 Joystick N (NO)
11 Fill SW 2
19 ECMV 1 (-) 16 Joystick F (NO)
12 NC
20 ECMV 2 (-) 17 Joystick R (NO)
21 P GND
10-187
STRUCTURE AND FUNCTION SENSORS
SENSORS
FUNCTION
The sensors are a contact type sensor with one Sensor detection Sensor When When
end grounded to the chassis. The signal from the item method normal abnormal
sensor is input directly to the monitor panel, and
when the contacts are closed, the panel judges the Speedometer Electro- - -
signal to be normal. However, the engine oil sensor magnetic
pressure uses a relay to reverse the sensor signal.
Engine oil level Contact ON OFF
Radiator water Contact ON OFF

level
Engine oil Contact OFF ON

pressure
Engine water Resistance - -

temperature
Torque converter Resistance - -

oil temperature
Engine speed Electro- - -

sensor magnetic
Fuel level sensor Resistance - -
SPEEDOMETER SENSOR
FUNCTION
The speedometer sensor is installed to the
transmission output gear. A pulse voltage is
generated by the rotation of the gear teeth, and
signal is sent to the machine monitor to display the
travel speed.
1. Connector
2. Magnet
3. Case
10-188
ENGINE SPEED SENSOR
1. Magnet FUNCTION
2. Terminal The engine speed sensor is installed to the ring gear
3. Case portion of the flywheel housing. A pulse voltage is
4. Boot generated by the rotation of the gear teeth, and a signal
5. Connector is sent to the controller and monitor panel.
ENGINE OIL PRESSURE SENSOR
1. Plug FUNCTION
2. Contact ring This sensor is installed to the engine block and the
3. Contact diaphragm detects the oil pressure. If the pressure
4. Diaphragm goes below the specified pressure, the switch is
5. Spring turned ON, and a relay is actuated to turn the
6. Terminal output OFF. This makes the maintenance monitor
flash to warn of the abnormality. The caution lamp
and alarm buzzer are also actuated at the same
time to warn of the abnormality.
10-189
RADIATOR WATER LEVEL SENSOR
1. Float FUNCTION
2. Sensor The sensor is installed to the top of the radiator. If
3. Connector the coolant goes below the specified level, the float
goes down and the switch is turned OFF. The
caution lamp and alarm buzzer are also actuated
at the same time to warn of the abnormality.
ENGINE OIL LEVEL SENSOR
1. Connector FUNCTION
2. Bracket This sensor is installed to the side face of the oil
3. Float pan. When the oil goes below the specified level,
4. Switch the float goes down ant the switch is turned OFF.
This makes the maintenance monitor flash, and the
check lamp to also light up at the same time to
warn of the abnormality.
10-190
FUEL LEVEL SENSOR
2. Float The fuel level sensor is installed to the side face of
3. Arm the fuel tank. The float moves up and down as the
4. Body level of the fuel changes. As the float moves up
5. Spring and down, the arm actuates a variable resistance,
6. Contact and this sends a signal to the maintenance monitor
7. Spacer to display the fuel level. When the display the
maintenance monitor reaches the specified level,
the warning lamp flashes.
10-191
ENGINE WATER TEMPERATURE SENSOR

TORQUE CONVERTER OIL TEMPERATURE SENSOR
2. Plug These sensors are installed to the engine cylinder
3. Thermistor block and transmission case. The change in the
temperature changes the resistance of the
thermistor, and a signal is sent to the maintenance
monitor to display the temperature. If the display
on the maintenance monitor reaches the specified
position, the lamp flashes and the buzzer sounds
to warn of the abnormality.
10-192
10-193
STRUCTURE AND FUNCTION ENGINE STARTING CIRCUIT
ENGINE STARTING CIRCUIT
Function
To ensure safety when starting the engine, the In addition, current flows from starting switch
system is equipped with a neutral safety circuit. terminal BR o
This makes it impossible for the engine to start if the battery relay switch is closed. This forms
the directional lever is not at the N (Neutral) posi- the following circuit.
tion.
[2] Battery (+)
Operation terminal B y
When the directional lever is placed at the N (Neu- relay terminal C ,
tral) position contacts of the directional lever switch and the engine starts.
are closed. In this condition, if the starting switch is
turned to the START position, current flows in the If the directional lever is at any position other
following circuit. than N (Neutral), circuit [1] is not formed, and
the engine does not start.
[1] Battery (+)
starting switch terminal C y
terminal S
directional lever switch terminal N
the safety relay is closed.
10-194
STRUCTURE AND FUNCTION ENGINE STARTING CIRCUIT
a) Safety relay.
10-195
STRUCTURE AND FUNCTION ENGINE STOP CIRCUIT
ENGINE STOP CIRCUIT

Operation
When the starting is turned ON, electric current When the starting switch is turned OFF, circuit [1] is
flows in the following circuit. shut off, but the engine is rotating, so there is still
voltage at terminal R of the alternator. For this
[1] Battery (+) reason, the following circuit is formed.
ing switch terminal BR
ground connection. [2] Alternator terminal R l
BR
When electric current flows to the fuel cut solenoid,
the fuel governor is put in the FREE position by the The battery relay is maintained, but because of the
fuel control linkage. diode inserted into the circuit, no electric current
flows to the fuel cut solenoid, so the engine stops.
Fuel flows to the fuel injection pump and the
engine starts.
10-196
STRUCTURE AND FUNCTION ETHER START CIRCUIT
ETHER START CIRCUIT
Function
• The ether injection system delivers a 3cc shot of
ether to the engine to aid in cold weather starting.
Operation
• With the lever in N (neutral) turn key to start position.
This completes cranking circuit as described in
engine starting section, and engine begins cranking.
This also completes circuit from start switch “B” to
start switch “R2" applying power to ether start switch.
• Move ether start switch to ON position then release
immediately (Do not hold it at ON position for more
than 5 seconds. This will cause failure of ether start
solenoid) This allows current to flow in the following
circuit. Start switch terminal “R2" to ether start switch
terminal “1" to ether start switch terminal “2" to ether
solenoid “1" to ground. This actuates ether start
solenoid, injecting ether.
10-197
STRUCTURE AND FUNCTION ELECTRIC TRANSMISSION CONTROL
ELECTRIC TRANSMISSION CONTROL
1. Transmission cut-off selector switch 6. Maintenance Monitor 11. Speed sensor

2. Parking brake switch 7. Relays 12. Transmission cut-off switch
3. Directional lever 8. Fuse boxes 13. Brake valve (left)
4. Speed lever 9. Transmission controller 14. Brake valve (right)
5. Kick-down switch 10. Transmission control valve
1 Selection of F, R, and N positions Using directional lever
2 Selection of speed range Using speed lever
3 Kick-down switch When traveling in F2, it is possible to shift down to lst using this switch without using the speed
lever. If directional lever is operated to R or N, speed range automatically returned to 2nd.
4 Transmission cut-off function Transmission is shifted to neutral when left brake is operated
5 Transmission cut-off selector function It is possible to select whether to actuate or not actuate the transmission cut-off function. In this
way, it is possible to obtain the same or greater ease of operation as on conventional loaders with
the left brake when carrying out scooping work or when loading or unloading the machine from a
trailer.
6 Neutralizer To prevent seizure of the parking brake when traveling with the parking brake applied, the
transmission is shifted to neutral when the parking brake is applied.
7 Neutral safety function If the directional lever is not at the N position, the engine will not start when the starting switch is
turned. This prevents the machine from starting suddenly. (For details, see STARTING CIRCUIT.)
8 Warning function When traveling in reverse, the backup lamp lights up and the backup horn sounds to warn people in
the area.
10-198
COMBINATION SWITCH
OUTLINE
The directional lever has three positions and the screws. When each lever is operated to the
speed lever switch has four positions. As an desired position, the switch, which is interconnected
individual part, the switch does not have a detent by a shaft, acts to allow electric current to flow to
mechanism; the detent mechanism is in the that circuit only.
combination switch. Each switch is positioned by
two pins, and is secured to the body by three
General locations, function

1 Directional lever switch Switches between F, R, and N
2 Speed lever switch Selects speed range
3 Speed lever stopper Stopper used to prevent speed lever from entering 3rd or 4th during
operations
4 Turn signal indicators Direction indicator lamps used when turning left or right
5 Self cancel Turn signal indicator lever automatically returns to central position after
machines turns left or right
6 Lamp switch Switches on clearance lamp, head lamp, parking lamp, etc.
7 Dimmer switch Selects high beam for travel and low beam for passing
8 Hazard switch Makes both left and right turn signal indicator lamps flash at the same
time
9 Emergency flashing pilot lamp Flashes at the same time as the emergency flashing lamp flashes
10 Parking brake switch Applies or releases parking brake
10-199
Operation
Directional lever (1) and shaft (2) of the speed lever
of the combination switch form one unit with
magnet (3), and magnet (3) also moves together
with lever (1).
Control switch (5) with built-in hole IC (4) is

installed at the bottom of magnet (3), and hole IC
(4) is positioned on the board to match each
position.
When directional lever (1) is operated to the F

position, magnet (3) is immediately above hole IC
(4) for the F position of the control switch. The
magnetism from magnet (3) passes through the
gap and case (6), and magnetism is applied to hole
IC (4).
When this happens, hole IC (4) is inside a

magnetism detection circuit, so it detects the
magnetism of magnet (3) and sends the F position
signal to the electric current amplification circuit. In
the electric current amplification circuit, a signal is
output to actuate the transmission.
10-200
STRUCTURE AND FUNCTION KICK-DOWN / HOLD SWITCH
KICK-DOWN / HOLD SWITCH
1. Kick-down switch
2. Spring
3. Spring
4. Hold switch
5. Wiring harness
KICK-DOWN SWITCH HOLD SWITCH

OPERATION The hold switch is installed to the boom lever, and
The kick-down (shifting down from 2nd s when the hold switch is pressed, the speed range
actuated only when traveling in F2. displayed on the main monitor transmission
When traveling in F2, if it is desired to shift down to indicator is held.
1st without operating the speed lever, operate the
kick-down switch on the boom lever to ON to shift Press the hold switch again to cancel.
down to F1.
After this, even if the kick-down switch is pressed,
the transmission is kept at F1.
Cancellation (or not actuated)

When directional lever is at N
When directional lever is at R
When speed lever is not at 2nd
When starting switch is OFF
10-201
STRUCTURE AND FUNCTION KICK-DOWN ELECTRICAL CIRCUIT
KICK-DOWN ELECTRICAL CIRCUIT DIAGRAMS

NORMAL OPERATION
(When directional lever is at F and speed lever is at 2nd)
1. When directional lever is at F. 2. When speed lever is at 2nd.

If the directional lever is set to the F position,the When the speed lever is at the 2nd
electric currentflowsfrom battery (+) l position,thesignal is inputtotransmission controller
lever terminals 1 - 2 r 2nd CNC3B terminal 15, and electricity flows as the
FORWARD CNC3B terminal 5, and then flows 2nd signal from CNC2 terminal 10
from CNC2 terminal 7 2 CNC2 terminal 20, and the 2nd solenoid is
terminal 17 as the FORWARD output signal, and actuated.
the FORWARD solenoid valve is actuated.
If the parking brake is placed at the RELEASED
position, electricity flows from battery (+)
brake safety relay terminals 5 - 3
switch terminals 3 - 2
1 - 2 e
neutralizer relay are connected.
10-202
WHEN KICK-DOWN SWITCH IS OPERATED

(Operation with speed lever at F2 position)
(When kickdown switch is pressed ON)
When the kick-down switch is pressed, the main In this way, if the kick-down switch is pressed when
monitor network signal (-) enters from CNLO8 the speed lever is at F2, the transmission is
terminal 2 to controller CNC5 terminal 5. The kick- automatically shifted to F1. At the same time, the
down circuit is formed inside the controller and the self-hold function of the kick-down circuit keeps the
solenoid output signal flows from CNC2 terminal 7 condition at F1 even if the switch is released or is
and terminal 9 to the F solenoid and 1st solenoid, pressed several times.
the solenoid valves are actuated, and the speed
range is set to F1.
This kick-down circuit continues to be actuated

even if the kick-down switch is returned. (Self-hold
circuit)
10-203
KICK-DOWN SWITCH OPERATION CANCELED

(When directional lever is set to N or R)
If the directional lever is operated to the R position, When the directional lever is set to the R position,
the contact of terminal F of the lever is turned off, current flows from battery speed lever terminals 1 -
so the electricity stops flowing from battery (+) 4 ransmission controller CNC3B terminal 6
speed lever switch terminals 1 - 2 n CNC 2-8 terminal (Reverse circuit formations R (+)
controller. signal inside controller) r
The FORWARD circuit inside the transmission (-) CNC2 terminal 18, and the REVERSE solenoid
controller is opened, so electricity stops flowing to valve is actuated.
the kick-down circuit. As a result, the kick-down At the same time, electricity flows from
self-hold circuit is canceled and the 1 st solenoid transmission controller 2nd signal (+) CNC2
stops actuating. (Even if the directional lever is set terminal 10 ,
to the N position, the same operation as above is and the 2nd solenoid valve is actuated to set to R2.
carried out and the kick-down circuit is canceled.)
The FORWARD circuit is also opened, so the F
solenoid also stops actuating.
10-204
STRUCTURE AND FUNCTION ELECTRIC PARKING BRAKE CONTROL
ELECTRIC PARKING BRAKE

CONTROL
1. Parking brake emergency release switch

2. Neutralizer relay
3. Parking brake safety relay (parking brake
emerge release relay)
4. Parking brake switch
6. Parking brake solenoid valve
7. Parking brake (built into transmission)
8. Parking brake emergency release valve
9. Charge valve
10. Accumulator
OUTLINE
l The parking brake is a wet type multiple disc
brake built into the transmission. When
electricity flows to the parking brake solenoid
valve, the oil pressure from the transmission
pump is applied to the parking brake cylinder
and releases the parking brake.
l When the flow of electricity is stopped, the
hydraulic pressure from the transmission pump
is shut off. The hydraulic pressure inside the
parking brake cylinder passes through the
parking brake solenoid valve and is drained. The
force of the brake spring then applies the
parking brake.
7 6 5 s0w02111
1O-205
Function
1. Applying and releasing parking brake 6. Parking brake emergency release solenoid
The parking brake is applied or released by using valve
the parking brake switch (combination switch). If the supply of pressure oil from the transmission
pump should stop because of some failure, it is
2. Automatic parking brake possible to actuate the emergency relief solenoid
When the engine stops (when the starting switch valve with the parking brake emergency release
is OFF), the parking brake is automatically applied switch in the operators compartment. This sends
to prevent the machine from running away when the accumulator charge pressure in the brake
the operator is away from his seat. piping to the parking brake cylinder to release the
parking brake.
3. Emergency brake
If the pressure in the oil pump should drop
because of damage to the hydraulic circuit and the
braking force can not be ensured, the parking
brake is applied automatically to act as an
emergency brake.
4. Parking brake safety

It is dangerous if the parking brake can be
released simply by turning the starting switch ON
after the automatic parking brake has been
applied. Therefore, to ensure safety, the system
is designed so the brake cannot be released
unless the starting switch is turned ON and then
the parking brake switch is also turned ON.
5. Neutralizer
The parking brake may seize if the machine is
driven with the parking brake still applied. To
prevent this problem, the caution lamp lights up
and the alarm buzzer sounds to warn the operator
of the mistaken operation. In addition to this, when
the parking brake is applied, the transmission is
forcibly shifted to neutral to make it impossible to
drive the machine. However, the braking distance
will become longer if the transmission is shifted to
neutral when the emergency brake is applied. It
may also be necessary to move the machine if it
stops in places where it is prohibited to stop (such
as on railway crossings). To overcome this, the
circuit is designed so that the transmission is not
shifted to neutral when the emergency brake is
applied.
IO-206
PARKING BRAKE EMERGENCY RELEASE SWITCH
EMERGENCY BRAKE SWITCH
10-207
PARKING SAFETY RELAY

NEUTRALIZER RELAY
10-208
OPERATION
1. Starting switch OFF
When the starting switch is turned OFF, the battery

relay is opened, so electricity does not flow to the
parking brake circuit. For this reason, if the starting
switch is at the OFF position, no electric current
flows to the parking brake solenoid valve,
regardless of whether the parking brake switch is
ON (applied) or OFF (released), so the parking
brake is actuated. (Automatic parking brake)
10-209
2. Starting switch ON
2-1 When parking brake switch is ON (actuated) before starting switch is turned ON.
The electric current flows in circuit e In this condition, electric current does not flow to
battery + the parking brake solenoid valve, so the parking
ground, so the battery relay is closed. When this brake is actuated.
happens, electric current flows in circuit
battery + h In addition, in this condition, neutralizer relay
terminal 1 - 3 ng brake safety relay terminal terminals 3 and 5 are open, so electric current
1-2 the parking safety relay does not flow to the transmission directional circuit,
is actuated and safety relay terminals 3 - 5 are and the transmission is shifted to neutral.
closed.
When this happens, circuit e

battery + y
terminal 5 - 3
d. From this point, the parking safety relay
is in the condition of circuit g
switch is turned OFF.
10-210
2-2 When parking brake switch is OFF (actuated) before starting switch is turned ON
Electric current flows in circuit In addition, the electric current does not flow to the
starting switch relay coil transmission directional circuit, so the machine
the battery relay is closed. However, in this case, does not move.
the parking brake switch is OFF (released), so the
parking safety relay is not actuated. For this
reason, the electric current does not flow to the
parking brake solenoid valve, so after the
automatic parking brake is applied, the parking
brake is not released automatically even when the
starting switch is turned ON.
10-211
3. Parking brake switch OFF (released)

When the parking brake switch is turned from ON to OFF after the starting switch is turned ON
If the parking brake switch is turned from ON This circuit is formed from the emergency
(actuated) to OFF (released), the circuit for brake switch arking brake solenoid valve
terminals 2 and 3 of the parking brake switch is ground, and the parking brake is released.
connected, and the parking brake safety relay is This circuit is formed from the battery +
also actuated. For this reason, electric current battery relay neutralizer relay terminal 3 - 5
flows in circuit transmission directional circuit, so when the
parking brake safety relay e directional lever is operated, the machine will
switch, and then flows to circuits n move.
below.
10-212
4. Parking brake switch ON (actuated)
If the parking brake switch is turned ON (applied) In addition, at the same time, the neutralizer relay
after carrying out operations with the parking brake is reset, so the circuit between terminals 3 and 5 is
switch OFF (released), the circuit in the diagram opened, and no electricity flows to the transmission
above is formed. directional circuit, so the transmission is shifted to
Electric current does not flow to the parking brake neutral. This kind of neutralizer relay shuts off the
solenoid valve, so the oil pressure from the electric current going to the transmission solenoid
transmission pump to the parking brake cylinder is valve when the parking brake is applied and shifts
shut off. At the same time, the oil pressure inside the transmission to neutral to prevent seizure of the
the parking brake cylinder passes through the parking brake if the operator should drive the
parking brake valve and is drained, so the parking machine with the parking brake still applied.
brake is applied by the force of the spring.
10-213
5. When main brake oil pressure drops (emergency brake actuated)
Operation
If the oil pressure in the main brake line drops, the For this reason, electric current flows to the
emergency brake switch installed to the transmission directional circuit, and it is possible to
accumulator is opened. engage the transmission clutch. In this way, it is
For this reason, the electric current stops flowing to possible to use the engine brake when the emergency
the parking brake solenoid valve, so the oil brake is applied, so the braking distance becomes
pressure inside the parking brake cylinder is shorter. At the same time, if the emergency brake has
drained and the parking brake is applied. been applied and it is necessary to move the machine
However, in this case, the condition is different from (for example, if the emergency brake is applied when
the case where the parking brake switch is ON the machine is on a railway crossing), it is possible to
(applied), because there is electric current flowing move the machine by operating the transmission lever.
to the neutralizer relay coil.
10-214
6. Parking brake emergency release
Operation
If the machine should stop because of engine The oil pressure stored in the accumulator in the
trouble, the oil pressure from the transmission main brake line then flows to the parking brake
pump to the parking brake cylinder is shut off and cylinder to release the parking brake.
the parking brake is applied. When this happens, The emergency release switch should normally be
the oil pressure in the main brake line is stored in kept at the OFF position and should be returned to
the accumulator. When the emergency release the OFF position after the emergency release.
switch is turned on (released), the buzzer sounds,
and at the same time, electric current flows to the
emergency parking brake release solenoid valve.
10-215
7. Function of parking brake neutralizer relay
OUTLINE
When the parking brake is being actuated, the 2. When the parking brake switch is OFF (released)
transmission is held at neutral to prevent the and the engine is started, the circuit in Item 1 is not
parking brakes from dragging if the machine is formed, so the parking brake switch must be turned
operated by mistake. ON.
3. When the parking brake is being actuated,

electricity does not flow to the neutralizer relay coil,
OPERATION so neutralizer relay terminal 3 and terminal 5 are
1. When the parking brake is actuated (ON), separated and no electricity flows to the
electricity flows from the battery relay g transmission directional circuit. In this way, when
brake switch terminals 1 - 3 the parking brake is applied, the transmission is
relay terminal 1 y held at neutral.
relay coil is actuated, and safety relay terminals 3
and 5 are connected to form the circuit.
10-216
20 TESTING, ADJUSTING AND
TROUBLESHOOTING
Standard value table for engine - in chassis . . . 20-3 Testing brake oil pressure . . . . . . . . . . . . . . . . . 20-57
Standard value table for chassis . . . . . . . . . . . . . 20-4 Measuring brake disc wear . . . . . . . . . . . . . . . . 20-58
Standard value table for electrical system . . . . . 20-9 Parking brake performance . . . . . . . . . . . . . . . 20-59
Service tools for testing, adjusting & Parking brake oil pressure . . . . . . . . . . . . . . . . 20-60
troubleshooting . . . . . . . . . . . . . . . . . . . . . . 20-22 Parking brake disc wear . . . . . . . . . . . . . . . . . . 20-62
Sketches of special tools . . . . . . . . . . . . . . . . . 20-23 Manual release method for parking brake . . . . 20-63
Measuring engine speed . . . . . . . . . . . . . . . . . . 20-24 PPC oil pressure . . . . . . . . . . . . . . . . . . . . . . . . 20-64
Measuring intake manifold pressure . . . . 20-25 Adjusting PPC valve linkage . . . . . . . . . . . . . . . 20-66
Measuring intake air restriction . . . . . . . . . 20-26 Accumulator charge pressure . . . . . . . . . . . . . 20-67
Measuring engine lubricating oil pressure . 20-27 Work equipment hydraulic pressure . . . . . . . . . 20-68
Measuring fuel filter inlet restriction . . . . . . 20-28 Releasing remaining pressure in
Measuring blow-by pressure . . . . . . . . . . . 20-29 hydraulic circuit . . . . . . . . . . . . . . . . . . . . . . 20-70
Measuring exhaust back pressure . . . . . . . 20-30 Adjusting work equipment lever linkage . . . . . . 20-71
Measuring coolant temperature . . . . . . . . . 20-31 Bleeding air . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-72
Measuring and adjusting valve clearance 20-32 Bucket positioner . . . . . . . . . . . . . . . . . . . . . . . . 20-73
Alternator drive belt . . . . . . . . . . . . . . . . . . . . . . 20-33 Boom positioner . . . . . . . . . . . . . . . . . . . . . . . . . 20-74
Air conditioner belt . . . . . . . . . . . . . . . . . . . . . . . 20-34 Transmission controller . . . . . . . . . . . . . . . . . . . 20-76
Measuring exhaust temperature . . . . . . . . . . . . 20-35 Adjusting main monitor
Exhaust gas color . . . . . . . . . . . . . . . . . . . . . . . 20-36 (speed module) . . . . . . . . . . . . . . . . . . . . . 20-78
Measuring engine stall speeds . . . . . . . . . . . . . 20-38 Points to remember when troubleshooting . . 20-202
Measuring torque converter stall . . . . . . . . . . . 20-38 Sequence of events in troubleshooting . . . . . 20-203
Measuring hydraulic stall . . . . . . . . . . . . . . . . . . 20-39 Points to remember when carrying
Measuring full stall . . . . . . . . . . . . . . . . . . . . . . . 20-39 out maintenance . . . . . . . . . . . . . . . . . . . . 20-204
Adjusting engine speed sensor . . . . . . . . . . . . . 20-40 Checks before troubleshooting . . . . . . . . . . . . 20-212
Measuring shift levers . . . . . . . . . . . . . . . . . . . . 20-41 Handling connectors . . . . . . . . . . . . . . . . . . . . 20-213
Measuring accelerator pedal . . . . . . . . . . . . . . 20-42 Precautions when troubleshooting . . . . . . 20-214
Measuring torque converter and Method of reading troubleshooting
transmission oil pressure . . . . . . . . . . . . . . 20-44 tables . . . . . . . . . . . . . . . . . . . . . . . . . 20-216
Flushing torque converter and Air conditioner / heater (Denso) . . . . . . . . . . . 20-902
transmission hydraulic circuit . . . . . . . . . . . 20-47 Visual and audible inspection . . . . . . . . . . 20-902
Moving machine when transmission Troubleshooting with manifold gauge . . . 20-903
valve fails . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-48 Troubleshooting the electrical circuit . . . . 20-907
Testing and adjusting steering wheel . . . . . . . . 20-50 Cooler circuit troubleshooting . . . . . . . . . 20-911
Steering oil pressure . . . . . . . . . . . . . . . . . . . . . 20-52
Steering stop valve . . . . . . . . . . . . . . . . . . . . . . 20-54
Measuring brake pedal . . . . . . . . . . . . . . . . . . . 20-55
Measuring brake performance . . . . . . . . . . . . . 20-56
20-1
WARNING! When carrying out testing, adjusting, or troubleshooting, park the machine on level
ground, insert the safety pins, and use blocks to prevent the machine from moving.
WARNING! When carrying out work together with other workers, always use signals and do not
let unauthorized people near the machine.
WARNING! When checking the coolant level, always wait for the coolant to cool down. If the
radiator cap is removed while the coolant is still hot, the coolant will spurt out and cause burns.
WARNING! Be careful not to get caught in the fan, fan belt or other rotating parts.
20-2
TESTING AND ADJUSTING STANDARD VALUE TABLE FOR ENGINE
STANDARD VALUE TABLE FOR ENGINE - In Chassis

Engine model Cummins N14
Item Measure condition Unit Standard value for Service limit value
new machine
High idle 2300 ± 50 2300 ± 100
Engine speeds Low idle kW / rpm 760 ± 50 760 ± 75
Rated speed 250 / 2100 250 / 2100
Intake manifold At T.C. stall and W.O.T mm Hg 1170 - 1500 1170 - 1500
pressure (Wide Open Throttle)
Intake air restriction At T.C. stall and W.O.T. at mm H 2O New element: 380 635 max.
restriction indicator port Used Element: 635
Lubricating oil Minimum at low idle kPa 70 70

pressure with SAE (kg/cm²) (0.70) (0.70)
15W-40 oil &
coolant temperature Minimum at high idle kPa 175 175
in operating range (kg/cm²) (1.75) (1.75)
Fuel filter inlet Maximum restriction at high mm Hg New filter: 102 New filter: 102
restriction idle Used filter: 203 Used filter: 203
Coolant temperature in
operating range:
Blow-by pressure Service Tool orifice size: mm H 2O 305 460
7.67 mm
At T.C. stall and W.O.T.
Exhaust back Maximum at T.C. stall and mm Hg 76 76

pressure W.O.T.
Coolant Maximum operating 80 - 90 100 max.

temperature temperature at engine outlet
Valve clearance Engine cold:

Intake valves mm 0.35 0.35
Exhaust valves 0.69 0.69
Alternator belt Deflection when pressed N 620 270 - 490

with finger force of approx. (lbf) (140) (60 - 110)
98 N (10 kg)
Air conditioner Deflection when pressed

compressor belt with finger force of approx. mm 10 - 15 10 - 15
tension 98 N (10 kg)
For further detailed information, refer to Engine Shop Manual.
20-3
TESTING AND ADJUSTING STANDARD VALUE TABLE FOR CHASSIS
STANDARD VALUE TABLE FOR CHASSIS
Engine model Cummins N14
Standard value for Service limit

Item Measurement condition Unit
new machine value
Engine stall speeds: Coolant temperature in

operating range 2140 ± 100 2140 ± 100
Torque converter Torque converter oil
temperature in operating rpm
Hydraulic range 2180 ± 100 2180 ± 150
Hydraulic oil at normal
Full operating temperature 1820 ± 100 1820 ± 200
Accelerator pedal:
71.05 ± 2.45
Operating force N (kg) Max. 97 (10)
(7.25 ± 0.25)
Operating angle:
degree 48
x1
degree 34 - 35
x2
---
Stopper height (L) mm 60
Standard value Service limit

for new machine value
Shift lever operating force and Measure at center of

stroke lever knob
Directional lever operating Engine stopped

force
N-F N (kg) 5.88 +4.9 / -2.94 Max. 16.66
N-R (0.6 +0.5 / -0.3) (1.7)
Speed lever operating
force
1st - 2nd N (kg) 5.88 +4.9 / -2.94 Max. 16.66
2nd - 3rd (0.6 +0.5 / -0.3) (1.7)
3rd - 4th
Directional lever travel
N-F mm 35 ±10 35 ±20
N-R
Speed lever travel
1st - 2nd -3rd -4th mm 35 ±10 35 ±20
20-4

Oil pressure of torque con-

verter and transmission.
Torque converter outlet 0.39 ±0.1 0.39 ±0.1
port oil pressure (4 ±1) (4 ±1)
Torque converter inlet port 0.83 ±0.1 0.83 ±0.1

oil pressure (8.5 ±1) (8.5 ±1)
Torque converter oil
ECMV output (clutch) oil
temperature: 60-80
pressure
1st MPa 3.28 ±0.2 3.28 ±0.2
Engine speed: High
kg/cm² (33.5 ±2) (33.5 ±2)
idling
2nd, 3rd, 4th, F-R 3.48 ±0.15 3.48 ±0.15
(35.5 ±1.5) (35.5 ±1.5)
Manual switch ON
Main relief valve
Low idling 3.23 ±0.15 3.23 ±0.15
(33 ±1.5) (33 ±1.5)
High idling 3.53 ±0.15 3.53 ±0.15
(36 ±1.5) (36 ±1.5)
Lubrication pressure (oil 0.21 ±0.08 0.21 ±0.08

cooler outlet port) (2.15 ±0.85) (2.15 ±0.85)
Tire and wheel Tire inflation pressure
Fitting of wheel lock ring Specified pressure
(A)
(B) Max. 2.5 -
Clearance of wheel lock Max. 4.0 -
ring
(C)
mm 2 - 10 -
Steering wheel Road surface: Flat,

Steering wheel play horizontal, dry, paved mm Max. 50 50-100
Steering wheel operating surface: N (kg) 12.25 ±2.45 Max.19.6 (2.0)
force Hydraulic temp.: (1.25 ±0.25)
Operating time of 45 -
steering wheel 55
Low idle Machine posture: Sec. Max. 5.5 Max. 6.5
High idle Facing straight Sec. Max. 3.1 Max. 4.5
Turning speed Engine speed: High Turns 3.6 ±0.4 Max. 4.5
idling
Clearance between front and Engine speed: 1200 rpm mm 25 ±2 -

rear frame
20-5

Testing and measuring item Measurement condition Unit
Steering oil pressure Hydraulic temperature: 45 20.58 +0.98 / 20.58 +0.98 /

Main relief oil pressure - 55 -0.29 -0.29
Engine speed: High idle (210 +10 / -3) (210 +10 / -3)
MPa
kg/cm2
Orbit-roll output pressure 3.72 +0.39 / 3.72 +0.39 /
-0.19 -0.19
(38 +4 / -2) (38 +4 / -2)
Brake pedal Engine speed: Low idle
Operating force Hydraulic temperature: N (kg) 294 ±29.4 Max. 421.4
45-55 (30 ±3) (43)
Operating angle degree 45 -
Play mm 15 +1 / -0 -
Accumulator Engine speed: Low idle
Charge cut-in pressure Hydraulic temperature: 5.88 +0.49 / -0 5.88 +0.49 / -0
Point where brake oil 45-55 (60 +5 / -0) (60 +5 / -0)
pressure warning lamp
goes out
MPa
kg/cm²
Charge cut-out pressure 9.8 +0.98 / -0 9.8 +0.98 / -0
Point where oil (100 +10 / -0) (100 +10 / -0)
pressure is going up
and then starts to go
down
Warning buzzer pressure
Actuating starting Coolant temperature: kg/cm² 6.0 ±0.1 6.0 ±0.1
Actuating stopping Inside operating range 6.0 +0.4 6.0 +0.4
Road surface: Flat,

horizontal, dry, paved
surface
Speed when applying
brakes: 20 km/h
Time lag when pressing
Brake performance the pedal:
m Max. 5 Max. 5
0.1 sec.
Brake pedal operating
force: 294 ±29.4 N (30
±3 kg)
Tire inflation pressure:
Specified pressure
Coolant temperature:
Drop in brake oil pressure Inside operating range
Test pressure: kg/cm² Max. 5 Max. 5
53 kg/cm²/5 min.
Wear of brake disc Piston stroke mm 2.2-5.5 Max. 8.0
20-6

Tire inflation pressure:

Specified pressure
Road surface:
Flat, dry, paved No
No
surface with 1/5 machine
Parking brake performance machine
(11 movement
movement
Machine:
In operating
condition
Thickness of pad With back plate 31.7 12.7

mm
Clearance between Total of both side 1.06 ±0.18 Max. 2.3
disc and pad
Dump and lift control levers

Lift arm control lever
operating force Max. 2.5 Max. 3.5
Hold 2-4 Max. 6
Raise Max. 2.5 Max. 3.5
Hold - -
Lower kg 2-4 Max. 6
Lower Hydraulic temperature: 2-4 Max. 6
Float 45 - 55
Engine speed: Low idle
Dump control lever Coolant temperature: Max. 2.5 Max. 3.5
operating force Inside operating Max. 2.5 Max. 3.5
Hold range 2-4 Max. 6
Hold
Tilt
52 - 82 37 - 97
Lift arm control lever travel 34 - 64 19 - 79
Hold 52 - 82 37 - 97
Hold
Hold mm
45 - 75 30 - 90
Dump control lever travel 45 - 75 30 - 90
Hold
Hold
Relief oil pressure Coolant temperature:

PPC valve Inside operating 38 - 40 36 - 42
Main control valve range kg/cm² 210 ±5 210 ±10
Hydraulic temperature:
45 - 55
Engine speed:
High idle
20-7

Operating speeds Coolant temperature:

Lift arm lifting time Inside operating 6.8 - 7.4 Max. 8.9
Lift arm lowering time range 3.0 - 4.0 Max. 4.8
Bucket dumping time Hydraulic temperature: sec. 1.4 - 2.0 Max. 2.4
Bucket tilt back time 45 - 55
(Full stroke) Engine speed: High idle 1.9 - 2.5 Max. 3.0
Bucket tilt back time Steering position:
(Horizontal position of Neutral 1.3 - 1.9 Max. 2.3
bucket) Bucket: empty
Hydraulic drift of lift arm and Coolant temperature:

bucket Inside operating
Retraction of lift cylinder range
rod Hydraulic temperature: mm Max. 40 Max. 40
45 - 55
Retraction of dump Stop engine, leave for 5 Max. 20 Max. 20
cylinder rod minutes, then measure
for next 15 minutes.
Lift arm horizontal
Bucket horizontal
Bucket: empty
Bucket positioner
Clearance of switch 3-5 -
mm
Boom kick-out
Clearance of switch 3-5 -
20-8
TESTING AND ADJUSTING STANDARD VALUE TABLE FOR ELECTRICAL SYSTEM
STANDARD VALUE TABLE FOR ELECTRICAL SYSTEM
Connector Inspection Measurement

Name of component Judgement table
number method conditions
If the condition is as shown in the table below, it is

normal
1. Turn starting
Between C1 (7), (13) - chassis
switch OFF
Power source C1 Measure voltage 2. Insert T-adapter
Between C2 (1), (12) - chassis
3. Turn starting
20 - 30 V
Between C1 (7), (13) - (6), (12) switch ON
Between C2 (1), (12) - (11), (21)

Transmission & Travel Damper Controller
If the condition is as shown in the table below, it is 1. Turn starting

normal switch OFF
2. Insert T-adapter
Power source (signal) C3A Measure voltage Between (6) - (17) 3. Turn starting
20 - 30 V switch ON
4. Apply parking
Between (6) - chassis
brake
If the condition is as shown in table below, the 1. Turn starting

sensor is normal switch OFF
CN 2. Insert T-adapter
Parking brake switch Parking brake ON, Between (1) - (3), 20 - 30V 3. Turn starting
L01
Measure voltage switch ON
Parking brake OFF, Between (1) - (3), Max. 1V
If condition is as shown in the table below, the 1. Turn starting

CN4 Measure 2. Disconnect
ECMV solenoid (1st) Between (1) - (2) 5 - 15 connector
(male) resistance
3. Connect T-
Between (1), (2) - chassis Min. 1 M adapter
If the condition is as shown in the table below, the 1. Turn starting

ECMV solenoid (2nd) Between (1) - (2) 5 - 15 connector
(male) resistance
3. Connect T-
If the condition is as shown in the table below, the 1. Turn starting

ECMV solenoid (3rd) Between (1) - (2) 5 - 15 connector
(male) resistance
3. Connect T-
20-9

ECMV solenoid CN8 Measure If the condition is as shown in the table below, it is 1. Turn starting
(4th) (male) resistance normal switch OFF
2. Disconnect
Between (1) - (2) 5 - 15 connector
3. Connect T-
adapter
Between (1), (2) - chassis Min. 1 M
ECMV solenoid (F) CN16 Measure If the condition is as shown in the table below, the sen- 1. Turn starting
(male) resistance sor is normal switch OFF
2. Disconnect
3. Connect T-
adapter
ECMV solenoid (R) CN14 Measure If the condition is as shown in the table below, it is 1. Turn starting
(male) resistance normal switch OFF
2. Disconnect
3. Connect T-
adapter
1st - CN5 Measure If the condition is as shown in the table below, it is 1. Turn starting
(male) resistance normal switch OFF.
2. Disconnect
2nd - CN7 connector.
(male) Speed lever at measurement 3. Connect T-
position: adapter.
3rd - CN13 4. Start engine.
(male) Between (1) - chassis Max. 1 5. Place directional
lever at N.
4th - CN9 Speed lever not at measurement 6. Turn manual
(male) position: switch ON.
Between (1) - chassis Min. 1

ECMV fill switch
F - CN17 Measure If the condition is as shown in the table below, it is 1. Turn starting
(male) resistance normal switch OFF.
2. Disconnect
R - CN15 connector.
(male) 3. Connect T-
Directional lever at measurement adapter.
position: 4. Start engine.
5. Turn
Between (1) - chassis Max. 1 transmission
cut-off (lamp
OFF)
Directional lever not at measurement 6. Turn parking
position: brake switch
OFF.
Between (1) - chassis Min. 1 7. Depress brake.
20-10

Transmission oil CN11 Measure If the condition is as shown in the table below, the sen- 1. Turn starting
temperature (male) resistance sor is normal switch OFF
sensor 2. Disconnect
Normal temperature (25 3.8 - 4.8 connector
Between (1) - chassis 3. Connect T-
adapter
100 3.6 - 3.9
Transmission oil C2 Measure If the condition is as shown in the table below, it is 1. Turn starting
temperature resistance normal switch OFF
(controller) 2. Disconnect
Normal temperature (25 connector
Between (11) - (17) 4.4 - 4.6 3. Connect T-
adapter
100
Between (11) - (17) 2.1 - 2.3
Engine speed E04 Measure If the condition is as shown in the table below, the 1. Turn starting
sensor (male) resistance sensor is normal switch OFF
2. Disconnect
3. Connect T-
Between (1) - (2) - chassis Min. 1 M adapter
Engine speed C4 Measure If the condition is as shown in the table below, it is 1. Turn starting
(controller) voltage normal switch OFF
2. Disconnect
Measure with AC range connector
Between (2) - (9) Max. 0.5 V 3. Start engine.
Engine speed ___ Adjust If the condition is as shown in the table below, the ___
sensor is normal
1. Screw in until speed sensor contacts ring gear, then

turn back 3/4 - 1 turn.
2. Sensor should work normally when adjusted as

above.
CN3 Measure If the condition is as shown in the table below, it is 1. Turn starting
(male) resistance normal switch OFF
2. Disconnect
3. Connect T-
Speed Between (1) - (2) - chassis Min. 1 M adapter
Adjust If the condition is as shown in the table below, the ___

___ sensor is normal
1. Screw in until speed sensor contacts ring gear, then

turn back 3/4 - 1 turn.
2. Sensor should work normally when adjusted as

above.
20-11

Speed lever If the condition is as shown in the table below, the sen-
(1st) sor is normal
Speed lever at 1st.

Between (7) - chassis 20 - 30 V
Speed lever not at 1st.

Between (7) - chassis Max. 1 V
Speed lever If the condition is as shown in the table below, it is

(2nd) normal
Speed lever at 2nd.

Speed lever not at 2nd.

Speed lever If the condition is as shown in the table below, the

(3rd) sensor is normal
Speed lever at 3rd.

Between (8) - chassis 20 - 30 V 1. Turn starting
Controller
switch OFF
C3B Measure Speed lever not at 3rd. 2. Disconnect
voltage Between (8) - chassis Max. 1 V connector
3. Turn starting
Speed lever If the condition is as shown in the table below, it is switch ON
(4th) normal
Speed lever at 4th.

Speed lever not at 4th.

Directional If the condition is as shown in the table below, the

lever (F) sensor is normal
Directional lever at F.
Directional lever at F.
Directional If the condition is as shown in the table below, it is

lever (R) normal
Directional lever at R.
Directional lever not at R.

Directional If the condition is as shown in the table below, the

lever (N) sensor is normal
Directional lever at N.
Directional lever not at N.

20-12

S-NET C3B Measure If the condition is as shown in the table below, the sensor 1. Turn starting
Controller
(between voltage is normal switch OFF

transmission 2. Insert T-
and main adapter
controller 3. Turn starting
Between (4), (12) - chassis 4-8V switch ON
Kick-down Switch If the condition is as shown in the table below, it is normal 1. Turn starting
switch OFF
2. Disconnect
Kick-down switch ON
connector
Between (1) - (2) Max. 1
3. Connect T-
Kick-down switch OFF adapter
Between (1) - (2) Min. 1 M
L15 Measure
Hold Switch (male) resistance If the condition is as shown in the table below, the sensor 1. Turn starting
is normal switch OFF
2. Disconnect
Hold switch ON connector
Between (3) - (4) Max. 1 3. Connect T-
adapter
Hold switch OFF
Transmission cut-off L12 Measure If the condition is as shown in the table below, it is normal 1. Turn starting
switch (male) resistance switch OFF
When operated normally 2. Disconnect
Between (1) - (2) Max. 1 connector
3. Connect T-
When left brake is depressed adapter
Manual Switch C5 Measure If the condition is as shown in the table below, the sensor 1. Turn starting
voltage is normal switch OFF
Controller
2. Insert T-
Manual switch ON adapter
Between (14) -chassis 20 - 30 V 3. Turn starting
switch ON
Manual switch OFF
Between (14) -chassis Max. 1 V
Power source CN3 Measure If the condition is as shown in the table below, it is normal 1. Turn starting
(male) voltage switch OFF
Between (1) - (2) - chassis 2. Insert T-
20 - 30 V adapter
3. Turn starting
Between (1) - (2) - (3)
Main Monitor
switch ON
Charge (alternator) L05 Measure If the condition is as shown in the table below, the sensor 1. Turn starting
voltage is normal switch OFF
2. Insert T-
Engine running (at above ½ throttle. 28 ± 2 V adapter
Between (5) - (3)
Starting switch ON Max. 1 V

Between (5) - (3)
* If the battery is old, or after starting in cold areas, the voltage may not rise for some time.
20-13

Directional switch L05 Measure If the condition is as shown in the table below, the sen- 1. Turn starting
(N) voltage sor is normal switch OFF
2. Insert T-
Directional lever at N adapter
Between (8) - (3) 20 - 30 V 3. Turn starting
switch ON
Directional lever not at N
Between (8) - (3) Max. 1 V
Starting switch L09 Measure If the condition is as shown in the table below, it is 1. Turn starting
terminal C (male) voltage normal switch OFF
2. Insert T-
Starting switch at start adapter
Starting switch at OFF or ON

Starting switch L04 Measure If the condition is as shown in the table below, the 1. Turn starting
terminal C voltage sensor is normal switch OFF
2. Insert T-
Engine started adapter
Maintenance Monitor Related
Between (4) - (3) 20 - 30 V
Starting switch OFF or ON

Between (4) - (3) Max. 1 V
Starting switch L09 Measure If the condition is as shown in the table below, it is 1. Turn starting
terminal BR (male) voltage normal switch OFF
2. Disconnect
Starting switch ON connector
Between (2) - chassis 20 - 30 V 3. Connect T-
adapter
Starting switch OFF Max. 1 V
Starting switch L07 Measure If the condition is as shown in the table below, the 1. Turn starting
terminal BR voltage sensor is normal switch OFF
2. Insert T-
Starting switch ON adapter
Starting switch OFF

Parking brake CN19 Measure If the condition is as shown in the table below, it is 1. Turn starting
indicator switch (male) resistance normal switch OFF
2. Disconnect
Parking brake ON connector
Between (1) - (2) Max 1 3. Connect T-
adapter
Parking brake OFF
Between (1) - (2) - chassis Min. 1 M
Directional switch L08 Measure If the condition is as shown in the table below, the 1. Turn starting
(F) voltage sensor is normal switch OFF
2. Insert T-
Directional lever at F adapter
switch ON
Directional lever not at F Max. 1 V
20-14

Directional lever L08 Measure If the condition is as shown in the table below, the sen- 1. Turn starting
(R) voltage sor is normal switch OFF
2. Insert T-
Directional lever at R adapter
switch ON
Directional lever not at R
Power source L18 Measure If the condition is as shown in the table below, it is 1. Turn starting
voltage normal switch OFF
2. Insert T-
Between (1), (2) - chassis adapter
20 - 30 V 3. Turn starting
Between (1), (2) - (3) switch ON
Engine water E06 Measure If the condition is as shown in the table below, the 1. Turn starting
temperature (male) resistance sensor is normal switch OFF
50 connector
Between (A) - (B) Approx. 19 3. Connect T-
adapter
100
Between (A) - (B) Approx. 3.6
Torque converter CN18 Measure If the condition is as shown in the table below, it is 1. Turn starting
oil temperature (male) resistance normal switch OFF
Normal temperature (25 connector

Between (1) - (2) Approx. 40 3. Connect T-
adapter
130 Approx. 1.7
Between (1) - (2)
Fuel level sensor R07 Measure If the condition is as shown in the table below, the 1. Turn starting
(male) resistance sensor is normal switch OFF
2. Disconnect
Float raised to stopper Approx. 4 connector
3. Drain fuel
4. Remove fuel
level sensor
Float lowered to stopper Approx. 85 5. Connect T-
adapter
Radiator water G01 Measure If the condition is as shown in the table below, it is 1. Turn starting
level sensor (male) resistance normal switch OFF
2. Disconnect
Water level normal connector
Between (1) - (2) Max 1 3. Connect T-
adapter
Water level low
Engine oil E11 Measure If the condition is as shown in the table below, the 1. Turn starting
pressure sensor resistance sensor is normal switch OFF
2. Disconnect
Engine oil pressure: Min. 0.13 MPa connector
(1.3 kg/cm2(Start engine) Between Min. 1 M 3. Connect T-
(A) - (C) adapter
4. Start engine
Engine oil pressure: Max. 0.07 MPa
(0.7 kg/cm2(Starting switch ON) Max. 1
Between (A) - (C)
20-15

Brake B08 Measure If the condition is as shown in the table below, the sen- 1. Turn starting
accumulator low (male) resistance sor is normal switch OFF
pressure switch B13 2. Disconnect
(male) Accumulator pressure: Min. 5.39 connector
±0.49 MPa (55 ±5 kg/cm2) Between Max. 1 3. Connect T-
(1) - (2) adapter
Depress brake and lower

accumulator pressure to below Min. 1 M
4.41 ±0.49 MPa (45 ±5 kg/cm2)
Between (1) - (2)
Charge L18 Measure If the condition is as shown in the table below, it is 1. Turn starting
(alternator) voltage normal switch OFF
2. Insert T-
Engine running (at above 1/2 adapter

throttle) 28 ±2 V 3. Start engine
Between (12) -(3), (14)
Starting switch ON
Between (12) -(3), (14) Max. 1 V
*If the battery is old, or after starting in cold areas, the

voltage may not rise for some time.
Engine oil level E10 Measure If the condition is as shown in the table below, the 1. Turn starting
sensor (male) resistance sensor is normal switch OFF
2. Disconnect
Oil level normal connector
Between (1) - (2) Max. 1 3. Connect T-
adapter
Oil level abnormal
Dust indicator E19 Measure If the condition is as shown in the table below, it is Measurement
(male) continuity normal conditions
E20
(female) Air cleaner normal
Between E19 (1) - E20 (1) Continuity
Air cleaner clogged or engine

stopped - No continuity No continuity
Between E19 (1) - E20 (1)
20-16
Check carefully that there is no one in the surrounding area before starting inspection.
When carrying out operations during inspection, raise the work equipment control lever stand for
operations, and lower it when traveling.
Turn the starting switch OFF before inserting the T-adapter, or making any connections.
Measurement
conditions
If the condition is as shown in Table 1, the monitor panel is normal
Table 1 (CHECK, CAUTION portion)
Connector Monitor item Measurement Display Sensor

No. (input connector) conditions signal input
Engine water level Engine stopped, Flashing 15 - 20 V

(8) - (3), (14) Starting switch ON
OFF Max. 1 V
CHECK, L18 Engine oil level Engine stopped, Flashing 15 - 20 V

CAUTION (male) (13) - (3), (14) Starting switch ON 1. Connect T-
portion OFF Max. 1 V adapter
Engine oil pressure Start engine Flashing 15 - 20 V
(10) - (3), (14)
OFF Max. 1 V
Brake oil pressure Start engine Flashing 15 - 20 V

(11) - (3), (14)
OFF Max. 1 V
Battery charge Start engine Flashing Max. 10 V

(12) - (3), (14)
OFF Min. 12 V
Air cleaner Start engine Flashing 15 - 20 V

(15) - (3), (14)
OFF Max. 1 V
20-17
Measurement
conditions
Table 2 (Gauge portion)
1. Turn starting
switch OFF,
then insert
dummy
resistance or
measure
resistance of
sensor.
Gauge portion 2. Turn starting
switch ON
and check
display
20-18

Parking brake L90 Measure If the condition is as shown in the table below, the sen- 1. Turn starting
emergency cancel voltage sor is normal switch OFF
switch 2. Insert T-
Parking brake emergency cancel adapter
switch ON 20 - 30 V 3. Turn starting
Between (1) -(2) and (3) - (4) switch ON
Parking brake emergency cancel

switch OFF Max. 1 V
Between (1) -(2) and (3) - (4)
Parking brake B14 Measure If the condition is as shown in the table below, it is 1. Turn starting
emergency cancel voltage normal switch OFF
solenoid 2. Insert T-
Parking brake emergency cancel 20 - 30 V adapter
switch ON 3. Turn starting
Between (1) -(2) switch ON
Parking brake emergency cancel Max. 1 V

switch ON
Between (1) -(2)
Emergency brake B09, B10 Measure If the condition is as shown in the table below, the 1. Turn starting
switch (male) resistance sensor is normal switch OFF
2. Disconnect
Others
Accumulator pressure: Min. 3.92 connector

±0.49 MPa (40 ±5 kg/cm2) Between Max. 1 3. Connect T-
B09 (1) - B10 (2) adapter

accumulator pressure to below
3.63 ±0.49 MPa (37 ±5 kg/cm2) Min. 1 M
Between B09 (1) - B10 (2)
Emergency brake BR1 Measure If the condition is as shown in the table below, it is 1. Turn starting
switch voltage normal switch OFF
2. Insert T-
Accumulator pressure: Min. 3.92 adapter
±0.49 MPa (40 ±5 kg/cm2) Between 20 - 30 V 3. Turn starting
(7) - (8) switch ON

accumulator pressure to below
3.63 ±0.49 MPa (37 ±5 kg/cm2) Max. 1 V
Between B09 (1) - B10 (2)
Bucket positioner F05 Measure If the condition is as shown in the table below, the 1. Turn starting
proximity switch voltage sensor is normal switch OFF
2. Insert T-
When When adapter
screwdriver is screwdriver is 3. Turn starting
Between brought close not brought switch ON
close
(1) - (2) 20 - 30 V Max. 3 V
(1) - (3) 20 - 30 V 20 - 30 V
(2) - (3) Max. 3 V 20 - 30 V
20-19

Boom kick-out F06 Measure If the condition is as shown in the table below, the sen- 1. Turn starting
proximity voltage sor is normal switch OFF
switch 2. Insert T-
When When adapter
screwdriver is screwdriver is 3. Turn starting
Between brought close not brought switch ON
close
Others
(1) - (2) 20 - 30 V Max. 3 V
(1) - (3) 20 - 30 V 20 - 30 V
(2) - (3) Max. 3 V 20 - 30 V
Boom kick-out L16 Measure If the condition is as shown in the table below, it is 1. Turn starting
solenoid resistance normal switch OFF
2. Disconnect
Between (1), (2) 19 - 23 connector
3. Connect T-
Bucket L17 Measure If the condition is as shown in the table below, the 1. Turn starting
positioner resistance sensor is normal switch OFF
solenoid 2. Disconnect
Between (1), (2) 19 - 23 connector
3. Connect T-
20-20

Power source L28 Measure If the condition is as shown in the table below, the 1. Turn starting
voltage voltage sensor is normal. switch OFF
2. Insert T-
Between (8), (17), (18) - (9), (18) adapter
3. Turn starting
When actuated 20 - 30 V switch ON
When not actuated Max. 1 V
Joystick R CNR Measure If the condition is as shown in the table below, it is 1. Turn starting
(right)solenoid (male) resistance normal switch OFF
2. Disconnect
3. Connect T-
Between (1) - chassis Min. 1 M adapter
Joystick L (left) CNL Measure If the condition is as shown in the table below, the 1. Turn starting
solenoid (male) resistance sensor is normal switch OFF
2. Disconnect
Joystick Controller

3. Connect T-
Between (1) - chassis Min. 1 M adapter
Joystick neutral NEUTRAL Measure If the condition is as shown in the table below, it is 1. Turn starting
switch resistance normal switch OFF
2. Disconnect
Joystick neutral switch between (1) - (3) connector
3. Connect T-
Not at N Max. 1 adapter
At N
Min. 1 M
Joystick L27 Measure If the condition is as shown in the table below, it is 1. Turn starting
potentiometer voltage normal switch OFF
2. Insert T-
Between (20) - (9) adapter
3. Turn starting
When actuated 0.5 - 4.5 V switch ON
Joystick JS7 Measure If the condition is as shown in the table below, the 1. Turn starting
potentiometer (male) resistance sensor is normal switch OFF
2. Disconnect
Between (1) - (2) 0-5 connector
3. Connect T-
Between (2) - (3) 4-5 adapter
Between (3) - (1) 0-5
20-21
TESTING AND ADJUSTING SERVICE TOOLS AND TROUBLESHOOTING
SERVICE TOOLS FOR TESTING, ADJUSTING & TROUBLESHOOTING
No. Check or Measurement Tool Description Tool Number Remarks

Item
1 Engine speeds Digital Optical 799-203-8001 Digital display
Tachometer 799-203-9000 L: 60 - 20,000 rpm
(Kit) H: 60 - 19,999 rpm
2 Intake manifold pressure Pressure gauge See Engine Shop Manual
3 Intake air restriction Water manometer See Engine Shop Manual
4 Lubricating oil pressure Pressure gauge See Engine Shop Manual
5 Fuel filter inlet restriction Vacuum gauge See Engine Shop Manual
6 Blow-by pressure Tool, adapter & See Engine Shop Manual
manometer
7 Exhaust back pressure Mercury See Engine Shop Manual

manometer
8 Coolant temperature Digital See Engine Shop Manual

temperature
gauge
9 Valve clearance Feeler gauge Commercially

available
10 Alternator, fan & water Tension gauge ST-1138

pump drive belts
Smoke detector 799-201-9000 Discoloration

11 Exhaust gas color 0-70% with standard color
Smoke meter Commercially % x 1/10
available
12 Brake oil pressure Brake test kit 793-520-1805
Nipple 793-520-1851
13 Operating effort Push-pull scale 79A-264-0020 0 - 294.2 N (0 - 30 kg)

79A-264-0090 0 - 490.3 N (0 - 50 kg)
14 Stroke, hydraulic drift Scale Commercially
available
15 Work equipment speed Stop watch Commercially
available
16 Measuring brake disc Calipers Commercially

wear available
20-22
TESTING AND ADJUSTING SERVICE TOOLS AND TROUBLESHOOTING
Check or Measurement
No Tool Description Tool Number Remarks
Item
17 Moving machine when Plate 793T-685- -

there is failure in 1110
transmission valve
18 Measuring voltage, Tester 79A-264-0210 -
resistance value
T-adapter 799-601-7400 -
assembly
19 Troubleshooting of wiring, 799-601-7310 SWP12P

harness, sensors 799-601-7320 SWP16P
Adapter
799-601-7340 M8P
799-601-7380 JFC2P
SKETCHES OF SPECIAL TOOLS

TOOL N
Note: Komatsu cannot accept any responsibility for special
tools manufactured according to these sketches.
20-23
TESTING AND ADJUSTING MEASURING ENGINE SPEEDS
MEASURING ENGINE SPEEDS

When measuring engine speeds, one worker should
measure the engine speed while the other sits in the
operator's seat to operate the controls. Always check that
the operation is safe, and use agreed upon signals.
When removing or installing the measuring equipment, be

careful not to touch any high temperature parts.
Measure the engine speed under the following conditions.

Coolant temperature: Within operating range
Torque converter oil temperature: 70 to 90
Hydraulic oil temperature: 45 to 55
1. Install the digital optical tachometer using the instructions

supplied with it.
When measuring engine speeds, be careful not to touch any high temperature parts or rotating parts.
2. Start the engine, and measure the engine speed when it is set to the conditions for measuring.
1) Measuring low idle and high idle speeds.
2) Measure the speed at near the rated speed.
When measuring speeds for items other than the above, such as torque converter stall, see the procedure for the
item as described in this section.
20-24
TESTING AND ADJUSTING MEASURING INTAKE MANIFOLD PRESSURE
MEASURING INTAKE MANIFOLD PRESSURE

Refer to ENGINE SHOP MANUAL for tools and proper
procedure.
20-25
TESTING AND ADJUSTING MEASURING INTAKE AIR RESTRICTION
MEASURING INTAKE AIR RESTRICTION

procedure.
20-26
TESTING AND ADJUSTING MEASURING ENGINE LUBRICATING OIL PRESSURE
MEASURING ENGINE LUBRICATING OIL PRESSURE

procedure.
20-27
TESTING AND ADJUSTING MEASURING FUEL FILTER INLET RESTRICTION
MEASURING FUEL FILTER INLET RESTRICTION

procedure.
20-28
TESTING AND ADJUSTING MEASURING BLOW-BY PRESSURE
MEASURING BLOW-BY PRESSURE

procedure.
20-29
TESTING AND ADJUSTING MEASURING ENGINE BACK PRESSURE
MEASURING EXHAUST BACK PRESSURE

procedure.
20-30
TESTING AND ADJUSTING MEASURING COOLANT TEMPERATURE
MEASURING COOLANT TEMPERATURE

procedure.
20-31
TESTING AND ADJUSTING MEASURING & ADJUSTING VALVE CLEARANCE
MEASURING AND ADJUSTING VALVE CLEARANCE

procedure.
20-32
TESTING AND ADJUSTING ALTERNATOR DRIVE BELT
ALTERNATOR DRIVE BELT

BELT TENSION CHART
Unit: N(lbf)
New tension Used tension

Belt tension 620 (140) 270 - 490
(60 - 110)
Testing alternator belt tension.

Belts will loosen during use. They must be adjusted to the
values listed in the Belt Tension Chart.
A belt is considered used if it has been in operation for 10
minutes or longer.
Use the belt tension gauge, Part No. ST-1138. Check the belt
tension.
To adjust the alternator belt tension, see the "Engine

Operation and Maintenance Manual"
20-33
TESTING AND ADJUSTING AIR CONDITIONER BELT
AIR CONDITIONER BELT

1. Testing
Measure deflection “c”of the belt when it is pushed with
force of approximately 98 N (10 kg) at a point midway
between the fan pulley and the air conditioner
compressor pulley.
Deflection “c”of belt (standard value): 10 - 15 mm
2. Adjusting
1) Loosen mount bolt and nut, and the adjustment plate bolt
and nut.
2) Move the position of the air conditioner compressor to adjust

the tension of the belt.
3) When the position of the air conditioner compressor is

correct, tighten adjustment plate bolt and nut, and the
mounting bolt and nut to secure it in position.
4) After adjusting the belt tension, repeat the testing procedure

above to check that the tension is adjusted within the
standard value.
20-34
TESTING AND ADJUSTING MEASURING EXHAUST TEMPERATURE
MEASURING EXHAUST TEMPERATURE

WARNING! The temperature sensor must be installed to
the exhaust manifold, so if the machine has been operated,
wait for the manifold temperature to drop before installing
the sensor.
Raise the coolant temperature to operating range
before measuring the exhaust temperature.
Measurement procedure
1. When measuring the maximum value during troubleshooting.
Carry out actual work and measure the maximum value during
operation.
Use the PEAK mode (it can store the maximum value in
memory) of the temperature gauge function.
NOTE:
The exhaust temperature varies greatly according to the
ambient temperature (temperature of the engine intake air),
so if any abnormal value is obtained, carry out temperature
compensation..
Compensation = Measured value + 2x (converted

ambient temperature - actual ambient temperature).
The converted ambient temperature is taken as 20
2. When measuring periodically (during preventive maintenance,

etc.)
1) Raise the exhaust temperature by using full stall (torque

converter stall + hydraulic pump relief).
Standard value: Approximately 700
2) In the above condition, cancel the hydraulic relief, and

carry out only torque converter stall. (The temperature
will start to go down. If it goes up without going down,
raise the set temperature shown in (1) of the right
figure).
3) Note the stable temperature when the temperature

starts to go down.
If only torque converter stall is used when
measuring the exhaust temperature, torque
converter will overheat before a stable value is
obtained.
20-35
TESTING AND ADJUSTING EXHAUST GAS COLOR
EXHAUST GAS COLOR

Measurement condition
Coolant temperature: Inside operating range
Valve clearance: Standard value
Special tools:
No. Part Number Part Name Qty.
A-1 799-201-9000 Handy smoke 1

checker
A-2 Commercially Smoke checker 1

available
For tests in the field where there is no air or elec-

tricity available, use A-1; for tests in a repair shop,
use A-2.
Measuring with A-1
WARNING! When measuring the exhaust

color, be careful not to touch the exhaust pipe.
When measuring the exhaust color, warm the

engine up thoroughly (oil temperature 60
1. Fit the filter paper in tool A-1.

2. Insert the exhaust gas suction port into the exhaust
pipe, accelerate the engine suddenly, and operate
the handle to catch the exhaust gas on the filter
paper.
3. Remove the filter paper and compare it with the
scale provided to judge the condition.
20-36
TESTING AND ADJUSTING EXHAUST GAS COLOR
Measuring with A-2
WARNING! When measuring the exhaust

color, be careful not to touch the exhaust pipe.
When measuring the exhaust color, warm the

engine up thoroughly (oil temperature 60
1. Insert probe (A) in outlet of exhaust pipe (1) and

secure to exhaust pipe with clip.
2. Connect probe hose, connector hose of
accelerator switch plug and air hose to tool A-2.
The pressure of the air supply should be under
15 kg/cm².
3. Connect power cord to AC 100 V socket.
Check that the power switch is OFF before
connecting the cord.
20-37
TESTING AND ADJUSTING MEASURING ENGINE STALL SPEEDS
MEASURING ENGINE STALL SPEEDS

Measurement conditions
Coolant temperature: Inside operating range
Hydraulic oil temperature: 45 - 55
Torque converter oil temperature: 70 - 90
Check that the low and high idle speeds are at the stan-
dard value.
Before measuring at each stall speed, install tachometer
(A), using the instructions that came with it.
Check that the engine speeds are the standard value. If
any item is outside the permitted range, check for any
looseness for play in the linkage.
Apply the parking brakes and block the tires
1. Measuring torque converter stall
1). Start the engine and run at low idle.
2). Put the directional lever in FORWARD or REVERSE,

and speed control lever in the highest speed range.
3) Using the brake, stop the machine and measure the

engine speed when the engine when the accelerator
pedal is fully depressed.
Turn the transmission cut-off selector switch (1)

to the OFF position, and use the left brake.
(Check that the pilot lamp is OFF).
Do not run at stall speed for more than 20
seconds, and do not let the torque converter oil
temperature raise above 120
Turn the parking brake switch OFF (release).
20-38
TESTING AND ADJUSTING MEASURING ENGINE STALL SPEEDS
2. Measuring hydraulic stall
1) Start engine and run at high idle.
2) Operate the dump or lift control lever to move

the cylinder to the end of its stroke and actuate
the relief valve of the main control valve.
3) Measure the engine at this point.

Do not run the engine at stall speed for more
than 20 seconds, and operate the control lever
quickly.
3. Measuring full stall
1) Measure the engine speed when the torque

converter stall and hydraulic stall are reached
at the same time.
Measure full stall when both the torque
converter and hydraulic stall speeds are
normal. If either stall speed is abnormal,
correct and measure the stall speed again.
20-39
TESTING AND ADJUSTING ADJUSTING ENGINE SPEED SENSOR
ADJUSTING ENGINE SPEED SENSOR

1. Engine speed sensor
1) Screw in until the tip of the sensor (1) contacts gear (2).
2) When sensor (1) contacts gear (2), turn back 1 turn.
3) Tighten locknut (3).
Locknut: 49 ±4.9 Nm (5.0 ±0.5 kgm)
Be particularly careful when handling the sensor

wiring to ensure that no excessive force is brought to
bear in the wiring.
Be careful not to let the tip of the sensor be
scratched, or let any foreign particles stick to it.
2. Transmission output shaft speed sensor

Adjust transmission output shaft speed sensor (4) using
the same procedure as for adjusting the engine speed
sensor.
However, in step 2, turn back 1/2 - 1 turn.
20-40
TESTING AND ADJUSTING MEASURING SHIFT LEVERS
MEASURING SHIFT LEVERS

Measurement conditions:
Engine stopped
Measure at center of lever knob
OPERATING FORCE OF SPEED LEVER

Install push-pull scale l2 or a spring balance to the center of
the control lever knob, and measure the operating force
when the lever is pulled in the direction of operation.
Carry out the measurement for each speed range.
TRAVEL OF SPEED LEVER

Make a mark (1) at the center of the control lever knob, and
measure the travel when the lever is operated in the direction
of operation.
20-41
TESTING AND ADJUSTING MEASURING ACCELERATOR PEDAL
MEASURING ACCELERATOR PEDAL

OPERATING FORCE
1. Measuring procedure
1) Put push-pull scale "A" in contact with the accelerator

pedal at point 150 mm from pedal fulcrum "a".
The center of push-pull scale n
contact with a point 150 mm from the pedal
fulcrum.
2) Start the engine, push the pedal in the direction of

operation and measure the maximum value when
pushing from low idle to the end of the pedal travel
(high idling).
2. Testing and adjusting
1) Stop the engine.
2) Disconnect cable (1) at the bottom of the accelerator

pedal, and check that plate (2) at the bottom of the
pedal moves smoothly.
3) Connect the cable at the bottom of the pedal, then

disconnect at the connection for the injection pump,
and check that cable (3) moves smoothly.
When performing this inspection, adjust or
replace parts as necessary. Measure the
operating force again and check that all
measurements are within the standard values.
20-42
TESTING AND ADJUSTING MEASURING ACCELERATOR PEDAL
OPERATING ANGLE
1. Measuring procedure
1. Stop the engine.
2. Put angle gauge "A" in contact with the accelerator

pedal, then measure the operating angle from low
idle to high idle, and calculate operating angle a = a1 -
a2.
2. Adjusting procedure
1. Remove the cover under the cab, and open the

inspection cover on the right side of the engine.
2. Loosen nut (1) and adjust bolt (2) so that mounting

height "L" of the accelerator pedal stopper is within a
range of 45 ± 5 mm.
3. Loosen locknut (4) and adjust length of cable (3) so

that the fuel pump lever contacts the high idle stopper
when the accelerator pedal is fully depressed (high
idle).
Check that the P.T. pump governor lever is in
contact with the low idle stopper when the
accelerator pedal is released (low idle).
Adjust the travel of the governor lever with joint of
cable (3).
After completing the above adjustments,
measure each part again to check that it is within
the standard values.
20-43
TESTING AND ADJUSTING TORQUE CONVERTER AND TRANSMISSION
MEASURING TORQUE CONVERTER

AND TRANSMISSION OIL PRESSURE
Coolant temperature: Inside operating range.
Engine speed: High idle
Manual switch ON
WARNING! Apply the parking brake and block the

tires.
1. Measuring main relief pressure

1) Remove the cover at the front of the engine and the
cover at the rear of the operator’s compartment.
2) Remove oil pressure measurement plug (PT1/8) (1),
then install oil pressure gauge C1 (5.9 MPa {60
kg/cm2}).
3) Start the engine and measure the oil pressure with
the engine at low idling and high idling.
2. Adjusting main relief valve
CAUTION: Adjust the main relief valve with the engine

stopped.
If the main relief pressure is not within the standard value,

adjust as follows:
1) Remove plug (1) and washer (2).
2) Remove inner spring (3) and outer spring (4).
3) Adjust by changing the thickness of shim (5).
Standard shim thickness: 3.0 mm (0.5 x 6)
Amount of adjustment for one shim: 0.04MPa
(0.4 kg/cm2)
20-44
3. Measuring torque converter relief (inlet port) pressure

then install oil pressure gauge C1 (5.9 MPa {60 kg/cm2}).
3) Start the engine and measure the oil pressure with the
engine at high idling. (If the pressure is not affected by
any adjustments, it may indicate possible need for
repair.)
4. Measuring torque converter outlet port pressure

1) Remove the cover at the left side of the transmission.
2) Remove oil pressure measurement plug (1) at the
bottom of the torque converter oil temperature sensor,
then install oil pressure gauge C1 (5.9 MPa {60 kg/cm2}).
engine at high idling. (If the pressure is not affected by
any adjustments, it may indicate possible need for
repair.)
20-45
5. Measuring ECMV output (clutch) pressure

2) Remove the oil pressure measurement plug for the
clutch to be measured.
Plug for measuring 1st clutch pressure: (1)
Plug for measuring 2nd clutch pressure: (2)
Plug for measuring 4th clutch pressure: (3)
Plug for measuring 3rd clutch pressure: (4)
Plug for measuring reverse clutch pressure: (5)
Plug for measuring forward clutch pressure: (6)
: Gasket sealant (LG-5)
3) Install oil pressure gauge C1 (5.9 MPa {60 kg/cm2}).

4) Start engine and measure the 1st, 2nd, 3rd, and 4th
clutch pressures under the following conditions at high
idling.
a) Leave the directional lever at neutral.
b) Turn the main monitor manual switch ON.
c) Place the gear shift lever at the speed range to be
measured.
5) Start the engine and measure the forward and reverse
clutch pressures under the following conditions at high
idling.
WARNING! Put blocks under the tires and depress the

brake securely.
a) Turn the transmission cut-off selector switch OFF

(lamp off).
b) Turn the parking brake switch OFF.
c) Depress the brake.
d) Turn the main monitor manual switch ON and place
the gearshift lever in 4th.
e) Keep the brake depressed and place the directional
lever at F or R.
6. Measuring lubricating oil pressure (oil cooler outlet port)

1) Remove the cover at the left side of the rear frame.
2) Remove the oil pressure measurement plug (1), then,
install oil pressure gauge C1 (5.9 MPa {60 kg/cm2}).
engine at high idling. (The pressure, not affected by
adjustments, may indicate possible need for repair.)
20-46
FLUSHING TORQUE CONVERTER AND TRANSMISSION HYDRAULIC

CIRCUIT
Metal particles and other dirt in the torque 3) Repeat the procedure in 4-1, and run the
converter and transmission hydraulic circuit will engine at low idling for approximately 20
reduce the life of the torque converter and minutes.
transmission, and will cause internal damage. To
prevent this, flush the system to remove the dirt or
metal particles in the hydraulic circuit. 5. Replace the flushing element.
1) Using the procedure in step 2-1, replace the
1. Flush the circuit if the following conditions flushing element with the standard element
apply. (424-16-11140).
1) If there has been any breakage of the torque
converter, transmission, or hydraulic CAUTION! If the flushing element is used for
equipment, and metal particles are circulating a long time, there will be premature clogging,
in the hydraulic circuit. so always replace the flushing element with the
2) When the torque converter and transmission standard element.
have been overhauled or repaired.
2) Add oil and check the level again.
2. Install the flushing element.
1) Drain the oil from the filter case. 6. Replace the transmission fail safe filter.
2) Remove the two transmission oil filters, then 1) Use a wrench to turn portion A of fail safe filter
install two flushing elements (561-15-55670). case (1) to remove it.
After flushing the system, assemble the If there is any dirt inside the filter case,
parts that were removed, and the parts wash the case.
inside the case. 2) Remove element (2) and replace with a new
element.
3. Fill the transmission case with oil. 3) Install new O-ring (3) to the outside
Add fresh oil through the oil filler port to the circumference of the case.
specified level, and run the engine to circulate Coat the outside circumference of the O-
the oil through the system. Then check the ring with a small amount of grease.
level again. 4) Install the case.
Transmission case: 62 Case: 39.2 Nm (4 kgm)
4. Carry out flushing as follows.

1) After starting the engine, run the engine for
approximately 20 minutes at low idling without
operating the speed lever or directional lever.
From time to time, raise the engine speed
to approximately 1500 rpm.
If the ambient temperature is low and the
engine coolant temperature gauge does
not enter the green range, continue the
warming-up operation longer.
2) Travel or carry out actual operations for at
least 20 minutes.
Use all the speed ranges (FORWARD,
REVERSE, and 1st - 4th).
20-47
MOVING MACHINE WHEN TRANSMISSION VALVE FAILS

If the machine cannot be moved because of a
failure in any part of the transmission valve system
(electrical system, solenoid valves, spools, etc.), it
is possible to move the machine by installing plate
N.
WARNING! Plate N is only for emergency use

when the machine cannot be moved by any
other means because of a failure in the
transmission control valve system. DO NOT
install plate N to the ECMV except when there
has been a failure and it is necessary to move
the machine from a dangerous working area to
a safe place for repairs.
WARNING! When carrying out this operation

keep strictly to the procedure and pay careful
attention to safety when moving the machine.
WARNING! To prevent the machine from

moving, lower the work equipment completely
to the ground, apply the parking brake, and put
blocks under the tires.
WARNING! Carry out the operation with the

engine stopped.
WARNING! Be careful not to burn yourself if

the oil is hot.
1. Remove the cover at the bottom of the operator’s

cab, and the cab at the bottom of the step on the
left side.
2. Remove valve cover (1).

Wash the area around the ECMV, clean and
remove all dirt and mud.
3. Disconnect wiring connectors (2) through (13).

For details of precautions when removing the
wiring connectors, see DISASSEMBLY AND
ASSEMBLY, REMOVAL OF TRANSMISSION
CONTROL VALVE ASSEMBLY.
20-48
4. Depending on the direction for moving the machine (forward

or reverse), remove the following 2 ECMV solenoids (14) and
install plate N.
FORWARD: F solenoid and 2nd solenoid
REVERSE: R solenoid and 2nd solenoid
If there is any mistake in the selection of the solenoid
to remove, there is danger that the transmission may
be damaged.
Install plate N with the protruding surface facing the
ECMV. Check also that there is an O-ring installed to
the mating surface.
Be careful not to let any dirt or mud get inside the
removed solenoid or valve
5. Depress the left brake pedal securely.
6. Start the engine, release the parking brake, then release the
brake pedal gradually to allow the machine to start, then
move the machine.
WARNING! Remove the blocks from under the tires.
WARNING! When the engine is started, the transmission

is also engaged to start the machine. To ensure safety
when starting the engine, check carefully that the
direction of travel and area around the machine are safe,
and always keep the brake pedal depressed when
starting.
WARNING! After moving the machine, stop the

engine, apply the parking brake, put blocks under the
tires.
20-49
TESTING AND ADJUSTING STEERING WHEEL
TESTING AND ADJUSTING

STEERING WHEEL
MEASURING PLAY OF STEERING WHEEL
Engine speed: Stopped
Machine posture: Facing straight forward
Method of measurement
1. Move the steering wheel 2 or 3 times lightly to the
left and right, check that the steering mechanism is
at the neutral position, then make a mark on the
outside frame of the machine monitor.
2. Turn the steering wheel to the right, and make a

mark at the position where the operating force
starts to become heavy (when the steering valve
lever starts to move).
3. Turn the steering wheel to the left in the opposite

direction from Step 2, and make a mark at the point
where the operating force becomes heavy (when
the steering valve lever starts to move). Then
measure the distance in a straight line between the
marks made in Step 2 and Step 3.
MEASURING OPERATING FORCE OF STEERING

WHEEL
Road surface: Flat, horizontal, dry paved
surface
Engine water temperature: Within green range
on engine water temperature gauge
Tire inflation pressure: Specified pressure
Engine speed: Low idling (bucket empty)
Measurement method
1. Install push-pull scale l2 to the steering wheel knob.
2. Start the engine.

After starting the engine, raise the bucket
approx. 400 mm and remove the safety bar.
3. Pull push-pull scale l2 in the tangential direction

and measure the value when the steering wheel
moves smoothly.
Avoid measuring when the steering wheel
starts to move.
20-50
TESTING AND ADJUSTING STEERING WHEEL
MEASURING OPERATING TIME FOR STEERING WHEEL
Road surface: Flat, horizontal, dry paved surface
Engine water temperature: Within green range on
engine water temperature gauge
Engine speed: Low and high idling
Measurement method
After starting the engine, raise the bucket
approx. 400 mm and remove the safety bar.
2. Operate the steering wheel to the end of its stroke

to turn the machine to the left or right.
3. Measure the time taken to operate the steering

wheel to the end of the stroke to the right (left).
Operate the steering wheel as quickly as
possible without using force.
Carry out the measurements both at low idling
and high idling, and to both the left and right.
20-51
TESTING AND ADJUSTING STEERING OIL PRESSURE
STEERING OIL PRESSURE

CAUTION! Install the safety bar to the frame.
Measuring
1. Measuring steering relief pressure
1) Remove oil pressure measurement plug (PT1/8) (1)
from the elbow at the right steering cylinder head
end, then install oil pressure gauge Cl (39 MPa {400
kg/cm2}).
2) Start the engine, run the engine at high idling, then

turn the steering wheel to the right and measure the
pressure when the relief valve is actuated.
When removing the oil pressure measurement
plug on the left steering cylinder, turn the steering
wheel to the left.
2. Measuring steering pilot pressure

1) Disconnect pilot hose (2) or (3) from steering valve
(1).
2) Install the adapter and oil pressure gauge (5.9 MPa

{60 kg/cm2}) inside tool Cl.
3) Start the engine and measure the oil pressure when

the steering wheel is turned with the engine running
at high idling.
Hose (2): Turn steering to right

Hose (3): Turn steering to left
20-52
TESTING AND ADJUSTING STEERING OIL PRESSURE
3. Measuring Orbit-roll output pressure

1) Disconnect Orbit-roll output hose (1) or (2).
2) Install the adapter and oil pressure gauge (5-9 MPa {60
kg/cm2}) inside tool Cl.
3) Start the engine and measure the oil pressure when the
steering wheel is turned with the engine running at high
idling.
Hose (1): Turn steering to right
Hose (2): Turn steering to left
Adjusting
WARNING! Always stop the engine before adjusting the

pressure
1. Adjusting steering relief valve

Loosen locknut (2) of steering relief valve (1), then turn
adjustment nut (3) to adjust.
Turn the adjustment screw to adjust the set pressure as
follows.
To INCREASE pressure, turn CLOCKWISE
To DECREASE pressure, turn COUNTER-
CLOCKWISE
Pressure adjustment for one turn of adjustment screw:
Approx. 14.8 MPa (151 kg/cm2)
20-53
TESTING AND ADJUSTING STEERING STOP VALVE
STEERING STOP VALVE

Testing
1. Set the front and rear frames facing straight.
2. Check that locknut (2) of stopper bolt (1) is not loose.
3. Start the engine, and check that there is a clearance between
the front frame stopper and rear frame stopper when the
steering is turned to the right or left.
CAUTION! measure the clearance with the engine

stopped.
Measure the clearance between the front frame and

rear frame when steering stop valve contact surface (3)
and stopper bolt (1) coming into contact and the turning
stops. - Standard clearance a: 40±5 mm
Adjusting
If the clearance between the front frame and rear frame is not within
the standard value, adjust as follows.
1. Loosen locknut (2), tighten stopper bolt (1), and make sure
that there is no contact with the steering stop valve.
2. Start the engine, run at low idling, then turn the steering
wheel slowly to bring the front and rear frames into contact.
When turning, be extremely careful not to get your arm or
any other part of your body caught between the front and
rear frames.
3. Stop the engine, then loosen the stopper bolt until it

contacts the steering stop valve contact surface.
4. Set the front and rear frames facing straight.
5. Loosen stopper bolt (1) 8.5 turns, then tighten locknut (2).
Carry out the procedure in Steps 1 - 5 to adjust both the
left and right sides.
6. Start the engine, turn the machine, and check that

clearance a between the front and rear frames is within the
standard value for both the left and right and that the
steering stopper valve and stopper bolt come into contact
and the steering is stopped.
20-54
TESTING AND ADJUSTING MEASURING BRAKE PEDAL
MEASURING BRAKE PEDAL

Engine water temperature: Within green range on engine
water temperature gauge
Engine speed: Low idling
Operating force of pedal
1. Install push gauge (1) to the operator's foot.

Align the center of the push gauge with the center of the
pedal.
2. Start the engine, run at low idling, and measure the operating
force when the pedal is depressed.
Travel of pedal
1. Install push gauge (1) to the operator's foot.

Align the center of the push gauge with the center of the
pedal.
2. Start the engine, and measure pedal angle a1 when running

at low idling, and pedal angel a2 when the pedal is depressed
with a force of 30 kg.
Install angle gauge (2) to the brake pedal when
measuring.
Pedal play
2. Push the brake pedal lightly by hand, and measure pedal

angle a3 when the pedal starts to become heavy.
20-55
TESTING AND ADJUSTING MEASURING BRAKE PERFORMANCE
MEASURING BRAKE
PERFORMANCE
Road surface: Flat, horizontal, dry paved
surface
Travel speed: 20 km/h when brakes are
applied
Delay in applying brakes: 0.1 sec.
Measurement method
1. Start the engine and move the machine.
2. Set the speed lever to the highest speed position

and drive the machine.
3. When the travel speed reaches 20 km/h, depress

the left brake pedal with the specified operating
force.
Before carrying out this operation, determine
the run-up path and the point for applying the
brakes, then apply the brakes when the
machine reaches that point.
Switch the transmission cut-off switch ON
when carrying out this operation.
4. Measure the distance from the point where the

brakes were applied to the point where the ma-
chine stopped.
Repeat this measurement three times and take
the average.
20-56
TESTING AND ADJUSTING TESTING BRAKE OIL PRESSURE
TESTING BRAKE OIL PRESSURE

CAUTION! Put blocks securely under the tires
1. Inspecting brake oil pressure

1) Remove bleeder screw (1), then install oil
pressure gauge tool l (39 MPa {400 kg/cm2}),
the joint, bleeder screw, and nipple.
2) Connect hose (2) to the bleeder screw and

bleed the air from the brake circuit. For details,
see BLEEDING AIR.
3) Depress the left brake and measure the brake

oil pressure.
2. Measuring drop in brake piston pressure

1) Remove bleeder screw (1), then install oil pressure
gauge tool l (39 MPa {400 kg/cm2}), the joint,
bleeder screw, and nipple.
2) Connect hose (2) to the bleeder screw and bleed

the air from the brake circuit. For details, see
BLEEDING AIR.
3) Stop the engine, depress the left brake pedal,

leave for 5 min. with the oil pressure at 4.9 MPa (50
kg/c M2 }, and measure the drop in pressure.
Be careful not to move the brake pedal for 5
minutes.
After completing the operation, bleed the air
from the brake circuit again.
20-57
TESTING AND ADJUSTING MEASURING BRAKE DISC WEAR
MEASURING BRAKE DISC WEAR

Brake oil pressure: 4.9 ±0.49 MPa (50 ±5 kg/cm2)
CAUTION! Park the machine on horizontal ground and

put blocks securely under the tires.
Measurement method
1. Remove plug (1).
2. Depress the brake pedal fully.
3. Use calipers M to measure depth a from the end face of the

housing to the spring guide.
When measuring, keep the brake pedal depressed.
4. Install a vinyl hose (3) to bleeder (2), then loosen the bleeder
and drain the brake oil.
After draining the brake oil, check that the brake piston
has returned to the end of its stroke.
5. Measure depth b from the end face of the housing to the

spring guide pin.
Calculating piston stroke

S=a-b S=Max.3.9mm
20-58
TESTING AND ADJUSTING PARKING BRAKE PERFORMANCE
PARKING BRAKE PERFORMANCE

Road surface: Flat, dry, paved surface with 1/5 (11
gradient.
Machine: In operation condition
Measuring procedure
1. Start the engine, ser the machine facing in a straight

line, then drive the machine up a 1/5 grade slope with the
bucket empty.
2. Depress the brake, stop the machine, set the directional

lever to the neutral position, then stop the engine.
3. Turn the parking brake switch ON, then slowly release

the brake pedal, and the machine must not move at all.
Carry out the measurement in two ways. Once with

the machine facing uphill, and once more with the
machine facing downhill.
20-59
TESTING AND ADJUSTING PARKING BRAKE OIL PRESSURE
PARKING BRAKE OIL PRESSURE

1. Measuring parking brake inlet port
1) Remove the transmission side cover.

2) Remove oil pressure measurement plug
(PT1/8) (1), then install oil pressure gauge Cl
(5-9 MPa {60 kg/cm2}).
3) Turn the parking brake switch OFF.
4) Start the engine and measure with the engine
running at low idling and high idling.
2. Measuring parking brake pilot pressure

1) Remove the cover at the front of the engine

and the cover at the top of the transmission.
2) Disconnect hose (1), then install adapter and
oil pressure gauge in tool Cl (5.9 MPa {60
kg/cm2}).
3) Start the engine and measure at high idling.
20-60
TESTING AND ADJUSTING PARKING BRAKE OIL PRESSURE
3. Measuring parking brake solenoid valve output pressure

cover at the top of the transmission.
2) Disconnect hose (1), then install adapter and oil pressure
gauge in tool Cl (5.9 MPa {60 kg/ cm2}).
3) Turn the parking brake switch OFF.
4) Start the engine and measure at high idling.
20-61
TESTING AND ADJUSTING PARKING BRAKE DISC WEAR
PARKING BRAKE DISC WEAR

If the parking brake effect becomes weak, measure the wear
of the parking brake disc as follows.
CAUTION! To prevent the machine from moving, lower

the work equipment completely to the ground and put
CAUTION! Always stop the engine before carrying out

this procedure.
1. Drain oil from the transmission case.
Transmission case: 62
2. Remove one of two plugs (1) on each side.
3. Using calipers M, measure depth a from the end face of cage

(2) to piston (3).
Standard depth a: Max. 40.3 mm
4. If depth a is greater than the specified value, remove parking

brake disc (4), and check thickness W of the disc. For details,
see DISASSEMBLY AND ASSEMBLY, REMOVAL OF
PARKING BRAKE DISC.
Dimension W: Min. 3.2 ±0.1 mm
If the thickness of the parking brake disc is below the

standard value, replace it.
20-62
TESTING AND ADJUSTING MANUAL RELEASE METHOD FOR PARKING BRAKE
MANUAL RELEASE METHOD FOR

PARKING BRAKE
The parking brake is controlled by hydraulic pressure, so if
there should be any failure in the transmission and it
becomes impossible to release the parking brake, it is
possible to release it manually to move the machine.
CAUTION! The manual release of the parking brake is

designed only to move the machine from a dangerous
working area to a safe place where repairs can be
carried out. This method must not be used except when
there has been a failure
CAUTION! To prevent the machine from moving, lower

the work equipment completely to the ground and put
CAUTION! Always stop the engine before carrying out

this procedure.
1. Remove two plugs (1).

After releasing the parking brake, coat the plugs with
gasket sealant (LG-5), then tighten the plugs.
2. Remove two cage mounting bolts (2), then screw them into
the plug mount gradually in turn.
When bolts (2) are screwed in, piston (3) is pulled and
the parking brake is released.
20-63
TESTING AND ADJUSTING PPC OIL PRESSURE
PPC OIL PRESSURE

Measuring
1. Measuring PPC pump pressure

1) Remove the cover at the top of the pump.
then install oil pressure gauge C1 (39 MPa {400
kg/cm2}).
3) Start the engine and measure the oil [pressure at high
idling.
2. Measuring PPC valve basic pressure (orbit-roll basic

pressure)
1) Disconnect hose (1), then install the adapter and oil
pressure gauge (5.9 MPa {60 kg/cm2}) in tool C1.
operate the work equipment control lever and measure
the oil pressure.
20-64
TESTING AND ADJUSTING PPC OIL PRESSURE
3. Measuring PPC valve output pressure
CAUTION! Loosen the oil filler cap slowly to release the

pressure inside the hydraulic tank.
CAUTION! Operate the control levers several times to

release the pressure in the PPC accumulator circuit.
1) Remove the main control valve cover.

2) Remove oil pressure detection plug (PT1/8) (1) of the
circuit to be measured, then install oil pressure gauge C1
(5.9 MPa {60 kg/cm2}).
Plug A: Boom LOWER, boom FLOAT
Plug B: Boom RAISE
Plug C: Boom DUMP
Plug D: Boom TILT

operate the work equipment control lever and measure
the oil pressure.
Adjusting
1. Adjusting PPC relief valve

Loosen locknut (2) of PPC relief valve (1), then turn
adjustment screw (3) to adjust.
Turn the adjustment screw to adjust as follows:
To INCREASE the pressure, turn clockwise.
To DECREASE the pressure, turn counter
clockwise.
Amount of adjustment - for one turn of adjustment screw:
1.8 MPa (18.3 kg/cm2)
Locknut: 83.4 ±4.9 Nm (18.3 ±0.5 kgm)
After completion of the adjustment, re-check the

accumulator charge cut-in pressure and cut-out pressure
again. Refer to ACCUMULATOR CHARGE PRESSURE,
see page 20-67.
20-65
TESTING AND ADJUSTING ADJUSTING PPC VALVE LINKAGE
ADJUSTING PPC VALVE LINKAGE

1. Remove cover (1) at the bottom of the work equipment
control lever.
2. Adjust dimension a from nut (1) of the PPC valve linkage to

the top surface of the floor.
Dimension a (target value): 54 mm
3. Loosen nuts (2) and (3), then adjust the installed height of
trunnion (5) so that there is no play in lever (4).
4. After adjusting, tighten nuts (2) and (3).
20-66
TESTING AND ADJUSTING ACCUMULATOR CHARGE PRESSURE
ACCUMULATOR CHARGE PRESSURE

Measuring
CAUTION! Stop the engine, then depress the brake

pedal at least 100 times to release the pressure inside
the accumulator circuit.
1. Disconnect accumulator inlet port hose (1), then install the

adapter and oil pressure gauge (30 MPa {400 kg/cm2}) in tool
C1.
2. Measure the accumulator charge cut-in pressure. Start the

engine, run at low idling, and measure the oil pressure when
the brake oil pressure warning pilot lamp on the
maintenance monitor goes out.
3. Measure the accumulator charge cut-out pressure. After the

accumulator charge cut-in, the pressure rises. Measure the
oil pressure at the point where the oil pressure gauge
indicator suddenly drops after rising.
Adjusting
When the accumulator charge cut-out pressure is
adjusted, the cut-in pressure also changes because of
the valve area ratio. For this reason, there is no cut-in
pressure adjustment nut.
1. Loosen locknut (2) of the accumulator charge cut-out valve

(1), then turn adjustment screw (3) to adjust.
Turn the adjustment screw to adjust as follows:
To DECREASE the pressure, turn counter
clockwise.
Amount of adjustment - for one turn of adjustment

screw: 5.6 MPa (57 kg/cm2)
Locknut: 10.78 ±0.98 Nm (1.1 ±0.1 kgm)
After completion of the adjustment, repeat the above

procedure for test to check the accumulator charge
cut-in pressure and cut-out pressure again.
20-67
TESTING AND ADJUSTING WORK EQUIPMENT HYDRAULIC PRESSURE
WORK EQUIPMENT HYDRAULIC

PRESSURE
CAUTION! Loosen the oil filler cap slowly to release the

pressure inside the hydraulic tank.
1. Measuring work equipment relief pressure

1) Raise bucket portion a approx. 30 - 50 mm and set
portion b in contact with the ground.
2) Stop the engine, then operate the work equipment
control lever and check that the bottom surface of the
bucket (both portion a and portion b) is in contact with the
ground.
After lowering the bucket to the ground, operate the
work equipment control lever several times to
release the remaining pressure in the piping.
3) Remove the cover at the top of the main control valve.

then install oil pressure gauge C1 (39 MPa {400
kg/cm2}).
20-68
TESTING AND ADJUSTING WORK EQUIPMENT HYDRAULIC PRESSURE
5) Start the engine, raise the lift arm approx. 400 mm, run
the engine at high idling, tilt the bucket back, then
measure the oil pressure when the relief valve is
actuated.
CAUTION! After measuring, repeat the procedure used

when installing the oil pressure gauge to release the
pressure inside the circuit, then remove the oil pressure
gauge.
Adjusting
1. Adjusting work equipment relief valve.

Loosen locknut (2) of work equipment relief valve (1), then
turn adjustment screw (3) to adjust.
Turn the adjustment screw to adjust as follows.
To DECREASE the pressure, turn counter clockwise.
Amount of adjustment for one turn of adjustment screw:
5.18 MPa {52.9 kg/cm2)
Locknut: 39.2 ±9.8 Nm (4 ±1 kgm)
After completion of the adjustment, repeat the above

procedure to measure the work equipment relief
pressure again.
20-69
TESTING AND ADJUSTING PRESSURE IN HYDRAULIC CIRCUIT
RELEASING REMAININ G
PRESSURE IN HYDRAULIC
CIRCUIT
1. Releasing remaining pressure between each
hydraulic cylinder and control valve.
If the piping between the hydraulic cylinder and
the control valve is to be disconnected, release
the remaining pressure from the circuit as
follows:
1) Stop the engine.

2) Release the oil filler cap slowly to release the
pressure inside the tank.
3) Operate the control levers.
When the levers are operated 2 - 3 times,
the pressure stored in the PPC
accumulator is removed. Start the engine,
run at low idling for approximately 5
minutes, then stop the engine and operate
the control levers.
Repeat the above operation 2 - 3 times to
release all the remaining pressure.
2. Releasing remaining pressure in brake

accumulator circuit.
If the piping between the brake accumulator
and emergency parking brake valve, between
the accumulator and check valve, and
between the accumulator and brake valve is to
be disconnected, release the remaining
pressure from the circuit as follows.
1) Stop the engine.
2) Depress the brake pedal at least 100 times to
release the pressure inside the brake
accumulator circuit.
3. Releasing remaining pressure PPC accumulator

circuit.
If the piping between the PPC accumulator and
PPC valve is to be disconnected, release the
remaining pressure from the circuit as follows:
Repeat the above operation 2 - 3 times to
release all the remaining pressure.
20-70
TESTING AND ADJUSTING WORK EQUIPMENT LEVER LINKAGE
ADJUSTING WORK EQUIPMENT LEVER

LINKAGE
Always stop the engine before adjusting the work equipment
lever linkage.
Check that the operating effort of the work equipment control
lever is within the standard value.
1. Do as follows to set solenoid (1) in a pulled condition.

1) Disconnect wiring connectors (F05) (2) and (F06) (3).
F05: Proximity switch for bucket positioner
F06: Proximity switch for boom kick-out
2) Connect a T-adapter, then connect the terminals
between (1) and (2).
Check that the solenoid is pulled l2 mm.
2. With the solenoid pulled, move solenoid (1) so that clearances

a between boom lever cam (4) and boom lever cam follower
(5) and between bucket lever cam (6) and bucket lever cam
follower (7) are each 0 - 0.5 mm.
Carry out the adjustment with the boom and bucket levers
at the HOLD position.
3. Operate the boom lever and adjust distance c between the

pins of rod (8) so that clearance b between the notches at both
ends of boom lever cam (4) and boom lever cam follower (5)
is 0 - 1 mm.
Distance c between pins of rod (8): 337 mm
4. Operate the bucket lever and adjust distance c between the

pins of rod (8) so that clearance d between the notches (1
place) bucket lever cam (6) and bucket lever cam follower (7)
is 0 - 1 mm.
Distance c between pins of rod (8): 337 mm
20-71
TESTING AND ADJUSTING BLEEDING AIR
BLEEDING AIR
CAUTION! Put blocks securely under the tires
1. Bleeding air from brake system

1) Remove cap (1) of the bleeder screw, insert a
vinyl hose into the screw, and insert the other
end in a container.
2) Start the engine.
3) Depress the brake pedal, then loosen the
bleeder screw and bleed the air.
This operation is carried out with two
workers. One worker operates the brake
pedal while the other bleeds the air from
the bleeder screw.
When depressing the brake pedal, use the
left pedal.
4) When no more air bubbles come out with the
fluid from the hose, depress the pedal fully and
tighten the bleeder screw while the oil is still
flowing.
Repeat the operation to bleed the air from
the other cylinders, and after completing
the operation, check the level in the oil
tank and add more oil if necessary.
To bleed the air completely, bleed the air
first from the cylinder which is farthest from
the brake pedal.
2. Bleeding air from the hydraulic cylinders.

1) Start the engine and run at idling for
approximately 5 minutes.
2) Run the engine at low idling, the raise and
lower the boom 4 - 5 times in succession.
Operate the piston rod to a point
approximately 100 mm before the end of
its stroke. Do not relieve the circuit under
any circumstances.
3) Run the engine at full throttle and repeat step
2). After that, run the engine at low idling, and
operate the piston rod to the end of its stroke to
relieve the circuit.
4) Repeat steps 2) and 3) to bleed the air from
the bucket cylinder.
When the cylinder has been replaced,
bleed the air before connecting the piston
rod.
20-72
TESTING AND ADJUSTING BUCKET POSITIONER
BUCKET POSITIONER
Testing
1. Start the engine, operate the bucket and actuate
proximity switch (1), then stop the engine and
measure clearance a between the proximity switch
and angle (2).
Standard clearance a: 3 - 5 mm
2. Run the engine at mid-range speed (1500 rpm),

actuate the proximity switch, and check that the
bucket angle is 0 - 1 e
bucket is lowered to the ground. Measure
dimension b between the center of the proximity
switch to the tip of the angle.
Measure three times and take the average.
Standard dimension b: 15 mm
Adjusting
1. If dimension a is not within the standard value,
adjust as follows:
1) Adjust mounting nut (4) so that clearance c
between the tip of the switch protector (3) and
the sensing surface of proximity switch (1) is
the standard value.
standard clearance c: 0.5 - 1.0 mm
Mounting nut: 17.15 ±2.45 Nm (1.75 ±0.25
kgm)
2) Adjust with washer (5) and shim (6) so that

clearance a between the sensing surface of
proximity switch (1) and angle (2) is the
standard value.
Adjust with shim (6) so that clearance a is
within the standard value for the whole
stroke of the angle.
Secure in position, making sure that the
center of proximity switch sensing surface
and the angle do not move away from the
center.
After adjusting, operate the bucket lever
and check that the proximity switch is
actuated normally.
2. If the bucket angle and dimension b are not within
the standard value, move the switch protector (3) to
adjust.
20-73
TESTING AND ADJUSTING BOOM POSITIONER
BOOM POSITIONER
CAUTION! Always be sure to apply the safety

lock to work equipment control lever.
Testing
1. Start the engine, operate the boom lever to actuate
proximity switch (1), then stop the engine and
measure dimension a between the center of
proximity switch (1) and the top of plate (2).
Standard clearance a: 0 - 5 mm
2. Measure dimension b between the proximity switch

sensing surface and the plate.
Standard dimension b: 3 - 5 mm
Adjusting
1. If the dimension a is not within the standard value,
move the plate to adjust.
2. If dimension b is not within the standard value,

adjust proximity switch mounting nut (3).
Mounting nut: 17.15 ±2.45 Nm (1.75

±0.25 kgm)
After adjusting, operate the boom lever and

check that the proximity switch is actuated
normally.
20-74
TESTING AND ADJUSTING BOOM POSITIONER
Proximity switch actuation pilot lamp (red)

The proximity switch is equipped with a pilot lamp which shows
when it is being actuated, so use this when adjusting.
Proximity switch Lights up Goes out

actuation
pilot lamp
Detector position When detector is positioned at detection When detector has moved away from detection
surface of proximity switch surface of proximity switch
Bucket
positioner
Boom kick-out
20-75
TESTING AND ADJUSTING TRANSMISSION CONTROLLER
TRANSMISSION CONTROLLER
The transmission controller is equipped with a
learning function to self compensate so that it
provides a constant gear shifting feeling to match
the changes in the transmission clutches occurring
with the wear.
If the transmission is overhauled or replaced, the

transmission controller keeps the control command
values learned to match the previous transmission.
For this reason, transmission shock or abnormal
noise may occur. After operating the machine for a
short time, the controller will learn to match the
condition of the new transmission and will
gradually return to the normal condition, but if it is
desired to reset the condition quickly and to carry
out learning again, it is possible to reset the
learning data and to carry out initial learning as
follows.
1. Method for resetting learning control data

Do as follows to return all the previously
learned control data in the controller to the
default values.
1) Check that the starting switch is at the OFF
position.
2) Remove the cover at the right side of the work
equipment control box.
3) Disconnect wiring connector (C3B) (1) and
connect T-adapter P to the controller only
(leave the harness hanging).
4) Turn the starting switch ON.
Do not start the engine.
5) Short circuit between terminals No. (1) to (16)
for at least one second, then return them to
free condition.
2. Initial learning method

To adjust the controller learning control data
for each clutch from the default settings to the
optimum values, first carry out the above Step
1 "Method of resetting learned control data”,
then do as follows.
1) Stall the torque converter. For details, see
MEASURING ENGINE SPEED.
2) Operate the speed lever and directional lever
as follows.
N
Operate the levers with the engine running
at low idling, the transmission cut-off
selector switch at OFF, and the manual
switch at ON.
20-76
TESTING AND ADJUSTING TRANSMISSION CONTROLLER
it is possible to carry out this operation with

the left brake pedal depressed fully, so
there is no need to travel.
3) When the torque converter oil temperature
gauge rises to the 2nd level on the
maintenance monitor, return the engine to low
idling.
Target value for torque converter oil
temperature: 40 - 50
There is no problem If the oil temperature
gauge goes down to the 1st level.
4) Operate the speed lever and directional lever
twice in succession as follows:
Operate the levers with the engine running

at low idling, the transmission cutoff
selector switch at OFF, and the manual
switch at ON.
Hold for the following periods of time for
each speed range.
Speed range 4 only: 3 seconds
Other speed ranges: 2 seconds
After carrying out the gear shifting
operation in Step 2), if the engine is
stopped before carrying out the gear
shifting operation in Step 4), repeat Step 2)
again.
It is possible to carry out this operation with
the left brake pedal depressed fully, so
there is no need to travel.
CAUTION! Check that the area around the

machine is safe and depress the left brake
securely when shifting gear.
20-77
TESTING AND ADJUSTING ADJUSTING MAIN MONITOR
ADJUSTING MAIN MONITOR

(SPEED MODULE)
The speedometer on the main monitor is a common part for
all machines, and the input signal for the travel speed differs
according to the machine, so it is necessary to adjust the
monitor for use with the particular model.
In addition, the tire diameter also differs according to the type
of tire fitted, so it is necessary to adjust to give the correct
travel speed.
It is also necessary to change the switches if the optional
E.C.S.S. (Electronically Controlled Suspension System) is
installed.
Adjustment procedure
Turn off the power, then remove the machine monitor and
adjust the switches at the back of the speedometer.
1. Setting machine model

1) Remove the rubber caps from dip switches (1), (2) and
(3) at the back of the speedometer.
2) When the rubber cap is removed, a rotary switch can be
seen inside. Using a flat-headed screwdriver, turn this
switch to adjust it to the settings in the table below.
Tire size Switch 1 Switch 2 Switch 3

Model Speedometer Tachometer
selection correction input
selection
km mile
per per
hour hour
26.5-25 5 D 7 0
29.5-25 5 D 4 0
20-78
TESTING AND ADJUSTING ADJUSTING MAIN MONITOR
3) When the cap is removed from dip switch (4) at

the back of the speedometer, an ON/OFF
switch can be seen. Adjust the setting if the
E.C.S.S. (Electronically Controlled Suspension
System) is installed
Switch Switch 4
number
W/O E.C.S.S. With E.C.S.S.
1 ON ON
2 ON ON
3 ON OFF
4 OFF OFF
4) After completing the adjustment, fit the rubber

caps securely and install the main monitor.
Reference: Amount of correction for switch (2)

Switch position 0 1 2 3 4 5 6 7
Amount of correction +14 +12 +10 +8 +6 +4 +2 0

(%)
Switch position 8 9 A B C D E F
Amount of correction 0 -2 -4 -6 -8 -10 -12 -14

(%)
20-79
TESTING AND ADJUSTING MEMORANDA
20-80
TABLE OF CONTENTS TROUBLESHOOTING
TROUBLESHOOTING
Points to remember when troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-202

Sequence of events in troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-203
Points to remember when carrying out maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-204
Checks before troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-212
Handling connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-213
Precautions when troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-214
Method of reading troubleshooting tables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-216
Preventing recurrence of trouble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-218
Connector types and mounting locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-220
Connection table for connector pin numbers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-229
Explanation of functions of electric control mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-240
Transmission control system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-240
Main monitor system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-244
Maintenance monitor system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-248
ECSS (Electronically Controlled Suspension System) control system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-252
Joystick steering control system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-256
Method of displaying action and failure code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-258
Chart of action codes and failure codes, and re-enaction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-260
Transmission controller LED display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-263
Method of using judgement table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-264
Method of using judgement charts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-266
Method of using matrix troubleshooting tables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-268
20-201
TROUBLESHOOTING POINTS TO REMEMBER WHEN TROUBLESHOOTING
POINTS TO REMEMBER WHEN TROUBLESHOOTING

WARNING! Stop the machine in a level place, and check that the safety pin, blocks, and parking brake
are securely fitted.
WARNING! When carrying out the operation with two or more workers, keep strictly to the agreed
signals, and do not allow any unauthorized person to come near.
WARNING! If the radiator cap is removed when the engine is hot, hot coolant may spurt out and cause
burns, so wait for the engine to cool down before starting troubleshooting.
WARNING! Be extremely careful not to touch any hot parts or to get caught in any rotating parts.
WARNING! When disconnecting wiring, always disconnect the negative (-) terminal of the battery first.
WARNING! When removing the plug or cap from a location which is under pressure from oil, water or air,
always release the internal pressure first. When installing measuring equipment, be sure to connect it
properly.
The aim of troubleshooting is to pinpoint the basic cause of the failure, to carry out repairs swiftly, and to prevent reoccurrence of the
failure.
When carrying out troubleshooting, an important point is to understand the structure and function of the machine. However, a short
cut to effective troubleshooting is to ask the operator various questions to form some idea of possible causes of the failure that would
produce the reported symptoms.
1. When carrying out troubleshooting, do not hurry to 5. Other maintenance items can be checked externally, so
disassemble the components. If components are check any item that is considered to be necessary.
disassembled immediately after a failure occurs: 4. Confirming the failure.
Parts that have no connection with the failure or other 1. Confirm the extent of the failure yourself, and judge
unnecessary parts will be disassembled. whether to handle it as a real failure or as a problem with
It will become impossible to find the cause of the failure. the method of operation, etc.
It will also cause a waste of man hours, parts, or oil and When operating the machine to reenact the
grease. At the same time, it will also lose the confidence of troubleshooting symptoms, do not carry out any
the user or operator. For this reason, when carrying out investigation or measurement that may make the problem
troubleshooting, it is necessary to carry out thorough prior worse.
investigation and to carry out troubleshooting in accordance 5. Troubleshooting
with the fixed procedure. 1. Use the results of the investigation and inspection in
2. Points to ask the user or operator. Steps 2 - 4 to narrow down the causes of the failure, then
1. Have any other problems occurred apart from the use the troubleshooting flowchart to locate the position of
problem that has been reported? the failure exactly.
2. Was there anything strange about the machine before 2. The basic procedure for troubleshooting is as follows.
the failure occurred? 1. Start from the simple points.
3. Did the failure occur suddenly, or were there problems 2. Start from the most likely points.
with the machine condition before this? 3. Investigate other related parts or information.
4. Under what conditions did the failure occur? 6. Measures to remove root cause of failure.
5. Had any repairs been carried out before the failure? 1. Even if the failure is repaired, if the root cause of the
When were these repairs carried out? failure is not repaired, the same failure will occur again.
6. Has the same kind of failure occurred before? 2. To prevent this, always investigate why the problem
3. Check before troubleshooting. occurred. Then, remove the root cause.
1. Check the oil level.
2. Check for any external leakage of oil from the piping or
hydraulic equipment.
3. Check the travel of the control levers.
4. Check the stroke of the control valve spool.
20-202
POINTS TO REMEMBER WHEN TROUBLESHOOTING TROUBLESHOOTING
SEQUENCE OF EVENTS IN TROUBLESHOOTING
20-203
TROUBLESHOOTING POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE
POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE

To maintain the performance of the machine over a long period, and to prevent failures or other troubles before they occur, correct
operation, maintenance and inspection, troubleshooting and repairs must be carried out. This section deals particularly with correct
repair procedures for mechanics and is aimed at improving the quality of repairs. For this purpose, it gives sections on “Handling
electric equipment”and “Handling hydraulic equipment”(particularly gear oil and hydraulic oil).
Points to remember when handling electric equipment
1. Handling wiring harnesses and connectors.

Wiring harnesses consist of wiring connecting one
component to another component, connectors used for
connecting and disconnecting one wire from another wire,
and protectors or tubes used for protecting the wiring.
Compared with other electrical components fitted in boxes
or cases, wiring harnesses are more likely to be affected by
the direct effects of rain, water, heat or vibration.
Furthermore, during inspection and repair operations, they
are frequently removed and installed again, so they are likely
to suffer deformation or damage. For this reason, it is
necessary to be extremely careful when handling wiring
harnesses.
a. Main failures occurring in wiring harness.

i. Defective contact of connectors (defective contact
between male and female). Problems with
defective contact are likely to occur because the
male connector is not properly inserted into the
female connector, or because one or both of the
connectors is deformed or the position is not
correctly aligned, or because there is corrosion or
oxidization of the contact surfaces.
20-204
POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE TROUBLESHOOTING
ii. Defective crimping or soldering of connectors. The

pins of the male and female connectors are in contact
at the crimped terminal or soldered portion, but if there
is excessive force brought to bear on the wiring, the
plating at the joint will peel and cause improper
connection or breakage.
iii. Disconnections in wiring. If the wiring is held and the

connectors are pulled apart, or components are lifted
with a crane with the wiring still connected, or a heavy
object hits the wiring, the crimping of the connector
may separate, or the soldering may be damaged, or the
wiring may be broken.
iv. High-pressure water entering connector. The

connector is designed to make it difficult for water to
enter (drip-proof structure), but if high pressure water is
sprayed directly on the connector, water may enter the
connector, depending on the direction of the water jet.
Since the connector is designed to prevent water from
entering, but at the same time, if water does enter, it is
difficult for it to be drained. Therefore, it water should
get into the connector, the pins will be short-circuited by
the water, so if any water gets in, immediately dry the
connector or take other appropriate action before
passing electricity through it.
20-205
v. Oil or dirt stuck to connector. If oil or grease is stuck to

the connector and an oil film is formed on the mating
surface between the male and female pins, the oil will
not let the electricity pass, so there will be defective
contact. If there is oil or grease stuck to the connector,
wipe it off with a dry cloth or blow dry with compressed
air and spray it with a contact restorer.
When wiping the mating portion of the connector,
be careful not to use excessive force or deform the
pins.
If there is oil or water in the compressed air, the
contacts will become even dirtier, so remove the oil
and water from the compressed air completely
before cleaning with compressed air.
2. Removing, installing, and drying connectors and wiring
harnesses.
a. Disconnecting connectors
i. Hold the connectors when disconnecting. When
disconnecting the connectors, hold the connectors
and not the wires. For connectors held by a
screw, loosen the screw fully, then hold the male
and female connectors in each hand and pull
apart. For connectors which have a lock stopper,
press down the stopper with your thumb and pull
the connectors apart.
Never pull with one hand.
b. When removing from clips
i. When removing a connector from a clip, pull the
connector in a parallel direction to the clip.
If the connector is twisted up and down or to the
left or right, the housing may break.
20-206
c. Action to take after removing connectors

i. After removing any connector, cover it with a vinyl
bag to prevent any dust, dirt, oil or water from
getting in the connector portion.
If the machine is left disassembled for a long
time, it is particularly easy for improper contact
to occur, so always cover the connector.
d. Connecting connectors
i. Check the connector visually
ii. Check that there is no oil, dirt, or water stuck to the
connector pins (mating portion).
iii. Check that there are no deformation, defective
contact, corrosion, or damage to the connector
pins.
iv. Check that there is no damage or breakage to the
outside of the connector.
If there is any oil, water, or dirt stuck to the
connector, wipe it off with a dry cloth. If any
water has got inside the connector, warm the
inside of the wiring with a dryer, but be careful
not to make it too hot as this will cause short
circuits.
If there is any damage or breakage, replace
the connector.
v. Fix the connector securely
vi. Align the position of the connector correctly, then
insert it securely.
vii. For connectors with lock stopper, push in the
connector until the stopper clicks into position.
viii. Correct any protrusion of the boot and any
misalignment of the wiring harness.
ix. For connectors fitted with boots, correct any
protrusion of the boot. In addition, if the wiring
harness is misaligned, or the clamp is out of
position, adjust it to its correct position.
If the connector cannot be corrected easily,
remove the clamp and adjust the position.
x. If the connector clamp has been removed, be sure
to return it to its original position. Check also that
there are no loose clamps.
20-207
e. Drying wiring harness. If there is any oil or dirt on the

wiring harness, wipe it off with a dry cloth. Avoid
washing it in water or using steam. If the connector
must be washed in water, do not use high-pressure
water or steam directly on the wiring harness. If water
gets directly on the connector, do as follows.
i. Disconnect the connector and wipe off the water
with a dry cloth.
If the connector is blown dry with compressed
air, there is the risk that oil in the air may
cause defective contact, so remove all oil and
water from the compressed air before blowing
with air.
ii. Dry the inside of the connector with a dryer. If

water gets inside the connector, use a dryer to dry
the connector.
Hot air from the dryer can be used, but
regulate the time that the hot air is used in
order not to make the connector or related
parts too hot, as this will cause deformation or
damage to the connector.
iii. Carry out a continuity test on the connector. After

drying, leave the wiring harness disconnected and
carry out a continuity test to check for any short
circuits between pins caused by water.
After completely drying the connector, blow it
with contact restorer and reassemble.
20-208
3. Handling control box

a. The control box contains a microcomputer and
electronic control circuits. These control all of the
electronic circuits on the machine, so be extremely
careful when handling the control box.
b. Do not open the cover of the control box unless
necessary.
c. Do not place objects on top of the control box.

d. Cover the control connectors with tape or a vinyl bag.
Never touch the connector contacts with your hand.
e. During rainy weather, do not leave the control box in a
place where it is exposed to rain.
i. Do not place the control box on oil, water, or soil,

or in any hot place, even for a short time. (Place it
on a suitable dry stand).
ii. Precautions when carrying out arc welding .
When carrying out arc welding on the body,
disconnect all wiring harness connectors
connected to the control box. Fit an arc welding
ground close to the welding point.
Points to remember when troubleshooting electric circuits

1. Always turn the power OFF before disconnecting or connecting connectors.
2. Before carrying out troubleshooting, check that all the related connectors are properly inserted.
Disconnect and connect the related connectors several times to check.
3. Always connect any disconnected connectors before going on to the next step.
If the power is turned ON with the connectors still disconnected, unnecessary abnormality displays will be generated.
4. When carrying out troubleshooting of circuits (measuring the voltage, resistance, continuity, or current), move the related wiring
and connectors several times and check that there is no change in the reading of the tester.
If there is any change, there is probably defective contact in that circuit.
20-209
Points to remember when handling hydraulic equipment

With the increase in pressure and precision of hydraulic equipment, the most common cause of failure is dirt (foreign material) in the
hydraulic circuit. When adding hydraulic oil, or when disassembling or assembling hydraulic equipment, it is necessary to be
particularly careful.
1. Be careful of the operating environment. Avoid adding
hydraulic oil, replacing filters, or repairing the machine in rain
or high winds, or in places where there is a lot of dust.
2. Disassembly and maintenance work in the field. If
disassembly or maintenance work is carried out on hydraulic
equipment in the field, there is danger of dust entering the
equipment. It is also difficult to confirm the performance
after repairs, so it is desirable to use a unit exchange.
Disassembly and maintenance of hydraulic equipment
should be carried out in a specially prepared dust proof
workshop, and the performance should be confirmed with
special test equipment.
3. Sealing openings. After any piping or equipment is

removed, the openings should be sealed with caps, tapes,
or vinyl bags to prevent any dirt or dust from entering. If the
opening is left open or is blocked with a rag, there is a
danger of dirt entering or of the surrounding area being
made dirty by leaking oil. Do not simply drain oil out on to
the ground. Collect it and ask the customer to dispose of it,
or take it back with you for disposal.
4. Do not let any dirt or dust get in during refilling operations.

Always keep the oil filler and the area around it clean, and
always use clean pumps and oil containers. If an oil
cleaning device is used, it is possible to filter out the dirt that
has collected during storage.
20-210
5. Change hydraulic oil when the temperature is high. When

hydraulic oil or other oil is warm, it flows easily. In addition,
the sludge can also be drained out easily from the circuit
together with the oil, so it is best to change the oil when it is
still warm. When changing the oil, as much as possible of
the old hydraulic oil must be drained out. (Drain the oil from
the hydraulic tank; also drain the oil from the filter and from
the drain plug in the circuit.) If any old oil is left, the
contaminants and sludge in it will mix with the new oil and
will shorten the life of the hydraulic oil.
6. Flushing operations. After disassembling and assembling

the equipment, or changing the oil, use flushing oil to
remove the contaminants, sludge, and old oil from the
hydraulic circuit. Normally, flushing is carried out twice:
primary flushing is carried out with flushing oil and secondary
flushing is carried out with the specified hydraulic oil.
7. Cleaning operations. After repairing the hydraulic equipment

(pump, control valve, etc.) or when running the machine,
carry out oil cleaning to remove the sludge or contaminants
in the hydraulic oil circuit. The oil cleaning equipment is
used to remove the ultra fine (about 3µ) particles that the
filter built into the hydraulic equipment cannot remove, so it
is an extremely effective device,
20-211
TROUBLESHOOTING CHECKS BEFORE TROUBLESHOOTING
CHECKS BEFORE TROUBLESHOOTING

xxxxxxxx xxxxxxxxx Item Standard Remedy
value
Checks Lubricating 1. Check fuel level -- Add fuel

before oil, cooling 2. Check for dirt or water in fuel -- Clean, drain
starting water 3. Check hydraulic oil level -- Add oil
4. Check hydraulic oil filter (Torque -- Clean, drain
converter, transmission oil)
5. Check brake oil level -- Add oil
6. Check engine oil level -- Add oil
7. Check cooling water level -- Add water
8. Check condition of dust indicator -- Clean or replace
Item Electrical 9. Check for loose or corroded battery -- Tighten or replace

Equipment terminals
10. Check for loose or corroded alternator -- Tighten or replace
terminals
11. Check for loose or corroded stating -- Tighten or replace
motor terminals
12. Check operation of instruments -- Repair or replace
Other Hydraulic 13. Check for abnormal noise or smell -- Repair

check items mechanical 14. Check for oil leakage -- Repair
components 15. Bleed air from system -- Bleed air
16. Check parking brake and wheel -- Repair or replace
brakes
Electrical 17. Check battery voltage (engine 24 - 26 V Replace

components stopped)
18. Check level of battery electrolyte -- Add or replace
19. Check for discolored, burnt, or bare -- Replace
wires
20. Check for missing wiring clamps, -- Repair
hanging wires
21. Checks for water leaking onto wiring -- Disconnect connector
(checks carefully water leakage at and dry connection
connectors and terminals)
22. Check for broken or corroded fuses Replace
23. Check alternator voltage (engine -- Replace
running at over ½ throttle) 28.5 - 29.5 V
(If the battery charge is low, the
voltage may be approximate, 25V
immediately after starting.)
24. Sound of actuation of battery relay Replace
(when switch starting is turned ON, --
OFF)
20-212
HANDLING CONNECTORS TROUBLESHOOTING
HANDLING CONNECTORS
1. When removing connectors from clips, pull the connector
in a parallel direction to the clip.
If the connector is twisted to the left and right or up
and down, the housing may break.
2. When disconnecting male and female connectors,

release the lock and pull in a parallel direction with both
hands.
Never try to pull apart with one hand.
3. When the wiring harness clamp of the connector has

been removed, always return it to its original condition
and check that is no looseness of the clamp.
20-213
TROUBLESHOOTING PRECAUTIONS WHEN TROUBLESHOOTING
PRECAUTIONS WHEN TROUBLESHOOTING

1. SAFETY b. Was there anything unusual before the machine broke
Stop the machine on level ground, and check that the down?
safety pins and parking brake are correctly applied, c. Did the breakdown occur suddenly, or had there been
and that the tires are blocked. signs of trouble before?
d. What was the machine doing when break down
When working in groups, use agreed upon signals and occurred?
do not allow unauthorized persons near machine. e. Had the machine been repaired before the breakdown?
If so, who carried out the repair, and when?
Be careful not to get burned by hot parts or get caught f. Had the same kind of failure occurred before?
in rotating parts.
2) Check the following items which can be checked
Always disconnect the cable from the negative (-) simply by visual checks etc.
terminals of the battery before disconnecting any a. Check oil level.
wiring. b. Check for leakage of oil from piping or hydraulic
Always release the pressure before removing the equipment.
plugs or caps of any place under hydraulic or air c. Check travel of control levers.
pressure, and connect all measuring tools d. Check stroke of spool in control valves.
correctly.
3) Reenact the failure and check the condition of the
2. METHODS FOR TROUBLESHOOTING machine (particular conditions at the time of failure).
Just because a failure occurs, do not immediately start a. Ask the user or operator if the decision about the failure
to disassemble the machine. was made based on measured values, or by comparison,
or by feeling.
The machine may be disassembled in such a way that b. Compare extent of failure with standard values.
the problem cannot be located, so the cause of the Check safety before carrying out any check.
problem will be unknown. Did not make any check or measurement that will
make the condition worse.
As a result,
4) Try to locate the possible causes for the failure.
The customer and operator will lose confidence in you. The transmission system consists of the transmission
itself, the transmission control valve, and the transmission
Time will be wasted, and unnecessary costs will be electrical control.
incurred for excess parts and greasing.
In particular, when trouble occurs in the transmission
To avoid these problems, use the following procedure when system, the probable location of the failure can be divided
troubleshooting. as follows;
Transmission itself, or transmission control valve.
1) Ask the customer and operator the following Transmission electric control.
questions about the breakdown.
a. Have there been any other problems apart from the
one reported?
20-214
HANDLING CONNECTORS TROUBLESHOOTING
To decide which of the two is the location of the failure, When removing parts, check their condition of
refer to “JUDGMENT ON POWER TRAIN”. mounting, and distinguish between front and rear,
left and right, and top and bottom.
5) Carry out troubleshooting using the troubleshooting
charts. Check the match marks, or make match marks to
There are the following two types of troubleshooting prevent mistakes when installing.
charts.
If part cannot be removed even when the nuts and
1. TROUBLESHOOTING TABLE bolts have been removed, do not use excessive
POWER TRAIN force to remove it. Check the part to see if there is
STEERING SYSTEM any problem with it and remove the problem before
BRAKE AND AIR SYSTEM trying to disassemble the part.
WORK EQUIPMENT SYSTEM
When installing or assembling, clean off all dust and
2. TROUBLESHOOTING FLOW CHART dirt and repair any scratches or dents. Remove all
ELECTRICAL SYSTEM grease or oil before coating with gasket sealant.
The troubleshooting charts consist of:

1) Items which can be checked easily.
2) Items which are likely to be the cause of such
failures.
Follow theses charts to carry out troubleshooting. At

the same time, do not forget the following points.
Check related items.
Check that there are no other failures or
breakdowns.
6) Investigate causes of breakdown

Even if the breakdown is repaired, if the original
cause of the problem is not removed, the same
breakdown will occur again. To investigate and
remove the original cause, see "Actions to take to
prevent failures from occurring again".
3. PRECAUTIONS WHEN REMOVING, INSTALLING,

DISASSEMBLING OR ASSEMBLING PARTS DURING
TROUBLESHOOTING
Carry out the various testing and adjusting while

observing the items on quality control given in
"Testing and Adjusting".
20-215
TROUBLESHOOTING METHOD OF READING TABLES
METHOD OF READING TROUBLESHOOTING Example 2:

TABLES Problem 1
Problem 2
the cause of the
DESCRIPTION OF SYMBOLS USED IN
fault is "b".
TROUBLESHOOTING TABLES
The following symbols are used in the "Remedy" column to
In example 2, it is evident that the cause is "e"
indicate the method of eliminating the cause of a fault.
without carrying out problem 2, however problem 2
X: Replace
is performed by way of an additional check.
A: Adjusting C: Clean
METHOD OF READING TROUBLESHOOTING TABLE

The symbol o in the table is inserted only for causes
which can be diagnosed. If a cause cannot be
diagnosed, the corresponding box is left blank.
If the result of problem 1 using the troubleshooting table
shown at right is abnormal, the cause of the trouble can
be assumed to lie between "a" and "d". Because it is not
passible to make a problem regarding "e", it is necessary
to perform the next problem (owing to the possibility of a
multiple fault).
If the result of problem 1 is normal, the cause of the fault
does not lie between "a" and "d". In such a case, before
diagnosing the causes as "e", however, carry out a check
by means of problem 2 or 5.
If now the result of problem 1 is abnormal and the result
of problem 2 normal, the cause is one of "a", "b" or "d". In
addition, if the result of problem 3 is abnormal, the cause
will be narrowed down to one of "b" or "d". To determine
which of "b" or "d" is the actual cause, perform problem
4.
If the result of problem is abnormal, blacken out the
corresponding o in the table and then perform the next
problem on these causes in order to narrow the likely
causes.
Example 1:
Problem 1
Problem 2
Problem 3
Problem 4
20-216
METHOD OF READING TABLES TROUBLESHOOTING
Example 3:
Problem 1 Abnormal From the table of ex-

ample 3, the cause
Problem 2 Abnormal is one of "a", "c"
Problem 3 Normal and "e".
Example 4:
Problem 1 Abnormal From table of exam-

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

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

to perform all the problems.
Also, looking at a particular cause, no matter how many

marks there are in the column corresponding to that cause, it
will cause to be an actual cause if there is even one o mark in
the same column.
20-217
TROUBLESHOOTING PREVENTING RECURRENCE OF TROUBLE
PREVENTING RECURRENCE OF TROUBLE

The troubleshooting table is used to establish the direct cause of damage or breakdown of a part or piece of equipment. It is not
able to establish the root cause of the damage or failure, however.
Also, this table only describes the action to be taken with the particular part or piece of equipment. It does not mention what action
should be taken to prevent a recurrence of the root cause.
In order to remove the root cause of a fault so as to prevent a recurrence, carefully investigate the real cause while referring to
the following items.
Regarding the method of checking and adjusting each part or piece of equipment, refer to "Testing and Adjusting" in the Shop
Manual.
HYDRAULIC EQUIPMENT
1. Oil checks
The fundamental cause of almost all faults occurring Water: Oil storage tank, breather, etc.
in hydraulic equipment is the inclusion of water, air or Sand: Oil replenishing or replacing method,
other foreign matter in the oil. Accordingly, it is etc.
necessary to check the oil to see whether or not it Rubber: Cylinder packing, etc.
contains any of the above substances, and then take Metal: Wear or damage to hydraulic
appropriate action. equipment such as pump and motor,
as well as transmission and torque
1) Oil checks converter, etc.
Check for water contamination.
Check the oil for possible water contamination by 3) Oil cleaning and replacement
means of a diesel engine oil checker or a hot If a large amount of metal particles or other
plate. foreign matter is discovered in the oil, either
Check for contamination of other foreign matter. wash the oil using an oil refresher or
Remove the drain plug and filter, then check the replace it.
bottom of the tank and also the filter to see if any If the oil is contaminated by water, it is not
foreign matter has collected there. Check the possible to remove the water by means of
degree of contamination by means of a an oil refresher.
contamination checker. When washing the oil, also wash or
Viscosity check replace the strainer and replace the filter.
Check the viscosity of the oil using a viscometer
in order to confirm whether or not the oil is 2. Cleaning fragments of damaged parts
satisfactory. If a part becomes damaged, fragments may pass
2) Check of contamination point into the oil line. It is thus necessary to wash the oil.
If, as a result of the above checks, it is dis- In addition, disassemble and wash such parts as
covered that the oil is contaminated by water or valves and cylinders which are liable to collect metal
other foreign matter, it is necessary to find out fragments and other foreign matter, thus helping to
where the contamination is occurring and also to prevent a recurrence of faults due to such fragments
take steps to prevent it. becoming lodged in various parts of the engine or
hydraulic equipment.
20-218
TROUBLESHOOTING CONNECTOR ARRANGEMENT DIAGRAM
20-219
CONNECTOR ARRANGEMENT DIAGRAM TROUBLESHOOTING
20-219-1
TROUBLESHOOTING CONNECTOR TYPES AND MOUNTING LOCATION
CONNECTOR TYPES AND MOUNTING LOCATIONS

The address column in the table below shows the address in the connector arrangement diagram.
Connector Type No. of Place of use Address

Number pins
A4 X 2 Air servo motor W5
A5 M 2 Thermistor U1
A6 SWP 6 Air mix servo motor V2
A7 M 6 Blower motor and resistor V2
A8A S 10 Intermediate connector (air conditioner relay) V2
A8B S 8 Intermediate connector (air conditioner relay) V2
A9 KES 0 4 Blower relay (Main) W3
A10 KES 0 4 Blower relay (Hi) W3
A11 KES 0 4 Blower relay (M2) W3
A12 KES 0 4 Condenser relay W3
A13 KES 0 4 Blower relay (M1) W2
A14 X 2 M6 switch W4
A14 KES 0 4 Condenser relay (Hi) W4
A15 2 Hi / Lo switch W5
A15 KES 0 4 Magnet clutch relay W2
A16 SWP 12 Air conditioner controller R1
A17 SWP 16 Air conditioner controller R1
A18 SWP 8 L.H. detection servo motor
A19 SWP 8 R.H. detection servo motor
AF1 X 2 Solenoid 1 (relief) E1
AF2 X 2 Solenoid 2 (Hi) F1
AF3 X 2 Solenoid 3 (Lo) F1
AF4 X 2 Solenoid 4 (selector) E1
AF5 X 2 Solenoid 5 (charge) B3
AF6 X 2 Boom bottom pressure switch B3
AF7 X 2 Charge pressure switch B2
B01 X 2 Condenser (upper) F9
B03 KES 1 2 Window washer M5
B04 KES 1 2 Window washer K4
20-220
CONNECTOR TYPES AND MOUNTING LOCATION TROUBLESHOOTING

Number pins
B05 KES 1 2 Diode
B06 KES 1 2 Diode
B07 X 2 Condenser (lower) F8
B08 X 2 Brake accumulator low pressure switch I2
B09 X 2 Emergency brake switch F7
B10 X 2 Emergency brake switch F7
B11 X 1 Condenser (upper) F9
B12 X 1 Condenser (lower) F9
B13 X 2 Brake accumulator low pressure switch I2
B14 X 2 Parking brake emergency release solenoid F8
BOOM X 3 Boom proximity switch
BR1 SWP 14 Intermediate connector (washer, condenser) J3
C01 M 6 Front wiper motor Q1
C02 9 Radio Q3
C03 M 2 Front working lamp R8
C04 M 2 Front working lamp T9
C05 4 Warning lamp switch R9
C06 KES 1 2 Room lamp T9
C07 M 4 Rear wiper motor W8
C1 MIC 13 Transmission and ECSS controller a5
C2 MIC 21 Transmission and ECSS controller a3
C3A AMP040 20 Transmission and ECSS controller Y4
C3B AMP040 16 Transmission and ECSS controller Y4
C4 AMP040 12 Transmission and ECSS controller Y4
C5 MIC 17 Transmission and ECSS controller Y3
CH1 AMP 13 For T-adapter connection
CH2 AMP 21 For T-adapter connection
CL1 S 12 Intermediate connector (working lamp, radio) Q2
CL2 S 10 Intermediate connector (air conditioner) Q2
CL3 M 6 Intermediate connector (air conditioner) Q1
CN3 X 2 Speed sensor H1
CN4 JFC 2 1st solenoid D7
20-221

Number pins
CN5 X 1 1st fill switch C8
CN6 JFC 2 2nd solenoid D7
CN7 X 1 2nd fill switch C9
CN8 JFC 2 4th solenoid D7
CN9 X 1 4th fill switch D9
CN10 X 2 Parking brake solenoid E7
CN11 X 2 Transmission oil temperature sensor I2
CN12 JFC 2 3rd solenoid E7
CN13 X 1 3rd fill switch D9
CN14 JFC 2 R solenoid E8
CN15 X 1 R fill switch D9
CN16 JFC 2 F solenoid E8
CN17 X 1 F fill switch E9
CN18 X 2 Torque converter oil temperature sensor I2
CN19 X 2 Parking brake indicator switch I2
CNL X 2 Joystick solenoid (L) S1
CNR X 2 Joystick solenoid (R) T1
D01 KES 1 2 Diode
D02 KES 1 2 Diode
D1 KES 1 2 Diode
D2 KES 1 2 Diode
E01 - 1 Slow blow fuse M3
E02 - 1 Slow blow fuse M2
E04 X 3 Engine speed sensor K3
E05 1 Engine water temperature sensor (Standard specification) L8
E06 X 2 Engine water temperature sensor (Standard specification) L4
E07 - 1 Heater relay
E08 - 1 Heater relay I9
E09 - 1 Heater relay H9
E10 X 1 Engine oil level sensor L4
E11 - 1 Engine oil pressure sensor G9
20-222

Number pins
E12 X 1 Air conditioner compressor J9
E13 X 2 Starting motor L4
E15 - 1 Alternator terminal B M7
E16 - 1 Alternator terminal R M6
E17 - 1 Alternator terminal E M6
E19 1-pin 1 Dust indicator H9

connector
E20 1-pin 1 Dust indicator H9

connector
E23 KES 1 2 Diode
ECSS SWP 8 Intermediate connector E7
ER1 SWP 14 Intermediate connector (air conditioner, engine water J3

temperature sensor)
EST X 3 Remove when installing emergency steering
F01 M 3 Head lamp (RH) D6
F02 M 3 Front combination lamp (RH) D6
F03 M 3 Front combination lamp (LH) B1
F04 M 3 Head lamp (LH) B1
F05 X 3 Proximity switch for bucket B4
F06 X 3 Proximity switch for boom kick-out E6
F07 - 1 Horn D6
F08 - 1 Horn G1
F09 - 1 Horn G1
F10 - 1 Horn C6
F11 X 2 Switch pump cut-off solenoid G1
F12 KES 1 2 Diode
F21 X 2 Boom RAISE switch B4
F22 X 2 Boom LOWER switch B5
F23 X 2 Boom lever detent switch B4
F26 X 2 Damping solenoid B5
F30 X 3 Boom cylinder oil pressure sensor
FR1 X 10 Intermediate connector (head lamp) H1
20-223

Number pins
FR2 X 4 Intermediate connector (boom, bucket SIG) H1
FR5 SWP 6 Intermediate connector
FS1 L 2 Power source W6
FS2 S 12 Fuse W6
FS3 M 6 Fuse W7
FS4 L 2 Power source W7
FS5 M 6 Fuse W7
FS6 M 4 Fuse W7
G01 X 2 Coolant level K9
G02 M 2 Working lamp (RH) K9
G03 M 2 Working lamp (LH) K9
GE01 SWP 8 Rack sensor
GER1 SWP 8 Intermediate connector
GER2 SWP 6 Intermediate connector
GLR1 SWP 8 Intermediate connector
GLR2 SWP 6 Intermediate connector
GR1 X 4 Intermediate connector (working lamp) L8
GRE SWP 6 Grease
GVN M 6 Model selection connector
HEAT M 2 Intermediate connector
JS1 S 1 Buzzer W5
JS3 1-pin 1 Cut-off switch power source W5

connector
JS4 1-pin 2 Cut-off switch GND W5

connector
JS5 KES 1 2 Joystick ON-OFF switch Q8
JS6 X 3 Neutral switch W4
JS8 KES 0 5 Caution relay a7
JS9 KES 0 5 Solenoid cut relay a8
JS10 KES 0 5 Selector switch a8
JS11 KES 0 3 Steering neutral interlock relay Z9
JS12 M 8 Intermediate connector (joystick switch) U1
20-224

Number pins
JS14 M 8 Intermediate connector (joystick lever switch) U1
JSA 1-pin 1 Intermediate connector (neutral) W3

(male) connector
JSB 1-pin 1 Intermediate connector (neutral) W4

(male) connector
JSC 1-pin 1 Neutral S1

connector
JSD 1-pin 1 Neutral S1

connector
L01 SWP 6 Parking brake switch Q5
L02 SWP 6 Light and dimmer switch Q5
L03 SWP 6 Turn signal and hazard switch Q4
L04 SWP 14 F/R and speed switch Q3
L05 AMP040 20 Main monitor Q4
L09 M 4 Starting switch Q3
L10 S 10 Wiper switch Q3
L12 X 2 Transmission cut-off switch U1
L13 X 3 Accelerator potentiometer R1
L14 X 3 Accelerator limit switch R1
L15 M 4 Kick-down and hold switch Q7
L16 KES 1 2 Boom kick-out solenoid Q7
L17 KES 1 2 Bucket positioner solenoid Q6
L18 AMP040 16 Maintenance monitor Q6
L21 KES 1 2 Maintenance monitor Q7
L22 KES 1 22 Maintenance monitor Q7
L23 10 Engine throttle controller
20-225

Number pins
L26 MIC 21 Work equipment and joystick controller T1
L27 MIC 20 Work equipment and joystick controller T1
L28 MIC 16 Work equipment and joystick controller U1
L32 M 2 Intermediate connector (power source, GND) Q5
L33 M 2 Intermediate connector (boom kick-out output) Q6
L34 S 8 Intermediate connector (network, buzzer output) S1
L42 1-pin 1 Caution buzzer T9

connector
L43 1-pin 1 Caution buzzer U9

connector
L44 KES 0 6 Wiper relay V8
L46 KES 1 3 Flasher unit V9
L48 KES 0 5 Bucket relay Z6
L49 KES 0 5 Boom relay a7
L52 KES 0 5 Hazard relay Y6
L53 KES 0 5 Stop lamp relay Y6
L54 KES 0 5 Back-up lamp relay a7
L55 KES 0 5 Horn relay a8
L56 KES 0 5 Spare relay a9
L57 KES 0 5 Neutral relay X6
L58 KES 0 5 Neutralizer relay X8
L59 KES 0 5 Parking brake safety relay Z9
L60 KES 0 6 Front working lamp relay a9
L61 KES 0 6 Rear working lamp relay a9
L62 KES 0 5 Engine stop relay Y9
L63 1-pin 1 Horn switch Q5

connector
L64 KES 0 5 Engine oil pressure relay X9
L75 KES 1 4 Pressure release switch V8
L80 KES 0 5 Dust indicator relay Y9
L81 X 2 Stop lamp switch T1
L82 KES 0 5 Switch pump cut-off relay
L90 KES 1 4 Parking brake emergency release switch W6
20-226

Number pins
L91 KES 0 5 ECSS relay Y9
LGL S 16 Intermediate connector
LGL2 M 2 Intermediate connector
LM1 S 10 MDC monitor panel
LR1 S 12 Intermediate connector (lamp) B7
LR2 SWP 14 Intermediate connector(air conditioner, washer) A7
LR4 SWP 14 Intermediate connector (monitor related) A7
LR5 X 4 Intermediate connector (power source, GND) B6
LR6 L 2 Intermediate connector (power source) A6
LR11 SWP 14 Intermediate connector (boom switch) E7
M01 MIC 20 MDC monitor panel (not used)
M04 L 2 MDC monitor controller (not used)
M05 M 4 Intermediate connector
M07 M 4 Cancel, sub total switch
M08 1-pin 1 Printer power source

connector
M09 1-pin 1 Printer GND

connector
M13 M 3 Intermediate connector
M15 1-pin 1 Intermediate connector

connector
M16 MIC 16 MDC monitor controller
M17 MIC 8 MDC monitor controller
M20 KES 1 2 Resistor
M21 KES 1 2 Resistor
MR1 SWP 8 Intermediate connector
OP1 1-pin 1 Fuse outlet W6

connector
OP2 1-pin 1 Fuse outlet (power source)

connector
R01 KES 1 2 Diode
R02 KES 1 2 Diode
20-227 20-227

Number pins
R03 KES 1 2 Diode
R04 KES 1 2 Diode
R07 X 2 Fuel level sensor K4
R08 M 6 Rear combination lamp (LH) M6
R09 M 6 Rear combination lamp (RH) J9
R11 Terminal 1 Battery L8
R12 Terminal 1 Battery relay K1
R13 Terminal 1 Battery relay L1
R15 Terminal 1 Slow blow fuse M4
R17 Terminal 2 Slow blow fuse M1
R18 1-pin 1 License lamp M7

connector
R19 1-pin 1 License lamp (GND) M8

connector
R20 X 1 Battery electrolyte level sensor
RES KES 1 2 Resistance
SEL1 M 2 Engine select Q3
SEL2 M 2 Joystick function selection Q2
TM1 SWP 14 Intermediate connector (transmission) B6
TM2 SWP 16 Intermediate connector (transmission) A6
20-228
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS TROUBLESHOOTING
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS

The terms male and female refer to the pins, while the terms male housing and female housing refer to the
mating portion of the housing.
20-229
TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
20-230
20-231
20-232
20-233
20-234
20-235
20-236
20-237
20-238
MEMORANDA TROUBLESHOOTING
20-239
TROUBLESHOOTING EXPLANATION OF FUNCTIONS OF ELECTRIC CONTROL MECHANISM
EXPLANATION OF FUNCTIONS OF ELECTRIC CONTROL MECHANISM

TRANSMISSION CONTROL SYSTEM
20-240
EXPLANATION OF FUNCTIONS OF ELECTRIC CONTROL MECHANISM TROUBLESHOOTING
1. Function of equipment at input end. (10) Transmission oil temperature sensor.

(1) F/R switch. This detects the temperature of the
This detects the condition of operation of transmission oil and inputs it to the controller
directional lever and inputs it to the controller as a analog (resistance) signal.
as a digital (ON-OFF) signal. (On machines
equipped with joystick, the signal from the (11) Speed range switch.
joystick switch is also input.) (F, R, 1st, 2nd, 3rd, 4th)
This detects the condition of actuation of the
(2) Speed range switch. ECMV flow detection valve and inputs it to the
This detects the condition of operation of controller as a digital (ON-OFF) signal.
speed lever and inputs it to the controller as a
digital (ON-OFF) signal. (12) Neutralizer relay.
(3) Manual selector switch. parking brake and inputs it to the controller as a
This detects the condition of operation of the digital (ON-OFF) signal.
manual selector switch and inputs it to the
controller as a digital (ON-OFF) signal. 2. Limit function of controller (outlet port).
Auto-shift function:
(4) Transmission cut-off selector switch. This calculates the optimum speed range
This detects the condition of operation of the from the signals from the switches and
transmission cut-off switch, and controls the sensors, and outputs it to the ECMV as an
signal of the ON-OFF signal from CUT-OFF analog (current) signal in order to shift up or
oil pressure switch to the controller signal. down.
(5) Hold switch. Modulation control function:

This detects the condition of operation of the This calculates the optimum modulation
hold switch or shift up switch (when using the pattern from the signals from the switches
joystick) and inputs it to the controller as a and sensors in order to reduce the shock
digital (ON-OFF) signal. when shifting up or down, and outputs it to
the ECMV of both the clutch to be engaged
(6) Kick-down switch. and the clutch to be disengaged as an
This detects the condition of operation of the analog (current) signal.
kick-down switch or shift-down switch (when
using the joystick) and inputs it to the Hold function:
controller as a digital (ON-OFF) signal. When the hold switch is turned ON, it outputs
a signal to the ECMV to stop the auto-shift
(7) Engine speed sensor. and hold it at the same speed range.
This detects the speed of the engine flywheel
as the engine speed and inputs it to the Kick-down function:
controller as a pulse (rotation) signal. When the kick-down switch is turned ON, if it
matches the control conditions, the signal is
(8) Cut-off oil pressure switch. output to the ECMV to shift down to 1st.
This detects the condition of operation of the
left brake pedal from the brake circuit oil
pressure, and inputs it to the controller as a
digital (ON-OFF) signal. (When the main
monitor cut-off switch is ON.)
(9) Speed sensor.

This detects the speed of the transmission
output shaft as the travel speed and inputs it
to the controller as a pulse (rotation) signal.
(The speed sensor is also used with the main
monitor system.)
20-241
Manual shift function: Network communication with main monitor:

When the manual shift is turned ON, the 1) The controller communicates the
signal is output to the ECMV to shift the actuated speed range through the
speed to the selected speed range with the network.
shift lever. 2) The controller communicates the
actuated F/R position through the
For machines with joysticks, when operating network. (Machines with joystick.)
in the manual mode, the hold switch
becomes the shift-up switch and the kick- 3) It communicates the condition of
down switch becomes the shift-down switch, actuation of the hold mode through the
so the transmission is shifted up or down network.
within the range of the speeds selected by
the speed range switch (the range of speeds 4) If any abnormality is detected by the self-
between 1st and the selected speed range). diagnostic function, it communicates the
details of the abnormality through the
Parking brake neutralizer function: network.
To prevent seizure of the parking brake, the
signal from the neutralizer relay stops the 3. Functions of output equipment.
out-put of the directional signal to the ECMV 1) ECMV solenoid valve.
and holds the transmission at neutral even if (F, R, 1st, 2nd, 3rd, 4th)
the directional lever is operated to F or R. The solenoid receives the signal from the
controller, is driven, and controls the
Back-up lamp drive function: transmission clutch oil pressure.
The signal from the directional switch is sent
to the back-up lamp relay as a digital (ON- 2) Back-up lamp relay.
OFF) signal. The relay receives the signal from the
controller, is driven, and turns the power for
Buzzer function: the back-up lamp relay ON-OFF.
The signal is sent through the main monitor
to the alarm buzzer as a digital (ON-OFF) 4. Main monitor display.
signal according to the condition of the input For details, see MAIN MONITOR.
signal.
Self-diagnostic function:
The controller always observes the
directional switch, speed range switch, speed
sensor, engine speed sensor, transmission
oil temperature sensor, the 6 ECMV fill
switches at the input side, and the 8 ECMV
solenoids at the output side to check that no
abnormality occurs in the back-up lamp relay
systems.
20-242
-MEMORANDA-
20-243
MAIN MONITOR SYSTEM
20-244
1. Functions of equipment at input end 10) Preheating relay.

1) Parking brake oil pressure switch This Optional equipment, detects actuation of the
detects the condition of actuation of the relay from the secondary outlet voltage of the
parking brake and inputs it to the main preheating relay, and inputs it to the main
monitor as a digital (ON-OFF) signal. monitor as a digital (ON-OFF) signal.
2) Engine speed sensor. 11) Maintenance monitor.

This detects the speed of the engine flywheel CHECK lamp signal.
as the engine speed and inputs it to the main This inputs the CHECK lamp drive signal
monitor as a pulse (rotation) signal. (the output signal from the maintenance
monitor) to the main monitor as a digital
3) Speed sensor. (ON-OFF) signal.
This detects the speed of the transmission CAUTION lamp signal.
output shaft as the travel speed and inputs it This inputs the CAUTION lamp drive
to the main monitor as a pulse (rotation) signal (the output signal from the
signal. (The speed sensor is also used with maintenance monitor) to the main
the transmission control system.) monitor as a digital (ON-OFF) signal.
Lamp synchronous signal.
4) Engine water temperature sensor. This inputs the lamp synchronous signal
This detects the temperature of the engine (the output signal from the maintenance
cooling water and inputs it to the main monitor) to the main monitor as a digital
monitor as an analog (resistance) signal. (ON-OFF) signal.
5) Transmission directional switch. 12) Starting switch.

This detects the condition of operation of the Terminal BR.
directional lever to the “N”position and inputs This detects the condition of operation of
it to the main monitor as a digital (ON-OFF) the starting switch to the ON position and
signal. (The transmission directional switch is inputs it to the main monitor as a digital
also used for the transmission control (ON-OFF) signal.
system.) Terminal C.
This detects the condition of operation of
6) Emergency steering detection switch. the starting switch to the START position
This detects the condition of actuation of the and inputs it to the main monitor through
emergency steering hydraulic circuit and the neutral relay as a digital (ON-OFF)
inputs into the main monitor as a digital (ON- signal.
OFF) signal.
13) Alternator (terminal R).
7) Turn signal, hazard switch. This detects the condition of electricity
This detects the condition of operation of the generated by the alternator and inputs it to
turn signal and hazard switch, and inputs it to the main monitor as an analog (voltage)
the main monitor as a digital (ON-OFF) signal.
signal.
2. Network communication with controllers.
8) Dimmer switch. With transmission, ECSS controller.
This detects the condition of operation of the 1) The speed range (1 - 4) now being used
dimmer switch and inputs it to the main is communicated.
monitor as a digital (ON-OFF) signal.
9) Head lamp relay/rear lamp relay.

relay from the secondary outlet voltage of the
head lamp relay and rear lamp relay, and
inputs it to the main monitor as a digital (ON-
OFF) signal.
20-245 20-245
2) The directional position (F, N, R) now Turn signal pilot lamp function:
being selected is communicated The left or right turn signal pilot lamps are
(machines with joystick). made to flash (in the case of hazard the
3) When the hold function is actuated, the lamps on both sides flash) by the signal from
actuation signal is communicated. the turn signal and hazard switch.
4) If any abnormality occurs in the Hi beam pilot lamp function:
transmission control system or ECSS When the Hi beam is used, the Hi beam pilot
control system, the details of the lamp is lighted up by the signal from the
abnormality are communicated. dimmer switch.
With work equipment, joystick controller: CHECK lamp function:

If any abnormality occurs in the transmission The CHECK lamp is made to flash by the
control system or joystick control system, the CHECK lamp signal from the maintenance
details of the abnormality are communicated. monitor. When this happens, the flashing of
the lamp on the maintenance monitor and
3. Functions of main monitor the flashing of the CHECK lamp are
Self-check function: synchronized by the flash synchronous signal
When the starting switch is turned ON, all from the maintenance monitor.
lamps and meters light up for 3 seconds and CAUTION lamp function:
the alarm buzzer sounds for 1 second to The CAUTION lamp is made to flash by the
carry out a self check. (If the starting switch is CAUTION lamp signal from the maintenance
turned to the START position during the 3 monitor. When this happens, the flashing of
seconds of the self check, the self check the lamp on the maintenance monitor and
stops.) the flashing of the CAUTION lamp are
Speedometer function: synchronized by the flash synchronous signal
The speedometer is displayed on the meter from the maintenance monitor.
portion by the signal from the speed sensor. Emergency steering indicator function:
(When the system is set to the tachometer The emergency steering pilot lamp is made
display specification, the tachometer is to flash by the signal from the emergency
displayed on the meter portion by the signal steering detection switch.
from the engine speed sensor.) ECSS switch function (machines equipped
Transmission shift indicator function: with ECSS):
The speed range or directional N is displayed For details, see ECSS CONTROL
on the shift indicator portion by the network SYSTEM.
communication from the transmission and Working lamp switch function (front, rear):
ECSS controller. The condition of operation of the working
Transmission directional indicator function: lamp switch is output to the working lamp
(Machines with joystick) relay as a digital (ON-OFF) signal. At the
The directional F or R is displayed at the same time, the indicator is lighted up by the
bottom of the speedometer portion by the signal from the working lamp relay.
network communication from the
transmission and ECSS controller. (Even on
machines with joystick, the directional N is
displayed on the shift indicator portion.)
Hold indicator function
When the hold mode is actuated, the hold
indicator is lighted up by the network
communication from the transmission and
ECSS controller.
2-246
Parking brake dragging warning function:

If the directional lever (switch) is set to the F
or R position when the parking brake is still
applied (ON), the CAUTION lamp flashes
and the alarm buzzer sounds intermittently.
Action code and failure code display function:
If an abnormality signal is received by
network communication from the controllers,
the action code (normally displayed) or
failure code (when failure code is displayed)
are displayed on the speedometer portion. At
the same time, when the abnormality code is
received, the total hours of operation of the
machine is calculated by the signal from the
alternator terminal R, and this is displayed as
the elapsed time since failure on the failure
mode display.
4. Functions of equipment at output end.

1) Alarm buzzer:
This receives the signal from the main
monitor and generates the alarm sound.
(The alarm buzzer is also used for the
maintenance monitor system.)
2) Front, rear working lamp relay:

This receives the signal from the controller
and switches the power for the front or rear
working lamp relay ON-OFF according to the
switching of the relay.
20-247
MAINTENANCE MONITOR SYSTEM
2-248
1. Functions of equipment at input end. 9) Alternator (terminal R):

1) Fuel level sensor: This detects the condition of generation of
This detects the fuel level in the fuel tank and electricity by the alternator and inputs it to the
inputs it to the maintenance monitor as an maintenance monitor as an analog
analog (resistance) signal. (electricity generation) signal.
2) Engine water temperature sensor: 10) Starting switch (terminal C):

This detects the temperature of the engine This detects the condition of operation of the
cooling water and inputs it to the starting switch to the START position and
maintenance monitor as an analog inputs it through the neutral relay to the
(resistance) signal. maintenance monitor as a digital (ON-OFF)
signal.
3) Torque converter oil temperature sensor:
This detects the temperature of the torque 2. Control functions of maintenance monitor.
converter oil and inputs it to the maintenance Self-check function:
monitor as an analog (resistance) signal. When the starting switch is turned ON, all
lamps and meters light up for 3 seconds and
4) Engine water level switch: the alarm buzzer sounds for 1 second to
This detects the level of the engine cooling carry out a self check. (If the starting switch is
water in the radiator reservoir tank and inputs turned to the START position during the 3
it to the maintenance monitor as a digital seconds of the self check, the self check
(ON-OFF) signal. stops.)
5) Engine oil level switch: Fuel gauge:

This detects the level of the oil in the engine The fuel gauge is displayed and the pilot
oil pan and inputs it to the maintenance lamp flashes or goes out according to the
monitor as a digital (ON-OFF) signal. signal from the fuel level sensor.
6) Brake accumulator low-pressure switch: Engine water temperature gauge:

This detects the oil pressure in the wheel The engine water temperature gauge is
brake accumulator circuit and inputs it to the displayed and the pilot lamp flashes or goes
maintenance monitor as a digital (ON-OFF) out according to the signal from the engine
signal. water temperature sensor.
7) Engine oil pressure switch: Torque converter oil temperature gauge:

This detects the engine oil pressure inputs it The torque converter oil temperature gauge
to the maintenance monitor as a digital (ON- is displayed and the pilot lamp flashes or
OFF) signal. goes out according to the signal from the
torque converter oil temperature sensor.
8) Air cleaner clogging switch:
This detects the clogging condition of the air Engine water level pilot lamp:
cleaner and inputs it to the maintenance The pilot lamp flashes or goes out according
monitor as a digital (ON-OFF) signal. to the signal from the engine water level
sensor.
20-249
Engine oil level pilot lamp: 3. Functions of equipment at output end.

The pilot lamp flashes or goes out according 1) Main monitor:
to the signal from the engine oil level sensor. This receives the signal from the
maintenance monitor and makes the CHECK
Brake oil pressure caution lamp: lamps or CAUTION lamps flash.
The caution lamp flashes or goes out
according to the signal from the brake 2) Alarm buzzer:
accumulator low-pressure switch. This receives the signal from the
maintenance monitor and makes the alarm
Engine oil pressure caution lamp: buzzer sound. (The alarm buzzer is also
The caution lamp lights up, flashes, or goes used for the main monitor system.)
out according to the signal from the engine
oil pressure switch.
Battery charge caution lamp:

The caution lamp lights up, flashes, or goes
out according to the signal from alternator
terminal R.
Air cleaner clogging caution lamp:

The caution lamp flashes or goes out
according to the signal from the air cleaner
clogging sensor.
Service meter:
The service meter is driven by the signal from
the engine oil pressure switch.
Output to main monitor:

The CHECK lamp signal, CAUTION lamp
signal, and flash synchronous signal are
output to the main monitor as a digital (ON-
OFF) signal according to the condition of the
input signal.
Alarm buzzer function:

The digital (ON-OFF) signal is output to the
alarm buzzer according to the condition of
the input signal.
2-250
-MEMORANDA-
20-251
ECSS (Electronically Controlled Suspension System) CONTROL SYSTEM

This system has functions in the transmission controller, and judges the function by the select signal from the
main monitor when the engine is started.
2-252
1. Functions of equipment at input end signal to the relief solenoid (SOL1), High-
1) ECSS actuation switch: pressure solenoid (SOL2), Low-pressure
This detects the condition of actuation of the solenoid (SOL3), and pressure release
ECSS switch and inputs it to the controller as solenoid (SOL4).
a digital (ON-OFF) signal.
Accumulator charge function:
2) Output speed range signal: To prevent the oil pressure in the
This detects the condition of the output speed accumulator circuit from dropping and the
range. (The ECSS system carries out control boom from going down when the damper
with the same controller as the transmission function is actuated, the signal from the
control system, so the speed range switch charge oil pressure sensor is output to the
signal is also used inside the controller.) charge solenoid (SOL5) as a digital (ON-
OFF) signal.
3) Speed sensor:
This detects the speed of the transmission Pressure release function:
output shaft as the travel speed (speed) and The pressure release switch signal drives the
inputs it to the controller as a pulse (rotation) pressure release solenoid (SOL4) to release
signal. (The ECSS system carries out control the remaining pressure in the boom cylinder
with the same controller as the transmission circuit during the disassembly and assembly
control system, so the speed sensor signal is operation. (The pressure release switch
also used inside the controller.) signal does not pass through the controller; it
can be input directly to the pressure release
4) Charge oil pressure switch: solenoid (SOL4).)
This detects the basic oil pressure of the
damper circuit and inputs it to the controller Self-diagnostic function:
as a digital (ON-OFF) signal. The controller always observes the system to
check that no abnormality has occurred in
5) Boom bottom oil pressure switch: the systems for the four solenoids at the
This detects the oil pressure of the boom output end.
cylinder bottom circuit and inputs it to the
controller as a digital (ON-OFF) signal. Network communication with main monitor:
If the self-diagnostic function detects any
6) Pressure release switch: abnormality, it communicates the details of
This switch is the drive power to the selector the abnormality through the network. (The
solenoid (SOL4) by the operation of the ECSS system carries out control with the
pressure release switch. (The signal from the same controller as the transmission control
pressure release switch does not pass system, so the network communication circuit
through the controller, and is output directly is used in both systems.)
to the selector solenoid (SOL4). It is actuated
at the same time has the normal return 3. Functions of equipment at output end.
solenoid valve (SOL1).) 1) Return solenoid valve (SOL1):
2. Control function of controller and the solenoid is driven to open or close
Damper function: the circuit between the boom cylinder head
To prevent pitching and bouncing of the circuit and the hydraulic tank.
bucket, the input signals from the switches
and sensors are output as a digital (ON-OFF)
20-253
2) High-pressure solenoid valve (SOL2):

and the solenoid is driven to open or close
the circuit between the boom cylinder bottom
circuit and the high-pressure accumulator.
3) High-pressure solenoid valve (SOL3):

the circuit between the boom cylinder bottom
circuit and the low-pressure accumulator.
4) Pressure release check solenoid valve

(SOL4):
The return solenoid valve (SOL1) and the
pressure release check solenoid valve
(SOL4) are turned ON-OFF through the
relay. The valve receives the signal from the
controller or the pressure release switch, and
the solenoid is driven to open or close the
circuit between the boom cylinder bottom
circuit and the damper (high-pressure, low-
pressure accumulator) circuit.
5) Accumulator pressure solenoid valve

(SOL5):
This receives the signal from the controller,
the circuit between the hydraulic pump circuit
and the damper (high-pressure, low-pressure
accumulator) circuit.
4. Main monitor display

For details, see MAIN MONITOR
SYSTEM.
2-254
-MEMORANDA-
20-255
JOYSTICK STEERING CONTROL SYSTEM
2-256
This section describes only the items related to Buzzer drive function:
steering in the joystick steering control system. If any abnormality occurs in the system, this
For details of the transmission, see turns the digital (ON-OFF) signal to the
TRANSMISSION CONTROL SYSTEM. caution relay OFF and actuates the buzzer.
Self-diagnostic function:
1. Functions of equipment at input end. The controller always observes the condition
1) Joystick ON-OFF switch: to check that there is no abnormality in the
This detects the condition of operation of the joystick potentiometer and joystick neutral
joystick ON-OFF switch and inputs it to the switch systems at the input end and the left
controller as a digital (ON-OFF) signal. and right steering solenoids, solenoid cut
relay, and caution relay systems at the output
2) System cut-off switch: end.
This detects the slide position of the joystick Network communication with main monitor:
lever stand and inputs it to the controller as a If the self-diagnostic function detects any
digital (ON-OFF) signal. abnormality, it communicates the details of
the abnormality to the main monitor through
3) Joystick neutral switch: the network. (The joystick control system
This detects the neutral position of the carries out control with the same controller
steering lever and inputs it to the controller as as the work equipment control system, so the
a digital (ON-OFF) signal. network communication circuit is used in both
systems.)
4) Joystick potentiometer:
This detects the angle of operation of the 3. Functions of equipment at output end
steering lever and inputs it to the controller as 1) Left, right steering solenoid valve This
an analog (current) signal. receives the signal from the controller and
drives the solenoid to control the solenoid
2. Control functions of controller. valve output pressure effortlessly.
System cut-off function:
This actuates or stops the system according 2) Steering neutral interlock relay:
to the signals from the system cutoff switch This receives the signal from the controller
and joystick ON-OFF switch. Joystick neutral and drives the solenoid to drive the neutral
interlock function When starting the engine, if safety relay when the engine is started.
the joystick is not at the neutral position, the
engine cannot be started. 3) Solenoid cut relay:
Steering function: This receives the signal from the controller
This calculates the signal from the steering and drives the solenoid to switch the circuit at
potentiometer and outputs an analog the return side of the steering solenoid ON-
(current) signal corresponding to this to the OFF.
left and right steering solenoids.
Solenoid stop function: 4) Caution relay:
If any abnormality occurs in the system, this This receives the signal from the controller
outputs a signal to the solenoid cut relay as a and drives the relay to switch the alarm
digital (ON-OFF) signal. buzzer circuit ON-OFF.
4. Main monitor display

For details, see MAIN MONITOR SYSTEM.
20-257
METHOD OF DISPLAYING ACTION

AND FAILURE CODE
1. Outline
The speedometer display on the main monitor is 4) If there are already 9 items in memory, and a
used to display the troubleshooting for each 10th failure occurs, the oldest item is deleted
control system. The nature of the and the new item is saved. It is possible to
troubleshooting is displayed as the failure action display the failure code and time elapsed
code, failure code, and the time elapsed since since failure for items saved in memory by
failure. The signals between the main monitor operating the main monitor set switch.
and each controller are transmitted in serial
through the network circuit. (Only the engine
controller uses a special parallel signal.)
2. Display of failure action code

This code informs the operator directly of the
abnormality, and takes action, such as stopping
the machine immediately. There are three types
of action code: EOO, EON + CALL (EON and
CALL are displayed alternately), and CALL. If a
failure occurs suddenly, one of these codes is
shown on the speedometer display.
3. Failure code and time elapsed since failure

The failures detected by each controller are
changed to a code and displayed. It is possible to
tell from this code which system in which
controller has failed, so carry out troubleshooting
for the applicable controller.
4. Saving failure code

The transmission controller writes the failure
codes to memory.
1) A total of 9 failure codes can be saved in
memory.
2) The data that is saved to memory is as fol-

lows:
A) Failure code
B) Time elapsed since failure (up to 1000
hours)
3) The failures are saved in the order that they

occur. If a failure code already exists in the
memory, the repeat failure code is not saved.
2-258
5. Switch operation procedure actuation

Switch operation Actuation
Trouble data memory

mode display
1) Stop engine The failure code is
2) Turn starting switch displayed on the
ON speedometer display
3) Push operation and the time elapsed
mode switch (1) since failure is
and head lamp displayed on the action
switch (2) code display.
simultaneously and If there is no failure,
keep pressed for at the speedometer
least 5 seconds. display shows [CC] and
the action code display
shows [0000].
Going to next failure

code
4) Press head lamp The failure code and
switch (2). time elapsed since
failure are displayed in
turn (when this is done,
the failure code for the
latest failure is
displayed first).
If the failure still exists,
the display flashes; if
the failure has been
restored, the display
lights up.
Clearing failure code

5) Keep rear lamp The failure and
switch (3) pressed elapsed time on the
for at least 2 display are cleared.
seconds. If the failure still exists,
the failure code is not
cleared.
Quitting trouble data

memory display mode
6) Push operation
mode switch (1)
and head lamp The display returns to
switch (2) the normal display.
simultaneously and
keep pressed for at
least 5 seconds. Or
start the engine.
20-259
TROUBLESHOOTING CHART OF ACTION CODES, FAILURE CODES, AND RE-ENACTION
CHART OF ACTION CODES, FAILURE CODES, AND RE-ENACTION

After an error occurs, turn the starting switch OFF, and if the display goes out, it is possible to re-enact the
problem as follows.
For details of the method of displaying the action codes and failure codes, see METHOD OF DISPLAYING
SELF DIAGNOSIS (ERROR CODE) AND SAVING TO MEMORY.
Re-enaction marks
Turn starting switch ON (with engine stopped)
Start engine
Carry out operation to actuate actuator.
1. Transmission controller
1) Transmission control system.
Main monitor Failure Item Failed system Re-enaction Memory Alarm

action code code buzzer
Short Discon- Short Discon-
circuit nection circuit nection
None 10 Back-up lamp relay O O O X
12 F ECMV solenoid O O O O
13 R ECMV solenoid O O O O
CALL 14 1st ECMV solenoid O O O O
15 2nd ECMV solenoid O O O O
16 3rd ECMV solenoid O O O O
17 4th ECMV solenoid O O O O
E00 19 Joystick directional switch O O O X
CALL 20 Directional switch signal O O O O
None 21 Range switch signal O O O X
22 Travel speed sensor X O O O

E00
23 Engine speed sensor O O O X
None 24 EEP ROM abnormality O X
E01+CALL 25 Transmission oil temperature sensor O X O O
2-260
Main monitor Failure Item Failed system Re-enaction Memory Alarm

action code code buzzer
Short Discon- Short Discon-
26 F ECMV fill switch O X O O
27 R ECMV fill switch O X O O
28 1st ECMV fill switch O X O O

CALL
29 2nd ECMV fill switch O X O O
30 3rd ECMV fill switch O X O O
31 4th ECMV fill switch O X O O
32 F, R ECMV fill switch X O O X

E00
33 1st, 2nd, 3rd, 4th ECMV fill switch X O O X
E23 (short circuit engine speed sensor) can only be detected if the machine is traveling at 4 km/h (3 mp/h) or more.
20-261
2) ECSS control system

Main Failure Item Failed system Re-enaction Memory Alarm
monitor code buzzer
action code Short Discon- Short Discon-
d0 Solenoid 1 (relief) O O O X
None d1 Solenoid 2 (high pressure) O O O X
d2 Solenoid 3 (high pressure) O O O X
d3 Solenoid 5 (high pressure) O O O X
2. Joystick controller
Main Failure Item Failed system Re-enaction Memory Alarm
monitor code buzzer
action code Short Discon- Short Discon-
None 56 Back-up lamp relay O O O X
57 F ECMV solenoid O O O O
58 R ECMV solenoid O O O O
59 1st ECMV solenoid O O O O

CALL
60 2nd ECMV solenoid O O O O
61 3rd ECMV solenoid O O O O
62 4th ECMV solenoid O O O O
E00 63 Joystick directional switch O O O O
E59 and E60 cannot be distinguished, so they are issued at the same time.
Disconnection cannot be detected for E56. It is always ON and is called up when there is a failure warning.
2-262
3. Action code table.

Action Transmission control system Joystick control system Action Action by
code buzzer operator
Problem system Action of machine Problem system Action of machine
Disconnection in Automatic gear Disconnection, Shifts to neutral Normal manual

travel speed sensor shifting not carried short circuit with (possible to switch gear shifting
system out (changes to ground, or short to manual) possible
manual gear circuit in joystick
shifting) FNR signal system
Disconnection, short Engine speed taken Normal

circuit, or as 2100 rpm (there operation
abnormality in is shock when possible but
__ __
E00 engine speed sensor shifting gear) No there is shock
system when shifting
gear
Disconnection in fill Clutch engaged Normal

switch with out fill signal operation
(there is shock possible but
__ __
when shifting gear) there is shock
when shifting
gear
Short circuit in Suitable gear Travel under

transmission oil shifting data for own power
temperature sensor transmission oil possible, move
E01 +
temperature cannot __ __ Yes to safe place
CALL
be selected (there then call for
is shock when service
shifting gear)
Short with ground in Shifts to neutral, Stop machine

fill switch travel impossible immediately,
__ __
(modulation output turn starting
OFF) switch OFF,
then call for
Disconnection, short Shifts to neutral, service
circuit with ground, travel impossible
__ __
or short circuit in (controller input
shift lever system judged as N)
CALL Disconnection, short Shifts to neutral, Yes

or short circuit in F,R (ECMV output __ __
ECMV solenoid OFF)
system
Disconnection, short Shifts to neutral,

or short circuit in (ECMV output __ __
speed range ECMV OFF)
solenoid system
20-263
TRANSMISSION CONTROLLER LED DISPLAY

The transmission controller uses two 7-segment LEDs to display the internal condition of the controller and
input/output errors. The display shows two characters at the same time, and changes these in turn to give the
display.
When the engine is started, “Program part No. display mode" appears, followed by "Output speed range
display mode". If there is any abnormality in the controller, it changes to "Troubleshooting mode".
The failure mode is saved to memory by the main monitor.
Method of displaying failure codes for transmission controller
Table 1 (Output speed range display mode)

Display Content Display Content
0. 1. NEUTRAL, 1st F. 4. FORWARD, 4th
0. 2. NEUTRAL, 2nd A. 1. REVERSE, 1st
0. 3. NEUTRAL, 3rd A. 2. REVERSE, 2nd
0. 4. NEUTRAL, 4th A. 3. REVERSE, 3rd
F. 1. FORWARD, 1st A. 4. REVERSE, 4th
F. 2. FORWARD, 2nd F. F. Neutral safety condition
F. 3. FORWARD, 3rd
2-264
TROUBLESHOOTING MEMORANDA
-MEMORANDA-
20-265
METHOD OF USING JUDGEMENT TABLE

This judgement table is a tool to determine if the problem with the machine is caused by an abnormality in the
electrical system or by an abnormality in the hydraulic or mechanical system. The symptoms are then used to
decide which troubleshooting table (E-00, H-00, etc.) matches the symptoms.
The judgement table is designed so that it is easy to determine from the self-diagnostic display which
troubleshooting table to go to.
The abnormality display given by the monitor panel leads directly to troubleshooting of the monitor system (M-
00, K-00, C-00).
(See troubleshooting of the machine monitor system)
[Method of using judgement table]

A 0 mark is put at the places where the failure mode and self-diagnostic display match, so check if an error
code is displayed on the graphic display portion of the monitor panel.
If an error code is displayed:

Go to the troubleshooting code at the bottom of the judgement table (E-00, etc.).
If there is a problem but no error code is displayed:

Go to the troubleshooting code on the right of the judgement table (H-00).
For failure modes where no 0 mark is given, go directly to the troubleshooting code on the right of the
judgement table.
2-266
-MEMORANDA-
20-267
TROUBLESHOOTING METHOD OF USING TROUBLESHOOTING CHARTS
METHOD OF USING JUDGEMENT CHARTS

1. Category of troubleshooting code number
Troubleshooting Code No. Component
S-00 Troubleshooting of engine system
T-00 Troubleshooting of transmission controller system
M-00 Troubleshooting of main monitor system
K-00 Troubleshooting of maintenance monitor system
E-00 Troubleshooting of electrical system
H-00 Troubleshooting of hydraulic, mechanical system
D-00 Troubleshooting of ECSS
J-00 Troubleshooting of joystick steering controller system
2. Method of using troubleshooting table

1) Troubleshooting code number and problem:
The top left of the troubleshooting chart gives the troubleshooting code number and the problem with the machine.
2) Distinguishing conditions:
Even with the same problem, the method of troubleshooting may differ according to the model, component, or problem.
In such cases, the troubleshooting chart is further divided into sections marked with small letters (for example, a), b)), so
go to the appropriate section to carry out troubleshooting.
If the troubleshooting table is not divided into sections, start troubleshooting from the first check item.
3) General precautions:
When using the troubleshooting chart, precautions that apply to all items are given at the top of the page and marked
with
The precautions marked
the check inside the box.
4) Method of following troubleshooting chart:
Check or measure the item inside E= , and according to the answer follow either the YES line or the NO line to go to
the next box. (Note: The number written at the top right corner of the box is an index number; it does not indicate
the order to follow.)
Following the YES or NO lines according to the results of the check or measurement will lead finally to the Cause
column. Check the cause and take the action given in the Remedy column on the right.
Below the box there are the methods for inspection or measurement, and the judgement values. If the judgement
values below the box are correct or the answer to the question inside the box is YES, follow the YES line; if the
judgement value is not correct, or the answer to the question is NO, follow the NO line.
Below the box is given the preparatory work needed for inspection and measurement, and the judgement values. If
this preparatory work is neglected, or the method of operation or handling is mistaken, there is danger that it may
cause mistaken judgement, or the equipment may be damaged. Therefore, before starting inspection or
measurement, always read the instructions carefully, and start the work in order from Item 1).
5) Troubleshooting tools:
When carrying out the troubleshooting, prepare the necessary troubleshooting tools. For details, see TOOLS FOR
TESTING, ADJUSTING, AND TROUBLESHOOTING.
6) Installation position, pin number:
A diagram or chart is given for the connector type, installation position, and connector pin number connection. When
carrying out troubleshooting, see this chart for details of the connector pin number and location for inspection and
measurement of the wiring connector number appearing in the troubleshooting flow chart.
2-268
METHOD OF USING TROUBLESHOOTING CHARTS TROUBLESHOOTING
<Example>
1) C-11 Monitor does not display abnormality, but warning lamp (CHECK lamp, CAUTION lamp) lights up.
2) Before carrying out troubleshooting, check that there is no abnormality display on the main monitor.
Before carrying out troubleshooting, check that all the related connectors are properly inserted.
Always connect any disconnected connectors before going on to the next step.
3) Division into a) CHECK lamp, and b) CAUTION lamp.
4) Main flow.
a) CHECK lamp.
b) CAUTION lamp.
C-11 Related electrical circuit diagram.
20-269
TROUBLESHOOTING METHOD OF USING MATRIX TROUBLESHOOTING TABLES
METHOD OF USING MATRIX TROUBLESHOOTING TABLES

The troubleshooting tables use the same method as for other troubleshooting table (YES/NO type) to locate the causes of failures
in the machine. The troubleshooting tables are divided broadly into categories for the main components, such as the steering
system and work equipment hydraulic system. Follow the procedure given below and carry out troubleshooting to locate the
problems accurately and swiftly.
Step 1. Questioning the operator 1. STEERING does not work symptom [Example]
The questions to ask the operator are given below the
failure symptom. If the answers to the questions match Ask the operator about the following points.
the information given, follow the arrow to reach the Did the steering suddenly stop working?
probable cause of the failure. Breakage in steering equipment
Consider the contents of the questions and consult the Had the steering gradually been becoming heavy?
table while proceeding to Steps 2 and 3 to grasp the Internal wear of steering equipment, defective seal
true cause.
Checks before starting [Example]
Step 2. Checks before troubleshooting Is the oil level in the hydraulic tank correct?
Before starting the main troubleshooting and Is the type of oil correct?
measuring the hydraulic pressure, first check the Is there any leakage of oil from the steering valve or
Checks before Starting items, and check for oil leakage Orbit-roll?
and loose bolts. These checks may avoid time wasted Has the safety bar been removed from the frame?
on unnecessary troubleshooting.
The items given under Checks before Starting are
items which must be considered particularly for that
symptom before starting troubleshooting.
Step 3. Using cross-reference table

1) Operate the machine to carry out the checks in
the troubleshooting item column. Mark the items
where the results match the symptom.
It is not necessary to follow the
troubleshooting checks in order; follow an
order which is easiest to carry out
troubleshooting.
2) Find the appropriate cause from the cause

column. If the symptom appears, the
that line indicate the possible causes. (For item No.
2 in the table on the right, the possible causes are
c or e.) If there is only one :
Carry out the other troubleshooting items (where
the same cause is marked with ), check if the
symptom appears, then repair.
If there are two :
Go on to Step 3) to narrow down the possible
causes.
20-270
METHOD OF USING MATRIX TROUBLESHOOTING TABLES TROUBLESHOOTING
3) Operate the machine and check the

troubleshooting items other than those in 1).
Operate the machine and check the items in the
same way as in 1), and if the symptom appears,
mark that item. (In the chart on the right, the
symptom appears again for item 5).
4) Find the appropriate cause from the cause

column. In the same way as in Step 2), if the
symptom appears, the marks on that line
indicate the possible causes. (For item No. 5 in the
table on the right, the possible causes are b or e.)
5) Narrow down the possible causes.

There is one common cause among the causes
located in Steps 2) and 4). (One cause marked
appears on the line for both items.) This cause is
common to both the symptoms in troubleshooting
Steps 1) and 3).
The causes which are not common to both
troubleshooting items (items which are not
marked for both symptoms) are unlikely
causes, so ignore them.
(in the example given on the right, the causes for
Troubleshooting Item 2 are c or e, and the cause
for Troubleshooting Item 5 are b or e, so cause e
is common to both.)
6) Repeat the operations in Steps 3), 4) and 5) until

one cause (one common cause) remains.
If the causes cannot be narrowed down to
one cause, narrow the causes down as far as
possible.
7) Remedy
If the causes are narrowed down to one common
cause, take the action given in the remedy column.
The symbols given in the remedy column
indicate the following:
X: Replace, : repair, A: Adjust, C: Clean
20-271
TROUBLESHOOTING METHOD OF USING MATRIX TROUBLESHOOTING TABLES
MEMORANDA
20-272
TROUBLESHOOTING OF TRANSMISSION
CONTROLLER SYSTEM
(T MODE)
Judgement table tor transmission controller system related parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-354

Action taken by controller when abnormality occurs and problems on machine . . . . . . . . . . . . . . . . . . . . . . . . 20-356
Electrical circuit diagram for transmission controller system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-364
T- 1 Failure code [10] (Short circuit, disconnection, short circuit with power source in back-up
lamp relay) is displayed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-366
T- 2 Failure code [12] (Short circuit, disconnection, short circuit with power source in F solenoid)
is displayed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-367
T- 3 Failure code [13] (Short circuit, disconnection, short circuit with power source in R solenoid)
is displayed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-368
T- 4 Failure code [14] (Short circuit, disconnection, short circuit with power source in 1st solenoid)
is displayed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-369
T- 5 Failure code [15] (Short circuit, disconnection, short circuit with power source in 2nd solenoid)
is displayed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-370
T- 6 Failure code [16] (Short circuit, disconnection, short circuit with power source in 3rd solenoid)
is displayed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-371
T- 7 Failure code [17] (Short circuit, disconnection, short circuit with power source in 4th solenoid)
is displayed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-372
T- 8 Failure code [19] (Short circuit, disconnection in joystick directional switch system) is displayed . . . . 20-373
T- 9 Failure code [201 (Short circuit, disconnection in directional switch system) is displayed . . . . . . . . . . 20-374
T-10 Failure code [211 (Short circuit, disconnection in range switch system) is displayed . . . . . . . . . . . . . . 20-378
T-11 Failure code [221 (Disconnection in travel speed sensor system) is displayed . . . . . . . . . . . . . . . . . . 20-381
T-12 Failure code [231 (Short circuit, disconnection in engine speed sensor system) is displayed . . . . . . . 20-382
T-13 Failure code [241 (Short circuit, disconnection in EEP ROM) is displayed . . . . . . . . . . . . . . . . . . . . . . 20-383
T-14 Failure code [251 (Short circuit in transmission oil temperature system) is displayed . . . . . . . . . . . . . 20-384
T-15 Failure code [26] (Short circuit in F ECMV fill switch system) is displayed . . . . . . . . . . . . . . . . . . . . . . 20-385
T-16 Failure code [27] (Short circuit in R ECMV fill switch system) is displayed . . . . . . . . . . . . . . . . . . . . . . 20-385
T-17 Failure code [281 (Short circuit in 1st ECMV fill switch system) is displayed . . . . . . . . . . . . . . . . . . . . 20-386
T-18 Failure code [291 (Short circuit in 2nd ECMV fill switch system) is displayed . . . . . . . . . . . . . . . . . . . 20-386
T-19 Failure code [301 (Short circuit in 3rd ECMV fill switch system) is displayed . . . . . . . . . . . . . . . . . . . . 20-387
20-351
TROUBLESHOOTING TABLE OF CONTENTS
T-20 Failure code [311 (Short circuit in 4th ECMV fill switch system) is displayed . . . . . . . . . . . . . . . . . . . . 20-387
T-21 Failure code [32] (Short circuit in F or R ECMV fill switch system) is displayed . . . . . . . . . . . . . . . . . . 20-388
T-22 Failure code [33] (Short circuit in 1st, 2nd, 3rd, or 4th ECMV fill switch system) is displayed . . . . . . . 20-390
T-23 Hold switch system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-392
T-24 Kick-down switch system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-392
T-25 Transmission cut-off signal system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-393
T-26 Neutralizer relay signal system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-394
T-27 Buzzer signal system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-395
T-28 Network system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-396
T-29 Transmission controller power source system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-397
T-30 Short circuit in travel speed sensor system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-398
T-31 Disconnection in transmission oil temperature sensor system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-399
T-32 Disconnection in F ECMV fill switch system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-400
T-33 Disconnection in R ECMV fill switch system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-400
T-34 Disconnection in 1st ECMV fill switch system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-401
T-35 Disconnection in 2nd ECMV fill switch system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-401
T-36 Disconnection in 3rd ECMV fill switch system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-402
T-37 Disconnection in 4th ECMV fill switch system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-402
20-352
20-353
TROUBLESHOOTING JUDGEMENT TABLE FOR TRANSMISSION CONTROLLER SYSTEM
JUDGEMENT TABLE FOR TRANSMISSION CONTROLLER

SYSTEM RELATED PARTS
20-354
JUDGEMENT TABLE FOR TRANSMISSION CONTROLLER SYSTEM TROUBLESHOOTING
20-355
TROUBLESHOOTING ACTION TAKEN BY CONTROLLER WHEN ABNORMALITY OCCURS
ACTION TAKEN BY CONTROLLER WHEN ABNORMALITY

OCCURS AND PROBLEMS ON MACHINE
(1) TRANSMISSION CONTROLLER SYSTEM
20-356
ACTION TAKEN BY CONTROLLER WHEN ABNORMALITY OCCURS TROUBLESHOOTING
20-357
20-358
20-359
20-360
20-361
20-362
20-363
TROUBLESHOOTING ELECTRICAL CIRCUIT DIAGRAM FOR TRANSMISSION CONTROLLER
ELECTRICAL CIRCUIT DIAGRAM FOR TRANSMISSION

CONTROLLER SYSTEM
20-364
ELECTRICAL CIRCUIT DIAGRAM FOR TRANSMISSION CONTROLLER TROUBLESHOOTING
20-365
TROUBLESHOOTING T-1
T-1 Failure code [10] (Short circuit, disconnection, short circuit with
power source in back-up lamp relay) is displayed
This troubleshooting is carried out when there is still an abnormality, so when disconnecting the connector
and inserting the T-adapter, or when removing the T-adapter and returning the connector to its original
position, if the error code is no longer displayed on the monitor display, the problem has been removed.
T-1 Related electrical circuit diagram
20-366
T-2 TROUBLESHOOTING
power source in F solenoid) is displayed
This troubleshooting is carried out when there is still an abnormality, so when disconnecting the connector and inserting
the T-adapter, or when removing the T-adapter and returning the connector to its original position, if the error code is no
longer displayed on the monitor display, the problem has been removed.
20-367
TROUBLESHOOTING T-3
power source in R solenoid) is displayed
20-368
T-4 TROUBLESHOOTING
power source in 1st solenoid) is displayed
20-369
TROUBLESHOOTING T-5
power source in 2nd solenoid) is displayed
20-370
T-6 TROUBLESHOOTING
power source in 3rd solenoid) is displayed
20-371
TROUBLESHOOTING T-7
power source in 4th solenoid) is displayed
20-372
T-8 TROUBLESHOOTING
T-8 Failure code [19] (Short circuit, disconnection in joystick

directional switch system) is displayed
20-373
TROUBLESHOOTING T-9
T-9 Failure code [20] (Short circuit, disconnection in directional switch

system) is displayed
20-374
T-9 TROUBLESHOOTING
20-375
TROUBLESHOOTING T-9
20-376
MEMORANDA
20-377
TROUBLESHOOTING T-10
T-10 Failure code [21] (Short circuit, disconnection in range switch

20-378
T-10 TROUBLESHOOTING
20-379
20-380
T-11 Failure code [22] (Disconnection in travel speed sensor system)is

displayed
20-381
T-12 Failure code [23] (Short circuit, disconnection in engine speed

sensor system) is displayed
20-382
T-13 Failure code [24] (Short circuit, disconnection in EEP ROM) is displayed
20-383
T-14 Failure code [25] (Short circuit in transmission oil temperature

20-384
T-15, T-16 TROUBLESHOOTING
T-15 Failure code [26] (Short circuit in F ECMV fill switch system) is
displayed
T-16 Failure code [27] (Short circuit in R ECMV fill switch system) is
displayed
This troubleshooting is carried out when there is still an abnormality, so when disconnecting the connector and
inserting the T-adapter, or when removing the T-adapter and returning the connector to its original position, if the error
code is no longer displayed on the monitor display, the problem has been removed.
20-385
TROUBLESHOOTING T-17, T-18
T-17 Failure code [28] (Short circuit in 1st ECMV fill switch system) is
displayed
T-18 Failure code [29] (Short circuit in 2nd ECMV fill switch system) is
displayed
20-386
T-19, T-20 TROUBLESHOOTING
T-19 Failure code [30] (Short circuit in 3rd ECMV fill switch system) is
displayed
Before carrying out troubleshooting, check that all the related connectors are property inserted.
T-20 Failure code [31] (Short circuit in 4th ECMV fill switch system) is
displayed
20-387
T-21 Failure code [32] (Short circuit in F or R ECMV fill switch system)
is displayed
20-388
MEMORANDA
20-389
T-22 Failure code [33] (Short circuit in 1st, 2nd, 3rd, or 4th ECMV fill
switch system) is displayed
20-390
20-391
T-23 Hold switch system

Always turn the starting switch OFF before disconnecting the connector or connecting the T-adapter (or socket).
T-24 Kick-down switch system
20-392
20-393
T-25 Transmission cut-off signal system

20-394
T-26 Neutralizer relay signal system

Check that the parking brake works normally.
Always turn the starting switch OFF before disconnecting the connector or connecting the T-adapter.
20-395
T-27 Buzzer signal system

Check that the main monitor and alarm buzzer work normally.
20-396
T-28 Network system

20-397
T-29 Transmission controller power source system

Check that fuse 11 @ is normal.
20-398
T-30 Short circuit in travel speed sensor system

20-399
T-31 Disconnection in transmission oil temperature sensor system

20-400
T-32 Disconnection in F ECMV fill switch system

T-33 Disconnection in R ECMV fill switch system

20-401
T-34 Disconnection in 1st ECMV fill switch system

T-35 Disconnection in 2nd ECMV fill switch system

20-402
T-36 Disconnection in 3rd ECMV fill switch system

T-37 Disconnection in 4th ECMV fill switch system

20-403
20-404
TROUBLESHOOTING OF MAIN MONITOR

SYSTEM
(M MODE)
Trouble data display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-453

Electrical circuit diagram for machine monitor system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-456
Electrical circuit diagram for lamp and horn system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-458
Electrical circuit diagram for turn signal and hazard system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-459
M- 1 Main monitor does not work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-460
M- 2 When starting switch is turned ON and engine is started immediately, all lamps stay
lighted up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-461
M- 3 Speedometer display does not work properly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-462
M- 4 Abnormality in shift indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-463
a) Displays N even when directional lever is at F . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-463
b) Displays N even when directional lever is at R . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-463
c) Does not display N even when directional lever is at N, and displays R when
directional lever is at F . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-463
d) Does not display N even when directional lever is at N, and displays R
when directional lever is at F . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-464
e) Does not display 1st - 4th . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-464
M- 5 High beam does not light up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-465
M- 6 Turn signal display does not light up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-466
a) L.H. turn signal display does not light up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-466
b) R.H. turn signal display does not light up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-466
M- 7 Abnormality in parking display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-467
a) Parking lamp display does not light up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-467
b) Parking lamp display stays lighted up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-467
M- 9 Night lighting does not light up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-469
M-10 Abnormality in front working lamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-470
a) Neither monitor display nor front working lamp light up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-470
b) Working lamp lights up but monitor display does not light up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-470
c) Monitor display lights up but working lamp does not light up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-470
M-11 Abnormality in rear working lamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-472
a) Neither monitor display nor rear working lamp light up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-472
b) Working lamp lights up but monitor display does not light up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-472
c) Monitor display lights up but working lamp does not light up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-472
M-12 Abnormality in transmission cut-off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-474

a) When monitor switch (transmission cut-off switch) is pressed, cut-off function is
not switched and display does not change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-474
b) When monitor switch (transmission cut-off switch) is OFF, monitor display goes
out but cut-off function is actuated when pedal is depressed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-474
c) When monitor display is turned off (transmission cut-off switch turned OFF),
cut-off function is always actuated . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-474
d) Cut-off function is always actuated regardless of monitor display
(transmission cut-off switch ON or OFF) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-474
e) Monitor display lights up (transmission cut-off switch turned ON), but
20-451
cut off function is not actuated . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-475

M-13 Abnormality in parking brake dragging warning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-476
a) When parking brake is applied, buzzer sounds (intermittently) and caution lamp
flashes even when directional lever is at N . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-476
b) When parking brake is applied, buzzer does not sound and caution lamp
does not light up even when directional lever is at position other than N . . . . . . . . . . . . . . . . . . . . . . 20-476
M-14 When parking brake dragging warning is given, buzzer and caution lamp are actuated
continuously, or they are not actuated . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-478
a) Actuated continuously . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-478
b) Not actuated . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-478
M-15 Abnormality in buzzer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-479
a) Buzzer does not sound when starting switch is at ON (for 3 seconds)
(during self-check) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-479
b) Buzzer always sounds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-479
M-16 Condition of monitor switches is not stored in memory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-480
M-17 Abnormality in failure display mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-481
a) Does not enter failure display mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-481
b) Count for time elapsed since failure in failure display mode does not advance . . . . . . . . . . . . . . . . . 20-481
M-18 Buzzer is not made to sound by transmission controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-482
M-19 Abnormality in emergency steering normal display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-483
a) Emergency steering normal display does not light up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-483
b) Emergency steering normal display stays lighted up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-483
M-20 Abnormality in emergency steering actuation display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-484
a) Emergency steering actuation display does not light up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-484
b) Emergency steering actuation display stays lighted up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-484
M-21 Abnormality in auto-greasing system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-486
a) Forced greasing cannot be carried out . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-486
b) Monitor display flashes rapidly (2 times/sec) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-486
c) When no more grease remains, monitor display flashes rapidly (2 times/sec) . . . . . . . . . . . . . . . . . . 20-486
d) Monitor display flashes slowly (1time/sec), confirm that grease is not empty . . . . . . . . . . . . . . . . . . . 20-487
e) Monitor display goes out . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-487
M-22 Abnormality in ECSS system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-488
a) Display does not change when switch is pressed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-488
b) Monitor display lights up but ECSS function does not work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-488
M-23 Failure code is not sent to main monitor (abnormality in network) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-489
20-452
TROUBLE DATA DISPLAY TROUBLESHOOTING
TROUBLE DATA DISPLAY

1. Outline
The speedometer display on the main monitor is used
to display the troubleshooting for each control system.
The nature of the troubleshooting is displayed as the
failure action code, failure code, and the time elapsed
since failure. The signals between the main monitor
and each controller are transmitted in serial through
the network circuit. (Only the engine controller uses a
special parallel signal.)
2. Display of failure action code

This code informs the operator directly of the
abnormality, and takes action, such as stopping the
machine immediately.
There are three types of action codes: E00, E01 +
CALL (E01 and Call are displayed alternately), and
CALL. If a failure occurs suddenly, one of these codes
is shown on the speedometer display.
3. Failure code and time elapsed since failure

The failures detected by each controller are changed
to a code and displayed. It is possible to tell from this
code which system in which controller has failed, so
carry out troubleshooting for the applicable controller.
For failure that have occurred and been reset, the
failure code and the time elapsed since the failure are
displayed to make it easy to check failures that are not
occurring at present.
The failure codes for failures that are now occurring
flash, and codes for failures that are not occurring
light up.
For details of the method of operating and transferring
data to the trouble data display mode, see
STRUCTURE AND FUNCTION for the main monitor.
Note: If the engine is not stopped, it is impossible
to switch to the trouble data display mode,
so the codes for failures which can only be
detected when the engine is operating light
up.
For the correspondence between the failure codes for
each controller and the failed system, see item 4.
20-453
TROUBLESHOOTING TROUBLE DATA DISPLAY
4. Action code table

Action Transmission control system ECSS control system Action Action by
code Buzzer operator
Problem system Action of machine Problem system Action of machine
Disconnection in travel Automatic gear shifting Normal manual

speed sensor system not carried out (changes __ __ gear shifting
to manual gearshifting) possible
Disconnection, short Engine speed taken as Normal

circuit, or abnormality 2100 rpm (there is operation
in engine speed sensor shock when shifting possible but
__ __
system gear) there is shock
E00 No when shifting
gear
Disconnection in fill Clutch engaged with out Normal

switch fill signal (there is shock operation
when shifting gear) possible but
__ __
there is shock
when shifting
gear
Short circuit in Suitable gearshifting Travel under

transmission oil data for transmission oil own power if
E01
temperature sensor temperature can not be possible, move
+ __ __ Yes
selected (there is shock to safe place
CALL
when shifting gear) then call for
service
Short circuit with Shifts to neutral, travel

ground in fill switch impossible (modulation __ __
output OFF)
Disconnection, short Shifts to neutral, travel

circuit with ground, or impossible (controller
__ __
short circuit in shift input judged as N) Stop machine
lever system immediately,
turn starting
CALL Yes
Disconnection, short Shifts to neutral, travel switch OFF,
circuit with ground, or impossible (ECMV then call for
__ __
short circuit in F, R output OFF) service
ECMV solenoid system
Disconnection, short Shifts to neutral, travel

circuit with ground, or impossible (ECMV
__ __
short circuit in speed output OFF)
range solenoid system
20-454
TROUBLE DATA DISPLAY TROUBLESHOOTING
Action Joystick control system Action Action by

code Buzzer operator
Problem system Action of machine
Disconnection, short
circuit with ground, or Shifts to neutral Normal manual
E00 short circuit in joystick (possible to switch to __ __ No gear shifting
FNR signal system manual) possible
E01
+ __ __ __ __ __ __
CALL
CALL __ __
__ __ __ __
20-455
TROUBLESHOOTING ELECTRICAL CIRCUIT DIAGRAM FOR MACHINE MONITOR SYSTEM
ELECTRICAL CIRCUIT DIAGRAM FOR MACHINE MONITOR SYSTEM
20-456
ELECTRICAL CIRCUIT DIAGRAM FOR MACHINE MONITOR SYSTEM TROUBLESHOOTING
20-457
TROUBLESHOOTING ELECTRICAL CIRCUIT DIAGRAM FOR LAMP AND HORN SYSTEM
ELECTRICAL CIRCUIT DIAGRAM FOR LAMP AND HORN SYSTEM
20-458
ELECTRICAL CIRCUIT DIAGRAM FOR TURN SIGNAL/HAZARD SYSTEM TROUBLESHOOTING
ELECTRICAL CIRCUIT DIAGRAM FOR TURN SIGNAL AND

HAZARD SYSTEM
20-459
TROUBLESHOOTING M-1
M-1 Main monitor does not work

20-460
M-2 TROUBLESHOOTING
M-2 When starting switch is turned ON and engine is started

immediately, all lamps stay lighted up
20-461
TROUBLESHOOTING M-3
M-3 Speedometer display does not work properly

Check that the gap between the speed sensor and gear is normal.
20-462
M-4 TROUBLESHOOTING
M-4 Abnormality in shift indicator

Check that the transmission shifts.
20-463
TROUBLESHOOTING M-4
20-464
M-5 TROUBLESHOOTING
M-5 High beam does not light up

Before starting troubleshooting, check that the lamp bulb is not blown.
20-465
TROUBLESHOOTING M-6
M-6 Turn signal display does not light up

Before starting troubleshooting, check that the lamp bulb of the turn signal indicator on the monitor is not blown.
20-466
M-7 TROUBLESHOOTING
M-7 Abnormality in parking display

20-467
TROUBLESHOOTING M-8
-MEMORANDA-
20-468
M-9 TROUBLESHOOTING
M-9 Night lighting does not light up

Before starting troubleshooting, check that the lamp bulbs are not blown.
Check that fuse 1-6 is normal. If it is blown, check for a short circuit with the chassis ground in the wiring harness between
FS2 (female) (5) and L05 (female) (16).
20-469
TROUBLESHOOTING M-10
M-10 Abnormality in front working lamp

Before starting troubleshooting, check that the monitor lighting is lighted up.
20-470
M-10 TROUBLESHOOTING
M-10 Related electrical circuit diagram
20-471
M-11 Abnormality in rear working lamp

Before starting troubleshooting, check that the monitor lighting is lighted up.
20-472
20-473
M-12 Abnormality in transmission cut-off

20-474
20-475
M-13 Abnormality in parking brake dragging warning

20-476
20-477
M-14 When parking brake dragging warning is given, buzzer and

caution lamp are actuated continuously, or they are not actuated
20-478
M-15 Abnormality in buzzer

20-479
M-16 Condition of monitor switches is not stored in memory

20-480
M-17 Abnormality in failure display mode

20-481
M-18 Buzzer is not made to sound by transmission controller

20-482
M-19 Abnormality in emergency steering normal display

20-483
M-20 Abnormality in emergency steering actuation display

20-484
-MEMORANDA-
20-485
M-21 Abnormality in auto-greasing system

20-486
20-487
M-22 Abnormality in ECSS system

ECSS : Electronic Controlled Suspension System.
20-488
M-23 Failure code is not sent to main monitor (abnormality in network)

Set dipswitch 3 at the rear of the main monitor to 'F".
MDC: Multiple Display and Condition.
20-489
-MEMORANDA -
20-490
TROUBLESHOOTING OF MAINTENANCE
MONITOR SYSTEM
(K MODE)

K- 1 When starting switch is turned ON, all lamps on maintenance monitor do not light up
for 3 seconds, maintenance monitor does not work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-506
a) No lamps on maintenance monitor light up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-506
b) Some lamps do not light up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-506
K-2 When starting switch is turned ON, all lamps on maintenance monitor light up but
do not go out (even after 3 seconds) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-507
K- 3 When engine is started immediately after starting switch is turned ON
(within 3 seconds), no lamps on maintenance monitor go out . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-508
K- 4 When starting switch is turned ON (engine stopped), CHECK items flash . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-509
a) Engine oil level display flashes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-509
b) Engine water level display flashes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-510
K- 5 When starting switch is turned ON (engine started), CAUTION items flash . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-511
a) Engine oil pressure display flashes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-511
b) Battery charge level display flashes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-512
c) Brake oil pressure display flashes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-513
d) Air cleaner display flashes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-514
K- 6 CAUTION items are flashing but caution buzzer does not sound . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-515
K-7 There is no abnormality in monitor display but caution buzzer sounds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-516
K-8 CAUTION items are flashing but warning lamp (CHECK lamp, CAUTION lamp) does
not flash . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-517
a) CHECK lamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-517
b) CAUTION lamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-517
K- 9 There is no abnormality in maintenance monitor display but warning lamp
(CHECK lamp, CAUTION lamp) lights up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-518
a) CHECK lamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-518
b) CAUTION lamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-518
K-10 Night lighting does not light up when lamp switch is turned ON (only lighting of maintenance
monitor does not light up) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-519
K-11 Night lighting lights up even when lamp switch is OFF, night lighting stays lighted up . . . . . . . . . . . . . . . . . . . 20-520
K-12 Service meter does not work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-521
20-501
K-13 Service meter is running even when engine is stopped . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-521

K-14 Abnormality in gauge items . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-522
a) Abnormality in fuel gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-522
b) Abnormality in engine water temperature gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-523
c) Abnormality in torque converter oil temperature gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-524
20-502
20-503
20-504
20-505
TROUBLESHOOTING K-1
K-1 When starting switch is turned ON, all lamps on maintenance

monitor do not light up for 3 seconds, maintenance monitor does
not work
before carrying out troubleshooting, check that all the related connectors are properly inserted.
20-506
K-2 TROUBLESHOOTING
K-2 When starting switch is turned ON, all lamps on maintenance

monitor light up but do not go out (even after 3 seconds)
20-507
TROUBLESHOOTING K-3
K-3 When engine is started immediately after starting switch is turned

ON (within 3 seconds), no lamps on maintenance monitor go out
20-508
K-4 TROUBLESHOOTING
K-4 When starting switch is turned ON (engine stopped), CHECK items

flash
a) Engine oil level display flashes

Before starting troubleshooting, check the engine oil level to make sure it is correct.
20-509
TROUBLESHOOTING K-4
20-510
K-4 TROUBLESHOOTING
b) Engine water level display flashes

Before starting troubleshooting, check the engine water level again. (Check that the water level is correct).
20-511
TROUBLESHOOTING K-5
K-5 When starting switch is turned ON (engine started), CAUTION items

flash
20-512
K-5 TROUBLESHOOTING
20-513
TROUBLESHOOTING K-5
20-514
K-5 TROUBLESHOOTING
20-515
TROUBLESHOOTING K-6
K-6 CAUTION items are flashing but caution buzzer does not sound
The buzzer does not sound for CHARGE or ENGINE OIL LEVEL
check that fuse 1-10 is normal. If it is blown, check for a short circuit with the chassis ground in the wiring harness between
fuse 1-10 - FS2 (9) - L42.
20-516
TROUBLESHOOTING K-7
K-7 There is no abnormality in monitor display but caution buzzer

sounds
Before carrying out troubleshooting, check that there is no abnormality display on the main monitor.
20-517
TROUBLESHOOTING K-8
K-8 CAUTION items are flashing but warning lamp (CHECK lamp,
CAUTION lamp) does not flash
Before carrying out troubleshooting, check that there are no blown lamp bulbs.
20-518
TROUBLESHOOTING K-9
K-9 There is no abnormality in maintenance monitor display but warning

lamp (CHECK lamp, CAUTION lamp) lights up
Always connect any disconnected connectors before going on to the next step
20-519
TROUBLESHOOTING K-10
K-10 Night lighting does not light up when lamp switch is turned ON (only
lighting of maintenance monitor does not light up)
20-520
K-11 Night lighting lights up even when lamp switch is OFF night lighting
stays lighted up
20-521
TROUBLESHOOTING K-12, K-13
K-12 Service meter does not work

K-13 Service meter is running even when engine is stopped

20-522
K-14 TROUBLESHOOTING
K-14 Abnormality in gauge items

a) Abnormality in fuel gauge

Before carrying out troubleshooting, check the fuel level and make sure the level is correct.
20-523
b) Abnormality in engine water temperature gauge
20-524
K-14 TROUBLESHOOTING
c) Abnormality in torque converter oil temperature gauge
20-525
TROUBLESHOOTING OF ELECTRICAL SYSTEM

(E MODE)
Electrical circuit diagram for power supply, engine starting / stop system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-552
Electrical circuit diagram for parking brake system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-553
Electrical circuit diagram for lamp and horn system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-554
Electrical circuit diagram for boom kick-out and bucket positioner system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-555
Electrical circuit diagram for transmission controller system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-556
E- 1 Engine does not start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-558
a) Starting motor does not turn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-558
b) Starting motor turns . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-562
E- 2 Engine does not stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-564
E- 3 Engine stops when machine is traveling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-564
E- 4 Not used
E- 5 Parking brake does not have effect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-567
a) Parking brake has no effect when parking brake switch is turned ON (actuated) . . . . . . . . . . . . . . . 20-567
b) Parking brake has no effect when brake pressure drops
(Does not work as emergency brake) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-567
E- 6 Parking brake is applied when machine is traveling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-568
E- 7 Parking brake is released when starting switch is turned ON . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-570
E- 8 Transmission does not change to neutral when parking brake is applied
(But parking brake works normally) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-570
E- 9 Kick-down switch does not work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-572
a) Kick-down switch does not work (shift works correctly during normal gear
shift operations) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-572
b) Kick-down is not canceled . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-573
E-10 Boom kick-out cannot be used . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-574
E-11 Abnormality in bucket positioner function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-578
E-12 Abnormality in lighting up of front working lamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-581
E-13 Abnormality in lighting up of rear working lamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-581
E-14 Abnormality in transmission cut-off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-581
E-15 Abnormality in parking brake dragging warning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-581
E-16 Abnormality in buzzer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-581
20-551
TROUBLESHOOTING ELECTRICAL CIRCUIT DIAGRAMS
ELECTRICAL CIRCUIT DIAGRAM FOR POWER SUPPLY,

ENGINE STARTING / STOP SYSTEM
20-552
ELECTRICAL CIRCUIT DIAGRAMS TROUBLESHOOTING
20-553
ELECTRICAL CIRCUIT DIAGRAM FOR PARKING BRAKE SYSTEM
20-554
ELECTRICAL CIRCUIT DIAGRAM FOR LAMP AND HORN SYSTEM
20-555
ELECTRICAL CIRCUIT DIAGRAM FOR BOOM KICK-OUT AND

BUCKET POSITIONER SYSTEM
20-556
ELECTRICAL CIRCUIT DIAGRAM FOR TRANSMISSION

CONTROLLER SYSTEM
20-557
20-558
E-1 TROUBLESHOOTING
E-1 Engine does not start

When connecting or disconnecting the T-adapter (or socket adapter) or short connector to carry out checks, always turn the
starting switch OFF before starting.
When connecting the T-adapter (or socket adapter), connect to the connector specified as CNOA( ).
After checking, connect the disconnected connectors and disconnect the T-adapter immediately to return to the original
condition before going on to the next check.
a) Starting motor does not turn
20-559
TROUBLESHOOTING E-1
20-560
E-1 TROUBLESHOOTING
20-561
TROUBLESHOOTING E-1
20-562
E-1 TROUBLESHOOTING
b) Starting motor turns
20-563
TROUBLESHOOTING E-1
20-564
E-1 TROUBLESHOOTING
E-2 Engine does not stop

E-3 Engine stops when machine is traveling

Check if the starting motor turns. If it does not turn, check E-1, a) Starting motor does not turn.
20-565
TROUBLESHOOTING E-2, E-3
E-1, E-2, E-3 Related electrical circuit diagram
20-566
E-1, E-2, E-3 TROUBLESHOOTING
-MEMORANDA-
20-567
TROUBLESHOOTING E-4
E-5 Parking brake does not have effect
When carrying out troubleshooting of the brake system, stop the machine on flat ground.
When connecting the T-adapter (or socket adapter), connect to the connector specified as CNOA().
20-568
E-6 TROUBLESHOOTING
E-6 Parking brake is applied when machine is traveling

When carrying out troubleshooting of the brake system, stop the machine on flat ground.
20-569
TROUBLESHOOTING E-6
20-570
E-6 TROUBLESHOOTING
E-7 Parking brake is released when starting switch is turned ON

When connecting the T-adapter (or socket adapter), connect to the connector specified as CNOL( ).
E-8 Transmission does not change to neutral when parking brake is

applied (but parking brake works normally)
20-571
TROUBLESHOOTING E-7, E-8
E-6, E-7, E-8 Related electrical diagram
20-572
E-9 TROUBLESHOOTING
E-9 Kick-down switch does not work

a) Kick-down switch does not work (shift works correctly during normal gear shift operations)
20-573
TROUBLESHOOTING E-9
b) Kick-down is not canceled
20-574
E-10 TROUBLESHOOTING
E-10 Boom kick-out cannot be used

Check that fuse I (10) is normal. If it is blown, check for a short circuit with the ground in the wiring harness between fuse I
(10) - FS2 (10) - L49 (3) - LR2 (1) - FR2 (1) - F06 (female) (1), or FS2 (10) - L32 (1) - L33 (1) - L40 (female) (1)
20-575
TROUBLESHOOTING E-10
20-576
E-10 Related electrical circuit diagram
20-577
-MEMORANDA -
20-578
E-11 Abnormality in bucket positioner function

Check that fuse I (10) is normal. If it is blown, check for a short circuit with the ground in the wiring harness between fuse I
(10) - FS2 (10) - L48 (1), (3), or FS2 (10) - LR2 (1) - FR2 (1) - F05 (female) (1)
Figure 284
20-579
20-580
E-11 Related electrical circuit diagram
20-581
E-12 Abnormality in lighting up of front working lamp

Go to Troubleshooting M-10.
E-13 Abnormality in lighting up of rear working lamp

Go to Troubleshooting M-11
E-14 Abnormality in transmission cut-off

Go to Troubleshooting M-12.
E-15 Abnormality in parking brake dragging warning

Go to Troubleshooting M-13, M-14.
E-16 Abnormality in buzzer

Go to Troubleshooting M-15, M-18.
20-582
E-12, E-13, E-14, E-15, E-16 TROUBLESHOOTING
-MEMORANDA -
20-583
TROUBLESHOOTING OF HYDRAULIC AND

MECHANICAL SYSTEM
(H MODE)
Power train
H- 1 Machine does not start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-602
H- 2 Travel speed is slow, thrusting power is weak, lacks power on slopes,
Does not shift gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-605
H- 3 Excessive shock when starting machine of shifting gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-609
H- 4 Excessive time lag when starting machine of shifting gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-611
H- 5 Torque converter oil temperature is high . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-613
Steering system
H- 6 Steering does not turn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-614
H- 7 Steering does not turn (machine with joystick) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-615
H- 8 Turning, response of steering is poor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-616
H- 9 Turning, response of steering is poor (machine with joystick) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-618
H-10 Steering is heavy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-620
H-11 Joystick is heavy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-620
H-12 Steering wheel shakes or jerks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-621
H-13 Steering shakes or there is excessive shock (machine with joystick) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-622
H-14 Turning radius is different between left and right at maximum steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-623
Brake system
H-15 Wheel brakes do not work or braking effect is poor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-624
H-16 Wheel brakes are not released or brakes drag . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-626
H-17 Parking brake does not work or braking effect is poor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-627
H-18 Parking brake is not released or brake drags (including emergency release system) . . . . . . . . . . . . . . . . . . . . 20-628
Work equipment
H-19 Neither boom nor bucket move . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-629
H-20 Both boom and bucket are slow or lack power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-630
H-21 Boom does not move . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-631
H-22 Not used
H-23 Boom is slow or boom lacks power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-633
H-24 Not used
H-25 Boom cannot be set to FLOAT or cannot be released from FLOAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-635
H-26 Boom drops momentarily when control lever is operated from HOLD to RAISE . . . . . . . . . . . . . . . . . . . . . . . . 20-635
H-27 Not used
H-28 Excesseve hydraulic drift of boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-637
H-29 Bucket does not move . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-638
H-30 Bucket is slow or lacks power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-639
H-31 Excesseve hydraulic drift of bucket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-640
H-32 ECSS does not work, and there is pitching and bouncing (machines with ECSS) . . . . . . . . . . . . . . . . . . . . . . 20-641
20-601
TROUBLESHOOTING H-1
H- 1 Machine does not start

Ask the operator the following questions. Is the transmission oil level correct? Is the type of
Did the problem suddenly start? oil correct?
Yes = Clutch seized, part broken Is the transmission oil deteriorated? Does the oil
Was there any abnormal noise when this happened? smell of burning?
Where did the noise come from? Is the transmission filter or strainer clogged? Is
there any damage or leakage of oil that can be
Checks before troubleshooting seen externally?
Does the main monitor function properly? Is the drive shaft broken?
Is any failure code for the electrical system displayed on Is the wheel brake or parking brake locked?
the main monitor?
20-602
H-1 TROUBLESHOOTING
20-603
TROUBLESHOOTING H-1
Method of determining defective clutch and ECMV (check using failure code)
For details of the method for checking the failure code display, see 'Method of displaying action code and failure code' and
'Action code and failure code table and re-enaction"
When replacing the ECMV and carrying out troubleshooting, remove all mud and dirt from around the ECMV, then wash it
and tighten the mounting bolts to the specified tightening torque.
Carry out the following troubleshooting with the manual mode for starting the engine.
20-604
H-2 TROUBLESHOOTING
H-2 Travel speed is slow, thrusting power is weak, lacks power on

slopes, does not shift gear
Ask the operator the following questions.
Did the problem suddenly start?
Yes = Related equipment broken
Was there any abnormal noise when this happened?
Where did the noise come from?
Did the problem gradually appear?
Yes = Wear of related parts, defective seal
Checking for abnormalities

Measure digging operations and speed when traveling
on level ground and on slopes, and check if there is
actually an abnormality or whether it is just the feeling
of the operator.
Checks before troubleshooting

Is the failure code for the electrical system displayed on
the monitor?
Is the transmission oil level correct? Is the type of oil
correct?
Is the transmission filter or strainer clogged?
Is there any oil leaking from the joints of the piping or
valves around the torque converter or transmission?
Is there any dragging of the wheel brake or parking
brake?
Is the tire inflation pressure and tread pattern correct?
Is the method of operation correct?
Note: If it is judged that there is a drop in the engine
performance, go to troubleshooting of the
engine system (S mode).
20-605
TROUBLESHOOTING H-2
20-606
H-2 TROUBLESHOOTING
20-607
TROUBLESHOOTING H-2
For details of the method for checking the failure code display, see 'Method of displaying action code and failure code" and
20-608
H-3 TROUBLESHOOTING
H-3 Excessive shock when starting machine or shifting gear

Ask the operator the following questions. Checks before troubleshooting
Did the problem suddenly start? Is the failure code for the electrical system
Yes = Related equipment broken displayed on the monitor?
Was there any abnormal noise when this happened? Is the transmission oil level correct? Is the type of
Where did the noise come from? Did the problem oil correct?
gradually appear? Is the transmission filter or strainer clogged?
Yes = Wear of related parts, defective seal Is there any oil leaking from the joints of the piping
or valves around the torque converter or
Checking for abnormalities transmission?
Is the travel speed slow, is the thrusting force weak,
does the machine lack power when traveling uphill, is it
impossible to shift gear, or are there any other
abnormalities occurring at the same time?
Yes = Carry out Troubleshooting H-2
Defective operation of solenoid or defective operation of pressure control valve spool and flow detector valve spool caused by
dirt.
Go to “Method of determining defective clutch and ECMV (check using failure code)”.
20-609
TROUBLESHOOTING H-3
For details of the method for checking the failure code display, see 'Method of displaying action code and failure code" and
"Action code and failure code table and re-enaction"
20-610
H-4 TROUBLESHOOTING
H-4 Excessive time lag when starting machine or shifting gear

Did the problem suddenly start? Is the failure code for the electrical system
Yes = Related equipment broken displayed on the monitor?
Was there any abnormal noise when this happened? Is the transmission oil level correct? Is the type of
Where did the noise come from? oil correct?
Did the problem gradually appear? Is the transmission filter or strainer clogged?
Yes = Wear of related parts, defective seal Is there any oil leaking from the joints of the piping
or valves around the torque converter or
Checking for abnormalities transmission?
Is the travel speed slow, is the thrusting force weak,
does the machine lack power when traveling uphill, is it
impossible to shift gear, or are there any other
abnormalities occurring at the same time?
Yes = Carry out Troubleshooting H-2
Defective operation of solenoid or defective operation of pressure control valve spool and flow detector valve spool caused by
dirt in the spool.
Go to “Method of determining defective clutch and ECMV (check using failure code)”.
20-611
TROUBLESHOOTING H-4
For details of the method for checking the failure code display, see "Method of displaying action code and failure code" and
20-612
H-5 TROUBLESHOOTING
H-5 Torque converter oil temperature is high

Does oil temperature rise during torque converter stall Are the radiator water level and fan belt tension
and go down when there is no load? correct?
Yes = Improper selection of transmission range Is the transmission oil level correct? Is the type of
Does oil temperature rise only when carrying out oil correct?
scooping work? Is the transmission filter or strainer clogged?
Yes = Improve method of operation
Note: If it is judged that there is a drop in the engine
Checking for abnormalities performance, go to troubleshooting of the engine
Measure the torque converter oil temperature. Is it system (S mode).
actually high?
No = Defective oil transmission gauge
20-613
TROUBLESHOOTING H-6
H-6 Steering wheel does not turn

Did the problem suddenly start? Is the oil level in the hydraulic tank correct? Is the
Yes = Related equipment broken type of oil correct?
Was there any abnormal noise when this happened? Is the steering shaft broken?
Where did the noise come from? Is the stop valve stopper properly adjusted?
Has the safety bar been removed from the frame?
There is a close connection between the steering circuit and the work equipment circuit, so if any abnormality is felt in the
steering, check the operation of the work equipment also.
20-614
H-7 TROUBLESHOOTING
H-7 Steering does not turn [machine with joystick]

Did the problem suddenly start? Is the oil level in the hydraulic tank correct? Is the
Yes = Related equipment broken type of oil correct?
Was there any abnormal noise when this happened? Is the steering shaft broken?
Where did the noise come from? Is the stop valve stopper properly adjusted?
Has the safety bar been removed from the frame?
Is the operation of the steering and the steering
mode switch correct?
20-615
TROUBLESHOOTING H-8
- MEMORANDA -
20-616
H-8 TROUBLESHOOTING
H-8 Turning, response of steering is poor

Did the problem suddenly start? Is the oil level in the hydraulic tank correct?
Yes = Related equipment broken Is the type of oil correct?
20-617
TROUBLESHOOTING H-8
-MEMORANDA -
20-618
H-9 TROUBLESHOOTING
H-9 Turning, response of steering is poor [machine with joystick]

Was there previously any symptom, such as difficulty in
steering?
Yes = Wear of related equipment, defective seal
20-619
TROUBLESHOOTING H-9
- MEMORANDA -
20-620
H-9 TROUBLESHOOTING
20-621
TROUBLESHOOTING H-10, H-11
H-10 Steering is heavy

Checking for abnormalities Checks before troubleshooting
Is the steering difficult to turn? Is the oil level in the hydraulic tank correct?
Yes = Go to H-8 or H-9 Is the type of oil correct?
Measure the operating effort and turning speed, and Is the tire inflation pressure correct?
check the STANDARD VALUE TABLE to see if they
are abnormal.

Was there previously any symptom, such as heavy
steering?
Yes = Wear of related equipment, defective seal
H-11 Joystick steering is heavy (machines equipped with joystick)

Causes and remedy
Abnormality of joystick (X)
(The joystick is an electrically operated lever, so if the operating effort is large, the abnormality is in the joystick).
20-622
H-12 TROUBLESHOOTING
H-12 Steering wheel shakes or jerks

Is the steering difficult to turn? Is the steering wheel play correct?
Yes = Go to H-8 Is there any abnormality in the connection between
Is there any abnormal noise from around the steering the steering shaft and the Orbit-roll?
equipment? Is the tire inflation pressure correct?
20-623
TROUBLESHOOTING H-13
H-13 Steering shakes or there is excessive shock [machine with joystick]

Is the steering difficult to turn? Is any failure code for the electrical system
Yes = Go to H-9 displayed on the main monitor?
Is there any abnormal noise from around the steering Is the steering wheel play correct?
equipment? Is there any abnormality in the connection between
the steering shaft and the Orbit-roll?
Is the tire inflation pressure correct?
20-624
H-14 Turning radius is different between left and right at maximum

steering
Causes and Remedy
Defective adjustment of stop valve (
20-625
H-15 Wheel brakes do not work or braking effect is poor

Measure the actual brake performance, and check if Is the oil level in the hydraulic tank correct? Is the
there is actually an abnormality or whether it is just the type of oil correct?
feeling of the operator. For details, see TESTING AND Is the brake pedal play correct?
ADJUSTING, Measuring brake performance. Is there any leakage of oil from the brake tube? Is
there any deformation of the tube?
Ask the operator the following questions. Is the tire inflation pressure and tread pattern
Did the problem suddenly start? correct?
The PPC pump is used for the wheel brake actuation pressure in the same way as for the work equipment circuit and
steering circuit, so if any abnormality is felt in the wheel brake, check the condition of actuation of the work equipment and
steering also. (The circuit set pressure is different).
20-626
20-627
H-16 Wheel brakes are not released or brakes drag

Did the problem suddenly start? Does the brake pedal come back fully?
Yes = Related equipment broken Is the parking brake still applied?
20-628
H-17 Parking brake does not work or braking effect is poor

Did the problem suddenly start? Is parking brake emergency release switch open?
Yes = Related equipment broken (Normally it is open)
Was there any abnormal noise when this happened? Is parking brake mechanical release operation
Where did the noise come from? being carried out?
20-629
H-18 Parking brake is not released or brake drags (including emergency

release system)
is there any abnormality in the power train system?
Yes = Carry out Troubleshooting H-1 - H-4
(Power train hydraulic system)
The power train main relief pressure is used for the parking brake release pressure, so if any abnormality is felt in the parking
brake release system, check the condition of actuation of the power train (the emergency release circuit uses the wheel brake
circuit presure).
20-630
H-19 Neither boom nor bucket move

20-631
H-20 Both boom and bucket are slow or lack power

20-632
H-21 Boom does not move

20-633
-MEMORANDA -
20-634
H-23 Boom is slow or boom lacks power

20-635
-MEMORANDA -
20-636
H-25, H-26 TROUBLESHOOTING
H-25 Boom cannot be set to FLOAT or cannot be released from FLOAT

Did the problem suddenly start? Can other operations of boom (RAISE, HOLD,
Yes = Related equipment broken LOWER) be carried out normally?
H-26 Boom drops momentarily when control lever is operated from HOLD
to RAISE
With the engine running at low idling, if the boom control lever is gradually moved from HOLD to RAISE, the boom moves
down momentarily under its own weight.
If the control lever is operated fully to the RAISE position, the condition becomes normal.
Causes and Remedy

Defective slow return check valve for control valve boom spool (X) or (
20-637
-MEMORANDA -
20-638
H-28 Excessive hydraulic drift of boom

Note: Before starting troubleshooting, the PPC accumulator must be charged, so run the engine at low idling for 5 - 10
seconds, then stop the engine.
20-639
H-29 Bucket does not move

20-640
H-30 Bucket is slow or lacks power

20-641
H-31 Excessive hydraulic drift of bucket

Note: Before starting troubleshooting, the PPC accumulator must be charged, so run the engine at low idling for 5 - 10
seconds, then stop the engine.
20-642
H-32 ECSS does not work, and there is pitching and bouncing [machines
with ECSS]
Ask the operator the following questions Checks before troubleshooting
Did the problem suddenly start? Is operation of ECSS switch correct?
20-643
-MEMORANDA -
20-644
TROUBLESHOOTING OF ECSS
(ELECTRONICALLY CONTROLLED
SUSPENSION SYSTEM)
(D MODE)
Judgement table for controller electrical system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-652
Electrical circuit diagram for ECSS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-654
D-1 ECSS does not work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-655
a) Error code [d0] is displayed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-656
b) Error code [d1] is displayed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-656
c) Error code [d2] is displayed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-657
d) Error code [d3] is displayed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-657
e) No abnormality display is given . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-659
D-2 ECSS cannot be canceled . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-662
20-651
TROUBLESHOOTING JUDGEMENT TABLE FOR CONTROLLER ELECTRICAL SYSTEM
JUDGEMENT TABLE FOR CONTROLLER ELECTRICAL SYSTEM

ECSS CONTROL SYSTEM
Failure code Abnormal system Nature of abnormality
1) Defective sol 1 and sol 14 relays.

2) Short circuit with power source, short circuit with ground, defective
contact, or disconnection in wiring harness between transmission
controller C1 (female) (3) and ECSS relay L90 (1).
d0 sol 1 (relief) and sol 14 relay 3) Defective contact or disconnection in wiring harness between sol 1
and sol 14 relay L90 (female) (2) and chassis ground.
4) Defective transmission controller.
1) Defective sol 2.
controller C1 (female) (10) - ECSS (2) - AF2 (1).
d1 sol 2 (high pressure) 3) Defective contact or disconnection in wiring harness between sol 2
connector AF2 (female) (2) and chassis ground.
1) Defective sol 3.
d2 sol 3 (low pressure) 3) Defective contact or disconnection in wiring harness between sol 3
connector AF3(female) (2) and chassis ground.
1) Defective sol 5.
d3 sol 5 3) Defective contact or disconnection in wiring harness between sol 5
connector AF5 (female) (2) and chassis ground.
20-652
JUDGEMENT TABLE FOR CONTROLLER ELECTRICAL SYSTEM TROUBLESHOOTING
Condition when normal (Voltage, current, resistance) Action by controller Problem that appears Trouble-
when abnormality is on machine when there shooting
detected is abnormality code
1) Resistance of relay coil: 200 - 400

2) Resistance of wiring harness between transmission
controller C1 (female) (3) and ECSS relay L90 (female)
(1): Max. 1 D-1
3) Voltage between transmission controller C1 (3) and a)
chassis ground: Less than 1 V (Command OFF); 20 V or
above (Command ON).
4) Resistance of wiring harness between ECSS relay L90
(female) (2) and chassis ground: Max. 1
1) Resistance of solenoid: 30 - 80
2) Voltage between transmission controller C1 (10) and
chassis ground at neutral: Less than 1 V.
3) Resistance between transmission controller C1 (female)
(10) and chassis ground: Min. 1 M D-1
4) Resistance of wiring harness between transmission b)
controller C1 (female) (10) - ECSS (2) - AF2 (1): Less
than 1
5) Resistance between sol 2 connector AF2 (2) - chassis
ground: Less than 1 ECSS function: OFF Swaying (pitching,
bouncing) of machine
1) Resistance of solenoid: 30 - 80 when traveling at high
2) Voltage between transmission controller C1 (5) and speed (2nd - 4th)
4) Resistance of wiring harness between transmission c)
controller C1 (female) (5) - ECSS (3) - AF3 (1): Less than
1
ground: Less than 1
1) Resistance of solenoid: 30 - 80
2) Voltage between transmission controller C1 (9) and
4) Resistance of wiring harness between transmission d)
controller C1 (female) (9) - ECSS (7) - AF5 (1): Less than
1
ground: Less than 1
20-653
TROUBLESHOOTING ELECTRICAL CIRCUIT DIAGRAM FOR ECSS
ELECTRICAL CIRCUIT DIAGRAM FOR ECSS
20-654
D-1 TROUBLESHOOTING
D-1 ECSS does not work

Carry out troubleshooting with the starting switch ON.
Check that the ECSS switch on the main monitor is ON.
20-655
TROUBLESHOOTING D-1
20-656
D-1 TROUBLESHOOTING
20-657
TROUBLESHOOTING D-1
D-1 a), b), c), d) Related electrical circuit diagram
20-658
D-1 TROUBLESHOOTING
e) No abnormality display is given

(1) Does not work at all
Before starting troubleshooting, check that the main monitor dipswitch is set to ON for ECSS function.
20-659
TROUBLESHOOTING D-1
20-660
D-1 TROUBLESHOOTING
20-661
TROUBLESHOOTING D-2
D-2 ECSS cannot be canceled

20-662
TROUBLESHOOTING OF JOYSTICK STEERING

CONTROLLER SYSTEM
(J MODE)
Judgement table for joystick controller system related parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-702
Action taken by controller when abnormality occur . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-704
Electrical circuit diagram for joystick system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-708
J- 1 Failure code [56] (short circuit, disconnection in caution relay output) is displayed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-709
J- 2 Failure code [57] (short circuit in steering right solenoid (detected when output)
is displayed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-710
J- 3 Failure code [58] (short circuit in steering left solenoid (detected when output)
is displayed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-711
J- 4 Failure code [59] (short circuit in steering right solenoid (HOT end) is displayed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-712
J- 5 Failure code [60] (short circuit in steering left solenoid (HOT end) is displayed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-713
J- 6 Failure code [61] (short circuit, disconnection in steering solenoid cut relay output)
is displayed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-714
J- 7 Failure code [62] (short circuit, disconnection in joystick steering neutral signal)
is displayed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-715
J- 8 Failure code [63] (short circuit, disconnection in joystick steering lever potentiometer
system) is displayed (Not used) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-716
J- 9 Abnormality in power source, voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-717
J-10 Abnormality in joystick steering ON-OFF signal system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-718
J-11 Disconnection in steering right solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-719
J-12 Disconnection in steering left solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-720
20-701
TROUBLESHOOTING JUDGEMENT TABLE FOR JOYSTICK CONTROLLER SYSTEM
JUDGEMENT TABLE FOR JOYSTICK CONTROLLER SYSTEM

RELATED PARTS
20-702
JUDGEMENT TABLE FOR JOYSTICK CONTROLLER SYSTEM TROUBLESHOOTING
-MEMORANDA-
20-703
TROUBLESHOOTING ACTION TAKEN BY CONTROLLER WHEN ABNORMALITY OCCUR
ACTION TAKEN BY CONTROLLER WHEN ABNORMALITY OCCUR

JOYSTICK CONTROLLER SYSTEM
1) Defective caution relay

2) Short circuit with ground, defective contact, or disconnection in
wiring harness between work equipment controller L28 (female)
56 Joystick caution relay system (13) and JS8 (1)
3) Defective contact or disconnection in wiring harness between
caution relay J8 (female) (2) and chassis ground
4) Defective work equipment controller
57 Steering (R) (right) sol. System 1) Defective R sol

2) Defective steering solenoid cut relay
3) Short circuit in wiring harness between work equipment controller
L26 (female) (6) and (16)
Short circuit with ground, defective contact, or disconnection in the
following wiring harness:
4) Wiring harness between work equipment controller L26 (female)
(6) and R (2)
(16) and JS9 (3)
6) Wiring harness between steering solenoid cut relay JS9 (5) and
R (1)
1) Defective L sol
2) Defective steering solenoid cut relay
3) Short circuit in wiring harness between work equipment controller
L26 (female) (7) and (16)
Short circuit with ground, defective contact, or disconnection in the
following wiring harness:
58 Steering (L) (left) sol. System 4) Wiring harness between work equipment controller L26 (female)
(7) and L (2)
(16) and JS9 (3)
6) Wiring harness between steering solenoid cut relay JS9 (5) and L
(1)
Short circuit with power source 1) Defective R sol

59 in wiring harness between 2) Short circuit with power source in wiring harness between work
steering (R) (right) sol. System equipment controller L26 (female) (6) and R (2)
Short circuit with power source 1) Defective L sol

60 in wiring harness between 2) Short circuit with power source in wiring harness between work
steering (L) (left) sol. System equipment controller L26 (female) (7) and L (2)
20-704
ACTION TAKEN BY CONTROLLER WHEN ABNORMALITY OCCUR TROUBLESHOOTING
Condition when normal (voltage, current, resistance) Action by controller Problem that appears Trouble-
when abnormality is on machine when shooting
detected there is abnormality code
1) Joystick caution relay: ON (voltage between L28 (15) and Caution output: OFF Joystick caution
chassis ground: 20 - 30 V) actuated
2) Resistance of relay coil between work equipment controller
L28 (female) (13) and J chassis ground: 200 - 400
3) Resistance of wiring harness between work equipment J-1
controller L28 (female) (13) and caution relay JS8 (female)
(1): Less than 1
4) Resistance of wiring harness between caution relay JS8
(female) (2) and chassis ground: Less than 1
1) Steering solenoid cut relay: ON (voltage between L26 (8) Steering R, L solenoid Impossible to use
and chassis groung: 20 - 30 V) output: OFF joystick
2) Resistance of steering R solenoid: 10 - 20 and steering solenoid and joystick caution
3) Resistance between work equipment controller L26 (female) cut relay output: OFF actuated
(6), (16) and chassis ground: Min. 1M and caution relay: OFF
Resistance of the following wiring harness: Less than 1 J-2
4) Wiring harness between work equipment controller L26
(female) (6) - R (female) (2)
(female) (16) - JS9 (female) (3)
6) Wiring harness between steering solenoid cut relat JS9
(female) (5) and L (female (1)
1) Steering solenoid cut relay: ON (voltage between L26 (8) Steering R, L solenoid Impossible to use
and chassis groung: 20 - 30 V) output: OFF joystick
2) Resistance of steering L solenoid: 10 - 20 and steering solenoid and joystick caution
3) Resistance between work equipment controller L26 (female) cut relay output: OFF actuated
(7), (16) and chassis ground: Min. 1M and caution relay: OFF
Resistance of the following wiring harness: Less than 1 J-3
(female) (7) - L (female) (2)
(female) (16) - JS9 (female) (3)
6) Wiring harness between steering solenoid cut relat JS9
(female) (5) and L (female (1)
Joystick lever at neutral Steering R, L solenoid Impossible to use

Voltage between work equipment controller L26 (female) (6) output: OFF joystick J-4
and chassis ground: Less than 1 V and steering solenoid and joystick caution
cut relay output: OFF actuated
and caution relay: OFF
Joystick lever at neutral Steering R, L solenoid Impossible to use

Voltage between work equipment controller L26 (female) (6) output: OFF joystick
and chassis ground: Less than 1 V and steering solenoid and joystick caution J-5
20-705
TROUBLESHOOTING ACTION TAKEN BY CONTROLLER WHEN ABNORMALITY OCCUR
1) Defective steering sol relay

wiring harness between work equipment controller L26 (female) (8)
61 Steering sol. cut relay system and JS9 (1)
NEUTRAL SW (1) and chassis ground
1) Defective joystick neutral SW

wiring harness between work equipment controller L27 (female)
62 Joystick neutral SW system (17) - D01 (2), (1) - NEUTRAL SW (3)
NEUTRAL SW (1) and chassis ground
63 Joystick potentiometer system 1) Defective boom angle potentiometer

contact, or disconnection in wiring harness between work
equipment controller L27 (female) (20) and JS7 (1)
20-706
ACTION TAKEN BY CONTROLLER WHEN ABNORMALITY OCCUR TROUBLESHOOTING
Condition when normal (voltage, current, resistance) Action by controller Problem that appears Trouble-
when abnormality is on machine when shooting
detected there is abnormality code
Resistance between work equipment controller L27 (female) Steering R, L solenoid Impossible to use
(17) and chassis ground: Min. 1 M output: OFF joystick
Less than 1 and steering solenoid and joystick caution J-6
Voltage between work equipment controller L27 (female) (20) Steering R, L solenoid Impossible to use
and L27 (9): 0.5 - 4.5 V output: OFF joystick
(voltage when joystick is at neutral: Approx. 2.5 V) and steering solenoid and joystick caution J-7
1) Steering solenoid cut relay: ON (voltage between L26 (8) Steering R, L solenoid Impossible to use J-8
and chassis ground: 20 - 30 V) output: OFF joystick
2) Resistance of relay coil between work equipment controller and steering solenoid and joystick caution
L28 (female) (8) and chassis ground: 200 - 400 cut relay output: OFF actuated
3) Resistance of wiring harness between work equipment and caution relay: OFF
controller L28 (female (8) and JS9 (female) (1)
4) Resistance of wiring harness between steering solenoid cut
relay JS9 (female) (2) and chassis ground: Less than
1
20-707
TROUBLESHOOTING ELECTRICAL CIRCUIT DIAGRAM FOR JOYSTICK SYSTEM
ELECTRICAL CIRCUIT DIAGRAM FOR JOYSTICK SYSTEM
20-708
J-1 TROUBLESHOOTING
J-1 Failure code [56] (Short circuit, disconnection in caution relay

output) is displayed
When the joystick steering lever is not being used, leave it at the neutral position and turn the joystick steering selector switch
ON.
Always turn the starting switch OFF before disconnecting any connector
20-709
TROUBLESHOOTING J-2
J-2 Failure code [57] (Short circuit in steering right solenoid (detected
when output)) is displayed
This troubleshooting is carried out when there is still an abnormality, so when disconnecting the connector and inserting the
T-adapter, or when removing the T-adapter and returning the connector to its original position, if the failure code is no longer
displayed on the monitor display, the problem has been removed.
ON.
20-710
J-3 TROUBLESHOOTING
J-3 Failure code [58] (Short circuit in steering left solenoid (detected
when output)) is displayed
ON.
20-711
TROUBLESHOOTING J-4
J-4 Failure code [59] (Short circuit in steering right solenoid (HOT end)
is displayed
ON.
20-712
J-5 TROUBLESHOOTING
J-5 Failure code [60] (Short circuit in steering left solenoid (HOT end) is
displayed
ON.
Always turn the starting switch OFF before disconnecting any connector to connect the T-adapter (or socket adapter).
20-713
TROUBLESHOOTING J-6
J-6 Failure code [61] (Short circuit, disconnection in steering solenoid

cut relay output) is displayed
ON.
20-714
J-7 TROUBLESHOOTING
J-7 Failure code [62] (Short circuit, disconnection in joystick steering

neutral signal) is displayed
ON.
20-715
-MEMORANDA-
20-716
J-9 TROUBLESHOOTING
J-9 Abnormality in power source, voltage

Check that fuse I (11) is normal.
ON.
20-717
TROUBLESHOOTING J-10
J-10 Abnormality in joystick steering ON-OFF signal system

Check that fuse I (11) is normal.
ON.
20-718
J-11 TROUBLESHOOTING
J-11 Disconnection in steering right solenoid

ON.
20-719
TROUBLESHOOTING J-12
J-12 Disconnection in steering left solenoid

ON.
20-720
TROUBLESHOOTING OF MDC (MULTIPLE DISPLAY

AND CONDITION) MONITOR SYSTEM
(C MODE)
Electrical circuit diagram for MDC (Multiple Display and Condition) monitor system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-804
C- 1 When engine is running, engine oil level display shows “Abnormal” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-808
C- 2 When engine is running, battery electrolyte level display shows “Abnormal” . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-809
C- 3 Abnormality in engine coolant level display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-810
a) Display shows “Abnormal” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-810
b) Display shows “Disconnection” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-810
c) Display shows “Short circuit” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-810
C- 4 Abnormality in brake oil pressure display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-812
a) When engine is running, display shows “Abnormal” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-812
b) Display shows “Disconnection” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-813
c) Display shows “Short circuit” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-813
C- 5 Abnormality in engine oil pressure display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-814
a) When engine is running, display shows “Abnormal” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-814
b) When engine is stopped or running, display shows “Disconnection” . . . . . . . . . . . . . . . . . . . . . . . . . 20-814
c) Only when engine is stopped, display shows “Disconnection” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-814
d) Display shows “Short circuit” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-815
C- 6 When starting switch is at “ON”(engine started), battery charge display shows “Abnormal” . . . . . . . . . . . . . . 20-816
C- 7 When starting switch is at “ON”(engine started), air cleaner display shows “Abnormal” . . . . . . . . . . . . . . . . . 20-817
C- 8 CAUTION item display shows “Abnormal”, but alarm buzzer does not sound . . . . . . . . . . . . . . . . . . . . . . . . . 20-818
C- 9 Monitor display does not show “Abnormality”, but alarm buzzer sounds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-819
C-10 CAUTION item display shows “Abnormal”, but warning lamp (CHECK lamp,
CAUTION lamp) does not flash . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-820
a) CHECK lamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-820
b) CAUTION lamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-820
C-11 Monitor display does not show any abnormality, but warning lamp (CHECK lamp,
CAUTION lamp) lights up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-821
a) CHECK lamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-821
b) CAUTION lamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-821
C-12 Service meter does not work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-822
C-13 Service meter is running when engine is stopped . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-822
C-14 Abnormality in fuel gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-823
a) Display shows “Disconnection”or low fuel level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-823
b) Display always shows FULL and does not go down . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-823
C-15 Abnormality in engine coolant temperature gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-824
a) Display shows “Short circuit” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-824
b) Display always shows lowest level and does not go up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-824
20-801
C-16 Abnormality in torque converter oil temperature gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-825

a) Display shows “Short circuit” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-825
b) Display always shows lowest level and does not go up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-825
C-17 When starting switch is turned ON, monitor is not actuated (KOMATSU is not displayed . . . . . . . . . . . . . . . . 20-826
a) Main monitor CHECK lamps do not light up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-826
b) Main monitor CHECK lamps light up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-827
C-18 Does not switch to working memory (engine running) mode, or switches to check
before starting mode when engine is running . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-828
C-19 Abnormality in MDC monitor display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-829
a) Display color is abnormal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-829
b) Display flickers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-829
C-20 Even when switch is operated, nothing functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-830
C-21 Does not switch to TV/video mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-832
a) Stays at PARKING BRAKE APPLIED display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-832
b) Display does not light up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-834
C-22 Abnormality in memory data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-836
a) Load meter data is not saved to memory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-836
b) Maintenance time is not saved to memory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-836
C-23 Engine speed stays at 0 rpm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-837
C-24 Pressure sensor display shows “Disconnection” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-838
a) Sensor power source display also shows “Abnormal”. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-838
b) Only pressure sensor display shows “Disconnection” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-838
C-25 Load meter cannot weigh load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-839
a) Cannot carry out calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-839
b) Can carry out calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-840
C-26 Abnormality in lever switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-841
a) Sub-total switch does not work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-841
b) Cancel switch does not work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-841
C-27 Printer does not print out . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-842
C-28 Abnormality in antenna system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-843
C-29 Abnormality in speaker system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-844
a) Abnormality in right speaker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-844
b) Abnormality in left speaker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-844
20-802
20-803
TROUBLESHOOTING ELECTRICAL CIRCUIT DIAGRAM FOR MDC MONITOR SYSTEM
ELECTRICAL CIRCUIT DIAGRAM FOR MDC (MULTIPLE DISPLAY AND

CONDITION) MONITOR SYSTEM
20-804
ELECTRICAL CIRCUIT DIAGRAM FOR MDC MONITOR SYSTEM TROUBLESHOOTING
20-805
20-806
20-807
TROUBLESHOOTING C-1
C-1 When engine is running, engine oil level display shows "Abnormal'
Before starting troubleshooting, check the engine oil level again. (The engine oil level must be correct.)
20-808
C-2 TROUBLESHOOTING
C-2 When engine is running, battery electrolyte level display shows

"Abnormal"
Check that the cell where the battery electrolyte level sensor is installed is normal.
20-809
TROUBLESHOOTING C-3
C-3 Abnormality in engine coolant level display

Before starting troubleshooting, check the engine coolant level again. (The engine coolant level must be correct.)
20-810
C-3 TROUBLESHOOTING
20-811
TROUBLESHOOTING C-4
C-4 Abnormality in brake oil pressure display

20-812
C-4 TROUBLESHOOTING
20-813
TROUBLESHOOTING C-5
C-5 Abnormality in engine oil pressure display

20-814
C-5 TROUBLESHOOTING
20-815
TROUBLESHOOTING C-6
C-6 When starting switch is at ON (engine started), battery charge

display shows "Abnormal"
20-816
C-7 TROUBLESHOOTING
C-7 When starting switch is at ON (engine started), air cleaner display shows
"Abnormal"
Check that the air cleaner is not clogged.
20-817
TROUBLESHOOTING C-8
C-8 CAUTION item display shows “Abnormal”, but alarm buzzer does
not sound
The buzzer does not sound for CHARGE or AIR CLEANER.
Check that fuse 1-10 is normal. If it is blown, check for a short circuit with the chassis ground in the wiring harness between
fuse 1-10 - FS2 (9) - L42 (1).
20-818
C-9 TROUBLESHOOTING
C-9 Monitor display does not show “Abnormal”, but alarm buzzer
sounds
20-819
TROUBLESHOOTING C-10
C-10 CAUTION item display shows “Abnormal”, but warning lamp

(CHECK lamp, CAUTION lamp) does not flash
20-820
C-11 TROUBLESHOOTING
C-11 Monitor display does not show any abnormality, but warning lamp
(CHECK lamp, CAUTION lamp) lights up
20-821
TROUBLESHOOTING C-12, C-13
C-12 Service meter does not work

C-13 Service meter is running when engine is stopped

20-822
C-14 Abnormality in fuel gauge

Before starting troubleshooting, check the fuel level again.
20-823
C-15 Abnormality in engine water temperature gauge

20-824
C-16 Abnormality in torque converter oil temperature gauge

20-825
C-17 When starting switch is turned to ON, monitor is not actuated

(KOMATSU is not displayed)
20-826
b) Main monitor CHECK lamps light up

Check that the WAITING display on the remote control receiver portion of the monitor is flashing.
It will flash if the chamber temperature is high, so in this case, lower the chamber temperature.
20-827
C-18 Does not switch to working memory (engine running) mode, or

switches to check before starting mode when engine is running
20-828
C-19 Abnormality in MDC monitor display
20-829
C-20 Even when switch is operated, nothing functions

Before starting troubleshooting, check that there is no mistake in the operation of the switch.
20-830
- MEMORANDA -
20-831
C-21 Does not switch to TV/video mode

After turning the starting switch ON, keep the TV/video mode switch pressed for at least 2 seconds.
If the parking brake switch (indicator switch) is not ON, the system does not switch to this mode.
20-832
20-833
20-834
20-835
C-22 Abnormality in memory data

20-836
C-23 Engine speed stays at 0 rpm

20-837
C-24 Pressure sensor display shows "Disconnection"

20-838
C-25 Load meter cannot weigh load

20-839
20-840
C-26 Abnormality in lever switch

20-841
C-27 Printer does not print out

Check that the printer power is switched on.
Check that the paper is set properly and that the platen lever is lowered.
20-842
TROUBLESHOOTING AIR CONDITIONING TROUBLESHOOTING
C-28 Abnormality in antenna system

20-843
C-29 Abnormality in speaker system

20-844
TROUBLESHOOTING AIR CONDITIONING TROUBLESHOOTING
TROUBLESHOOTING AIR CONDITIONING
Air conditioner / heater (Denso) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-902

Visual and audible inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-902
Troubleshooting with manifold gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-903
Troubleshooting the electrical circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-907
Cooler circuit troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-911
Wiring diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-919
20-901
TROUBLESHOOTING AIR CONDITIONER / HEATER
AIR CONDITIONER / HEATER

(DENSO)
TROUBLESHOOTING
Visual and Audible Inspection
Is the drive belt loose?

Are condenser fins blocked or clogged -- covered with
dirt or dust (condenser and air conditioner efficiency
both will suffer)?
Is the air filter clogged (clogged air filter will reduce air
flow and lower the cooling capacity)?
Are oil stains present in the refrigeration cycle
connections and joints (stains are evidence of
compressor oil, usually accompanied by refrigerant)?
Does the system contain the correct refrigerant quantity
as seen in the sight glass (only a small quantity of
bubbles appear)?
Is the system louder than usual (abnormal noise)?
Component Check these items
Compressor Shaft, cylinder head
Magnetic clutch Worn or damaged bearing

Contact between stator and rotor
Loose mounting screw on stator
Blower motor Upside down blower motor

Loose blower mounting
V-belt Improper tension
Idle pulley Worn mounting

Worn or damaged bearing
Piping parts Improper fastening or mounting of

bracket or clamp
Incorrect clearance.
20-902
AIR CONDITIONER / HEATER TROUBLESHOOTING
Troubleshooting with manifold gauge (refrigeration

cycle)
Trouble often can be detected and diagnosed for repair with

the help of a manifold gauge. The manifold gauge unit
indicates the refrigeration system pressure on both sides
(high and low pressure sides) simultaneously on the two
dials.
NOTE: Be sure air has been purged from the

charging hoses of the manifold gauge by
using the refrigerant pressure in the system.
Normal Conditions
After engine warm-up, check the following conditions:
Engine speed 1500 rpm
A/C inlet temperature 30-35
Blower speed HI
Temperature control Maximum cooling
NOTE: Gauge indications before A/C operation, both

high and low pressure sides: 5-8 kg/cm² (0.5 -
0.8 Mpa).
(B) Insufficient refrigerant
Problem Cause Check and

remedy
Pressure low on Quantity of -Check for gas

both low refrigerant is too leak and repair.
pressure side small.
and the high Replenish
pressure side refrigerant.
Bubbles visible in If pressure near

sight glass Gas leakage 0, evacuate air
after repairing
Air output is not leak.
cool
20-903
(C ) Refrigerant fails to circulate (system clogged)

remedy
Vacuum is Clogging of -Check condition

immediately A/C system. of receiver,
indicated on low expansion valves,
pressure side etc.
(completely
clogged). -A temperature
difference occurs
Vacuum between IN and
gradually OUT of the
indicated on low defective parts.
pressure side -Evacuate air after
(partially repair.
clogged).
(D) Moisture in system

remedy
Normal Moisture in -Check condition

operation at first; expansion valve of expansion
vacuum on low freezes. valve, etc.
pressure side is -Replace receiver
indicated after (or dryer)
time. -Evacuate air
after repair.
20-904
(E) Compressor failure

remedy
Pressure on low Compressor -Check

pressure side is defect. compressor
high; pressure condition.
on high pressure -Compressor unit
side is low. is cool to the
touch if there is a
When the A/C is compression
turned off, the malfunction.
low and high
pressure sides
quickly equalize.
(F) Excessive refrigerant or insufficient condenser cooling

remedy
Pressure high Excessive -Check refrigerant

on both sides. refrigerant. quantity and slowly
Bubbles not vent excess if
visible in the Poor overcharged.
sight glass. condenser -Check and repair
Poor cooling cooling. condenser fan.
performance. -Check engine
cooling system
20-905
(G) Air in the system

remedy
Pressure high Air has entered -Replace the

on both sides. the system. refrigerant.
Low pressure is -Evacuate the air
hot to the touch. after the repair.
Bubbles are
visible in the
sight glass.
(H) Expansion valve opens too far

remedy
Pressure is high Expansion valve -Check

on both sides. fault (problem condition of
Frost frequently expansion
(condensation) occurs after valves.
appears on low replacing -Check the
pressure side expansion temperature
piping. valves). sensing bulb
condition and
installation.
20-906
Troubleshooting the electrical circuit
The flow charts on the following pages break down air conditioning problems into two categories: blower-related problems and
cooling equipment related problems. Check for blower troubles first, including such items as gauge fuse, circuit breaker, heater
relay, blower motor, blower resistor, and blower switch. Then check other air conditioning electrical components like air
conditioner fuse and switch, magnetic clutch and relay, sensors and wiring (input to amplifier) and amplifier. Cooler circuit
troubleshooting steps are shown on the next flow chart.
Blower troubleshooting
Start the engine and allow it to run at idle speed with the vehicle stationary. Follow the steps as shown in the chart. Descriptions
of the inspection metthods can be found on the pages that follow the flow chart.
20-907
20-908
Electrical circuit checks
Heater relay (steps 4 and 5)
Turn on the ignition switch and check input voltage at

terminal 5 and 3. If no voltage (0V), there should be open
circuit between heater relay and gauge fuse, or between
heater relay and the battery. Inspect the continuity with a
circuit tester or ohmmeter. Repair or replace as necessary.
Standard: terminal No. 1-3 continuity

terminal No. 2-4 continuity
terminal No. 4-5 no continuity
Applying the battery voltage between terminal Nos. 1 and 3,

check continuity between terminal 4 and 5 (point is closed).
Blower switch (step 6)
If the blower doesn’t operate correctly, remove the blower

switch connector and check the continuity between the
terminals with each switch position. If all conditions are good
reconnect the blower switch.
Check continuity between the heater relay terminals and the

blower switch terminals as follows.
(a) Check continuity between the heater relay terminal 1

and blower switch terminal 12, and between blower
switch terminal 9 and vehicle ground.
(b) Check the resistance betwen the heater relay terminal 4

and blower switch terminal 9 with each blower switch
position.
When changing blower switch position from OFF to HI, the
resistance value should change from a high value to a low
value.
20-909
Consult this troubleshooting flow chart for procedures to check the cooler equipment after problems with the blower circuit have
been ruled out. Details about the procedures appear on the pages that follow.
20-910
Cooler circuit troubleshooting
Air Conditioner switch
Step 1-2
Turn on the blower switch and air conditioner switch, check
the voltage of the amplifier at terminal 10.
If 12 volts is not present (battery voltage), the wiring
between the air conditioner fuse and the amplifier input
terminals is faulty (open circuit) or the A/C swtich is
defective.
Magnetic clutch relay
Step 4 and 4-1

Check that continuity exists between terminal no. 1 and 3
but not between terminals 2 and 4.
Apply the battery voltage between terminal 1 and 3, check
the continuity between terminals 2 and 4 (the point is
closed).
20-911
Condenser fan operation circuit
Step 2-2
Turn on the blower switch and A/C switch. Then inspect
the condenser fan operation .
Conditions
Fan
A/C Mag. Coolant Refrigerant
speed
switch clutch temp. pressure
( (kg/cm²)
ON or below 83 Stop
OFF
OFF below 12.5
above 90 HI
ON ON below 83 LO
below 83 above 15.5
ON ON above 90 below 12.5 HI
above 15.5
Under the low coolant temperature and low thermal load

(low room and ambient temperature) conditions, the fan
rotates at low speed with the magnetic clutch on, while as
the coolant temperature increases, the fan starts high speed
rotation.
In the case of high thermal load, the fan rotates at high

speed also.
Check four relays used in the condenser fan operation.

(a) Engine main relay (identical to the heater relay)
(b) Condenser fan relay (3), identical to magnetic clutch
relay.
(c) Condenser fan relay (2) differs slightly from the heater
relay in the terminal layout. Check continuity as follows:
continuity between terminals 5 and 2, 1 and 3. No continuity
between terminals 1 and 4.
Applying the battery voltage between terminals 5 and 2,
check the continuity between terminals 1 and 4 (point is
closed). Note that the diode permits current flow between
terminal 5 and terminal 2 in only one direction.
20-912
If the thermistor signal is wrong, check the resistance of the

termistor. Its resistance characteristics are shown in the
illustration.
Idle speed check

When the air conditioner switch is turned ON, the idle
speed should increase. Make sure the speed change
20-913
20-914
Troubleshooting
Setup: Abbreviations:
Controller on Temp. 60
Defrost “off”, Fan on high
(A) Problem - EO error message display on the controller:
Possible Cause Inspection Remedy
1. Open EC power circuit Check the EC circuit breaker for power, a) Repair the wiring
voltage, and continuity b) Replace open circuit breaker
2. Defective EC relay (circuit) Check for output voltage on the yellow a) Repair the connections / wiring
wire, at the relay coil. Check the voltage b) Replace the defective relay
and continuity across the relay contacts.
3. Open EC voltage detection circuit Check for input voltage on the brown a) Repair the wiring or connector
wire, at the controller.
4. Improper wiring installation Applicable to systems without an EC a) See note #3
5. Defective controller Check for output voltage on the yellow a) Replace the controller
(B) Problem - E1 error message display on the controller:
1. Abnormal A/C refrigerant Check the refrigerant pressures with a) Check the condenser operation
pressure(s). gauges. for air and refrigerant blockage
* Cool weather operation may cause b) Leak check system, repair the
low pressure short cycling High side greater than: leaks and recharge the system
320 psig (R12), or 350 psig (R134a). c) Relocate the low pressure switch
Low side less than: to the evaporator outlet
3 - 6 psig.*
2. Opened compressor clutch circuit Check for output voltage on the green a) Repair the connections/wiring
wire at the compressor. Check the wire b) Replace the defective switch(es)
connections. Check for continuity across or the thermostat
the pressure switch(es) and thermostat. c) Replace the defective compressor
Check the continuity of the clutch clutch
solenoid to ground.
3. Opened pressure switch detection Check for an input voltage on the tan a) Repair the connections/ wiring
circuit wire, at the controller.
4. Defective controller Check for output voltage on the green a) Replace the controller
20-915
(B) Problem continued
False E1 error message / cold weather charging problems:

(Occurs particularly when vapor charging in cold weather)
1. E1 error message may occur during charging when the low pressure switch (LPS) opens at 3 psig. The suction
side pressure must rise above 45 psig to reset the E1 error message.
2. When the system is fully charged, the E1 error message should not appear under normal operating conditions.
3. In order to continue charging, by-pass the LPS, turn the controller “off”then “on”, and set the controller to 60
This will reset the controller and force into the air conditioning mode.
4. If the LPS can’t be easily reached, disconnect the clutch wire at the compressor, and run a hot wire directly to the
compressor clutch solenoid. Take care not to short out the controller clutch circuit.
5. E1 error message may occur while charging, when the compressor is wired hot.
(C) Problem - No Heat
1. Opened heat solenoid circuit. Check for an output voltage on the white a) Repair connections/wiring
Poor connection, loss of voltage. wire, at the heat solenoid valve. Check
the solenoid continuity to ground.
2. Defective heat solenoid or improper Check for coolant blockages in the heat a) Repair or replace the valve.
installation. solenoid valve and hoses. b) Reverse the coolant hoses to the
Check the direction of coolant flow (feel valve.
the hoses).
3. Defective controller Check for output voltage on the white a) Replace the controller
20-916
(D) Problem - No display, the blower fan will not turn off, when the power is turned on.
1. Fan wires shorted to ground or Disconnect the controller from the a) Unground and repair the shorted
vehicle chassis external harness, Individually check the wiring.
continuity of the orange and black fan
wires to ground, in the external harness.
(E) Problem - Compressor clutch will not engage, unless defrost button is pushed.
1. Defective preset thermostat inside Push, hold defrost / temperature a) If “CL”, go to step 2.
evaporator. Opened preset thermostat decrease buttons simultaneously. Check b) If “OP”, repair connections or
circuit. Broken thermostat wiring. display for “OP”or “CL”readout. wiring to preset thermostat.
Evaporator coil temperature too cold for Disconnect red leads, and check for c) Replace preset thermostat.
a/c operation. continuity across thermostat terminals.
2. Ambient cab temperature too cool Set controller at 68-70 a) Verify if compressor clutch will pull
(below 60 Warm-up ambient temperature probe in or not.
with fingers or heat gun. b) If not go to step 3.
3. Opened ambient cab temperature Push, hold temp. Decrease/increase a) If display reads 49F, at room
probe (thermistor) buttons simultaneously. Display will read temperature, replace thermistor.
40F if probe is defective. Disconnect the b) Repair connections/wiring.
controller, check for continuity across c) If 10K ohms +/- 20%, thermistor is
black probe leads. Check resistance of good. If 100K-1M ohms, replace
thermistor. thermistor.
Notes:
1. Wire colors may vary with installation. Refer to the wiring schematic.
2. For 24V controllers, resistor (R17) must be clipped and removed from the circuit board. (Refer to figure below) If the resistor
is not clipped on the 24V system, the controller display will light up, but the blower fan will not turn on.
20-917
3. For air conditioning systems that do not use an electric condenser, the blue and brown wires must be connected together, on
the external harness. The brown wire must be connected to the battery voltage, or the EO error message will result.
4. Care must be taken during installation, not to pinch or cut wiring from the controller. Shorted wiring may result in damage to
the controller.
5. Improper probe location of the evaporator coil thermostat sensor, or ambient cab temperature sensor, may cause short
cycling of the compressor.
6. Eagle climate controllers are designed to use normally closed heat solenoid valves.
7. Disconnect the vehicle battery leads, if a machine is to be inactive, or put into storage, for a period of a week or more. The
current drain from the controller’s memory may result in a dead vehicle battery. An optional ignition relay may be installed to
disable the controller’s memory function, when the key switch is turned off.
20-918
WIRING DIAGRAM
NOTES:
1. Position the ambient temperature probe near waist high level, out of air flow and sun load.
2. Insert the sensing tube from present thermostat down into the evaporator coil, parallel to the coil face, between the
1st and 2nd rows, to a depth of the coil height minus 1 inch.
Wire Chart CONNECTOR DETAIL
Socket Size Color Wire function
1 10GA Red Battery positive in
2 18GA Red ½ evap coil thermostat in
3 18GA Black ½ ambient thermistor in
4 18GA Red ½ evap coil thermostat in
5 N/A N/A Not used
6 18GA Black ½ ambient thermistor in
7 14GA Orange Fan positive out
8 16GA Dk. Green Clutch out
9 18GA Dk. Blue Ignition switch in
10 14GA Black Fan negative out
11 18Ga Brown Condenser blown fuse in
12 16GA White Heat solenoid out
13 18GA Tan Pressure switch detect in
14 16GA Yellow Condenser fan relay out
15 12GA Black Battery negative in
16 N/A N/A Not used
20-919
Main inspection areas
Sensor circuit
Wire harness
Body ground
Servomotors
Connectors
No. Problem
Others inspection items
Fuses
1 Fuse blows easily
2 No blower operation Heater relay, blower motor, blower

resistor, blower switch
3 Blower speed does not change Blower resistor, blower switch
4 No compressor operation Magnetic clutch and relay,

compressor, heater relay, A/C switch,
A/C amplifier
5 A/C lamp doesn’t light Engine speed signal lines, A/C

amplifier, A/C switch
6 A/C lamp flashes (only for compressor with Compressor, drive belt, A/C amplifier,
lock sensor) magnetic clutch
7 No A/C operation (cooled air does not come

out)
8 Cab temperature does not decrease Water temperature switch (for variable
(insufficient cooling). compressor type) A/C amplifier
9 Warm air doesn’t come out. Engine coolant volume, A/C

temperature control , heater radiator
10 No condenser fan operation. Relays (for condenser fan, radiator

fan), condenser fan motor, condenser
fuse
11 No engine idle speed increase when A/C Idle-up actuator, vacuum hose line, air
switch is turned on. conditioner amplifier
20-920
30 DISASSEMBLY AND ASSEMBLY
Precautions when carrying out operation . . . . . . . . . . . 30-3 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-104
Special tool list . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-6 Transmission control valve (ECMV assembly)
Sketches of special tools . . . . . . . . . . . . . . . . . . . . . . 30-11 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-108
Starting motor assembly . . . . . . . . . . . . . . . . . . . . . . 30-14 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-108
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-14 Disassembly of center
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-14 support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-110
Alternator assembly . . . . . . . . . . . . . . . . . . . . . . . . . . 30-15 Assembly of center support . . . . . . . . . . . . . . . . . . . 30-112
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-15 Disassembly of drive shaft. . . . . . . . . . . . . . . . . . . . . 30-115
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-15 Assembly of drive shaft . . . . . . . . . . . . . . . . . . . . . . 30-118
Engine oil cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-16 Removal of front axle assembly . . . . . . . . . . . . . . . . 30-121
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-16 Installation of front axle assembly . . . . . . . . . . . . . . 30-122
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-16 Removal of front differential assembly . . . . . . . . . . . 30-123
Fuel injection pump assembly . . . . . . . . . . . . . . . . . . 30-17 Installation of front differential assembly . . . . . . . . . 30-125
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-17 Removal of rear axle assembly . . . . . . . . . . . . . . . . 30-126
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-17 Installation of rear axle assembly . . . . . . . . . . . . . . . 30-131
Water pump assembly . . . . . . . . . . . . . . . . . . . . . . . . 30-18 Removal of rear differential assembly . . . . . . . . . . . 30-132
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-18 Installation of rear differential assembly . . . . . . . . . . 30-133
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-18 Disassembly of differential gear assembly . . . . . . . . 30-134
Injector assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-19 Fine disassembly of pinion assembly . . . . . . . . . . . . 30-136
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-19 Fine disassembly of differential gear
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-19 case assembly . . . . . . . . . . . . . . . . . . . . . . . . . 30-137
Turbocharger assembly . . . . . . . . . . . . . . . . . . . . . . . 30-20 Fine assembly of differential gear
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-20 case assembly . . . . . . . . . . . . . . . . . . . . . . . . . 30-138
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-20 Disassembly of final drive assembly . . . . . . . . . . . . . 30-146
After cooler assembly . . . . . . . . . . . . . . . . . . . . . . . . . 30-22 Assembly of final drive assembly . . . . . . . . . . . . . . 30-149
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-22 Removal of orbit-roll assembly . . . . . . . . . . . . . . . . . 30-153
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-23 Installation of orbit-roll assembly . . . . . . . . . . . . . . . 30-153
Cylinder head assembly . . . . . . . . . . . . . . . . . . . . . . . 30-24 Disassembly of orbit-roll assembly . . . . . . . . . . . . . . 30-154
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-24 Assembly of orbit-roll assembly . . . . . . . . . . . . . . . . 30-159
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-26 Removal of steering cylinder assembly . . . . . . . . . . 30-166
Radiator assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-29 Installation of steering cylinder assembly . . . . . . . . . 30-167
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-30 Disassembly of steering cylinder assembly . . . . . . . 30-168
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-31 Assembly of steering cylinder assembly . . . . . . . . . 30-170
Damper assembly Removal of steering valve assembly . . . . . . . . . . . . 30-172
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-32 Installation of steering valve assembly . . . . . . . . . . . 30-174
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-32 Removal of brake valve assembly . . . . . . . . . . . . . . 30-175
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-33 Installation of brake valve assembly . . . . . . . . . . . . . 30-176
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-36 Removal of slack adjuster assembly . . . . . . . . . . . . 30-177
Torque converter and transmission Installation of slack adjuster assembly . . . . . . . . . . . 30-177
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-41 Disassembly of slack adjuster . . . . . . . . . . . . . . . . . 30-178
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-44 Assembly of slack adjuster . . . . . . . . . . . . . . . . . . . 30-179
Disconnection . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-45 Removal of brake assembly (front, rear) . . . . . . . . . 30-180
Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-45 Installation of brake assembly (front, rear) . . . . . . . . 30-180
Torque converter Disassembly of brake assembly (front, rear) . . . . . . 30-181
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-46 Assembly of brake assembly (front, rear) . . . . . . . . 30-184
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-50 Removal of hydraulic pump (switch &
Transmission PPC, loader, torque converter-transmission, steering)
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-58 assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-188
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-75 Installation of hydraulic pump (switch &
Transfer assembly PPC, loader, torque . . . . . . . . . . . . . . . . . . . . . 30-189
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-92 Removal of hydraulic tank assembly . . . . . . . . . . . . 30-190
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-96 Installation of hydraulic tank assembly . . . . . . . . . . . 30-191
Parking brake assembly Removal of hydraulic filter assembly . . . . . . . . . . . . 30-192
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-92 Installation of hydraulic filter assembly . . . . . . . . . . . 30-192
30-1
DISASSEMBLY AND ASSEMBLY TABLE OF CONTENTS
Removal of PPC valve assembly . . . . . . . . . . . . . . . 30-193

Installation of PPC valve assembly . . . . . . . . . . . . . 30-193
Disassembly of PPC valve assembly . . . . . . . . . . . . 30-194
Assembly of PPC valve assembly . . . . . . . . . . . . . . 30-194
Removal of main control valve assembly . . . . . . . . . 30-195
Installation of main control valve assembly . . . . . . . 30-197
Assembly of main control valve . . . . . . . . . . . . . . . . 30-202
Removal of bucket cylinder assembly . . . . . . . . . . . 30-206
Installation of bucket cylinder assembly . . . . . . . . . . 30-207
Removal of boom cylinder assembly . . . . . . . . . . . . 30-208
Installation of boom cylinder assembly . . . . . . . . . . 30-209
Disassembly of boom and bucket
cylinders assembly . . . . . . . . . . . . . . . . . . . . . . 30-210
Assembly of boom and bucket cylinders
assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-212
Removal of center hinge pin . . . . . . . . . . . . . . . . . . 30-215
Installation of center hinge pin . . . . . . . . . . . . . . . . . 30-221
Removal of work equipment . . . . . . . . . . . . . . . . . . 30-225
Installation of work equipment assembly . . . . . . . . . 30-229
Removal of bulkhead assembly . . . . . . . . . . . . . . . . 30-230
Installation of bulkhead assembly . . . . . . . . . . . . . . 30-231
Installation of engine hood assembly . . . . . . . . . . . . 30-232
Removal of floor frame assembly . . . . . . . . . . . . . . . 30-233
Installation of floor frame assembly . . . . . . . . . . . . . 30-235
Removal of counterweight . . . . . . . . . . . . . . . . . . . 30-236
Installation of counterweight . . . . . . . . . . . . . . . . . . 30-236
Removal of fuel tank assembly . . . . . . . . . . . . . . . . 30-237
Installation of fuel tank assembly . . . . . . . . . . . . . . . 30-238
Removal of cab assembly . . . . . . . . . . . . . . . . . . . . 30-239
Installation of cab assembly . . . . . . . . . . . . . . . . . . . 30-241
Removal of air conditioner
unit assembly . . . . . . . . . . . . . . . . . . . . . . . . . . 30-242
Installation of air conditioner unit
assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-243
condenser assembly . . . . . . . . . . . . . . . . . . . . . 30-244
Installation of air conditioner
condenser assembly . . . . . . . . . . . . . . . . . . . . . 30-244
Removal of receiver tank . . . . . . . . . . . . . . . . . . . . . 30-245
Installation of receiver tank . . . . . . . . . . . . . . . . . . . . 30-245
compressor assembly . . . . . . . . . . . . . . . . . . . . 30-246
Installation of air conditioner compressor
assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-246
30-2
DISASSEMBLY AND ASSEMBLY PRECAUTIONS WHEN CARRYING OUT OPERATION
PRECAUTIONS WHEN CARRYING OUT OPERATION

When carrying out removal or installation (disassembly or assembly) of units, be sure to following general
precautions.
1. Precautions when carrying out removal work.

If the coolant contains anti-freeze, dispose of it Fit wires and hoses with tags to show thei r
correctly. installation position to prevent any mistake
After disconnecting hoses or tubes, cover them when installing.
or fit blind plugs to prevent dirt or dust from Check the number and thickness of the shims,
entering. and keep in a safe place.
When draining oil, prepare a container of When raising components, be sure to use
adequate size to catch the oil. lifting equipment with ample strength.
Confirm the match marks showing th e When using forcing screws to remove any
installation position, and make match marks in components, tighten the forcing screws
the necessary places before removal to uniformly in turn.
prevent any mistake when assembling. Before removing any unit, clean the
To prevent any excessive force from being surrounding area. Fit a cover to prevent any
applied to the wiring, always hold connectors dust or dirt from entering after removal.
when disconnecting. Do not pull the wires.
Precautions when handling piping during disassembly.

Fit the following blind plugs into the piping after disconnecting it during disassembly operations.
1) Hoses and tubes using sleeve nuts.

Nominal Plug (nut end) Sleeve nut (elbow end) Use the two items below as a set
number
02 07376-50210 07221-20210 (Nut), 07222-00210 (Plug)
03 07376-50315 07221-20315 (Nut), 07222-00312 (Plug)
04 07376-50422 07221-20422 (Nut), 07222-00414 (Plug)
05 07376-50522 07221-20522 (Nut), 07222-00515 (Plug)
06 07376-50628 07221-20628 (Nut), 07222-00616 (Plug)
10 07376-51034 07221-21034 (Nut), 07222-01018 (Plug)
12 07376-51234 07221-21234 (Nut), 07222-01219 (Plug)
2) Split flange type hoses and tubes.

Nominal Flange (hose end) Sleeve head (tube end) Split flange
number
04 07379-00400 07378-10400 07371-40400
05 07379-00400 07378-10500 07371-30500
30-3
3) If the part is not under hydraulic pressure, the following corks can be used
Nominal Part Number Dimensions
number
D d L
06 07049-00608 6 5 8
08 07049-00811 8 6.5 11
10 07049-01012 10 8.5 12
12 07049-01215 12 10 15
14 07049-01418 14 11.5 18
16 07049-01620 16 13.5 20
18 07049-01822 18 15 22
20 07049-02025 20 17 25
22 07049-02228 22 18.5 28
24 07049-02430 24 20 30
27 07049-02734 27 22.5 34
2. Precautions when carrying out installation work.

Tighten all bolts and nuts (sleeve nuts) to the Clean all parts, and correct any damage,
specified (KES) torque. dents, burrs, or rust.
Install the hoses without twisting or Coat rotating parts and sliding parts with
interference. engine oil.
Replace all gaskets, O-rings, cotter pins, and When press fitting parts, coat the surface with
lock plates with new parts. anti-friction compound (LM-P).
Bend the cotter pins and lock plates securely. After fitting snap rings, check that the snap ring
When coating with adhesive, clean the part is fitted securely in the ring groove.
and remove all oil and grease, then coat the When connecting wiring connectors, clean the
threaded portion with two - three drops of connector to remove all oil, dirt, or water, then
adhesive. connect securely.
When coating with gasket sealant, clean the When using eye bolts, check that there is no
surface and remove all oil and grease, check deformation or deterioration, screw them in
that there is no dirt or damage, then coat fully, and align the direction of the hook.
uniformly with gasket sealant. When tightening split flanges, tighten uniformly
in turn to prevent excessive tightening on one
side.
When operating the hydraulic cylinders for the first time after reassembling cylinders, pumps and other hydraulic
equipment removed for repair, always bleed the air as follows:
1. Start the engine and run at low idling.
2. Operate the work equipment control lever to operate the hydraulic cylinder four - five times, stopping the
cylinder 100 mm from the end of its stroke.
30-4
3. Next, operate the steering, bucket, and boom cylinders to the end of their
stroke three - four times, stop the engine, loosen air bleed plug (1), bleed
the air from the hydraulic tank, then tighten plug (1) again.
4. Raise the engine speed, repeat Step 3 to bleed the air, and repeat this
operation until no more air comes out from the plug.
5. After doing this, run the engine at normal speed.
When using the machine for the first time after repair or long storage,
follow the same procedure.
3. Precautions when completing the operation.

If the coolant has been drained, tighten the drain valve, and add water to the specified level. Run the engine
to circulate the water through the system. Then check the water level again.
If the hydraulic equipment has been removed and installed again, add engine oil to the specified level. Run the
engine to circulate the oil through the system. Then check the oil level again.
If the piping or hydraulic equipment have been removed, always bleed the air from the system after
reassembling the parts.
For details, see TESTING AND ADJUSTING, Bleeding air.
Add the specified amount of grease (molybdenum disulfide grease) to the work equipment parts.
30-5
DISASSEMBLY AND ASSEMBLY SPECIAL TOOL LIST
SPECIAL TOOL LIST

Tools with part number 790T-000-0000 cannot be supplied (they are items to be locally manufactured).
Necessity: Cannot be substituted, should always be used.
Extremely useful if available, can be substituted with commercially available part.
New/remodel: N: Tools with new part numbers, newly developed for this model.
R: Tools with upgraded part numbers, remodeled from items already available for other models.
Blank: Tools already available for other models, used without any modification.
Tools marked O in the sketch column are tools introduced in special sketches (See SKETCHES OF SPECIAL
TOOLS).
Component Symbol Part No. Part Name Nece Qty New/ Sketch Nature of work, remarks
ssity remodel
Installation of engine 1 790-331-1110 Wrench 1 Tightening of head

cylinder head assembly
1 795-521-1110 Push tool 1
2 2 790-101-5221 Grip 1 Press fitting of front seal
Installation of engine 3 01010-51225 Bolt 1

front seal, rear seal A
4 01050-31640 Bolt 3
1 795-931-1210 Sleeve jig 1
3 2 795-931-1220 Sleeve jig 1 Press fitting of rear seal

3 01050-31625 Bolt 3
4 01050-31645 Bolt 3
1 793T-615-1230 Push tool 1 N O
Assembly of damper 1 2 793T-615-1240 Spacer 1 N O Press fitting of oil seal and

dust seal
3 790-101-5421 Grip 1
4 01010-51240 Bolt 1
2 790-102-1871 Wrench 1 Removal, installation of

round nut
B
1 790-201-2730 Spacer 1
Disassembly, assembly 2 791-520-4140 Screw 1

of PTO Press fitting of PTO gear
3 3 02215-11622 Nut 2 bearing inner race
4 01643-32780 Washer 2
5 790-101-2102 Puller (294.2 1

kN {30 ton})
6 79-101-1102 Pump 1
30-6
New/ Nature of work,

Component Symbol Part No. Part Name Necessity Qty Sketch
remodel remarks
1 790-501-5200 Repair stand 1

Disassembly,
assembly of torque C 2 790-901-2110 Bracket 1
converter assembly
3 790-310-2160 Plate 1
799-301-1500 Oil leak 1 Checking

tester actuation of
clutch piston
1 796-514-2000 Remover 1 Removal of

2 No.3 planet
Disassembly, 2 796-515-2140 Adapter 1 gear shaft
assembly of
transmission 790-201-1702 Push tool kit 1
assembly D 1
1741 Press fitting of
4 No.3, No.4
1 carrier bushing
5021
790-452-1200 Pilot ring tool 1 Centering of

Disassembly, 1 body and upper
assembly of cover
F
Orbit-roll
assembly 790-452-1100 Installer set 1 Press fitting of
2
spacer
Removal, 1 790-520-2510 Bracket 1 Removal,

installation of installation of
1
differential differential
assembly 2 790-520-2610 Plate 1
assembly
790-501-5000 Repair stand 1 100V

1
790-501-5200 Repair stand 1 220V, 240V
2
2 790-901-2110 Bracket 1
H 3 793-310-2160 Plate 1
Disassembly,
1 793T-622-1120 Push tool 1 N O
assembly of
differential Press fitting of
2 793T-622-1130 Spacer 1 N O dust seal and
assembly 3
3 790-101-5421 Grip 1 oil seal of
coupling cage
4 01010-51240 Bolt 1
1 792-525-1000 Micrometer 1 Adjusting

4 preload of
2 792-525-1230 Adapter 2 bearing
30-7
New/
Component Symbol Part No. Part name Necessity Qty Sketch Nature of work, remarks
remodel
1 793T-622-1110 Plate 1 N O
Press fitting of oil seal of
5 2 790-101-5421 Grip 1 outer drum
3 01010-51240 Bolt 1
793T-622-1150 Fixture 3 N O Removal, installation of

6
wheel hub
1 793-520-1805 Brake tester 1 N

Checking leakage of brake
7
oil
2 793-520-1851 Nipple 1 N
1 793-520-2680 Installer 1
Disassembly, assembly 2 791-580-1600 Push tool 1

of final drive assembly
3 1
4 4
5 1
Installation of floating seal
8
(gear end)
6 4
H
7 8
8 4
9 4
10 792-530-1630 Stud 4
1 793-520-2680 Installer 1
2 793-622-1200 Push tool 1 N
3 4 N
4 1 N
Disassembly, assembly Installation of floating seal
9 5 1
of brake assembly (hub end)
6 4
7 4
8 4
9 4
30-8
New/
remodel
1 793-520-2630 Bar 2
2 793-520-2640 Push tool 1
3 793-520-2530 Guide 1
4 790-101-2300 Push puller 1
Press fitting of bearing of
1 5 1 top center hinge portion
6 2
Puller (294.2
Removal, installation of 7 790-101-2102 kN {30 ton}) 1
K
center hinge 8 790-101-1102 Pump 1
1 793-520-2550 Guide 1
2 01010-31480 Bolt 2
3 01643-31445 Washer 2 Press fitting of bearing of
2 4 793-520-2640 Push tool 1 bottom center hinge
portion
Puller (294.2
5 790-101-2102
kN {30 ton}) 1
6 790-101-1102 Pump 1
790-502-1003 Repair stand
1 or 1
1 790-502-2000
2 790-101-1102 Pump 1
Wrench Removal, installation of
2 790-330-1100 1
assembly cylinder head
Socket (width
Disassembly, assembly Removal, installation of
3 790-302-1290 across flats 1
of hydraulic cylinder U nut
60 mm)
assembly
1 790-201-1500 Push tool 1 Press fitting of dust seal
2 1 Steering cylinder
3 1 Boom cylinder
4
4 1 Bucket cylinder
5 1
All cylinders
6 1
30-9
New/
remodel
1 790-201-1702 Push tool kit 1 Press fitting of roll bushing
2 1 Steering cylinder
3 1 Boom cylinder
5
4 1 Bucket cylinder
5 1
All cylinders
6 1
Disassembly, assembly of
hydraulic cylinder U 1 790-720-1000 Expander 1 Expansion of piston ring
assembly
2 796-720-1660 Ring 1
Steering cylinder
3 07281-01159 Clamp 1
6 4 796-720-1690 Ring 1
Boom cylinder
5 07281-02169 Clamp 1
6 796-720-1720 Ring 1
Bucket cylinder
7 07281-02429 Clamp 1
Wrench
1 790-102-2303 1
assembly
Removal, installation of round
1 Wrench
2 790-102-4300 1 head
assembly
3 790-102-4310 Pin 1
Disassembly, assembly of
accumulator assembly 1 790-720-1000 Expander 1 Expansion of piston ring
2 2 796-720-1660 Ring 1
3 07281-01159 Clamp 1
X
Charging tool
3 792-610-1700 1 Charging with N2 gas
assembly
Service tool
1 799-703-1200 1
kit
2 799-703-1100 1 110V
Charging air conditioner Vacuum
4 3 799-703-1110 1 220V
with gas pump
4 799-703-1120 1 240V
Gas leak
5 799-703-1400 1
tester
30-10
DISASSEMBLY AND ASSEMBLY SKETCHES OF SPECIAL TOOLS
SKETCHES OF SPECIAL TOOLS

Note: Komatsu cannot accept any responsibility for special tools manufactured according to these sketches.
H3-2
H6
30-11
DISASSEMBLY AND ASSEMBLY SKETCHES OF SPECIAL TOOLS
H5-1
H3-1
30-12
DISASSEMBLY AND ASSEMBLY DISASSEMBLY AND ASSEMBLY
B1-2
B1-1
30-13
DISASSEMBLY AND ASSEMBLY STARTING MOTOR ASSEMBLY
STARTING MOTOR ASSEMBLY

REMOVAL OF
WARNING! Stop the machine on level

ground and install the safety bar on the
frame. Lower the bucket to the ground and
stop the engine. Then apply the parking
brake and put blocks under the wheels to
prevent the machine from moving.
WARNING! Disconnect the cable from the

negative (-) terminal of the battery.
1. Remove catch, open side cover, then remove two

side covers.
2. Disconnect connector (1) and wire (2).
3. Remove ground connection (3), then remove
starting motor assembly (4).
4. For details, see Cummins Engine "Troubleshooting
and repair manual.”
INSTALLATION OF
1. Fit gasket and install starting motor assembly (4),

then tighten together with ground connection (3).
2. Connect wire (2) and connector (1).
3. Install cover, close two side covers, then lock with
catch.
4. Connect cable to negative (-) terminal of battery.
30-14
DISASSEMBLY AND ASSEMBLY ALTERNATOR ASSEMBLY
ALTERNATOR ASSEMBLY
REMOVAL OF

WARNING! Disconnect the cable from the

1. Remove catch, then open side cover.

2. Disconnect wires (1, 2 and 3).
3. Remove bolt (4) of adjustment plate, then loosen
mounting bolt and nut (5).
4. Remove adjustment plate (6).
5. Move alternator assembly towards lower position to
loosen belt tension, then remove belt (7).
6. Remove mounting bolt and nut, then remove
alternator assembly.
INSTALLATION OF
1. Install alternator assembly (8), then partially tighten
mounting bolt and nut (5).
2. Fit belt (7) in pulley groove and install.
3. Install adjustment plate (6), and partially tighten
bolt (4) of adjustment plate.
4. Insert a bar between the alternator assembly and
cylinder block, raise the alternator and adjust the
belt tension.
The belt should deflect about 15mm when
pushed with a finger pressure of 6kg at a point
midway between the alternator and the fan
pulley.
5. Tighten the adjustment plate bolt, and the
alternator assembly bolt and nut.
6. Connect wires (3, 2 and 1).
7. Close cover, then lock with catch.
8. Connect cable to negative (-) terminal of battery.
30-15
DISASSEMBLY AND ASSEMBLY ENGINE OIL COOLER
ENGINE OIL COOLER

REMOVAL OF

1. Remove catch, then open left engine side cover.

2. Loosen drain valve (1), and drain the cooling water.
If the coolant contains antifreeze, dispose of it
correctly.
3. Remove the turbocharger oil supply tube (3) and
the by-pass filter return tube (4).
4. Remove the cover and the water transfer tube (2).
5. Remove the full flow and by-pass filters (5).
6. Remove the oil cooler assembly, then remove the
remaining bolts from the support.
INSTALLATION OF
1. Install the oil cooler support.

2. Install the oil cooler assembly (6).
3. Install the cover and the water transfer tube (2).
4. Install the turbocharger oil supply tube (3), and the
by-pass filter return tube (4).
5. Install the full flow and by-pass filters (5).
30-16
DISASSEMBLY AND ASSEMBLY FUEL INJECTION PUMP ASSEMBLY
FUEL INJECTION PUM P

ASSEMBLY
REMOVAL

1. Remove the three engine side covers on the left

side.
2. Disconnect wire (1) to the fuel shut-off valve.
3. Remove control rod (2).
4. Disconnect the fuel inlet hose (3) and the air supply
hose (4).
5. Remove fuel tubing (5, 6, and 7).
6. Remove fuel pump (8).
INSTALLATION OF
1. Install fuel pump (8), then install the drive spider

coupling.
2. Install fuel tubing (5, 6, and 7).
3. Connect the fuel inlet hose (3) and air supply hose
(4).
4. Connect fuel shut-off valve wire (1).
5. Install control rod (2).
6. Install the three engine side covers, then lock with
catch.
30-17
DISASSEMBLY AND ASSEMBLY WATER PUMP ASSEMBLY
WATER PUMP ASSEMBLY

REMOVAL OF

1. Remove radiator assembly (see removal of

radiator)
2. Remove water pump belt (1).
3. Remove fan hub (2), and the water pump idler
pulley assembly (3).
4. Remove fan hub support bracket (4).
5. Remove air compressor coolant outlet tube (5).
6. Remove thermostat by-pass tube (6).
7. Remove coolant inlet transfer connection (7) from
the water pump.
8. Remove water pump assembly (8).
INSTALLATION OF
1. Install water pump assembly (8) with a new gasket.

2. Install coolant inlet transfer connection (7) with a
new gasket.
3 Install coolant outlet tube (5), and the thermostat
by-pass tube (6).
4. Install fan hub support bracket (4).
5. Install fan hub (2), and the water pump idler pulley
(3).
6. Install water pump belt (1).
30-18
DISASSEMBLY AND ASSEMBLY INJECTOR ASSEMBLY
INJECTOR ASSEMBLY
REMOVAL

Preparatory work
Remove engine side covers, hood, and exhaust
pipe.
Remove cylinder head assembly, injector as-
sembly, muffler, intake connector, and air
cleaner assembly, then disconnect all
injectors.
1. Remove mounting bolt (1) of the head cover, then

remove head cover (2).
2. Loosen adjusting screw locknut (3) and move the
injector push rod to the side.
3. Remove the injector link.
4. Remove injector hold down clamp (4).
5. Using injector puller (Cummins part #3376497),
remove injectors (5).
INSTALLATION OF
Replace the three o-rings on each injector.
1. Install injectors (5) in the cylinder head injector

bore.
2. Install injector hold down clamp (4).
3. Install the injector link in each injector.
4. Align the push rod with the injector rocker lever,
turn the adjusting screw, and tighten locknut (3).
5. Install rocker lever head cover (2), and mounting
bolts (1).
30-19
DISASSEMBLY AND ASSEMBLY TURBOCHARGER ASSEMBLY
TURBOCHARGER ASSEMBLY
REMOVAL OF

Preparatory work
Remove hood, engine side covers, and exhaust
muffler.
To remove exhaust muffler and air cleaner
assembly
1. Disconnect inlet connector (1).

2. Disconnect oil supply tube (2), and drain tube (3).
3. Remove mount bolts (4), and remove turbocharger
assembly (5).
INSTALLATION OF
Replace gaskets and o-rings with new.
1. Fit new gasket and install turbocharger assembly

(5), then tighten turbocharger mounting bolts (4).
2. Fit new gasket, connect drain tube (2), and supply
tube (3).
3. Fit new o-ring and gasket, install inlet connector
(1).
4. Install exhaust muffler, hood, and side covers.
30-20
DISASSEMBLY AND ASSEMBLY MEMORANDA
- MEMORANDA -
30-21
DISASSEMBLY AND ASSEMBLY AFTER COOLER ASSEMBLY
AFTER COOLER ASSEMBLY

REMOVAL OF
1. Engine hood and radiator grille.

a) Remove exhaust pipe (1), remove radiator
grille (2).
b) Refer to REMOVAL OF ENGINE HOOD
ASSEMBLY.
2. Ether injector.
a) Remove ether injector (3), and bracket (4).
3. Draining water.
a) Open radiator drain valve (5), and drain
coolant.
b) Open after cooler drain valve (6), and drain
coolant.
If the coolant contains antifreeze, dispose
of it properly.
4. Crossover connection.
b) Remove air crossover connection (7).
5. Hoses and hose clamps.

a) Loosen hose clamps (8).
b) Remove after cooler inlet hose (9), and outlet
hose (10).
c) Remove air compressor air inlet tube (11), and
after cooler signal tube (12).
d) Remove any other hoses which are attached to
the after cooler assembly.
6. After cooler assembly.

a) Remove after cooler assembly (13), and
mounting bolts.

30-22
DISASSEMBLY AND ASSEMBLY AFTER COOLER ASSEMBLY
INSTALLATION OF
1. After cooler assembly.

a) Install the guide studs (14) in the cylinder head,
then install the after cooler assembly (13).
2. Hoses and clamps.

a) Install after cooler inlet hose (9), and outlet
hose (10), and tighten the hose clamps (8).
b) Install air compressor air inlet tube (11), and
after cooler signal tube (12).
c) Remove any other hoses which are attached to
the after cooler assembly.
3. Crossover connection.
a) Install air crossover connection (7).
4. Ether injector.
a) Install ether injector (3), and bracket (4).
5. Refilling coolant.
a) Close radiator drain valve (5), and after cooler
drain valve (6)
b) Add coolant through the radiator filler neck to
the specified level.
Run the engine to circulate the coolant through
the system.
Then check the coolant level again.
Coolant: 81
21.4 gal.
6. Hood and engine side covers.

a) Install left and right hand engine side covers.
b) Install hood (2), and exhaust pipe (1).

30-23
DISASSEMBLY AND ASSEMBLY CYLINDER HEAD ASSEMBLY
CYLINDER HEAD ASSEMBLY

REMOVAL OF


grille (2).
ASSEMBLY.
grille (2).
ASSEMBLY.
2. Draining coolant.
1) Open radiator drain valve (3), and drain
coolant.
If the coolant contains antifreeze,
dispose of it properly.
3. Bracket.
1) Disconnect fuel control cable bracket (4).
4. Drain tube.
1) Remove muffler drain tube (5).
5. Muffler.
1) Remove exhaust pipe (6), then loosen the
pipe clamps.
2) Disconnect aspirator pipe (7), then remove
clamp (8).
3) Sling muffler (9), then lift off.
30-24
6. Intake connector assembly

1) Disconnect aspirator intermediate hose (10).
2) Remove mounting bolts (11), loosen connector
clamp (13), then remove intake connector
(12).
7. Air cleaner assembly.

1) Remove air cleaner mounting band.
2) Remove intake connector bracket mounting
bolts (14).
3) Sling air cleaner assembly (15), then remove
air cleaner and intake connector as one unit.
Air cleaner assembly: 35 kg

(77 lb)
8. Cylinder heads.
1) Remove after cooler assembly (16).
2) Remove turbocharger assembly (17).
3) Remove exhaust manifold (18).

4) Remove water manifold (19).
5) For details, see Cummins Engine
"Troubleshooting and repair manual.”
30-25
INSTALLATION OF
1. Cylinder head assembly.

1) Install new head gaskets on the dowel pins in
the cylinder block.
Make sure the side of the gasket marked
"TOP" is facing up.
2) For details, see Cummins Engine

"Troubleshooting and repair manual.”
3) Install water manifold (19).

4) Install exhaust manifold (18).
5) Install turbocharger assembly (17).
6) Install after cooler assembly (16).
30-26
2. Air cleaner assembly.

1) Sling air cleaner assembly and intake
connector as one unit, then install the air
cleaner assembly (15).
2) Tighten the intake connector bracket mounting
bolts (14).
3) Secure the air cleaner mounting band.
3. Intake connector assembly.

1) Install a new gasket, then install the air intake
connector (12), tighten mounting bolts (11),
and install connector clamp (13).
2) Connect aspirator intermediate hose (10).
4. Muffler.
1) Sling the muffler assembly (9), then install.
2) Connect aspirator pipe (7), then install
clamp (8).
3) Install exhaust pipe (6), then tighten the pipe
clamps.
30-27
5. Drain tube.
1) Connect the muffler drain tube (5).
6. Bracket.
1) Connect fuel control cable bracket (4).
7. Refilling coolant.
1) Close radiator drain valve (5), and after
cooler drain valve (6)
2) Add coolant through the radiator filler neck
to the specified level.
Run the engine to circulate the coolant
through the system.
Then check the coolant level again.
Coolant: 81
21.4 gal.

1) Install hood, refer to INSTALLATION OF
ENGINE HOOD ASSEMBLY.
2) Install radiator grille (2), and exhaust pipe (1).
30-28
DISASSEMBLY AND ASSEMBLY MEMORANDA
MEMORANDA
30-29
DISASSEMBLY AND ASSEMBLY RADIATOR ASSEMBLY
RADIATOR ASSEMBLY
REMOVAL OF
Loosen the oil cap slowly to release the

pressure inside the hydraulic tank. Then
operate the control levers several times
to release the remaining pressure in the
hydraulic piping.
1. Remove engine hood assembly, see “REMOVAL

OF ENGINE HOOD ASSEMBLY”.
2. Open radiator drain valve (1), and drain coolant.
If the coolant contains antifreeze, dispose of it
properly.
Coolant: 88
23.23 gal.
3. Disconnect aeration hose (2) and return hose (3).

4. Disconnect make-up line (4).
5. Remove fan guard (5).
6. Disconnect radiator outlet hose (6).

7. Disconnect torque converter cooler outlet and inlet
hoses (7).
8. Disconnect hydraulic cooler outlet and inlet hoses
(8).
9. Remove cover (9) at front bottom of radiator.

10. Loosen radiator mounting bolts (10).
30-30
DISASSEMBLY AND ASSEMBLY RADIATOR ASSEMBLY
11. Sling radiator assembly (11) and remove mounting

bolt (10).
Disconnect supports from radiator, loosen
supports at frame, and rotate out of way.
12. Lift off radiator assembly.

Sling the radiator assembly, and lift off while
moving radiator to the rear.
Be careful, and make sure the cooling fan
does not interfere with the radiator core.
Radiator assembly: 330 kg

(728 lb.)
INSTALLATION OF
Carry out installation in the reverse order to
removal.
Install so that the clearances between the fan and
fan guard at the left and right, and the top and
bottom are the same.
Add coolant through the radiator filler neck to the
specified level.
Coolant: 88
23.23 gal.
Add transmission oil through the oil filler to the

specified level.
Run the engine to circulate the oil and coolant
through the system.
Recheck oil and coolant levels again.
30-31
DISASSEMBLY AND ASSEMBLY DAMPER ASSEMBLY
DAMPER ASSEMBLY
REMOVAL OF
WARNING! Stop the machine on level ground
and install the safety bar on the frame. Lower the
bucket to the ground and stop the engine. Then
apply the parking brake and put blocks under the
wheels to prevent the machine from moving.
1. Remove engine hood assembly. For details, see

REMOVAL OF ENGINE HOOD.
2. Remove bulkhead assembly. For details, see REMOVAL
OF BULKHEAD.
3. Disconnect switch pump suction tube (1) and outlet hose
(2), then remove switch pump + PPC pump (3).
4. Disconnect hydraulic pump suction tube (4) and outlet
tube (5), then remove hydraulic pump (6).
5. Disconnect steering pump outlet hose (7), remove tube
(8) at pump end.
6. Disconnect damper lubrication tubes (9) and (10).
7. Disconnect drive shaft (11). (Refer to note “A”).
8. Pull out flange (12).
9. Remove mounting bolt (13).
Remove the mounting bolt, insert a guide bolt, then
sling the cover and push the cover out with forcing
screws.
10. Lift off cover assembly (14).
Cover: 32 kg
(71 lb)
11. Sling damper assembly (15), then remove mounting bolt

(16) and insert guide bolt.
Pull out the damper assembly using forcing screws.
Damper assembly: 60 kg
(132 lb)
INSTALLATION OF
Carry out installation in the reverse order to removal.
Note A:
Mounting bolts: 110.7 ± 12.7 Nm
(11.3 ± 1.3 kgm)
(81.5 ± 9 lbf.ft)
DISASSEMBLY OF 1) Remove elbows (1) and (2).
1. Cover assembly.
30-32
2) Remove mounting bolts, then using forcing

screws, remove cover (3).
Tighten the two forcing screws uniformly.
3) Remove oil seal (4) and o-ring (5) from cover

(3).
4) Turn over cover (6), then pull out shaft (7).
Cover: 29 kg
(64 lb)
30-33
5) Remove snap rings (8) and bearing (9) from

shaft (7).
6) Remove snap rings (10). (11), and oil seal (12)

from cover (6).
2. Damper.
1) Remove spacer (14).
2) Using forcing screws, remove flange (13).

Tighten the two forcing screws evenly.
30-34
3) Remove inner body (15) and rubber (16).
4) Remove snap ring (17) and oil seal (18) from

the inner body.
5) Remove flange (20) from outer body (19).

Screw in the mounting bolts, then tap with
a hammer to remove.
30-35
ASSEMBLY OF
1. Damper assembly.
1) Install flange (20) at bottom of outer body (19).
Contact surface of flange and outer body: Gasket

sealant (LG-4).
2) Press fit oil seal (18) in the inner body (15), then
assemble snap ring (17).
Fit the snap ring securely in the groove.
Set the oil seal with the sleeve on the snap ring
side, and fit it close in contact with the snap
ring.
Inside surface portion (hatched portion) of inner

body (15): Lithium base molybdenum disulphide
extreme pressure grease.
Fill the circumference uniformly with grease.
Lip of oil seal: Lithium base molybdenum

disulphide extreme pressure grease.
Brand of Lithium base molybdenum disulphide

Kyoto Oil Malleolus No.2 or equivalent.
Show Shell Sunlight TB-2 or equivalent.
Nippon Sekiyu Molytex No.2 or equivalent.
3) Assemble inner body (15) in outer body (19), then

assemble rubber (16).
Whole surface of rubber: Grease (G2-LI)
Outer surface of inner body: Grease (G2-LI)
Inner surface of outer body: Grease (G2-LI)
Between inner body and rubber: Grease (G2-LI)
30-36
Fill clearance "b" at four places evenly with

270g of grease.
4) Install flange (13), and tighten mounting bolts.
Contact surface of flange and outer body:

Gasket sealant (LG-4).
Mounting bolts: 66.6 ±6.9 Nm

(6.8 ±0.7 kgm)
(49 ±5 lbf.ft.)
2. Cover assembly.
1) Fit snap ring (11), then fit snap ring (10) after
press fitting the oil seal (12) in cover (6).
Press fit the oil seal with the lip face on the
bearing side.
2) Assem ble snap rings (8) and bearing (9) to

shaft (7).
Bearing portion "C" (hatched portion):

Lithium base molybdenum disulphide
Do not leave any space when filling with

grease.
Brand of Lithium base molybdenum
Kyoto Oil Malleolus No.2 or
equivalent.
Show Shell Sunlight TB-2 or
equivalent.
Nippon Sekiyu Molytex No.2 or
equivalent.
30-37
3) Press fit shaft (7) into cover (6).
4) Press fit oil seal (4) into cover (3), and install o-
ring (5).
Oil seal portion "d" (hatched portion):

Brand of Lithium base molybdenum disulphide

Kyoto Oil Malleolus No.2 or equivalent.
Show Shell Sunlight TB-2 or equivalent.
Nippon Sekiyu Molytex No.2 or equivalent.
30-38
5) Set cover (3) on mounting position, and tighten

the mounting bolts.
6) Install elbows (1) and (2).
Elbow (1) and (2): Thread tightener (LT-2).
Elbow (1): 3.9 ±1.0 Nm

(0.4 ±0.1 kgm)
(3.0 ±0.7 lbf.ft)
Be careful of the direction of elbow (2).
30-39
3. Greasing.
1) Assemble damper to the engine, and connect
the grease hose, then fill the inside of the
damper with grease (310g) from portion "e".
Damper portion "e" (hatched portion):

Brand of Lithium base molybdenum

Kyodo Oil Molylex No.2 or equivalent.
Showa Shell Sunlight TB-2 or equiva-
lent.
Nippon Sekiyu Molytex No.2 or
equivalent.
30-40
DISASSEMBLY AND ASSEMBLY TORQUE CONVERTER, TRANSMISSION
TORQUE CONVERTER AND

TRANSMISSION
REMOVAL OF

Loosen the oil cap slowly to release the

pressure inside the hydraulic tank. Then
operate the control levers several times
to release the remaining pressure in the
hydraulic piping.
1. Drain oil.
Hydraulic oil: 120

31.7 gal.
Transmission: 62
16.4 gal.
2. Remove bulkhead assembly. For details, see

REMOVAL OF BULKHEAD ASSEMBLY.
3. Remove floor frame assembly. For details, see

REMOVAL OF FLOOR FRAME ASSEMBLY.
4. Remove drive shaft between switch + PPC pump,

loader pump, and engine - torque converter. For
details, see REMOVAL OF HYDRAULIC PUMP
ASSEMBLY
5. Disconnect drive shaft (1) between transmission

and rear differential at the transmission end. (Refer
to note “A”).
6. Disconnect drive shaft (2) between transmission

and center support at the differential end. (Refer to
note “A”).
30-41
7. Disconnect hose (3) from oil cooler on left side of

transmission and hose (4) leading to transmission
valve.
8. Disconnect transmission oil outlet tube (5)
9. Disconnect hoses (6) and (7) leading to steering

valve at right side of transmission.
10. Disconnect hose (8) to loader control valve.
11. Disconnect hydraulic tank outlet hose (9).
12. Remove clamps (10) and (11), then remove tube

(12).
13. Disconnect hoses (13) and (14) leading to

emergency brake valve from transmission control
valve.
14. Disconnect grease supply hose (15) at bottom of

transmission support.
30-42
15. Disconnect connectors (16), (17), and (18) at

bottom left of floor frame. (LR1 - 6 and TM1, 2).
16. Disconnect (19) at left side of center of machine.

(FR1, 2).
17. Remove filler tube (20).
18. Remove two mount bolts (21) at torque converter

end. (Refer to note “B”).
19. Disconnect parking brake hose (22) at bottom left

of transfer.
20. Remove four mount bolts (23) at transfer end.

(Refer to note “B”).
21. Raise transmission assembly (24) and remove

cushion.
22. Remove mounting bolts (26), then remove bracket

(27). (Refer to note “C”).
Remove the bracket and move the
transmission assembly to the left while slowly
raising the assembly.
30-43
INSTALLATION OF
removal.
Adjust the mount at the transfer end as shown i n

the diagram to the right.
Note “A”:
Drive shaft: 110.7 ±12.7 Nm
(11.3 ±1.3 kgm)
(81.0 ±9.0 lbf.ft)
Note “B”:
Mount bolt: 744.8 ±83.3 Nm
(76.0 ±8.5 kgm)
(549.0 ±61.0 lbf.ft)
Note “A”:
Bracket mounting bolts:
274.4 ±29.4 Nm
(28.0 ±3.0 kgm)
(202.0 ±22.0 lbf.ft)
Refilling hydraulic tank and transmission case

with oil.
Add oil through oil filler to the specified level. Run
the engine to circulate the oil through the system.
Then check the oil level again.
30-44
DISCONNECTION OF
1. Remove torque converter and transmission
assembly. For details, see REMOVAL OF
TORQUE CONVERTER, TRANSMISSION
ASSEMBLY.
2. Disconnect suction tube (1).
3. Remove flange (2).
4. Remove tube (3) between torque converter and

transfer.
5. Remove support (4).
6. Disconnect connector (5).
7. Remove mounting bolts (6), then lift off torque

converter assembly (7).
Using a lever block set, set with the torque
converter end at the top.
After setting the assembly in position, check
that it is stable, before removal of the lifting
tool.
CONNECTION OF
Carry out connection in the reverse order to
disconnection.
Note “A”:
Input shaft seal ring: G2-LI
Make the protrusion from the shaft equal.

Be careful when pushing in. If the assembly is
pushed in by force, the seal ring (8) may be
damaged.
Torque converter mounting bolts:

110.7 ±12.7 Nm
(11.3 ±1.3 kgm)
(81.0 ±9.0 lbf.ft)
30-45
DISASSEMBLY AND ASSEMBLY TORQUE CONVERTER ASSEMBLY
TORQUE CONVERTER ASSEMBLY

DISASSEMBLY OF
1. Disconnect torque converter and PTO
assembly from transmission assembly.
For details, see DISCONNECTION OF TORQUE
CONVERTER, TRANSMISSION ASSEMBLY.
2. PTO assembly
1) Set tool C to torque converter and PTO
assembly (1).
2) Remove holder (2) and coupling (3).
3) Using eye bolts “a”, sling PTO assembly.
4) Using forcing screw “b”, lift off PTO assembly

(4).
5) Disassemble PTO assembly as follows.

I) Remove retainer (5).
ii) Remove oil seal (6) from retainer (5).
iii) Remove bearing (7).
30-46
iv) Using tool B2, remove nut (8).

v) Using puller “d”, push out gear (9).
At this point, put in contact with the
bearing outer race and push the gear
out. Do not remove the gear.
vi) Remove bearing (10a).

vii) Using snap ring pliers, remove snap ring
(11)
viii) Remove spacer (12).
ix) Using gear puller “e”, pull out outer races

(13a) and (13b) approx. 10 mm.
x) Remove gear (9), then remove outer races
(13a) and (13b) and spacer (14).
xi) Remove spacer (40) and bearing (10b)
from gear (9).
3. Turbine case assembly

1) Leave two pump mounting bolts (15) on
diagonally opposite sides and remove other
mounting bolts.
2) Set with case at top and remove remaining two
mounting bolts.
3) Using eye bolt “c” , remove turbine and case
assembly (16).
30-47
4) Disassemble turbine and case assembly as

follows.
I) Remove shaft (17) and gear (18).
ii) Using snap ring pliers, remove snap ring
(19).
iii) Remove spacer (20).
iv) lnsert two round bars “f” from l

hole and remove turbine assembly (21).
Push the inner race of the bearing with
a forcing screw.
v) Using snap ring pliers, remove snap ring

(23) from case (22).
vi) Using push tool “g”, remove bearing (24).
4. Stator
1) Remove snap ring (25).
2) Remove stator (26).
30-48
5. Stator shaft, pump assembly.

1) Remove 10 mounting bolts (27).
2) Remove stator shaft and pump assembly (28)
from housing (29).
3) Disassemble stator shaft and pump assembly

as follows.
I) Remove two plugs (31) of stator shaft (30).
ii) Using round bar (h), knock out bearing

inner race from hole where plug has been
removed, then remove pump assembl y
(32).
iii) Remove bolts, then remove retainer (33),

pump (34), and guide (35).
iv) Remove bearing (36) from guide (35).
30-49
ASSEMBLY OF
1. Stator shaft, pump assembly.

1) Assemble stator shaft and pump assembly as
follows:
I) Using push tool (j), press fit bearing (36)
(outside diameter: 120 mm) to guide (35).
After press fitting the bearing, apply
drops (6 cc) of engine oil (EO10-CD
or EO30-CD) and rotate 10 times.
ii) Align with oil groove and install guide (35)

and retainer (33) to pump (34).
Mounting bolt: Thread tightener (LT-2)
Mounting bolt: 59 - 74 Nm
(6 - 7.5 kgm)
(43.5 - 54.6 lbf.ft)
iii) Install seal ring (39) to stator shaft (30).

Apply grease to the seal ring and
make the protrusion from the shaft
uniform.
iv) Using push tool (k), press fit pump

assembly (32) to stator shaft (30).
30-50
v) Install two plugs (31) to stator shaft (30).

Do not coat the plugs with adhesive.
Plug: 3 - 6 Nm
(0.3 - 0.6 kgm)
(2.2 - 4.4 lbf.ft)
2) Set housing (29) to tool C.

3) Install stator shaft and pump assembly (28).
(6 - 7.5 kgm)
(43.5 - 54.6 lbf.ft)
2. Stator.
1) Install stator (26).
2) Using snap ring pliers, install snap ring (25).
3. Turbine case assembly.

1) Assemble turbine case assembly as follows:
i) Using push tool (g), press fit bearing (24)
to case (22).
ii) Using snap ring pliers, install snap ring
(23).
30-51
iii) Using push tool (1), press fit turbine

assembly (21) to case (22).
Support the inner race of the case
bearing and press fit the turbine
assembly.
After press fitting, apply drops (6 cc) of
engine oil (EO10-CD or EO30-CD)
and rotate 10 times.
iv) Install spacer (20).

v) Using snap ring pliers, install snap ring
(19).
vi) Using push tool (m), press fit inner race
(37) to shaft (17).
vii) Install gear (18) and shaft (17) to case

(22).
(6 - 7.5 kgm)
(43.5 - 54.6 lbf.ft)
30-52
2) Using eyebolt (c), install turbine and case

assembly (16), then tighten 24 mounting bolts
(15).
(5 - 6 kgm)
(36 - 43.5 lbf.ft)
4. PTO assembly.
1) Assemble PTO assembly as follows:
i) Using push tool (n), press fit bearing (10b)
(inside diameter: 50 mm) to gear (9).
ii) Set gear (9) to each pump mount portion

of housing (38).
Gear (spline portion): Grease (G2-LI)
iii) Using push tool (p), press fit outer race

(13b) (outside diameter: 90 mm).
Be careful of the mounting direction.
30-53
iv) Install spacer (14).
v) Using push tool (p), press fit outer race

(13a) (outside diameter: 90 mm).
Be careful of mounting direction.
vi) Fit spacer (40), the using puller (q), press

fit bearing (10a) (inside diameter: 50 mm).
vii) Install spacer (12).

viii) Using snap ring pliers, install snap ring
(11).
30-54
ix) Using tool B2, tighten mounting nut (8).
Mounting nut: Thread tightener (LT-2)
Mounting nut: 392 - 441 Nm

(40 - 45 kgm)
(289 - 325 lbf.ft)
After tightening the mounting nut,

apply drops (6 cc) of engine oil
(EO10-CD or EO30-CD) to bearings
(10a) and (10b) and rotate 10 times.
Then check the tightening torque of
the mounting nut again.
x) Using push tool (r), press fit bearing (7)

(outside diameter: 130 mm) to coupling
mount portion of housing (38).
After tightening the mounting nut,
apply drops (6 cc) of engine oil
(EO10-CD or EO30-CD) to bearings
(7) and rotate 10 times.
xi) Using push tool, press fit oil seal (6) to

retainer (5).
Lip of oil seal: Grease (G2-LI)
Coat the oil seal press-fitting surface

of the retainer with gasket sealant
(LG-5).
When coating with gasket sealant,
coat the hole in the housing thinly, and
wipe off all gasket sealant that is
squeezed out.
xii) Fit O-ring and install retainer (5).
O-ring: Grease (G2-LI)
2) Fit O-ring, then using eyebolts (a), install PTO

assembly (4).
30-55
3) Fit O-ring and install coupling (3) and holder

(2).

(16 - 20 kgm)
(116 - 145 lbf.ft)
30-56
- MEMORANDA -
30-57
DISASSEMBLY AND ASSEMBLY TRANSMISSION ASSEMBLY
TRANSMISSION ASSEMBLY
DISASSEMBLY OF
1. Torque converter and PTO assembly.
Disconnect torque converter and PTO assembly.
For details, see DISCONNECTION OF TORQUE
CONVERTER, TRANSMISSION ASSEMBLY.
2. Cover.
Remove cover (1) from top of transmission control
valve.
3. Main relief valve.

Remove main relief valve (3).
4. Transmission control valve.

1) Remove wiring harness (4).
Disconnect the ECMV solenoid connector.
For details, see REMOVAL OF
ASSEMBLY (ECMV ASSEMBLY).
2) Remove parking brake hose (5).
3) Lift off transmission control valve assembly (6).
Remove the bolts at the positions marked
by arrows in the diagram on the right.
5. Lubrication tube.
Remove lubrication tube (7) from front of transfer.
6. Sleeves.
Using eyebolt “a”, remove four sleeves (8) (length:
74mm) and 1 sleeve (9) (length: 79mm).
30-58
7. Transmission, transfer assembly.

1) Using eyebolts “b” and chain block, raise
transmission and transfer assembly (10), then
set on block “c” with transfer assembly at
bottom.
2) Using eyebolts “d”, sling transmission

assembly (11), then using forcing screw “e”,
disconnect from transfer assembly.
8. Transmission assembly.
1) Remove 6 mounting bolts (12) from output
shaft end of transmission case assembly (11).
2) Set transmission case assembly (11) on block

“c”.
3) Remove 15 mounting bolts (13) from input

shaft of transmission case assembly (11).
30-59
4) Remove two tie bolts (14) shown in diagram on

the right, and install eyebolts “f”.
5) Lift off transmission assembly (16) from
transmission case (15), and set to “g”.
9. Checking actuation of clutch piston.

1) Install four sleeves (8) and 1 sleeve (9) to
transmission assembly (16).
2) Using tool D1, check actuation of piston before
disassembling.
3) After checking actuation of piston, remove four
sleeves (8) and 1 sleeve (9).
10. Input shaft, No. 1 carrier, housing assembly.

1) Remove remaining 10 tie bolts (14).
2) Using eyebolts “h”, remove input shaft and No.
1 carrier and housing assembly (17), and put
on block “c”.
3) Disassemble input shaft, No. 1 carrier and

housing assembly (17) as follows:
i) Using snap ring pliers, remove snap ring
(19).
ii) Remove No. 2 sun gear (20).
30-60
iii) Support housing (21), then using push tool

“i”, push input shaft (22) with press and
remove.
iv) Using snap ring pliers, remove snap ring
(166) from input shaft (22).
v) Remove seal ring (167).
vi) Using snap ring pliers, remove snap ring

(25).
Remove from the bearing inner race
end.
vii) Support housing (21), then using push tool

“j”, push No. 1 carrier assembly (26) with
press and remove.
viii) Remove spacer (27).
ix) Using snap ring pliers, remove snap ring

(169).
x) Remove bearing (170).
xi) Remove seal ring (171).
30-61
4) Disassemble No. 1 carrier assembly as

follows:
i) Remove snap ring (23).
ii) Remove No. 1 ring gear (24).
iii) Remove shaft (29) and ball (173) from No.
1 carrier.
Be careful not to lose ball (173).
iv) Remove two thrust washers (174), needle
bearing (175), and planetary gear (176).
v) Remove sun gear (30) and spacer (31).
vi) Using push tool “k”, remove spacer and

bearing assembly (32).
vii) Using snap ring pliers, remove snap ring
(33) from spacer and bearing assembly
(32).
viii) Using push tool “l”, remove bearing (34).
ix) Using snap ring pliers, remove snap ring

(36) from No. 1 carrier.
x) Using push tool “m”, remove bearing (37).
30-62
11. No 1 spring.
Remove No. 1 spring (38).
12. No 1 plates, springs, No 1 discs.

Remove four No. 1 plates (39), 20 springs (41),
and four No. 1 discs (40).
13. Guide pins, plate.

Remove five guide pins (42) and plate (43).
14. Valve, spring.

Remove valve (44) and spring (45).
30-63
15. No 1, No 2 piston, housing assembly.

1) Using eyebolts “n”, lift off No. 1 and No. 2
piston and housing assembly (46).
Tap with a copper hammer to pull out the
dowel pin, then remove.
When raising the housing assembly, be
careful not to drop the No. 2 piston.
2) Using eyebolt “o”, remove No. 1 piston (48)
from No. 1 housing (47).
3) Turn over No. 1 housing, then remove No. 2
piston (52).
4) Remove seal ring (49) from No. 1 piston (48).

6) Remove seal rings (50) and (51) from No. 1

housing (47).
16. Plate.
Remove plate (54).
17. No. 2 springs.

Remove 10 No. 2 springs (164).
30-64
18. No. 2 discs, springs, No. 2 plates.

Remove four No. 2 discs (55), 20 springs (56), and
four No. 2 plates (57).
19. Spacer.
1) Using snap ring pliers, remove snap ring (58).
2) Remove spacer (59).
20. No. 2 carrier, housing assembly.

1) Using eyebolts “p”, lift off No. 2 carrier and
housing assembly (60).
2) Using snap ring pliers, remove snap ring (61)
from bearing inner end.
3) Support No. 2 housing assembly (62), then

using push tool “q”, push No. 2 carrier assem-
bly (63) with press and remove.
Push the No. 2 carrier.
30-65
4) Disassemble No. 2 housing assembly (62) as

follows:
(64).
ii) Support No. 2 housing (65), then using
push tool “r”, push bearing (66) with press
and remove.
iii) Remove seal ring (67) from No. 2 housing

(65).
5) Disassemble No. 2 carrier assembly (63) as

follows:
i) Remove spacer (68).
ii) Remove ring gear (69).
iii) Insert thin rods into four holes (70) for

removing snap ring, then push snap ring
(71), and remove No. 2 carrier assembly
(163) from ring gear (72).
30-66
iv) Remove shaft (73) and ball (74) from No.

2 carrier (163).
v) Remove two thrust washers (75), needle
21. No. 3 springs.


Remove three No. 3 discs (79), 20 springs (80),
and two No. 3 plates (81).
23. No 3 piston.
1) Remove No. 3 piston (82).
2) Remove seal ring (158).
24. Guide pins.

Remove five guide pins (162).
25. No. 3 ring gear.

Remove No. 3 ring gear (83).
26. No. 3, No. 4 housing, No. 4 piston assembly.

1) Using eyebolts “s”, liftoff No. 3 and No. 4
housing and piston assembly (159).
2) Turn over No. 3 and No. 4 housing (84), and
remove No. 4 piston (86).
30-67

4) Remove two seal rings (85) from No. 3 and
No. 4 housing (84).
27. No. 4 springs.


29. No. 3, No. 4 carrier assembly.

1) Using bar “t”, push up No. 3 and No. 4 carrier
assembly (92) and remove.
2) Disassemble No. 3 and No. 4 carrier assembly

as follows:
i) Using tool D2, pull out No. 3 shaft (93) and
remove.
ii) Remove two thrust washers (95), needle
bearing (96), and No. 3 planetary gear
(97).
30-68
iii) Using round bar, knock pin (98) into No. 4

shaft (99).
iv) Using round bar “u”, knock out No. 4 shaft
(99) from No. 3 carrier end and remove.
v) Remove two thrust washers (100), needle

bearing (101), and No. 4 planetary gear
(102).
vi) Using push tool “v”, push bearing (103)

with press and remove.
vii) Remove bushing (161).

viii) Remove No. 3 and No. 4 seal ring (104).
30-69
30. No. 4 sun gear.

2) Remove spacer (106) and No. 4 sun gear
(107).

1) Remove snap ring (108).
2) Remove No. 4 ring gear (109).
32. No. 5 housing, No. 5 piston assembly.

1) Using eyebolts “w”, lift off No. 5 housing and
No. 5 piston assembly (110).
When raising the housing, be careful not to
drop the No. 5 piston.
2) Using eyebolt “o”, remove No. 5 piston (112)
from No. 5 housing (181).
3) Remove seal ring (113) from No. 5 piston

(112).
4) Remove seal ring (111) from No. 5 housing
(110).
30-70
33. No. 5 plate.

Remove No. 5 plate (114).
34. No. 5 springs.

35. No. 5 discs, springs, No. 5 plate.

Remove two No. 5 discs (116), 10 springs (117),
and No. 5 plate (118).
36. Guide pins.

Remove 5 guide pins (119).

Remove No. 5 ring gear (120).
38. No. 5 plate.

Remove No. 5 plate (121).
39. No. 5 carrier assembly.

1) Remove nine mounting bolts (122).
2) Remove No. 5 carrier assembly (123).
3) Remove spacer (124) from No. 5 carrier
assembly (123).
4) Disassemble No. 5 carrier assembly (123) as

follows.
(182).
30-71
ii) Remove shaft (125) and ball (126).

Be careful not to Iose baII (126).
iii) Remove two thrust washers (127), needle
40. No. 5 sun gear.

Remove No. 5 sun gear (130).
41. Spring, pin.

Remove spring (131) and pin (132).

43. No. 6 piston.

1) Remove No. 6 piston (136).
2) Remove seal ring (156).
44. Guide pins.

Remove five guide pins (153).
45. Seal ring.

Remove seal ring (154) from housing (149).
30-72
46. No 6 hub.
Remove No. 6 hub (137).
47. Output shaft.

1) Support cage, then push output shaft (139)
2) Remove two seal rings (140) from output shaft
(139).
48. Cage assembly.

2) Support No. 6 housing assembly (143), then
using push tool “x”, push cage assembly (144)
3) Using push tool “nn”, push bearing (145) with

press and remove from cage (146).
4) Remove two seal rings (147).
30-73
49. No. 6 housing assembly.

2) Using push tool “y”, remove bearing (150),

bushing (151), and ball (152) from housing
(149).
30-74
TRANSMISSION ASSEMBLY
ASSEMBLY OF
1) Using push tool “z”, press fit bearing (150) to
No. 6 housing (149).
2) Using push tool “aa”, press fit bushing (151)
and ball (152) to No. 6 housing (149).
2. Cage assembly.
1) Install two seal rings (147) to cage (146).
Seal ring: Grease (G2-LI)
2) Using push tool “bb”, No. 6 housing assembly

(143) to cage assembly (144) with press.
Push the inner race of bearing (150).
3. Output shaft.
1) Install two seal rings (140) to output shaft
(139).
30-75
2) Using push tool “cc”, press fit bearing (145) to

output shaft (139) with press.
3) Set No. 6 housing assembly (143) to “g”.
4) Using push tool “dd”, press fit output shaft and
Push bearing (145) of the output shaft.
4. Seal ring.
Install seal ring (154) to No. 6 housing (149).
Set the groove of the seal ring facing the
direction receiving the pressure.
5. Guide pin.
Install guide pin (153).
6. No. 6 piston.
1) Install seal ring (156) to No. 6 piston (136).
7. No. 6 gear.
1) Install No. 6 gear (137).
30-76
2) Install No. 6 piston (136).
8. No. 6 plates, springs, No. 6 discs.

Install two No. 6 plates (135), 15 springs (134), and
three No. 6 discs (133).
9. Pin, spring.
Install pin (132) and spring (131).
10. No. 5 sun gear.

Install No. 5 sun gear (130).

1) Assemble No. 5 carrier assembly as follows:
i) Assemble needle bearing (128) to
planetary gear (129), put washers (127) to
both ends, then set to No. 5 carrier.
Align the center of each part with the
shaft hole.
ii) Install shaft (125) and ball (126).
Check that the gear rotates smoothly.
30-77
3) Align position of dowel pin and install No. 5

carrier assembly (123).
Tap with a copper hammer to knock in the
dowel pin.
4) Install 9 mounting bolts (122).

(16 - 18 kgm)
(116 - 131 lbf)
5) Assemble spacer (124).

1) Assemble No. 5 housing assembly as follows:
i) Install No. 5 ring gear (120) to No. 5 plate
(121).
ii) lnstall guide pins (119).
iii) Install two No. 5 discs (116), 10 springs
(117), and No. 5 plate (118).
iv) Install 10 No. 5 springs (115).
v) Install No. 5 plate (114).
vi) Install seal ring (113) to No. 5 piston (112).
Set the groove of the seal ring facing
the direction receiving the pressure.
vii) Install seal ring (111) to No. 5 housing

(181).
Set the groove of the seal ring facing
the direction receiving the pressure.
viii) Install No. 5 piston (112) to No. 5 housing.
30-78
ix) Align position of dowel pin and install No.

5 housing and No. 5 piston assembly
(110).
Be careful not to drop the No. 5 piston.
Tap with a copper hammer to knock in
the dowel pin.
2) Fit clamps “ee” to No. 5 housing assembly

(157) to hold in position.
3) Using eyebolts “w”, install No. 5 housing
assembly (157).

1) Install No. 4 ring gear (109).
2) Install snap ring (108).

Install three No. 4 discs (89), 15 springs (90), and
two No. 4 plates (91).
15. Springs.
Install 10 springs (88).
30-79
16. No. 4 piston.

Install seal ring (87) to No. 4 piston (86).
17. No. 3 piston.

Install seal ring (158) to No. 3 piston (82).
18. No. 3, No. 4 housing.

1) Install two seal rings (85) to No. 3 and No. 4
housing (84).
2) Install No. 3 piston (82) and No. 4 piston (86)

to No. 3 and No. 4 housing (84).
3) Using eyebolts “s”, lift off No. 3 and No. 4
When raising the housing, be careful not to
drop the No. 4 piston.
dowel pin.
19. No. 4 sun gear, spacer.

1) Install No. 4 sun gear (107) and spacer (106).
20. No. 3, No. 4 carrier assembly.

1) Assemble No. 3 and No. 4 carrier assembly as
follows:
i) Install seal ring (104) to No. 3 and No. 4
carrier (160).
30-80
ii) Using tool D3, press fit bushing (161) to

No. 3 and No. 4 carrier (160).
iii) Using push tool “ee”, press fit bearing

(103) to No. 3 and No. 4 carrier (160).
iv) Assemble needle bearing (101) to No. 4

planetary gear (102), put thrust washers
(100) to both ends, then set to No. 4
carrier.
shaft hole.
v) Align roll pin hole and install No. 4 shaft
(99).
The deviation between the position of
the No. 4 shaft and carrier roll pin hole
must be less than 0.2 mm.
vi) Install roll pin (98).
Install so that the side of the roll pin
with the slit is facing the planetary
gear.
vii) Assemble needle bearing (96) to No. 3
planetary gear (97), and put thrust
washers (95) to both ends, then set to No.
4 carrier.
viii) Install No. 3 shaft (93) and ball (94).
30-81
2) Install No. 3 and No. 4 carrier assembly (92).

Put plate “ff” to No. 3 and No. 4 carrier
assembly (92), then press fit the bearing
inner race portion to the output shaft.

Install No. 3 ring gear (83).
22. Guide pins.

Install guide pins (162).

Install three No. 3 discs (79), 20 springs (80), and
two No. 3 plates (81).
24. No. 3 springs.

Install 10 No. 3 springs (78).
25. No. 2 carrier, housing assembly.

1) Assemble No. 2 carrier assembly as follows:
i) Set snap ring to No. 2 carrier (163) and
install ring gear (72).
ii) Set snap ring (71) in groove of ring gear
(72).
30-82
iii) Assemble needle bearing (76) to planetary

gear (77), put thrust washers (75) to both
ends, then set to No. 2 carrier.
shaft hole.
iv) Install shaft (73) and ball (74).
v) Install spacer (68) and ring gear (69) to

No. 2 carrier assembly.
2) Assemble No. 2 housing assembly as follows:

i) Install seal ring (67) to No. 2 housing (65).
ii) Support No. 2 housing (65), then using

push tool “gg”, press fit bearing (66) with
press.
iii) Using snap ring pliers, install snap ring
(64).
30-83
3) Support No. 2 carrier assembly (63), then

using push tool “hh”, press fit No. 2 housing
assembly (62) with press.
Press fit the bearing inner race.

5) Using eyebolts “p”, lift off No. 2 carrier and
26. Spacer.
1) Install spacer (59).

Install four No. 2 plates (57), 20 springs (56), and
four No. 2 discs (55).
30-84
Assemble discs (55), springs (56), and plates

(57) in the order shown in the diagram.
28. No. 2 springs.

29. Plate.
Install plate (54).
30. No. 1 piston, housing assembly.


3) Install seal rings (50) and (51) to No. 1 housing

(47).
4) Install No. 1 piston (48) and No. 2 piston (52)

to No. 1 housing (47).
30-85
5) Using eyebolts “n”, lift off No. 1 piston and

When raising the housing assembly, be
careful not to drop the No. 2 piston.
dowel pin.
31. Spring, valve.

Install spring (45) and valve (44).

1) Using push tool “ii”, press fit bearing (37) to No.
1 carrier (165).
3) Assemble needle bearing (175) to planetary

gear (176), put thrust washers (174) to both
ends, then set to No. 1 carrier.
Align the center of each part with the shaft
hole.
4) Install shaft (29) and ball (173).
5) Set No. 1 ring gear (24) to No. 1 carrier
assembly.
30-86
33. Input shaft.

1) Install seal ring (167) to input shaft (22).

3) Support No. 1 carrier assembly (26), then
using push tool “i”, press fit input shaft (22) with
press.
Press fit until snap ring (166) of the input
shaft contacts the bearing.
34. Spacer, sun gear.

Install spacer (31) and sun gear (30).
35. Bearing, spacer.

1) Using push tool “jj”, press fit bearing (34) to
spacer (136).
2) Using push tool “kk”, press fit spacer and

After assembling, check that the bearing
rotates easily.
36. No. 2 sun gear.

1) Install No. 2 sun gear (20).
37. Input shaft, No. 1 carrier assembly.

Raise input shaft and No. 1 carrier assembly (1 68)
and install.
30-87
38. Guide pins.

Install five guide pins (42).
39. Plate.
Install plate (43).

Install four No. 1 plates (39), 20 springs (41), and
four No. 1 discs (40).
Assemble in the order shown in the diagram.
41. No. 1 springs.

30-88
42. Housing.
1) Install seal ring (171) to housing (21).
2) Using push tool “al”, press fit bearing (170).

4) Install spacer (27) to No. 1 carrier assembly.
5) Install housing (21).
Fit eyebolt “an” to the input shaft, then fit
the wire, apply slight tension to the wire,
and press fit the housing.
7) Install 10 tie bolts (14).
Tie bolt: 157 - 177 Nm

(16 - 18 kgm)
(116 - 131 lbf)
Do not install the two tie bolts at the

position where the eyebolts are installed.
43. Checking actuating condition and travel of pis-

ton.
1) Install four sleeves (8) and 1 sleeve (9) to
2) Using tool D1, check actuating condition and
travel of piston.
Air pressure: 0.29 - 0.49 MPa
(3 - 5 kg/cm)
(42 - 71 psi)
(mm)
Piston Travel
No. 1 4
No. 2 5.5
No. 3 3.5
No. 4 4.5
No. 5 3
No. 6 4.2
3) Remove four sleeves (8) and 1 sleeve (9) from

30-89
44. Transmission assembly.

1) Install dowel pin (171) from output shaft end.
2) Install eyebolts “f”at positions shown by arrows
in diagram on right.
3) Put transmission case (15) on block “c”.
4) Raise transmission assembly (16) and install to
transmission case (15).
Align the position of the mounting bolt hole
on the top of the transmission.
Check that dowel pin (171) has entered
the transmission case.
5) Remove eyebolts “f”, and install remaining two
tie bolts (14).
Tie bolt: 157 - 177 Nm

(16 - 18 kgm)
(116 - 131 lbf)
6) Install six mounting bolts (12) to output shaft

end.
7) Install 15 mounting bolts (13) to input shaft
end.

(10 - 12.5 kgm)
(72 - 91 lbf)
45. Transmission case assembly.

1) Set transfer assembly (172) to block “c”.
2) Fit O-ring, then using eyebolts “d”, raise
transmission case (11) and install.

(10 - 12.5 kgm)
(72 - 91 lbf)
30-90
46. Sleeves.
Fit O-ring and install four sleeves (8) (length:
74mm) and 1 sleeve (9) (length: 79mm).
47. Lubrication tube.

Install lubrication tube (7) to transfer.
48. Transmission control valve.

1) Fit O-ring to transmission case and valve seat,
then raise transmission control valve assembly
(6) and install.
Tighten the mounting bolts in the positions
shown in the diagram on the right.
Check that there is an O-ring fitted to the
rear of the transmission case.
2) Install parking brake hose (5).
3) Install wiring harness (4).
Install the ECMV solenoid connector. For
details, see INSTALLATION OF
(ECMV ASSEMBLY).
49. Main relief valve.

Fit O-ring and install main relief valve (3).
(4.5 - 5.5 kgm)
(33 - 40 lbf)
50. Cover.
Install cover (1) to top of transmission control valve.
51. Torque converter, PTO assembly.

Connect torque converter and PTO assembly to
transmission assembly. For details, see
CONNECTION OF TORQUE CONVERTER AND
TRANSMISSION ASSEMBLY.
30-91
DISASSEMBLY AND ASSEMBLY TRANSFER ASSEMBLY
TRANSFER ASSEMBLY
DISASSEMBLY OF
1. Transmission.
Remove transmission assembly from transfer. For
details, see DISASSEMBLY OF TRANSMISSION
ASSEMBLY.
2. Parking brake assembly.

Remove parking brake assembly. For details, see
DISASSEMBLY OF PARKING BRAKE ASSEMBLY.
3. Input shaft cage assembly.

1) Using forcing screws “a”, remove input shaft
cage assembly (1).
2) Remove shims (2).
Check the number and thickness of the
shims at each mounting position, and keep
in a safe place.
4. Input shaft gear assembly.

1) Remove input shaft gear assembly (3).
2) Remove bearings (4) and (5) from input shaft
gear assembly (6).
5. Outer race.
1) Using push tool “b”, remove outer race (7)
from input shaft cage (34).
2) Remove outer race (35).
30-92
6. Strainer.
1) Remove cover (8).
2) Remove spring (9).

3) Remove strainer (10).
7. Intermediate shaft cage assembly.

1) Turn over transfer.
2) Using forcing screws “c”, remove intermediate
cage assembly (11) and shims (12).
shims at each mounting position, and keep
in a safe place.
8. Intermediate shaft gear assembly.

1) Remove intermediate shaft gear assembly
(14).
2) Remove two bearings (16) from intermediate
shaft gear (15).
30-93
9. Outer race.
1) Remove outer race (13) from intermediate
cage (32).
2) Remove outer race (17) from transfer case.
10. Coupling.
Remove holder (18) and coupling (19).
11. Cover.
1) Using forcing screws “c”, remove cove r
assembly (22) and shims (23).
2) Remove dust seal (25) and oil seal (26) from
cover(35).
30-94
12. Output shaft.

Using tool D4, remove output shaft (20) and spacer
(21).
13. Cage.
1) Using forcing screws “d”, remove cage and
2) Using push tool “e”, remove outer races (28a)
and (28b), collar (28c), and bearings (28d) and
(28e) from cage (29).
The two bearings are not
interchangeable, so keep them as
separate sets.
14. Spacer.
Remove spacer (30).
15. Output shaft gear.

Remove output shaft gear (31).
30-95
TRANSFER ASSEMBLY
ASSEMBLY OF
1. Outer race.
Using push tool “f”, press fit outer race (17) to
transfer case.

1) Using push tool “g”, press fit two bearings (16)
to intermediate shaft gear.
2) Install intermediate gear assembly (14).
3. Intermediate shaft cage assembly.

1) Using push tool “h”, press fit outer race (13) to
intermediate shaft cage (32).
2) Fit O-ring and install shims (12) and

intermediate shaft cage assembly (11).
Standard shim thickness: 2 mm
4. Adjusting preload of intermediate shaft bearing.

1) Remove cover (33).
30-96
2) Using tool D6 and torque wrench, measure

preload of intermediate shaft.
3) Adjust shims as follows:
i) Adjust with shims (12) so that preload is
0.29 - 0.54 Nm (0.03 - 0.055 kgm).
ii) After adjusting, add a further 0.1 mm o f
shim.
There are four types of shim
thickness: t=0.15, t=0.2, t=0.3, and
t=1.0
Check that there is no play in the gear.
If there is any play, adjust the shims
again.
4) After adjusting preload, remove intermediate
shaft cage assembly (11), shims (12), and
intermediate shaft gear assembly (14).
5. Outer race.
1) Using push tool “i”, press fit outer race (35) to
transfer case.
2) Using push tool “i”, press fit outer race (7) to
input shaft cage (34).
6. Input shaft gear assembly.

1) Using push tool “j”, install bearings (4) and (5)
to input shaft gear (6).
2) Install input shaft gear assembly (3).
7. Input shaft cage assembly.

Install shims (2) and input shaft cage assembly (1).
Standard shim thickness: 2 mm
30-97
8. Adjusting preload of input shaft bearing.

Using tool D7 and torque wrench, measure preload
of input shaft. If measurement is not within
standard, adjust with shim (2).
Preload standard value: 0.1 - 0.98 Nm (0.01 -
0.1 kgm)
There are four types of shim thickness: t=0.15,
t=0.2, t=0.3, and t=1.0
Check that there is no play in the gear. If there
is any play, adjust the shims again.
Reference: Standard value for preload when
assembling input shaft and intermediate shaft
(measure at input shaft end): 0.2 - 1.27 Nm
(0.02 - 0.13 kgm)
9. Output shaft gear.

Assemble output shaft gear (31) to transfer case.
10. Spacer.
Install spacer (30).
11. Outer race.

Using push tool “k”, press fit outer race (28a) to
cage (29).
12. Output shaft.

Assemble output shaft (20) and spacer (21), and
support with block “l”.
13. Cage assembly.

Fit O-ring and install cage assembly (36).
30-98
14. Bearing.
1) Using tool D5, press fit bearing (28d).
2) Press fit bearing (28e) in same way.
15. Outer race.

1) Install collar (28c).
2) Using push tool “l”, press fit outer race (28b).
16. Cover.
1) Using push tool, press fit oil seal (26) and dust
seal (27) to cover (37).
Oil seal: Grease (G2-LI)
Oil seal press-fitting surface:

Gasket sealant (Three Bond 1110B)
When coating with gasket sealant, coat the

inside surface of the hole in the housing
thinly, and wipe off all the gasket sealant
that is squeezed out.
Dust seal: Grease (G2-LI)
2) Adjust shims as follows:

i) Fit O-ring and install shims (23) and cover
assembly (22).
Do not tighten the mounting bolts.
ii) Put feeler gauge between shims (23) and

cover assembly (22) and measure
clearance, adjust number of shims so that
clearance is 0.05 - 0.10 mm, then tighten
mounting bolts.
Standard shim thickness: 0.25 mm
30-99
17. Coupling.
1) Install coupling (19).
2) Fit O-ring and install holder (18).

(67.5 - 84.5 kgm)
(488 - 611 lbf)

Install intermediate shaft gear assembly again. For
details, see steps 2, 3, and 4.
Assemble the shims adjusted in step 4.
30-100
DISASSEMBLY AND ASSEMBLY PARKING BRAKE
PARKING BRAKE ASSEMBLY

DISASSEMBLY OF
1. Transmission.
Disconnect transmission assembly from transfer.
For details, see DISASSEMBLY OF
TRANSMISSION ASSEMBLY.
2. Coupling.
Remove holder (1) and coupling (2).
3. Sleeve.
1) Remove flange (3).
2) Using eyebolt “I”, remove sleeve (4).

1) Remove 12 mounting bolts (5).
Do not remove four mounting bolts (6).
2) Using forcing screws “a”, disconnect parking
brake assembly (7).
3) After removing forcing screws “a”from parking

brake assembly (7), fit eyebolts “b”and lift off.
30-101
5. Cover assembly.
1) Remove cover assembly (8).
2) Disassemble cover assembly as follows”
i) Remove dust seal (9) and oil seal (10).
ii) Remove bearing (11).
iii) Remove dowel pin (29).
6. Springs.
Remove 18 outer springs (12) and 18 inner springs
(13).
7. Spacer assembly.
1) Remove spacer assembly (14).
2) Using push tool “c”, remove inner race (15)
from spacer (16).
8. Piston.
1) Using eyebolts “d”, lift off piston (17).
2) Remove seal rings (18) and (19).
30-102
9. Snap ring.
Using snap ring pliers, install snap ring (20).
10. Plates, springs, discs.

Remove 9 plates (21), 8 springs (22), and 8 discs
(23).
11. Gear.
Remove gear (24).
12. End plate.

Remove end plate (25).
13. Housing.
Using snap ring pliers, install snap ring (26) from
housing (27).
30-103
PARKING BRAKE ASSEMBLY

ASSEMBLY OF
1. Cover.
1) Assemble cover assembly as follows:
i) Using push tool “f”, press fit bearing (11).
ii) Install two dowel pins (29).
iii) Using push tool, press fit oil seal (10) and dust
seal (9).
Oil seal: Grease (G2-LI)
Oil seal press-fitting surface:

Gasket sealant (Three Bond 1110B)
Dust seal: Grease (G2-LI)
When coating with gasket sealant, coat the

inside surface of the mount thinly, and wipe off
all the gasket sealant that is squeezed out.
2. Spacer assembly.
1) Using push tool “e”, press fit inner race (15) to
spacer (16).
2) Install spacer assembly (14) to cover assembly (8).
3. Springs.
Install 18 outer springs (12) and 18 inner springs (13) to
cover assembly (8).
4. Piston.
1) Install seal rings (18) and (19) to piston (17).
direction shown in the diagram on the right.
2) Set piston (17) on outer spring (12) and inner spring

(13).
Align the position of the hole in piston (17) and
dowel pin (27) of the cover assembly.
30-104
5. Housing.
1) Using snap ring pliers, install snap ring (20) to
housing (27).
2) Fit O-ring and install housing (27) to cover
assembly (8), then tighten four mounting bolts
(6).
Be careful not to twist the piston against
housing (27), and tighten the bolts
uniformly a little at a time.
6. Plugs.
1) Remove two plugs (28).
2) Tighten two mounting bolts of parking brake
assembly together with washers to mounting
portion of plug (28).
Tighten the bolts a little at a time in turn.
The piston is pulled when the bolts are
tightened.
7. Gear.
Install gear (24).
Be careful of the direction of mounting.
8. Plates, springs, discs.

Install 9 plates (21), 8 springs (22), and 8 discs
(23).
30-105
9. End plate.
Install end plate (25).
10. Snap ring.

Using snap ring pliers, install snap ring (26).
11. Mounting bolts.

Remove two mounting bolts installed in Step 6 - 2),
then install two plugs (28).
Loosen the two mounting bolts a little at a time
in turn.
Plug: Gasket sealant (LG-5)

Using eyebolts “b”, fit O-ring, raise parking brake
assembly (7) and install.
When installing, gradually mesh the spline on
the inside of spacer assembly (14) and gear
(24) with the spline of the output shaft, and
install.

(10 - 12.5 kgm)
(72 - 91 lbf)
13. Sleeve.
1) Fit O-ring and install sleeve (4).
2) Fit O-ring and install flange (3).
30-106
14. Coupling.
1) Install coupling (2).
2) Fit O-ring and install holder (1).

(67.5 - 84.5 kgm)
(488 - 661 lbf)
15. Transmission.
Connect transmission assembly and transfer. For
details, see ASSEMBLY OF TRANSMISSION
ASSEMBLY.
30-107
DISASSEMBLY AND ASSEMBLY TRANSMISSION CONTROL VALVE ASSEMBLY
TRANSMISSION CONTROL
VALVE ASSEMBLY (ECMV
ASSEMBLY)
REMOVAL
1. Remove cover (1) between bulkhead and cab.
2. Remove transmission top cover (2).
3. Disconnect solenoid connector (3) and fill

connector (4).
When disconnecting the solenoid connector, hold
the ECMV body lightly with one hand, and hold the
connector housing with the other hand as shown in
the diagram on the right. Then lift up the connector
housing lightly in direction A and in this condition,
pull it in direction B to disconnect.
4. Remove four mounting bolts (5), then remove

ECMV assembly (6).
INSTALLATION
Carry out installation in the reverse order to removal.
Clean around the valve before installing the ECMV

assembly.
When fitting the solenoid connector, align the lock
and guide as shown in the diagram on the right,
and push in.
Do not twist when inserting.
ECMV assembly mounting bolt:

31.4 ± 3.9 Nm
(3.2 ± 0.4 kgm)
(23 ± 3 lbf)
30-108
DISASSEMBLY AND ASSEMBLY CENTER SUPPORT ASSEMBLY
CENTER SUPPORT ASSEMBLY

REMOVAL
Disconnect center drive shaft (1) from center

support.
Set a block under the drive shaft when removing.
Center drive shaft: 36.4 kg (80.1 lb)
2. Sling front drive shaft (2) and disconnect from

center support.
Front drive shaft: 44 kg (97 lb)
3. Disconnect grease tube.
4. Sling center support (4), remove mounting bolts,

then remove.
If there are shims between the center support and
frame, check the number and thickness of the
shims and use as a guide when assembling.
Center support: 43 kg (94.8 lb)
30-109

removal.
Center drive shaft mounting bolt:

110.7 ± 12.7 Nm)(800.7 ± 91 lbf ft)
Front drive shaft mounting bolt :

110.7 ± 12.7 Nm)(800.7 ± 91 lbf ft)
Center support mounting bolt

548.8 ± 58.8 Nm)(405.1 ± 43.4 lbf ft)
30-110
DISASSEMBLY OF CENTER
SUPPORT
1. Coupling
Remove center bolt (1), then remove retainer (2),
O-ring (3), and coupling (4).
2. Retainer
Remove mounting bolts (5) or retainer.
Remove all mounting bolts while rotating
coupling.
3. Shaft
1) Set shaft case assembly (6) on press stand.
2) Push out shaft (7) with press.
Be careful because the shaft will fall out
suddenly.
3) Remove spacer (8), bearing cone (9) and retainer

(5) from shaft.
30-111
4. Oil seal
1) Remove oil seal (10 )and O-ring (11) from
retainer.
2) Remove oil seal (12) from case.
5. Case
Remove bearing cone (13) and bearing outer race
(14) and (15).
30-112
ASSEMBLY OF CENTER
SUPPORT
1. Bearing outer race
Assemble bearing outer race (14) and (15), in case
(16).
2. Oil seal
Assemble oil seal (10) in retainer (5).
Outer circumference of oil seal
Grease (G2-LI)
3. Bearing cone
Assemble retainer (5) shaft and press fit bearing
cone (9).
After assembling bearing, check that there is
no clearance at tip of shaft.
Assemble spacers.
Lip of seal : Grease (G2-LI)
Inner circumference of bearing

Grease (G2-LI)
4. Case
1) Assemble O-ring (11) in retainer.
Insert O-ring completely in groove.
30-113
2) Stand shaft and insert case (16).

Fill “a" and "b" of case and inner
circumference of oil seal completely with
grease.
5. Retainer
Secure retainer (5) in case.
Be careful that O-ring does not get caught or
damaged when installing.
Mounting bolt:
65.7 ± 6.9 Nm)(48.5 ± 5.1 lbf ft)
6. Bearing seal
1) Press fit bearing (13) to shaft.
2) Assemble oil seal (12) in case.
Dimension of seal press fit and outer edge
of case:± 0.5 mm
Seal: Grease (G2-LI)
7. Coupling
Assemble coupling (4), install O-ring (3) and
retainer (2), and secure center bolt (1).
Center bolt: 931 ± 98 Nm (687.1 ± 7.2

lbf ft)
30-114
8. Inspection of end play

Check that end play is within specified range.
End play: Less than 0.22 mm
If end play is “0", with the seal and bearing
coated with grease check that the free rotating
torque is less than 3.9 Nm (0.4 kgm).
30-115
DISASSEMBLY AND ASSEMBLY DRIVE SHAFT
DISASSEMBLY OF DRIVE SHAFT

1. Shaft
1) Remove shaft (2)
Make match marks a before removing to
ensure that the direction of the spider
assembly does not change.
Cover (1) and (1A) is caulked with a punch

at four places, so it must not be remove d
unless necessary.
When removing cover (1) and (1A) be
extremely careful not to damage cover (1),
(1A) and yoke (3).
When removing the caulking, raise the
caulking with a screwdriver.
2) Remove mounting bolts (4), then remove

spider assembly (5).
Make match marks on yoke and spider.
30-116
3) Remove bearing caps (6) from spider

assembly.
Remove strap (7) of cap.
4) When replacing bearing (8), seal (9), and

derling washer (10) from bearing cap (6),
replace whole cap assembly.
2. Yoke
1) Remove mounting bolts (11) from yoke (3),
then remove spider assembly (12).
Stamp match marks on the yoke and
spider.
2) Remove bearing caps (13) from spider

assembly.
30-117
3) When replacing bearing (14), seal (15), and

derling washer (16) from bearing cap (13)
replace whole cap assembly.
30-118
ASSEMBLY OF DRIVE SHAFT

1. Yoke
1) Install bearing (14), and seal (15) to bearing
cap (13).
Bearing, seal : Grease (G2-LI)
2) Assemble derling washer (16), and bearing

cap (13) to spider assembly (12)
Be careful not to damage bearing with
heat when welding strap.
Bearing cap: Grease (G2-LI)
3) Assemble spider assembly (12) to yoke (3).

Carefully align match marks.
Clean the mounting face of the bearing
cap by wiping with a clean cloth.
Mounting bolts :
142.2 ± 9.8 Nm (104.9 ± 7.2 lbf ft)
2. Shaft
1) Assemble bearing (8) and seal (9) in bearing
cap (6).
Bearing seal : Grease (G2-LI)
30-119
2) Assemble derling washer (10 )and bearing cap

(6) to spider assembly (5).
Be careful not to damage bearing with
heat when welding strap.
Bearing cap: Grease (G2-LI)
3) Assemble spider assembly (5) to shaft (2).

Carefully align match marks.
Clean the mounting face of the bearing
cap by wiping with a clean cloth.
Mounting bolt:
142.2 ± 9.8 Nm (104.9 ± 70.8 lbf ft)
4) Align match marks “a”, then install shaft (2) to

yoke (3).
Check that the direction of the spider
assembly is the same.
If the spline is worn, replace the whole
drive shaft assembly.
Spline: Grease (G2-LI)
30-120
5) lf cover (1) and (1A) has been removed, do as

follows.
Front and rear drive shaft.
Insert seal and retainer to cover (1) and
shaft (2), assemble cover (1), then caulk
with a punch on diagonally opposite sides.
Center drive shaft.
Insert shaft (2) to cover (1A), assemble
cover (1A), then caulk with a punch on
diagonally opposite sides.
30-121
DISASSEMBLY AND ASSEMBLY FRONT AXLE ASSEMBLY
REMOVAL OF FRONT AXLE

ASSEMBLY
ground, install the safety bar on the frame,
and put blocks under the wheels to prevent
the machine from moving.
1. Insert block n top face (1) of left and right

rear axle housings and frame (2).
2. Start engine, operate work equipment to raise front

axle, then set block er front frame on left and
right sides and operate work equipment to lower
frame.
Check that the front wheels can be removed,
then lower the work equipment to the ground.
3. Sling left and right wheels (3), remove hub nuts,

then lift off.
Tire, wheel: 660 kg (1452 lb)
4. Disconnect front drive shaft (4) at differential end.
Make counter marks to act as a guide when

assembling.
5. Disconnect brake tube (5) from slack adjuster.
6. Remove brake tubes (6) and (7).

Seal the brake system with blind plugs after
disconnecting the piping.
30-122
DISASSEMBLY AND ASSEMBLY FRONT AXLE ASSEMBLY
7. Sling one side of front axle assembly (8) and

set garage jack to other side.
8. Remove mounting bolts (9).

9. Operate crane and garage jack to lower the
axle assembly.
Be careful not to let the slack adjuster on
top of the axle housing hit the frame.
Front axle assembly: 1,850 kg (4070

lb)
10. Pull out front axle assembly from chassis.
INSTALLATION OF FRONT AXLE

ASSEMBLY
Carry out installation procedure in reverse order to
remove.
Hub nut: 470.4 ± 49.0 Nm (347.2 ± 36.2

lbf ft)
Drive shaft mounting bolt:
110.7 ± 12.7 Nm (81.7 ± 9.4 lbf ft)
Axle mounting bolt:

2744.0 ± 294.0 Nm (2025 ± 217 lbf ft)
30-123
FORWARD FRONT DIFFERENTIAL ASSEMBLY
REMOVAL OF F R O NT
DIFFERENTIAL ASSEMBLY
ground, install the safety bar on, the frame,
1. Remove drain plugs (1) and (2), and drain oil.
Axle oil : 78
2. Operate work equipment to raise front axle, then

set stand under left side of axle.
3. Sling left wheel (3), then remove hub nut and lift
off.
4. Remove left and right final drive covers (4).
5. Using forcing screws )

approx. 200 mm together with sun gear (6).
30-124
6. Remove front drive shaft (7).

Sling the drive shaft and lower it
slowly.
7. Remove two mounting bolts of differential

(8), and install guide bolt
Screw in the guide bolt fully and check that all

the threads have entered the hole.
First, screw in the guide bolt, then remove the
remaining mounting bolts.
8. Set lever block ntial case (9), and set so

that differential assembly does not fall over.
Fit both ends of a lever block to the front frame
inspection window.
9. Pull out differential (8) approx. 20 mm from axle
housing (10) along guide bolts.
Be careful not to damage the O-ring.
10. Install tools H1-1 and H1-2 to garage jack, and

insert between differential and axle housing, then
install differential to tool H1-1.
11. Adjust lever block and height of jack, and remove

differential assembly slowly.
Differential assembly: 282 kg (620.4 lb)
12. Operate jack and pull out differential assembly (8)

to outside of chassis.
13. Remove O-ring (11).
30-125
INSTALLATION OF FRONT
remove.
Drain valve
151.9 ± 24.5 Nm (112.1 ± 18.1 lbf ft)
Hub nut: 470.4± 49.0 Nm (347.2 ± 36.2 lbf ft)

110.7 ± 12.7 Nm (74.5 ± 9.4 lbf ft)
Differential mounting bolt:

548.8 ± 58.8 Nm (405.1 ± 43.5 lbf ft)
Refilling with oil (axle)

Add oil through the oil filler to the specified level.
30-126
DISASSEMBLY AND ASSEMBLY REAR AXLE ASSEMBLY
REMOVAL OF REAR AXLE

ASSEMBLY
1. Jack up chassis, set block under rear frame, and

support bottom of counterweight with stand
2. Sling left and right wheels (1), then remove hub nut
and lift off.
3. Disconnect rear drive shaft (2) from rear

axle.
Rear drive shaft: 37 kg (81.4 lb)
4. Disconnect hose (3) between brake pedal and

slack adjuster at slack adjuster end.
5. Disconnect tubes (4) and (5) between slack

adjuster and left and right wheel brakes.
Be sure to remove the brake tube before
removing the axle. There is danger that it may
be crushed.
30-127
6. Disconnect grease tubes (6) and (7) from axle

support at rear end.
7. Disconnect grease tube (8) from axle support at

front end.
Remove the clamps of the brake hose from
the support.
8. Secure axle support and rear axle with chain.
9. Remove mounting bolts, then using garage jack to

maintain balance, lower axle assembly.
Rear axle assembly: 1,710 kg (3762 lb)
10. Pull out rear axle assembly (9) from chassis.

Support both ends of the axle with jacks.
30-128
11. Remove front support (10) from rear axle.

Be careful not to damage the packing.
Front support: 95 kg (209 lb)
12. Remove packings (11) and (12) from front support.
13. Remove bushing (13) from front support.

Remove all dirt and oil from the bushing
mounting surface inside the front support.
14. Sling rear support, and remove thrust cap (14).
30-129
15. Remove thrust washer (15), thrust plate (16), and

thrust washer (17) from rear axle.
16. Lift off rear support (18).
Rear support: 115 kg (253 lb)
17. Remove packing (19) from rear support.
30-130
18. Remove bushing (20) from rear support.

Remove all dirt and oil from the bushing
mounting surface inside the rear support.
30-131
INSTALLATION OF REAR AXLE

ASSEMBLY
Installation is the reverse of removal procedure.
Hub nut: 471 ± 49 Nm (347.2 ±36 lbf

ft)

110.7 ± 12.7 Nm (745 ± 7.9 lbf ft)
Rear support mounting bolt:

1,568 ± 196 Nm (1157.3 ± 144.7 lbf ft)
Soak a cloth with primer for Loctite Prism
adhesive, then wipe the adhesion surface at
the bushing end.
Adhesion surface at rear support end:

Instant adhesive Loctite Prism 411
(approx. 3g)
Install the bushing within five minutes of
coating it with primer.
Do not mix the primer with adhesive whe n
using it.
Be careful to install the packing with the lip
facing in the correct direction.
Lip of packing: Grease (G2-LI)
Rear axle mount portion: Grease (G2-LI)
Front support mounting bolt:

1,568 ± 196 Nm (1157.3 ± 144.7 lbf ft)
Coat the bushing the same as the rear axle.
Lip of packing: Grease (G2-LI)
Front axle mount portion: Grease (G2-

LI)
Thrust cap mounting bolt:

279.3 ± 29.4 Nm (206.14 ± 21.7 lbf ft)
Thrust plate mounting bolt:

279.3 ± 29.4 Nm (206.14 ± 21.7 lbf ft)
30-132
DISASSEMBLY AND ASSEMBLY DIFFERENTIAL ASSEMBLY
REMOVAL OF REAR DIFFERENTIAL

ASSEMBLY
WARNING! Stop the machine on level ground, install
the safety bar on the frame, and put blocks under the
1. Remove rear axle assembly from chassis. For details, see

REMOVAL OF REAR AXLE ASSEMBLY.
Do not remove the rear support from the rear axle.
2. Remove plug (1) and drain axle oil.
Set so that the drain plug is at the bottom.
Axle oil: 78
3. Remove cover (2).
4. Using forcing screws, pull out drive shaft (3).

Pull the drive shaft out approx. 200 mm (7.8 in).
5. Using eyebolts, lift off rear differential assembly (4).
Rear differential assembly: 282 kg (620.4 lb)
Remove the O-ring from the housing mating surface.
30-133
INSTALLATION OF REAR
remove.

Thread tightener (LT-2)

548.8 ± 58.8 Nm (405.1 ± 43.4 lbf ft)
Adjusting shims on shaft

Adjust the shims on the shaft if the differential
assembly or axle housing have been replaced.
1) Tighten mounting bolts of shaft (5) uniformly,
then measure clearance a between axle
housing and shaft.
(Do not assemble the shims. Tighten th e
mounting bolts to 3.9 ± 0.1 Nm (2.89 lbf ft).)
2) Add 0.1 ± 0.05 mm to the measurement fo r

clearance a, then select a shim within that
range and assemble it.
Shim thickness:
Clearance a + (0.1 ± 0.05 mm)
Mounting bolt:
112.7 ± 9.8 Nm (83.18 ± 7.2 lbf ft)
30-134
DISASSEMBLY OF DIFFERENTIAL
GEAR ASSEMBLY
1. Set differential assembly (1) on special tools H2-1,
H2-2, and H-3.
Differential assembly: 230kg (506 lb)
2. Pinion assembly
1) Remove case (2).
2) Remove oil seal (3) and dust seal (3A) from

case.
3) Screw in jack screw (D (Thread dia. = 18 mm,

Pitch = 1.75 mm), and lift out pinion assembly
(4).
Check number of shims (5).
30-135
3. Differential gear case assembly

1) Remove left and right locks (6), and with a bar,
turn nut (7) until it become loose.
2) Remove mounting bolts (9) of cap (8).
3) Remove nut and lift out differential gear case

assembly (10).
30-136
FINE DISASSEMBLY OF PINION

ASSEMBLY
4. Bearing, collar, cage
1) Support cage (11), push shaft with press and
tack out pinion.
2) Remove bearing (12) and collar from cage.
3) Remove outer races (13) and (14) from cage

(11).
5. Pinion, bearing
1) Remove snap ring (15), then remove bearing
(16).
2) Remove bearing (17).
30-137
FINE DISASSEMBLY OF
DIFFERENTIAL GEAR CASE
ASSEMBLY
6. Bevel gear (large)
Remove mounting bolts, using eye-bolts (2)
(Thread dia. = 16 mm, Pitch = 2.0 mm), lift of f
bevel gear (18).
7. Bevel gear (small)

Remove thrust plate (19) and bevel gear (20).
8. Pinion gear, cross shaft

Remove pinion gear (21), cross shaft (22), and
washer (23) as one unit.

Remove bevel gear (24) and thrust plate.
10. Bearing
Remove bearing (26) from case (25).
30-138
FINE ASSEMBLY OF
DIFFERENTIAL GEAR CASE
ASSEMBLY
1. Bearing
Using press fit kit (3) (120 mm inner diameter),
press fit bearing (26) to case (25).

Install thrust and small bevel gear (24) in case.
Align thrust with dowel pin and install.
3. Pinion gear, cross shaft

Assemble pinion gear (21) and washer (23) with
cross shaft (22).
Align washer groove with dowel pin of case
and install.

Install bevel gear (20) and thrust plate (19).
30-139
5. Bevel gear (large)

Using eye-bolts (2) (thread dia. = 16 mm, Pitch =
2.0 mm), lift and install bevel gear (18).
Align pin hole of thrust and dowel pin on case
side and install.
FINE ASSEMBLY OF PINION

ASSEMBLY
6. Bearing
1) Using press fit kit (4) (26 mm inner diameter).
Install pinion bearing (17).
2) Using press fit kit (5) (55mm inner diameter),

install bearing (16).
Rotating surface of bearing:

Engine oil (EO30-CD)
7. Cage
1) Install outer races (14) and (13).
2) lnstall cage (11) to pinion assembly.
30-140
8. Collar
Install collar (27).
9. Bearing
Using press fit kit (4) (76 mm inner diameter),
install bearing (12).
ASSEMBLY OF DIFFERENTIAL
ASSEMBLY
Set differential case on special tools Hl-I, H2-2, and
H2-3.
10. Pinion assembly

1) Assemble shims (5) removed whe n
disassembled.
Standard shims thickness: 2.1 mm.
2) Using eye-bolts (5) (Thread dia.=12mm, Pitch
1.75 mm), install pinion assembly (4).
3) Remove oil seal (3) and dust seal (3A) to case.
Lip of oil seal : Grease (G2-LI)
Rear Lip of dust seal: Grease (G2-LI)
4) Fit O-ring to case, and install case (2).
Mounting bolt:
279.3 ± 29.4 Nm (206.14 ± 21.7 lbf ft)
Mounting bolt: Thread tightener (LT-
2)
30-141
5) Insert coupling (28), fit O-ring and tighten

holder.
Mounting bolt:
Mounting bolt:
921 ± 98 Nm (607.6 ± 72.3 lbf ft)
Fit the balancer (6) to bolt hole of coupling,

and measure the rotating torque.
Rotating torque: Max. 50.0 N (11.22 lb)
11 Differential gear assembly

Sling differential gear assembly (10) and install
case.
12. Nut, cap

1) Align nut (7) with differential case groove and
install.
2) Install cap (8) and tighten (9).
Mounting bolt:
Mounting bolt:
Check match marks on bearing cup
before installing.
Rotate bevel gear 20 - 30 times to settle in,
then tighten bolt.
30-142
Bearing pre-load adjustment steps are as

follows.
1) Install tool H4-1 and H4-2 to cap on both sides.
2) Measure clearance "a" between tool H4-2 with

tool H4-1.
3) Add 0.26 ± 0.07 mm to measuremen t

dimension and set scale on tool H4-1.
The added dimension becomes the amount of
bending of the case, given before pre-load and
given after pre-load.
4) Tighten adjusting nut with bar until increased

amount becomes 0.26 ± 0.07 mm.
Caution for pre-load adjustment

When adjusting nut is overtightened (in case
the amount of increased bending surpasses
the standard measurement), return adjusting
nut to position before adjusting. Then, while
rotating bevel gear, lightly tap bearing cap and
bevel gear with plastic hammer, and check that
there is no clearance in position b.
30-143
13. Adjusting tooth contact, backlash

Adjust the backlash, and at the same time adjus t
tooth contact.
1) Adjust backlash as follows:
i) Movement of bevel gear is done with
adjusting nut (7). At this time, so as not to
change pre-load pressurization of bearing,
turn nuts on both sides, the same amount
each, in same direction.
ii) Put dial gauge (3) in vertical contact with
forward and reverse sides of outer edge of
bevel gear tooth face, and while turning
adjusting nut, adjust until gauge meter
fluctuation becomes 0.3 - 0.4 mm.
Measure at three or four places, and keep the
pinion gear fixed when measuring.
2) Adjust tooth contact as follows:

i) Adjust bevel pinion by adjusting shims
between differential case and bearing
cage.
ii) Adjusting tooth contact
For details, see ADJUSTING TOOTH
CONTACT.
30-144
3) Adjusting tooth contact
Coat face 7 or 8 teeth of bevel pinion lightly with red lead (minimum). Hold the bevel gear by hand to act as
a brake, rotate the pinion gear forward and backward and inspect the pattern left on the teeth.
When adjusting the driven gear do not change the pre-load of the bearing. Turn the left and right adjusting nut, the
same amount each (check by the number of notches), in the same direction.
30-145
14. Lock
After adjusting tooth contact and backlash, install
lock (6).
30-146
DISASSEMBLY AND ASSEMBLY FINAL DRIVE ASSEMBLY
DISASSEMBLY OF FINAL DRIVE

ASSEMBLY
1. Tire assembly
Loosen hub nut, raise chassis with work equipment
or jack, insert support stand under axle, then sling
tire assembly, remove hub nuts, and lift off tire
assembly (1).
Tire assembly: 660 kg (1452 lb)
2. Draining oil
1) Remove drain plug (2) and drain oil.
Set so that the drain plug is at the bottom.
Axle oil: 78 d
rear)
3. Cover
Remove mounting bolts (3), then remove cover (4).
4. Drive shaft
Screw in bolt (1) (Thread dia.=12 mm, Pitch = 1.75
mm) in drive shaft, then pull out drive shaft
assembly (5) and remove.
5. Planetary carrier assembly

Remove mounting bolts (6), then using eyebolt (2)
(Thread dia.=12 mm, Pitch=1.75 mm), lift of f
planetary carrier assembly (7).
Use a bar to adjust the position of the center of
gravity when removing.
Planetary carrier assembly: 90 kg

(198.42 lb)
30-147
6. Ring gear
1) Using tool H6, secure wheel hub (8) and brake
housing (9).
Install tool H6 at three places at equal
distances.
Do not remove tool H6 until assembly Step 3.
2) Remove mounting bolts (10), then remove

retainer (11) and ring gear (12).
Check the number and thickness of shims on
the inside of the retainer.
Ring gear: 50 kg (110 lb)
7. Disassembly of planetary carrier

Using press, pull out shaft (13), then remove pinion
gear (14).
Lock ball (15) is fitted in the shaft, so be careful
not to lose the ball.
Write the serial number on the case and be
careful not to mix the removed parts with other
parts.
The bearings and other parts have settled as a
set, so make identification marks and be
careful not to mix with other parts.
30-148
8. Disassembly of ring gear

1) Remove lock plates (18) from ring gear hub
(17), then remove ring gear (19)
2) Pull out bearing (20) from ring gear hub (17).
30-149
ASSEMBLY OF FINAL DRIVE

ASSEMBLY
1. Assembly of ring gear
1) Press fit bearing (20) on ring gear hub (17).
After press fitting the bearing, check that there
is not clearance between the rib and bearing.
2) Set ring gear hub (17) on ring gear (19), then
install lock plates (18).
Install the lock plates with the wider ones on
the inside.
Remove all grease and oil from the bolt.
Mounting bolt:
Mounting bolt:
31.4 ± 2.9 Nm (23.1 ± 2.2 lbf ft)
2. Assembly of planetary carrier

Set pinion gear (14) in carrier case, insert ball (15)
in shaft (13), then press fit.
Press fit so that the hole for the lock ball is on
the outside circumference, then stop with the
hole at the front and align the holes.
After press fitting the shaft, check that the gear
rotates smoothly.
30-150
3. Wheel bearing adjustment

1) Insert ring gear assembly (12) in axle hous-
ing, fit retainer (11) tighten temporarily with
mounting bolts (10), and remove tool H6.
Measure thickness "b" of retainer before

installing. Do not insert shims in the retainer
when tightening temporarily.
Rotate the wheel hub 20 - 30 times and
tighten the bolts to a uniform torque.
Mounting bolt:
78.4 ± 4.9 Nm (57.9 ± 3.6 lbf ft)
2) Using a depth micrometer or dial gauge,

insert through measuring hole of retainer (21)
and measure clearance "a" from retainer to
face of housing.
ure at two places and take the
average.
0.3 mm added to measured valu e
difference C = a - b, becomes shim thickness.
the smallest number of shims whic h
gives the required thickness.
30-151
3) After installing tool H6 to brake housing and

wheel hub, remove retainer, insert the re-
quired number of shims and retainer, then
tighten mounting bolts.
When assembling shims, after installing
tool H6, always tighten the mounting
bolts uniformly to the specified tightening
torque.
Mounting bolt:
Mounting bolt:
279.5± 29.4 Nm (206.1 ± 21.7 lbf ft)
4. Planetary carrier
Fit O-ring, using eye-bolts (2) ( Thread dia. = 12
mm, Pitch = 1.75 mm) sling planetary carrier
assembly (7), set in mounting position and
tighten mounting bolts (6).
Because balance is bad, adjust the center of
gravity with a bar and install.
5. Axle shaft
Screw in bolt (D (Thread dia. = 12 mm, Pitch=
1.75 mm) in axle shaft and insert axle shaft as-
sembly (5).
If the position of the sun gear does not match,
rotate the wheel hub to align.
6. Cover
Fit O-ring, install final drive cover (4), then tighten
mounting bolts (3).
Mounting bolt:
68.6 ± 9.8 Nm (50.6 ± 7 lbf ft)
30-152
7. Refilling with oil

Tighten drain plug (2), then remove level plug,
and add oil through oil filter to specified level. Set
the machine so that the level plug of the final drive
is at the bottom when refilling with oil.
Axle oil: Approx. 78
8. Tire assembly
Raise tire assembly (1), set to wheel hub, and
tighten temporarily with wheel nuts. Then jack up
chassis with work equipment and jack, remov e
stand under axle, lower chassis to ground and
tighten wheel nuts to specified torque.
Wheel nut: 470 ± 49.0 Nm (347.4 ± 36.2

lbf ft)
(Width across flats: 30 mm)
30-153
DISASSEMBLY AND ASSEMBLY ORBIT-ROLL ASSEMBLY
REMOVAL OF ORBIT-ROLL
ASSEMBLY
ground and turn the steering fully to the
right. Then stop the engine and put blocks
under the wheels to prevent the machine
from moving.
1. Remove cover (1) from steering column.
2. Remove joint lock bolt (2).
3. Disconnect four hoses (3).

Mark the hoses and their destinations to facilitate
reassembly.
4. Remove three mounting bolts (4), then remove

Orbit Roll assembly (5).
5. Remove joint lock bolt (6), then remove joint as-

sembly (7).
6. Remove bolt (8), then remove bracket

(9).
INSTALLATION OF ORBIT-ROLL
ASSEMBLY
Carry out installation in the reverse order to re-
moval.
Joint lock bolt:

55.9 ± 7.8 Nm (41.2 ± 5.8 lbf ft)
Bracket mounting bolt :
51.9 ± 7.8 Nm (38.3 ± 5.8 lbf ft)
30-154
DISASSEMBLY OF ORBIT-ROLL
ASSEMBLY
Ensure a clean working environment.
1. Dirt or debris in the hydraulic system will cause

premature wear and erratic operation. Keep all
dirt and dust out of the hydraulic circuit.
2. Use a clean work bench when disassembling or

assembling the equipment.
3. Remove dirt from the exterior of the unit before

disconnecting any piping.
4. Always wipe dirt off the unit before placing it on

the work bench.
After disassembling, wash with a clean petro-
leum-base solvent, and blow dry with clean air.
Always ensure that there are no impurities in the
solvent or air.
If any other solvent is used, it may lead to
deterioration of the rubber seal. Never wipe
any part with a cloth or apply steam to the
unit.
The solvent is flammable. Keep flames and

sparks away.
PREPARATORY WORK
1) Fit blind plugs in the five ports in the valve
body, clean the outside, then remove the
blind plugs.
2) Install tube nut (1) to one of the ports.
3) Install in a vise (2) with the end cover at the
top.
Do not clamp the valve body directly in the
vise, which could damage or break the unit.
1. Remove 7 mounting bolts (1), insert screwdriver

between end cover assembly (2) and sleeve (3),
then remove end cover assembly (2).
After removing, check that there is no
damage to the edge of the hole in the end
cover.
30-155
2. Remove commutator (5) and washer (6).

Do not remove pin (4).
3. Using two mounting bolts (1), remove commutator

ring (7) and manifold (8).
4. Using two mounting bolts (1), remove rotor set (9)

and wear plate (10) in the same way as commu-
tator ring and manifold.
5. Insert screwdriver between sleeve (3) and valve

body (11), then remove sleeve (3).
6. Remove drive link(12).
7. Remove ball (13).
8. Remove rod (14), roller (15), rod (16), and spring

(17).
30-156
9. Install in vise with input shaft (18) at the top, and

make counter marks with a punch in upper cover
(19) and valve body (11).
10. Remove four mounting bolts (20), then grip input

shaft (18), move it up, and remove input shaft,
upper cover, and valve spool assembly (23).
The valve spool is fitted in the body with an

extremely small clearance, so if a horizontal
force is applied, it will be impossible to
remove it. When removing the valve spool
from the housing, never apply any excessive
force.
11. Remove upper cover assembly (22) from input

shaft and valve spool assembly (23), then remove
shim (24) and spacer (25).
shims, and keep in a safe place.
12. Remove seal (26) and snap ring (27), then

remove spacer (28), seal (29), and seal ring
(30) from upper cover (19).
30-157
Seal (29) and seal ring (30) may form one unit.
13. Remove snap ring (31), thrust washer (32),

thrust bearing (33), thrust washer (34), and
wave washer (35) from input shaft (18).
14. Use punch pin (3) (3.0 mm dia, 16 mm length),

to remove needle roller (36) from input shaft
(18).
Cushion the input shaft with a wooden block to

prevent damage when striking with the hammer.
30-158
15. Set valve spool (37) facing bottom, then remove

torsion bar (38) and spacer (39) from input shaft
and valve spool assembly.
Do not remove needle roller (40) from the
torsion bar.
16. Set valve spool (37) facing bottom, then rotate

input shaft (18) until drive link (41) comes out.
17. Set valve spool (37) facing bottom, then rotate

input shaft (18) clockwise to a point where ball
comes out.
Ball (42) may come out by itself, so be
careful not to lose it.
Do not remove ball retaining spring (43)

unless it is to be replaced. When removing
it, hold the flat end with pliers and pull up
until it comes completely out from valve
spool (37). When doing this, be careful not
to damage the outside of the valve spool or
the control edge.
30-159
ASSEMBLY OF ORBIT-ROLL
ASSEMBLY
Before assembly, wash all parts with clean
petroleum based solvent and dry with air. Never
wipe with a cloth.
Check carefully that there is no debris or paint
on the edge of the lapped surface.
If there are no special instructions, do not coat
any parts with oil when assembling.
1. Set thrust washer (34), thrust bearing (33), and

thrust washer (32) to input shaft (18), and install
snap ring (31).
2. Install wave washer (35) to thrust bearing (33)
and thrust washer (34).
3. Install ball (42) inside valve spool (37).
4. To mesh the groove and ball, rotate

counterclockwise and insert input shaft (18) into
valve spool (37).
Keep the spool horizontal when doing this.
5. Fit center portion of torsion bar (38) between

thrust washer (34) and valve spool (37).
30-160
The positioning of the valve spool and input

shaft is carried out by inserting the torsion bar.
6. Check spline of input shaft (18) and drive link

(41), and align spline of valve spool (37), then
install drive link (41).
If the drive link and input shaft do not mesh,

rotate the input shaft slightly to carry out the
meshing.
When inserting the drive link, make sure that the
torsion bar is securely held in position.
If the drive link is assembled correctly, there will
be a clearance of 8.89 mm between the thrust
washer and valve spool.
If the relationship between the spool, drive link,
and input shaft is not correct, the steering unit
will not work properly.
7. Measure diameter L of pin (40) of torsion bar

(38) at several points and check that the
difference does not exceed 0.025 mm.
8. Set spacer (39) to torsion bar (38), then insert in

valve spool and input shaft assembly (23).
30-161
9. Using pin (3) (outside diameter: 3 mm), align pin

hole of input shaft (18) and torsion bar (38).
10. Using pin (1), knock pin (36) 0.8 mm in from

end face of input shaft.
11. Install spacer (25) on valve spool and input

shaft. If there is a lip at one end inside the
spacer, install so that the lip surface is facing
the wave washer.
12. Install input shaft and valve spool assembly (23)

to valve body (11).
The clearance is extremely small, so if any
sideways pressure is applied during assembly, it
will not work properly.
13. Set shim (24) on top of thrust washer, fit seal,

align counter marks of upper cover (19), then
install and tighten mounting bolts (20)
temporarily.
14. Set tool F1 in position, and install so that valve

body and upper cover are centered.
15. Tighten mounting bolts (20) and remove tool

F1.
Mounting bolt :
27.4 ± 2.5 Nm (19.9 ±1.8 lbf ft)
30-162
16. Measure width

several places and check that the difference
does not exceed 0.025 mm.
17. Pull input shaft down, align drive link (12) with
spline of valve spool, then rotate spool so that
end face of spool and valve body are level with
each other.
18. Align pin (40) and drive link (12) and install.
19. Using depth gauge (6), measure installed height

h of end face of valve body and valve spool.
30-163
h = Within 0.063 mm.....

Not necessary to adjust shim.
If installed height h = 0.064 mm or more, repea t
Steps -12 through 19 to adjust the shim height so
that h = Within 0.063 mm.
20. Install ball (13).
21. Set rod (17) to spring (16), then fit to valve body
(11) and install roller (15) and rod (14).
22. Fit seal to valve body.
23. Before installing rotor, check rotor as follows.

1) Set the pin end of end cover assembly at top
and spline end of rotor assembly (9) at bot-
tom, then check that rotor rotates freely inside
stator.
2) Measure thickness of rotor and stator, and

check that the difference is less than 0.18
mm.
3) Using feeler gauge (7), check that the clear-

ance of the rotor from the stator is less than
0.18 mm.
30-164
24. Using guide pin (8), install wear plate (10), rotor
assembly (9), and manifold (8).
25. Fit seal to end cover assembly (2).
26. Set sleeve (3) and end cover assembly (2) in

position, tighten mounting bolts (1) uniformly, then
install sleeve, and remove end cover assembly.
27. Fit washer (6) to end cover assembly (2), and

install commutator (5).
Install the commutator so that the concav e
part is at the end cover assembly end.
Determine the position so that the oval hole of

the commutator is in line with one of the bolt
holes of the end cover assembly.
30-165
28. Install commutator ring (7).

29. Rotate input shaft so that tip of drive shaft is
aligned with oval hole in commutator.
30. Set end cover assembly (2) on sleeve (3), then

tighten five mounting bolts uniformly.
Mounting bolt:
6.9 ± 0.6 Nm (60.7 ± 5.2 lbf in)
31. Set input shaft end facing top, then install seal
ring (30) and seal (29).
Install the seals from the small diameter
end.
Seal ring (30) and seal (29) are stuck
together and are supplied as one unit.
Coat the new seal with oil and install from
the lip end.
When doing this, coat the inside with a
small amount of grease.
32. Using tool F2, install spacer (28) from small di-
ameter end.
33. Install snap ring (27).
34. Fit seal (26) to input shaft, and fit to upper cover.
30-166
DISASSEMBLY AND ASSEMBLY STEERING CYLINDER
REMOVAL OF STEERING
CYLINDER ASSEMBLY
ground, install the safety bar on the
frame, and put blocks under the wheels
to prevent the machine from moving.
1. Remove bolts (1), loosen bolt (2), then rotate

cover (3) carefully towards rear of machine.
Rotate the cover using bolt (2) as the fulcrum.
The operating space is confined, so be

extremely careful when carrying out the opera-
tion.
2. Disconnect bottom hose (4).
3. Disconnect grease tube (5).
4. Remove mounting bolt (6), then pull out pin (7).

Note the number and thickness of the shims
to use as a guideline when assembling.
5. Disconnect head hose (8).
30-167
DISASSEMBLY AND ASSEMBLY STEERING CYLINDER ASSEMBLY
6. Remove mounting bolt (9), then pull out pin

(10).
Note the number and thickness of the shims
to use as a guideline when assembling.
7. Using lever block, lift off steering cylinder (11).

Carry out the removal operation for the
cylinder using two workers.
Be careful not to damage the cylinder rod.
Steering cylinder : 47 kg (103.4 lb)
INSTALLATION OF STEERING
CYLINDER ASSEMBLY
Carry out installation in the reverse order to re-
moval.
WARNING! When aligning the position of

the pin hole, use a bar. Never insert your
fingers in the pin hole.
Adjust the shims so that the clearance is

specified value.
Clearance a + b = Less than 1.0 mm
(The specified value is the same for both
the rod end and the bottom end.)
30-168
DISASSEMBLY OF STEERING
CYLINDER ASSEMBLY
1. Set cylinder assembly (1) in tool U1.
2. Raise lock of cylinder head (2), then using tool

U2, remove cylinder head (2) from cylinder.
3. Pull cylinder head and piston rod assembly (3)

out from cylinder (4), then lift off.
Oil will come out when the piston rod
assembly is removed from the cylinder, so
catch it in a container.
4. Remove cylinder (4) from tool U1.
5. Set cylinder head and piston rod assembly in

tool U1, and, using power wrench (1) and
socket U3, loosen nut (5).
Power wrench: x 16
Socket U3: Width across flats: 60 mm
6. Remove nut (5), then remove piston assembly

(6), and cylinder head assembly (7) from rod
(8).
30-169
7. Disassembly of piston assembly

1) Remove wear ring (9).
2) Remove piston ring (10) from piston (11).
8. Disassembly of cylinder head assembly

1) Remove snap ring (16), then remove dust
seal (17).
2) Remove rod packing (18).

3) Remove buffer ring (19).
4) Remove O-ring (20) and backup ring (21).
5) Remove O-ring (22).
6) Remove bushing (23) from cylinder head
(24).
30-170
ASSEMBLY OF STEERING
CYLINDER ASSEMBLY
Clean all parts, and check for dirt or damage.
Coat the sliding surfaces of all parts with engine
oil before installing. Be careful not to damage
the rod packing, dust seals or O-ring when
assembling.
1. Assembly of cylinder head assembly

1) Using tool U5, press fit bushing (23) to
cylinder head (24).
Be extremely careful not to deform the
bushing when press fitting.
2) Install buffer ring (19).
3) Install rod packing (18).
Be careful to install rod packing (18)
facing in the correct direction.
4) Using push tool, install dust seal (17) to
cylinder head (24).
6) Install O-ring (22).
7) Install backup ring (21) and O-ring (20).
Do not try to force the backup ring into
position.
Warm it in water (50 - 60
2. Assembly of piston assembly

1) Using tool U6-1, expand piston ring (10).
Place the piston ring on the expander
and turn the handle 8 - 10 times to
expand the ring.
2) Remove piston ring (10) from tooI U6-1, and
assemble on piston (11).
3) Fit tooI U6-2, on piston ring, then using clamp

U6-3, contact piston ring.
4) Assemble wear ring (9).
30-171
3. Set piston rod (8) in tool U1.
4. Assemble cylinder head assembly (7) and piston

assembly (6) no rod, then fit nut (5).
5. Using power wrench (1) and socket U3 tighten nut

(5).
Piston nut:
Power of power wrench (1) X16
Width across flats of nut (5) 60 mm
Tightening torque of nut 1,765 ± 176 Nm

(1302 ±132 lbf ft)
6. Remove piston rod and head assembly from tool

U1.
7. Set cylinder (4) in tool U1.
8. Raise piston rod and head assembly (3), and

assemble in cylinder (4).
9. Using tool U2, tighten cylinder head nut (2).
Cylinder head nut:

932.0 ± 93.2 Nm (687.1 ± 68.7 lbf ft)
10. Bend lock into notch on cylinder side.
11. Remove cylinder assembly from tool U1.
30-172
DISASSEMBLY AND ASSEMBLY STEERING VALVE
REMOVAL OF STEERING VALVE

ASSEMBLY
ground and turn the steering fully to the
right. Then stop the engine and put
blocks under the wheels to prevent the
machine from moving.
1. Remove bolt (1), Ioosen bolt (2),then rotate cover

(3) carefully towards rear of machine.
Rotate the cover using bolt (2) as the
fulcrum.
extremely careful when carrying out the
operation.
2. Remove side cover (4).
3. Remove mounting bolts (5), and disconnect

bracket (6).
4. Remove mounting bolts (7), and disconnect

bracket (8).
5. Disconnect hose (9) between cut-off valve and

hydraulic tank.
6. Disconnect hoses (10) and (11) between cut-off

valve and loader circuit.
7. Disconnect hose (12) between steering valve and

cut-off valve.
Hose (12) is at the rear of the cut-off valve.
30-173
8. Disconnect tubes (13) between steering valve and

steering cylinder.
9. Disconnect tube, (14) between steering valve and

hydraulic tank.
10. Disconnect hose (15) between stop valve and

steering valve.
11. Disconnect hose (16) between stop valve and

steering valve.
It is connected to both ends of the steering
valve.

steering pump.
13. Disconnect tube (18) between switch pump and

steering valve.

cut-off valve.
15. Remove mounting bolt (20).
16. Using guide bolt (1), pull out steering valve

assembly (21) together with bracket approx. 200
mm to center of machine.
Remove the cut-off valve at this point.
30-174
17. Lift off steering valve assembly (21) together with

bracket.
INSTALLATION OF STEERING
VALVE ASSEMBLY
removal.
Install the cut-off valve after lowering the

steering valve assembly together with the
bracket to the mounting position.
After installing the cut-off valve, use the guide
bolt to move close to the frame and install.
30-175
DISASSEMBLY AND ASSEMBLY BRAKE VALVE
REMOVAL OF BRAKE VALVE

ASSEMBLY
ground and put blocks under the wheels to
1. Remove clamp (1) at front of brake valve.
2. Disconnect hose (2) between valve and hydraulic

tank.
3. Disconnect hoses (3) and (4) between

accumulator and valve.
Fit a wrench to the joint to stop it from turning.
4. Remove hoses (5) between R.H. brake valve and

slack adjuster.
5. Remove clamp (6).
6. Disconnect hose (7) between R.H. brake valve

and L.H. brake valve.
7. Disconnect hose (8) between valve and hydraulic

tank.
8. Disconnect hose (9) between accumulator and

valve.
9. Remove pedal (10).
10. Pull out snap pin (11), then pull out pin (12).
Be careful not to lose L-shaped pin (13).
30-176
DISASSEMBLY AND ASSEMBLY BRAKE VALVE
11. Remove mounting bolts (14), then remove brake

valve assembly (15).
Carry out the operation with two workers and
remove the valve assembly from under the
floor plate.
INSTALLATION OF BRAKE
VALVE ASSEMBLY
Reverse the removal procedure to install a brake
valve assembly.
30-177
DISASSEMBLY AND ASSEMBLY SLACK ADJUSTER
REMOVAL OF SLACK
ADJUSTER ASSEMBLY
1. Remove cover (1) on top of front frame.
2. Disconnect tube (2) between brake valve and

slack adjuster.
3. Disconnect tube (3) between slack adjuster and

left and right brake pistons.
4. Remove mounting bolts, then remove slack

adjuster (4).
operation.
INSTALLATION OF SLACK
ADJUSTER ASSEMBLY
removal.
Tube: 80.9 ± 12.3 Nm (60 ± 9.4 lbf ft)
Tube: 68.6 ± 9.8 Nm (50.6 ± 7.2 lbf ft)
30-178
DISASSEMBLY OF SLACK
ADJUSTER
1. Bleeder
Remove bleeder (2) from body (1).
2. Cylinder
Remove mounting bolts, then disconnect body (1)
and cylinder (4) together with bracket (3).
WARNING! There is spring tension inside the

cylinder, so hold the contact surfaces and be
careful when removing.
3. Piston
1) Remove spring (5) and O-ring (6).
2) Remove piston (7), then remove O-ring
Use a rod of 10 mm diameter and pus h
out the piston slowly.
Be careful not to damage the thread with
the rod.
4. Poppet
Do not disassemble the poppet unless
necessary. If it is disassembled, replace the
whole cylinder assembly.
1) Remove cover (8) from cylinder (4), then
remove plug (9), spring (10) and poppet (11).
When removing the poppet, blow in air

from the oil hole in the cylinder.
Hold the oil port of the cylinder by hand,
and do not pump in air suddenly.
Be careful not to change the combination
of poppet (11) and cylinder (4).
When replacing, replace the poppet and
cylinder as an assembly.
2) Remove O-ring (12) from poppet.
30-179
ASSEMBLY OF SLACK
ADJUSTER
1. Poppet
1) Fit O-ring (12) on poppet (11).
2) Install poppet (11), spring (10), plug (9) and
cover (8), then assemble cylinder (4).
2. Piston
1) Install O-ring (13) on piston (7).
2) Insert piston (7) in cylinder (4).
Check that the piston moves smoothly.
3. Cylinder
1) Install O-ring (6) and spring (5) in cylinder.
Installed load of spring 43.1 Nm (4.4 kg)
(9.68 lb)
2) Install body (1) and cylinder (4) together with
bracket (3).
4. Bleeder
Install bleeder (2).
30-180
DISASSEMBLY AND ASSEMBLY BRAKE
REMOVAL OF BRAKE
ASSEMBLY (FRONT, REAR)

1. Remove final drive assembly. For details, see

DISASSEMBLY OF FINAL DRIVE ASSEMBLY.
2. Disconnect brake tube (1).
3. Set tooI H6 in position, and sling brake and wheel

hub assembly, remove mounting bolts (2), then lift
off brake and wheel hub assembly (3).
Brake, wheel hub assembly: 280 kg

(617.3 lb)
4. Remove bearing (5) and retainer (6) from axle (4).
INSTALLATION OF BRAKE
• Carry out installation in the reverse order to
removal.
Brake tube: 68.6 ± 9.8 Nm (50.6 ± 7.2 lbf

ft)
Brake, wheel hub mounting bolt:

548.8± 58.8 Nm (405.1 ± 43.4 lbf ft)
30-181
DISASSEMBLY OF BRAKE
1. Cylinder
Using eye-bolt (1) (Thread dia. = 16 mm, Pitch =
2.0 mm), lift out cylinder (1).
Disassemble cylinder with following steps:

1) Screw in eye-bolts (1) (Thread dia.=16 mm,
Pitch 2.0 mm), push in spring with bar (2),
then pull out pin (2).
2) Remove spring (3) and shaft (4).
3) Remove piston (5).
2. Plate, disc
1) Remove plate (6).
30-182
2) Remove disc (7).

When removing the disc and plates, put
match marks on the inner gear and disc, and
outer gear and plate before removing.
The discs are made of soft material, so b e
careful not to damage them during removal.
Remove discs and plates alternately.
3. Gear assembly
1) Remove tool H6.
2) Using eyebolt (3) (Thread dia.=12 mm, Pitch

=1.75 mm), lift off gear (8).
3) Remove plate (9) from gear (8).
4) Remove floating seal (10) and oil seal (11)

from gear (8).
30-183
4. Floating seal, outer race

1) Remove floating seal (12) from hub (13).
2) Remove outer races (14) and (15) from hub
(13).
30-184
ASSEMBLY OF BRAKE
1. Outer race, floating seal
1) Using push tool (4), press fit outer race (15)
to hub (13).
2) Using push tool (5), press fit outer race (14 )
to hub (13).
3) Using tooI H9, install floating seal (12) to hub

(13).
Seal contact surface:

Engine oil (EO30-CD)
Assemble O-ring (12) to floating seal.
Use alcohol to completely remove any white
blooming from the surface of the O-ring.
Remove all oil and grease from the floating
seal and hub O-ring contact surface.
Tighten tool H9 uniformly to prevent twisting
of the floating seal O-ring. After press fitting,
measure height at four places around the
circumference and check that the difference
in dimension t at all four places is within 1
mm.
2. Gear assembly
1) Using tool H5, install oil seal (11) to gear (8).
Mating surface of oil seal hub:

Thread tightener (Loctite #648)
30-185
2) Using tooI H8, install floating seal (10) to gear

(8).
Seal contact surface:
Engine oil (E030-CD)
Assemble O-ring (10) to floating seal.
Use alcohol to completely remove any white
blooming from the surface of the O-ring.
Remove all oil and grease from the floating
seal and retainer O-ring contact surface.
Tighten tool H8 uniformly to prevent twisting
of the floating seal O-ring. After press fitting,
measure height t at four places around the
circumference and check that the difference
in dimension t at all four places is within 1
mm.
3. Assemble plate (9), then using eyebolt (3)

(Thread dia.=12 mm, Pitch= 1.75 mm), raise gear
(8) and install.
4. Install tool H6.
30-186
5. Disc, plate
1) Install disc (7).
2) Install plate (6).

Align notched portion of outer teeth of plate
and assemble.
Align the counter marks on the disc and inner
gear, and plate and outer gear, then
assemble the plates and discs in turn.
6. Cylinder
Assemble cylinder with following steps:
1) Set piston (5) at bottom.
2) Install shaft (4) and spring (3).

3) Screw in eye-bolts (1) (Thread dia. = 6 mm,
Pitch = 2.0 mm), push in spring with bar (2),
then install pin (2).
30-187
4) Fit O-ring and using eye-bolts (1) (Thread dia. =

16 mm, Pitch = 2.0 mm), match with guide bolt (i)
and lift and install cylinder assembly (1).
Mounting bolt:
Mounting bolt:
176.5 ± 19.6 Nm (130.2 ± 14.5
lbf ft)
30-188
DISASSEMBLY AND ASSEMBLY HYDRAULIC PUMP
REMOVAL OF HYDRAULIC
PUMP (SWITCH & PPC,
LOADER, TORQUE
CONVERTER-TRANSMISSION,
STEERING) ASSEMBLY
1. Remove engine hood assembly.

For details, see REMOVAL OF ENGINE
HOOD ASSEMBLY.
2. Remove bulkhead assembly.

For details, see REMOVAL OF BULKHEAD
ASSEMBLY.
3. SWITCH+PPC pump assembly

1) Disconnect hose (1) and tube (2).
2) Remove mounting bolt (3).
3) Lift off pump assembly (4).
4. Loader pump assembly

1) Remove bolts (5), and disconnect tube
(6) together with hose.
2) Disconnect hose (7).
3) Remove U-bolts (8), then remove

bracket (9).
4) Remove bolt (10), then remove tube (11).
5) Remove bolt (12), then remove pump
assembly (13).
6) Disconnect tube (14).
30-189
DISASSEMBLY AND ASSEMBLY HYDRAULIC PUMP
5. Steering pump assembly

1) Remove drive shaft assembly (15).
2) Disconnect tube (16).

3) Remove bolt (17), then remove pump
assembly (18).
6. Transmission, torque converter pump

assembly
1) Disconnect hose (18).
2) Disconnect tube(19).
3) Remove mounting bolt (20), then remove
pump assembly (21).
INSTALLATION OF HYDRAULIC
PUMP (SWITCH & PPC,
LOADER, TORQUE
CONVERTER-TRANSMISSION,
STEERING) ASSEMBLY
removal.
Drive shaft:
110.7 ± 12.7 Nm (81.0 ± 9.4 lbf ft)
30-190
DISASSEMBLY AND ASSEMBLY HYDRAULIC TANK
TANK ASSEMBLY
WARNING! Loosen the oil filler cap slowly to

release the pressure inside the hydraulic
tank. Then operate the steering wheel and
control levers several times to release the
remaining pressure in the hydraulic piping.
• Remove cover (1).
• Loosen plug (2) on top of the hydraulic tank filter
and bleed the air from tank.
1. Remove plug (3), then loosen valve (4) and drain

hydraulic oil.
Hydraulic oil: 175
2. Sling ladder floor (5), then remove mounting bolts

and lift off.
Be careful of the center of gravity when lifting
off the ladder floor.
Ladder floor: 90 kg (198 lb)
3. Disconnect main suction tube (6).
4. Disconnect return tube (7) from cooler.
5. Disconnect main return tube (8).
30-191
DISASSEMBLY AND ASSEMBLY HYDRAULIC TANK
6. Disconnect hose (9) between brake valve and

hydraulic tank.
7. Disconnect stop valve, charge valve, PPC,

Orbit-roll, and drain hoses (10).
8. Sling hydraulic tank, then remove mounting bolts

(11) and (12).
9. Lift off hydraulic tank assembly (13).

Hydraulic tank assembly: 240 kg (308 lb)
TANK ASSEMBLY
removal.
Plug: 11.8 ± 1.0 Nm (8.7 ± 7.2 lbf ft)
Hydraulic tank bolt: 277.3± 32.3 Nm

(205 ± 23.9 lbf ft)
30-192
DISASSEMBLY AND ASSEMBLY HYDRAULIC FILTER
FILTER ASSEMBLY
tank.
1. Remove cover (1).
2. Loosen plug (2) and bleed air from tank, then

remove mounting bolts, and remove cover (3).
WARNING! The cover is under pressure

from a spring. Remove the cover slowly and
carefully.
3. Remove spring (4).
4. Remove bypass valve (5).
5. Remove filter (6).
FILTER ASSEMBLY
removal.
Plug: 11.8 ± 1.0 Nm (8.7 ± 7.2 lbf ft)
30-193
DISASSEMBLY AND ASSEMBLY PPC VALVE
REMOVAL OF PPC VALVE

ASSEMBLY
and put blocks under the wheels td prevent

• Open cover (1).
• Loosen plug (2) on top of the hydraulic tank filter
and bleed the air from tank.
1. Remove console box cover (3) on right side of

operator's seat.
2. Disconnect rods (4).
3. Disconnection of hoses from PPC valve

1) Disconnect hoses P1 (5) and P4 (6) for
bucket control
2) Disconnect hoses P3 (7) and P2 (8) for boom
control
3) Disconnect hose (9) from PPC pump
4) Remove eyebolt (10) of return hose leading
to hydraulic tank.
After disconnecting the hoses, fit tags to
distinguish them.
4. Remove mounting bolts (11), then remove PPC

valve assembly (12).
INSTALLATION OF PPC VALVE

ASSEMBLY
removal.
Plug: 11.8 ± 1.0 Nm (8.7 ± 7.2 lbf ft)
30-194
DISASSEMBLY AND ASSEMBLY PPC VALVE
DISASSEMBLY OF PPC VALVE

ASSEMBLY
1. Remove bolt (1).
2. Remove plate (2).
3. Remove seal (3), then remove collar (4).
4. Remove valve assembly and center spring (7)

from valve body (10).
5. Remove collar (11), then remove retainer (6),

shim (12), and spring (8) from valve (9).
ASSEMBLY OF PPC VALVE

ASSEMBLY
1. Push shim (12), spring (8), and retainer (6) into
valve (9), and install collar (11).
2. Install center spring (7) and valve assembly to

valve body (10).
3. Install spool (5).
4. Fit O-ring and install collar (4).
5. Install seal (3).
6. Fit plate (2) and install bolt (1).
Bolt: 44.1 ± 4.9 Nm (325.5 ± 36.2 lbf ft)
30-195
DISASSEMBLY AND ASSEMBLY MAIN CONTROL VALVE
REMOVAL OF MAIN CONTROL

VALVE ASSEMBLY
1. Open cover (1).
2. Loosen plug (2) on top of the hydraulic tank filter

and bleed air from tank.
3. Remove bucket cylinder assembly. For details,

see REMOVAL OF BUCKET CYLINDER
ASSEMBLY.
4. Remove bolt (3), then remove cover (4).
5. Remove bolt (5), and loosen bolt (6), then rotate

cover (7) carefully to right.
Rotate the cover on the right side of the
chassis to the left.
Rotate the cover using bolt (6) as the fulcrum.
operation.
6. Disconnect hose (13) for bucket spool between

PPC valve (P1) and main control valve (PB1).
30-196
7. Disconnect hose (14) for boom spool between

PPC valve (P3) and main control valve (PB2).
8. Disconnect hose (15) for bucket spool between

PPC valve (P4) and main control valve (PA1).
9. Disconnect hose (16) for boom spool between

PPC valve (P2) and main control valve (PA2).
Remove the hose clamp.
After disconnecting the hose, move it to the
rear of the machine.
distinguish them.
10. Disconnect hose (17) between main control valve

and hydraulic tank.
11. Remove tube (18) between main control valve

and bucket cylinder together with hose.

and boom cylinder.
13. Disconnect tube (20) from manifold.
14. Remove bracket (21) of tube.

main control valve from main control valve.
16. Disconnect tube (23) between hydraulic tank and

main control valve from main control valve.
30-197

and bucket cylinder together with hose.
18. Disconnect tube (25) between main control valve

and boom cylinder from main control valve.
Loosen the tube clamp.
19. Remove mounting bolts and rotate main control

valve (26) 90
20. Using eyebolts, lift off main control valve.

Be careful of the slack adjuster bleed screw
when removing.
Main valve: 91 kg (200.2 lb)
INSTALLATION OF MAIN
CONTROL VALVE ASSEMBLY
removal.
Plug: 11.8 ± 1.0 Nm (8.68 ± .7 lbf ft)
To refill with oil (hydraulic tank), add oil

through oil filler to the specified level.
Run the engine to circulate the oil through the
system. Then check the oil level again.
30-198
DISASSEMBLY OF MAIN CONTROL VALVE
1. Spool assembly 1) Remove sleeve (1), then remove case (2).
30-199
2) Remove spring (3) and retainer (4).

3) Remove spring (5) and retainer (6).
4) Remove piston (7), spring (8), and spacer (9).
5) Remove spool assembly (10).
Disassemble spool assembly.
Remove plugs (12) and (13) from spool
(11).
2. Main relief valve

1) Remove main relief valve assembly (14).
Disassemble main relief valve assembly.
i) Loosen nut (15), and pull out adjustment
screw (16), then remove retainer (17),
spring (18), spacer (19), and poppet (20)
Before loosening nut (15), measure
the protrusion of screw (16) from the
end face of the nut.
ii) Loosen nut (21), then remove holder
(22), seat (23), and backup ring (24).
iii) Remove snap ring (25), then remove
retainer (26), valve (27), and spring (28)
from sleeve (29).
iv) Remove backup ring (30) from sleeve.
If there is any abnormality in the
sleeve or valve, replace as an
assembly.
3. Safety valve assembly with suction

Remove safety valve assembly (31).
The safety valve cannot be adjusted when it
is on the machine, so do not disassemble it.
30-200
4. Suction valve assembly

Remove suction valve assembly (32).
Disassemble suction valve assembly (32).
i) Remove valve (33) together with seal
(34).
ii) Remove seal (34) from valve (33).
iii) Remove spring (35) from sleeve (36).
If there is any abnormality in the sleeve or
valve, replace as an assembly.
5. Selector valve assembly

Remove selector valve assembly (37).
1) Remove sleeve (38) together with seat (39).
Seat (39) is press fitted to sleeve (38)
(press fitting load: 1,177 - 7,845 N (120 -
800 kg), so if there is any abnormality
replace as an assembly. (The same
applies for the sleeve.)
2) Remove nipple (40), then remove shim (41),
spring (42), and piston (43).
shims, and keep in a safe place.
6. Check valve assembly

1) Remove plate (44), then remove spring (45)
and check valve (46).
2) Remove flange (47), then remove spring (48),
seal (49), and valve (50).
30-201
MEMORANDA
30-202
ASSEMBLY OF MAIN CONTROL VALVE
30-203
1. Check valve assembly

1) Assemble valve (50), seal (49), and spring
(48) in valve body (51), then fit O-ring and
install flange (47).
Flange surface: Thread tightener (LT-2)
2) Assemble check valve (46) and spring (45) in

valve body, then fit O-ring and install plate
(44).
88.2 ± 9.8 Nm (65.1 ± 7.2 lbf ft)
2. Selector valve assembly

Assemble selector valve assembly.
1) Assemble piston (43), spring (42), and shim
(41) in sleeve (38), then fit O-ring and install
nipple (40).
Nipple: 22.1 ± 2.5 Nm (162.5 ± 18.1 lbf ft)
Fit O-ring and install selector valve assembly (37).
Selector valve
68.6 ± 9.8 Nm (50.6 ± 7.2 lbf ft)
3. Suction valve assembly

Assemble suction valve assembly.
i) Assemble spring (35) in sleeve (36).
ii) Assemble seal (34) in valve (33), and

install to sleeve (36).
Fit O-ring and install suction valve assembly (32).
Suction valve assembly:

186.2 ± 9.8 Nm (130.2 ± 7.2 lbf ft)
4. Safety valve assembly with suction

Fit O-ring and install safety valve assembly (31).
Safety valve :
186.2 ± 9.8 Nm (130.2 ± 7.2 lbf ft)
30-204
5. Main relief valve assembly

Assemble main relief valve.
i) Install backup ring (30) and O-ring to
sleeve (29).
ii) Assemble spring (28), valve (27), and
retainer (26) in sleeve (29), and install
snap ring (25).
iii) Fit backup ring (24) and O-ring, and
assemble seat (23) in sleeve.
iv) Screw nut (21) into holder (22), then fit
O-ring and assemble in sleeve, and
tighten nut.
Holder: 39.2 ± 9.8 Nm (28.9 ± 7.2 lbf

ft)
Nut thread Thread tightener (LT-2)
Nut: 152.0 -± 24.5 Nm (112.1 ± 18.1

lbf ft)
v) Assemble poppet (20), spacer (19),

spring (18), and retainer (17), and screw
in adjustment screw (16). Adjus t
protrusion from end face of nut (15) to
same dimension as at time of
disassembly, then tighten with nut (15).
Nut thread: Thread tightener (LT-2)
Nut: 39.2 ± 4.9 Nm (28.9 ± 3.6 lbf ft)
Fit O-ring and install main relief valve assembly

(14).
Main relief valve assembly:

323.6 ± 44.1 Nm (238.7 ± 32.5 lbf ft)
6. Spool assembly
Assembly of spool assembly.
Install plugs (13) and (12) to spool (11).
Nut thread: Tightener (LT-2)
Nut: 24.5 ± 4.9 Nm (18.1 ± 3.6 lbf ft)
1) Assemble spool assembly (10) in valve body.

2) Assemble spacer (9), spring (8), and piston
(7).
3) Assemble retainer (6), spring (5), retainer (4),
and spring (3), then fit O-ring and install case
(2) and sleeve (1).
30-205
DISASSEMBLY AND ASSEMBLY BUCKET CYLINDER
REMOVAL OF BUCKET
CYLINDER ASSEMBLY
WARNING! Pressure in the hydraulic system

must be released. Loosen the oil filler cap
slowly to release pressure inside the hydraulic
tank. Operate steering wheel and control
levers several times to release the remaining
pressure in the hydraulic piping.
1. Disconnect connector (1) for bucket positioner.
2. Disconnect grease tube (2) from bottom pin.
3. Disconnect head hose (3).
4. Disconnect bottom hose (4).
5. Sling cylinder then remove lockbolt, and remove

head pin (5).Sling from two points and be careful
of the center of gravity.
6. Remove lock bolt, then remove bottom pin (6).
If there are shims, check the number and

thickness of the shim.
30-206
DISASSEMBLY AND ASSEMBLY BUCKET CYLINDER
7. Remove bucket cylinder assembly (7).

Bucket cylinder assembly: 286 kg

(629.2 lb)
INSTALLATION OF BUCKET
CYLINDER ASSEMBLY
removal.
When aligning the pin hole at the bottom end,

assemble shims so that the total clearance
between the cylinder and frame is within the
specified value, then assemble pin (6) and
lock with the bolt.
WARNING! Align the position of the pin hole

with a bar. Never insert a finger in the pin
hole.
30-207
DISASSEMBLY AND ASSEMBLY BOOM CYLINDER
REMOVAL OF BOOM CYLINDER

ASSEMBLY
1 Lift off fender (1).

Fender: 25 kg (55 lb)
2. Sling boom cylinder, then remove lock bolt,

and remove pin (3).
Start the engine and operate the control
lever to retract the cylinder rod of the
cylinder where the pin has been
removed.
After stopping the engine, release the
remaining pressure from the hydraulic
piping.
3. Disconnect head hose (4) and bottom hose

(5).
4. Fit lifting tool to bottom of boom cylinder (2),

then use lever block (1) to pull out to rear of
machine.
5. Using forcing screws, remove bottom pin (6)

If there are shims, check the number and
thickness of the shim.
30-208
DISASSEMBLY AND ASSEMBLY BOOM CYLINDER
6. Lift off boom cylinder assembly (2).

Boom cylinder assembly: 272 kg

(598.4 lb)
INSTALLATION OF BOOM
CYLINDER ASSEMBLY
removal.
When aligning the pin hole at the bottom end,

assemble shims so that the total clearance
between the cylinder and frame is within the
specified value, then assemble pin (6) and
lock with the bolt.
WARNING! When aligning the position of the

pin hole, use a bar. Never insert your fingers
in the pin hole.
30-209
DISASSEMBLY AND ASSEMBLY BOOM AND BUCKET CYLINDERS
DISASSEMBLY OF BOOM AND

BUCKET CYLINDERS
ASSEMBLY
1. Set cylinder assembly (1) tool U1.
2. Remove mounting bolts (2) of cylinder head.
3. Pull cylinder head and piston rod assembly (3) out

from cylinder (4), then lift off.
Oil will come out when the piston rod

assembly is removed from the cylinder, so
catch it in a container.
4. Remove piston bolts (5), then remove spacer (6),

piston assembly (7) and cylinder head assembly
(8).
5. Remove O-ring (10) and backup ring (11) from

piston rod (9).
30-210
6. Disassembly of piston assembly

Remove wear ring (12) and piston ring (13) from
piston (14).
7. Disassembly of cylinder assembly

1) Remove O-ring (15 )and back up ring(16).
2) Remove snap ring, then remove dust seal
(17).
3) Remove rod packing (18).

4) Remove bushing (19).
30-211
ASSEMBLY OF BOOM AND

BUCKET CYLINDERS
ASSEMBLY
Clean all parts, and check for dirt or damage.
Coat the sliding surfaces of all parts with engine
oil before installing. Be careful not to damage the
U-packings, dust seals or O-ring when
assembling.
1. Assembly of cylinder head assembly

1) Using push tooI U5, press fit bushing (19) on
cylinder head (20).
Be careful not to deform the bushing
when press fitting.
2) Assemble rod packing (18).
Be careful to install the rod packing facing in
the correct direction.
3) Assemble buffer ring (21).
4) Assemble backup ring (16) and O-ring (15) in
order.
Do not try to force the backup ring into
position. Heat the backup ring in warm
water (50
5) Using push tool U4, install dust seal (17) to

cylinder head, then secure with snap ring.
30-212
2. Assembly of piston assembly

1) Using tool U6-1, expand piston ring (13).
Set the piston ring on the expander and
turn the handle 8 - 11 times to expand
the ring.
2) Remove piston ring from tool U6-1, and
assemble on piston (14).
3) Fit tools U6-2, on piston ring, then using
clamp U6-3, compress piston ring.
4) Assemble wear ring (12) on piston.
3. Assemble O-ring (10) and backup ring (11) on

piston rod (9).
4. Assemble cylinder head assembly (8) and piston

assembly (7) on piston rod.
Coat backup ring (11) with grease so that it
does not stick out, and assemble carefully.
5. Assemble spacer (6), then tighten piston bolts (5).
Piston bolt :
176.5 ± 19.6 Nm (130.2 ± 14.5 lbf ft)
Piston bolt: Adhesives (LT-2)
30-213
6. Set cylinder (4) in tool U1, then raise piston rod

and head assembly (3), and assemble in cylinder
(4).
Tighten cylinder head mounting bolts (2).
Cylinder head mounting bolt:

662 ± 74 Nm (501 ± 542.5 lbf ft)
Remove cylinder assembly (1) from tool U1.
30-214
DISASSEMBLY AND ASSEMBLY CENTER HINGE PIN
REMOVAL OF CENTER HINGE

PIN
Warning! Stop the machine on level ground,
install the safety bar on the frame, and block
the wheels to prevent the machine from
moving.
Warning! Loosen the oil filler cap slowly to
1. Open cover (1) and loosen plug (2) on top of

hydraulic tank to prevent oil from flowing out from
tank.
2. Remove bolt (3), then remove cover (4).
3. Remove plug (5), then loosen valve (6) and drain

hydraulic oil. When draining thehydraulic oil, drain
to the level of the bottom of each pipe.
Hydraulic oil :
140 f
piping)
4. Remove covers (7) and (8) at bottom of cab.
30-215
5. Remove left and right steering cylinder pins (9).

If there are shims between the pin and frame,
check the number and thickness.
6. Remove guard (10), then remove center drive

shaft (11).
Center drive shaft assembly: 31 kg (68.2

lb)
7. Disconnect hose (12) between brake valve and

slack adjuster.
8. Disconnect connectors (13) FR1 and (14) FR2.

Disconnect the clamps under the floor.
9. Disconnect hoses (15) and (16) between steering

valve and stop valve at steering valve end.

oil cooler.
11. Disconnect hose (18) between work equipment

control valve and hydraulic tank.
12. Disconnect hose (19) between work equipment

control valve and loader pump.
30-216
13. Disconnect bypass hose (20) from hydraulic

circuit at top of tank.
14. Disconnect hoses P1 (21) and P4 (22) for bucket

control.
15. Disconnect hoses P3 (23) and P2 (24) for boom

control.
Disconnect the clamps at the rear frame end.
16. Using hydraulic jack to rear frame, insert block (1)

while adjusting height.
Put support stands (2) under the left and right
side of the frame.
17. Put support stand (2) under counterweight.
18. Using jack under front frame, insert block (3).
19. Remove mounting bolts, then remove retainer

(25).
If there are shims between the retainer and
frame, check the number and height.
30-217
20. Adjust height carefully so that lower hinge pin (26)

can be removed easily by hand.
21. Remove spacer (27).

(28).
23. Using puller, remove upper hinge pin (29) and

spacer(30).
30-218
24. Remove safety bar, then pull out front frame

towards front and disconnect frame.
Be careful not to let the spacer at the top of
the lower hinge get caught in the rear frame.
Carry out the operation carefully and pay
attention to maintaining the balance.
Move approx. 100 mm (3.9 in) at a time.

(31).
frame, check the number and thickness.
26. Remove dust seal (32) from retainer (31).
27. Remove spacer (33) and dust seal (34) from front
frame.
30-219
28. Remove bearing (35).
29. Remove retainer (36).

frame, check the number and thickness.
30. Remove dust seal (37) from retainer.

Remove dust seal (38) at the frame end.
31. Remove bearing (39).
30-220
INSTALLATION OF CENTER
HINGE PIN
removal.
Plug: 11.8 ± 1.0 Nm (8.68 ± .7 lbf ft)
Adjust the shims so that the clearance is the

specified value.

110.7 ± 12.7 Nm (752.2 ± 94 lbf ft)
Outer circumference of hinge pin:

Grease (G2-LI)
Measure clearance c between the retainer
and frame at four places on the inside
circumference, and select a shim thickness to
make the value 0.08 - 0.18 mm less than the
measured value.
When adjusting the shim, temporarily tighten
the retainer mounting bolts to act as a
stopper.
When tightening the mounting bolts, first
tighten the retainer mounting bolts to the
specified torque, then tighten the pin
mounting bolts.
After selecting the shim, assemble the
retainer to the specified torque.
Remove all oil and grease from the mounting
bolts and mount holes.
Mounting bolt:
Thread tightener (Loctite 262)
Mounting bolt (48) when adjusting shims:
276.3 ± 29.4 Nm (206 ± 21.7 lbf ft)
Mounting bolt (48):
276.3 ± 29.4 Nm (206 ± 21.7 lbf ft)
Mounting bolt (49) when adjusting shims
382.2 ± 34.3 Nm (282.1 ± 25.3 lbf ft)
30-221
Assemble spacer (30), insert upper hinge

(29), then tap three times with a copper
hammer to settle the parts.
Never coat spacer (30) with grease.
Outer circumference of hinge pin

Grease (G2-LI)
Mounting bolt (46):
Thread tightener (Loctite 262)
Mounting bolt (46):
176.4 ± 19.6 Nm (130.2 ± 14.5 lbf ft)
Mounting bolt (47):
176.4 ± 19.6 Nm (130.2 ± 14.5 lbf ft)
Grease on spacer (28) may prevent the
mounting bolts being tightened to the
specified tightening torque. Remove any
grease and tighten again.
Use tool K2 to press fit the bearing and

spacer to the frame. Make sure the bearing is
not at an angle.
Fill the inside of the bearing with grease.
When assembling the bearing, be sure to
assemble the spacer.
The clearance of the bearing is adjusted, so
do not change the combination of bearing
and spacer.
When replacing, replace as a set.
Press fit so that the lip of the dust seal is
facing the outside.
Measure clearance a between retainer (31)

and hinge at four places on the inside
make the value 0.08 - 0.18 mm less tha n
the measured value.
Mounting bolt (when adjusting shims):
98.0 ± 9.8 Nm (72.3 ± 7.2 lbf ft)
Mounting bolt:
176.4 ± 19.6 Nm (130.2 ± 14.5 lbf ft)
30-222
Using tool K1, press fit the bearing and

spacer to the frame.
When press fitting the bearing, be careful that
the bearing is not at an angle.
Fill the inside of the bearing with grease.
When assembling the bearing, be careful not
to forget to assemble the spacer.
The clearance of the bearing is adjusted, so
do not change the combination of bearing
and spacer.
When replacing, replace as a set.
Press fit so that the lip of the dust seal is
facing the outside.
Measure clearance a between retainer (36)

and the hinge at four places on the inside
make the value 0.08 - 0.18 mm less than the
measured value.
Mounting bolt (when adjusting shims):

58.8 ± 5.9 Nm (43.4 ± 4.3 lbf ft)
Mounting bolt:
176.4 ± 19.6 Nm (130.2 ± 14.5 lf ft)
After completion of mounting the hinge pin, fill
with oil and bleed the air.
1) Tighten the plug on the top of the hydraulic tank

filter, then add hydraulic oil through oil filler to the
specified level.
Plug on top of filter

11.8 ± 1.0 Nm (8.7 ± .7 lbf ft)
Hydraulic oil: Approx. 140
Run the engine to circulate the oil
through the system. Then check the oil
level again.
2) Bleed the air from the brake system. For details,

see TESTING AND ADJUSTING.
30-223
DISASSEMBLY AND ASSEMBLY WORK EQUIPMENT
REMOVAL OF WORK
EQUIPMENT
install the safety bar on the frame, block the
1. Remove mounting pin (1) of bucket link.

Remove cord ring.
Tie the bucket link to the tilt lever with wire.
Mounting pin: 25 kg (55 lb)
2. Remove mounting pin (2) of bucket hinge.

Remove cord ring.
Warning! Use a bar to align the pin
holes. Never use your fingers.
3. Move machine to rear and disconnect bucket.
4. Temporarily sling bucket cylinder (3), pull pin (4),

then disconnect cylinder rod and tilt lever.
Attach lifting tool to bucket cylinder and
secure in the rear.
Bucket cylinder: 285 kg (627 lb)
5. Attach lever block (1) to boom cylinder (5), pull

machine to rear and remove mounting pin (6).
Boom cylinder: 272 kg (598.4 lb)
30-224
6. Temporarily sling bellcrank (7) and bucket link,

remove mounting pin (8), then lift out from boom
(9).
Remove with the bucket link still fitted.
Three technicians are necessary for removal
of mounting pin operation.
Bellcrank and bucket link: 615 kg (1365

lb)
Mounting pin: 59 kg (129.8 lb)
7. Temporarily sling bucket link (10), remove

mounting pin (11), then lift out from bellcrank (7).
Remove cord ring.
Bucket link: 103 kg (226.6 lb)
Note the number of shims at this location for

reference when installing.
8. Remove boom kickout switch (13).
9. Temporarily sling boom (9), pull out mounting pin

of boom, then lift out boom.
Shims are installed at connecting point of
front frame and boom, so check the number
of shims.
Boom: 2,025 kg (4455 lb)
30-225
10. Pull out dust seal (14) and bushing (15) from
boom (9).
bellcrank (7)
30-226
bucket link (10).
After long use, wear can make the pin difficult to

remove. A puller (pin puller jig) such as the one
shown here can be helpful when removing a pin.
30-227
INSTALLATION OF WORK
EQUIPMENT ASSEMBLY
removal.
Clearance g + h = Less than 1.0 mm

Be careful not to get cord ring (22) caught.
Clearance e + f = Less than 1.0 mm

Secure the bucket link and bellcrank with

wire.
Insert shims so that the clearance is equal on
the left and right.
Clearance c + d = Less than 1.0 mm
Align the hole in the boom mount and the

front frame, then insert shims to make th e
clearance equal on the left and right.
After assembling the pin, set the support
stand to the tip of the boom.
Grease each pin.
30-228
DISASSEMBLY AND ASSEMBLY BULKHEAD
REMOVAL OF BULKHEAD
ASSEMBLY
Warning! Stop the machine on level ground
1. Remove engine hood assembly (1). For details,

see REMOVAL OF ENGINE HOOD ASSEMBLY.
2. Remove bulkhead left side cover (2).
Disconnect the connector (BR1) at the
bottom at the engine end of the left side of
the bulkhead.
Reach in at the point marked by the arrow,

and disconnect the connector (BR1).
3. Remove bulkhead hood (3).
4. Remove floor plate (4).
5. Remove covers (5) and (6).
6. Disconnect hose (7) at receiver tank end.
7. Disconnect hose (8) at condenser end.

Disconnect the accelerator control cable at
the fuel pump end.
30-229
DISASSEMBLY AND ASSEMBLY BULKHEAD
8. Disconnect brake hoses (9), (10), and (11).
9. Disconnect emergency brake valve connecting

hoses (12), (13), and (14).
10. Disconnect accumulator charge valve connecting

hoses (15), (16), and (17).
11. Disconnect PPC pump connecting hose (18).
12. Disconnect PPC accumulator inlet hose (19).
13. Disconnect window washer hoses (20).
14. Disconnect transmission breather (21).

distinguish them.
15. Remove four mounting bolts (22) and (23).
16. Lift off bulkhead assembly (24).
Bulkhead assembly: 220 kg (484 lb)
INSTALLATION OF BULKHEAD
ASSEMBLY
Install the hoses without twisting or

interference.
When installing the hoses, be careful not to
let dirt, dust, or moisture get inside the hoses.
Using a gas charger (X3), charge with new
freon gas (R134a).
30-230
DISASSEMBLY AND ASSEMBLY ENGINE HOOD
REMOVAL OF ENGINE HOOD

ASSEMBLY
set the parking brake to the PARKING
position, and block wheels to prevent the
machine from moving.
Open the left and right inspection covers.
1. Remove exhaust tube (1).
2. Remove radiator grille (2).

Remove the baffle plate on both sides of the
radiator.
3. Disconnect head lamp connector (3).
4. Disconnect water level sensor connector (4).
5. Remove six mounting bolts (5) and four mounting

bolts (6).
6. Remove radiator support (7).
7. Lift off engine hood (8).

There are clamps for the air conditioner
hoses at two places inside the engine hood
on the right, so disconnect them.
Use a lever block to maintain the balance
when lifting off.
Engine hood assembly: 470 kg (1034 lb)
INSTALLATION OF ENGINE
HOOD ASSEMBLY
removal.
30-231
DISASSEMBLY AND ASSEMBLY FLOOR FRAME
REMOVAL OF FLOOR FRAME

ASSEMBLY
moving.
1. Remove cab assembly.

For details, see REMOVAL OF CAB ASSEMBLY.
2. Remove left and right ladders (1) and (2).
Ladder: 90 kg (198 lb)
3. Remove floor plate (4) and cover (3) of bulkhead.
4. Disconnect wiring connectors (5) (TM1, 2, LR1-

6).
5. Disconnect ground connection (6).
6. Disconnect hoses (7) between brake valve and

slack adjuster.
7. Disconnect hose (9) between Orbit-roll (8) and

hydraulic tank.
8. Disconnect hose (10) between Orbit-roll (8) and

accumulator.
9. Disconnect hoses (11) between Orbit-roll (6) and

stop valve.
10. Disconnect return hose (12) between Orbit-roll

valve and hydraulic tank.
11. Disconnect return hose (13) coming from PPC

valve.
12. Disconnect return hose (14) coming from brake

valve.
After disconnecting the hose, install a blind

plug to prevent contamination.
30-232
13. Remove mounting bolts (15), then remove brake

hose bracket (16).
14. Disconnect PPC hoses (17).

The hoses are fitted with self-seal couplings.
15. Disconnect hose (18) from accumulator.
16. Disconnect accumulator charge valve connecting

hoses (19) and (20).
17. Disconnect PPC accumulator connecting hose

(21).
18. Disconnect two window washer hoses (22).
19. Disconnect two hoses (23) from brake valve.
20. Disconnect air conditioner compressor hose (24).
There are hose clamps at two places inside

the engine hood. Remove the hose clamps.
21. Remove clamp (25) and joint (26), then remove

accelerator cable (27).
22. Disconnect heater hoses (28) and (29).

Hose (29) is installed under the connector at
the suction end of the water pump.
Drain the coolant.
30-233
23. Remove floor frame mount mounting nuts (30 )

(four places).
24. Lift off floor frame assembly (31).

Check that all the clamps and wiring
harnesses have been disconnected.
Floor frame assembly: 280 kg (617 lb)
INSTALLATION OF FLOOR
FRAME ASSEMBLY
removal.

interference.
When installing the hoses, be careful to

prevent dirt, dust, or moisture from getting
inside the hoses.

freon gas (R134a).
Mount nut:
277.3 ± 32.3 Nm (202.5 ± 23.9 lbf ft)
Refilling with coolant

Tighten radiator drain valve and add coolant
through water filler to the specified level.
Run the engine to circulate the coolant through
the system. Then check the water level again.
30-234
DISASSEMBLY AND ASSEMBLY COUNTERWEIGHT
REMOVAL OF COUNTERWEIGHT
moving.
1. Sling counterweight (19), then remove mounting

bolts, and lift off.
When lifting off the counterweight, be careful

to maintain the balance.
Counterweight: 1,500 kg (3,300 lb)
INSTALLATION OF
COUNTERWEIGHT
removal.
Counterweight mounting bolt:

1,568 ± 196 Nm (1157 ± 144 lbf ft)
30-235
DISASSEMBLY AND ASSEMBLY FUEL TANK
REMOVAL OF FUEL TANK

ASSEMBLY
moving.
1. Loosen drain valve (1) and drain fuel.

Check the fuel level before draining.
Fuel (when full): 486 )
2. Remove engine oil drain valve (2) from fuel tank.

3. Disconnect hose (3) between injection pump and
fuel tank.
4. Disconnect hose (4) between fuel tank and feed

Pump.
5. Disconnect spill hose (5).
6. Disconnect connector (6) for fuel level sensor.
7. Remove hoses (7) of blow-by and muffler.
8. Sling fuel tank assembly (8), then remove

mounting bolts and slowly lower the tank.
Put a pallet under the tank, then be careful to
maintain the balance of the tank assembly,
and lower it on to the pallet.
Fuel tank assembly: 246 kg (541.2

lb)
Before pulling out the fuel tank assembly,

remove breather tube (9).
The bottom surface of the tank is not flat,
and there is danger that it may slip, so be
extremely careful when handling it.
30-236
DISASSEMBLY AND ASSEMBLY FUEL TANK
INSTALLATION OF FUEL TANK

ASSEMBLY
removal.
Fuel tank mounting bolt:

931.0 ± 98.0 Nm (686 ± 72 lbf ft)
Be careful of breather tube (9) when raising
the tank.
30-237
DISASSEMBLY AND ASSEMBLY CAB ASSEMBLY
REMOVAL OF CAB ASSEMBLY

moving.
1. Remove covers (1) at bottom of floor frame.
2. Remove right cover (2) inside cab.
3. Disconnect electric wiring connectors (3).
4. Disconnect window washer hose (4).
5. Remove two steering post lock bolts (5).
30-238
6. Remove plastic mounting bolts and pull up rubber

boot (6) at bottom of steering post.
7. Remove four bolts (7), then tip steering post over

fully towards operator's seat.
At the same time, set the column tilt lever to
the unlock position and tip the steering
column over fully toward the operator's seat.
8. Remove two cab mounting bolts (8) and four

mounting bolts (9) each at intermediate position
and rear.
9. Raise cab assembly (10) slowly and keep

horizontal when lifting off.
Be careful that there is no interference with
the electric wiring at the rear right of the floor
frame.
Cover the steering post and plastic cover with
a sheet to prevent any damage.
30-239
INSTALLATION OF CAB
ASSEMBLY
removal.
When installing the cab assembly, be sure to

install the seal.
Coat the seal uniformly with adhesive.
Seal: Adhesive (Cemedyne 366E)
30-240
DISASSEMBLY AND ASSEMBLY AIR CONDITIONER UNIT
REMOVAL OF AIR CONDITIONER

UNIT ASSEMBLY
moving.
Warning! Disconnect the cable from the

1. Remove cab assembly. For details, see

REMOVAL OF CAB ASSEMBLY.
2. Remove connector (1)

3. Install freon gas collector and regenerator to plug
(2), and collect refrigerant.
4. Remove operator's seat (3).
Operator's seat assembly: 40 kg (88 lb)
5. Remove rear console box (4).
6. Remove console box cover (5).
7. Remove console box (6).
8. Disconnect connector (7) (CL3).
9. Disconnect connector (8) (CL2).
10. Disconnect tubes (9).
11. Disconnect heater hoses (10).
30-241
11. Remove mounting bolt (11), then remove air

conditioner unit assembly (12).
Pull the unit out to the left and remove it.
INSTALLATION OF AIR
CONDITIONER UNIT ASSEMBLY
removal.
Using a gas charger (X3), charge with new freon

gas (R134a).
30-242

CONDENSER ASSEMBLY
and block the wheels to prevent the machine
from moving.
1. Disconnect connector (1) (E1 2).
2. Install freon gas collector and regenerator to

plugs (2), and collect refrigerant.
3. Remove bulkhead cover (3).
4. Disconnect connectors (4) (B07 and B12).
5. Disconnect hose (5) between condenser and air

conditioner compressor.
Always fit a wrench to the condenser end.
6. Disconnect connectors (6) (B01 and B11).
7. Disconnect hose (7) between top and bottom

condensers.
8. Disconnect hose (8) between receiver tank and

condenser.
9. Remove mounting bolts (9), then remove

condenser assembly (10).
INSTALLATION OF AIR
CONDITIONER CONDENSER
ASSEMBLY
removal.

interference.
When installing the hoses, be careful not
to let dirt, dust, or moisture get inside the
hoses.
Using a gas charger (X3), charge with
new freon gas (R134a).
30-243
REMOVAL OF RECEIVER TANK

from moving.
1. Disconnect connector (1) (E12).

3. Remove bulkhead cover (3).
4. Disconnect hose (4) between air conditioner

compressor and receiver tank
5. Disconnect hose (5) between receiver tank and

condenser.
6. Remove U-bolts (6), then remove receiver tank

assembly (7).
INSTALLATION OF RECEIVER
TANK

interference.
freon gas (R134a).
30-244

COMPRESSOR ASSEMBLY
from moving.
1. Disconnect connector (1) (E12).

3. Loosen adjustment bolt (3) and lock bolt (4), then

remove belt (5) and remove from compressor.
4. Disconnect hoses (6).
5. Remove four mounting bolts (7), then remove air

conditioner compressor assembly (8).
INSTALLATION OF AIR
CONDITIONER COMPRESSOR
ASSEMBLY
removal.

interference.
freon gas (R134a).
30-245
MEMORANDA
30-246
40 MAINTENANCE STANDARD
Enginemount .............................................................................. 2
Transmission mount .................................................................................. .
Torqueconverterchargingpump ........................................................................ .
Damper ......................................................................................... ...6
TorqueconverterandPTO .......................................................................... ...8
Transmission .................................................................................... ..I 0
Transfer ........................................................................................ ..I 4
Main relief, torque converter relief valve. ................................................................. 16
Lubricationreliefvalve ............................................................................. ..I 7
Driveshaft ...................................................................................... ..I 8
Centersupport ................................................................................... ..I 9
Differential ...................................................................................... ..Z 0
Final drive ....................................................................................... ..2 4
Axlemount ...................................................................................... ..2 6
Centerhingepin .................................................................................. ..2 8
Steering column .................................................................................. ..3 0
Steering pump ................................................................................... ..3 1
Steeringvalve......................................................................................3 2
Steeringcylindermount ............................................................................ ..3 3
Brakevalve........................................................................................3 4
Slackadjuster.. .................................................................................. ..3 8
Brake .......................................................................................... ..4 0
Parking brake .................................................................................... ..4 2
Hydraulicpump.....................................................................................4 4
Switchand PPCpump ............................................................................. ..4 5
PPCvalve.. ..................................................................................... ..4 6
Cut-offvalve ..................................................................................... ..4 8
Maincontrolvalve...................................................................................5 0
Hydrauliccylinders.. .............................................................................. ..5 4
Bucketlinkage ......................................................................................
Bucket............................................................................................5 8
Bucketpositionerandboomkick-out .................................................................. ..5 9
ROPSCab ...................................................................................... ..6 0
40-I
MAINTENANCE STANDARD ENGINE MOUNT
ENGINE MOUNT
El
LlZAD066
Unit: mm
No. Check item Criteria Remedy
1 Clearance between engine mounting bracket and adjusting bolt 3.0 - 7.0 Adjust
40-2
MAINTENANCE STANDARD TRANSMISSION MOUNT
TRANSMISSION MOUNT
B-B
SDW02122
Unit: mm
No Check item Criteria Remedy
1 Thickness of shim for Shim thickness: 0.5mm

mounting (Decide the shim thickness so that the misalignment between the
damper output shaft and input shaft is less than 2.0mm).
Adjust
2 Clearance between There must be a clearance of at least 2mm between the stopper and
stopper and bracket bracket around the whole circumference.
40-3
MAINTENANCE STANDARD TORQUE CONVERTER CHARGING PUMP
TORQUE CONVERTER CHARGING PUMP
6p-l ’
277.0 '-31.ONm
(28.25 '-3.25kgmI
SEW02124
Unit: mm
I I I
No 1 Check item Criteria Remedy
I I I
I I
Clearance between gear case and Standard clearance Clearance limit
1 side plate, gear
0.10 - 0.15 0.19
I 2
I Clearance between inside diameter
plain bearing and outside diameter of
of
0.06 - 0.149 0.20
Replace
gear shaft
3 1 Insertion depth of pin 14 +o/-0.5

I
Rotating torque of spline shaft 6.9 - 11.8 Nm (0.7 - 1.2 kgm}
Revolution Pressure Standard Repair limit

ti (rpm) MPa discharge discharge
{kg/cm? (P/min) (Plmin)
2500 3.5 MPA 192 176

(35.9)
40-4
MAINTENANCE STANDARD MEMORANDA
40-5
MAINTENANCE STANDARD DAMPER
DAMPER
A-A
7 8
SDWO2123
40-6
MAINTENANCE STANDARD DAMPER
Unit: mm
Clearance between bearing Standard Tolerance Standard Clearance

1 and shaft. size clearanc limit
Shaft Hole e
40 -0.009 0 -0.003 0.05

-0.034 -0.012 -0.034
2 Clearance between bearing 80 0 0 -0.03 0.035

and housing. -0.013 -0.030 -0.013 Replace
3 Clearance betweenbearing 75 +0.012 0 -0.027 0.025

and shaft. -0.007 -0.015 -0.007
4 Clearance between bearing 130 0 +.018 0.007 0.05

and cover. -0.018 +.007 0.036
5 Clearance between retainer 135 -0.014 +0.04 0.014 0.13

and cover. -0.054 0 0.094
Standard size Tolerance Repair limit
6 Wear of surface in coupling 95 0 -0.12

and oil seal. -0.087
7 Wear of surface in shaft and 105 0 -0.12

seal. -0.087
8 Backlash of spline (shaft, 0.071 - 0.177

coupling, and body).
40-7
MAINTENANCE STANDARD TORQUE CONVERTER AND PTO
TORQUE CONVERTER AND PTO
/
m 66 5*7.5Nm
, (6. 75* 0. 75kd
SKW02125
Unit: mm
Standard Tolerance Repair limit

1 inside diameter of seal ring surface of size Repair
retainer chrome
120 +0.035 120.5
0 plating or
replace
2 Inside diameter of seal ring surface of sleeve 65 +0.025 65.1
0
Width 3.95 0 3.55

3 Width and thickness of seal -0.1
ring Replace
4.6 *O.l 4.14
Thickness
4 Backlash of PTO gear (Drive gear) 0.18 - 0.49
40-8
40-9
MAINTENANCE STANDARD TRANSMISSION
TRANSMISSION
SKW02126
40-I 0
Unit: mm
No
Installation load
1 No. 1 clutch spring (X 10)
utch spring (X 10)
No. 4 clutch spring (10
each) 17.5 kg) 16.4 kg1
5 No. 5 clutch spring (X 10) 39.8 32.5 101.0 N 37.4 86.3 N

(10.3 kg} (8.8 kg)
6 No. 6 clutch spring (10 39.8 34.2 77.5 N 37.4 65.7 N

each) 17.9 kg) 16.7 kg)
Thickness of 4 discs and 3 plates for No. 1 clutch Standard Tolerance Repair limit
size
35 50.26 31.8
Thickness of 4 discs and 3 plates for No. 2 clutch 35 kO.26 31.8
9 Thickness of 3 discs and 2 plates for No. 3 clutch 25 io.22 22.6
Thickness of 3 discs and 2 plates for No. 4 clutch 25 *to.22 22.6
Thickness of assembled 2 discs and 1 plates for 15 *0.17 13.4

No. 5 clutch
12 Thickness of assembled 3 discs and 2 plates for 25 rto.22 22.6

No. 6 clutch
13 Thickness of 1 disc 5 *to.1 4.2
14 Thickness of 1 plate 5 Zto.1 4.5 Replace

I I
15 Clearance between transmission Standard Tolerance Standard Clearance
input shaft bearing and housing size clearance Limit
Shaft Hole
90 0 +0.016 +0.031 +0.037

-0.015 -0.006 -0.006
16 Clearance between transmission 72 0 +0.016 +0.026 +0.031

outout shaft bearina and carrier -0.013 -0.006 -0.006
17 Clearance between transmission 100 0 +0.016 +0.031 +0.037

output shaft bearing and housing -0.015 -0.006 -0.006
40-I 1
SKW02127
40-12
Unit: mm

I I I I I
1 Wear of seal ring for input Width I Standard size I Tolerance I Reoair limit
shaft
-0.01
3.0 -0.03 2.6
Thickness 3.5 *0.1 3.35
-0.01
2 Wear of seal ring for Width 4.0 -0.03 3.5
output shaft
Thickness 5.1 *0.12 4.95
3 Backlash between No. 1 sun gear and planet 0.13 - 0.32

gear
4 Backlash between No. 1 planet gear and ring 0.15 - 0.38

gear inside teeth
Replace
gear

gear inside teeth

gear

gear inside teeth

gear

gear inside teeth

gear

gear inside teeth I
40-I 3
I
14
45*63Nm _
6*8.5bd
10.3* 12.3Nm
1.25* 1.25ka
40-14
MAINTENANCE STANDARD TRANSFER
Unit: mm
Standard Tolerance Standard

size clearance
Shaft Hole
1 Clearance between drive gear and bearing
85 +0.045 0 -0.023
+0.023 -0.020 -0.065
2 Clearance between drive gear bearing and cage 150 0 -0.012 0.006
-0.018 -0.052 -0.052
3 Clearance between drive gear bearing and cage 150 0 0 0.018

-0.018 -0.040 -0.040
4 Clearance between idler gear and bearing 95 +0.059 0 -0.037

-0.037 -0.020 -0.079
Clearance between drive gear bearing and case 170 0 0 0.025

(cover) -0.025 -0.040 -0.040 _ Replace
Clearance between output shaft and bearing 80 +0.039 0 -0.020

-0.020 -0.015 -0.054
7 Clearance between output shaft bearing and cage 140 0 -0.012 0.006
-0.018 -0.052 -0.052
8 Clearance between spacer and bearing 95 +0.045 0 -0.023

+0.023 -0.020 -0.065
9 Clearance between output shaft bearing and 170 0 -0.012 0.013

housing -0.025 -0.052 -0.052
10 Coupling oil seal contact surface Standard Tolerance Repair limit

size
95 0 94.8
-0.087
11 Clearancebetweencageandcase 2 (Shim) Preload:

0.1 - 1.0 Nm (0.01 - 0.1 kgm} Adjust
(Drive gear as individual part)
12 Clearance between cover and case 2 (Shim) Preload:

0.3 - 0.55 Nm (0.03 - 0.055 kgm}
Then add 0.1 mm of shim (idler
gear as individual part)
13 Clearance between cage and cover 0.25 Preload:

(Shims) 0.5 - 1 .O Nm (0.05 - 0.1 kgm}
(Output shaft as individual part)
14 Backlash between drive gear and idler gear 0.17 - 0.44
15 Backlash between idler gear and driven gear 0.17 - 0.44 Replace
40-I 5
MAINTENANCE STANDARD MAIN RELIEF, TORQUE CONVERTER RELIEF VALVE
MAIN RELIEF, TORQUE CONVERTER RELIEF VALVE
A-A
SDWO2129
Unit: mm
No Check item Criteria Remedv
1 Clearance between main Standard Tolerance Standard Clearance

relief valve and valve body size clearance limit
Shaft Hole
25 -0.035 +0.013 0.035 0.08

-0.045 0 0.058
2 Clearance between torque 22 -0.035 +0.013 0.035 0.08

converter relief valve and -0.045 0 0.058
valve body
3 Main relief valve spring Standard size Repair limit Replace

(outer)
Free Installa- Installation Free Installation load
Length tion load Length
length
128 75.3 509 N 124.2 483 N

(51.9 kg} (49.3 kg}
4 Main relief valve spring 108 75.3 402 N 104.8 382 N

(inner) (41 .O kg} (39.0 kg}
5 Main relief valve spring 50 42 153N 48.5 145 N

{I 5.6 kg} (14.8 kg}
40-I 6
MAINTENANCE STANDARD LUBRICATION RELIEF VALVE
LUBRICATION RELIEF VALVE
SDWO2130
Unit: mm
No Check item Criteria Remedv
Standard size Repair limit
Free Length Installation Installation Free Length Installation load

1 Lubrication relief length load Replace
valve spring 26 23.7 11.8 N 25.2 10.8 N
(1.2 kg) (1.1 kg}
40-I 7
MAINTENANCE STANDARD DRIVE SHAFT
DRIVE SHAFT
_-
I, 47
‘\y-’
d-
~~____yf~Y&-’
---_-
__-_ _ __-.
’ .
40-I 8
MAINTENANCE STANDARD CENTER SUPPORT
CENTER SUPPORT
6 5
SEW02132
Unit: mm
Standard Tolerance Standard Clearance

size clearance limit
Shaft Hole
1 Clearance between case 140 0 -0.036 -0.018 -0.015

and bearing -0.018 -0.061 -0.061
2 Clearance between case 130 0 -0.036 -0.018 -0.015

and bearing -0.018 -0.061 -0.061
3 Clearance between cou- 80 +0.051 0 0.032 0.029 Replace

pling shaft and bearing +0.032 -0.015 0.066
4 Clearance between cou- 75 +0.051 0 0.032 0.029

pling shaft and bearing +0.032 -0.015 0.066

Repair
95 0 -0.18 chrome
5 Wear of oil seal surface plating or
-0.087
replace
6 Wear of oil seal surface 105 0 -0.18
-0.087
7 End play of coupling shaft Preload max. 3.9 Nm (0.4 kgm} Replace
40-I 9
MAINTENANCE STANDARD DIFFERENTIAL
DIFFERENTIAL
13
14
15
i2
40-20
Unit: mm
T
No. Check item Criteria remedy

size clearance
Shaft Hole
1 Clearance of side bearing (outer race) in 180 0 +0.054 0.014

differential gear assembly -0.025 +0.014 0.079
2 Clearance of side bearing (inner race) in differ- 120 +0.045 0 -0.023

ential aear assemblv +0.023 -0.020 -0.065
3 Clearance of pinion shaft bearing (outer race) 171.45 +0.025 +0.026 0.026
0 -0.014 -0.039
11
4 Clearance of pinion shaft bearing (inner race)
5 Clearance of pinion shaft bearing (inner race) Replace
Clearance of pilot bearing (outer race) 120 I 0 I +0.034 I 0.012 I

1 -0.015 1 +0.012 0.049
I I I
Clearance of pilot bearing (inner race)
8 Clearance between differential carrier and cage

1 -0.060 1 +0.010 1 0.106
I I I
9 Clearance between spider and differential pinion
bushina
10 Backlash of bevel gear 0.30 - 0.41
11 Backlash of differential aear 0.30 - 0.41
12 End olav of pinion aear Max. 0.064
13 Free rotating torque of bevel gear Max. 8.34 Nm 10.85 kam\
14 Rear face runout of bevel gear 0.1 Replace
15 Standard thickness of shims for stop shaft Clearance “a” +(O.l f 0.05)
G -
40-2 1
r
277*32Nm
:28.25* 3.25kpml
927* 103Nm
.94.5* 10.5koml
\
-+QV-T-Z
II I _I
SOW02352
40-22
Unit: mm
1 Thickness of side gear washer 4 +0.05 3.8

-0.05
Replace
2 Thickness of pinion gear washer 1.5 +O.OQ 1.35
3 Wear of oil seal surface 100 0

-0.087
40-23
MAINTENANCE STANDARD FINAL DRIVE
FINAL DRIVE
SOW02135
Unit: mm

Shaft Hole
1 Clearance between plane- 55 +0.015 0 -0.002 -

+0.002 -0.015 -0.030
tary shaft and bearing Replace
2 Clearance between ring gear 190 +0.033 0 -0.004 -

hub and bearing +0.004 -0.030 -0.063
3 Thickness of spacer 22 +O.l /-0.1 21.5
4 Backlash between planet gear and sun gear 0.18 - 0.43
5 Backlash between planet gear and ring gear 0.18 - 0.54

Replace
6 Thickness of shim for wheel hub 2.0
40-24
40-25
MAINTENANCE STANDARD AXLE MOUNT
AXLE MOUNT
\
‘-.____-- /.’
1569*196Nm
~160~20bnl
3
217*32Nm
4 I28.25*3.25bml
I ill’ -5
I .--- P
A-A __/
/*
stlwoz136
40-26
MAINTENANCE STANDARD AXLE MOUNT
I Init. mm

Shaft Hole
1 Clearance of shaft and hole 310 -0.056 +0.489 0.056 1.6

front support side (after press -0.137 0 0.626
fitting bushing)
2 Clearance of shaft and hole 320.2 +2.300 +0.089

front support side (before -0.800 0
installing bushing)
Replace
3 Clearance of shaft and hole 260 -0.056 +0.481 0.048 1.6 (see
rear support side (after press -0.137 -0.008 0.618 note)
fitting bushing)
4 Clearance of shaft and hole 270.2 +2.300 +0.081

rear support side (before +0.800 0
installing bushing)
Thickness of wear plate 20 -0.10

-0.25
Thickness of wear plate 5 +O.l

-0.3 Replace
Thickness of rear bushing 5 *0.1
Thickness of front bushing 5 *O.l
* Note: The bushings must be in contact with the support at both the front and rear.
40-27
MAINTENANCE STANDARD CENTER HINGE PIN
CENTER HINGE PIN
m 5&6*5.9Nm
(6.0i0.6kra) (Yhsn
17
m 277.0*31.9&
(26.25*3.25kaml (When adjust ina shim)
~$~!~~!$?I, (Final value) SDWO2353
40-28
MAINTENANCE STANDARD CENTER HINGE PIN
Unit: mm

size clearance
Shaft Hole
1 Clearance between lower hinge 100 -0.036 +0.054 0.036

pin and rear frame -0.058 0 0.112

pin and spacer (small) -0.058 0 0.112
3 Clearance between lower hinge 100 -0.036 0 0.016

pin and bearing -0.058 -0.020 0.058

pin and spacer (large) -0.058 0 0.112
5 Clearance between rear frame and 130 -0.043 +0.063 0.043

spacer (large) -0.106 0 0.169
6 Clearance between front frame 155 0 -0.048 -0.023

and upper hinge bearing -0.025 -0.088 -0.088
7 Clearance between upper hinge 100 -0.036 +0.054 0.036 Replace

pin and rear frame -0.058 0 0.112
8 Clearance between upper hinge 100 -0.036 0 0.016

pin and bearing -0.058 -0.020 0.058
9 Clearance between front frame 160 0 -0.050 -0.025

and lower hinge bearing -0.025 -0.090 -0.090
10 Clearance between rear frame and 125 -0.043 +0.063 0.043

bushing -0.084 0 0.146
11 Clearance at press fitted part of 115 +0.280 +0.054 -0.126

seal of upper hinge pin +0.180 0 -0.28
12 Clearance at press fitted part of 135 +0.310 +0.063 -0.147

seal of lower hinge pin +0.210 0 -0.31
Standard size Tolerance

13 Height of lower hinge spacer
(small) 35 *0.1
14 Height of lower hinge spacer 101.5 *0.1

(large)
15 Shim thickness for lower hinge and 2.3

retainer
16 Shim thickness for lower hinge and 1.6

Adjust
retainer
17 Shim thickness for upper hinge 1.6

and retainer
40-29
MAINTENANCE STANDARD STEERING COLUMN
STEERING COLUMN
D-D
-__-__-__
----__-__
SDWO2138
Unit: mm

I I
size Clearance
Shaft Hole
1 Clearance between steering shaft 19 0 +0.150 0.05 Replace

and column bushing -0.080 +0.050 0.23
40-30
MAINTENANCE STANDARD STEERING PUMP
STEERING PUMP
A-A I
SEW02124
I Init. mm
Standard clearance Clearance limit
1 Clearance between gear case 0.10 - 0.15 0.19

and side plate, gear
2 Clearance between inside diame- 0.06 - 0.149 0.20

Replace
ter of plain bearing and outside
diameter of gear shaft
3 Insertion depth of pin 14 +o/-0.5
4 Rotating torque of spline shaft 0.7 - 1.2 kgm
Discharge Revolution Discharge Standard Repair limit

EOI O-CD (RPM) pressure discharge discharge -
45” - 55” (kg/cm’) @/min.) @/min.)
2500 210 184 170
40-31
MAINTENANCE STANDARD STEERING VALVE
STEERING VALVE
4
SLW01253
Unit: mm
I I I
No. 1 Check item Criteria Remedy
Free Installed Installed load Free Load

length length length limit
1 Steering spool return spring 37.2 32.0 56.9 N 45.1 N

15.8 kg1 14.6 kg1
2 Load check valve spring 20.9 13.2 9.3 i4.9 N - 7.8 N

(0.95 kO.5 kg} IO.8 kg) Replace
3 Demand spool return spring 75.2 68.5 136.3 N 111.8 N
{I 3.9 kg} {I 1.4 kg}
4 Relief valve spring 24.0 22.19 182.4 N 145.1 N

(18.6 kg) (14.8 kg}
5 Check valve return spring 21.6 17.0 2.3 N 1.8 N

1 (0.23 kg} 1 (0.18 kg}
40-32
MAINTENANCE STANDARD STEERING CYLINDER MOUNT
STEERING CYLINDER MOUNT
3 A
I I
b'
A-A
SDWO2140
Unit: mm

size clearance
Shaft Hole
1 Clearance between mounting pin and 60 0 +0.200 0.100

bushing connection of steering -0.074 +O.lOO 0.248
cylinder rod and frame
Replace
2 Clearance between mounting pin and 60 0 +0.200 0.100
bushing at connection of steering -0.074 +O.lOO 0.248
cylinder bottom and frame
Width of Width of Standard clearance

boss hinge (Clearance a + b)
3 Connection of steering cylinder and Max. 1.0
70 +0.8 74 *I 2.2 - 5.0
front frame after ad-
0
justing shim
4 Connection of steering cylinder and 70 -0.5 74 il 3.0 - 5.5
rear frame 0
40-33
MAINTENANCE STANDARD BRAKE VALVE
BRAKE VALVE
(RIGHT)
SOW02141
40-34
Unit: mm
No Check item r Criter 1 Remedv

1 Clearance between pedal
mount hole and bracket
Shaft Hole
hole
IO -0.025 +O.l 0.175 0.25

-0.075 0 0.025
Clearance between roller IO -0.025 +O.l 0.175 0.25

and pin -0.075 0 0.025
Replace
Standard size I Tolerance I Repair limit

Outside diameter of roller
30 0
I ~
4 Control spring
6 Return spring
8 Return spring 16.7 N 28

{I .7 kg}
40-35
(LEFT)
SDWD2142
40-36
Unit: mm
No Check item T Criter Remedv

1 Clearance between pedal
mount hole and bracket
Shaft Hole
hole
10 -0.025 +O.l 0.175 0.25

-0.075 0 0.025
-I---
2 Clearance between roller 10 -0.025 +0.1 0.175 0.25
and pin -0.075 0 0.025
Replace
Standard size 1 Tolerance Repair limit

3 Outside diameter of roller I I
29.2
Standard Size Repair limit
Free length Test height Test load Free length Test load
4 Control spring 34 21.8 93.2 N 33

19.5 kg)
5 Control spring 46.3 34.3 459.0 N 45.3

(46.8 kg}
6 Return spring 86.2 58 60.8 N 78

16.2 kg)
7 Spring 17 15 69.6 N 16.2

(7.1 kg)
8 Return spring 31.5 19.5 16.7 N 28
40-37
MAINTENANCE STANDARD SLACK ADJUSTER
SLACK ADJUSTER
SEW02143
Unit: mm
-

size clearance Limit
Shaft Hole
1 Clearance between body and

oiston
Replace
Free Test Test Free Test

length length load length load
198 38 43.2 N
14.4 kg)
39.2 1 33 1 66.7 N 1 - 1 -
L
-
40-38
40-39
MAINTENANCE STANDARD BRAKE
BRAKE
I
/I: !
’
___-_-___-_____________-_I
--kL/~ __--
:
b_----____-_____-__-____ ---___
14J
I+
7’
i.J
/
40-40
MAINTENANCE STANDARD BRAKE
Unit: mm
Free Install Install Free Install

1 Return spring
80.2 69.9 600.2 N 72.2 539.4 N
(61.2 kg} 155 kg)
Standard size Tolerance Repair

limit
2.3 kO.08 2.0

2 Thickness of plate
3 Thickness of disc 3.8 *to.1 4.6
4 Total thickness of plates 38.8 kO.98 35.0

and discs
Replace
5 Wear of piston seal contact 42.0 +0.097
surface 0
6 Wear of piston seal contact 38.3 +0.089

surface 0
7 Backlash between outer 0.21 - 0.65

gear and plate
8 Backlash between inner 0.31 - 0.74

gear and disc
40-41
MAINTENANCE STANDARD PARKING BRAKE
PARKING BRAKE
SDWcl2145
Unit: mm
Free Install Install Free Install

1 Parking brake spring
(outside)
77.7 54.0 1425 &22 N 69.9 1258 N
(145.2 Q.2 kg} (128.3 kg}
2 Parking brake spring 77.8 54.0 535 k5.3 N 70.0 482 N

(inside) (54.6 55.4 kg} (49.1 kg}
Standard size Tolerance Repair

limit
3 Separate Thickness
4.0 *0.05 3.9
of plate
Distortion 0.15 0.6
Thickness 3.2 *o. 1 35.0

Replace
4 Brake Depth of lining 0.45 +0.175 0.235
disc groove 0
Thickness if 0.7 +0.075

lining
5 Load of wave spring
40-42
40-43
MAINTENANCE STANDARD HYDRAULIC PUMP
HYDRAULIC PUMP
SAR(4)-160
.6Nm
sDwo2146
Unit: mm
10. Check item Criteria Remedy
Standard size Clearance limit
1 Clearance between gear case 0.11 - 0.16 0.19

and side plate gear
Replace
2 Clearance between inside 0.06 - 0.140 0.20
diameter of plain bearing and
outside diameter of gear shaft
3 Insertion depth of pin 14 0

-0.5
4 Rotating torque of spline shaft 9.8 - 14.7 Nm

{I .O - 1.5 kgm}
Revolution Discharge Standard Repair limit

Discharge: (rpm) pressure Discharge Discharge
Oil: EOIO-CD MPa {kg/cm’) (PI min.) @/min.) -
Temperature: 45 - 55°C
20.6
2,200 12101 328 303
40-44
MAINTENANCE STANDARD SWITCH, PPC PUMP
SWITCH, PPC PUMP

SAR(3)-63 + SAR(I)-28
I- SAR(3)-63 I. SAR(l)-28
A-A SOW02147
Unit: mm
“V. UIICZCIR 1LsilII “I ,LG, IQ I\FillE”J
1 Clearance between gear Model Standard clearance Clearance limit

case and side plate gear
SAR(3) - 63 0.10 - 0.15 0.19
SAR(l) - 28 0.10 - 0.15 0.19
2 Clearance between SAR(3) - 63 0.06 - 0.149 0.20

inside diameter of plain
Replace
bearing and outside SAR(l) - 28 0.064 - 0.119 0.20
diameter of gear shaft
3 Insertion depth of pin Model Standard size Tolerance
SAR(3) - 63 10 0
-0.5
SAR(l) - 28 10 0
-0.5
4 Rotating torque of spline SAR(3) - 63 6.9 - 11.8 Nm

shaft (0.7 - 1.2 kgm}
SAR(l) - 28 2.0 - 4.9 Nm

(0.2 - 0.5 kgm}
Discharge Model Revolution Discharge Standard Repair limit

Oil: EOI O-CD (rpm) pressure discharge discharge
Temperature: 45 - 55°C MPa {kg/cm? (P/min) (P/min)
SAR(3) - 63 2,500 20.6 145 134

1210)
SAR(l) - 28 2,500 3.7 67 60

1381
40-45
MAINTENANCE STANDARD PPC VALVE
PPC VALVE
FOR BUCKET, BOOM
SEW02148
Unit: mm
Free length Installed Installed Free length Installed

Replace
X O.D. length load load
spring if
1 Centering spring 52.8 X 12.3 36.0 29.4 N 23.5 N damaged or
(bucket DUMP, boom (3.0 kg) 12.4 kg} deformed
LOWER)
2 Centering pin (bucket 52.8 X 12.3 36.0 39.2 N 31.4 N

TILT, boom RAISE) 14.0 kg) 13.2 kg)
3 Metering spring 31.4 x 7.4 29.4 16.7 N 13.7 N

Il.7 kg) Il.4 kg)
40-46
MAINTENANCE STANDARD PPC VALVE
OPTION
SEW02149
Unit: mm
No. Check item Remedv
Standard size Repa r limit

Replace
X O.D. length load load
spring if
1 Centering spring 52.8 X 12.3 36.0 29.4 N 31.4 N damaged or
(3.0 kg) (3.2 kg) deformed
2 Centering pin 52.8 X 12.3 36.0 39.2 N 23.5 N

14.0 kg) 12.4 kg)
3 Metering spring 31.4 x 7.4 29.4 16.7 N 13.7 N
40-47
MAINTENANCE STANDARD CUT-OFF VALVE
CUT-OFF VALVE
A-A
Qq 34.3*4.9Nm
(3.5*0.5lmd
n n
n
B
L
B-B
SDW02150
Unit: mm
I I
No. 1 Check item I Criteria 1 Remedy
I I I

length load load
1 Unload valve spring 36.95 3.0 35.3 N 26.4 N Replace

(3.6 kg1 (2.9 kg)
2 Check valve spring 33 2.0 16.7 N 1.4 N

(0.17 kg} (0.14 kg}
40-48
40-49
MAINTENANCE STANDARD MAIN CONTROL VALVE
MAIN CONTROL VALVE

2-SPOOL VALVE
10
-5 -kg. 186.3* 9.8Nm
‘6
11
\
SEW02151
40-50
Unit: mm
No. 1 Check item Criteria - Remedv
T
Standard size T Repair limit
Free length Installed length Installed load Free length Installed load
Bucket spool return 64.4 62.2 190N 152 N

spring (Large) {I9.4 kg) (15.5 kg}
Bucket spool return 18.6 14.9 112.8 N 90 N

spring (Small) {I 1.5 kg} (9.2 kg)
Boom spool return 64.4 62.7 149 N 119.6 N

spring (Large) (15.2 kg} (12.2 kg}
4 Boom spool return 18.6 15.2 104N 83.4 N

spring (Small) (10.6 kg} (8.5 kg)
5 Boom spool return 89.2 82.0 616 N 554N

Replace
6 Boom spool return 42.0 42.0 0
spring (Small)
7 Bucket spool return 82.4 82.0 182.4 N 163.8 N

8 Bucket spool return 42.0 42.0 0

spring (Small)
9 Main valve spring 52.3 38.0 86.3 N 68.6 N

18.8 kg) 17.0 kg1
10 Check valve spring 78.2 52.0 18.8 N 14.7 N

{I .92 kg} (1.5 kg)
11 Suction valve spring of 27.9 18.0 6.9 N 5.9 N

safety valve (0.70 kg} IO.6 kg)
12 Suction valve spring 27.9 18.0 6.9 N 5.9 N

(0.70 kg) IO.6 kg1
13 Float selector valve 53.0 42.1 137 N 123.6 N

spring (14.0 kg) (12.6 kg}
14 Unloader valve spring 82.7 47 49 N 39 N

15.0 kg1 14.0 kg)
15 Relief valve poppet 49.3 43.3 209.9 N 167.7 N

spring (21.4 kg} (17.1 kg}
-
40-51
3-SPOOL VALVE
__
17 m 68.6*9.8Nm cv 22.1*2.5Nm
/ (2.25*0.25kpm)
\ ,('i'bmt
SEW02152
40-52
Unit: mm
1 Remedy
Boom spool return spring

Replace
Boom spool return s
16 Suction valve spring 27.9 18.0 6.9 N 5.9 N

(0.70 kg} (0.6 kg)
17 Float selector valve 53.0 42.1 137N 123.6 N

spring (14.0 kg} {I 2.6 kg}
18 Unloader valve spring 82.7 47 49 N 39 N

16.0 kg1 14.0 kg1
19 Relief valve poppet 49.3 43.3 209.9 N 167.7 N

spring j21.4 kg) (17.1 kg)
40-53
MAINTENANCE STANDARD HYDRAULIC CYLINDERS
HYDRAULIC CYLINDERS
STEERING CYLINDER
(Width across flats: 60 n
BOOM CYLINDER
SOW02154
BUCKET CYLINDER
? 4
40-54
0
MAINTENANCE STANDARD HYDRAULIC CYLINDERS
Unit: mm
No. Check item f

- Criteria - TRemedv
Name of
cylinder
Std.
size
T Tolerance T Standard
Clearance
Clearance
limit
Shaft Hole
-L
Clearance between rod Steering 55 -0.030 +0.151 0.036 0.327

and bushing -0.076 +0.006 0.227
Boom 110 -0.036 +0.274 0.096 0.469

-0.090 +0.060 0.364
Bucket 120 -0.043 +0.203 0.091 0.469 Replace

-0.106 +0.048 0.309
Clearance between Steering 60 0 +o. 174 0.100 1.0

piston rod mounting pin -0.074 +o. 100 0.248
and diameter of hole
Boom 120 +o. 1
0
Bucket 120 +0.307

+0.220
3 Clearance between Steering 60 0 +0.174 0.100 1.0

cylinder bottom -0.074 +O.lOO 0.248
mounting pin and
Boom 120 +0.307
bushing
+0.220
Bucket 120 +0.307

+0.220
4 Cylinder bore 1 Standard size Tolerance Repair limit
Steering 110 0
+0.15
Boom 200 0
I
+0.2
225 0
+0.2
-
40-55
MAINTENANCE STANDARD BUCKET LINKAGE
BUCKET LINKAGE
a Section A-A b b
a b 'b
"
Section D-D Section E-E Section F-F
7 r
Section G-G
a'
Section H-H
'b
Section J-J
-b
40-56
MAINTENANCE STANDARD BUCKET LINKAGE
Unit: mm

I I I
Shaft Hole
1 Clearance between pin and bushing 110 -0.036 +0.307 0.256 1.0
at boss ends and bucket link.
2 Clearance between pin and bushing

at joint of and bucket
Replace,
3 Clearance between pin and bushing also if
at joint of and frame -0.090 +0.220 0.397 other
120 -0.036 +0.307 0.256 parts are
-0.090 +0.220 0.397 biting into
at joint of bucket cylinder bottom
pin.
and frame

at joint of bucket cylinder rod and
lever

at joint of tilt lever and

at joint of boom cylinder bottom and
frame
8 Clearance between pin and bushing 120 -0.036 +0.307 0.256 1.0
at joint of boom cylinder rod and -0.090 +0.220 0.397
Width between Width Standard clearance

bosses of hinge (Clearance a + b)
Joint of bucket cylinder and frame
143 140 3.0
9
Insert
10 Joint of and frame 153 150 3.0 shims on
180 176.8 3.2 both
11 Joint of and bucket
sides to
12 Joint of bucket link and bucket 145 142 3.0 make
clearance
13 Joint of tilt lever and bucket link 144 142 2.0 on both
240 237 3.0 left and
14 Joint of tilt lever and
right
15 Joint of bucket lever and bucket 143 140 3.0 sides less
cylinder than
1.5mm
16 Joint of boom cylinder and boom 125 122 3.0
17 Joint of boom cylinder and frame
40-57
MAINTENANCE STANDARD BUCKET
BUCKET
/ ‘2
Section A-A 1 Section B-B
L17CZO25
Unit: mm
No Criteria Remedy
1 Wear of bucket tooth 61 23 Replace
2 Thickness of shims for tooth (Clearance between

tooth and bucket)
3 Tightening torque of mounting bolt for bucket tooth
4 Tightening torque of mounting bolt for corner tooth
40-58
MAINTENANCE STANDARD BUCKET POSITIONER AND BOOM KICK-OUT
BUCKET POSITIONER AND BOOM KICK-OUT
View Z
1 Section A-A L17DV004
Unit: mm
1 Clearance of bucket positioner switch

3-5 Adjust
2 Clearance of boom kick-out switch
3 Tightening torque of mounting bolt for adjuster 9.Ok3.5 kgm

Retighten
4 Tightening torque of mounting bolt for switch 1.85.2 kgm
40-59
MAINTENANCE STANDARD ROPS CAB
ROPS CAB
----_ *
#;’ ;;
“,/
-1--j-K
__LT_
.-__A-
!r
$7
SDWO2159
40-60
Komatsu America International Company
440 North Faitwav Drive I I
Vernon Hills, IL 66061-8112 U.S.A.
Attn: Technical Publications
1 PROPOSAL FOR MANUAL REVISION 1
Fax No. (847) 970-4186 1 I
FOR INTERNAL USE ONLY No. PMR
NAME OF COMPANY: LOCATION:
PHONE NO:
DEPARTMENT: DATE:
NAME:
VlANUAL NAME:
MANUAL NO:
MACHINE MODEL:
j/N IF APPLICABLE:
‘AGE NO:
‘ROBLEM:
Attach photo or sketch.

If more space is needed, use another sheet.
FOR INTERNAL USE ONLY

CORRECTIVE ACTION:
H-
PFMRI 081696

Shop Manual Wa500 PDF

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CEBM001202

WA500-3LE A70001 and up

10 STRUCTURE AND FUNCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-1

20 TESTING, ADJUSTING, AND TROUBLESHOOTING . . . . . . . . . . . 20-1

30 DISASSEMBLY AND ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . 30-1

40 MAINTENANCE STANDARD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-1

DESCRIPTION FORM NUMBER

PARTS BOOK - PAPER:

Engine and Chassis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BEPB002201

PARTS BOOK - MICROFICHE:

Engine and Chassis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BEPM002201

OPERATION & MAINTENANCE MANUAL:

SAFETY MANUAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WLT70-1

STREET ADDRESS ORDER DATE

PHONE NO. FAX NO. SHIPPING METHOD DISTR/BRANCH CODE

KDC91D 081696 CURRENT PRICES WILL BE CHARGED

( ) Pages to be deleted Discard

LIST OF ORIGINAL, NEW AND REVISED PAGES

IMPORTANT SAFETY NOTICE

PREPARATIONS FOR WORK

STRUCTURE AND FUNCTION

TESTING AND ADJUSTING

DISASSEMBLY AND ASSEMBLY

HOW TO READ THE SHOP MANUAL

Any additions, amendments or other changes will be sent to your

10 - 3 Weight of parts or systems.

Heavy parts (25 kg or more) must be lifted with a

The allowable load value is estimated to be 1/6 or 1/7 of

2) Sling wire ropes from the middle portion of the hook.

Category Code Part No. Qty Container Main applications, features

STANDARD TORQUE REQUIREMENTS

Thread diameter of bolt Width across flat

6 10 1.35 ±0.15 13.2 ±1.4

TORQUE REQUIREMENTS OF SPLIT FLANGE BOLTS

Thread diameter of bolt Width across flat torque requirement values

10 14 6.70 ±0.7 65.7 ±6.8

TORQUE REQUIREMENTS FOR FLARED NUTS

Use these torque values for flared part of nut.

Thread diameter of bolt Width across flat torque requirement values

14 19 2.5 ±0.5 24.5 ±4.9

ELECTRIC WIRE CODE

CLASSIFICATION BY COLOR AND CODE

Code WG --- --- RG YL GB LB

Code --- --- --- RL YW GL ---

2. Convert 550 mm into inches.

0 0 0.039 0.079 0.118 0.157 0.197 0.236 0.276 0.315 0.354

0 0 0.039 0.079 0.118 0.157 0.197 0.236 0.276 0.315 0.354

0 0 2.20 4.41 6.61 8.82 11.02 13.23 15.43 17.64 19.84

Liter to U.S. Gallon

0 0 0.264 0.528 0.793 1.057 1.321 1.585 1.849 2.113 2.378

Liter to U.K. Gallon

0 0 0.220 0.440 0.660 0.880 1.100 1.320 1.540 1.760 1.980

0 0 7.2 14.5 21.7 28.9 36.2 43.4 50.6 57.9 65.1

0 0 14.2 28.4 42.7 56.9 71.1 85.3 99.6 113.8 128.0

-40.4 -40 -40.0 -11.7 11 51.8 7.8 46 114.8 27.2 81 117.8

-28.3 -19 -2.2 -8.9 16 60.8 10.6 51 123.8 30.0 86 186.8

-25.6 -14 6.8 -6.1 21 69.8 13.3 56 132.8 32.8 91 195.8

-22.8 -9 15.8 -3.3 26 78.8 16.1 61 141.8 35.6 96 204.8

-20.0 -4 24.8 -0.6 31 87.8 18.9 66 150.8 40.6 105 221.0

-17.2 1 33.8 2.2 36 96.8 21.7 71 159.8 54.4 130 266.0

-14.4 6 42.8 5.0 41 105.8 24.4 76 168.8 68.3 155 311.0

DIMENSIONS ............................. . . . . . . 01-2

SPECIFICATIONS ......................... ..... 01-4