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WA1200-3
MACHINE MODEL SERIAL NO.
• This shop manual may contain attachments and optional equipment that are not available
in your area. Please consult your local Komatsu distributor for those items you may
require.
Materials and specifications are subject to change without notice.
© 2004 1
All Rights Reserved
00-1
Printed in Japan 10-04(01) (9)
CONTENTS
No. of page
90 OTHERS........................................................................... 90-1
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LIST OF REVISED PAGES
WA1200-3 00-2-1
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LIST OF REVISED PAGES
00-2-2 WA1200-3
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LIST OF REVISED PAGES
20-109 (8) 20-146 (1) 20-186 (8) 20-214 (2) 20-255 (2)
20-110 (8) 20-147 (1) 20-187 (8) 20-215 (2) 20-256 (2)
20-111 (5) 20-148 (1) 20-188 (8) 20-216 (2) 20-257 (2)
20-112 (1) 20-149 (1) 20-189 (8) 20-217 (2) 20-258 (2)
20-113 (1) 20-150 (4) 20-190 (8) 20-218 (2) 20-259 (2)
20-114 (8) 20-151 (4) 20-191 (8) 20-220 (2) 20-260 (2)
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20-121 (1) 20-159 (8) 20-199 (8) 20-228 (2) 20-268 (2)
20-122 (1) 20-160 (8) 20-199-1 (8) 20-229 (2) 20-269 (2)
20-123 (1) 20-161 (8) 20-199-2 (8) 20-230 (2) 20-270 (2)
20-124 (1) 20-162 (8) 20-199-3 (8) 20-231 (2) 20-271 (2)
20-125 (1) 20-163 (8) 20-199-4 (8) 20-232 (2)
20-126 (1) 20-164 (8) 20-199-5 (8) 20-233 (2) 20-301 (2)
20-127 (8) 20-165 (8) 20-199-6 (8) 20-234 (2) 20-302 (2)
20-128 (8) 20-166 (8) 20-199-7 (8) 20-235 (2) 20-303 (2)
20-129 (1) 20-167 (8) 20-199-8 (8) 20-236 (2) 20-304 (2)
20-130 (1) 20-168 (8) 20-199-9 (8) 20-237 (2) 20-305 (2)
20-131 (1) 20-169 (8) 20-199-10 (8) 20-238 (2) 20-306 (2)
20-132 (1) 20-170 (8) 20-199-11 (8) 20-239 (2)
20-133 (8) 20-171 (8) 20-199-12 (8) 20-240 (2) 20-401 (2)
20-134 (1) 20-172 (8) 20-241 (2) 20-402 (2)
20-135 (8) 20-173 (8) 20-201 (2) 20-242 (2) 20-404 (2)
20-136 (8) 20-174 (8) 20-202 (2) 20-243 (2) 20-405 (2)
20-137 (1) 20-175 (8) 20-203 (2) 20-244 (2) 20-406 (2)
20-138 (1) 20-176 (8) 20-204 (2) 20-245 (2) 20-407 (2)
20-139 (1) 20-177 (8) 20-205 (2) 20-246 (2) 20-408 (2)
20-140 (1) 20-178 (8) 20-206 (2) 20-247 (2) 20-409 (2)
20-141 (1) 20-179 (8) 20-207 (2) 20-248 (2) 20-410 (2)
20-142 (1) 20-180 (8) 20-208 (2) 20-249 (2) 20-411 (2)
20-143 (6) 20-181 (8) 20-209 (2) 20-250 (2) 20-412 (2)
20-144 (6) 20-182 (8) 20-210 (2) 20-251 (2) 20-413 (2)
20-144-1 (6) 20-183 (8) 20-211 (2) 20-252 (2) 20-414 (2)
20-144-2 (8) 20-184 (8) 20-212 (2) 20-253 (2) 20-415 (2)
20-145 (1) 20-185 (8) 20-213 (2) 20-254 (2) 20-416 (2)
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LIST OF REVISED PAGES
20-417 (2) 20-501 (2) 20-601 (2) 20-703 (2) 20-807 (2)
20-418 (2) 20-502 (2) 20-602 (2) 20-704 (2) 20-808 (2)
20-419 (2) 20-503 (2) 20-604 (2) 20-705 (2) 20-809 (2)
20-420 (2) 20-504 (2) 20-605 (2) 20-706 (2) 20-810 (8)
20-421 (2) 20-505 (2) 20-606 (2) 20-707 (2) 20-811 (8)
20-422 (2) 20-506 (2) 20-607 (2) 20-708 (2) 20-812 (8)
20-423 (2) 20-507 (2) 20-608 (2) 20-709 (2) 20-813 (8)
20-424 (2) 20-508 (2) 20-609 (2) 20-710 (2) 20-814 (2)
20-425 (2) 20-509 (2) 20-610 (2) 20-711 (2) 20-815 (2)
20-426 (2) 20-510 (2) 20-611 (2) 20-712 (2) 20-816 (8)
20-427 (2) 20-511 (2) 20-612 (2) 20-713 (2) 20-817 (2)
20-428 (2) 20-512 (2) 20-613 (2) 20-714 (2) 20-818 (2)
20-429 (2) 20-513 (2) 20-614 (2) 20-715 (2) 20-819 (2)
20-430 (2) 20-514 (2) 20-615 (2) 20-716 (2) 20-820 (8)
20-431 (2) 20-515 (2) 20-616 (2) 20-717 (2) 20-821 (8)
20-432 (2) 20-516 (2) 20-617 (2) 20-718 (2) 20-822 (2)
20-433 (2) 20-517 (2) 20-618 (2) 20-719 (2) 20-823 (2)
20-434 (2) 20-518 (2) 20-619 (2) 20-720 (2) 20-824 (8)
20-435 (2) 20-519 (2) 20-620 (2) 20-721 (2) 20-825 (2)
20-436 (2) 20-520 (2) 20-722 (2) 20-826 (2)
20-437 (2) 20-521 (2) 20-651 (2) 20-723 (2) 20-827 (2)
20-438 (2) 20-522 (2) 20-652 (2) 20-724 (2) 20-828 (2)
20-439 (2) 20-523 (2) 20-654 (2) 20-725 (2) 20-829 (2)
20-440 (2) 20-524 (2) 20-655 (2) 20-726 (2) 20-830 (2)
20-441 (2) 20-525 (2) 20-656 (2) 20-727 (2) 20-831 (2)
20-442 (2) 20-526 (2) 20-657 (2) 20-728 (2) 20-832 (2)
20-443 (2) 20-527 (2) 20-658 (2) 20-729 (2) 20-833 (2)
20-444 (2) 20-528 (2) 20-659 (2) 20-730 (2) 20-834 (2)
20-445 (2) 20-529 (2) 20-660 (2) 20-731 (2) 20-835 (2)
20-446 (2) 20-530 (2) 20-661 (2) 20-732 (2) 20-836 (2)
20-447 (2) 20-531 (2) 20-662 (2) 20-733 (2) 20-837 (2)
20-448 (2) 20-532 (2) 20-663 (2) 20-734 (2) 20-838 (2)
20-449 (2) 20-533 (2) 20-664 (2) 20-735 (2) 20-839 (2)
20-450 (2) 20-534 (2) 20-665 (2) 20-840 (2)
20-451 (2) 20-535 (2) 20-666 (2) 20-801 (8) 20-841 (2)
20-452 (2) 20-536 (2) 20-667 (2) 20-802 (8) 20-842 (2)
20-453 (2) 20-537 (2) 20-668 (2) 20-803 (2) 20-843 (2)
20-454 (2) 20-538 (2) 20-804 (2) 20-844 (2)
20-455 (2) 20-539 (2) 20-701 (2) 20-805 (8) 20-845 (2)
20-702 (2) 20-806 (2) 20-846 (2)
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20-847 (2) 20-887 (2) 20-928 (2) 30-014 (5) 30-050 (5)
20-848 (2) 20-888 (2) 20-929 (2) 30-015 (5) 30-051 (5)
20-849 (2) 20-889 (2) 20-930 (2) 30-016 (5) 30-052 (5)
20-850 (2) 20-890 (2) 30-017 (5) 30-053 (5)
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20-853 (2) 20-893 (2) 20-1003 (2) 30-020 (5) 30-056 (5)
20-854 (2) 20-894 (2) 20-1004 (2) 30-021 (5) 30-057 (5)
20-855 (2) 20-896 (2) 20-1005 (2) 30-022 (5) 30-058 (5)
20-856 (2) 20-897 (2) 20-1006 (2) 30-023 (5) 30-059 (5)
20-857 (2) 20-898 (2) 20-1007 (2) 30-024 (5) 30-060 (5)
20-858 (8) 20-899 (2) 20-1008 (2) 30-025 (5) 30-061 (5)
20-859 (2) 20-900 (2) 20-1009 (2) 30-026 (5) 30-062 (5)
20-860 (2) 20-901 (2) 20-1010 (2) 30-027 (5) 30-063 (5)
20-861 (2) 20-902 (2) 20-1011 (2) 30-028 (5) 30-064 (5)
20-862 (2) 20-903 (2) 20-1012 (2) 30-029 (5) 30-065 (5)
20-863 (2) 20-904 (2) 20-1013 (2) 30-030 (5) 30-066 (5)
20-864 (2) 20-905 (2) 20-1014 (2) 30-031 (5) 30-067 (6)
20-865 (2) 20-906 (2) 20-1015 (2) 30-032 (5) 30-068 (5)
20-866 (2) 20-907 (2) 20-1016 (2) 30-033 (5) 30-069 (5)
20-867 (2) 20-908 (2) 20-1017 (2) 30-034 (5) 30-070 (5)
(20-868) 20-909 (2) 20-1018 (2) 30-035 (5) 30-070-1 (5)
20-869 (2) 20-910 (2) 20-1019 (2) 30-036 (5) 30-071 (5)
20-870 (2) 20-911 (2) 20-1020 (2) 30-037 (5) 30-072 (5)
20-871 (2) 20-912 (2) 30-038 (5) 30-073 (5)
20-872 (2) 20-913 (2) 30-039 (5) 30-074 (5)
20-873 (2) 20-914 (2) ‡ 30-001 (9) 30-040 (5) 30-075 (5)
20-874 (2) 20-915 (2) ‡ 30-002 (9) 30-041 (5) 30-076 (5)
20-875 (2) 20-916 (2) ‡ 30-003 (9) 30-042 (5) 30-076-1 (5)
20-876 (2) 20-917 (2) ‡ 30-004 (9) 30-043 (5) 30-076-2 (5)
20-877 (2) 20-918 (2) ‡ 30-005 (9) 30-044 (5) 30-076-3 (5)
20-878 (2) 20-919 (2) ‡ 30-006 (9) 30-045 (5) 30-076-4 (5)
20-879 (2) 20-920 (2) fi 30-006-1 (9) 30-046 (5) 30-076-5 (5)
20-880 (2) 20-921 (2) 30-007 (5) 30-047 (5) 30-076-6 (5)
20-881 (2) 20-922 (2) 30-008 (5) 30-048 (5) 30-076-7 (5)
20-882 (2) 20-923 (2) 30-009 (5) 30-049 (5) 30-076-8 (5)
20-883 (2) 20-924 (2) 30-010 (5) 30-049-1 (5) 30-076-9 (5)
20-884 (2) 20-925 (2) 30-011 (5) 30-049-2 (5) 30-076-10 (5)
20-885 (2) 20-926 (2) 30-012 (5) 30-049-3 (5) 30-077 (5)
20-886 (2) 20-927 (2) 30-013 (5) 30-049-4 (5) 30-078 (5)
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LIST OF REVISED PAGES
00-2-6 WA1200-3
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SAFETY SAFETY NOTICE
SAFETY
SAFETY NOTICE
Proper service and repair is extremely important for safe machine operation. The service and
repair techniques recommended by Komatsu and described in this manual are both effective
and safe. Some of these techniques require the use of tools specially designed by Komatsu for
the specific purpose.
To prevent injury to workers, the symbol k is used to mark safety precautions in this manual.
The cautions accompanying these symbols should always be followed carefully. If any danger-
ous situation arises or may possibly arise, first consider safety, and take the necessary actions
to deal with the situation.
00-3
SAFETY SAFETY NOTICE
PRECAUTIONS DURING WORK 19.Be sure to assemble all parts again in their origi-
nal places.
11.When removing the oil filler cap, drain plug or Replace any damaged parts with new parts.
hydraulic pressure measuring plugs, loosen • When installing hoses and wires, be sure
them slowly to prevent the oil from spurting out. that they will not be damaged by contact
Before disconnecting or removing components with other parts when the machine is being
of the oil, water or air circuits, first remove the operated.
pressure completely from the circuit. 20.When installing high pressure hoses, make sure
12.The water and oil in the circuits are hot when the that they are not twisted. Damaged tubes are
engine is stopped, so be careful not to get dangerous, so be extremely careful when install-
burned. ing tubes for high pressure circuits. Also, check
Wait for the oil and water to cool before carry- that connecting parts are correctly installed.
ing out any work on the oil or water circuits. 21.When assembling or installing parts, always use
13.Before starting work, remove the leads from the the specified tightening torques. When installing
battery. Always remove the lead from the nega- protective parts such as guards, or parts which
tive (–) terminal first. vibrate violently or rotate at high speed, be par-
14.When raising heavy components, use a hoist or ticularly careful to check that they are installed
crane. correctly.
Check that the wire rope, chains and hooks are 22.When aligning two holes, never insert your fin-
free from damage. gers or hand. Be careful not to get your fingers
Always use lifting equipment which has ample caught in a hole.
capacity. 23.When measuring hydraulic pressure, check that
Install the lifting equipment at the correct places. the measuring tool is correctly assembled before
Use a hoist or crane and operate slowly to pre- taking any measurements.
vent the component from hitting any other part.
24.Take care when removing or installing the tracks
Do not work with any part still raised by the hoist
of track-type machines.
or crane.
When removing the track, the track separates
15.When removing covers which are under internal suddenly, so never let anyone stand at either
pressure or under pressure from a spring, end of the track.
always leave two bolts in position on opposite
sides. Slowly release the pressure, then slowly
loosen the bolts to remove.
16.When removing components, be careful not to
break or damage the wiring. Damaged wiring
may cause electrical fires.
17.When removing piping, stop the fuel or oil from
spilling out. If any fuel or oil drips onto the floor,
wipe it up immediately. Fuel or oil on the floor
can cause you to slip, or can even start fires.
18.As a general rule, do not use gasoline to wash
parts. In particular, use only the minimum of
gasoline when washing electrical parts.
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 judge-
ments. 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 chapters; these chapters are fur-
ther divided into the each main group of components.
MAINTENANCE STANDARD
This section gives the judgment standards for inspection of disassembled parts.
The contents of this section may be described in STRUCTURE AND FUNCTION.
OTHERS
This section mainly gives hydraulic circuit diagrams and electric circuit diagrams.
In addition, this section may give the specifications of attachments and options together.
NOTICE
The specifications contained in this shop manual are subject to change at any time and without any
advance notice. Use the specifications given in the book with the latest date.
00-5
FOREWORD HOW TO READ THE SHOP MANUAL
SYMBOLS
These various volumes are designed to avoid dupli-
cating the same information. Therefore, to deal with So that the shop manual can be of ample practical
all repairs for any model , it is necessary that chas- use, important safety and quality portions are
sis, engine, electrical and attachment volumes be marked with the following symbols.
available.
2
Places to be coated with
12 - 5 Coat adhesives and lubricants,
etc.
Unit number (1. Engine) Places where oil, water or
5
Item number (2. Testing and Adjust- Oil, water fuel must be added, and
ing) the capacity.
Consecutive page number for each
Places where oil or water
6
item.
Drain must be drained, and
quantity to be drained.
3. Additional pages: Additional pages are indicated
by a hyphen (-) and number after the page
number. File as in the example.
Example:
10-4 12-203
10-4-1 12-203-1
Added pages
10-4-2 12-203-2
10-5 12-204
00-6
FOREWORD HOISTING INSTRUCTIONS
HOISTING INSTRUCTIONS
HOISTING
00-7
FOREWORD METHOD OF DISASSEMBLING, CONNECTING PUSH-PULL TYPE COUPLER
Disconnection
1) Release the residual pressure from the hydrau-
lic tank. For details, see TESTING AND
ADJUSTING, Releasing residual pressure from
hydraulic tank.
Connection
1) Hold hose adapter (1) or hose (5) and insert it in
mating adapter (3), aligning them with each
other. (See Fig. 4)
★ Do not hold rubber cap portion (4).
00-8
FOREWORD METHOD OF DISASSEMBLING, CONNECTING PUSH-PULL TYPE COUPLER
Type 2 Type 3
1) Hold the mouthpiece of the tightening portion 1) Hold the mouthpiece of the tightening portion
and push body (2) in straight until sliding pre- and push body (2) in straight until sliding pre-
vention ring (1) contacts contact surface a of vention ring (1) contacts contact surface a of
the hexagonal portion at the male end. the hexagonal portion at the male end.
2) Hold in the condition in Step 1), and turn 2) Hold in the condition in Step 1), and push
lever (4) to the right (clockwise). until cover (3) contacts contact surface a of
the hexagonal portion at the male end.
Disassembly
3) Hold in the condition in Steps 1) and 2), and 3) Hold in the condition in Steps 1) and 2), and
pull out whole body (2) to disconnect it. pull out whole body (2) to disconnect it.
• Hold the mouthpiece of the tightening portion • Hold the mouthpiece of the tightening portion
and push body (2) in straight until sliding pre- and push body (2) in straight until sliding pre-
vention ring (1) contacts contact surface a of vention ring (1) contacts contact surface a of
the hexagonal portion at the male end to con- the hexagonal portion at the male end to con-
nect it. nect it.
Connection
00-9
FOREWORD COATING MATERIALS
COATING MATERIALS
★ The recommended coating materials such as adhesives, gasket sealants and greases used for disassembly
and assembly are listed below.
★ For coating materials not listed below, use the equivalent of products shown in this list.
Category Komatsu code Part No. Q'ty Container Main applications, features
00-10
FOREWORD COATING MATERIALS
Category Komatsu code Part No. Q'ty Container Main applications, features
00-11
FOREWORD STANDARD TIGHTENING TORQUE
mm mm Nm kgm
Tightening torque
Thread diameter Width across
of bolt flats
mm mm Nm kgm
Sealing surface
mm mm Nm kgm
00-12
FOREWORD STANDARD TIGHTENING TORQUE
mm mm Nm kgm
10 14 59 – 74 6 – 7.5
12 17 98 – 123 10 – 12.5
16 22 235 – 285 23.5 – 29.5
00-13
FOREWORD STANDARD TIGHTENING TORQUE
2) EYE JOINTS
Use these torques for eye joints (unit: mm) of Cummins Engine.
Thread diameter Tightening torque
mm Nm kgm
6 802 0.81 0 0.20
8 10 0 2 1.02 0 0.20
10 12 0 2 1.22 0 0.20
12 24 0 4 2.45 0 0.41
14 36 0 5 3.67 0 0.51
3) TAPERED SCREWS
Use these torques for tapered screws (unit: inch) of Cummins Engine.
Thread diameter Tightening torque
inch Nm kgm
1 / 16 301 0.31 0 0.10
1/8 802 0.81 0 0.20
1/4 12 0 2 1.22 0 0.20
3/8 15 0 2 1.53 0 0.41
1/2 24 0 4 2.45 0 0.41
3/4 36 0 5 3.67 0 0.51
1 60 0 9 6.12 0 0.92
TIGHTENING TORQUE TABLE FOR HOSES (TAPER SEAL TYPE AND FACE SEAL TYPE)
★ Tighten the hoses (taper seal type and face seal type) to the following torque, unless otherwise specified.
★ Apply the following torque when the threads are coated (wet) with engine oil.
Taper seal
Tightening torque (Nm {kgm}) Face seal type
type
Nominal size Width across
of hose flats Nominal thread
Thread size size Root diameter
Range Target - Threads per
(mm) inch, Thread series (mm) (Reference)
9
34 – 54 {3.5 – 5.5} 44 {4.5} – — – 18UN 14.3
02 19 16
34 – 63 {3.5 – 6.5} 44 {4.5} 14 – –
11
22 54 – 93 {5.5 – 9.5} 74 {7.5} – — – 16UN 17.5
03 16
24 59 – 98 {6.0 – 10.0} 78 {8.0} 18 – –
13
04 27 84 – 132 {8.5 – 13.5} 103 {10.5} 22 — – 16UN 20.6
16
05 32 128 – 186 {13.0 – 19.0} 157 {16.0} 24 1 – 14UNS 25.4
3
06 36 177 – 245 {18.0 – 25.0} 216 {22.0} 30 1 — – 12UN 30.2
16
(10) 41 177 – 245 {18.0 – 25.0} 216 {22.0} 33 – –
(12) 46 197 – 294 {20.0 – 30.0} 245 {25.0} 36 – –
(14) 55 246 – 343 {25.0 – 35.0} 294 {30.0} 42 – –
00-14
FOREWORD ELECTRIC WIRE CODE
CLASSIFICATION BY THICKNESS
Copper wire
Norminal Cable O.D. Current
number Dia. of Cross (mm) rating Applicable circuit
Number of strands section (A)
strands
(mm2) (mm2)
Circuits
Priori- Charging Ground Starting Lighting Instrument Signal Other
ty Classi-
fication
Code W B B R Y G L
Pri-
1 mary
Color White Black Black Red Yellow Green Blue
Code WR — BW RW YR GW LW
2
Color White & Red — White & Black Red & White Rellow & 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 & Yellow
Code WL — BR RY YG GY LY
Auxi-
4 liary Yellow & Green &
Color White & Blue — Black & Red Red & Yellow Blue & Yellow
Green Yellow
Code WG — — RG YL GB LB
5
Color White & Green — — Red & Green Yellow & Blue Green & Black Blue & Black
Code — — — RL YW GL n
6
Color — — — Red & Blue Yellow & White Green & Blue n
00-15
FOREWORD CONVERSION TABLE
CONVERSION TABLE
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 A, then draw a horizontal line
from A.
(2) Locate the number 5 in the row across the top, take this as B, then draw a perpendicular line down
from B.
(3) Take the point where the two lines cross as C. This point C gives the value when converting from mil-
limeters to inches. Therefore, 55 mm = 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 point 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 point
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
0 1 2 3 4 5 6 7 8 9
C
40 1.575 1.614 1.654 1.693 1.732 1.772 1.811 1.850 1.890 1.929
A 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
00-16
FOREWORD CONVERSION TABLE
Millimeters to Inches
1 mm = 0.03937 in
0 1 2 3 4 5 6 7 8 9
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
0 1 2 3 4 5 6 7 8 9
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
00-17
FOREWORD CONVERSION TABLE
0 1 2 3 4 5 6 7 8 9
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
0 1 2 3 4 5 6 7 8 9
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
00-18
FOREWORD CONVERSION TABLE
kgm to ft. lb
1 kgm = 7.233 ft. lb
0 1 2 3 4 5 6 7 8 9
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
00-19
FOREWORD CONVERSION TABLE
kg/cm2 to lb/in2
1kg/cm2 = 14.2233 lb/in2
0 1 2 3 4 5 6 7 8 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
00-20
FOREWORD CONVERSION TABLE
Temperature
Fahrenheit-Centigrade Conversion ; a simple way to convert a Fahrenheit temperature reading into a Cen-
tigrade temperature reading or vice versa is to enter the accompanying table in the center or boldface col-
umn 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°C = 33.8°F
°C °F °C °F °C °F °C °F
00-21
FOREWORD UNITS
UNITS
In this manual, the measuring units are indicated with Internatinal System of units (SI).
As for reference, conventionally used Gravitational System of units are indicated in parentheses { }.
Example:
N {kg}
Nm {kgm}
MPa {kg/cm2}
kPa {mmH2O}
kPa {mmHg}
kW/rpm {HP/rpm}
g/kWh {g/HPh}
00-22 10-04
01 GENERAL
SJWO4720
Gradeability deg 25
I
Center of outside wheel mm 12,000
Min. turning
radius Outside portion of chassis mm 14,300
Wheelbase mm 7,100
Tread mm 4,300
Fuel consumption ratio g/kW-h {g/HP-h} 214 {ISO} (at rated output, gross)
Alternator 24V140A
Battery 12 V 200 Ah x 6
Tire 55.5/80-57-68PR(L-5)
[65/65-57-62PR(L-511
Wheel rim 44.00 x 57i6.0 [52.00 x 57i6.01
Inflation pressure kPa {kg/cm21 588 (6.01
-
Main brake Front/rear wheel braking, separate
front/rear wheel, wet disc,
1 hydraulically actuated
?
a Parking brake Drive shaft (Transmission output
shaft) braking, multiple wet disc,
hydraulically release spring apply
WEIGHT TABLE
A This weight table is a guide for use when transporting or handling components.
Unit: kg
Engine 7,250
Transmission 3,690
Damper I 359
Steering valve 68
PPC valve 4
Unit: kg
Rear frame
Battery (each) 59
Operator’s seat
Floor plate
Brake Brake 60 Q 45 Q
tank Cooling 280 Q 270 Q
Axle
(Front and rear) See Note 1 670 Q 670 Q
(each)
Auto-grease Grease
REMARK
When fuel sulphur content is less than 0.5%,
change oil in the oil pan every periodic mainte-
nance hours described in this manual.
Change oil according to the following table if
fuel sulphur content is above 0.5%.
WA1200-3 10-1
(7)
STRUCTURE AND FUNCTION OUTLINE
OUTLINE
SWWO4721
SWW04722
23. Torque converter, transmission pump
24. Brake cooling pump
25. Brake pump
26. Rear final drive
27. Rear tire
28. Rear axle
29. Rear differential
30. Rear brake
31. Rear drive shaft
32. Center support
33. Parking brake
,______-----
I
Y
SJW04723
DAMPER
3 4 5 6
SJW04724
1. Shaft FUNCTION
2. Breather . The damper reduces the torsional vibration
3. Rubber cushion caused by changes in the engine torque, and
4. Inner body acts to protect the units of the power train
5. Rubber cushion beyond the engine from the effects of tor-
6. Outer body sional vibration.
OPERATION
. The power of the engine is transmitted from
the flywheel to outer body (6). The torsional
vibration of the engine is absorbed by rub-
ber cushions (3) and (51, passes through in-
ner body (4) and shaft (I), and is transmitted
to the upper drive shaft between the torque
converter.
SWW04725
1. Transmission
2. Transmission control valve
3. Transfer (input)
4. Torque converter oil cooler
5. Torque converter charging pump
6. Torque converter
7. Torque converter oil filter
8. Transmission oil level gauge
9. Transfer (output)
TORQUE CONVERTER
(INPUT TRANSFER, PTO, MODULATED CLUTCH, TORQUE CONVERTER)
lZ
W
7
9JA00061
G ! H
.\...
F
J
IO
9JBOOO62
A: Torque converter outlet port 1. Mounting port for steering pump, control
B: Outlet oil pressure pick-up port of torque pump, and PPC pump
converter 2. Mounting port for switch pump
c: Torque converter inlet port 3. Mounting port for transmission charging
D: Lubrication port for PTO, input transfer, pump, torque converter charging pump,
and modulated clutch brake cooling pump, and brake pump
E: Interconnection port 4. Regulator valve of torque converter outlet
F: Torque converter inlet port 5. Mounting port for work equipment pump
G: Inlet oil pressure pick-up port of torque 6. Mounting port for work equipment pump
converter 7. Output rotation sensor of modulated clutch
H: Main oil pressure pick-up port 8. ECMV for modulated clutch
J: Torque converter relief port 9. Torque converter valve
K: Drain port 10. Input rotation sensor of input transfer
14
A-A
9JB00063
9JBOOO64
Specifications
Model: 42C-13-11002
Type: 3-elemet, single stage, single phase
Stall torque ratio: 2.23 (T3/Tl)
2.84 (T3/T2)
T3
Operation
Power transmission route
9JBOOO66
l The torque converter is installed between The power transmitted to modulated clutch
the damper and transmission. outer drum (18) is further transmitted
The power from the damper is transmitted through modulated clutch output shaft (16)
through the upper drive shaft to coupling and coupling (20) to torque converter input
(II). shaft (21).
The speed of the rotation is heightened with Since torque converter input shaft (211, drive
drive gear (121, idler gear (151, and driven case (22). and pump (25) are secured with
gear (28) of the input transfer, then trans- bolts, they are rotated with the power from
mitted to modulated clutch inner drum (19). the modulated clutch.
If oil pressure is applied to the back of modu- The power of pump (25) rotates turbine (23)
lated clutch piston (171, modulated clutch to drive transmission input shaft (271, using
piston (171 presses modulated clutch disc the oil as medium.
(29) against modulated clutch plate (30) to l The power of coupling (11) is used to drive
transfer the power to modulated clutch outer the pump, too, through drive gear (121, PTO
drum (18). gear (131, or idler gear (15).
Flow of oil
9JBOOO67
l The oil flows through the main relief valve The oil from turbine (23) flows to stator (24)
and its pressure is regulated below the set and flows in pump (25) again. At this time, a
pressure by the torque converter relief valve, part of the oil flows through stator (24) and
then it flows in inlet port A and merges with outlet port B to the torque converter outlet
the oil sent from the torque converter charg- regulator valve.
ing pump through torque converter case (26), The oil that flows in the torque converter
then the merged oil flows in pump (25). outlet regulator valve flows further through
Set pressure: 1.05 MPa (IO.7 kg/cm*} the oil cooler to cool itself, then it is used to
The oil is given centrifugal force by pump lubricate the transmission.
(251, then it flows in turbine (23) and gives
its energy to turbine (23).
Outline
l The modulated clutch is installed between
the input transfer and torque converter.
l The clutch can be engaged or slipped by
adjusting the clutch oil pressure with ECMV.
l The power transmitted to the torque con-
verter can be reduced by slipping the clutch.
Operation
I E 23
D 7
A-A
P4 A4
\
Pi
9JB00069
Outline
. Main relief valve to the torque converter inlet circuit, and it
The main relief valve keeps the transmis- keeps the oil pressure at the torque con-
sion oil pressure at the set level. verter inlet circuit below the set pressure to
Set pressure: 2.65 MPa (27 kg/cm21 protect the torque converter from abnormally
(At the rated engine speed) high pressure.
l Torque converter relief valve Set pressure: 1.05 MPa 110.7 kg/cm*)
The torque converter relief valve is installed (Cracking pressure)
To torque To transmission
converter lubrication
SXW04736
To torque To transmission
converter lubrication
sxwo4737
lo-18 WA 1200-3
STRUCTURE AND FUNCTION MAIN RELIEF VALVE AND TORQUE CONVERTER RELIEF VALVE
To toraue To transmission
converter lubrication
sxwo473a
9JBOOO73
Operation
l The oil from the torque converter flows
through port A and orifice a into chamber B.
Since the oil pressure in chamber B is lower
than the tension of valve springs (2) and (31,
spool (4) does not move.
8
From torque
converter
sxwo4739
/ ii
A From torque
converter
sxwo4740
ECMV
(For modulated clutch)
9JBOOO76
A: To clutch 1. Connector
B: Drain 2. Spring
C: From pump 3. Flow sensor valve spool
P: Clutch oil pressure pick-up port 4. Spring
5. Fill switch
6. Proportional solenoid
7. Pressure control valve spool
8. Load piston
9. Spring
Outline
Outline of ECMV
l ECMV (Electronic Control Modulated Valve) A , E , D
consists of one pressure control valve and
one flow sensor valve.
. Pressure control valve
This valve receives the current sent from the
controller with a proportional solenoid, then
converts it into oil pressure.
SXW04742
WA1 200-3
1 O-23
STRUCTURE AND FUNCTION ECMV
Operation
Operation of ECMV
l ECMV is controlled with the command cur-
rent sent from the controller to the propor-
tional solenoid and the fill switch output sig-
nal.
The relationship among the proportional so-
lenoid command current of ECMV, clutch in-
put pressure, and fill switch output signal is
shown at right.
Set
Range A: L
Before shifting gear (when draining)
Range B: Fill starts (during trigger)
Range C: Fill completed
Range D: Pressure adjustment
Range E: During filling
i;; 4 Time
,Sec
t-l
1 OFF 1 ON
esec
Time
sxwo474 1
9JEOOO77
9JBOOO78
9JBOOO79
9JBOOO80
9JROOORl
9JBOOO82
TRANSMISSION
(Transmission, transfer, and parking brake)
9JB00083
9JBOO 004
44 6
x-x +
SJBOOOB5
Outline
l The transmission system consists of a for-
ward 3-gear speed and reverse 3-gear speed+
transmission consisting of planetary gear
mechanisms and disc clutches, transfer, park-
ing brake, and transmission control valve.
l Among the five sets of a planetary gear
mechanism and a disc clutch, 2 clutches are
operated with a control valve and fixed hy-
draulically to select one rotation direction
and one rpm.
l Clutch No. 1 is fixed for reverse travel, clutch
No. 2 for forward travel, clutch No. 3 for
travel at 3rd speed, clutch No. 4 for travel at
2nd speed, and clutch No. 5 for travel at 1st
speed.
Clutch No. 1 7 8
Clutch No. 2 8 9
Clutch No. 3 4 5
Clutch No. 4 3 4
Clutch No. 5 8 9
Operation
Operation of clutch
l The clutch consists of piston (361, plate (41,
disc (3), pin (411, piston return spring (401,
washer spring (421, etc. to secure ring gear
(38).
l The inside teeth of disc (3) are engaged with
the outside teeth of ring gear (38).
l The cut part of the outside of plate (4) is
engaged with pin (41) fixed to clutch hous-
ing (6).
9J800087
9J800088
95800089
Power train
Forward 1st speed
9J 800090
l When the transmission is set in the forward l At this time, rotation of carriers No. 2 and
1st speed, clutches No. 2 and No. 5 are con- No. 3 (32) is transmitted as rotary power in
nected and ring gear No. 2 (9) is fixed and the rotation direction of sun gear No. 2 (34).
clutch No. 5 hub (25) is directly coupled with l Since clutch No. 5 is engaged, ring gear No.
output shaft (22) to output the power. 3 (13), carrier No. 4, clutch No. 5 drum (24),
l The power from the torque converter is trans- and clutch No. 5 hub (25) are fixed as one
mitted to input shaft (I), then transmitted unit.
through sun gear No. 2 (34) to planetary l Since carriers No. 2 and No. 3 (32) rotate
pinion No. 2 (10). under this condition, the whole unit of ring
Since ring gear No. 2 (9) is fixed, planetary gear No. 3 (13), carrier No. 4, clutch No. 5
pinion No. 2 (10) rotates and revolves along drum (24), and clutch No. 5 hub (25) rotates,
ring gear No. 2 (9) around sun gear No. 2 and the rotary power is output through out-
(34) simultaneously. put shaft (22) in the rotation direction of sun
gear No. (2) (34).
9JB00091
When the transmission is set in the forward l Since clutch No. 4 is engaged, ring gear No.
2nd speed, clutches No. 2 and No. 4 are 4 (18) is fixed.
connected and ring gears (9) and (18) are . Since carriers No. 2 and No. 3 (32) rotate
fixed to output the power. under this condition, the power is transmit-
The power from the torque converter is trans- ted from ring gear No. 3 (13) through carrier
mitted to input shaft (I), then transmitted No. 5 to clutch No. 5 drum (24). Planetary
through sun gear No. 2 (34) to planetary pinion No. 4 (16) rotates and revolves along
pinion No. 2 (IO). ring gear No. 4 (18) around sun gear No. 4
Since ring gear No. 2 (9) is fixed, planetary (261, and its rotary power is output to output
pinion No. 2 (IO) rotates and revolves along shaft (22) in the rotation direction of sun
ring gear No. 2 (9) around sun gear No. 2 gear No. 2 (34).
(34) simultaneously.
At this time, rotation of carriers No. 2 and
No. 3 (32) is transmitted as rotary power in
the rotation direction of sun gear No. 2 (34).
QJBOOO!32
l When the transmission is set in the forward . At this time, rotation of carriers No. 2 and
3rd speed, clutches No. 2 and No. 3 are con- No. 3 (32) is transmitted as rotary power in
nected and ring gears No. 2 (9) and No. 3 the rotation direction of sun gear No. 2 (34).
(13) are fixed to output the power. l Since ring gear No. 3 (13) is fixed, as carri-
l The power from the torque converter is trans- ers No. 2 and No. 3 (32) rotate, planetary
mitted to input shaft (I), then transmitted pinion No. 3 (12) rotates along ring gear No.
through sun gear No. 2 (34) to planetary 3 (13) and revolves around sun gear No. 3
pinion No. 2 (IO). (291.
l Since ring gear No. 2 (9) is fixed, planetary l Under this condition, the rotary power of
pinion No. 2 (10) rotates and revolves along carriers No. 2 and No. 3 (32) rotates sun
ring gear No. 2 (9) around sun gear No. 2 gear No. 3 (29) and is output to output shaft
(34) simultaneously. (22) in the rotation direction of sun gear No.
2 (34).
9JEOOO93
l When the transmission is set in the reverse l At this time, since clutch No. 1 fixes carrier
1st speed, clutches No. 1 and No. 5 are con- No. 1 (391, the rotary power of planetary
nected and ring gear No. 1 (38) is fixed and pinion No. 1 (5) is transmitted to carriers
clutch No. 5 hub (25) is directly coupled with No. 2 and No. 3 (32) to rotate ring gear No. 1
output shaft (22) to output the power. (7) in the opposite direction to sun gear No.
l The power from the torque converter is trans- 1 (36).
mitted to input shaft (I), then transmitted . As a result, the power in the reverse direc-
through sun gear No. 1 (36) and planetary tion is transmitted to output shaft (22). The
pinion No. 1 (5) to ring gear No. 1 (7). power train after this point in the reverse
l Since ring gear No. 1 (38) is fixed, planetary lst, 2nd, or 3rd speed is similar to that in
pinion No. 1 (5) rotates and revolves around the forward Ist, 2nd, or 3rd speed described
sun gear No. 1 (36) simultaneously. before.
9JBOOO94
Outline
When the piston volume of a clutch is large,
if only ECMV is used, it takes long time to
fill the clutch, that is, the fill time is length-
ened and the operator feels time lag in gear
shifting operation.
To solve this problem, by-pass valves are
installed, which are operated simultaneously
with ECMV to fill the large-piston volume
clutches with oil quickly.
l Each bv-oass
, . fill valve is controlled with the
command current from the transmission con-
troller. The relationship between ECMV and
operation of this valve is shown at right.
Operation
5 C4PA T32 I
9JEIOOO96
9JB00097
Outline
l When a clutch is “disengaged”, the oil in
the clutch piston is drained through ECMV
into the transmission case.
When the piston volume of the clutch is
large, if only ECMV is operated as past, it
takes long time to discharge the oil. If the
next gear shifting operation starts before the
all oil is discharged, a shock may be gener-
ated.
To prevent this, a by-pass drain valve is in-
stalled to discharge the oil quickly from a
large-piston volume clutch without through
ECMV.
Operation
9JBOOO98
ECMV
(For transmission)
SJBOOlOO
A: To clutch 1. Connector
B: Drain 2. Spring
C: From pump 3. Flow sensor valve spool
P: Clutch oil pressure pick-up port 4. Spring
5. Fill switch
6. Proportional solenoid
7. Pressure control valve spool
8. Load piston
9. Spring
Outline
Outline of ECMV
l ECMV (Electronic Control Modulated Valve)
consists of one pressure control valve and
one flow sensor valve.
. Pressure control valve
This valve receives the current sent from the -L
transmission controller with a proportional !k=i
solenoid, then converts it into oil pressure. z-a
LC
. Flow sensor valve zg
This valve operates according to the trigger z 5s:
a. u-
sinnals sent from the pressure control valve
and has the following functions.
I) Closes and outputs a signal (a filling sig-
nal) to the controller to notify that filling
is completed when the clutch is filled
with oil.
2) Keeps outputting signals (filling signals)
to the controller to notify that oil pres-
sure is applied or not while oil pressure
is applied to the clutch.
Range A:
Before shifting gear (when draining)
Range B: Fill starts (during trigger)
Range C: Fill completed Time (Set)
sxwo4742
Operation
Operation of ECMV
. ECMV is controlled with the command cur-
rent sent from the transmission controller to
the proportional solenoid and the fill switch
output signal.
The relationship among the proportional so-
lenoid command current of ECMV, clutch in-
put pressure, and fill switch output signal is
shown at 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
Tine (Sec)
9JBOOlOl
0 A 7
9JBOOlO2
9JBOO103
95800104
9JB00105
A-A
9JBOO106
1. Spool
2. Valve body
Function
l This valve is installed to the transmission
valve and prevents the pressure of the trans-
mission lubricating oil from rising abnor-
mally.
Set pressure: 0.26 MPa 12.7 kg/cm*)
(Cracking pressure)
TRANSFER
9JBOO107
Outline
l The transfer is installed on the output side
of the transmission and secured to the trans-
mission case with bolts.
Operation
Power train
l Since transmission output shaft (I) and trans-
fer input gear (2) are fixed with the spline,
the power is transmitted through transfer
idler gear (3) to transfer output gear (41, then
transmitted to output shaft (5). One part of
the power transmitted to output shaft (5) is
further transmitted through the center drive
shaft and front drive shaft to the front axle.
The other part of the power is transmitted
through the rear drive shaft to the rear axle.
9JEIOOlO8
CENTER SUPPORT
FUNCTION
1. Front coupling
l The center support is installed to the front
2. Case
frame between the center drive shaft and
3. Grease nipple
the front drive shaft.
4. Rear coupling
l With the articulating frame, this part is con-
stantly twisting from side to side, so there is
liable to be large stress on the drive shaft.
Therefore, the center support is used to
transmit the power smoothly, to reduce the
stress on the drive shafts, and in this way
improve the durability of the drive shafts.
AXLE
FRONT AXLE
SJW04727
1. Front axle
2. Final drive
3. Brake
4. Front differential
5. Drain plug
FRONT DIFFERENTIAL
SJWO4728
1. Housing 5. Shaft
2. Bevel gear (Teeth 39) 6. Bevel pinion (Teeth IO)
3. Differential side gear (Teeth 28) 7. Coupling
4. Differential pinion gear (Teeth 22)
REAR AXLE
lZ
\ b---=-t
5
SJWO4729
1. Rear axle
2. Rear differential
3. Brake
4. Final drive
5. Drain plug
REAR DIFFERENTIAL
SJWO4730
Outline
The power of the engine is transmitted
through the damper, upper drive shaft,
modulated clutch, torque converter, trans-
mission, and drive shaft to the front and
rear axles.
In the axle, the rotation is transmitted from
pinion gear (I) to bevel gear (5) and its di-
rection is changed by 90 degrees and its
speed is reduced, then it is transmitted
through differential (4) to axle shaft (2).
The rotation speed of the axle shaft is fur-
ther reduced by the final drive of planetary
gear type, then transmitted to the wheels.
sEwooo77
SEW00078
When turning
l When turning, the rotating speed of the left
and right wheels is different, so pinion gear
(4) and side gear (3) inside the differential
assembly rotate in accordance with the dif-
ference between the rotating speed of the
left and right wheels. The motive force of
carrier (6) is then transmitted to axle shafts
(2).
FINAL DRIVE
SJW04731
AXlE MOUNT
I 2
Z
c
A-A B-B
SJWO4732
SJWO4733
3
\
STEERING PUMP
Model: HPV160+ 160
l This pump consists of 2 fixed-displacement For the operation of this pump, see the sec-
swash plate piston pumps, 2 gear pumps tion of work equipment pump.
and 1 impeller pump between them.
PS PGSl PGSP
9JYOO227
PAI: Front pump discharge port PGSI : Gear pump suction Port
PA2: Rear pump discharge port PGSS: Gear pump suction Port
PADI: Gear pump discharge port PS: Pump suction port
PAD2: Gear pump discharge port
PDII: Drain port 1. Front pump
PD12: Drain port 2. Rear pump
PD21: Drain port 3. Gear pump
PD22: Drain port 4. Gear pump
STEERING PUMP
c-c
2 3 4
B-0
I!
9JYOO228
SWITCH PUMP
Model HPV160+ HPF160
PIN
9JYOO229
SWITCH PUMP
X Y
9JYOO230
PSVI : Servo valve main pressure port PSVP: Servo valve main pressure port
PSVIA: Servo valve output port PSV2A: Servo valve output port
PSVlB: Servo valve output port PSVSB: Servo valve output port
WA1 200-3
1O-69
STRUCTURE AND FUNCTION SWITCH PUMP
SWITCH PUMP
A-A
Cd
18
c-c
9JYOO231
SERVO VALVE
1. Servo valve assembly (For front of switch)
PA ,c2 ‘AC1
Pl
P2
\
PECN
9JYOO232
PI: Main pump pressure IN pot-t PIN: Main pump pressure input port
P2: Main pump pressure IN port PPO: Servo main pressure IN port
PACl: Servo actuator port
PACS: Servo actuator port 1. CO + NC valves
PDR: Servo drain OUT port 2. Servo valve
PECN: CO + NC valves output pressure OUT port 3. Plate
Pl I P2 I
CN
A-A
9JYOO233
PECN
PPO
PDR
P2
Pl
9JYOO234
Pl: Main pump pressure front IN port PPO: Servo main pressure IN port
P2: Main pump pressure rear IN port PECN: CO + NC valves output pressure OUT port
PDR: CO + NC valves drain OUT port
PEO
,PDR
A-A
SJYOO235
PB PI
PI
A. To steering cylinder
6. To steering cylinder
PI. From steering pump
P2. From switch pump
PB. To main control valve
T. To hydraulic tank
(through hydraulic oil cooler)
5’ i
A-A
SEW01395
1. Poppet
2. Relief valve poppet
3. Check valve poppet
4. Pilot poppet
5. Spring
i i i ‘5 SDW01396
FUNCTION
OPERATION
SDW01397
A
SDW0139S
A
SDW01399
A B
SDW01400
A e
SDWO1401
1. Adjustment screw
2. Spring
3. Plug
4. Pilot poppet
5. Valve seat
FUNCTION
To main
control valve
sxwo4904
From switch
sxwo4905
l The oil from the steering pump enters port A l When the pressure in pressure receiving cham-
and the oil from the switch pump enters port ber (I) reaches a certain value (set by spring
B. (3)), notch f opens and the oil from the steer-
* When steering spool (2) is at the neutral posi- ing pump goes to the drain circuit. Notch g is
tion, pressure receiving pressure chamber (II) closed, so the oil from the switch pump all
is connected to the drain circuit through ori- flows to the main control valve.
fice b, and notch c is closed.
. Notch c is closed, so the pressure of the oil at
port A and port B rises. This pressure passes
through orifice a, goes to pressure receiving
chamber (I) and moves demand spool (I) to
the left.
From switch
SXWO4906
. When the steering is operated, oil flows from l The merged oil passes through notches c and
the rotary valve to steering spool (2) and d, pushes load check valve (51, and flows to
pushes steering spool (2) to the right. The cir- the cylinder. The return oil from the cylinder
cuit between pressure receiving chamber (II) passes through notch e and flows to the drain
and the drain circuit is shut off, and at the same circuit.
time, notch c opens. . When this happens, the pressure before
As a result, the pressure in pressure receiving passing through notch c is sent to pressure
chamber (II) rises, and demand spool (I) receiving chamber (I) and the pressure after
moves to the right until notch h closes. passing through notch c is sent to pressure
The passage from port B to the main control receiving chamber (II). Demand spool (I) is
valve is shut off, so the oil from the switch actuated so that the difference in pressure
pump pushes up pump merge-divider check on both sides of notch c is kept constant.
valve (4) and merges with the oil from the Therefore, an oil flow corresponding to the
steering pump at port A. opening of notch c is supplied to the cylinder
port. These pressure differences (control pres-
sure) are set by spring (3).
To main
control valve
%
%
From steering
Porno
sxwo4907
There is no need for supply of extra oil from . The oil from the steering pump passes through
l
the switch pump, so the steering pump pres- notches c and d, pushes load check valve (51,
sure rises until notch g closes and shuts off and flows to the cylinder. The return oil from
the merge passage from port B. the cylinder passes through notch e and flows
l The pressure difference on both sides of notch to the drain circuit.
. Notch g is closed, so the oil from the switch
c is controlled only by notch f, and the excess
oil from the steering pump is drained from pump all flows from port B and is sent to the
notch f to the drain circuit. (At this point, notch main control valve.
g is completely closed.)
SXWO4908
Turning to right
From ro
From steerin
sxwo4909
. If the steering lever is moved to the right, the side of the right cylinder to turn the machine
rotary valve operates and the steering spool to the right. The oil from both cylinders is
(2) moves to the left. drained through load check valve (5) of the
The oil from the steering pump flows in port steering spool. The oil from the switch pump
A, then flows through flow control spool (I) flows in port 6, then flows through flow con-
to steering spool (2) and pushes load check trol spool (I) to push check valve (4) open
valve (6) of the spool open to supply oil to and merges with the steering pump oil.
the bottom side of the left cylinder and rod
Turning to left
From rotary
valve
control valve
sxw04910
. If the steering lever is moved to the left, the side of the right cylinder to turn the ma-
rotary valve operates and the steering spool chine to the left. The oil from both cylinders
(2) moves to the right. is drained through load check valve (6) of
The oil from the steering pump flows in port the steering spool. The oil from the switch
A, then flows through flow control spool (1) pump flows in port B, then flows through
to steering spool (2) and pushes load check flow control spool (I) to push check valve
valve (5) of the spool open to supply oil to (41 open and merges with the steering pump
the rod side of the left cylinder and bottom oil.
.b
swwa94
Outline
l The steering lever is connected to the top of
the rotary valve. The direction of the oil sent
from the PPC pump through the EPC valve
to this valve is changed with the steering
lever to move the spool of the steering de-
mand valve. As a result, the steering cylin-
der is operated to set the steering direction
of the machine.
l The link installed to the front frame is con-
nected to the bottom of the rotary valve to
feed back the steering angle of the machine.
Accordingly, the position of the steering le-
ver is matched to the steering angle of the
machine.
Structure
l Spool (4) is connected through pin (IO) Steerina lever
4
Link
Operation
. If the steering lever is operated, spool (4)
rotates along sleeve (5), against neutral po-
sition spring (I).
By this rotation, the port of spool (4) is
matched to that of sleeve (5) to form an oil
passage, then the oil flows in the steering
demand valve.
If the steering lever is operated more than
the allowable displacement of neutral posi-
tion spring (I), loose spring (8) absorbs the
displacement through drive shaft (9).
. If the oil flows in the steering cylinder and
steering operation starts, the link installed
to the front frame turns sleeve (5) through
feedback spool (6) and drive shaft (9) so that
the deviation of sleeve (5) from spool (4)
will be offset.
If the machine is steered to the position
matched to the operating distance of the
steering lever, deviation of spool (4) from
sleeve (5) is eliminated and the oil passage
is closed.
EPC VALVE
e
r---------7
I ,_+_______A-
D
I 11 P2
_I L ( T
c
T i
Ii Pl
T
i:--_.____i
SJWO4896
Outline
l The EPC valve controls the oil flow to the l Even if the electromagnetic proportional
rotary valve with the electromagnetic pro- valve does not work because of a controller
portional valve controlled with the command trouble, the minimum pressure assurance
current from the work equipment and joy- pressure reducing valve supplies the mini-
stick controller. mum oil pressure to the rotary valve.
DIVERTER VALVE
1. Main valve
2. Valve seat
3. Pilot poppet
4. Spring
5. Adjustment screw
m Kzr SDW01420
FUNCTION
Compared to the steering valve relief pressure
of 31.4 MPa 1320 kg/cm*}, the rated pressure of
the emergency steering pump and diverter valve
are both 20.6 MPa (210 kg/cm*). Therefore, to
protect the emergency steering pump and
diverter valve, there is a relief valve in the pip-
ing from the diverter valve to the steering valve.
When the emergency steering is being oper-
ated, and the hydraulic pressure generated by
the steering exceeds 20.6 MPa (210 kg/cm*}, the
relief valve is actuated.
OPERATION
. Port A is connected to the pump circuit, and
port C is connected to the drain circuit. The
oil passes through the orifice in main valve
(I) and fills port B. Pilot poppet (3) is in
contact with valve seat (2).
I
l When the pressure inside port A and B A I B
reaches the pressure set by the poppet spring
(set pressure), pilot poppet (3) opens and
the hydraulic pressure at port B escapes from
port D to port C. This lowers the pressure at
port B.
l When the pressure at port B drops, the ori-
fice of main valve (I) generates a difference
in pressure between port A and port B. Main
valve (I) is opened by the pressure at port A
and the oil at port A is relieved.
6 6
BRAKE VALVE
BRAKE VALVE (RIGHT)
swwo4aa5
II\_J U
SDWOO108
Outline
l There are two brake valves installed in par- In addition, the left brake pedal operates the
allel under the front of the operator’s cab, transmission cut-off switch to actuate the
and these are actuated by depressing the transmission solenoid valve electrically and
pedal. set the transmission to neutral.
l When the right pedal is depressed, oil is
sent to the brake cylinder to apply the brakes.
l 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 de-
pressed.
Operation
Brake applied (right brake valve)
Upper portion
l When brake pedal (1) is depressed, the op-
erating 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 cylinders.
Lower portion
l When brake pedal (1) is depressed, the op-
erating force is transmitted ‘to spool (3)
through rod (2) and spring (4). When spool
(3) goes down, spool (5) is also pushed down
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 D
and actuates the front brake cylinders.
To front brake
Lower portion
l 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 cylin-
der 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.
l The pressure in the space in the upper por-
tion is balanced with the operating force of From pump
the pedal, and the pressure in the space in
To front brake
the lower portion is balanced with the pres-
sure in the space in the upper portion. When
From pump
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.
Lower portion
l When the pedal is released, spool (3) in the
upper portion moves up. At tlie same time,
the back pressure from the brake cylinder
From pump From rear brake
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 hy-
From pump rom front brake
draulic tank return circuit to release the front
brake. SEW00113
CHARGE VALVE
PP
ACC
_-_-_~-_---_--‘--_-,
I
I
ACC
PP
i_ -__--__________~I
T
SXWO4764
A-A
Operation
1. When no oil is being supplied to accumula-
tor (cut-out condition)
I) Cut-in condition
l When the pressure at port B is lower than
the set pressure of the relief valve (RI), pis-
ton (8) is pushed back down by spring (5).
Valve seat (7) and poppet (6) are brought
rant accumulator
into tight contact, and port C and port T are i lot oresaura
shut off.
l The spring chamber at the right end of spool
(15) is also shut off from port T, so the pres-
sure rises, and the pressure at port P also
rises in the same way.
l When the pressure at port P goes above 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 pres-
sure difference (equivalent to the load on
spring (14)) generated on both sides of the
orifice. A fixed amount is supplied regard-
less of the engine speed.
1. Valve
2. Top cover
3. Cylinder
4. Piston
sxwo4770
Function Specifications
l The accumulator is installed between the Gas used: Nitrogen gas
charge valve and the brake valve. It is Charge amount: 20 e
charged with nitrogen gas between cylinder Charging pressure: 11.8 f 0.49 MPa
(3) and free piston (41, and uses the 020 * 5 kg/cm21
compressibility of the gas to absorb the pulse
of the hydraulic pump or to maintain the
braking force and to make it possible to op-
erate the machine if the engine should stop.
SLACK ADJUSTER
sxwo4771
1. Bleeder SPECIFICATIONS
2. Cylinder Piston operating oil pressure:
3. Check valve O.O1’~oo’MPa {O.l’~“’ kg/cm*)
4. Piston Check valve cracking pressure:
5. Spring 17.4 r 0.05 MPa (17.8 -c 0.5 kg/cm*})
Check valve closing pressure:
A. Inlet port 1.09 + 0.05 MPa (11.1 + 0.5 kg/cm9
B. Outlet port
FUNCTION
l The slack adjuster is installed in the brake
oil line from the brake valve to the brake
piston. It acts to keep the clearance between
the brake piston and discs constant even
when the brake discs are worn. In this way it
acts to keep a constant time lag when the
brake is operated.
OPERATION
1. When brake pedal is depressed
. Before the brake is depressed, piston (4) is
returned by the distance of stoke S (full Right brake
stroke). When the brake pedal is depressed,
the oil discharged from the brake valve flows c
lo-108 WA 1200-3
STRUCTURE AND FUNCTION BRAKE
BRAKE
I 2 3
VT) ;:7,
I ’ _~_____________ ---_s;
JJ.-J ----
II i \:- I / \-
9 1
SXW04772
PARKING BRAKE
9JEIOO109
--
/
swwo4773
HYDRAULIC TANK
A-A
SJWO4782
1. Strainer OUTLINE
2. Oil filler l Oil is sent from the hydraulic tank through
3. Oil filler strainer the work equipment valve to each cylinder.
4. Filter bypass valve Then, it merges with the oil from various
5. Filter parts in the return circuit, and a part of it is
6. Breather cooled by the oil cooler and filtrated by the
7. Drain valve oil filter, then returned to the hydraulic tank.
l The oil filter filtrates the all oil in the return
A. Steering return port circuit from the work equipment valve. If this
B. Loader return port filter is clogged, the bypass valve operates
C. Emergency steering return port to let the oil return to the tank directly for
D. Main suction port prevention of breakage of the filter. The by-
E. Emergency steering suction port pass valve also operates when negative pres-
F. PPC, control suction port sure is generated in the circuit.
l Strainer (I 1 is installed to the suction port of
the hydraulic tank.
To main control
@
From hydraulic tank SDW02313
BREATHER
1. Body
2. Filter element
3. Poppet
4. Sleeve
SEW00141
FUNCTION
PA1 PA2
PS ? ?
CZ
9JYOO236
f
A
X Y
9JYOO237
PSVI: Servo valve main pressure port PSV2: Servo valve main pressure port
PSVIA: Servo valve output port PSVPA: Servo valve output port
PSVIB: Servo valve output port PSVPB: Servo valve output port
c-l A-A
I8
c-c
9JYOO238
Servo valve
1. Servo valve (For front No. 1)
PDR
A-A
9JYOO239
PPO
PAC 1
PES PEbN
D-D
9JYOO241
Structure
9JYOO242
(cc/rev1
Function
Discharge amounts Ql and 02 of main pumps a
Pl and P2 are controlled individually by the re- z=
spective servo valves. The relationship between E
pump discharge amount 0 and input signal
PECN to the servo valve is as shown in the
graph on the right. 0 varies in proportion to
PECN.
(MPa(kdcm’l)
CWNC valve output pressure PECN SWP06953
SWPO6954
Operation
The control, pump pressure PPO is taken to l At the same time, port a is interconnected
port a. \ with port h, so the pressure oil flows through
Signal pressure PECN from the NC valve is port i to servo piston chamber j, pushes
taken from port b to chamber c. servo piston (19) to the right, increases the
When signal pressure PECN rises, piston (8) swash plate angle in the main piston pump
is pushed to the right by the pressure in and increases the pump discharge amount.
chamber c, and stops at a point where it l When servo piston (19) moves, arm (6) ro-
balances the pressure of springs (4) and (4A). tates counterclockwise with its center at pin
At the same time, arm (6) uses servo piston (7) and moves guide spool (13) to the left.
(19) as a fulcrum and sways to the right in Port a, port d and port h close, so the dis-
the same way as piston (8). This moves guide charge increases by an amount that matches
spool (13) to the right. signal pressure PECN.
When guide spool (13) moves, port a and
port d are closed and port d is connected to
drain chamber e. As a result, servo piston
chamber f is also interconnected with drain
chamber e through port g and port d.
1 NCvalve 1
TVC valve
SWPO6955
Operation
l When signal pressure PECN goes down, pis- . At the same time, port a is interconnected
ton (8) moves to the left and stops at a point with port d, so the oil flows through port g
where the pressure in chamber c balances to servo piston chamber f, pushes servo pis-
the pressure of springs (4) and (4A). ton (19) to the left, decreases the swash plate
l At the same time, arm (6) uses servo piston angle in the main piston pump and decreases
(19) as a fulcrum and sways to the left in the the pump discharge amount.
same way as piston (81. This moves guide l When servo piston (19) moves, arm (6) ro-
spool (13) to the left. tates clockwise with its center at pin (7).
l When guide spool (13) moves, port a and Guide spool (13) is moved to the right and
port h are closed and port h is connected to closes port a, port d and port h, so the dis-
drain chamber e. As a result, servo piston charge decreases by an amount that matches
chamber j is also interconnected with drain signal pressure PECN.
chamber e through port i and port h.
PECti
PDR
P2
9JYOO243
9JYOO244
CO valve NC valve
1. Cover 8. Cover
2. Sleeve 9. Sleeve
3. Piston 10. Piston
4. Spool 11. Spool
5. Spring 12. Spring
6. Seat 13. Cover
7. Plug
1. CO valve
Function
l When the load becomes large during opera- The CO valve is controlled by balancing the
tions and the main pump discharge pres- spring with the total of main pump discharge
sure rises to a point close to relief pressure, pressure P and CO valve output pressure
the cut-off function of the CO valve acts to PEC.
reduce the pump discharge in order to re-
duce relief loss.
w Servo
Sma I I
Piston
r) Large
Operation
. Spool (4) is being pushed down fully by
spring (3). As a result, port a and port b are
fully open and TVC valve output pressure
PE and CO valve output pressure PEC are
equal. In this way, CO valve output pressure
PEC becomes the maximum and the main
pump discharge amount also becomes the
maximum.
Servo valve
Servo Piston
Smal I+ Large
@
sxwo4747
Operation
. If the load increases and main pump dis- l As a result, the flow of oil from port a to
charge pressure P comes close to the relief port b is throttled by the notch in the spool,
pressure, main pump discharge pressure P and the area of the opening at port b and
pushes piston (5). At the same time, CO valve port c (drain port) becomes larger. In this
output pressure PEC pushes piston (51, and way, CO valve output pressure PEC goes
spool (4) moves up. down, and the pump discharge amount be-
comes the minimum.
J L PA2 PA1
I
PS’V
PS
\
PSG
9JYOO247
9JYOO248
PSVI: Servo valve main pressure port PSV2: Servo valve main pressure port
PSVIA: Servo valve output port PSV2A: Servo valve output port
PSVIB: Servo valve output port PSVSB: Servo valve output port
A-A
9JYO0’249
Servo valve
1. Servo valve assembly (For front No. 21
PEiN
PDR
P2
PPO
PACl
PAC2
Z
9JYOO250
@
isiik!
0
0
H
QO
CZ
A-A
k-E
9JYOO251
POkl PCiRP
PES
PECN’
PDR P2
Pl
PACl
PPO PAC2
9JYOO252
H4 I--D
M-0
+
Y
D-D E-E
9JYOO253
PI: Main pump pressure OUT port PPO: Servo main pressure OUT port
P2: Main pump pressure OUT port PECN: CO + NC valve output pressure IN port
PDR: ES valve drain IN port
9JYOO254
Function
Discharge amounts Ql and Q2 of main pumps
PI and P2 are controlled individually by the re-
spective servo valves. The relationship between
pump discharge amount 0 and input signal
PECN to the servo valve is as shown in the
graph on the right. Q varies in proportion to
PECN.
(MPa{ktdcm'l)
CO+NC valve output oressure PECN SUP06953
SXWO4748
Operation
Signal pressure PI acts on chamber E of the l Consequently, arm (4) turns counterclockwise
control piston through port D. Control pump around pin (13) to move guide spool (12) to
pressure PC is led in port B. the left. Since ports B, A, and C are closed,
If PI rises, the oil pressure applied to cham- the discharge is increased by the quantity
ber E rises and control piston (9) moves to corresponding to signal pressure PI.
the right until the oil pressure force in cham-
ber E is balanced with the force of spring
(IO).
At the same time, arm (4) rocks to the right,
using servo piston (11) as a fulcrum, and
moves guide spool (12) to the right.
As guide spool (12) moves, port B is con-
nected to port A, then control pump pres-
sure PC is applied to chamber F of servo
piston (I 1) to push servo piston (II) to the
right. As a result, the swash plate angle of
the main piston is increased to increase the
discharge.
From rear
servo @
valve
PI-
Operation
. If PI lowers, piston (9) moves to the left until . At this time, port B is connected to port C
the oil pressure force in chamber E is bal- and the pressurized oil flows in servo piston
anced with the force of spring (IO). chamber H and pushes servo piston (11) to
l At the same time, arm (4) rocks to the left, the left, together with the force of spring
similarly to piston (9) and using servo pis- (14). As a result, the swash plate angle of
ton (I I) as a fulcrum, and moves guide spool the main pump is reduced to decrease the
(12) to the left. pump discharge.
l As guide spool (12) moves, port B is discon- l As servo piston (11) moves, arm (4) turns
nected from port A, the port A is connected clockwise around pin (13) to move guide
to drain chamber T. Accordingly, servo pis- spool (12) to the right. Since ports B, C, and
ton chamber F is connected through port A A are closed, the discharge is decreased by
to drain chamber T. the quantity corresponding to signal pres-
sure PI.
0/
0
l--A
9JYOO257
A-A
9JYOO258
CO valve NC valve
1. Cover 8. Cover
2. Sleeve 9. Sleeve
3. Piston IO. Piston
4. Spool 11. Spool
5. Spring 12. Spring
6. Seat 13. Cover
7. Plug
1. CO valve
Function
l When the load becomes large during opera- * The CO valve is controlled by balancing the
tions and the main pump discharge pres- spring with the total of main pump discharge
sure rises to a point close to relief pressure, pressure P and CO valve output pressure
the cut-off function of the CO valve acts to PEC.
reduce the pump discharge in order to re-
duce relief loss.
Servo piston
Operation
l Spool (4) is being pushed down fully by
spring (3). As a result, port a and port b are
fully open and TVC valve output pressure
PE and CO valve output pressure PEC are
equal. In this way, CO valve output pressure
PEC becomes the maximum and the main
pump discharge amount also becomes the
maximum.
Servo Piston
-
,I ’ f ’ , ,,‘,,,‘/ I I I I , YI I, , , , , , , , , , , ,‘
1 ‘“I fl IPPoy
sxwo4751
Operation
. If the load increases and main pump dis- l As a result, the flow of oil from port a to
charge pressure P comes close to the relief port b is throttled by the notch in the spool,
pressure, main pump discharge pressure P and the area of the opening at port b and
pushes piston (5). At the same time, CO valve port c (drain port) becomes larger. In this
output pressure PEC pushes piston (51, and way, CO valve output pressure PEC goes
spool (4) moves up. down, and the pump discharge amount be-
comes the minimum.
PES
PPO
POR
9JYOO261
PDR: ES valve drain OUT port PES: ES valve output pressure OUT port
PE: NC valve output pressure front-rear PPO: Servo main pressure IN port
connecting port
1,1
0
7
G
f G
9JYOO262
1. Cover 7. Cover
2. Plug 8. Sleeve
3. Rod 9. Piston
4. Plug 10. Spool
5. Nut 11. Cover
6. Screw
lo-146 WA 1200-3
STRUCTURE AND FUNCTION WORK EQUIPMENT PUMP No. 2
FUNCTION
l A variable displacement piston pump is used
for the hydraulic pump to save energy by
reducing the consumption of hydraulic pres-
sure when the engine is running at low
speed. At the same time, it is also used to
increase the engine acceleration from low
speed. ;
a o.l4*oD1 O-37*0.02
Pilot pressure
For this reason, a pressure difference valve {IA4*0.11 (3.8*0.21difference
is used to detect the engine speed by using
a pressure difference system. The delivery
(delivery per rotation) is then adjusted to Approx.800 A~~t0~.1100
SDW01721
C A
P2 P4
P : From pump
T : To tank (drain)
PI : To boom cylinder (Raise)
P2 : To bucket cylinder (Dump)
P3 P3 : To boom cylinder (Lower)
P4 : To bucket cylinder (Tilt)
SEW01483
A-A
D-D
1. Bolt
2. Piston c-c SWWO3476
3. Plate
4. Collar
5. Retainer
6. Center spring
7. Metering spring
8. Valve
9. Body
OPERATION
WA1 200-3
PPC RELIEF VALVE
STRUCTURE AND FUNCTION
1. Main valve
2. Valve seat
3. Pilot poppet
4. Spring
5. Adjustment screw
Set pressure:
For PPC: 3.73 MPa 138.0 kg/cm*}
For pump control circuit:
9JYOO264 2.94 MPa (30.0 kg/cm*)
Function
1. PPC relief valve 2. Pump control circuit relief valve
l The PPC relief valve is installed between the l The pump control circuit relief valve is in-
PPC pump and PPC valve. While the PPC stalled between the main pump control
valve is not operating or when abnormally pump and main pump. The oil sent from the
high pressure is generated, this valve re- control pump is relieved through this valve
lieves oil sent from the pump to prevent to keep the pressure in the main pump con-
breakage of the pump and circuit. (It sets trol circuit constant.
the maximum pressure in the circuit.)
Operation
. Ports A and C are connected to the pump
circuit and drain circuit respectively. The oil
is filled in port B through the orifice of main
valve (I). Pilot poppet (3) is in contact with
valve seat (2).
9JYOO265
9JYOO266
I
. If the pressure in port B lowers, discharge
pressure is generated between ports A and
B because of the orifice of main valve (I),
then main valve (I) is opened by the pres-
sure of port A and the oil flows out of port
A.
9JYOO267
1. Cap 4. Bladder
2. Nut 5. Oil port
3. Body 6. Nut
Specifications
Type of gas: Nitrogen gas
Gas amount: 3,000 cc
Max. actuation pressure: 2.9 MPa (30 kg/cm*)
Min. actuation pressure: 1.6 MPa (16 kg/cm*)
FUNCTION
l The accumulator is installed between the
hydraulic pump and PPC valve. An inflatable
‘4 bladder is filled with nitrogen gas, and the
compressibility is used to store the pressure
of the oil. As a result, the boom and bucket
can be lowered under their own weight even
after the engine has been stopped.
SEW0
t +
From PPC pump To PPC valve
SEW0 1494 SE
Pl
PA2 .PB2
PA1
‘PBl
Al P 61
9JYOO268
A-A
D-D E-E
B-B
9JYOO269
FUNCTION
l The three main control valves control the l There are two safety valves (with suction
actuation of the attachments and the bucket valves) (IO) to protect the circuit if abnormal
in the hydraulic system. It has a tandem cir- pressure is generated in the bucket circuit. If
cuit which gives priority to the bucket cir- one of the two safety valves is acting as a
cuit. relief valve, the other valve acts as a suction
l The oil from the pump enters port P. The valve to make up any lack of oil.
maximum pressure is set by main relief valve
(I). The oil passes through the bypass cir-
cuit of bucket spool (5) and boom spool (4).
It then flows from port T to the drain circuit,
passes through the filter and returns to the
tank. If the bucket and boom spools are ac-
tuated, the oil flows to the bucket and boom
cylinders.
However, the circuit gives priority to the
bucket, so when the bucket spool is being
operated, even if the boom spool is operated,
the boom will not move.
RELIEF VALVE
I 2 3 45 6
1. Main valve
2. Valve seat
3. Pilot poppet
4. Pilot poppet spring
5. Adjustment screw
6. Lock nut
FUNCTION
l The relief valve is installed at the inlet of the
main control valve. When the oil goes above
the set pressure, the relief valve drains the
oil to the tank. In this way, it sets the maxi-
mum pressure in the hydraulic circuit and
protects the circuit.
OPERATION
Port A is connected to the pump circuit, and
port C is connected to the drain circuit. The
oil passes through the orifice of main valve
(I) and flows to port B. Pilot poppet (3) is in
close contact with valve seat (2).
When the hydraulic pressure in the circuit
inside port A and port B reaches the set
pressure of pilot poppet spring (41, pilot pop-
pet (3) opens, and the pressurized oil from
port B flows from port D to port C, so the
pressure at port B drops.
When the pressure at port B drops, the ori-
fice effect of main valve (I) generates a dif-
ference in pressure between port A and port
B. The main valve is pushed open and the
oil from port A passes through port C and SDW01500
flows to the drain circuit to release the ab-
normal pressure.
SDWOlSOl
SAFETY-SUCTION VALVE
1. Suction valve
2. Main valve
3. Piston
4. Piston spring
5. Poppet
6. Poppet spring
7. Suction valve spring
8. Sleeve
9. Adjustment screw
10. Locknut
9JYOO270
Set pressure: 36.8 MPa 1375 kg/cm21
FUNCTION
. If any impact is applied to the cylinder and
abnormally high pressure is generated, that
pressure is relieved through the safety-suc-
tion valve to protect the cylinder and other
hydraulic devices.
. If any negative pressure is generated in the
cylinder circuit, the safety-suction valve func-
tions as a suction valve.
\
D
SJYOOP 71
I f\ \\\
I C 5 60
9JYOO272
9JYOO2
12 ‘6
9JYOO274
FUNCTION
l The float selector valve and unload valve
are inside the work equipment valve. If the
boom lever is set to the FLOAT position, the
float selector valve operates. As a result, the
unload valve operates to set the boom to
the floating position.
OPERATION
1. LOWER position
. In the figure at right, the boom lever is set
to the LOWER position.
8
From steering
valve
2. FLOAT position
. If the boom lever is pushed further from the
LOWER position, it is set to the FLOAT posi-
tion.
Boom spool (I) of the work equipment valve
is kept under the same condition as at the
LOWER position.
Since oil pressure in port A becomes higher
than that at the LOWER position, float selec-
tor valve (2) moves to the right and the back
pressure on unload valve (3) is released.
Accordingly, unload valve (3) opens and the
boom is floated.
From steering
va I ve
WA1 200-3
STRUCTURE AND FUNCTION MAIN CONTROL VALVE
Pump
8
From steering
valve
8
From steering
va I ve
I n I4 k
OPERATION
l Oil flows through the steering valve and work l The oil from the PPC pump flows through
equipment pumps 1 and 2 to port A, then its check valve (13) to port L of the PPC valve.
maximum pressure is regulated by relief Since the boom and bucket levers are in the
valve (11). neutral position, however, the oil returns
l Since bucket spool (I) is in the neutral posi- through PPC relief valve (12) to the hydrau-
tion, the bypass circuit is open and the oil in lit tank.
port A flows through the periphery of the
spool to port B. Since boom spool (2) is also
in the neutral position, the bypass circuit is
open and the oil in port B flows through the
periphery of the spool to port C of the drain
circuit, then it returns through the filter in
the hydraulic tank.
Hydraul
tank
OPERATION
l When boom lever (3) is pulled, the oil flows and flows to the bypass circuit of boom
from port L of the PPC valve to port N and spool (2). The bypass circuit is closed by the
port S. In addition, the oil at port T passes spool, so the oil pushes open check valve
through port M and flows to the drain cir- (IO). The oil flows from port H to port I, and
cuit. The oil pressure at port S pushes boom flows to the cylinder bottom.
spool (2) and moves it to the RAISE posi- . At the same time, the oil at the cylinder rod
tion. end enters drain port C from port K and
l The oil from the steering valve passes returns to the tank. Therefore, the boom
through the bypass circuit of the bucket spool rises.
tank
- r,
L1,,,,,,,,,,,,.,,,,........ SXW,-,A7Fiq
OPERATION
l When boom lever (3) is pushed, the oil flows (2). The bypass circuit is closed by the spool,
from port L of the PPC valve to port M and so the oil pushes open check valve (IO). The
port T. In addition, the oil at port S flows to oil flows from port J to port K, and flows to
the drain circuit. the cylinder rod end.
The oil pressure at port T pushes boom spool l At the same time, the oil at the cylinder
(2) and moves it to the LOWER position. bottom enters drain port C from port I and
l The oil from the steering valve passes returns to the tank. Therefore, the boom goes
through the bypass circuit of the bucket spool down.
and flows to the bypass circuit of boom spool
HYdrauI ic ii!&_ 1
tank
SXWO4760
OPERATION
l When boom lever (3) is pushed to the FLOAT opens port Cl and port C, and connects to
position, the PPC valve spool moves beyond the drain circuit. When port Cl is connected
the LOWER position to the FLOAT position. to the drain circuit, unload valve (8) moves
The pressure oil at port L flows to port M, up and the oil from the pump flows to the
and at the same time, it also flows to port T drain circuit.
and port W. In addition, the pressurized oil l Therefore, the oil at the cylinder rod end
at port S flows to port N. passes from port K through unload valve (8)
l The pressurized oil at port T pushes boom and flows to the drain circuit. The oil at the
spool (2) to the LOWER position. cylinder bottom flows from port I to port C,
. If a difference in pressure greater than the and then flows to the drain circuit. There-
specified pressure is generated at port W fore, the boom is set to the FLOAT condi-
and port X, valve (7) moves to the right, tion.
OPERATION
l When bucket lever (4) is pushed, the pres- valve (IO). The oil from checkvalve (IO) flows
sure oil at port L of the PPC valve flows from port F to port G, and then flows to the
from port Q to port V. In addition, the oil at cylinder rod end.
port R flows to the drain circuit. The pres- At the same time, the oil at the cylinder
sure oil at port V moves bucket spool (1) to bottom flows from port D to drain port C,
the DUMP position. and returns to the tank, so the bucket is
l The bypass circuit is closed by bucket spool dumped.
(I), so the oil from port A pushes open check
w PPC valve lx
SXW04762
OPERATION
l When bucket lever (4) is pulled, the pressure (I 1, so the oil from port A pushes open check
oil at port L of the PPC valve flows from port valve (IO). The oil from check valve (IO) flows
P to port R. In addition, the oil at port V from port E to port D, and then flows to the
flows to the drain circuit. The pressure oil at cylinder bottom.
port R moves bucket spool (I) to the TILT l At the same time, the oil at the cylinder rod
position. end flows from port G to drain port C, and
l The bypass circuit is closed by bucket spool returns to the tank, so the bucket is tilted.
;; I,
Ii Ii
;--..--____.__._.____,--
i~~_~___-,____.,_-il
1. Bucket 5. Boom
2. Bucket link 6. Boom cylinder
3. Bellcrank 7. Tooth with tip
4. Bucket cylinder 8. Sweeper wing
B-B
G-G H-H
SJWO4764
SVW03369
Cam
Bucket lever
\ Solenoid
SEW02327
II Positioner relay
SVW03369
Bucket lever
Cam
Bucket lever
SEW02329
Proximity switch
Lights up Goes out
actuation display
AIR CONDITIONER
AIR CONDITIONER PIPING
SWWO4785
1. Air vent
2. Air vent
3. Condenser (right)
4. Dry reservoir
5. Compressor
6. Condenser (left)
7. Air conditioner Unit
Specifications
Type: Piston pump type
Refrigerant used: R134a
4707
DRY RESERVOIR
1. Body
2. Drier
3. Filter
OUTLINE
• The machine monitor system monitors the • The main monitor has a function to send
machine condition by means of the sensors and receive signals through the network cir-
installed to various parts of the machine and cuit to display the following items.
displays the result immediately on the moni- 1 Shift indicator: 1st – 3rd gear speeds, N,
tor panel to notify the operator of the machine F, R
condition. 2 Remedy code, failure code, time after fail-
• The machine monitor system consists of a ure (failure history mode)
main monitor, CGC monitor, various sen- • The CGC monitor consists of a display and
sors, switches, relays, an alarm buzzer, and touch switches. The monitor screen to dis-
a power supply unit. play the gauges, maintenance screen, fuel
• The displayed items are roughly classified consumption screen, positioner screen, load
into two groups; The items in one group are meter screen, etc. can be selected on the
various caution items displayed on the moni- display. If any trouble occurs, the CGC moni-
tor when any trouble occurs in the machine, tor receives signals from the VHMS control-
and those in the other group are the ma- ler and displays the warning screen.
chine conditions which are displayed con- • The VHMS controller monitors the data of
stantly by the gauges, speedometer, service the machine condition and maintenance con-
meter, pilot lamps, etc. dition, and saves them in itself.
• There are various switches inside the moni-
tor panel which are used to control the ma-
chine.
WA1200-3 10-175
10-175
(7)
STRUCTURE AND FUNCTION MACHINE MONITOR SYSTEM
System configuration
I INPUT
I
1
Alternator R terminal voltage
D
Small lamp ON voltage
A
Boom cylinder bottom pressure
D
Boom proximity sensor
D
Sub total switch
D
Cancel switch
A
PPC relief pressure
A
Torque converter outlet oil pressure
A
Transmission modulation oil pressure
A
Steering relief pressure
A
Work equipment relief pressure
OUTPUT
P: Pulse signal
A: Analog signal
D: ON-OFF signal
MAIN MONITOR
5C
5D
SE
4F 4E
SWWO4789
Division
Symbol Indicated item Display range Display method
of display
Operation of
emergency steeringI When system operates Flashing of displayed items
system
0
CAUTION Caution
When maintenance
Flashing of displayed items
(Buzzer may sound)
monitor trouble is (For details, see display functions
displayed of maintenance monitor)
c
$w p
Parking brake
When parking brake is
applied
If parking brake is applied while
shift lever is not in N, buzzer
sounds.
If controller detects
failure and operator Digital display
Remedy must, take remedy, Sounding of buzzer
code Remedy code CALL is displayed, (For failure history mode, see
or CALL and E 0 0 failure history mode)
(Remedy code) are
displayed alternately.
Forward/Reverse
Shift (When joystick
LF/R dilrllr F, R Digital display
indicator steering system is
SDW02342
installed)
While small lamp lights up, ON Rear working lamp lights up.
Working lamp front working lamps are turned
(Rear) on and off each time switch is
pressed. OFF Rear working lamp goes off
Method of switching to With engine stopped and starting All switch displays (LEDs) go out, and
trouble data display switch turned ON, press 2nd switch failure code is displayed on speedometer
mode from top on left side of main display and time elapsed since failure is
monitor (switch below emergency displayed on failure action code display.
steering display) and working lamp (I) Failure code is a two-digit display
(front) switch simultaneously given in numbers or letters.
for at least 5 seconds. The display for the failure now
occurring flashes and the display for
past failures lights up.
If there is no failure, CC is displayed
(000 is displayed for time elapsed
since failure)
(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 items are stored
in memory for the failure code.
Method of sending Press working lamp (front) switch Failure code and time elapsed since
failure code failure change to next item.
SDW01254
swwo479 1
Clearing failure code Press working lamp (rear) switch Failure code and time elapsed 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 Changes to normal display
data display mode side of main monitor (switch below
emergency steering display) and
working lamp (front) switch
simultaneously for at least
5 seconds, or start the engine.
CGC MONITOR
Outline
• On the CGC monitor, the monitor screen to • In addition to the screen for operator which
display gauges, maintenance screen, setting is normally displayed, the screen for serv-
screen, fuel consumption screen, etc. can be iceman is available to check and set the ma-
selected with the buttons on the screens chine data and clear the saved data. (A spe-
(touch switches). cial ID is required to open the screen for
• If any trouble occurs in the machine, the serviceman).
warning screen appears automatically.
WA1200-3 10-181
10-181
(7)
STRUCTURE AND FUNCTION CGC MONITOR
Monitor screen
After the initial screen disappears, the monitor screen appears automatically. This screen is composed
of the following gauges and buttons (touch switches).
• Engine water temperature gauge: The display range is 60 – 108°C. The red range is above
102°C. If the pointer enters the red range, its color changes
from green to red.
• Torque converter temperature gauge: The display range is 27 – 140°C. The red range is above
120°C. If the pointer enters the red range, its color changes
from green to red.
• Fuel gauge: The display range is 555 – 3700 ¬. The yellow range is
below 1250 ¬. If the pointer enters the yellow range, its
color changes from green to yellow.
• Clock: This clock indicates the present time. For setting method of
this clock, see the setting screen.
• Tachometer: This meter indicates the engine speed digitally.
• Brightness adjustment button: This button is used to select the brightness and contrast
adjustment screen.
Brightness button: Used to adjust bright-
ness.
Contrast button: Used to adjust con-
trast.
EXIT button: Used to turn off the
screen and display
the monitor screen.
10-182
10-182 WA1200-3
(7)
STRUCTURE AND FUNCTION CGC MONITOR
• Maintenance screen button: This button is used to select the maintenance screen. See the
maintenance screen. The color of this button changes to dis-
play the maintenance condition.
• Setting screen button: This button is used to select the setting screen.
• Fuel consumption screen button: This button is used to select the fuel consumption screen.
• Positioner screen button: This button is used to select the positioner screen.
• Load meter screen button: This button is used to select the load meter screen.
• Failure list screen button: This button is used to select the failure list screen
WA1200-3 10-183
10-183
(7)
STRUCTURE AND FUNCTION CGC MONITOR
Maintenance screen
If the maintenance screen button is pressed on the monitor screen, the maintenance screen appears.
10-184
10-184 WA1200-3
(7)
STRUCTURE AND FUNCTION CGC MONITOR
Setting screen
1. DATE button
2. TIME button
3. UNIT button
4. USER ID button
5. SET button
6. Monitor screen button
7. Language selection button
When the setting screen button is pressed on the monitor screen, the screen changes to the setting
screen.
This screen is used to set the unit for displaying the data and to set the user ID. To confirm or set the
present time and date, use the PC tool (see TESTING AND ADJUSTING).
10-186
10-186 WA1200-3
(7)
STRUCTURE AND FUNCTION CGC MONITOR
WA1200-3 10-187
10-187
(7)
STRUCTURE AND FUNCTION CGC MONITOR
• SET button: If this button is pressed, the input date, time, unit, and user ID are saved.
If this button is not pressed, the input data are not saved, and the present
data not updated.
• Monitor screen button: This button is used to select the monitor screen.
10-188
10-188 WA1200-3
(7)
STRUCTURE AND FUNCTION CGC MONITOR
If the fuel consumption screen button on the monitor screen is pressed, the fuel consumption
screen appears.
The fuel consumption is calculated from the data recorded on the load meter screen, then the data
measurement period, productivity in Ton/Hour, and fuel consumption ratio in Liter/Hour are dis-
played.
The displayed data are based on the kind or material (KIND) selected on the load meter screen. The
unit set on the setting screen is used for the displayed data.
• Productivity history screen button: This button is used to select the productivity history screen.
• Monitor screen button: This button is used to select the monitor screen.
WA1200-3 10-189
10-189
(7)
STRUCTURE AND FUNCTION CGC MONITOR
If the productivity history screen button on the productivity screen is pressed, the productivity history
screen appears.
The fuel consumption ratio in Liter/Hour and productivity data in Ton/Hour for each kind of load (KIND)
are calculated from the data recorded on the load meter screen, then displayed.
The unit set on the setting screen is used for the displayed data.
• Memory clear button: This button is used to clear the data of the selected kind of load (KIND).
If this button is pressed, the pop-up
screen to ask if your are really clearing
the data of the selected kind of load
(KIND) appears.
• Fuel consumption screen button: This button is used to select the fuel consumption screen.
10-190
10-190 WA1200-3
(7)
STRUCTURE AND FUNCTION CGC MONITOR
Positioner screen
If the positioner screen button on the monitor screen is pressed, the positioner screen appears.
This screen is used to set ON/OFF and stopping positions of the remote positioner function. (The set
condition is saved even if the starting switch is turned off.)
• UPPER STOP selector button: Each time this button is pressed, it lights up (green) and
goes off alternately. While this switch is lighting up, the
upper stopping function is effective.
• UPPER STOP POSITION setting button: After setting the upper stopping position according to the
given procedure, press this button to save the set data.
• LOWER STOP selector button: Each time this button is pressed, it lights up (green) and
goes off alternately. While this switch is lighting up, the
lower stopping function is effective.
• LOWER STOP POSITION setting button:After setting the lower stopping position according to the
given procedure, press this button to save the set data.
• Monitor screen button: This button is used to select the monitor screen.
WA1200-3 10-191
10-191
(7)
STRUCTURE AND FUNCTION CGC MONITOR
If the load meter screen button on the monitor screen is pressed, the load meter screen appears.
The load is measured each time, and the bucket load and integrated load are displayed.
The integrated load is added up and displayed for each of the seven kinds of load (KIND).
• Kind of load selector button: This button is used to select the kind of load (KIND).
If this button is pressed, the pop-up screen to select the kind of load
(KIND) appears. Select one of seven kinds A – G.
• Subtraction mode button: This button is used to select the load meter screen (subtraction mode).
10-192
10-192 WA1200-3
(7)
STRUCTURE AND FUNCTION CGC MONITOR
• Calibration screen button: This button is used to select the calibration screen.
• Total load screen button: This button is used to select the total load screen.
• Monitor screen button: This button is used to select the monitor screen.
• Gauge display button: This button is used to display the gauges on the right side of the screen.
If this button is pressed, the engine water temperature gauge, torque
converter oil temperature gauge, and fuel gauge are displayed. If it is
pressed again, the displayed gauges disappear.
WA1200-3 10-193
10-193
(7)
STRUCTURE AND FUNCTION CGC MONITOR
If the subtraction mode button on the load meter screen (Integration mode) is pressed, this screen
appears.
The load measured each time is subtracted from the subtraction standard value which is set in
advance, and the bucket load and the remaining load are displayed.
• Kind of load selector button: This button is used to select the kind of load (KIND).
If this button is pressed, the pop-up screen to select the kind of load
(KIND) appears. Select one of seven kinds A – G.
10-194
10-194 WA1200-3
(7)
STRUCTURE AND FUNCTION CGC MONITOR
• Subtraction standard value setting button: This button is used to set the subtraction standard
value.
If this button is pressed, the screen to input the sub-
traction standard value appears.
• Integration mode button: This button is used to select the load meter screen (Integration mode).
• Calibration screen button: This button is used to select the calibration screen.
• Total load screen button: This button is used to select the total load screen.
• Monitor screen button: This button is used to select the monitor screen.
• Gauge display button: This button is used to display the gauges on the right side of the screen.
If this button is pressed, the engine water temperature gauge, torque
converter oil temperature gauge, and fuel gauge are displayed. If it is
pressed again, the displayed gauges disappear.
WA1200-3 10-195
10-195
(7)
STRUCTURE AND FUNCTION CGC MONITOR
Calibration screen
2
CALIBRATION I/cw
1. Display of calibration method
2. Engine water temperature gauge
3. Torque converter oil temperature gauge
4. Fuel gauge
5. Load meter screen button
buctet at carrl mition.
2. Raise t
If the calibration screen button on the load meter screen in the integration mode or subtraction mode
is pressed, the calibration screen appears.
Operate the machine according to the displayed procedure for calibration, and the load meter is
calibrated automatically.
. Load meter screen button: This button is used to select the load meter screen again.
(For the engine water temperature gauge, torque converter oil temperature gauge, and fuel gauge, see
the monitor screen.)
If the total load screen button on the load meter screen in the integration mode or subtraction mode
is pressed, the total load screen appears.
On this screen, the total number of loading times, load, and date when the data are cleared are
displayed for each kind of load (KIND).
The unit set on the setting screen is used for the displayed data.
• Data clear button: This button is used to clear the data of each kind of load (KIND) or the data of
the total load.
If the display area of a kind of load (KIND) is
pressed, the pop-up screen to clear the data
appears.
• Load meter screen button: This button is used to select the load meter screen in the integration
mode or subtraction mode.
WA1200-3 10-197
10-197
(7)
STRUCTURE AND FUNCTION CGC MONITOR
If the failure list screen button is pressed on the service menu selection screen, the screen changes to
this screen.
The currently existing failures are displayed in turn starting from the newest. (Only the error codes
displayed on the CGC monitor are displayed on the failure list screen.)
If the problem is removed, the problem is automatically deleted.
• Display item UP/DOWN button: The display goes up or down one item
• Display page selector button: The display goes up or down one page
• Service menu selection screen button: The screen changes to the service menu selection screen
10-197-1 WA1200-3
(7)
STRUCTURE AND FUNCTION CGC MONITOR
Warning screen
If any trouble occurs, the CGC monitor automatically displays the warning screen. The CGC monitor
then displays the currently used screens (displays in item order) and the warning screen alternately.
• Display of warning item: Each warning item is displayed in yellow or red, depending on its type.
• Display of warning page: The position of the currently detected trouble is displayed.
(Example: 1/5 means the first of five troubles.)
• Cancel switch: If the cancel switch is displayed on a warning screen, this screen can be
put out temporarily by pressing the cancel switch. (A warning screen
which does not have the cancel switch on it cannot be put out.)
If the trouble displayed on the warning screen is not repaired, it is
detected again and displayed on the warning screen when the starting
switch is turned on next time. It is possible to cancel any warning
display that has been canceled with the cancel switch when the user ID
has been changed.
• Hold switch: If the hold switch is pressed, the currently displayed warning item is
held for 2 minutes. The hold switch changes into the cancel switch.
• Jump switch: If the cancel switch is pressed, the screen displays the next warning
item. The cancel switch changes into the hold switch and the monitor
screen is held for 2 minutes. If the trouble is not repaired, the screen
returns to the warning display screen after 2 minutes.
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STRUCTURE AND FUNCTION CGC MONITOR
Warning output
Error
Warning Main monitor output Cancel
No. Item Display range display Color on Buzzer switch code Remarks
screen CHECK CAUTION No.
on CGC
lamp lamp
1 Engine oil level Below LOW level Abnormal Red Flashing ––– ––– Displayed C253
2 Engine oil pressure Below specified pressure Abnormal Red ––– Flashing ON Not displayed C143
3 Engine water temperature Above 102°C Abnormal Red ––– Flashing ON Displayed C151
Below specified level Insufficient Yellow Flashing ––– ––– Displayed B@BFZK Before engine starts
4 Fuel level
Below specified level Insufficient Yellow ––– Flashing ––– Displayed b@BFZK While engine is running
Below 14.7 MPa Being raised Yellow ––– Flashing ––– Displayed 2G41BM
7 Brake oil pressure (F)
{150 kg/cm2} Abnormal Red ––– Flashing ON Not displayed 2G42ZG
Below 14.7 MPa Being raised Yellow ––– Flashing ––– Displayed 2G41BM
8 Brake oil pressure (R)
{150 kg/cm2} Abnormal Red ––– Flashing ON Not displayed 2G43ZG
9 Battery fluid level (1) Below LOW level Abnormal Yellow Flashing ––– ––– Displayed B@GAZK
10 Battery fluid level (2) Below LOW level Abnormal Yellow Flashing ––– ––– Displayed B@GBZK
11 Battery fluid level (3) Below LOW level Abnormal Yellow Flashing ––– ––– Displayed B@GCZK
Below specified level Abnormal Yellow Flashing ––– ––– Displayed B@C5ZK Before engine starts
12 Brake oil level
Below specified level Abnormal Red ––– Flashing ON Not displayed b@C5ZK While engine is running
Below LOW level Abnormal Yellow Flashing ––– ––– Displayed B@BCZK Before engine starts
13 Engine water level
Below LOW level Abnormal Red ––– Flashing ON Not displayed b@BCZK While engine is running
14 Clogging of transmission Above specified pressure Abnormal Yellow Flashing ––– ––– Displayed 15BONX
15 Clogging of air cleaner (1) Above specified pressure Abnormal Yellow Flashing ––– ––– Displayed AA1ANX
16 Clogging of air cleaner (2) Above specified pressure Abnormal Yellow Flashing ––– ––– Displayed AA1BNX
17 Clogging of air cleaner (3) Above specified pressure Abnormal Yellow Flashing ––– ––– Displayed AA1CNX
18 Clogging of air cleaner (4) Above specified pressure Abnormal Yellow Flashing ––– ––– Displayed AA1DNX
19 Abnormal charging voltage When charge is abnormal Abnormal Yellow Flashing ––– ––– Displayed AB00MA
WA1200-3 10-199
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STRUCTURE AND FUNCTION CGC MONITOR
The service ID inputting screen buttons are hidden at the right bottom and right top of the setting
screen (They are not displayed on the screen).
Press the lower button, then press the upper button, and the screen changes to the following service
ID input screen.
1. Display of message
2. Operator display screen button
Input the correct service ID (the service ID is the VHMS controller part No. (with no hyphens), first nine
digits + 0) through the keys and press the enter key, and the screen for serviceman appears. If a wrong
service ID is input, the message changes to “Please input Service ID”.
• Operator display screen button: If this button is pressed, the serviceman display screen does not
appear, but the operator display screen appears again.
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STRUCTURE AND FUNCTION CGC MONITOR
If the correct ID is input on the service ID inputting screen, the service menu selection screen appears.
If each screen button on this screen is pressed, the selected screen appears.
If the operator display screen button is pressed, the operator display screen appears.
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STRUCTURE AND FUNCTION CGC MONITOR
If the real-time monitor screen button on the service menu selection screen is pressed, the real-time
monitor screen appears.
On this screen, select the data of a desired controller.
If a display button is pressed, the data of the selected system are displayed.
If the service menu selection screen button is pressed, the service menu selection screen appears
again.
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STRUCTURE AND FUNCTION CGC MONITOR
Engine
Transmission
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STRUCTURE AND FUNCTION CGC MONITOR
Load meter
0.01MPa
1/1 BOOM BOTTOM PRESSURE 2s {0.1kg/cm2} VHMS —
0.01MPa
1/1 MEASURED PRESSURE 2s {0.1kg/cm2} VHMS —
0.01MPa
1/1 CAL. PRESSURE 2s {0.1kg/cm2} VHMS —
0.01MPa
1/1 NO LOAD PRESSURE 2s {0.1kg/cm2} VHMS —
1/1 MEASURED LOAD 2s 1 TON VHMS —
Modulated clutch
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STRUCTURE AND FUNCTION CGC MONITOR
Remote positioner
Joystick steering
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STRUCTURE AND FUNCTION CGC MONITOR
If the maintenance time setting screen button on the service menu selection screen is pressed, this
screen appears.
l Display of maintenance items: The maintenance items are displayed.
The buttons to select maintenance items are formed
in this area.
The color of each button changes to display the
maintenance condition.
Yellow:The time before periodic maintenance is
shorter than 30 hours.
Red: The displayed part has passed the main-
tenance time (The time before periodic
maintenance is negative).
. Display of time before periodic maintenance: The time before the next periodic maintenance is
displayed. If the displayed part has passed the
planned maintenance time, a negative value is dis-
played.
. Display of maintenance period: The maintenance period set for each maintenance
item is displayed.
The buttons to set the maintenance period are
formed in this area.
. Page button: This button is used to turn over the displayed page.
l Service menu selection screen button: This button is used to select the service menu se-
lection screen.
. Maintenance item selector button: If this button is pressed, it flashes. If it is pressed
again, a pop-up screen appears, and the time be-
fore periodic maintenance is displayed again. (This
function is the same with the maintenance screen.)
• Maintenance period setting button: If this button is pressed, the screen to set the maintenance
period appears.
If a new maintenance period is input and the enter button is
pressed, the maintenance period is updated.
Then, the time before the next periodic maintenance is calcu-
lated again on the basis of the new maintenance period.
For the maintenance items and maintenance period, see the
maintenance screen.
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STRUCTURE AND FUNCTION CGC MONITOR
If the failure history screen button on the service menu selection screen is pressed, this screen
appears.
On this screen, the failures are displayed in the order of the time from the newest one.
If a trouble has not been repaired, the “time when detection was finished” is not displayed for that
trouble.
• History un-display button: If this button is pressed, the corresponding history is
not displayed. Once a history is set un-displayed, it
cannot be displayed on the CGC monitor any more.
(The memory of the VHMS controller is kept, however.)
If a history is set un-displayed, it is not counted in the
detected failures. (If one history is set un-displayed, the
number of the detected failures is reduced by one.)
• Display item UP/DOWN button: This button is used to move the displayed items up or
down one by one.
• Page button: This button is used to turn over the displayed page.
• Service menu selection screen button: This button is used to select the service menu selection
screen.
• Display of number of failure occurrences: If the same failure occurs repeatedly within a short time,
the number of occurrences is displayed.
If more than 30 minutes passes after the failure was
canceled, the display is added to a different column and
the number of occurrences is fixed.
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STRUCTURE AND FUNCTION CGC MONITOR
PM clinic screen
1. Display of items
2. Display of page
3. Display of data
4. Page button
5. Service menu selection screen button
6. Hold button (cancel button)
If the PM clinic screen button on the service menu selection screen is pressed, this screen appears.
On this screen, the data necessary to the PM clinic are displayed.
• Page button: This button is used to turn over the displayed page.
• Service menu selection screen button: This button is used to select the service menu selection
screen.
• Hold button (cancel button): If the hold switch is pressed, the data for the display is
held. The hold switch changes into the cancel switch.
If the cancel switch is pressed, the latest data is displayed,
and the cancel switch changes into the hold switch.
PM clinic items
DISPLAYED NAME OF SIGNAL SAMPLING UNIT DETECTED
PAGE TIME COMPONENT
1/4 ENGINE SPEED 2s rpm VHMS
1/4 ENGINE OIL PRESSURE 2s kPa Quantum
1/4 ENGINE OIL TEMP 2s °C CENSE
1/4 COOLANT TEMP 2s °C Quantum
2/4 ENGINE SPEED 2s rpm VHMS
2/4 BLOW-BY PRESSURE 2s Pa Quantum
2/4 BOOST PRESSURE 2s kPa Quantum
2/4 EXH GAS TEMPERATURE 2s °C CENSE
2/4 AMBIENT AIR TEMP 2s °C VHMS
2/4 FUEL RAIL PRESSURE 2s kPa Quantum
3/4 T/C TEMP 2s °C VHMS
3/4 T/C IN PRESSURE 2s MPa VHMS
3/4 T/C OUT PRESSURE 2s MPa VHMS
3/4 T/M MAIN PRESSURE 2s MPa VHMS
3/4 T/M LUB PRESSURE 2s MPa VHMS
3/4 T/M MOD PRESSURE 2s MPa VHMS
4/4 HYD. OIL TEMP 2s °C VHMS
4/4 PPC. OIL PRESSURE 2s MPa VHMS
4/4 HYD. OIL PRESSURE 2s MPa VHMS
4/4 S/T PUMP PRESSURE 2s MPa VHMS
4/4 F BRAKE OIL PRESSURE 2s MPa VHMS
4/4 R BRAKE OIL PRESSURE 2s MPa VHMS
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STRUCTURE AND FUNCTION CGC MONITOR
If the machine serial No. setting screen button on the service menu selection screen is pressed, this
screen appears.
Confirmation is carried out for the serial No. display and the setting, or for the machine model,
specification, and type. Use the PC tool to set the machine model, specification, and type. (See
TESTING AND ADJUSTING)
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STRUCTURE AND FUNCTION CGC MONITOR
If the component serial No. setting screen button on the machine serial No. setting screen is pressed,
this screen appears.
Confirmation is carried out for the component serial No. display and the setting, or for the engine
model. Use the PC tool to set the engine model. (See TESTING AND ADJUSTING)
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STRUCTURE AND FUNCTION CGC MONITOR
If the confirmation screen button for satellite communications ground station (GCC) is pressed on the
machine serial No. setting screen or component serial No. setting screen, the screen changes to this
screen.
The present set value is displayed. If no setting has been made in the VHMS, the value displayed is
248 to show that the satellite communications ground station (GCC) is not effective.
Use the confirmation screen for satellite communications ground station (GCC) for checking the set
value.
Use the PC tool to carry out the setting. (See TESTING AND ADJUSTING)
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STRUCTURE AND FUNCTION CGC MONITOR
1. Clock
2. Snapshot start button
3. Tachometer
4. Torque converter oil temperature gauge
5. Display of message
6. Service menu selection screen button
If the snapshot operation screen button on the service menu selection screen is pressed, this screen
appears.
This screen is used to take in the snapshot data and save them manually.
(Normally, the snapshot data are taken in automatically by using an error as the trigger. See “Snap-
shot items”.)
When a manual snapshot has been taken, the error code is recorded as MFAO.
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STRUCTURE AND FUNCTION CGC MONITOR
• Snapshot cancel button: This button is used to cancel the data take-in operation.
• Service menu selection screen button: This button is used to select the service menu selection
screen.
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STRUCTURE AND FUNCTION CGC MONITOR
Snapshot items
If an error is made, the data in set time before and after that error (5 minutes 30 seconds before the
error and 2 minutes after the error) are saved.
The cause of the error can be found out easily by checking the data of the sensors concerned to the
error.
1) This system can be applied to an error which cannot be reproduced.
2) Troubleshooting can be executed by collecting the data freely with the manual trigger func-
tion.
Sampling period of data
Every 10 seconds in the period from 5 minutes 30 seconds to 30 seconds before the error
Every 1 second in the period from 30 seconds before the error to 2 minutes after the error
Transmission, torque
Engine related MOD/C related Hydraulic related
converter related
Engine overrun
Coolant level
Coolant temperature
Trigger item/memory,
data item Coolant pressure
Intake temperature
Fuel temperature
Blow-by pressure
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STRUCTURE AND FUNCTION CGC MONITOR
1. Display of message
2. ID inputting button
3. Service menu selection screen button
If the memory clear screen button on the service menu selection screen is pressed, this screen
appears.
The memory clear screen appears only when the person of the input ID is proved to be qualified for
clearing the memory.
Input the memory clear ID with the ID inputting button, then press the enter button.
If a wrong ID is input, the message changes to “Please Input Memory Clear ID”.
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STRUCTURE AND FUNCTION CGC MONITOR
1. Display of message
2. Memory clear buttons
2A. Failure history data
2B. Trend data
2C. Snapshot data
2D. Maintenance data
2E. Load map data
3. Service menu selection screen button
If the correct ID is input on the memory clear ID inputting screen, this screen appears.
This screen is used to clear various saved data.
• Service menu selection screen button: This button is used to select the service menu selection
screen.
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STRUCTURE AND FUNCTION CGC MONITOR
On the memory clear screen, the SMR confirmation screen button is hidden at the bottom right of the
screen (it is not displayed on the screen). If the SMR confirmation button is pressed, it is possible to
change to the next SMR confirmation screen.
Use the SMR confirmation screen for checking the set value.
Use the PC tool to carry out the setting. (See TESTING AND ADJUSTING)
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ALL-RANGE ELECTRONIC CONTROL AUTOMATIC
STRUCTURE AND FUNCTION TRANSMISSION (ATM) SYSTEM
Manual shift
Kickdown function
t Safety functions
Self-diagnosis function
Display of condition (Output, failure code)
t Troubleshooting (Detection of system trouble, wire breakage and short circuit in system)
Communicating function
SYSTEM CONFIGURATION
1 D
J/S R SW b
1 Dx2
J/S SHIFT UP SW ECMV 1
1 Dx2
1J/S SHIFT DOWN SW
Transmission cut-off SW
1 D 1
+ ECMV 3
ID
Manual/Auto gear shift selector SW b
Engine speed
1 P
b
D
IP
Travel speed b
1 D <Display> Monitor
Neutralizer relay signal b ---_-.-.-.-_-_-_-_-_-_-_-,
s j I
Shift indicator I
I
(Actual gear speed) I
-1 D
I
Steering lever lock signal b I
s I+ I
Main monitor F.N.R
I I
I I
<Display> Monitor I
___________-_-_-_-_-_-_-_-_-_- Troubleindicatingbuzzeroutput i
I i S
i Tire correction l L_-_-_-_-_-_-_-_-_-_-_-__J
I
I I \
I
I
I I
I~__________________-_-_-_-_-_-A Auto gear
shift call
Memory clear signal
1 A
display
b
1 D
Fill SW F b
1 D
Fill SW R ä Fl output
J
D
Fill SW 1 b
R clutch drain valve
Fill SW 2
1 D
b
1 D S: S-NET signal
Fill SW 3 b D: Digital signal
I A A: Analog signal
Transmission oil temperature b P: Pulse signal
FUNCTIONS
1. Auto gear shift function If the modulated clutch outlet speed
When the modulated clutch outlet speed is is below 1,450 rpm, however, ECMV
1,450 rpm or higher, shifting up and shifting is kept in the 3rd gear speed. (Coast-
down operations of the transmission are con- ing)
trolled with the signals of the travel direc- 4) When direction switch is in “R” position
tion, gear shift range, and travel sensor, ac- Similarly to the operation in the F posi-
cording to the “automatic gear shift change tion, the 2nd or 3rd gear speed (when
points table” (Table 1) stored in the trans- the gear shift range is 3) is selected au-
mission controller. tomatically according to the travel speed
See combination of gear speeds and when the modulated clutch outlet speed
output ECMV (Table 4), auto gear shift is 1,450 rpm or higher.
operation table (Table 21, and the sec- 5) Skip shift
tion of contents of control by transmis- If the accelerator pedal is pressed while
sion controller. the machine is coasting in the 3rd gear
1) Gear shift range (I - 3) speed at speed below 8 km/h (with the
The highest gear speed (gear shift range) auto gear shift function turned OFF), the
for the auto gear shift is limited. 2nd gear speed is selected immediately
Example: so that the machine can be accelerated
Gear shift range 3: Between 2nd and easily. If the travel speed is 8 km/h or
3rd gear speeds higher, however, the present gear speed
Gear shift lever 2: Only 2nd gear speed is maintained.
Gear shift lever 1: Only 1st gear speed 6) Period in which gear speed cannot be
2) When direction switch is in “N” position changed
If the direction switch is in the neutral A certain period to keep each gear speed
position, only the gear speed clutch of after gear shifting operation is set to pre-
the transmission is operated. vent gear shift hunting. This period de-
3) When direction switch is in “F” position pends on the gear shifting pattern. See
If the direction switch is set from the N “automatic gear shift change points ta-
position to F position, ECMV of F of the ble” (Table I).
transmission is turned on. If the gear
shift range is 2 or 3 at this time, the 2. Modulation control
machine starts with the 2nd gear. The modulation control system controls the
a) When the gear is shifted up (when clutch oil pressure (including the rising char-
gear shift range is 3) acteristics) matched to the condition of the
When the accelerator pedal is hydraulic circuit in the all gear speeds ac-
pressed to accelerate the machine cording to the engine speed, transmission
and the modulated clutch outlet oil temperature, gear shifting pattern, and
speed is 1,450 rpm or higher, if the data stored in the transmission controller to
travel speed reaches about 10.4 km/ reduce the shocks made when the gear
h, the 3rd gear speed of ECMV is speed is changed (when the clutch is en-
turned “ON” and the second gear gaged).
speed is turned “OFF”. (The trans- The modulation control system is also ap-
mission is set in the F3 position.) plied to ECMV to be turned off to prevent
b) When the gear is shifted down (when lowering of the torque.
gear shift range is 3)
If the accelerator pedal is released
and the travel speed lowers to about
9.8 km/h while traveling in the 3rd
gear speed, the second gear speed
of ECMV is turned “ON” and the 3rd
gear speed is turned “OFF”. (The
transmission is set in the F2 posi-
tion.)
Remarks
Operation of only
accelerator pedal
(During coasting or
acceleration after braking)
o_ @
All range
protection of transmission.
6. Self-diagnosis function
The transmission controller constantly moni-
tors the input and output signals of the travel
control system, and executes self-diagnosis
and displays the result with the LED of the
controller.
The transmission controller also transmits
the following data to the main monitor.
I) Normal display: The output gear speed
is displayed with the LED of the trans-
mission controller.
2) Display of failure code: If any trouble is
detected, its contents are displayed by
the code (See the table below).
Table 3 Failure codes table
INPUT SIGNALS
1. Steering lever lock signal are operated simultaneously, their operations
This signal is a GND/OPEN digital signal, are judged as follows.
which becomes OPEN when the steering le- . After either switch is turned ON, the turn-
ver is stopped (locked) and becomes GND on operation of the shift-up switch or
when the steering lever is operated (free). shift-down switch is not accepted for 0.2
If the steering lever is operated, the direc- seconds.
tion switch becomes effective. . If the shift-up and shift-down switches
are operated simultaneously (for 0.01
2. Neutralizer relay signal second), the operation of the shift-down
This signal is a +24V/OPEN digital signal. If switch is accepted.
the parking brake switch is turned off, +24 V
is input. 7. Fill switch
When this signal is OPEN, the transmission (F, R, 1st gear, 2nd gear, 3rd gear) signal
controller keeps itself in neutral state. (The This signal is a GND/OPEN digital signal,
machine cannot travel.) which becomes GND when each ECMV is
turned ON and becomes OPEN when each
3. Transmission cut-off switch signal ECMV is turned OFF.
This signal is a GND/OPEN digital signal,
which becomes OPEN when the left brake is 8. Engine rotation sensor signal
used (pressed) while the transmission cut- This signal is a pulse signal. The number of
off switch is effective, and becomes GND pulses sent from the electromagnetic pickup
when the left brake is released. sensor is converted into rpm and used for
If the left brake is used, the transmission control.
controller outputs the neutral signal. If the
transmission controller is reset, the gear 9. Modulated clutch outlet rotation sensor
speed matched to the current travel speed is signal
set. This signal is a pulse signal. The number of
pulses sent from the electromagnetic pickup
4. Manual/Auto gear shift selector switch sensor is converted into rpm and used for
signal control.
This signal is a GND/OPEN digital signal, The mode where the engine speed is 1,450
which becomes GND when the switch is rpm or higher is called the “auto-shift ON”
pressed and becomes OPEN when the switch mode, and the mode where the engine speed
is released. is below 1,450 rpm is called the “auto-shift
If this signal changes from OPEN to GND, OFF” mode.
the manual and auto travel modes are se-
lected alternately. 10. Travel speed sensor signal
This signal is a pulse signal. The number of
5. Direction switch (F, N, RI signal pulses sent from the electromagnetic pickup
This signal is a +24V/OPEN digital signal. sensor is converted into rpm and used for
When the machine is normal, one of the F control.
(Forward), N (Neutral), and R (Reverse) sig- When this signal is converted into the travel
nals is input (+24 V). speed, the tire correction data (sent from
the main monitor) are added to it.
6. Shift-up/Shift-down switch signal
This signal is a +24V/OPEN digital signal. If 11 Communication signal (S-NET)
the switch is pressed, its N.C side is opened The tire correction data set in the main moni-
and its N.0 side becomes +24 V. If the switch tor are received and used for control.
is released, its N.C side becomes +24 V and The accurate travel speed is obtained by
its N.0 side is opened. The operation of the adding the correction value (ranging from
switch is judged by these signals. 0.86 to 1.14) to the rpm data sent from the
If both shift-up switch and shift-down switch travel speed sensor.
OUTPUT SIGNALS
1. Transmission modulation valve 4. Fl (Cut-off) signal
(ECMV) Command current This signal is a Lo side output, which be-
This signal is a current output (0 - 1 A). comes GND when the forward 1st gear (Fl)
There are five types of ECMV for directions is selected by the kickdown operation, etc.
of “R” and “F”, and for gear speeds of “Ist”,
“2nd”, and “3rd”. 5. Gear shift range display LED
This valve is a pressure control valve which I) This LED indicates the gear shift range
converts the current supplied to the sole- (range of auto gear shift operation) in
noid into the pressure. Accordingly, the oil the auto mode.
pressure on the clutch selected for each gear Gear shift range “1”:
speed is controlled to control the engage- LED 1 is turned on and only the 1st
ment of the clutches independently. gear speed is selected.
When the transmission is in neutral, only Gear shift range “2”:
the gear speed clutch is turned on. (The gear LED 2 is turned on and only the 2nd
speed is selected according to the gear shift gear speed is selected.
range and travel speed in the auto mode. In (If the gear is shifted down to the 1st
the manual mode, the gear speed before the gear speed by the kickdown opera-
transmission is set in neutral is maintained. tion, the 2nd gear speed is selected,
When the engine is started, the 2nd gear depending on the travel speed.)
speed is selected.) Gear shift range “3”:
LED 3 is turned on and the 2nd or
Table 4 Combination of gear speed and drive 3rd gear speed is selected automati-
ECMV (Holding state) cally.
2) This LED goes off in the manual mode.
7. Communication signal
(Data of disolav on main monitor)
I) Display of gear speed
1st gear speed output: “I”
2nd gear speed output: “2”
t R3 1 - 1 - 3rd gear speed output: “3”
0: ON In neutral: “N”
AZ One of 1 - 3 is turned on according to the condition. 2) Display of F and R
When travel direction is forward: “F”
When travel direction is reverse: “R”
2. Bypass valve (For F, R, and 1st gear speed) In neutral: Nothing is displayed.
This signal is a digital (ON/OFF) output of
+24 V, which is turned ON for the stored
period (data) when each ECMV is turned ON.
LED DISPLAY
When the engine is started, the LED is set in 1. “Program part No. display mode”, then 2. “Output gear
speed display mode”.
If any trouble is detected, however, the LED is set in the “Troubleshooting display mode” immediately.
1. Program part No. display mode
When the power is turned on, the following are displayed in order at the interval of 1 second.
-0 -0 70 80 20 30 1, 9, A, 1, 0, 1, + To display mode 2
Al Al Al ti hl
w
I
N Gear shifting (Gear speed F2 is displayed continuously)
-+ Repeat
+=I=%
E, -0 20 30 E, -0 1, 80 + Repeat
hl Ll Ll
ti
KDS 0 0
Display of gear shift range (In AT) 0 OFF Displayed with LED (Only in auto shift mode)
2. Actual gear speed (II, gear shift range (III, and travel mode (Auto shift/Manual) (Ill)
I) Actual gear speed (1) and gear shift range (II) when manual shift and auto shift modes are
changed to each other
Manual/Auto shift
Before change After change
selector switch
@ Auto shift [Auto shift1 ä [Manuall
J (1)Actual gear speed b (1)Actual gear speed is the same as that in auto shift mode.
Manual
(II) Gear shift range --------------------b x (II)Gearshiftrangeisnotapplied,andisturnedoff.
F 0 F 0
N 0 N 0
R 0 R 0
g I@Ei5q
g
1 Range 1 &
h
I ’’ II !I - Actual gear speed (Solenoid output) . .2nd (s)
E
r ’’ I II 3,: 1%) . . When gear shift range is [ll, 1st gear speed is selected.
”
4 0
*,
m 5 ’ i “an~2~’
- Gear shift range.. Gear shift range before power is turned o
1 $z$&
01
O 0
KICK DOWN SW ,AUtmlBflC
resetwhenLiirenion
i* changed between F and FL)
I
I b
I) Control of kickdown
Gear speed
Command from controller
before kickdown
3rd is held
Brd+lst 1st (Kickdown signal
is ignored).
2nd is held
2nd+lst 1st (Kickdown signal
is ignored).
\t
Travel speed o ’ ’ ’ ’ ’ ’ ’ ’ 9’ ’ ’ ’ 13
’ 15
’ ’ ’ ’ ’ 20’ ’ ’ ’
5
(km/h)
Operation of
shift-down Command from controller
switch 14
Gear speed
Gear speed after change of direction
before change
(Command from controller)
of direction
Travel speed
(km/h)
Operation of
shift-down Command from controller
switch 14
3rd+2nd
3rd+lst
/ 1 1 accepted2 times
Travel speed I I I I I I I I I I I I I I I I I I I I I I I I
(km/h)
0 5 9 1314 20
(The following control is also applied when the direction is changed to F or R while the machine is
coasting with the gear is in NJ
I 1 ,
Travel speed i ’ ’ ’ ’ ’ ’ ’ ’ ’ ’ ’ ’ ’ ’ ’ ’ ’ ’ ’ ’ ’ ’ ’ ’
5 10 15 20
(km/h)
Travel speed o ’ ’ ’ ’ ’ ’ ’ ’ ’ ’ ’ ’ ’ ’ ’ ’ ’ ’ ’ ’ ’
5 9 14 20
(km/h)
‘0,
g:
oi
5’ Modulated clutch ECMV current
2i
D
RPM set ON/OFF switch signal
D ?
SET/ACCEL switch signal E
Electronic governor voltage command
D 8
RESUME/DECEL switch signal
::
D S
2 A: Analog signal
D
Low idle switch signal
5 D: Digital signal
A e P: Pulse signal
S: S-NET signal
Control function
Modulated clutch control
Travel speed control function
Drive force control function
I- Tire slip control function
RPM set control function
I Troubleshooting function
Since the operator can set the idling speed of 2) How to lower set engine speed
the engine freely, unnecessary lowering of the i) Setting with accelerator pedal
engine speed can be prevented while the opera-
a) Press the right brake pedal, and the
tor is working with the accelerator, and the en-
memory of the engine speed is
gine is accelerated sharply and the cycle time is canceled temporarily and the engine
shortened. speed is lower to the low idling level.
Since the travel speed can be kept constant dur-
b) Press the accelerator pedal until the
ing load-and-carry operation, the operator is less
engine speed rises to the desired
fatigued and the machine consumes less fuel. level.
c) Press the SET/ACCEL switch to save
How to set engine speed
the new engine speed data.
1) Turn on the RPM set ON/OFF switch. Then, even if the accelerator pedal is
2) The RPM set pilot LED lights up. released, the engine runs at the
3) Press the accelerator pedal until the engine saved speed.
speed rises to the desired level. ii) Setting with switch
4) Press the SET/ACCEL switch to save the en-
a) Press and hold the RESUME/DECEL
gine speed data.
switch for more than 0.5 seconds,
Then, even if the accelerator pedal is re-
and the engine speed lowers.
leased, the engine runs at the saved speed.
b) When the engine speed lowers to the
desired level, release the RESUME/
How to change set engine speed
DECEL switch, and the new engine
Use the following method to change the save speed data is saved.
engine speed.
1) How to raise set engine speed How to cancel memory of engine speed
i) Setting with accelerator pedal temporarily
a) Press the accelerator pedal until the Press the right brake pedal, and the memory of
engine speed rises to the desired
the engine speed is canceled temporarily and
level. the engine speed lowers to the low idling level.
b) Press the SET/ACCEL switch to save
the new engine speed data. How to restore canceled engine speed
Then, even if the accelerator pedal is
Press the RESUME/DECEL switch, and the en-
released, the engine runs at the gine speed rises to the saved level again.
saved speed. (Note)
ii) Setting with switch If the engine starting switch or the RPM set
a) Press and hold the SET/ACCEL switch ON/OFF switch is turned OFF, the saved en-
for more than 0.5 seconds, and the gine speed is cleared, then the engine runs
engine speed rises. at the low idling speed. In this case, repeat
b) When the engine speed rises to the the above procedure to set the engine speed
desired level, release the SET/ACCEL again.
switch, and the new engine speed
data is saved.
Troubleshooting function
The controller constantly monitors the electronic
devices such as the potentiometers to receive
input signals, solenoid valves to receive output
signals, etc. If any one of those devices has a
trouble, the controller detects it and displays is
as a “failure code” on the main monitor to no-
tify the operator.
SYSTEM CONFIGURATION
S
Display of upper setting of remote positioner
-1 s
Lower setting switch of remote positioner
x:: j
Steering lever potentiometer
% Joystick main pressure control EPC SOL
A: Analog signal
D: Digital signal
P: Pulse signal
S: S-NET signal
10-238
10-238 WA1200-3
(7)
STRUCTURE AND FUNCTION WORK EQUIPMENT AND JOYSTICK STEERING CONTROL SYSTEM
Steer ins
lever
Travel
Speed Steering lever
Potentiometer
I
I
I I
lever lock I fI
valve II I
switch
______--__-___--I II
r I
Frame angle
I
Potentiometer 0 i I ! t
- I I
sxw0491.3
Control function
Outline
l With the remote positioner control function, l With the joystick steering control function,
the operator can set the boom stopping (le- the flow gain in the steering hydraulic sys-
ver kick-out) position freely so that the boom tem is controlled according to the deviation
will stop smoothly. As a result, the operator of the frame angle from the operating angle
can operate the machine safely and easily of the joystick steering lever to improve the
when driving in reverse, digging the earth, narrow steering characteristics and response
or approaching a dump truck. to high-speed steering for higher
maneuverability.
(
button.
4) The “LOWER” button flashes (for 2.5
seconds).
5) If the “LOWER” button lights up again,
the lower stop position is saved.
. If the FNR switch is not in the “N” position, the neutral safety function prevents the engine from
starting.
Troubleshooting function
The controller constantly monitors the electronic devices such as the potentiometers to receive input
signals, solenoid valves to receive output signals, etc. If any one of those devices has a trouble, the
controller detects it and displays is as a “failure code” on the main monitor to notify the operator.
Failure code on
E44 and E45 cannot be distinguished, and they are turned on simultaneously.
POTENVOMETER
A-A
A4
SW04882
1. Connector 5. Bearing
2. Case 6. Contact
3. Shaft 7. Mold
4. Element
Potentiometer output
Function
The potentiometer senses the operating angle. the above signal in this area, it judges that the
In the potentiometer, the source voltage of 5 V potentiometer system has a trouble such as wire
is converted with a variable resistor into a sig- breakage, short circuit, etc. Since the correct po-
nal voltage according to the angle, then sent to sition cannot be sensed in this case, the control
the controller. output is turned off and the failure code is dis-
The hatched area in the above figure is the ab- played on the main monitor.
normality detection area. If the controller receives
Connector signal
/ i 1Frameangle”““iometer / In: 1
- I - I 121 - I -1
1 3 1Boom PPC dumping SOL2 (+)I Output 1 - I - I
I41 - I - I - I - I 1 ,” ~:;,9:~;,s,p,e,e,“,s:gnal
(+) 1;;w;;1
5 Boom PPC dumping SOL1 (t) Output I 5 I Boom RAISE pressure switch Input I
6 J/S EPC SOL (+) output 6 Boom LOWER pressure switch Input 6 Remote positioner UPPERstop LED Output
I 7 I - I - I
1 8 I - I - I
I101 - I - I
I 11 I - I - I I I
I 15
I 17
Boom PPC dumpmg
I Input I
15
16
17
-
-
-
-
I 15
16
I J/S caution
Buzzer output
buzzer output I Output
output
I
tiler
Starting switch - xrv~ce meter
Main monitor
t
Slow blow
fuse 30A
Cummins engine
inject ion
solenoid
Voltage
Alternator Prelub
_-__- s regulator
r----r 1 ‘I I timer
rreluu 0 - Conventional
l___ -.- __-__
IE !I’
E:-___I
Pressure starter
,.
& swltcn
sxwo4920
Function Operation
l When the direction switch and the joystick . If the starting switch is turned to the ON
steering lever are in the N (Neutral) position, position, a current flows from the BR termi-
the neutral safety circuit prevents the engine nal of the starting switch to the battery relay,
from starting to secure the safety when the then the battery relay contacts are “closed”.
engine is started. The power is supplied to the machine by this
. If the starting switch is set to the START operation.
position, the engine oil is circulated first by . If the direction switch is set to the N (Neu-
the pre-lubricating function. After the oil pres- tral) position, a current flows in the neutral
sure has risen, the engine is started. relay, then the contacts 5 and 3 of this relay
are connected to each other.
On the other hand, when the joystick steer-
ing lever is set to the N (Neutral) position,
contacts 6 and 3 of the steering neutral relay
are connected to each other, and the con-
tacts 6 and 3 of the alternator hold relay are
also connected to each other.
At this time, if the starting switch is set to
the START position, the current flows through
the following route.
-VHMS controller
Start ine switch -Service meter
-Main monitor
Slow blow
fuse 30A
rPrelub
hold
relay
Battery
r
Alternator _
I
t
I , starter G
I
Pr club oil Conventional
i-.---c____-3 pr essure : starter
3 switch
sxwo4921
l Several seconds after pre-lubrication is com- . If the starting motor rotates slowly and
pleted, a current flows from terminal 5 of meshes with the gear of the engine, the con-
the pre-lubrication timer to terminal 1 of the tacts of the starting motor are “closed” by
safety relay to “close” the contacts of the the suction force of the pull-in coil, then the
safety relay, then the electric power is sup- starting motor starts quick rotation to start
plied to the pre-lubrication starting motor the engine.
and conventional starting motor. The current does not flow in the pull-in coil
l At this time, the current flows in both hold- any more, but the contacts of the starting
ing coil and pull-in coil of each starting mo- motor are kept “closed” by the current flow-
tor to “close” the contacts. Since the current ing in the holding coil.
also flows through the pull-in coil to the
motor, the starting motor starts slowly.
VHMS controller
Sta rtins switch Service meter
3 Main monitor
3
3
------I Slow blow
Battery
LLllrl
- I I
injection & 11 / I
Cummins engine
controller
Ether
injection
9
solenoid
:i
SafZ ’ c
relay T
+
Conventional
pressure = starter
8 switch
sxwo4922
. If the engine starts, the alternator starts gen- connection between terminals 6 and 3 of the
eration and outputs the power through ter- alternator hold relay, then the starting cir-
minal B. At this time, the same voltage is cuit is not held any more.
generated at terminals B and L, and a cur- The current from terminal L of the alternator
rent flows into terminal 2 of the safety relay is supplied as the signal that the engine is
to “open” the contacts of this relay to break rotating to the service meter, etc.
the power for the starting motor. . If the direction switch and/or the joystick
The current flows from terminal L of the steering lever is not in the N (Neutral) posi-
alternator through the alternator hold relay tion, the circuit is broken by the steering
coil to the ground, and the circuit to the pre- neutral relay and the engine does not start.
lubrication hold relay is broken to break the
VHMS controller
Starting switch
Service meter
Main monitor
Cummins engine
Voltage
Alternator
----__-__-_B reeulato r
-
+
Prelub oi Conventional
IE E: 111;
-__- Pressure starter
switch
sxwo4923
Operation
. If the starting switch is turned to the OFF nals B and L any more, and the signal that
position, the signal from terminal BR of the the engine is rotating is stopped.
starting switch to the CUMMINS electronic The power is not supplied from terminal BR
governor controller is turned off, and the of the starting switch to the battery relay
fuel supply to the engine is stopped to stop any more, and the contacts of the battery
the engine. relay are “opened” to turn off the power
If the engine speed lowers, the alternator supplied to the machine.
does not generate the voltage at its termi-
VHMS controller
Starting switch Service meter
Main monitor
Cummins engine
Ether
injection
solenoid
Voltage
Alternator regulator
-__-__-__--8
sxwo4924
Operation
l The ether injection system can operate only 3 and 5 of the ether start relay, and ether
while the starting switch is at the START injection solenoid to the ground is formed,
position. If the ether injection switch is turned then the ether is injected.
on while the starting switch is at the START . If the ether injection switch is turned to the
position, a current flows as follows. OFF position, the current flowing in the ether
l The current flows from terminal R2 of the start relay coil is broken to stop injection of
starting switch through ether injection switch ether. If the starting switch is not at the
and ether start relay coil to the ground, and START position, the current does not flow
terminals 3 and 5 of the ether start relay are from terminal R2 of the starting switch, and
closed. As a result, the circuit from terminal ether is not injected accordingly.
R2 of the starting switch through terminals
Y
SWWO4852
OUTLINE
l The parking brake is a wet multi-disc brake 1. Parking brake switch
built in the transmission. If the current flows 2. Emergency parking brake reset switch
in the parking brake solenoid valve, the oil 3. Parking brake display switch
pressure from the transmission pump is ap- 4. Accumulator
plied to the parking brake cylinder to release 5. Emergency brake switch
the parking brake. If the current is broken, 6. Parking brake solenoid valve
the oil pressure from the transmission pump 7. Emergency parking brake reset solenoid valve
is shut off and the pressurized oil in the 8. Neutralizer relay
parking brake is drained through the park- 9. Parking safety relay
ing brake valve, then the parking brake is
operated with the spring force.
FUNCTION
1. Applying and releasing parking brake 6. Parking brake emergency release solenoid
The parking brake is applied or released by valve
using the parking brake switch. If the supply of pressure oil from the trans-
mission pump should stop because of some
2. Automatic parking brake failure, it is possible to actuate the emer-
When the engine stops (when the starting gency relief solenoid valve with the parking
switch is OFF), the parking brake is auto- brake emergency release switch in the op-
matically applied to prevent the machine erator’s compartment. This sends the accu-
from running away when the operator is mulator charge pressure in the brake piping
away from his seat. 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.
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 opera-
tion. 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 dis-
tance 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.
OPERATION
To transmission
controller
Start ins
switch Emergency brake switch
(installed to accumulator)
sxwo4925
2-l.ln case where parking brake switch has been turned ON (operated) before starting switch is turned
ON
Battery
Battery
_-
--!i%~~-~l
L---A L-_
t -
Starting
switch Emergency brake switch
(installed to accumulator)
SXWO4926
l @ Since the current flows from the positive relay + Terminals 5 - 3 of the parking safety
(+I terminal of the battery through the start- relay + Terminals 1 - 2 of the parking safety
ing switch and battery relay coil to the relay + Ground. From this time on, the park-
ground, the battery relay is “closed”. Then, ing safety relay is kept in the circuit of @
@ the current flows from the positive (+) until the starting switch is turned to the OFF
terminal of the battery through the battery position.
. Under this condition, since the current does
relay, terminals 1 - 2 of the parking brake
switch, and terminals 1 - 2 of the parking not flow in the parking brake solenoid valve,
safety relay to the ground. As a result, the the parking brake is applied.
parking safety relay operates and its termi- . Under this condition, since the terminals 3
nals 3 and 5 are “closed”. and 5 of the neutralizer are “opened”, the
l Then, @the following circuit is formed; Posi- transmission is set in neutral by the trans-
tive (+) terminal of the battery + Battery mission controller.
2-2.ln case where parking brake switch has been turned OFF (released) before starting switch is turned
ON
5 @ To t.an!mission
controller
Start ins
switch Emergency brake switch
(installed to accumulator)
sxwo4927
l @ Since the current flows from the positive valve. Even if the starting switch is turned to
(+I terminal of the battery through the start- the ON position after the automatic parking
ing switch and battery relay coil to the brake is operated, the parking brake is not
ground, the battery relay is “closed”. Since released automatically.
the parking brake switch is turned off (re- l Since the current does not flow in the trans-
leased), however, the parking safety relay mission controller, the machine does not
does not operate. Accordingly, the current move.
does not flow in the parking brake solenoid
Battery
Battery
y Alternator
R terminal L
@ To !ran!nission
controller
Start ine
switch Emergency brake switch
(installed to accumulator)
SXWO4928
. If the parking brake switch is turned “OFF” @ The circuit of the emergency brake switch
(released), its terminals 2 and 3 are con- through the parking brake solenoid valve to
netted to each other. Since the parking brake the ground is formed, and the parking brake
safety relay is turned on at this time, @ the is released.
current flows from positive (+I terminal of @ The signal flows from terminal 3 of the neu-
the battery through the battery relay and tralizer to the transmission controller, and
parking brake safety relay to parking brake the machine can travel.
switch, then it flows as follows.
Battery
Bat terv relay
y Alternator
n terminal L
@ To !ran!mission
controller
Start ina
switch Emergency brake switch
(installed to accumulator)
SXWO4926
. If the parking brake switch is turned ON (op- l Since the neutralizer is reset at this time, the
erated) after operating the machine with the circuit of 3 and 5 is “opened” and the signal
parking brake switch turned “OFF”, the does not flow from terminal 3 of the neutral-
above circuit is formed. izer to the transmission controller, then the
l Since the current does not flow in the park- transmission is set in neutral. In this way,
ing brake solenoid valve, the pressurized oil the transmission is set in neutral while the
supplied to the parking brake cylinder is shut parking brake is operated to prevent the
off and the pressurized oil in the parking machine from traveling with the parking
brake cylinder is drained through the park- brake applied to seizure of the parking brake.
ing brake valve. As a result, the parking brake
is operated with the spring force.
5. When main brake oil pressure lowers (When emergency brake operates)
Neutralizer
Battery relay
Battery
Battery
controller
Starting
switch Emergency brake switch
(installed to accumulator)
sxwo4930
Operation
. If the oil pressure in the main brake line l As a result, the signal flows to the transmis-
lowers, the emergency brake switch installed sion controller and the transmission clutch
to the accumulator is “opened”. can be engaged. By this operation, the en-
Accordingly, the current does not flow in gine can be used as a brake when the emer-
the parking brake solenoid valve and the gency brake is operated. Consequently, the
pressurized oil in the parking brake cylinder braking distance can be shortened. In addi-
is drained and the parking brake operates. tion, when the emergency brake operates
In this case, however, the current is still flow- but the machine needs to be moved (e.g.
ing in the neutralizer coil, unlike the case when the emergency brake operates while
where the parking brake is turned ON (oper- the machine is traveling through a railroad
ated). crossing), the machine can be moved by op-
erating the transmission switch.
I Battery --”
relay_ Buzzer
I I
III IOA
I
Parking brake
BR emergency release
8- solenoid valve
Start ins
switch sxwo4931
Operation
. If the machine should stop because of en- The oil pressure stored in the accumulator
gine trouble, the oil pressure form the trans- in the main brake line then flows to the park-
mission pump to the parking brake cylinder ing brake cylinder to release the parking
is shut off and the parking brake is applied. brake.
When this happens, the oil pressure in the l The emergency release switch should nor-
main brake line is stored in the accumulator. mally be kept at the OFF position and should
l When the emergency release switch is turned be returned to the OFF position after the
on (released), the buzzer sounds, and at the emergency release.
same time, electric current flows to the emer-
gency parking brake release solenoid valve.
3
1
6 Relay connection chart
5 2 Relay actuation table
Terminal No. 1
I I
I I
0 0
0
:a @g--D
SWWO4860
Connection table
OFF
4 2
If3
SEW00319
I
SWWO486I
1. Valve assembly
2. Solenoid valve
A. To parking brake
B. From parking brake solenoid valve
C. From transmission
T. Drain
P. From brake (Accumulator circuit)
SWWO4862
Function
l The emergency parking brake reset solenoid
valve is installed between the transmission
and brake circuit. When the transmission
pump cannot supply oil pressure because of
an engine trouble, etc., the solenoid of the
parking brake reset switch on the operator’s
seat is turned on to apply the accumulator
charge pressure of the brake circuit to the To Parking From parking
brake brake solenoid
parking brake cylinder.
Operation
. If emergency parking brake reset switch @
is turned “ON”, solenoid valve @ operates.
As a result, the pressurized oil in accumula-
tor @ flows in port P to change the circuit
with the pilot pressure, then flows through
port A to the parking brake to reset the park-
ing brake.
Kick-down switch
10-262
10-262 WA1200-3
(7)
KICK-DOWN SWITCH AND AUTO SHIFT/MANUAL SHIFT
STRUCTURE AND FUNCTION SELECTOR SWITCH
Resetting
(In manual shift mode)
• When the direction switch is set to the “N”
or “R” position
• When the shift-up switch or shift-down
switch is pressed
(When the shift-down switch is pressed, the
gear is kept in the 1st gear speed.)
• When the starting switch is turned off
(In auto shift mode)
• When the direction switch is set to the “N”
position
• When F or R of the direction switch is
changed to the opposite direction
• When the shift-up switch or shift-down
switch is pressed
• When the travel speed rises
• When the starting switch is turned off
Operation
• The auto shift/manual shift selector switch
is installed to the boom lever. Each time it is
pressed, the travel mode (auto shift/manual
shift) is changed.
• In the auto shift mode, the indicator (one of
the three) under the main monitor lights up.
• When the starting switch is turned ON, the
travel mode (auto shift/manual shift) saved
when the starting switch was turned off last
time is selected.
WA1200-3 10-263
10-263
3
(7)
20 TESTING AND ADJUSTING
Note the following when making judgements using the standard value tables for testing, adjusting, or
troubleshooting.
The standard value for a new machine given in the table is the value used when shipping the machine from
the factory and is given for reference. It is used as a guideline for judging the progress of wear after the
machine has been operated, and as a reference value when carrying out repairs.
The service limit value given in the tables is the estimated value for the shipped machine based on the results
of various tests. It is used for reference together with the state of repair and the history of operation to judge
if there is a failure.
These standard values are not the standards used in dealing with claims.
a 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.
g When carrying out work together with other workers, always use signals and do not let unauthorized people
near the machine.
g When checking the water level, always wait for the water to cool down. If the radiator cap is removed when
the water is still hot, the water will spurt out and cause burns.
g Be careful not to get caught in the fan, fan belt or other rotating parts.
h-
(Watertemperaturein operatingrange)
Oil pressure
(I 5W-40 oil) {k;::? )
Oil temperature
All rotation range
(In oil pan) I "C
I 80 - 110 Min. 120
4.9 +:
(0 .5+q
0
;;:zrting wi l Stop engine. N{kgI
l Measure at center of lever knob. 6.9 + 1.0 6.9 f 1.0
(0.7 f 0.11 IO.7 f 0.11
HOLD-tRAISE 67_+ 15 67 ?I 30
I
t
8 HOLD+LOWER 53_+ 15 53 + 30
m
l Run engine at low idling.
HOLD-FLOAT l Hydraulic oil temperature: mm 672 15 67 ?I 30
45 - 55°C
HOLD-DUMP 60+_ 15 60 + 30
z
5
m3
HOLD-TILT 60f 15 60 + 30
Machine model
I
l---i
l
Low idling
l Hydraulic oil temperature:
Operating 45 - 55°C
time l Left lock position - Right lock
High idling
position.
58.8 f 2.45
Pressing force NIkgl Max. 88.2 (9.0)
IS.0 + 0.25)
*See Fig. B. 45 -
Pressing Run engine at low idling.
tTq--T-
l
2
Play
Fitting condition of
wheel lock ring
A
*See Fig. C.
y--e+-+
mm Max. 4.0 -
B l Tire inflation pressure:
i= Specified pressure
Clearance of wheel c 2 - 10 -
rock ring
0
TESTING AND ADJUSTING STANDARD VALUE TABLE FOR CHASSIS
Machine model
I WA1 200-3
I 21
{27 C+ 0.2
2.8 I 2.8 21
(27 +f 0.2
I 6.3 f 0.3
I
6.3 + 0.3
l Stop engine.
l Continue pressing brake pedal
Brake oil pressure drop to 4.9 MPa 150 kg/cm3 and
measure oil pressure drop
after 5 minutes.
*See Fig. D.
Wear of disc l Measure wear of disc by mm 0 7.0
measuring piston stroke.
set
I}I 5.0 f 0.5
I
Max. 7.0
*See Fig. H.
C Hydraulic drift of Hydraulic oil temperature: Max. 250
l Max. 250
g bucket hinge pin 45 - 55°C
l Stop engine and leave it for
mm
!-----I 15 min, then measure for I5
min. Max. 100 Max. 100
5 Hydraulic drift of (Excluding (Excluding
l Empty bucket and set boom
s bucket tooth edge hydraulic drift of hydraulic drift of
and bucket level.
bucket hinge pin) bucket hinge pin)
*Fie.A
face
*Fig. C *Fig. D
*Fig. E ) f Fio. F
*Fig.G *Fig. H
When fully
I Work equipment
Posture
Horizontal
rim A
I TWW0243 I
0
TESTING AND ADJUSTING STANDARD VALUE TABLE FOR ELECTRICAL PARTS
T
Systen n
Name of
comioonent T
(Zonnector
No.
Judgement table
Measurement
conditions
Normal ranges are as follows. I) Turn starting
switch OFF.
2) Insert T-
SW power
supply
-1 20_30”
adapter.
3) Turn starting
switch ON.
C3A
Normal ranges are as follows. I) Turn starting
switch OFF.
Kickdown 2) Insert T-
switch adapter.
3) Turn starting
switch ON.
C3B
Normal ranges are as follows. II Turn starting
switch OFF.
Joystick 2) Insert T-
FNR button adapter.
switch “N” 3) Turn starting
switch ON.
Syste:m
T Name of
comDonent
Connect0
No.
Judgement table
Measurement
conditions
c5
Normal ranges are as follows. 1) Turn starting
switch OFF.
Joystick 2) Insert T-
shift-down adapter.
switch (N.0 3) Turn starting
switch ON.
0
TESTING AND ADJUSTING STANDARD VALUE TABLE FOR ELECTRICAL PARTS
7
Syste!m
Name of
comeonent
I Connectc
No.
iOll
Od
Judgement
Measure in AC range.
table
Measurement
conditions
1) Turn starting
Engine :, switch OFF.
rotation 1 Between (1) - (9) Min. 0.5 V 2) Insert T-
sensor j adapter.
3) Start engine
WA 1200-3 20-11
0
TESTING AND ADJUSTING STANDARD VALUE TABLE FOR ELECTRICAL PARTS
0
TESTING AND ADJUSTING STANDARD VALUE TABLE FOR ELECTRICAL PARTS
T
Systern
Name of
comDonent
-I-
T
(Ionnectoi
No.
Judgement table
Measurement
conditions
Normal ranges are as follows. 1) Turn starting
switch OFF.
I Work equipment I I I 2) Insert T-
adapter.
PPC pres-
3) Start engine
sure switch
&:)r
* Operate lever just a little (to degree that
work equipment does not move) (for only
detection PPC pressure signal).
I-
Systern
Name of
lmponent T
Connector
No.
Xl
d
Judgement table
Measurement
conditions
Normal ranges are as follows. 1) Turn starting
switch OFF.
2) Insert T-
RPM set
adapter.
IDLE-DOWN
3) Turn starting
signal
switch ON.
M02A
Normal ranges are as follows. 1) Turn starting
switch OFF.
Between M02A(lO) - M02A(9) 14.75 - 5.25 V 2) Insert T-
Between M02Al19) - M02A(9) 1 0.5 - 4.75 V adapter.
3) Turn starting
switch ON.
I
Syste m
Name of
comoonent
Connector
No.
Judgement table Measurement
conditions
Normal ranges are as follows. 1) Turn starting
switch OFF.
Between M02A(lO) - M02A(9) 2) insert T-
adapter.
Between M02BHO) - M02A(9)
3) Turn starting
switch ON.
-
Name of Conner% ion Measurement
Judgement table
comoonent No. od conditions
Normal ranges are as follows. 1) Turn starting
RPM set switch OFF.
:,
)
ON/OFF 2) insert T-
3 adapter.
switch 5
indicator . 3) Turn starting
switch ON.
MO1
Normal ranges are as follows. 1) Turn starting
Travel switch OFF.
speed 2) Insert T-
switch adapter.
indicator 3) Start engine.
T
Syste m
Name of
)mponent -TConnector
NO.
m
d
Judgement table
0
TESTING AND ADJUSTING STANDARD VALUE TABLE FOR ELECTRICAL PARTS
T
System
m
Name of
‘mponent T
(Zonnector
No.
Judgement table
Measurement
conditions
Normal ranges are as follows. 1) Turn starting
switch OFF.
When boom angle 2) Insert T-
Boom angle is UPPER. 4.33 ?:0.33 V
Between adapter.
sensor When boom angle (19) - (9) o 66 + o 33 V 3) Start engine.
is LOWER.
L27
Normal ranges are as follows. 1) Turn starting
switch OFF.
Steering 2) Insert T-
lever angle adapter.
sensor 3) Start engine.
Boom angle
F04
sensor
Normal ranges are as follows. 1) Turn starting
switch OFF.
Between (1) - (2) o-5kQ 2) Disconnect
connector.
Between (3) - (2) 4-5kQ 3) Connect T-
adapter.
Frame angle
L30
sensor 1) Turn starting
Normal ranges are as follows.
switch OFF.
1 Between (1) - (2) I o-5kQ 2) Disconnect
connector.
Between (3) - (2) 3) Connect T-
adapter.
0
TESTING AND ADJUSTING STANDARD VALUE TABLE FOR ELECTRICAL PARTS
l-
Systern
Name of
comcronent T
IZonnector
No.
Judgement table
Measurement
conditions
Normal ranges are as follows. I) Turn starting
Flashing switch OFF.
synchroniz- Whenflashingsynchro- 2) Insert T-
ing signal nizingsignalis ON Between Max. 1 V
(13) - adapter.
(For main Whenflashingsynchro- 3) Turn starting
monitor) chassis 20 - 30 v
nizingsignalis OFF switch ON.
T
Syster n
-
Name of
lmponent T
(lonnector
No.
Judgement table
Measurement
conditions
Normal ranges are as follows. 1) Turn starting
switch OFF.
Hydraulic oi 1oo”c 2) Disconnect
temperature connector.
25°C 3. Insert T-
adapter.
Systenn
T Name
co mponent
of
Tc lonnector
No.
Kp.40
nethoc
Judgement table
Measurement
conditions
WA1 200-3
TESTING AND ADJUSTING STANDARD VALUE TABLE FOR ELECTRICAL PARTS
I I , 1
WA1200-3 20-101
20-101
1
(8)
TESTING AND ADJUSTING ITEMS TO BE PREPARED
ITEMS TO BE PREPARED
LIST OF DEVICES FOR TROUBLESHOOTING
inspection/Adjustment item Symbol Part No. Part Name Remarks
799-101-5002 Hydraulic tester Pressure gauge: 2.5, 5.9, 39.2, 58.8 MPa
1 {25,60, 400, 600 kg/cm21
Oil pressure C
790-261-I 203 Digital hydraulic tester Pressure gauge: 68.6 MPa 1700kg/cm21
2 799-401-2320 Hydraulic gauge 1.0 MPa {lo kg/cm21
799-601-7500 AMP070connectoradapterassembly
0
TESTING AND ADJUSTING ITEMS TO BE PREPARED
Contact size #8
• 799-601-7740
(Used for both DT Series and HD31 Series)
Contact size #4
• 799-601-7750
(Used for both DT Series and HD31 Series)
WA1200-3 20-102-1
(8)
TESTING AND ADJUSTING ITEMS RELATED TO ENGINE
WA1200-3 20-103
20-103
1
(8)
TESTING AND ADJUSTING ITEMS RELATED TO ENGINE
L 9JFOO366
9JFOO386
MEASURING BLOW-BY
PRESSURE
fl Before measuring the blow-by pressure, increase
the coolant temperature to the operating range.
• Check the coolant temperature on the PM-
Clinic screen (1/4).
WA1200-3 20-107
20-107
1
(8)
TESTING AND ADJUSTING ITEMS RELATED TO ENGINE
20-108
20-108 WA1200-3
1
(8)
TESTING AND ADJUSTING ITEMS RELATED TO ENGINE
MEASURING EXHAUST
TEMPERATURE
fl Before measuring the exhaust temperature, in-
crease the coolant temperature to the operating
range.
• Check the coolant temperature on the PM-
Clinic screen (1/4).
Measuring
1. When measuring maximum value for trouble-
shooting
Operate the machine actually and measure the
maximum exhaust temperature.
(Note)
The exhaust temperature largely depends on
the outside air temperature (intake air tem-
perature of the engine). Accordingly, if any
abnormal value is obtained, correct it by the
following calculation.
fl Corrected value = Measured value + 2 x (Con-
verted outside air temperature – Outside air
temperature)
fl Set the converted outside air temperature to
20°C.
2. When measuring periodically for preventive and
safety service
1) Stall the torque converter fully (Relieve the
torque converter and work equipment pump)
and raise the exhaust temperature
(Approx. 700°C: Standard value)
2) Stop relieving the hydraulic circuit and keep
stalling the torque converter. (At this time,
the temperature starts lowering. If the tem-
perature does not lower but rises, increases
the temperature at (1) in the figure at right.)
3) After the temperature lowers and is stabi-
lized, measure it.
fl If only the torque converter is stalled, it
will be overheated before the exhaust
temperature is stabilized.
WA1200-3 20-109
20-109
1
(8)
TESTING AND ADJUSTING ITEMS RELATED TO ENGINE
MEASURING BOOST
PRESSURE
fl Before measuring the boost pressure, increase
the coolant temperature to the operating range.
• Check the coolant temperature on the PM-
Clinic screen (1/4).
20-110
20-110 WA1200-3
1
(8)
TESTING AND ADJUSTING ITEMS RELATED TO ENGINE
Adjusting
Adjusting 9JFOO391
I
1. Loosen mounting bolts and nuts (31, (41, and (51,
and locknut (6).
ADJUSTING ROTATION
SENSOR
Engine rotation sensor
I 9JFOO444
WA1 200-3
TESTING AND ADJUSTING ITEMS RELATED TO ENGINE
9JFOO446
POWER TRAIN
TESTING AND ADJUSTING
TORQUE CONVERTER AND
TRANSMISSION OIL
PRESSURE
Measuring
20-114
20-114 WA1200-3
1
(8)
TESTING AND ADJUSTING POWER TRAIN
Adjusting
9JFOO458
TWW02613
TWW02614
I i9 17
TWW02615
WA1 200-3
TESTING AND ADJUSTING POWER TRAIN
STEERING SYSTEM
TESTING AND ADJUSTING
STEERING OIL PRESSURE
Measuring
Adjusting
20-120
20-120 WA1200-3
1
(8)
TESTING AND ADJUSTING STEERING SYSTEM
Measuring
WA1 200-3
TESTING AND ADJUSTING STEERING SYSTEM
Adjusting
TKWOllt8
WeI
ADJUSTING STEERING
STOPPER BOLT
1. Running the engine at low speed, steer the ma-
chine and measure clearance a between frame
end stopper (2) of front frame (I 1 and rear frame
(3). If clearance a is out of the standard range,
adjust it according to the following procedure.
* Clearance a: 37 - 40 mm
1) Loosen locknut (4) and adjust clearance a to
the standard range with steering angle ad-
justment bolt (5).
ARun the engine at low speed and oper- 9JFOO397
ate the joystick steering lever slowly.
ATake care not to catch your body, arm,
etc. between the front frame and rear
frame. I I\
9JFOO399
BRAKE SYSTEM
TESTING DROP OF WHEEL ? I!
BRAKE OIL PRESSURE
A the
Put blocks under the wheels
machine from moving.
securely to prevent
1. Start the engine and drive the machine with the directional lever in F (Forward) and the gear shift
lever in 3rd.
2. Keep the travel speed at 20 km/h, then press the brake pedal with the specified force.
* Set the run-up path and the point to start measurement in advance. Keep the travel speed at 20
km/h on the run-up path and press the brake pedal when the machine passes the point to start
measurement.
* Perform this test with the transmission cut-off switch turned ON.
3. Measure the distance between the point to start measurement and the stopping point of the
machine.
Ir Perform the above measurement 3 times, then obtain the average.
+ --
Stoooino Point Point where braking Point where operator Put
effect started foot on brake Pedal
looeration Point1
I
TWW02433
WA1200-3 20-127
20-127
1
(8)
TESTING AND ADJUSTING BRAKE SYSTEM
Adjusting
Charge cut-out and cut-in pressure of accumulator
fl If the charge cut-out pressure of the accumula-
tor is adjusted, the valve area ratio cut-in pres-
sure is changed. Accordingly, a cut-in pressure
adjustment screw is not installed.
20-128
20-128 WA1200-3
1
(8)
TESTING AND ADJUSTING BRAKE SYSTEM
TWW02435
A ure
Manual resetting of the parking brake is a meas-
to move the machine from a dangerous work
site to a safety place. Use this method only in
an emergency
A Lower the work equipment to the ground and
put blocks under the wheels to prevent the ma-
chine from moving.
A When resetting the parking brake, stop the en-
gine.
A-A 9JFOO413
HYDRAULIC EQUIPMENT
TESTING AND ADJUSTING
WORK EQUIPMENT OIL
PRESSURE
• Hydraulic oil temperature: 45 – 55°C
Measuring
WA1200-3 20-133
20-133
1
(8)
TESTING AND ADJUSTING HYDRAULIC EQUIPMENT
Adjusting
3 4
9JFOO417
Measuring
WA1200-3 20-135
20-135
1
(8)
TESTING AND ADJUSTING HYDRAULIC EQUIPMENT
Adjusting
20-136
20-136 WA1200-3
1
(8)
TESTING AND ADJUSTING HYDRAULIC EQUIPMENT
9. Oil flows out of plugs (I), (21, (31, (41, and hose
(5) in order. After the all air is bled, tighten the
plugs and hose adapter.
-
9JFOO426
RELEASING RESIDUAL
PRESSURE FROM HYDRAULIC
CIRCUIT
Releasing residual pressure from piping
between a hydraulic cylinder and control
valve
A
f
When adjusting, stop the engine.
Check that the operating effort of the work equip-
ment control lever is in the standard range.
48 lr)l 9JFOO428
I 9JFOO429
WA1 200-3
20-141
0
TESTING AND ADJUSTING WORK EQUIPMENT SYSTEM
of 12 mm.
-
5. Move boom kick-out solenoid (9) so that clear-
ance d between boom lever cam (3) and cam
I
follower (2) will be 0 - 0.5 mm when the sole-
noid is in the pull state. 3 7
* When adjusting, keep the boom lever in neu- 00
tral. go 0
+
6. Move bucket positioner solenoid (IO) so that 2 e
d 6
clearance e between bucket lever cam (7) and
q %
cam follower (6) will be 0 - 0.5 mm when the
solenoid is in the pull state.
9JFOO431
7. If the boom lever canceling force and the bucket
lever canceling force are not 19.6 N (2 kg) and
9.8 N (1 kg) respectively, adjust them by chang-
ing installing holes d (at 4 places) of spring (13).
Ir When the machine is shipped, the spring is
installed to the second installing hole from
the top.
I 9JFOO437
0
TESTING AND ADJUSTING ELECTRICAL EQUIPMENT
ELECTRICAL EQUIPMENT
TESTING AND ADJUSTING
BUCKET PROXIMITY SWITCH
Testing
Adjusting
WA1200-3 20-143
20-143
1
6
TESTING AND ADJUSTING ELECTRICAL EQUIPMENT
20-144
20-144 WA1200-3
1
6
TESTING AND ADJUSTING ELECTRICAL EQUIPMENT
WA1200-3 20-144-1
6
TESTING AND ADJUSTING ELECTRICAL EQUIPMENT
20-144-2 WA1200-3
(8)
TESTING AND ADJUSTING ELECTRICAL EQUIPMENT
CHECKING PROXIMITY
SWITCH ACTUATION PILOT
LAMP
Proximitv switch actuation Dilot IamD (Red1
fctuation Pilot lamp
. nn I
The proximity switch has a pilot lamp to indi-
cate its operating condition. Use it for adjust-
ment.
Proximity switch
actuation Lights UP Goes out
Pilot lamp
~--r--L_ I
__-_____-
_-______j j j
.-_-___A j II
j
Bucket I I +__-._-__-
positioner l-l_-__
Proximity switch
\ \
Reading of
load-meter
Detector
TWW02436
1
Adjusting procedure
TWW01722
. Turn off the power and remove the main moni-
tor, then adjust the adjustment section of the
rear side of the speedometer.
DIP SW 1.2.3
DIP SW 4
ON
piigq OFF
- -
Switch posisiton
TWW02437
9JFOO398
4. Slide the armrest to the auxiliary position (the
backmost position).
* If the armrest is set to this position, the con-
sole switch is turned “ON”.
9JFOO438
9JFOO439
1. Put the red (+) end of the test pin in contact with
the anode (PI of the diode, and the black (-1 end
in contact with the cathode (N).
* There is a mark showing the direction of TLPO0663
continuity on the surface of the diode.
l---z--
Diode included in wiring harness
range, the voltage of the internal battery is
displayed.
The value indicates the following.
. No change: No continuity
l Changes: There is continuity (normal)
(Note)
l Value is 0 or near 0: Short circuit inside
diode
BLPO1357
METHOD OF ADJUSTING
AUTO-GREASE INJECTOR
DISCHARGE AMOUNT
1. The injector is actuated by pressure from the
pump and sends the set amount of grease to
the bearing.
Screwed in clockwise to
0.3 cc (minimum)
contact stopper
METHOD OF SETTING
AUTO-GREASE TIMER
. The timer is installed to control the greasing
interval for the auto-greasing system.
. The timer is installed in box @ at the rear of the
operator’s seat.
. The timer can be adjusted to the desired greas-
ing interval according to the following table by
turning the blue dial.
Note that there is a tolerance of approx. +15%.
(Both the operation and rest periods)
AW43740B
WA1 200-3
TESTING AND ADJUSTING GREASING SYSTEM
Position of switch 1 2 3 4 5 6 7 8 9
Greasing interval (min) 3.75 7.5 11.25 15 18.75 22.5 28.25 30 33.75
Position of switch A B C D E F
AW437415
Position of switch 1 2 3 4 5 6 7 8 9
Position of switch A B C D E F
VHMS CONTROLLER
For the system to provide the above func-
BASIC PRECAUTIONS tions, it is necessary to have a power
supply that is connected directly to the
1. Handling machine, safety, inspection and battery and always supplies electricity
maintenance (permanent power source) in addition to
For details of safety items, operation, inspec- the power source (switch power source)
tion, and maintenance of the machine, see that is cut when the starting switch is
the Operation and Maintenance Manual for turned OFF or the engine is stopped.
the machine. Because this switch power source and
permanent power source are provided,
2. Handling monitoring system the period needed for collecting data is
Always obey the following precautions when clearly known and it becomes possible
handling the monitoring system. to store this data in the internal memory.
1) When disassembling, repairing, or modi- In other words, the VHMS uses the per-
fying the machine or system, follow the manent power source to save to memory
instructions in the manual. the data accumulated from the moment
2) Do not touch the system (equipment) the starting switch is turned ON to the
when operating the machine. moment the starting switch is turned
3) Do not damage or get the wiring har- OFF. Then the VHMS controller itself
nesses, connectors, or sensors of the turns off the permanent power source.
system (equipment) caught or pulled by 2) Precautions when turning the permanent
force. This may cause short circuits or power source OFF
disconnections that will lead to failure When the starting switch is turned OFF,
or fire on the machine or system (equip- the power supply is maintained for at
ment). least 3 minutes (the VHMS system shut-
4) Do not get water, dirt, or oil on the sys- down time: the time taken for the VHMS
tem (equipment) system to save the data to memory and
switch off), and then the permanent
3. Permanent power source for VHMS (battery power source is turned OFF.
direct power source) If the VHMS system shut-down time is
1) Meaning and need of permanent power shorter than 3 minutes, the accumulated
source data may be damaged.
The VHMS has the function of checking a. When removing VHMS from perma-
and collecting data on the condition of nent power source
the machine from the moment the start- When removing the VHMS from the
ing switch is turned ON to the moment permanent power source (for ex-
the starting switch is turned OFF. There- ample, when carrying out repairs),
fore, its power supply is different from check that the monitor display (7-seg-
many of the electronic equipment and ment LED in the diagram below) of
electrical parts. the VHMS controller is out.
WA1200-3 20-153
(8)
TESTING AND ADJUSTING VHMS CONTROLLER
20-154 WA1200-3
(8)
TESTING AND ADJUSTING VHMS CONTROLLER
WA1200-3 20-155
(8)
TESTING AND ADJUSTING VHMS CONTROLLER
SETTING UP VHMS
CONTROLLER • The setup operation is carried out
by trained personnel under the
1. Setting up VHMS controller guidance of the person respon-
• In the following cases, always carry out sible at your company.
the setup. • Or contact Komatsu
1) When making the initial installation
of the VHMS system 2. Setting items
2) When replacing or overhauling the • VHMS: For details of the setup method,
following components see the instruction manual for the tech-
• VHMS controller nical analysis tool box (for service).
• Engine 1) Calendar (date, time, time difference
• Transmission from GMT, summer time (daylight
3) When the ORBCOMM communica- saving time))
tion system (optional) is installed 2) Machine model, Serial No., variation
• When carrying out the setup, the follow- code
ing are needed 3) Engine model, Serial No.
1) PC (personal computer) 4) Transmission serial No.
2) VHMS analysis tool (software) 5) Setting of integration of load meter
(799-608-3211) • Starting ORBCOMM station
3) Download cable (799-608-3220) 1) Communication method (Stop/Start,
• For details of the setup method, Interval, Transmission time)
see the instruction manual for the 2) Country code of communication con-
technical analysis tool box (for troller (GCC)
service)
Turn starting switch ON (starting switch Check that no error is generated by the VHMS controller or
ON) other controller
1 • Check for generation of errors If there is any error, repair or correct to return condition to
• Start setup tool normal
20-156 WA1200-3
(8)
TESTING AND ADJUSTING VHMS CONTROLLER
Start
Display Display
VHMS controller starts up, LEDs flash
Engine, transmission controllers show
(see diagram below) and aggregate
Normal past errors, then give [00] display (no Normal
numerals are displayed in order (no
error exists)
error exists)
No display No display
Turn starting switch [OFF], then check connection of wiring harnesses again
Display Display
VHMS controller starts up, LEDs flash
Engine, transmission controllers show
(see diagram below) and aggregate
Normal past errors, then give [00] display (no Normal
numerals are displayed in order (no
error exists)
error exists)
No display No display
5. Collection of data
fl If there is no abnormality in the system, the machine will operate and the operation data for
the machine will automatically be saved by the VHMS controller.
WA1200-3 20-157
(8)
TESTING AND ADJUSTING VHMS CONTROLLER
Turn starting switch ON (starting switch Check that no error is generated by the VHMS controller or
ON) other controller
1 • Check for generation of errors If there is any error, repair or correct to return condition to
• Start setup tool normal
• Saving settings
3 Starting switch OFF (Key switch OFF) • Setup completion report
3. Executing quick PM
fl See TESTING AND ADJUSTING, Executing PM Clinic with manual snap shot.
• Before downloading data to the PC, execute the quick PM (equivalent to PM clinic) to collect
the data under the normal operating condition and those under the conditions of stall of the
torque converter, high idling operation, etc.
20-158 WA1200-3
(8)
TESTING AND ADJUSTING VHMS CONTROLLER
WA1200-3 20-159
(8)
TESTING AND ADJUSTING VHMS CONTROLLER
20-160 WA1200-3
(8)
TESTING AND ADJUSTING VHMS CONTROLLER
1 Lowering of engine oil pressure C143 21 High exhaust temperature (L #7) C647
2 Rise of engine coolant temperature C151 22 High exhaust temperature (L #8) C648
3 Rise of intake air temperature at left front C155 23 High exhaust temperature (R #1) C651
4 Rise of intake air temperature at left rear C158 24 High exhaust temperature (R #2) C652
5 Rise of intake air temperature at right front C162 25 High exhaust temperature (R #3) C653
6 Rise of intake air temperature at right rear C165 26 High exhaust temperature (R #4) C654
7 Rise of engine oil temperature C214 27 High exhaust temperature (R #5) C655
8 Lowering of engine coolant pressure C233 28 High exhaust temperature (R #6) C656
10 Lowering of engine coolant level C235 30 High exhaust temperature (R #8) C658
11 Lowering of engine oil level C253 31 Sharp rise of left front inlet temperature C783
12 Abnormal rise of fuel temperature C261 32 Sharp rise of left rear inlet temperature C2157
13 Excessive lowering of engine oil level C471 33 Sharp rise of right front inlet temperature C2158
14 High blow-by pressure C555 34 Sharp rise of right rear inlet temperature C2159
15 High exhaust temperature (L #1) C641 35 High torque converter oil temperature B@CENS
16 High exhaust temperature (L #2) C642 36 High hydraulic oil temperature B@HANS
19 High exhaust temperature (L #5) C645 39 Lowering of left brake charge pressure 2G42ZG
20 High exhaust temperature (L #6) C646 40 Lowering of right brake charge pressurea 2G43ZG
WA1200-3 20-161
(8)
TESTING AND ADJUSTING VHMS CONTROLLER
20-162 WA1200-3
(8)
TESTING AND ADJUSTING VHMS CONTROLLER
2. Testing items
fl Test and check each item. If it is abnor-
mal, take a proper remedy.
1) At check before starting (Ask the cus-
tomer to perform the following check)
i) Check that the sensors are installed
normally. (Check the fitting parts for
looseness, damage, and dirt.)
ii) Check the wiring harnesses, cables,
and connectors for disconnection and
damage.
iii) Check the sensor fitting parts for oil
leakage and gas leakage.
2) At 1000-hour maintenance
i) Communication antenna (if installed)
• Check the antenna fitting parts
for looseness and play.
• Check the antenna for flaw, loose-
ness, and play.
• If the antenna is abnormal, re-
place it.
3) At irregular maintenance
i) If a downloaded value is abnormal,
check each sensor.
3. Remedy
If any part is abnormal, repair, replace, or
re-install (retighten) it.
WA1200-3 20-163
(8)
TESTING AND ADJUSTING VHMS CONTROLLER
20-164 WA1200-3
(8)
TESTING AND ADJUSTING VHMS CONTROLLER
WA1200-3 20-165
(8)
TESTING AND ADJUSTING VHMS CONTROLLER
20-166 WA1200-3
(8)
TESTING AND ADJUSTING VHMS CONTROLLER
WA1200-3 20-167
(8)
TESTING AND ADJUSTING VHMS CONTROLLER
6) If the information in the [SMR] box is 8) After checking and changing all the data
not correct, change it according to the of [Machine information], press [Exit]
following procedure: button (4) to finish [VHMS Setting Tool].
i) Press the [Alt] and [S] buttons to dis-
play the correction screen. (Press 7. Check of saving operation of VHMS control-
both keys simultaneously.) ler
ii) Input the correct information directly 1) Set the starting switch in the ON posi-
and press the [OK] button. (You can tion.
input the value to the 1st decimal 2) Check the 7-segment LED of the VHMS
place.) controller and confirm that the control-
iii) The confirmation screen appears ler is turned OFF.
again. Press the [Y] button. fl When the starting switch is turned
OFF, the VHMS controller records
and updates the data.
fl The power is still held for several
seconds to save the data after the
starting switch is turned OFF. Accord-
ingly, check that the 7-segment LED
of the controller is turned OFF.
20-168 WA1200-3
(8)
TESTING AND ADJUSTING VHMS CONTROLLER
WA1200-3 20-169
(8)
TESTING AND ADJUSTING VHMS CONTROLLER
20-170 WA1200-3
(8)
TESTING AND ADJUSTING VHMS CONTROLLER
WA1200-3 20-171
(8)
TESTING AND ADJUSTING VHMS CONTROLLER
iii) Press the [Apply] button. 12. Check of saving operation of VHMS control-
• Only the changed data are dis- ler
played. Check them and press 1) Set the starting switch in the ON posi-
[OK] button (9). tion.
2) Check the 7-segment LED of the VHMS
controller and confirm that the control-
ler is turned OFF.
fl When the starting switch is turned
OFF, the VHMS controller records
and updates the data.
fl The power is still held for several
seconds to save the data after the
starting switch is turned OFF. Accord-
ingly, check that the 7-segment LED
of the controller is turned OFF.
20-172 WA1200-3
(8)
TESTING AND ADJUSTING VHMS CONTROLLER
13. Procedures for executing Quick Pm 6) Operate the switches and levers at each
1) Run the engine at low idling. execution time according to the “Oper-
2) Set the safety lock lever in the FREE po- ating procedure for quick PM clinic”
sition. shown on the following parts.
3) Set the machine control monitor (CGC) fl The execution times are displayed on
to display the service menu selection the machine control monitor (CGC).
screen. ¤ Since the work equipment and ma-
fl See “Functions and operations of chine are operated actually during
machine control monitor (CGC)”. the quick PM clinic, take care of the
4) Select [Snap shot]. safety around the vehicle extremely
during the work.
WA1200-3 20-173
(8)
TESTING AND ADJUSTING VHMS CONTROLLER
(*1)Before measuring the brake accumulator cut-in and cut-out oil pressures while the engine is
running at low idling, press the brake pedal at least 10 times to lower the brake accumulator
circuit pressure to below the cut-in pressure.
¤ The error of the operating condition changing time must be ±5 seconds.
1/4 fl Value: Page No. of PM clinic on CGC
fl: When a personal computer is not used, read each value.
20-174 WA1200-3
(8)
TESTING AND ADJUSTING VHMS CONTROLLER
WA1200-3 20-175
(8)
TESTING AND ADJUSTING VHMS CONTROLLER
20-176 WA1200-3
(8)
TESTING AND ADJUSTING VHMS CONTROLLER
Model name
Serial No.
Check of machine information, Current service meter reading (by 0.1 h)
1 engine information, and Engine serial No.
controller information
Transmission serial No.
VHMS controller serial No.
ORBCOMM controller serial No.
5 Starting of VHMS setting tool Is setting tool set in “Data clear and set up”? yes no
Check of saving operation of Were Apply button and Exit button pressed in order? yes no
7 VHMS controller Turn starting switch OFF → Wait for 3 min → Turn starting switch ON yes no
9 Starting of VHMS setting tool Is setting tool set in [Set up]? yes no
Check of saving operation of Were Apply button and Exit button pressed in order? yes no
12
VHMS controller Turn starting switch OFF → Wait for 3 min → Turn starting switch ON yes no
13 Execution of quick Pm clinic Was snap shot operated according to correct procedure? yes no
WA1200-3 20-177
(8)
TESTING AND ADJUSTING VHMS CONTROLLER
20-178 WA1200-3
(8)
TESTING AND ADJUSTING VHMS CONTROLLER
WA1200-3 20-179
(8)
TESTING AND ADJUSTING VHMS CONTROLLER
20-180 WA1200-3
(8)
TESTING AND ADJUSTING VHMS CONTROLLER
WA1200-3 20-181
(8)
TESTING AND ADJUSTING VHMS CONTROLLER
20-182 WA1200-3
(8)
TESTING AND ADJUSTING VHMS CONTROLLER
WA1200-3 20-183
(8)
TESTING AND ADJUSTING VHMS CONTROLLER
6) After checking and changing all the data 10. Check of saving operation of VHMS control-
in [Machine Information], press [Apply] ler
button to settle the setting. • Turn the starting switch OFF and wait
fl If the [Apply] button is pressed, the for 3 minutes, and then turn the starting
screen for checking the setting ap- switch ON again.
pears. Check the setting again and
press the [OK] button when the set- 11. Startup of VHMS setting tool
ting is correct. 1) Click the icon of [Setting Tool] on the
personal computer screen to start the
VHMS setting tool.
2) Input the 10-digit service ID to [Service
ID].
fl Service ID: Part No. of VHMS con-
troller
• Input 0 to the position at the right
end.
3) Select [Set up] in the [Select Function]
box.
4) Press the [OK] button to go to the set-
ting screen.
20-184 WA1200-3
(8)
TESTING AND ADJUSTING VHMS CONTROLLER
WA1200-3 20-185
(8)
TESTING AND ADJUSTING VHMS CONTROLLER
4) To change setting of [SHORT TREND 14. Check of saving operation of VHMS control-
ANALYSIS], follow the procedures be- ler
low. 1) Set the starting switch in the ON posi-
i) Select [SHORT TREND ANALYSIS] on tion.
the screen and press the [Edit] but- 2) Check the 7-segment LED of the VHMS
ton at the left lower part of the [File controller and confirm that the control-
Transfer Setting] block to display the ler is turned OFF.
setting screen. fl When the starting switch is turned
ii) Change the current setting to the set- OFF, the VHMS controller records
ting recorded before the replacement and updates the data.
and then press the [OK] button. fl The power is still held for several
seconds to save the data after the
starting switch is turned OFF. Accord-
ingly, check that the 7-segment LED
of the controller is turned OFF.
20-186 WA1200-3
(8)
TESTING AND ADJUSTING VHMS CONTROLLER
16. Procedures for executing Quick PM-clinic 6) Operate the switches and levers at each
1) Run the engine at low idling. execution time according to the “Oper-
2) Set the safety lock lever in the FREE po- ating procedure for quick PM clinic”
sition. shown on the following parts.
3) Set the machine control monitor (CGC) fl The execution times are displayed on
to display the service menu selection the machine control monitor (CGC).
screen. ¤ Since the work equipment and ma-
fl See “Functions and operations of chine are operated actually during
machine control monitor (CGC)”. the quick PM clinic, take care of the
4) Select [Snap shot]. safety around the vehicle extremely
during the work.
WA1200-3 20-187
(8)
TESTING AND ADJUSTING VHMS CONTROLLER
(*1)Before measuring the brake accumulator cut-in and cut-out oil pressures while the engine is
running at low idling, press the brake pedal at least 10 times to lower the brake accumulator
circuit pressure to below the cut-in pressure.
¤ The error of the operating condition changing time must be ±5 seconds.
1/4 fl Value: Page No. of PM clinic on CGC
fl: When a personal computer is not used, read each value.
20-188 WA1200-3
(8)
TESTING AND ADJUSTING VHMS CONTROLLER
WA1200-3 20-189
(8)
TESTING AND ADJUSTING VHMS CONTROLLER
20-190 WA1200-3
(8)
TESTING AND ADJUSTING VHMS CONTROLLER
8. Start of VHMS setting tool Is setting tool set in [Set up]? yes no
9. Re-setting of VHMS controller Date/Time [Local Time] Is setting matched to record before replacement? yes no
SMR Is 0.1 h added to record before replacement for new setting? yes no
Machine Is setting matched to record before replacement? yes no
Engine Is setting matched to record before replacement? yes no
10. Writing of set data Were Apply button and Exit button pressed in order? yes no
Turn starting switch OFF → Wait for 3 min → Turn starting switch ON yes no
11. Start of VHMS setting tool Is setting tool set in [Set up]? yes no
12. Setting of PLM data Setting of PLM Is setting matched to record before replacement? yes no
13. Setting of ORBCOMM communication Short Fault History Is setting matched to record before replacement? yes no
[For only ORBCOMM specification] Short Trend Analysis Is setting matched to record before replacement? yes no
Short Load Meter Is setting matched to record before replacement? yes no
GCC Is setting matched to record before replacement? yes no
14. Check of saving operation of VHMS controller Were Apply button and Exit button pressed in order? yes no
Turn starting switch OFF → Wait for 3 min → Turn starting switch ON yes no
15. Check of operation of VHMS controller Is 7-segment LED operating normally? yes no
16. Execution of quick Pm clinic Was snap shot operated according to correct procedure? yes no
WA1200-3 20-191
(8)
TESTING AND ADJUSTING VHMS CONTROLLER
OUTLINE OF MEASUREMENT
PROCEDURE FOR PM CLINIC
There are the following 3 types of measurement
procedure for PM clinic of WA1200-3.
fl Basically, apply measurement procedure 1
or 2.
20-192 WA1200-3
(8)
TESTING AND ADJUSTING VHMS CONTROLLER
PREPARATION FOR
MEASUREMENT FOR PM
CLINIC
WA1200-3 20-193
(8)
TESTING AND ADJUSTING VHMS CONTROLLER
MEASUREMENT PROCEDURE
BY CGC MONITOR
1. Start of engine
1) Check that the CGC monitor is not display-
ing the abnormality screen.
2) Prepare the PM clinic sheet. Check safety
around the vehicle, sound the horn, and start
the engine.
3) Turn the steering lock switch in the OFF po-
sition.
4) Set the safety lock lever in the FREE posi-
tion.
20-194 WA1200-3
(8)
TESTING AND ADJUSTING VHMS CONTROLLER
WA1200-3 20-195
(8)
TESTING AND ADJUSTING VHMS CONTROLLER
MEASUREMENT PROCEDURE
BY DOWNLOADING DATA IN
VHMS CONTROLLER
1. Connection of personal computer
1) Check that the starting switch is in the OFF
position.
¤ Be sure to connect and disconnect the
personal computer while starting switch
is in the OFF position.
2) Connect personal computer Q3 and the
download connector DL1 by wiring harness
Q2.
fl Connect the personal computer to the
RS232C terminal.
2. Start of engine
1) Check that the CGC monitor is not display-
ing the abnormality screen.
2) Prepare the PM clinic sheet. Check safety
around the vehicle, sound the horn, and start
the engine.
3) Turn the steering lock switch in the OFF po-
sition.
4) Set the safety lock lever in the FREE posi-
tion.
20-196 WA1200-3
(8)
TESTING AND ADJUSTING VHMS CONTROLLER
WA1200-3 20-197
(8)
TESTING AND ADJUSTING VHMS CONTROLLER
(*1)Before measuring the brake accumulator cut-in and cut-out oil pressures while the engine is
running at low idling, press the brake pedal at least 10 times to lower the brake accumulator
circuit pressure to below the cut-in pressure.
¤ The error of the operating condition changing time must be ±5 seconds.
1/4 fl Value: Page No. of PM clinic on CGC
fl: When a personal computer is not used, read each value.
20-198 WA1200-3
(8)
TESTING AND ADJUSTING VHMS CONTROLLER
WA1200-3 20-199
(8)
Pm clinic check sheet WA1200-3
Basic information
User name Address Date of delivery
Year: Month: Day:
Specifications
Tire, front/rear Bucket
55.5/80-57-68PR(L5) m3 (cu.yd)
65 /65-57-62PR(L5) 20.9 (25.9)
Type of work
Quarry, mining Construction
Coal Construction, civil engineering
Gold Road
Limestone Others
Others
Type of soil
Specific gravity t/m3
Rock
Soft Gravel
Ordinary Sand
Hard Clay
Coal
Contents of work
V-shape loading Remarks
Cross drive loading
Load and carry
hours
Distributor/Dealer name
20-199-1 WA1200-3
(8)
Pm clinic service WA1200-3 Chassis serial No.
Max. level of coolant temperature Max. torque converter oil temperature Ambient temperature
Blue Red Blue Red Max. °C
1 2 3 4 5 6 7 8 9 1 2 3 4 5 6 7 8 9 Min. °C
1/2
WA1200-3 20-199-2
(8)
Pm clinic service
Standard value Service
Item Condition Unit Measurement result Accepted Rejected
of new machine limit value
4 4 Steering relief Engine: Full throttle MPa 31.07 – 32.34 30.09 – 32.34
pressure Oil temperature: 45 – 55°C {kg/cm2} {317 – 330} {377 – 330}
T/C
5 5–1
Parking brake Flat ground, F3, engine at full throttle Vehicle is stopped
Brake
Set lift arm and bucket in measuring positions and stop engine.
Hydraulic Lift arm and Bucket hinge pin mm Max. 250 Max. 250
drift bucket: Horizontal Bucket edge /15min Max. 100 Max. 100
Memo: Enter phenomena and information you noticed during today’s check.
2/2
20-199-3 WA1200-3
(8)
TESTING AND ADJUSTING METHOD OF DISPLAYING REMEDY CODES AND ERROR CODES
METHOD OF DISPLAYING
REMEDY CODES AND ERROR
CODES
1. Display on CGC monitor
1) Outline
The VHMS controller sends various types of in-
formation via CAN (network) to the CGC moni-
tor. The “Failure history” in that information can
be displayed on the service menu selection
screen.
WA1200-3 20-199-4
(8)
TESTING AND ADJUSTING METHOD OF DISPLAYING REMEDY CODES AND ERROR CODES
20-199-5 WA1200-3
(8)
TESTING AND ADJUSTING METHOD OF DISPLAYING REMEDY CODES AND ERROR CODES
Display of failure
history mode
i) Stop the engine. • The error code and
ii) Turn the starting remedy code are dis-
switch ON. played in the speed-
iii) Hold switch (1) ometer display sec-
(the 2nd switch tion and the elapsed
from the top on time after failure is
the left side) and displayed in the rem-
headlamp switch edy code section.
(2) for 5 seconds. • If there is not a fail-
ure, “CC” is dis-
played in the speed-
ometer display sec-
tion and “0000” is
displayed in the rem-
edy code display
section.
WA1200-3 20-199-6
(8)
TESTING AND ADJUSTING METHOD OF DISPLAYING REMEDY CODES AND ERROR CODES
20-199-7 WA1200-3
(8)
TESTING AND ADJUSTING METHOD OF DISPLAYING REMEDY CODES AND ERROR CODES
WA1200-3 20-199-8
(8)
TESTING AND ADJUSTING METHOD OF DISPLAYING REMEDY CODES AND ERROR CODES
1 Engine oil level Below low level H: Abnormal fi ––– 2 When condition at left is not satisfied
L: Abnormal
2 Engine oil Below specified See CUMMINS Maintenance Manual. ––– fi 2 When condition at left is not satisfied
pressure pressure
3 Engine coolant Above 105°C Above 105°C fi fi 10 When condition at left is not satisfied
temperature
5
Fuel level
Below specified level Below 1 segment of gauge (11%) fi ––– 10 When condition at left is not satisfied
6 Below specified level Below 1 segment of gauge (11%) ––– fi 10 When condition at left is not satisfied
Temperature is above 120°C but alarm
7 Torque converter Above 120°C for above 130°C is not detected. fi fi 2 When condition at left is not satisfied
8 oil temperature Above 130°C Above 130°C fi fi 2 When condition at left is not satisfied
9 Hydraulic oil Above 105°C Above 105°C fi fi 10 When condition at left is not satisfied
temperature
10 Brake oil Below 150 kg/cm2 ––– fi ––– When condition at left is not satisfied
pressure (F) For 60 sec after engine is started.
Below 150 kg/cm2
11 (Cut-in/Cut-out Below 150 kg/cm2 ––– fi 5 When condition at left is not satisfied
pressure) At 60 sec after engine is started.
13 Brake oil Below 150 kg/cm2 ––– fi ––– When condition at left is not satisfied
pressure (R) For 60 sec after engine is started.
Below 150 kg/cm2
14 (Cut-in/Cut-out Below 150 kg/cm2 ––– fi 5 When condition at left is not satisfied
pressure) At 60 sec after engine is started.
16 Battery fluid level (1) Below low level OPEN (When fluid level is insufficient)
= 6-V cell is below 2 V
17 Battery fluid level (2) Below low level OPEN (When fluid level is insufficient) fi fi 10 When condition at left is not satisfied
= 6-V cell is below 2 V
18 Battery fluid level (3) Below low level OPEN (When fluid level is insufficient)
= 6-V cell is below 2 V
19 Below specified level OPEN = 24 V (When oil level is insufficient) fi ––– 10 When condition at left is not satisfied
Brake oil level
20 Below specified level OPEN = 24 V (When oil level is insufficient) ––– fi 10 When condition at left is not satisfied
21 Below low level OPEN = 24 V (When coolant level is insufficient) fi ––– 2 When condition at left is not satisfied
Coolant level
22 Below low level OPEN = 24 V (When coolant level is insufficient) ––– fi 30 When condition at left is not satisfied
23 Transmission filter Above specified OPEN = 24 V (When clogged) and torque ––– fi 2 When condition at left is not satisfied
differential pressure pressure converter oil temperature is above 50°C
24 Clogging of air Above specified OPEN = 24 V (When clogged) ––– fi 2 When condition at left is not satisfied
cleaner (1) negative pressure
25 Clogging of air Above specified OPEN = 24 V (When clogged) ––– fi 2 When condition at left is not satisfied
cleaner (2) negative pressure
26 Clogging of air Above specified OPEN = 24 V (When clogged) ––– fi 2 When condition at left is not satisfied
cleaner (3) negative pressure
27 Clogging of air Above specified OPEN = 24 V (When clogged) ––– fi 2 When condition at left is not satisfied
cleaner (4) negative pressure
Below 9.3 V (while engine is running)
28 Alternator
R voltage
terminal When charging is
abnormal
(Condition for judging rotation of engine:
Terminal R voltage is above 9.3 V ––– fi 2 When condition at left is not satisfied
or engine speed is above 600 rpm)
20-199-9 WA1200-3
(8)
TESTING AND ADJUSTING METHOD OF DISPLAYING REMEDY CODES AND ERROR CODES
Alarm output
Main monitor
output Massage display (CGC)
Alarm Saving of Sensor Constant Real-time monitor,
Screen Cancel Check Caution Error detecting display Remarks
display on Buzzer PM clinic
color switch lamp lamp No. failure history component (Reference)
CGC Saved: fi (Reference)
918 fi
Abnormal Yellow Installed Flashing ––– ––– 925 fi ––– –––
VHSM
Abnormal Red Not installed ––– Flashing ON 926 fi ––– –––
Abnormal Yellow Installed Flashing ––– ––– 927 fi ––– –––
VHSM
Abnormal Red Not installed ––– Flashing ON 928 fi ––– –––
Abnormal Yellow Installed Flashing ––– ––– 931 fi VHMS ––– –––
Abnormal Yellow Installed Flashing ––– ––– 937 fi VHMS ––– –––
WA1200-3 20-199-10
(8)
TESTING AND ADJUSTING ERROR CODES TABLE
20 CALL Short circuit or disconnection in joystick steering FNR switch system DDF2KZ E020
21 Short circuit or disconnection in joystick steering shift-up/shift-down switch system DDF3KZ E021
22 CALL Disconnection in travel speed signal sensor system DLT3KZ E022
23 CALL Short circuit or disconnection in engine rotation sensor system DLE2KZ E023
24 Abnormality in memory DAQ0KT E024
25 E01 Short circuit in transmission oil temperature sensor system DGF1KB E025
26 CALL Grounding fault in F. fill switch system DDTQKB E026
27 CALL Grounding fault in R. fill switch system DDTNKB E027
28 CALL Grounding fault in 1st fill switch system DDTKKB E028
29 CALL Grounding fault in 2nd fill switch system DDTLKB E029
30 CALL Grounding fault in 3rd fill switch system DDTMKB E030
32 E00 Grounding fault in F/R fill switch system DDTDKA E032
33 E00 Disconnection in 1st, 2n, or 3rd fill switch system DDT8KA E033
34 CALL Disconnection or short circuit with power source in F bypass solenoid signal system DW23KZ E034
35 E01 Grounding fault in F bypass solenoid signal system DW23KB E035
36 CALL Disconnection or short circuit with power source in R bypass solenoid signal system DW24KZ E036
37 E01 Grounding fault in R bypass solenoid signal system DW24KB E037
38 CALL Disconnection or short circuit with power source in 1st bypass solenoid signal system DW25KZ E038
39 E01 Grounding fault in 1st bypass solenoid signal system DW25KB E039
70 Disconnection in boom RAISE/LOWER, bucket TILT/DUMP pressure switch system DDNJL4 E070
72 E01 + CALL Short circuit, disconnection, or short circuit with power source in accelerator pedal sensor system DK10L5 E072
Modulated clutch controller
73 CALL Grounding fault in F/R ECMV fill switch system DDTDKB E073
74 E00 Disconnection in 1st, 2nd, or 3rd fill switch system dDT8KA E074
75 CALL Grounding fault in 1st, 2nd, or 3rd fill switch system DDT8KB E075
76 E00 Grounding fault in RPM-SET IDLE-UP/RESUME IDLE-DOWN system DDA7LD E076
77 E00 Grounding fault, disconnection, or short circuit in drive force control dial system DDD8KX E077
78 E00 Grounding fault, disconnection, or short circuit in travel speed control dial system DDD7KX E078
80 E00 Grounding fault, disconnection, or short circuit in wheel rotation sensor system DLF6L8 E080
81 E00 Grounding fault, disconnection, or short circuit in modulated clutch outlet rotation signal sensor system DLT2KZ E081
82 CALL Short circuit, disconnection, or grounding fault in engine rotation sensor system dLE2KZ E082
83 CALL Short circuit, disconnection, or grounding fault in travel speed sensor system dLT3KZ E083
84 Short circuit, disconnection, or grounding fault in neutral-cut solenoid system DWNAKZ E084
85 CALL Short circuit, disconnection, or grounding fault in modulated clutch ECMV solenoid system DXHPKZ E085
43 Disconnection, short circuit, or grounding fault in dumping solenoid system DXHNKZ E043
44 E01 + CALL Short circuit with power source on hot side of dumping solenoid DXHNKY E044
Work equipment controller
45 CALL Short circuit with power source on return side of dumping solenoid DXHNKB E045
49 Disconnection or grounding fault in boom lever kick-out solenoid system DW72KZ E049
51 Disconnection in boom RAISE/LOWER pressure switch system DDNGL4 E051
52 Disconnection, grounding fault, or short circuit in boom angle sensor system DKA0KX E052
55 E00 Short circuit or disconnection in travel speed sensor system DLt3KZ E055
56 Disconnection, grounding fault, or short circuit in joystick caution buzzer relay system D100KZ E056
57 E01 + CALL Disconnection, grounding fault, or short circuit in steering lever angle sensor system DK5FLX E057
58 E01 + CALL Deviation of potentiometer signal of steering lever angle sensor/frame angle sensor system DKD0KZ E058
59 E01 + CALL Disconnection, grounding fault, or short circuit in frame angle sensor system DKD0KX E059
61 E01 + CALL Disconnection or grounding fault in steering lever lock switch system DDQ2L6 E061
62 E00 Disconnection, grounding fault, or short circuit in joystick neutral interlock relay system D191KZ E062
63 E01 + CALL Disconnection, grounding fault, or short circuit in joystick basic pressure control EPC solenoid system DXF0KZ E063
20-199-11 WA1200-3
(8)
TESTING AND ADJUSTING ERROR CODES TABLE
fl Error codes related to engine controller (marked with *) are also displayed on the CGC.
WA1200-3 20-199-12
(8)
TROUBLESHOOTING POINTS TO REMEMBER WHEN TROUBLESHOOTING
A Stop the machine in a level place, and check that the safety pin, blocks, and parking brake are securely fitted.
A 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.
A the
If the radiator cap is removed when the engine is hot, hot water
engine to cool down before starting troubleshooting.
may spurt out and cause burns, so wait for
A Be extremely careful not to touch any hot parts or to get caught in any rotating parts.
A When disconnecting wiring, always disconnect the negative (-1 terminal of the battery first.
A 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, and important point is of course to understand the structure and function.
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 4) Check the stroke of the control valve spool.
to disassemble the components. 5) Other maintenance items can be checked ex-
If components are disassembled immediately any ternally, so check any item that is considered
failure occurs: to be necessary.
. Parts that have no connection with the fail- 4. Confirming failure
ure or other unnecessary parts will be disas- Confirm the extent of the failure yourself, and
sembled. judge whether to handle it as a real failure or as
. It will become impossible to find the cause a problem with the method of operation, etc.
of the failure. + When operating the machine to reenact the
It will also cause a waste of manhours, parts, or troubleshooting symptoms, do not carry out
oil or grease, and at the same time, will also lose any investigation or measurement that may
the confidence of the user or operator. make the problem worse.
For this reason, when carrying out troubleshoot- 5. Troubleshooting
ing, it is necessary to carry out thorough prior Use the results of the investigation and inspec-
investigation and to carry out troubleshooting in tion in items 2 - 4 to narrow down the causes of
accordance with the fixed procedure. failure, then use the troubleshooting flowchart to
2. Points to ask user or operator locate the position of the failure exactly.
I) Have any other problems occurred apart from * The basic procedure for troubleshooting is
the problem that has been reported? as follows.
2) Was there anything strange about the ma- 1) Start from the simple points.
chine before the failure occurred? 2) Start from the most likely points.
3) Did the failure occur suddenly, or were there 3) Investigate other related parts or infor-
problems with the machine condition before mation.
this? 6. Measures to remove root cause of failure
4) Under what conditions did the failure occur? Even if the failure is repaired, if the root cause of
5) Had any repairs been carried out before the the failure is not repaired, the same failure will
failure? occur again.
When were these repairs carried out? To prevent this, always investigate why the prob-
6) Has the same kind of failure occurred be- lem occurred. Then, remove the root cause.
fore?
3. Check before troubleshooting
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.
ber of machine
Step 4
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 re-
pairs must be carried out. This section deals particularly with correct repair procedures for mechatronics
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).
I TEwoo192
TEwGm93
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 solder-
ing may be damaged, or the wiring may be
broken.
TEwOOl94
tact restorer.
f When wiping the mating portion of the
connector, be careful not to use exces-
sive 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 clean-
ing with compressed air.
0 Disconnecting connectors
Hold the connectors when disconnecting.
When disconnecting the connectors, hold the
connectors and not the wires. For connec-
tors 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 con-
nectors apart.
* Never pull with one hand.
0 Connecting connectors
Check the connector visually.
1) Check that there is no oil, dirt, or water
stuck to the connector pins (mating por-
tion).
2) Check that there is no deformation, de-
fective contact, corrosion, or damage to
the connector pins.
3) Check that there is no damage or break-
age 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 connec-
tor, 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, re-
place the connector.
-
II TEWC0206
31 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 en-
tering. If the opening is left open or is blocked
with a rag, there is danger of dirt entering or of
the surrounding area being made dirty by leak-
ing oil so never do this.
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.
TEwOO209
6) Flushing operations
After disassembling and assembling the equip-
ment, or chanoing the oil, use flushing oil to
oil
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 sec-
ondary 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 ma-
chine, carry out oil cleaning to remove the sludge
or contaminants in the hydraulic oil circuit.
The oil cleaning equipment is used to remove
the ultrafine (about 3~11particles that the filter
built into the hydraulic equipment cannot re-
move, so it is an extremely effective device.
10. Check for looseness, corrosion of alternator terminal, wiring - Tighten or replace
11. Check for looseness, corrosion of starting motor terminal, wiring - Tighten or replace
21. Check for water leaking on wiring (be particularly careful attention - Disconnect
to water leaking on connectors or terminals) :onnector and dry
Add-
Mounting location ress
~1
FO9 Terminal 1 Horn (315 Hz) A-5
F10 Terminal 1 Horn (315 Hz) A-5
Fll - 2 Working lamp (Optional) B-l GRl DTlA 12 lntermedtate connector
F12 - 2 Working lamp (Optional) A-2
F13 DT2 3 Bucket positioner A-4
F14 DT2 3 Boom head oressure sensor A-3 HRl lDT2 1 2 I NC (Neutral) solenoid t G-9 l
F15 I DT2 1 3 1 Wheel rotation sensor I A-2 1 I HR2 I DT2 I 2 I Diode I G-l 1
F20 I Terminal
I 1 I Chassis ground I D-8 I I HR3 I DT2 I 2 I Bucket TILT switch I C-8 I
F21 I Terminal1 1 I Horn (add) I C-1 I HR4 DT2 2 Bucket DUMP switch C-8
F22 Terminal 1 Horn (add) C-l HR6 DTI 2 Rear brake level E-l
F23 TeninaI 1 Horn (add) A-5 HR8 DT2 2 Boom dump solenoid B-7
F24 Terminal 1 Horn (add) A-4 HR9 DT2 2 Boom dump solenoid B-7
FL1 HD-2608614 Intermediate connector A-9 HRlO DTI 2 Front brake level D-l
FL2 HD-25085 14 Intermediate connector B-9 HRll DT2 2 Boom lever detent switch C-8
FRl HD-86J8623 Intermediate connector B-9 I HR12 I DT2 I 2 I Boom RAISE switch 1 B-7 I
FR2 I HP4W82l21 I Intermediate connector I B-8 I I HR13 I DT2 I 2 I Boom LOWER switch I C-8 I
FSl lL I 2 I Fuse box I h-7 I I HR14 I DT2 I 2 I Parkina brake solenoid I F-l l
20-214
0
TROUBLESHOOTING CONNECTOR TYPES AND MOUNTING LOCATIONS
Con- No.
Add-
nectar Type of Mounting location ress
No. pins
JL9 DT2 6 Joint connector a-2
JLlO DT2B 8 Joint connector a-2
~ HR17 l DT2 l 2 l Ememencv brake switch 1 E-I 1 JLII DTI 6 Joint connector a-l
~ HR18 1DT2 l 2 l Ememencv brake switch / E-I 1 JL12 DT2 6 Joint connector a-l
HR19 1DT2 I brakeresetsolenoid1
2 I Emergencvoarking F-l 1 1 JL13 1DTI I 6 I Joint connector I a-1
1 HSl DT2 2 Hydraulicoil temperaturesensor A-6 JL14 DT2 6 Joint connector a-l
HS2 DT2 3 Workequipment oil pressure sensor A-7 JL15 DT2 6 Joint connector a-l
~ HS3 DT2 3 Steering oil pressure switch C-I JL16 DT2 6 Joint connector a-l
HS4 DT2 3 PPC oil pressure sensor G-9 JL17 DT2 6 Joint connector a-l
JBl DTl 8 Joint connector V-9 JL18 DT2 6 Joint connector a-l
JB2 DTl 6 Joint connector v-9 JLI9 DT2 6 Joint connector a-l
JEI 1DTl 1 6 1Joint connector I T-9 1 I JL20 l DT2 I 6 I Joint connector I a-l
JE2 DTl 6 Joint connector V-8 1 JL21 1DTIB I 8 l Joint connector I a-l
JE3 DTIB 8 Joint connector v-9 JL22 DT2B 8 Joint connector a-l
JE4 DTl 6 Joint connector v-9 JL23 DTPB 8 Joint connector a-l
JFl DTI 6 Joint connector O-I JL24 DT2 6 Joint connector c-l
JF2 DTl 6 Joint connector N-l JL25 DTI 6 Joint connector C-l
JF3 DT2 6 Joint connector M-4 JL26 DT2 6 Joint connector C-I
JF4 I DTZB I 8 1Joint connector 1M-4 I JM4 DTI 6 Joint connector Q-9
JF5 1DTlBl 8 / Joint connector I M-3 I I JRI i DTIB 1 8 1Joint connector 1W-6
JF6 DTI 6 Joint connector M-4 I JR2 I DTI I 6 I Joint connector I w-5
JGl DTlB 8 Joint connector w-7 JR3 DTI 6 Joint connector T-2
JG2 DTI 6 Joint connector w-7 JR4 DT2 6 Joint connector T-2
JG3 DTlB 8 Joint connector w-7 JR5 DT2 6 Joint connector T-l
JG4 DTI 6 Joint connector W-8 JR7 DTl 6 Joint connector u-2
JG7 DTIB 8 Joint connector W-8 JR8 DTlB 8 Joint connector Q-I
JG8 l DTI I 6 I Joint connector I W-8 I JR9 DT2 6 Joint connector R-I
JGN l DTl I 6 l Joint connector 1M-2 I I JR10 I DT2 I 6 I Joint connector l Q-I
JGN I DTl I 6 1Joint connector I M-6 I I JRII I DT2 I 6 l Joint connector l Q-9
JR12 DTI 6 Joint connector Q-9
JR13 DTlB 8 Joint connector O-8
JR14 DT2 6 Joint connector N-7
JR15 DTl 6 Joint connector O-8
JR16 DTl 6 Joint connector N-7
JLl1 DT2 1 6 1Joint connector I z-2 I JRA DT2 6 Joint connector T-9
JL2 I DT2 I 6 I Joint connector 1 Z-2 I I JSI I SWP 1 12 I Jovstick lever switch I i-7
JL3 1DT2Bl 8 \ Joint connector I z-2 I I JS2 I x I 3 I Potentiometer I i-5
l-pin
JL4 DTI 6 Joint connector z-4 JS3 COllWCt0r 1 Console switch i-6
l-pin
JL5 DTlB 8 Joint connector z-4 JS4 connector I Console switch i-5
JL6 DTZB 8 Joint connector z-4 JTI DT2 6 Joint connector w-5
JL7 DT2 6 Joint connector z-2 JT2 DT2 6 Joint connector w-6
JL8 DT2 6 Joint connector z-2 JT3 DT2B 8 Joint connector w-5
Con- No.
Add-
lector Type of Mounting location ress
No. pins
L127 1Reiavl 5 1Steerina neutral relav 1 n-8 1
L128 1DT2 1 2 1 Diode I r-9 I
L129 I - I 2 I Resistor I r-9 I
L130 &$&, 1 Travel speed “ON/OFF” indicator u-2 MT5 DT2 3 modulating
Transmission oilpressure
sensor ab-6
l-pin
L131 &$&), 1 Travel speed “ON/OFF” indicator t-2 OPl COtNECtOf 1 Fuse box v-7
L132 Relay 5 Dust indicator 1 relay m-9 QP2 l-pin
connector 1 Fuse box v-7
L133 Relav 5 Dust indicator 2 relav n-9 OP3 z-tn. 1 Fuse box v-7
L134 1Relavl 5 I Dust indicator 3 relav I n-9 I 0~4 I,2L,I I I Fuse box Iv-71
~135 I Relay1 5 I Dust indicator 4 relav I n-8 1 0~5 I,Z’L,,I I I Fuse box
L136 &F&r 1 Remote positioner RAlSEindicator n-8
L137 &$&, 1 Remotepositioner RAlSEindicator o-8
L138 g& 1 Remote positionerLOWER indicator n-7
L139 l-P’”
COlXECtO~ 1 RemotepositionerLOWERindicator o-8
L140 &:&tor 1 PRE-LUBE indicator r-9
L141 &!$&,, 1 PRE-LUBE indicator o-9
L142 I&&orl 1 Turn signal switch n-7 I 01 IHD-~w I 21 I Enaine controller I T-9
L143 I,i.2~l 1 I Turn sianal switch n-7 I ~2 lH5~ I 31 I Engine controller I T-9 I
~144 I&$!&,/ 1 ( Turn signal switch I n-7 I ROl I DT2 I 2 l Torqueconverteroil fiiterdoggingsensorI S-l I
L145 I&!$,,r/ 1 1DC converter (24 V/12 VI ) v-5 R02 ( DT2 1 2 1Torqueconverter
oil filtercloggingSensor1 S-l
._.
L146 mnnector
‘-p’” 1 DC converter (24 V/12 VI v-6 R03 DT2 2 Diode u-2
l-147 KES 2 DC converter (24 VI12 V) v-5 R04 DT2 2 Diode u-2
L150 I
KES
~- I
2-,-- Service meter
~~~ I
s-9 R05 DTl 2 Fuel level sensor v-9
L152 I Relavl 5 I Alternator sianal relav I n-9 R06 Terminal 1 Slow blow fuse W-8
L160 I;;{$;rl 1 Alternator indicator I q-9 I R07 ITerminalI I I Slow blow fuse IW-81
L161 l,Z~,,l 1 I Alternator indicator I o-9 I R08 \Terrninal
I I I Slow blow fuse IW-81
LRI 1~~95086131 I Intermediate connector I N-9
FL2 +
AR02
FL1. I AR01
I
. ..._” \
I I
Rl8 HR14
HRi9
F22
BwWOl5Ol +
.E03
GRl
GR6
E05
\ E07
El3
GO4
E‘ll
\ ERl
El4 ER6
ER7
I ER8
16
AiOl
AL02
BWWO1502
LRl
RA9 RAlO +
LR2 I 11.. \ I._ I_._
JR1 1
1119
-..--
R30 JM4
R3-
WORK1
WORK2
WORK3
JHD
JGN
WORK3
WORK2
WORK1
JF6
JF3
/ / /
Rll JF2 JFl TURN’ SMAlLL Ri2
BWW01503 +
JE4
R07
JG4
/
/JG7
,JG3
,JGl
bJG2
‘JR2
\
RA’
RA3
‘JGRP
RAS
RA4
RA12
\
R01
si2
RA13
R02
+
+-
c2
C3B I
CO6
co4
\ \
JLb
JL6
0
TROUBLESHOOTING CONNECTOR ARRANGEMENT DIAGRAM
FS6
FS6
I I / FS4
JS2
33
/ I I YY\M\\\ 'A10
1 1 \ \ ‘Al2 ‘A14
\ A\8B
A16 DLi
+ ’ A14 1542
BWWO
L6iil:4L73L;L91 17;;z3/:::
+
Lf 19
Ll14 L133
L69 & -1134 L39
L69
L92 I ‘~j;l?T I
L61
L99
L68
L67
L63
L62
RESP
RES4
LO6
L26
Li6
I I
L96 L97 ,
+
Ll03 L160 LO1 L128 Ll50
t en
I. OP2.OP3
OP6
\
Tl4
Ti2
T18
/
Tl
!!
A17
Al6
Cl3
c12
!ll \ \\\ 1
Cl7
Cl4
Cl6
Cl8 C23
C27
C24
.C26
.
‘cne
1 3
EElI
2 4
TEwoozz5
No.
of
T SWP type connector
‘6
TFNc4l235
1 5
4 8
1 4
5 8
9 12
BLFWO34 BlPOKl35
1 4 8 11 11 8 4 1
14
3 i io ?14
TEwooz39 TEwoo240
4 1 4
1
5 8
16
9 2
No.
of
T M type connector
2
e7
1
BLFOCO38
TEwoo244
3 1
4
ElS
4 2
TEwca245 lEwoo246
1 4 4 1
6
cl
3’ ‘6
TEWOO247
8
Qzl 8’ ‘5
BLFWXO BLPOOO41
NO.
of
T S type connector
Ezl ‘8
TEwKQ49
1 6
\ /
10
(White
$3 5 10
Two0251
I 6
12
(White
i
5 12
BEL00113 BEL00114
16
(White
WA1 200-3
is- 0
i i6 BEL00115
16 7 BEL00116
20-233
0
TROUBLESHOOTING CONNECTlON TABLE FOR CONNECTOR PIN NUMBERS
No.
of
T S type connector
10
(Blue
i 10
BEL00117
BELO
1 6
6 1
12
(Blue
5 12
ElFwx3
1 8 8 1
16
(Blue
El
0
16 7 TEwoozs6
13
8
13
H BLFOOO4B
9 9
Bl.Pooo50
00 0
17 17 10
17
BLPmo52
21
No.
of
T AMP040 type connector
a 4
6 12
8LFwos5
i i BLFUOOBB
a 16
16
20
ai 11 1
lEww234
No.
of
l- AMP070 type connector
10
EWWOl601 BWWO1602
12
i
5 12 BWW01603 5 NW01604
14
6 BWWO1605
aI EWWOl606
18
8 18 BWWO1607 18 8 8WWO1608
10 1
20
20 Y
EWWOl609 BWWOl6lO
No.
of
T L type type connector
I I
ELI
a
2
m
No.
of
T Automobile (KESI 1 connector
WLOI 140
it3 2 3
BVLOI 141
BVLOl142
.
k BLFQWW
4 1
8
Em f?3 I
5
\
BU%QQ?2
8
T
Type HD30 series connector
Shell
size
code 1 Body (Plug) Body (Receptacle)
EWWO1612
18-8
Pin (female terminal) Pin (male terminal)
(1)
NW01614
BWWO1616
18-14
Pin (female terminal) Pin (male terminal)
(2)
BWWO1617
BWWO1820
18-2C
Pin (female terminal) Pin (male terminal)
(3)
BWWO1621 BWWO1622
fn\
0
'00
IlO
o
'2
::O
90
O
200
03 o 060'6
0405
,' 0 O'6
15
02'
,07
0'7
020
0'9
BWWO1623 BWWO1624
18-21
Pin (female terminal) Pin (male terminal)
(4)
BWWO1625 BWWOl626
Type
Shell
T HD30 series connector
I size
code
Body (Plug)
oT
0
ova
0
OS
f\ oz 0”
owoy ox
BWWO1627 BWW01628
24-9
Pin (female terminal) Pin (male terminal)
(5)
l-3 0
SOT ” lT
u
OS
ooopooV
/OR .Z
oy ox ow lwl l X y
BWWOI
629 BWW01830
BWWO1631 BWWO1632
24-16
Pin (female terminal) Pin (male terminal)
(6)
BWWOl633 BWW01634
EWWO1636
24-21
Pin (female terminal) Pin (male terminal)
(7)
BWWO1639 BWWOl640
24-23
Pin (female terminal) Pin (male terminal)
(8)
BWWO1642
T
Type HD30 series connector
Shell
size
code 1 Body (Plug)
BWWO1644
24-31
Pin (female terminal) Pin (male terminal)
(9)
BWWO
I646
No.
of
T DT series connector
2
2 fiE3
lzzil
I
BWWO1647
EWWO1649 6WWO1650
BWW01652
No.
Of
T DT series connector
BWWOl653 BWWO1654
a
@f!a!@
I
Em
08
4 BWWO1655 4 1 BWW01656
12
1 6
BWWO1657 I
BWWO1656
No.
of
T DTM series connector
2
2 B
ihdi
0 0
1 1 c3
m 2
BWWOl659 BWW01660
No.
of
T DTHD series connector
0Q 0
EWWO1661
0 4%
BWWO1662
_I
ECMV 3rd
Shift-down c
0
ECHV R
Transmission
cut-off switch
:....r:,...-
Auto/Manual
I Backup lamp relay
Transmission
controller
psolenoid 1
*7-
Fill switch I
*7-
Fill switch 2
*F”----
Fill switch 3
Work ewipsent
-7-
Transmission oil
temPerature
1 TXW02438
I
Drive force
control voltaoe $---_H
Travel speed
control voltaoe
Sneed settins LE
Modulated clutch
(MOD/C) controller
a7
1
*7
Transmission F clutch sisnal
-7
Transmission R clutch signal
I
O?
Transmission 1st clutch sinnal
q
F
Transmission 2nd clutch sisnal
q
=7
Transmission 3rd clutch signal
q
TXW02439
+?!!I
A: Analog signal
B: Dioital sional
P: Pulse signal
S: S-NET sional
@Booa lever detent snitch (3) Remote Positioner snitch inout check
buzzer outout
Main monitor
R-IIxzI
@ nettino twitch (4) Diselar of lower settino
of remote positioner
Q) ~:y;;:,m:j;;ner raise
(5) Disolav of raise setting
of remote positioner
@ Remote positioner raise Work eouionent
eta0 selector witch controller (6) Disolav of raise stop
of remote positioner
@ Remote mritioner lower
tten selector switch (7) Disolar of lower stop
of remote Positioner
@Frame angle
Potentiometer
!y;;; caution buzzer ’ 1 F
MAINMONITORSYSTEM
1
, Network t c -
.Uodel shional
.Abnormalitr signal
[ .Neutcal sional
Alarm buzzer
Main monitor
Joystick FNR
+
lever INisht Iishtinr sisnaf imi
L switch
I VHYS
controller
I
Starting switch ON signal
WA1 200-3
TROUBLESHOOTING EXPLANATION OF FUNCTIONS OF ELECTRIC CONTROL MECHANISM
Engine speed
I 1
Electromaonet ic
Fuel level
1
Toraue converter
oil temperature
.
a
Hydraulic oil
tenperature Brake fluid level
.
g
~ Ataos~~ temperature
Coolant level
Transmission oil filter
differential pressure I
~;pa~;a 4; air cleaner
1
%
F
Alternator terminal R
+24V
Brake differential
wemutt
+24V I +24V
I
Transmission lubricatino
oil preswr.2
+24vfTj+q Tranmission
oi I Prefmre
I
modulation
i24V
+24V +24V
I
Steering relief
outlet Pressure
nb
+24V- 1
-+24V
relief Dressure
I
7h I
I
I I
TXW02442
+24\
+24V
L
+*4”m!i
VHMS
controller
Subtotal switch
-7
Cancel switch
1 Mele;ase disDlav 1
TXW02443
1. Display on CGC
1) Outline
The VHMS controller transmits information of
various types through CAN (network) to the CGC
monitor, and the “Failure history information”
in that information is displayed on the SERVICE
MENU SELECT SCREEN of the CGC monitor.
the order of time from the oldest one. If the Memory Clear Snapshot Trigger
failure still exists, the “finishing time of failure
detection” is not displayed.
The number of the all past failures is displayed
in section (21, the failure No. in section (31, the BWWOl551
failure code and its contents in section (41, and
the time when the failure occurred in section 5.
1) Outline
The speedometer display on the main monitor
is used to display the troubleshooting for each
control system. The nature of the troubleshoot-
ing is displayed as the failure action code, fail-
ure 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 Examole: When action code CALL is displayed
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 (a): EOO,
I SPEED \
BWWOl532
Screen Component
Name of signal Unit Remarks
No. name
REAL TIME MONITOR
T/M UP SHIFT SW
114 (ON/OFF)
(MOD/C OUTPUT
SPEEDJAENGINE SPEED
Screen Component
Name of signal Unit Remarks
No. name
516 (ON/OFF)
LOAD METER
I I
l/l BOOM BOTTOM PRESSURE O.OlMPa 10.1 kg/cm? 1 VHMS 1 Di$?~;~?~~fafr;;~~
I I
l/l MEASURED PRESSURE O.OlMPa (0.1 kg/cm21 VHMS Measured trigger
pressure
I I
l/l NO LOAD PRESSURE O.OlMPa IO.1 kg/cm*] VHMS Default calibration
pressure
JOYSTICK STEERING
PM CLINIC
___
H: Normal -__
1 Engine oil level Below LOW level
lz Abnormal 0 2 When left is not satisfied
1
oil pressure in kPa)
Below followina linear
interpolation graph
Below specified
2 Engine oil pressure
pressure (0.0) 0 2 When left is not satisfied
(800, 138)
;;;3 $4r71
12200:345)
Above 130°C
Above 105oC
but 130°C alarm is not detected
Above 130°C
Above 10S°C
--I-O
0
0
0
10
10
10
When left is not satisfied.
Below 14.7 MPa Below 14.7 MPa (150 kg/cm3 __- ___
(150 kglcmq and within 60 set after engine starts 0 When left is not satisfied.
-i-
Below 14.7 MPa (150 kg/cm?
and atter 60 set after engine starts
---
l 0 5 When left is not satistied.
Below 14.7 MPa Below 14.7 MPa I150 kg/cm9 ___ ___
(150 kg/cm? and within 60 set after engine starts
0 When left is not satisfied.
-I--
= 6 V cell is below 2 V
OPEN (Fluid level is low)
Batteryfluid level (3) Below LOW level
-_-
= 6 V ceil is below 2 V
___
_-_
Belowspeciiiedlevel OPEN = 24 V (Fluid level is low) 0 10 When left is not satisfied.
0
___
Belowsoecifiedlevel OPEN = 24 V (Fluid level is low) 10 When left is not satisfied.
4
‘1 Coolant level Below LOW level
Below LOW level
Above specified
pressure
OPEN = 24 V (Coolant is insufficient)
OPEN = 24 V (Coolant is insufficient)
OPEN = 24 V (Clogging) and torque
converteroil temoeratureis above 50°C
=I=
--_
0
0
0
2
2
2
When left is not satisfied.
When left is not satisfied.
Alarm output
w
T,
ompent &ference) Clinic(Reference)
I I , I
I 1 1
Abnormal Yellow Installed - - - Flashing Gauge 0
CENSE
Gauge 0
VHMS Gauge ---
-__ 1 966 ) X Gauge ---
Gauge 0
0 VHMS
Gauge 0
+-
39 E01 1Short circuit with chassis ground in 1st bypass solenoid signal system I 1 E039
70 1 Disconnection in boom RAISE/LOWER, bucket TILT/DUMP pressure switch system 1 E070
72 EOl + CALL Short circuit, disconnection, or short circuit with power source in accelerator pedal sensor system / E072
a4 1 Short circuit, disconnection, or short circuit with chassis ground in neutral cut solenoid system ( E084
a5 ( CALL I Short circuit. discunnsction,or short circuit with chassis gmund in modulated clutch ECMV solenoid system 1 E085
* Failure codes related to VHMS are not displayed on the main monitor (They are displayed on only
CGC monitor).
* For display of cautions related to alarm, see the List of alarm items displayed on CGC monitor.
* In “Display of history”, EOOO + Contents of failure + Time when failure occurred + Time when
failure is rest are displayed.
CGC monitor
)e,,ke Failure Action Failed system
code code Real-time Displayof
display history
43 Disconnection, short circuit, or short circuit with chassis ground in dumping solenoid E043
44 EOl + CALL Short circuit of hot side of dumoina solenoid with Dower source E044
45 CALL Short circuit of return side of dumping solenoid with power source E045
=g 49 Disconnectionor short circuitwith chassisground in boom lever kick-outsolenoidsystem E049
2
51 Disconnection in boom RAISE/LOWER pressure switch system E051
g
U 52 Disconnection,
short circuitwith chassisground or short circuitin boom angle sensorsystem E052
2 55 EOO Short circuit or disconnection in travel sDeed sensor svstem E055
: 56 shortcircuitwithchassisground or short circuit in joystick cautionbuzzerrelaysystem
Disconnection, E056
‘3
57 shortcircuitwithchassis ground or short circuit in steering lever angle sensor system
EOl t CALL Disconnection, EO57
B
Y 58 EOlt CALL Deviationof potentiometer signal in steering lever angle sensor/frsmeangle sensor system E058
z
59 EOl t CALL Disconnection,
short circuitwith chassisgroundor short circuitin frame angle sensorsystem E059
61 EOl t CALL Disconnection or short circuit with chassis ground in steering lever lock switch system E061
62 EOO Disconnection,
shortcirceitwithchassis
aroundor shortcinxitin iovstkkneutrelinterfcck
relevsystem E062
Disconnection, short circuit with chassis ground or short circuit in joystick main
63 EOl t CALL E063
pressure control EPC solenoid system
lE8ii I 1 Disconnection or short circuit with Dower source in NSW Dower sutmlv svstem 1 I E811 I
E812 1 1 Short circuit with chassis ground in 24-V system of sensor power supply 1 E812
E813 1 1Short circuit with chassis around in 12-V svstem of sensor Dower SUDDIY I 1 E813
E814) ) Short circuit with chassis ground in 5-V system of sensor power supply I 1 E814
E818 I I Wrong connection of connector I E818
I E821 l I Failure in controller (Failure in securino of memorv) I I E821 I
E824 1 1Failure in communication with CGC and engine controller ! 1 E824
Disconnection, short circuit with chassis ground or short circuit with power
E825 E825
source in S-NET (Between transmission controllers)
Disconnection, short circuit with chassis ground or short circuit with power
E826 E826
source in S-NET (Between modulated clutch controllers)
Disconnection, short circuit with chassis ground or short circuit with power
E827 E827
source in S-NET (Between work eauioment controllers1
lE4 I Disconnection, short circuit with chassis ground or short circuit with power
source in S-NET (Between main monitors) I I E828 I
IE8311 I Failure in controller (Handle error) I l E831 I
E841 1 Short circuit of buzzer output with power source 1 E841
E843 I 1Short circuit of check lamp with power source I E843
E844 Short circuit of flash synchronizing signal with power source E844
E861 Disconnection
or short circuitwith chassisground in boom bottompressuresensorsystem E861
E862 Disconnectionor short circuit with chassisaround in boom head oressure sensor svstem E862
E863 ) Disconnectionor short circuitwith chassisground in rear brake oil pressuresensor system 1 ) E863
E864 1 or shortcircuitwith chassisgroundin work equipment relief pressure sensor system 1
1Disconnection 1 E864
E865 Disconnection
or short circuitwith chassisground in front brakeoil pressuresensorsystem E865
E866 or shortcircuitwithchassisgmundin transmission main relief pressure senscrsystem
Disconnection E866
E867 Disconnectionor short circuitwith chassisaround in steerinarelief oressuresensorsystem E867
E8681 Disconnectionor short circuit with chassis
groundin torque converter outlet oil pressure sensor system 1 E866
E871 I 1Disconnectionor short circuit with chassis around in transmission modulation oil pressure sensor system 1 1 E871
lE8721
I Disconnection, short circuit with chassis ground or short circuit with power
source in transmission lubricating oil pressure sensor system
* Failure codes related to VHMS are not displayed on the main monitor (They are displayed on only
CGC monitor).
* For display of cautions related to alarm, see the List of alarm items displayed on CGC monitor.
* In “Display of history”, EOOO + Contents of failure + Time when failure occurred + Time when
failure is rest are displayed.
1 CGC monitor 1
Failed system 1 Real-time 1Displayof 1
1 display 1 history
E874 Short circuit with chassis ground in torque converter oil temperature sensor system E874
E875 Shortcircuit
withchassis
ground
or shortcircuit
withpowersource
in hydraulic
oiltemperature
senscr
system E875
Disconnection, short circuit with chassis ground or short circuit with power
ES77 E877
source in atmosoheric temoerature sensor svstem
1
E878 Disconnectionor short circuit with chassisground in PPC relief pressure sensor system ES78
5884 Diicnnectionor shortcircuitwithchassis
groundin torqueconverterinletoil pressuresecscrsystem E884
E901 Enaine oil level below LOW level DkhvofcautbnE901
* For display of failure codes related to engine controller, see “Troubleshooting for engine controller
system (G-mode)“.
<Example>
0* 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.
* Before starting troubleshooting, check that the lamp bulb of the turn signal indicator on
the monitor is not blown.
1 YES
IS voltage
between Lo6 (14)
and chassis DefBcdve cowact 0,
groundnormal? d&connection in wirina
hamessbetweenLO6” Repairor
. Repeats0 V and NO (female)(14) and L144
M-30V. (male)(1)
*Turn startingswitchON.
. Turn LH. turn signalON.
Repair or
replace
L.H. turn
signal
I alllo
- (25W)
Step 1. Questioning the operator 1. Steering does not work t Symptom [Example]
-The questions to ask the operator are given
below the failure symptom. If the answers Ask the operator about the following points.
to the questions match the information given, Did the steering suddenly stop working +
follow the arrow to reach the probable cause
of the failure. Had the steering gradually been becoming
heavy? + Internal wear of steering equipment,
Consider the contents of the questions and
consult the table while proceeding to Steps
2 and 3 to grasp the true cause.
71 Remedy
If the causes are narrowed down to one com-
mon cause, take the aciton given in the rem-
edy column.
The symbols given in the remedy column 4 101 1 JOI i I
indicate the following: 5_--__I_+3c_I_
X: Replace, a: Repair, A; Adjust, C: Clean
Display method of CUMMINS engine controller failure codes and contents of display .............. 20-302
Failure codes and actions table .... ........ .................. ..... ..... ...... ...... ..... ........-.......................................... 20-303
1. The failure codes from the CUMMINS engine controller are transmitted through communication
(CAN) line to the VHMS controller, where they are processed.
2. The failure codes and contents of the failures (displayed messages) are saved as failure history.
3. The failure codes are displayed on the alarm screens corresponding to the operator codes (for the
customer).
4. Operator codes [Oil - I041 and other five screens are set for the alarm screens (for the customer).
5. If a failure which is not shown in this list occurs, the alarm screen of occurrence of an un-
registered error appears.
Contents of failure
1 C6:
Judgement table for transmission control system related parts ...................................................... 20-404
Operations of controller against abnormality and conditions of
machine caused by abnormality .......................................................................................................... 20-406
Electrical circuit diagram for transmission controller system ........................................................... 20-416
T- 1 Failure code [IO] (Short circuit, disconnection, short circuit with
power source in backup lamp relay) is displayed ................................................................. 20-418
T- 2 Error code [l II (Disconnection in modulated clutch outlet rotation signal
sensor system) is displayed ..................................................................................................... 20-419
T- 3 Error code 1121 (Short circuit, disconnection, or short circuit with
power source in F solenoid system) is displayed ................................................................. 20-420
T- 4 Error code 1131 (Short circuit, disconnection, or short circuit with
power source in R solenoid system) is displayed ................................................................ .20-421
T- 5 Error code 1141 (Short circuit, disconnection, or short circuit with
power source in 1st solenoid system) is displayed .............................................................. 20-422
T- 6 Error code II51 (Short circuit, disconnection, or short circuit with
power source in 2nd solenoid system) is displayed ............................................................. 20-423
T- 7 Error code [161 (Short circuit, disconnection, or short circuit with
power source in 3rd solenoid system) is displayed.. ........................................................... .20-424
T- 8 Error code 1181 (Short circuit, disconnection, or short circuit with
power source in R clutch drain valve solenoid system) is displayed ................................ -20-425
T- 9 Error code 1201 (Short circuit or disconnection in
joystick FNR switch system) is displayed.. ............................................................................. 20-426
T-IO Error code 1211 (Short circuit or disconnection in
joystick shift-up/shift-down switch system) is displayed ...................................................... 20-427
T-II Error code [221 (Disconnection in travel speed sensor system) is displayed.. .................. 20-428
T-12 Error code 1231 (Short circuit or disconnection in
engine speed sensor system) is displayed.. ........................................................................... 20-429
T-13 Failure code 1241 (Short circuit, disconnection in EEP ROM) is displayed ........................ 20-430
T-14 Error code 1251 (Short circuit in transmission oil temperature sensor system)
is displayed ................................................................................................................................ 20-431
T-15 Error code 1261 (Short circuit in F ECMV fill switch system) is displayed ......................... 20-432
T-16 Error code 1271 (Short circuit in R ECMV fill switch system) is displayed.. ....................... 20-432
T-17 Error code I281 (Short circuit in 1st ECMV fill switch system) is displayed ...................... 20-433
T-18 Error code 1291 (Short circuit in 2nd ECMV fill switch system) is displayed.. ................... 20-433
T-19 Error code [301 (Short circuit in 3rd ECMV fill switch system) is displayed.. .................... 20-434
T-20 Error code [321 (Disconnection in F or R ECMV fill switch system) is displayed ............. 20-435
Location of failure
Failure mode
controlle
Diagnosis code when failure code is displayed T-1 T-2 T-3 T-4 T-5 T6 T-7 T-8 T-9 T-10T-11T-12T-13T-14
I) In ‘F’: Machine
stops.
I) Voltage between C3B (14) - chassis ground 2) In ‘N’ or ‘R’: Ma-
When joystick FNR switch is in ‘F’: 17 - 30 V 1) When “N’ signal is
input: Sets in ‘N’ chine travels for-
When joystick FNR switch is not in ‘F’: ward suddenly.
Max. 1 V 2) $h:$i$$y;ignal is 3) Ins;N~r;l~~ ~~tpllt is
!) Voltage between C9B (7) - chassis ground
When joystick FNR switch is in ‘N’: 17 - 30 V input: Sets in ‘N”
immediately. 4) In ‘F’ or ‘R’: Gear is T-9
When joystick FNR switch is not in ‘N’: set in neutral
Max. 1 V 3) When no signals
are input: Holds for suddenly.
1)Voltage between C3B (15) - chassis ground 5) In ‘R’: Machine
When joystick FNR switch is in ‘N’: 17 - 30 V 2 set, then sets in
‘N’. stops.
When joystick FNR switch is not in ‘N’: 6) In ‘N’ or ‘F’: Ma-
Max. 1 V chine travels in
reverse suddenly.
0
OPERATIONS OF CON-IXOLLER AGAINST ABNORMALlTY AND
TROUBLESHOOTING CONDITIONS OF MACHINE CAUSED BY ABNORMALlTY
I) When harness is
disconnected:
Cannot operate at
all. (Since this
failure cannot be
distinguished from 1) F clutch makes gear
1) F bypass solenoid short circuit with shift shocks and it
Resistance between T22 (male) (I) - 12): power source, takes long time to
5-15R controller sets in engage (It engages T-22
Resistance between T22 (male) (I), (2) - chassis neutral and cannot at last).
ground: Min. 1 MR travel.) 2) F clutch cannot be
2) When harness has disengaged.
short circuit with
power source:
Controller sets in
neutral and can
travel.
1) When harness is
.disconnected:
Cannot operate at
all. (Since this
failure cannot be
distinguished from 1) R clutch makes gear
1) R bypass solenoid short circuit with shift shocks and it
Resistance between T21 (male) (1) - (2): power source, takes long time to
5-15P controller sets in engage (It engages T-24
Resistance between T21 (male) (I), (2) - chassis neutral and cannot at last).
ground: Min. 1 ML? travel.) 2) R clutch cannot be
2) When harness has disengaged.
short circuit with
power source:
Controller sets in
neutral and can
travel.
1) When harness is
disconnected:
Cannot operate at
all. (Since this
failure cannot be
distinguished from 1) 1st clutch makes
1) 1st bypass solenoid short circuit with gear shift shocks
Resistance between T20 (male) (I) - (21: power source, and it takes long
5-15R controller sets in time to engage (It T-26
Resistance between T20 (male) (I), (2) - chassis neutral and cannot engages at last).
ground: Min. 1 ML2 travel.) 2) 1st clutch cannot be
2) When harness has disengaged.
short circuit with
power source:
Controller sets in
neutral and can
travel.
20-416
0
ELECTRICAL CIRCUIT DIAGRAM FOR TRANSMISSION
TROUBLESHOOTING CONTROLLER SYSTEM
Auto shift
indicator
i'
TXWO2561
T-l Failure code [lo] (Short circuit, disconnection, short circuit with
power source in backup lamp relay) is displayed
is carried out when there is still an abnormality, so when disconnecting the
* This troubleshooting
removing the T-adapter and returning the connector
connector and inserting the T-adapter, or when
error code is no longer displayed on the monitor display, the
to its original position, if the
problem has been removed.
are properly inserted.
* Before carrying out troubleshooting, check that all the related connectors
to the next step.
f Always connect any disconnected connectors before going on
Cause Remedy
f
4YES
cGotoA
Is resistance
yes between L54
- (female) (2) and - Defective contact or
3
~- chassis ground disconnection in wiring
Is resistance normal? Repair or
harness between L54
YES between Cl . Max. 1 R replace
- (female) (11) and - * Turn starting NO (female) (2) and chassis
chassis ground ground
2 switch OFF.
- - normal? * Disconnect Cl Short circuit with chassis
Is resistance and L54. Repair or
* Min. 1 MR ground in harness
YES between Cl (female)
(17) and w (female) - *Turn starting NO between Cl (female) (11) replace
(1) normal? switch OFF. and L54 (female1 (1)
1
' * Disconnect Cl Defective contact or
Is failure code lo-
l Max. 1 R and L54. disconnection in wiring Repair or
displayed when
backup relay is _ * Turn starting harness between Cl replace
switch OFF. NO
replaced with other (female) (11) and L54
relay of same type? l Disconnect Cl (female) (1)
*Turn starting and L54.
switch OFF. I Defective backup lamp
Repair
* Replace backup NO I relay
relay with other relay of same type.
-Turn startino switch ON.
* Set directional lever to Ft. 5 YES Defective transmission
Repair
controller
Is vottage between
From A _ Cl (female) (11) _
and chassis Short circuit with power
ground normal? source in wiring harness ?epair or
l Turn starting .eplace
switch ON.
l Disconnect Cl
and L54.
* Max. 1 V
Transmission
controller
Cl (MICl3)
Backurr lamp relay 1 23 11 11 ‘. 5fG
Backup lam
relay
TXW02444
0
TROUBLESHOOTING T-7
* 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.
+ 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.
Cause Remedy
RT2 (HD-85086)
TXWO2445
T-3 Error code [I21 (Short circuit, disconnection, or shot-t circuit with
power source in F solenoid system) is displayed
* This troubleshooting is carried out when there is still an abnormality, so when disconnecting the
the connector
connector and inserting the T-adapter, or when removing the T-adapter and returning
on the monitor display, the
to its original position, if the error code is no longer displayed
problem has been removed.
* Before carrying out troubleshooting, check that all the CaUSe Remedy
related connectors are properly inserted.
* Always connect any disconnected connectors before
going on to the next step.
4YES
GotoA
Disconnection or defective
contact in wiring harness Repair or
between C2 (female) (2) - reolace
T13 (female) (1)
l-l
Is
* Min. 1 MD ground in wiring harness Repair or
YES ween C2 (female) between C2 (female) 113) - replace
* Turn startina NO
(13) and T13 T13 (female1 (2)
--
I
switch OFF.-
* Disconnect C2 Disconnection or defective
T13 (male) (1) and (2) - Max. 1R and T13. contact in wiring harness Repair or
and between (1). (2) * Turn starting between C2 (female) (13) - replace
and chassis ground switch OFF. T13 (female) (2)
* Disconnect CZ
- Between (1) - and T13.
(2): 5 - 15 n I Defective F solenoid Replace
Between (1). (2) - NO
chassis ground:
Min. 1 MD
-Turn starting 8YES Defective transmission Repair or
switch OFF. controller replace
* Disconnect T13.
Shon circuitwith power
source in wiring harness Repair or
Ez C2 (female) (2) and _ -Turn starting awitch NC between C2 (female) (13) - replace
chassis ground ON. T13 (female) (21
6 * DisconnectC2 and 113.
,- normal? Short circuit with power
Is resistance - -Max. 1V Repair or
- Turn starting source in wiring harness
YES between C2 between C2 (female) (2) -Tl: replace
- sGtch ON. NO
(female) (2) and (female) (1)
* Disconnect C2
5
and Tl3. Short circuit in wiring
-From 1 harnessbetween C2 (female) Repair or
(2) -T13 (female) (1) and
replace
between C2 (female) (13l-
T13 (female1(2)
Short circuit with chassis
ground in wiring harness Repair or
* Turn starring I
between C2 (female) (2) - T13 replace
switch OFF. NO
(female) (1)
* Disconnect C2
and T13.
Transmission
controller
F solenoid
TXW02446
0
TBOUBLESHOOTING T-4
T-4 Error code [I31 (Short circuit, disconnection, or short circuit with
power source in R solenoid 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.
Before carrying out troubleshooting, check that all the
Cause Remedy
related connectors are properly inserted.
Always connect any disconnected connectors before
going on to the next step.
QYES
Gotok
Is resistance bet-
YES ween ~2 (female)
3 - (3) and TM1 Disconnectionor defective
pIs resistance (female) (1) normal?
contact in wiring harness Repair or
YES between C2 between C2 (female1(3l-
.Max.lR NO replace
- (female) (14) and - TM1 (female) (7)
chassis ground * Turn starting switch
2 OFF.
- normal? Short circuitwith chassis
Is resistance bet- * DisconnectCt and Tll. ground in wiring harness Repair or
YI * Min. 1 M R
ween C2 (female) between C2 (female) (14) - replace
(14) and 111 - -Turn staning switch NO
Tl 1 (female) (2)
1 (female) (2) normal? OFF.
p . DisconnectC2 and
Disconnectionor defective
* Max. 1 R Tll.
contact in wiring harness Repair or
TM1(male1(11and(2) . Turn starting
andbetween(11,(21and batween C2 (female) (14l- replace
switch OFF. NO
chassis
groundnormal? ill (female) 12)
* Disconnect C2 and
Tll.
* Between (1) - (2):
5-154-t Defective R solenoid
l Between (1). (2) - NO
chassis ground:
Min. 1 MS-I
- Turn starting Defective transmission
switch OFF. controller
* DisconnectTMl.
Transmission
controller
R solenoid
TXW02447
T-5 Error code 1141 (Short circuit, disconnection, or short circuit with
power source in 1st solenoid 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.
* Before carrying out troubleshooting, check that all the Cause Remedy
related connectors are properly inserted.
* Always connect any disconnected connectors before
going on to the next step.
Go to A.
Disconnectionor defective
contact in wiring harness IRepair or
between C2 (female) (7) - T3 Ireplace
(female) (1)
Transmission
controller
id
TXWQ2448
0
TROUBLESHOOTING T-6
T-6 Error code [I!51 (Short circuit, disconnection, or short circuit with
power source in 2nd solenoid 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.
Before carrying out troubleshooting, check that all the Cause Remedy
related connectors are properly inserted.
Always connect any disconnected connectors before
going on to the next step.
4YES
Go to A.
Is resistance bet-
YES ween c2 (fernate)
3 (8) and T5 (female) Disconnection or defective
P (1) normal? contact in wiring harness
Is resistancebet- - ?epair or
YES ween ~2 (female) -Max. IR between C2 (female) (8) - T5 Feplace
NO
(18) and chassis (female) (1)
- Turn starting switch
_2 ground normal? OFF.
Short circuit with chassis
Is resistance bet- * Disconnect CZ and T5. Repair or
* Min. 1 MR ground in wiring harness
yes ween C2 (female1
between C2 (female) (18) -T? replace
(18) and T5 - * Turn startingswitch NO
OFF. (female) (21
(female) (2)
1
- 1 normal7 I l DisconnectC2 and
IS resistsnce
belwee” Disconnection or defective
* Max. 1 R Ts.
T5 (male)Ill and12) contact in wiring harness Repair or
andbetweenIll, (2) - . :I; starting switch NO between CZ (female) (18) -I? replace
andchassisground (female) (2)
n0tmai? ~ * DisconnectC2 and
l Between (l)-(2): T5.
5-15R Defective 2nd solenoid Replace
* Between 11). 12)- NO
chassis ground:
Min. 1 MR
* Turn starting switch BYE! Defective transmission ?eplace
OFF. controller
Is voltage between
* DisconnectT5.
YES ~2 (female) (18) and
7 chassis ground
Short circuit with power
- normal? 3epair or
Is voltage between source in wiring harness
Transmission
controller
id
TXW02449
WA 1200-3 20-423
0
TROUBLESHOOTING T-7
T-7 Error code [IS] (Short circuit, disconnection, or short circuit with
power source in 3rd solenoid 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.
* Before carrying out troubleshooting, check that all the
Cause Remedy
related connectors are properly inserted.
* Always connect any disconnected connectors before
going on to the next step.
4YEL
Gotok
I Is resistancebet-
lfrxnalel 1
Disconnectionor defective
normau Repair or
IL contact in wiring harness
between C2 (female) (9) -l7 replace
-.. . -1 NO
(female) (1)
‘- -‘=2ing switch
Short circuit with chassis
Is I st C2 and 17. ground in wiring harness Repair or
YE bek,e.x,w between C2 (female) (19) -T; replace
staning switch NO
(female) (19) antd ~7 H *Turn
__ (female) (2)
1 (fema,e)(“‘__--_‘, I I W-F.
I
z.LrzJ
l7 Imale) (1)and12)
. Max. 1 R I * DisconnectC2 and
17.
Disconnectionor defective
contact in wiring harness
between C2 (female) (19) -T;
Repair or
replace
and betwean(1). (2)
and chassisground (female) (2)
- Disconnect C2 and
17.
l Between (1) - (2):
5-15R Defective 3rd solenoid bolace
* Between (11, (2) - 0
chassis ground:
Min. 1 MR
. Turn STartin swirch SYES Defective transmission
OFF. -I- controller
Is voltage between
* Disconnect17.
7 r-l
YES cz (female) (19) and
chassis around u
Short circuit with power
source in wiring harness Repair or
between C2 (female) (19) -Ti replace
Ifemale) (2)
Transiaission
controller
id
TXW02450
0
TROUBLESHOOTING T-8
T-8 Error code [I81 (Short circuit, disconnection, or short circuit with
power source in R clutch drain valve solenoid 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.
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.
Cause Remedy
Go to A.
YE
Disconnection or defective
Transmission
controller R clutch drain
valve solenoid
FRI (HO-660661 RTI (HD-860661
11 TXW02451
1: 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.
* Check that fuse ii (6) is normal.
* 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.
Remedy
Defective transmission
Replace
controller
Disconnection, defective
I:;showninTable 11 contact, short circuit with
chassis ground, or short Repair or
circuit in wiring harness
- Turnstarting NO between JSl (female) (2). (3). replace
switch ON. [;;;C3B (female) (71, (14).
TXW02452
* 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.
* Check that fuse II (6) is normal.
* 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.
Remedy
Replace
Is
__ ._
v&agebetween
.-.
yes L5 (ternale) v3). (9).
Disconnection,defective
- (16). (17) and contdct, short circuit with
2
_ chassisground as chassisground. or short
Is voltage shown in Table 17 circuit in wiring harness Repair or
YES_ between JSl (I) NO between JSl (female) (5). (6). replace
_ - Turn starting
(7). (8) - C5 (female) (8), (9).
and chassis switch ON. 116).(17)
1
p ground normal?
ISvoitage between Disconnectionor defective
JSl (5). (6). (7). (8) -2O-30V cOntactin wiring harness Repair or
and chassisground - -Turn starting NO between Cl (male) VI, (131 or replace
as shown in Table switch ON. C2 (male) (lb, 112)- JSl
17 (female) (1)
-Turn starting
switch ON. Replace
Shift-up Shift-down
Terminals switch ON switch ON
TXW02452
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.
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.
Cause Remedy
I
C5, M02A. L28, and L07.
normal? Ii * Turn starting switch OFF.
. Between (1) - (2):
Defective travel speed
wo- lOM)R Replace
NO sensor
* Between (l), (2) -
chassis ground:
Min. 1 MR
* Disconnect T15.
* Turn starting
switch OFF.
Work equipment
controller
TXW02453
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.
Before carrying out troubleshooting, check that all the Cause
related connectors are properly inserted.
Always connect any disconnected connectors before
going on to the next step.
QYE!
Go to A.
Is resistance
YES between c4
3 (female) (9) and T17
Disconnection or defeotive
- Is resistance (female) (2) normal?
contact in wiring harness Repair or
YES between C4 between C4 (female) (9) - T17 replace
- (female) 11)and -
.Max.lR NC
- DisconnectC4,T1J. LOJ, (female) (2)
2 chassis ground
and MO2B
*Turn starting switch OFF. Short circuitwith chassis
ground in wiring harness Repair or
nect C4, NO between C4 (female) (1) -T17 replace
(female) (1)
)7, and M02B
, switch Disconnection or defective
contact in wiring harness Repair or
between C4 (female) (1) - T17 replace
(female) (1)
* Turn starting
~100-500R
switch OFF. Defective engine speed
- Disconnect T17. qeplace
NO sensor
* Turn starting
switch OFF.
TXW02454
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.
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.
Remedy
Defective transmission
Replace
controller
J, 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.
f 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.
Cause Remedy
Transmission
controller
C3A(040201
T/M oil temerature 328 11 ‘. 5’u J T3 (DTZB)
T-15 Error code [26] (Short circuit in F 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.
* Before carrying out troubleshooting, check that all the Cause Remedy
related connectors are properly inserted.
Jr Always connect any disconnected connectors before
going on to the next step.
2 YES Defective transmission
Replace
controller
Is resistance bat-
T-16 Error code [271 (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.
* Before carrying out troubleshooting, check that all the Cause Remedy
related connectors are properly inserted.
* Always connect any disconnected connectors before
going on to the next step.
2 YES Defective transmission
Replace
controller
__/lsresistancebet- 1 Ii
Short circuit with chassis
ground in wiring harness Repair or
between C3B (female) replace
(10) -T12 (female) (1)
TXW02456
T-17 Error code E281 (Short circuit in 1st ECMV fill switch svstem)
I 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.
Before carrying out troubleshooting, check that all the related connectors are orooerly inserted.
Always connect any disconnected connectors before going on to the next step. ’
ChUSe Remedy
T-18 Error code 1291 (Short circuit in 2nd 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.
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.
Cause Remedy
T-19 Error code [30] (Short circuit in 3rd ECMV fill switch svstem)
. 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.
* 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.
Transmission
TXW02457
* 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.
* 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.
Cause Remedy
M
3
* DisconnectT12.
tf T14 (female) (1) - Start engine.
YES is grounded to * Turn transmissioncut-oiR
switch OFF (Put out
chassis, is ‘32” lame).
2 displayed? . Turi parking brake
Is resistance - - switch OFF.
n between C3B *Turn startingswitch * Press brake.
. (female) (10) and - OFF. . Set directionalswitchin FI. I3efective F ECMV fill
T12 (female) (1) - Disconnect Tl4. Replace
IUO switch
n0ITlall -Start engine.
l Max. 1 R *Turn transmissioncut-offswitchOFF(Putout lamp).
*Turn parkingbrakeswitchOFF.
l Turn starting * Pressbrake. IDisconnection or defective qepair or
(female) (2) and T14 switch OFF. * Set directionalswitchto F. ,:ontact in wiring harness ‘eplace
(female) (11 normal? . Disconnect C3B, Ibetween C3B (female) (10)
T12, and M02k NO -T12 (female) (1)
* Max. 1 R
* Turn starting IDisconnection or defective
,Contact in wiring harness 3epair or
switch OFF.
NO Ibetween C3B (female) (2) - pplace
l Disconnect C3B.
T14 (female) (1)
T14, and M02A.
Transmission
Mod
CC”
TXW02456
T-21 Error code 1333 (Disconnection in lst, 2nd, or 3rd ECMV fill
switch system) is displayed
* This troubleshooting is carried out when there is still an abnormalii, 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.
* 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.
Cause Remedy
,
Is resistance Defective 1st ECMV fill
_rl
Replace
YES betweenC5 switch
Ifemale) (11) and T6 _m_^^^
_- T,.
Disconnection or defective
contact in wiring harness Repair or
* Turn starting
I T8. and M02A
Disconnection or defective
contact in wiring harness Repair or
NO between C3B (female) (11) replace
switch OFF.
. Disconnect C3B. - T6 (female) (1)
Transmission
TXWO2457
* 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.
* Before carrying out troubleshooting, check that all the related connectors are properly inserted.
f Always connect any disconnected connectors before going on to the next step.
Cause Remedy
Transmission
controller F brrass
k TXW02458
This troubleshooting is carried out when there is still an abnormalii, 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.
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.
GWX! Remedy
2 Defective transmission
controller Replace
Is resistance bet-
ween Cl (female)
(3) and chassis Short circuit with chassis
ground normal? ground in wiring harness Repair or
between Cl (female) (3) - replace
* Min. 1 MR
* Turn starting switch T22 (female) (1)
OFF.
* Disconnect Cl and T22. Defective F bypass
. Between (1) - (2): Replace
5-15R solenoid
* Between (1 L (2) -
chassis ground:
Min. 1 MR
. Turn starting
switch OFF.
* Disconnect T22.
Transmission
controller F bylass
TXW02458
Cause Remedy
Defective transmission
Replace
controller
Transmission
controller
Tl TXW0.2459
Cause Remedy
Defective transmission
controller Replace
Is resistance bet-
YES ween Cl (female)
1 (10) and chassis Short circuit with chassis
Is resistance ground normal? ground in wiring harness Repair or
between l-21 tmale)
(11and (21and _ lMin.lMQ NO between Cl (female) (10) replace
between (1). (2) and l Turn starting switch OFF. - T21 (female) (1)
chassis ground
n0nllall l Disconnect Cl and T21.
. Between (1) - (2): Defective R bypass
Replace
5-15n NO solenoid
* Between (1). (2) -
chassis ground:
Min. 1 MD
. Turn starting
switch OFF.
* Disconnect T21.
I74
11 TXW02459
T-26 Error code 1381 (Disconnection or short circuit with power source
in 1st bypass solenoid 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.
Sr 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.
I Cause 1 Remedy 1
11 TXW0.2460
Cause Remedy
Transmission
controller
TI TXWO2460
* Before carrying out troubleshooting, check that all the related connectors are properly inserted.
f Always connect any disconnected connectors before going on to the next step.
+ Always turn the starting switch OFF before disconnecting the connector or connecting the T-
adapter (or socket).
Cause Remedy
I
- Max. 1 R NO (female) (4) -chassis
(1) and L15 lfemalel * Disconnect Ll5. ground
I
Short circuit with chassis
ground, disconnection, or
* Disconnect C3B. Repair or
defective contact in wiring
* Auto/Manual replace
(male) (3) and (4) NO harness between C38
selector switch
(female) (1) - L15 (female)
ON: Max. 1 R (3)
OFF: Min. 1 MR
- Auto/Manual I Defective Auto/Manual
Replace
selector switch No selector switch
ON: Max. 1 R
OFF: Min. 1 MD
TXW0246 1
f Before carrying out troubleshooting, check that all the related connectors are properly inserted.
f Always connect any disconnected connectors before going on to the next step.
f Always turn the starting switch OFF before disconnecting the connector or connecting the T-
adapter (or socket).
Remedy
Transmission
ed when stwoino on
left brake Pedal. 1
TXW02462
0
TROUBLESHOOTING T-31
Cause Remedy
Is voltage between
C3B (female) (9)
and chassis 2 YES Defective steering lock
Replace
ground normal? switch
- Is voltage between
- Stat-t engine. _ STL (male) (1) and _ Short circuit with chassis
l Steering lock NO chassis ground ground, disconnection,
lever normal? or defective contact in Repair or
LOCK: 17 - 30 v - Start engine. NO wiring harness between replace
FREE: Max. 1 V * Steering lock C3B (female) (9) - STL
lever (female) (1)
LOCK: 17 - 30 v
FREE: Max. 1 V
Sleeri ng lock
Transmission
co
controller
WA 1200-3 20-445
0
TROUBLESHOOTING T-32
Cause Remedy
Neutralizer
relay
Fuse (I 1
FS2 (S12)(t?luel
L59
Parkino brake 88E 0.5fY t,
safety relay 0.75fU LR~ (HD-760861
0 5fB
; li3A;i 0:5tIf ”
lpn I- --
4
JLIE (DT2)
Transmission
controller
or
TXW02465
f 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.
* Always turn the starting switch OFF before disconnecting the connector or connecting the T-
adapter (or socket).
Call93 Remedy
l
Disconnect c3B. LO8, MOl, L26, and V3A
Short LO8 (female) (1). (3) to chassis.
Shon circuit with chassis
ground in wiring harness
between C3S (female) (41,
Repair or
replace
-Turn starting (12) -LOS (female) (1). (3).
switch OFF. MO1 (female) (1). (121or L26
(female) (1). (12). or V3A
- Disconnect C3B. (female) (8). (18)
L08, MOl, L26,
and V3A
TXW02466
Fuse (II)
Transmission FS5 (M6)
controller f
Cl I
” 6 90A
=Yz=
TXW02467
Ir 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.
Cause Remedy
1’
between C5 (female) (2) - TlE
-Turn starting
(female) (1)
switch OFF.
. Disconnect C5,
L07, M028, L28,
and T15.
York esuiumcot
controller
FR2 (HD-46082)
TXW02453
f 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.
J L26 (LIT21
Tra
con
Mod
con
TXW02445
* Before carrying out troubleshooting, check that all the related connectors are properly inserted.
Ir Always connect any disconnected connectors before going on to the next step.
Cause Remedy
Transmission
contr
JT3 (LIT261
temperature sensor
0
TROUBLESHOOTING T-39
* 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.
r Replace
IS reStStSnCe
_
bet-
normal?
II Defective transmission
controller
Repair or
- Stan engine. NO replace
ween C2 (female)
16) and chassis . Set FNR switch in ‘F” and shift-down
ground normal? switch to ‘Fl”: Max. 1 V
L Other setting than above: 17 - 30 V Shortcircuit with chassis
Min. 1 MQ ground in wiring harness Repair or
* Turn starting between M02A (female) replace
NO (13) - C2 (female) (6)
switch OFF.
* Disconnect C2 Disconnection or
* Max. 1 Q and M02.A. defective contact in
* Turn starting wiring harness between
switch OFF. NO
M02A (female) (13) - C2
- Disconnect C2 (female) (6)
and M02A.
Transmission h
joystick steering Modulated clutch
controller control I
c2 ~YIC21)
p. 5fW
FI signal 518 6
TXW02466
* 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.
* Perform diagnosis steps 2 - 6 when all of the lst, 2nd, and 3rd auto shift indicator lamps are
defective.
CaUSe Remedy
1YES
Go to A.
Is resistance
YES between ~92
3 r (male) (1) and (2)
Is resistance be- normal?
Defective resistor V-92) Replace
YES tween L69 (male) * 5 - 6.2 Id2 NO
(6) and chassis . Turn starting switch
2 ground normal? OFF. Disconnection or
If L69 is replaced . DisconnectW2. defective contact in
*Max.lD Repair or
with another relay, - wiring harness between
* Turn starting NO replace
is operation L69 (female) (6) -chassis
switch OFF. ground
normal?
. l Disconnect L69.
*Turn starting
Defective illumination
switch ON. Replace
relay (L69)
* Turn auto/manual NO
selector switch
OFF (Auto shift mode).
* Turn starting Defective auto shift
* Turn startina switch ON.
switch ON. indicator lamp (1st. 2nd, Replace
_ .
- Turn IJO or 3rd)
auto/manual
selector switch OFF
(Auto shift mode). lyE! -
GotoB
* Turn starting switch kmktawbrtweaaL95
ON. YES haleImadI.87 h!&
Ill.temen
L96
Ifemak)
(21 _ Disconnection or defect%
6- andL86ImaW (11.and contactintiring haineaa
- klwemL97WrcidOland betweanLWfemale) (2) - L67
Is voltagebatweanL55 LBSImaIell11
lbxrf?al? Repair or
yEs tfemafe)(1).I.% Imale)(1). betweenL96(female)
*Max.lQ N( (2) - L66lmale)(1). or between replace
- (female)11).I.97 *Turn startingawitch
(female)(1) andL66 U7 ffemale)I21- L65(male)(1)
5 OFF.
_ lfemalell2)normal? . Disconnect lJ5, LS6,L67, Disconnectionor defective
Is resistance contact in wiring harness
-Max.lD l.57.L56,andI.% qepair or
between L69 between W5 (female) (1). L96
From A - (female) (5) and - Turn starting Pplace
l NO (female) (1L LS7 (female) (1)
chassis ground switch OFF. - L69 (female) 121
normal7 . Disconnect L95, L96, L97.
Disconnection or defective
-5-6.2 kcz and L69.
contact in wiring harness Repair or
* Turn starting
NO between L&9 (female) (5) - replace
switch OFF.
chassis ground
. Disconnect L69.
Auto shift
indicator
Transmission
controller
51
T
illumination
TXW02563
Judgement table for modulated clutch control system related parts .............................................. 20-502
Operations of controller against abnormality and conditions of machine caused
by abnormality ................................................................................................................................. 20-504
Electric circuit diagram of modulated clutch control system .......................... .................................. 20-510
MC- 1 Error code [701 (Disconnection in boom RAISE/LOWER or bucket TILT/DUMP
pressure switch system) is displayed ............................................................................... 20-512
MC- 2 Error code 1721 (Abnormality in accelerator pedal sensor system) is displayed ............ 20-514
MC- 3 Error code 1731 (Short circuit in F/R ECMV fill switch system) is displayed.. .................. 20-515
MC- 4 Error code 1741 (Disconnection in Ist, 2nd, or 3rd ECMV fill switch system)
is displayed .......................................................................................................................... 20-516
MC- 5 Error code 1751 (Short circuit with chassis ground in lst, 2nd, or 3rd ECMV
fill switch system) is displayed ......................................................................................... 20-517
MC- 6 Error code 1761 (Short circuit in RPM-SET IDLE-UP/RESUME IDLE-DOWN
switch system) is displayed ............................................................................................... 20-518
MC- 7 Error code 1771 (Short circuit or disconnection in drive force control dial
system) is displayed ........................................................................................................... 20-519
MC- 8 Error code [781 (Short circuit or disconnection in travel speed control dial
system) is displayed ........................................................................................................... 20-520
MC- 9 Error code 1801 (Short circuit or disconnection in wheel rotation sensor
system) is displayed ........................................................................................................... 20-521
MC-10 Error code 1811 (Short circuit, disconnection, or short circuit with power source
in modulated clutch outlet rotation sensor system) is displayed ................................ .20-522
MC-11 Error code 1821 (Short circuit, disconnection, or short circuit with power source
in engine speed sensor system) is displayed .................................................................. 20-523
MC-12 Error code 1831(Short circuit or disconnection in travel speed sensor system)
is displayed .......................................................................................................................... 20-524
MC-13 Error code [841 (Short circuit, disconnection, or short circuit with power source
in neutral cut solenoid system) is displayed ................................................................... 20-526
MC-14 Error code 1851 (Short circuit, disconnection, or short circuit with power source
in modulated clutch ECMV solenoid system) is displayed ............................................ 20-527
MC-15 Short circuit in boom RAISE/LOWER or bucket TILT/DUMP pressure switch
system ................................................................................................................................ 20-528
MC-16 Disconnection in F ECMV fill switch system ....................................................................... -20-529
MC-17 Disconnection in R ECMV fill switch system ....................................................................... 20-529
MC-18 Disconnection in RPM-SET IDLE-UP/RESUME IDLE-DOWN switch system. .................... 20-530
MC-19 Abnormality in electronic governor voltage command system ........................................ -20-531
MC-20 Abnormality in transmission cut-off signal system ............................................................. 20-532
MC-21 Abnormality in modulated clutch ECMV fill switch system .............................................. .20-533
MC-22 Abnormality in right brake pedal switch system ................................................................. 20-534
MC-23 Abnormality in travel speed control ON/OFF switch system ............................................. 20-535
MC-24 Abnormality in RPM-SET ON/OFF switch system ............................................................... 20-536
MC-25 Abnormality in engine rotation output signal system ........................................................ 20-537
MC-26 Abnormality in power supply system of modulated clutch control system ................... 20-538
MC-27 Abnormality in network system ............................................................................................ 20-539
MC-28 Abnormality in Fl (Forward 1st gear) input signal system ............................................... -20-539
;;E
Location of failure 2
3
m
P
E
8
-0
ii
,P
T
2
z
.E
5
._
z
I
2
::
s
8
.%
2
.k
E
I%
Failure mode
-
Bte
78
-
1 Machine cannot travel
7 Drive force does not change even if drive force control dial is turned 0
-
8 Drive force control system operates while gear speed is not Fl
-
9 Drive force control system does not follow up drive force control dial
1) Voltage between M02A (8) - chassis ground 1) NC solenoid = OFF 1) Machine condition
When work equipment control lever is in neutral: Max. 1 V
does not change
When work equipment control lever is in boom RAISE
position: 15 - 30 V particularly.
2) Voltage between M02A (7) - chassis ground 2) Hydraulic loss is
When work equipment control lever is in neutral: Max. 1 V increased if
When work equipment control lever is in boom LOWER machine travels at
position: 15 - 30 V
3) Voltage between M02A (6) - chassis ground speed of 10 km/h or
When work equipment control lever is in neutral: Max. 1 V below in F3 gear.
When work equipment control lever is in bucket TILT C-l
position: 15 - 30 V
4) Voltage between M02A (5) - chassis ground
When work equipment control lever is in neutral: Max. 1 V
When work equipment control lever is in bucket DUMP
position: 15 - 30 V
Note: Move each lever a little (to degree that work
equipment does not move actually) (for detection
of PPC pressure signal).
1) Voltage between M02A (10) - M02A (9): 4.75 - 5.25 V 1) Controls for low Engine speed does not
2) Voltage between M02A (19) - M02A (9): 0.5 - 4.75 V idling. rise even if accelerator
3) Voltage between M02A (19) - M02A (9) fat low idling):
0.5 - 1.6 V pedal is pressed.
4) Voltage between M02A (19) - M02A (9) (at high idling):
[Voltage at low idling + 2.1) - 4.75 V
Note: Above table shows standard potentiometer voltage c-2
by which controller can recognize dial area normally.
When adjusting potentiometer again, leave margin
to error judgment area. Adjust voltage in range
from 1.3 to 1.6 V at low idling. (Error judgment
area is as follows; Potentiometer voltage < 0.5 V or
Potentiometer voltage x- 4.5 V)
1) Resistance between F ECMV fill switch T14 (male) (1) - 1) Engages modulated 1) Drive force doesnot
chassis ground: clutch directly. changeevenif driveforce
When forward switch is set to measuring point: Max. 1 R 2) NC so)enojd = OFF controldial is operated.
When forward switch is set out of measuring point Min. 1 MC
2) Resistance between I? ECMV fill switch T12 (male) (1) 2) Tire slip control system C-3
- chassis ground: does not work.
When reverse switch is set to measuring point: Max. 1 R 3) Shock time lag is made
When reverseswitch is set out of measuring point Min. 1 MR when travel direction is
t Start engine, turn transmission cut-off switch OFF, turn
changed.
parking brake OFF, and press brake pedal.
1) Resistance between lstJ2nd/3rd ECMV fill switch T4, 1) Engages modulated 1) Drive force does
T6, T6 (male) (I) - chassis ground: . clutch directly. not change even if
$r;_n,se; to measunng point with shrft-up/down switch: 2) NC solenoid = OFF
drive force control
When set out of measuring point with shift-up/down dial is operated.
switch: Min. 1 MR 2) Shock time lag is
It Starl engine, set forward/reverse lever in N, and turn made when travel
manual switch ON. c-4
direction is
Note: Default when engine is started is 2nd. If shift-down
switch is pressed and held, gear is shifted down to changed.
1st. If shift-up switch is pressed and held, gear is
shifted up to 3rd.
1) Resistance between lstf2nd/3rd ECMV fill switch T4, 1) Engages modulated 1) Drive force does
T6, T8 (male) (1) - chassis ground:. clutch directly. not change even if
KzF;;t to measurmg pomt wrth shrft-up/down switch: 2) NC solenoid = OFF drive force control
dial is operated.
When set out of measuring point with shift-up/down
switch: Min. 1 MR 2) Shock time lag is
t Start engine, set forward/reverse lever in N, and turn made when travel c-5
manual switch ON. direction is
Note: Default when engine is started is 2nd. If shift-down
changed.
switch is pressed and held, gear is shifted down to
1st. If shift-up switch is pressed and held, gear is
shifted up to 3rd.
I) Voltage between M02A (15) - chassis ground: I) Turns off RPM-SET Engine speed does not
When RPM-SET IDLE-UP/RESUMEIDLE-DOWNswitch IDLE-UP/RESUME change even if RPM-
is set to RESUME IDLE-DOWN position: Max. 1 V IDLE-DOWN SET switch is
When RPM-SET IDLE-UP/RESUME IDLE-DOWN function. operated.
switch is set to SET IDLE-UP position: 15 - 30 V
C-6
!I Voltage between M02A (16) - chassis ground:
When RPM-SET IDLE-UP/RESUMEIDLE-DOWN switch
is set to RESUME IDLE-DOWN position: 15 - 30 V
When RPM-SET IDLE-UP/RESUMEIDLE-DOWN switch
is set to RPM SET IDLE-UP position: Max. 1 V
I) Voltage between M02A (IO) - M02A (9): I) Slip ratio by drive 1) Drive force does
4.75 - 5.25 V force control dial = not change even if
!) Voltage between M02A (I) - M02A (9kO.5 - 4.75 V 100% drive force control
3) Voltage between M02A (I) - M02A 19) (Min.): dial is operated.
0.5 - 1.6V 2) Tire slip control
1) Voltage between M02A (19) - M02A (9) (Max.): system does not
[Min. voltage + 2.11 - 4.75 V work. c-7
Jote: Above table shows standard potentiometer voltage 3) Travel speed cannot
by which controller can recognize dial area be controlled.
normally. When adjusting potentiometer again,
leave margin to error judgment area. Adjust
voltage in range from 1.3 to 1.6 V at low idling.
(Error judgment area is as follows; Potentiometer
voltage c 0.5 V or Potentiometer voltage > 4.5 VI
I) Voltage between M02A (10) - M02A (9): 4.75 - 5.25 V I) Slip ratio by travel I) Drive force does
!) Voltage between M02A (10) - M02A (9): 0.5 - 4.75 V speed control dial not change even if
$1Voltage between M02A (10) - M02A (9) (Min.): 0.5 - 1.6 V = 100% drive force control
1) Voltage between M02A (IO) - M02A (9) (Max.): 2) Max. travel speed dial is operated.
[Min. voltage + 2.71 - 4.75 V = 12 km/h 2) Tire slip control
rlote: Above table shows standard potentiometer system does not
voltage by which controller can recognize dial work. C-8
area normally. When adjusting potentiometer 3) Travel speed cannot
again, leave margin to error judgment area. be controlled.
Adjust voltage in range from 1.3 to 1.6 V at low
idling. (Error judgment area is as follows;
Potentiometer voltage e 0.5 V or Potentiometer
voltage > 4.5 VI
I) Resistance between wheel rotation sensor PI5 1) Turns off tire slip I) Drive force does
(male) (2) - (3): 100 - 500 R control. not change even if
drive force control
dial is operated.
2) Tire slip control
system does not c-9
work.
3) Travel speed cannot
be controlled.
I) Modulated clutch outlet rotation sensor I) Turns off I) Drive force does
Resistance between T16 (male) (I) - (2): modulated clutch not change even if
500 - 1000 R control (Engages drive force control
Resistance between T16 (male) (I), (2) - chassis clutch directly). dial is operated.
ground: Min. 1 MS2 2) Tire slip control C-IO
system does not
work.
3) Travel speed cannot
be controlled.
1
(Voltage, current, resistance) against abnormality caused by abnormality code
I
1) Travel speed sensor
Resistance between T15 (male) (1) - (2):
500 - 1000 R
Resistance between T15 (male) (11, (2) - chassis
ground: Min. 1 MR
I) Turns off tire slip
control.
2) Turns off
modulated clutch
control (Engages
clutch directly).
3) NC solenoid = OFF
1) Drive force does
not change even if
drive force control
dial is operated.
2) Tire slip control
system does not
work.
3) Travel speed cannot
be controlled.
c-12
Voltage between MO1 (female) (21) - chassis 1) NC solenoid output Work equipment does
OFF not rise quickly. (When
ground short CkCUit with
(When short circuit
When work equipment control lever is operated: power source is made)
17-3ov with power source
is made, NC Neutral cut control
When work equipment control lever is in neutral: system does not work
Max. 1 V solenoid output c-13
(Machine condition
cannot be turned
off.) does not change
lte) Move the lever a little (to degree that work particularly). (When
equipment does not move actually) (for disconnection or short
detection of PPC pressure signal). circuit with chassis
ground is made)
WA 1200-3 20-509
0
ELECTRIC CIRCUIT DIAGRAM OF MODULATED
TROUBLESHOOTING CLUTCH CONTROL SYSTEM
IMP-SET
IDLE-UP/
RESUME
Boom LOWER
switch
1st Ii I rmitcb
I-
0uMTuY
TXW02470
CaUSe Remedy
4M!
GotoA -
Is resistance
YES between HR12
3 (female) (1) and
-
Is resistance (2) normal? Defective boom LOWER
YES between HR13 -Start engine. pressure switch Replace
- *bornLOWER operation
NC
- (female) (1) and Whenleveris operated
2
(2) normal? aliie:Max.lQ
‘Is- Whenleverisin
YES between HR3
l Start engine. neutral:Min. 1 MQ Defective boom RAISE
Replace
- (female) (1) and - * ‘Oorn RA’SE NO pressure switch
operation
1 (2) normal?
_ When lever is operated a little: Max. 1 R
Is resistance * Start engine. When lever is in neutral: Min. 1 MR Defective bucket TILT
between HRb . Bucket TILT Replace
(female) (1) and - pressure switch
operation NO
(2) normal? . When lever is operated a little: Max. 1 R
* Start engine. When lever is in neutral: Min. 1 MR
Defective bucket DUMP
Replace
operation NO pressure switch
When lever is
operated a little:
Max. 1 R 7YEs -
When lever is in Go to B.
Is resistance
neutral: YES between M02A
Min. 1 MR (female)6) and HR3 -
6 Disconnection or defective
- (female1(1) normal?
Is resistance contact in wiring harness Repair or
YES between MO24 - Max. 1 Q NO between M02A (female) (6) replace
(female) (5) and HR4 * Turn starting switch - HR3 (female) (1)
5
_ (female) (11normal? OFF.
- - DisconnectMO2and
- Max. 1 R _ HR3. contact in wiring harness Repair or
From A HR13 (female)(2) and 7 Turn starting
l NO between M02A (female) (5) replace
switch OFF.. ._- - HR4 (female) (1)
* Disconnect MO2 Disconnection or defective
- Max. 1 R and HRb. contact in wiring harness Repair or
Turn starting between HR3, HR4, HR12, replace
l
Disconnection or defective
contact in wiring harness Repair or
between MO% (female) (8) replace
From 8 - HR13 (female) (1)
Disconnection or defective
contact in wiring harness Sepair or
*Turn starting between M02A (female) (7) replace
NO
switch OFF. - HR12 (female) (1)
. Disconnect MO2
and HR12.
Wor
con
switch
ChUSe Remedy
3 YES
GotoA -
Is resistance
yEs between M02A
- Ifemale) (10) and -
2 Disconnection or defective
_ L25 (female) (3)
Is resistance normal? contact in wiring harness Repair or
YES between MWA
Max. 1 R
l NO between MOZA (female) replace
- (female) (19) and -
* Turn starting (10) - L25 (female) (1)
1 chassis ground
- Is resistance normal? switch OFF.
Short circuit with chassis
- * Disconnect MO2 and l.25.
between MOZA * Min. 1 MR ground in wiring harness Repair or
(female) (19) and - lTurn starting NO between M02A (female) replace
LZ5 (female) (1) switch OFF. (19) -L25 (female) (1)
normal? - lDisconnect MO2
- Max. 1Q Disconnection or defective
and l.25.
contect in wiring harness Repair or
*Turn starting
NO between M02A (female) replace
switch OFF.
(19) - L25 (female) 41)
and l-25.
6 YES Defective modulated
clutch controller Replace
YES Is voltage
- between I_25 (1) -
5
_ and (2) normal?
Isrssistsncebetween ~ ._ Defective accelerator
n ; M02A (female)110). *At low idling: NO pedal potentiometer Replace
(19) and chassis - 0.5-1.6V
4 At high idling: Short circuit of wiring
groundnormal?
harness between MO2A
I Is resistance 1 ~ (Low idling voltage + 2.1 VI - 4.75 V
- Min. 1 MQ -Turn staning switch ON. (female) (10) - L25 (female) Repair or
Fro~~j;~d ] * Turn starting (3) with wiring harness replace
NO
switch OFF. between M02A (19) - L25
* Disconnect MO2 (female) 11)
* Min. 1 MR and L25. Short circuit with chassis
* Turn starting ground in wiring harness Repair or
switch OFF.
uo between M02A (female) replace
l Disconnect MO2 (10) - L25 (female) (3)
and L25.
Accelerator
Pedal
Madulated clutch
con
ri+r TXW02472
MC-3 Error code [73] (Short circuit in F/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.
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.
Call!% Remedy
Defective modulated
Replace
clutch controller
Transnission
TXWO2456
MC-4 Error code [741 (Disconnection in lst, 2nd, or 3rd 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.
* Before carrying out troubleshooting, check that all the related connectors are properly inserted.
It Always connect any disconnected connectors before going on to the next step.
Cause Remedy
4YE
Go to A.
If T4 (female) (1)
YES is grounded to
3- chassis, is ‘74”
displayed? Defective 1st ECMV fill
Is resistance
switch Replace
YES between MOZA -TUT” starting Switch N(
(14) and T8 -
OFF.
(female1
* Discomen 14.
2 (female) (1) normal? -Start engine.
- *Setf0WwdlmmrselsvsrinN Disconnection or defective
Is resistance *SOt~~~ShiilOV~illlSt.
*Max.lR contact in wiring harness Repair or
fis between MOZA
- * Turn starting NO between M02A (female) replace
(female) (1) and T6
switch OFF. (14) - T8 (female) (1)
1 (female) (1) normal?
- * Disconnect C5,
Is resistance Max. 1 R Disconnection or defective
l TB, M02A.
between M02A contact in wiring harness Repair or
* Turn starting
(female) (2) and T4 - NO between MO24 (female) (1) replace
switch OFF.
(female) (1) normal? -T6 (female) (1)
l Disconnect C3B.
*MaxlR TS, M02A. Disconnection or defective
* Turn starting contact in wiring harness Repair or
switch OFF. NO between M02.A (female) (2) replace
* Disconnect UB, - T4 (female) (1)
T4, M02k
6 YES Defective modulated
If T8 (female) (1) clutch controller
YES is grounded to
5 chassis, is ‘74”
If T6 (female) (1) , displayed? Defective 3rd ECMV fill
is grounded to *T$;; starting switch NO switch
From A -
chassis, is ‘74” * Disckct T8.
displayed? * Stan engine.
- * Set forward/reverse lever in N.
* Turn starting . Set gear shift lever in 3rd. Defective 2nd ECMV fill
switch OFF. NO switch
* Disconnect T6.
l Start engine.
* Set forward/reverse
lever in N.
l Set gear shift lever
in 2nd.
TXW0.2457
MC-5 Error code 1751 (Short circuit with chassis ground in Ist, 2nd, or
3rd 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.
* Before carrying out troubleshooting, check that all the related connectors are Drooerly inserted.
* Always connect any disconnected connectors before going on to the next step. ’
CaUSe Remedy
4YE! -
GotoA
YES_ [
(female) (21 and
Short circuit with chassis
Is resistance ground in wiring harness Repair or
YES between ~8 (mate) -Min.1 MQ NC between M02A (female) (2) replace
(1) and chassis *Turn starting switCh -T4 (female) (1)
_ 2 ground normal? OFF.
Is resistance - * DisconnactM&U, 635,
Min. 1 MD
l and TO. Defective 3rd ECMV fill
YES between T6 (male) Replace
- Turn starting
l NO switch
(1) and chassis
1 ground normal? switch OFF.
* Disconnect T8.
Is resistance lMin. 1 MR
between T4 (male) Defective 2nd ECMV fill
* Turn starting Replace
(1) and chassis - NO switch
switch OFF.
ground normal?
* Disconnect T6.
* Min. 1 MD
*Turn starting I Defective 1st ECMV fill
switch OFF. NO switch
l Disconnect T4.
I
I&a~.sground 1 * Turn starting
switch OFF. Short circuit with chassis
* Min. 1 MR * Disconnect M02A. C5, and T8. ground in wiring harness ?epair or
Turn starting between MOZA (female) (1) *eplace
l NO
switch OFF. -T6 (female) (1)
* Disconnect
M02A. C3B, and
T6.
CaUSt? Remedy
Table 1
RPM-SET IDLE- RESUMEJDLE-
UP switch ON DOWN switch ON
Between LllO (female) (1) - (2) Min. 1 MR Max. 1 R
Between LllO (female) (3) - (2) Max. 1 R Min. 1 MC?
Modulated clutch
con
TXW02473
Remedy
GotoA -
fi TXW02474
* 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.
* 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.
Remedy
GotoA -
Modulated clutch
Vehicle speed
controller
- MOZA (04020)
rffr TXW02475
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.
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.
I CaUSe Remedy
GotoA -
Replace
H I
between MOZB
From A Short circuit of wiring
(female) (11) and Vl
-I (female) (3) normal? harness between M02B
Repair or
’- Min. 1..-
MS2 replace
- Disconnect M02B
Vl, and F15.
*Turn starting
switch OFF.
WA1 200-3
TROUBLESHOOTING MC-IO
Disconnection or defective
resistence
Is contact in wiring harness Repair or
yRS between MO26 'MaX.lQ between M02B (female) replace
- (female) (4)and - NC
* DisconnectTX, (12) -T16 (female) (2)
2 chassisgmund
M02B. and C4.
- normal? Short circuit with chassis
Is resistance *Turn starting switch OFf
l Min. 1 MR ground in wiring harness Repair or
Eg between M02B
betwean MOZB (female) (41 replace
(female) (4) and T16 - .DisconnectT16,
NO
M02B, and C4. -T16 (female) (1)
1 (female) ~llnorrnal?
P l Turn starting
Is resistance *Max. 1 R Disconnection or defective
switch OFF.
between T16 _ * Disconnect T16,
contact in wiring harness Repair or
(male) (1) and (2) between MO26 (female) (4) replace
M02B, and C4. ND
normal? -TN (female)(1)
* Turn starting
l600-1,OOOR switch OFF.
Defective modulated
* Disconnect T16.
clutch outlet rotation Replace
*Turn starting NO
sensor
switch OFF.
Defective modulated
From*Jijg%jf 1normal?
clutch controller
TXW02445
GotoA -
yES between MOZB
- (female) (12) and -
3 Disconnection or defective
- T17 (female) (2)
‘Is resistance normal? contact in wiring harness Repair or
yes between MOZB
*MaX.1R N( between C4 (female) (9) - replace
- (female) (5) and -
* Disconnecr C4, T17, T17 (female) (2)
! chassis ground
L07, and MOZB.
- normal? Short circuit with chassis
- -Turn starting switch
l Min. 1 MR OFF. ground in wiring harness Repair or
- *Disconnect C4, NO between C4 (female) (1) - replace
T17 (female) (1)
I
1 (female) (1) normal? T17, L07, and
M02B.
lMax.lR Disconnection or defective
*Turn starting switch OFF.
contact in wiring harness Repair or
*Disconnect C4,
(male) (1) and (2) NO between C4 (female) (1) - replace
T17, L07, and
T17 (female) (1)
MOZB.
*500-1,ooon I* Turn starting
1 switch OFF. Defective engine speed
* Disconnect T17.
l Turn starting NO jensor
switch OFF.-
Modulated clutch
controller
MOZB (040 16)
TXW02454
f 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.
Sr 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.
C.WSB Remedy
4YE!
GotoA -
Is resistance
yRG between MO25
- Ifemale) (12) and -
-
3 Disconnection or defective
T15 (female) (2)
Is resistance contact in wiring harness Repair or
normal?
yes between M02E between M02B (female)
*Max.lQ NC replace
- (female) (13) and -
(12) - T15 (female) (2)
*Disconnect Cf. T15,
? chassisgmund
L07, and M02B.
- Pnormal? *Turn starting switch Short circuit with chassis
lMin. 1 MR OFF. ground in wiring harness Repair or
- lDisconnectC5, NO betwesn M02B (female) replace
T15, L07, and (13) -T15 (female) (1)
I l
M02B.
Turn starting switch OFF.
Disconnection or defective
contact in wiring harness
between MOZB (female)
Repair or
NO replace
normal? (13)-T15 (female) (1)
1 M02B.
*5oo-wo0R *Turn starting
* Disconnect T15. switch OFF. Defective travel speed
Replace
sensor
l Turn starting NO
switch OFF.
n ES
5
figi%Jj- clutch controller
I
source in wiring harness Repair or
I
From A
-I
Is resistence
between MOZB
(female) (13) and
- l
Max. 1 V
Disconnect C5,
NO
between M02B (female)
(13) - T15 (female) (11
replace
Transmission I II
TXW02453
* 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.
Ir 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.
Cause Remedy
OYE!
GotoA -
[Is resistance lr-
Disconnection or defective
contact in wiring harness Repair or
Yf between HRl (female) (2) - replace
chassis ground
2
Is rssistance Short circuit with chassis
YES between MO1 ground in wiring harness Repair or
- (female) (21) and - *Turn starting NO between MO1 (female) (21) replace
HRl (female) (11 mitch OFF. - HRl (female) (1)
1
- normal? * Disconnect Mol.
Is resistancebetween ’ Disconnection or defective
*Max.lR HRI, and HR2.
HRl (male) (1) and contact in wiring harness Repair or
(2) and between (1). - ‘Turn atarting between MO1 (female) (21) replace
(2) and chassis switch OFF. 10
- HRl (female) (1)
mound normal? * Disconnect MO1
+ Between (1) - (2): and HRl.
5-15Q I Defective neutral cut
Replace
* Between (1). (2) - NO solenoid
chassis ground:
Min. 1 MR
*Turn starring switch OFF.
5 YES Defective modulated
* Disconnect HRl. Replace
Is v&age between clutch controller
MO1 (female) (21)
From A
-I and chassis ground l-l
Short circuit with power
normal?
I source in wiring harness Repair or
- Max. 1V NO between MO1 (female) replace
* Turn starting (21) - HRl (female) (1)
switch OFF.
* Disconnect Mol. HRl,
and HR2.
*Turn starting switch ON.
JR3 (DTl)
Modulated clutch
controller
Nuetral cut
solenoid
HRZ (DTZ)
R2D TXW02477
20-526 WAIZOQ-3 .
0
TROUBLESHOOTING MC-14
Hodulated clutch
CO” solenoid
TXW02478
Cause Remedy
4YE
Is resistance
r GotoA -
YES between M02A
- (female) (81 and -
3 Short circuit with chassis
- chassis ground
Is resistence “O”Tlel? ground in wiring harness Repair or
L
YES between MO2A *Min. 1 MR between M02A (female) (8) replace
- (femele) (7) end- .T;;;.mning
&t,.hN’ - HA13 (female) (1)
2 chassis ground
PIs resistance - normal? *Disconnect MO24 Short circuit with chassis
YES between MOZA * Min. 1 MD HR13, and i27. ground in wiring harness Repair or
(female) (6) and - Turn starting
l
NO between M02A (female) (7) replace
, chassis ground switch OFF. - HR12 (female) (1)
I Disconnect MOZA,
I
normal? l
Short circuit with chassis
l Min. 1 MD HR12. and L27.
between M02A ground in wiring harness Repair or
(female) (5) and *Turn starting
NO beween M02A (female) (6) replace
switch OFF.
- HR3 (female) (1)
* Disconnect MOZA
and HR3. Short circuit with chassis
* Min. 1 MD
I ground in wiring harness Repair or
*Turn starting
NO between M02A (female) (5) replace
awitch OFF.
- HR4 (female) (1)
* Disconnect MOZA
and HR4.
5 YES Defective modulated
Replace
Is resistance II clutch controller
between M02A Short circuit of wiring
From A -
(female) (5). 16).(71, - harness between M02A
and (8) normal? (female) (5) - HR4 (female) Repair or
(1). between MOZA(female)
* Min. 1 MR NO replace
(6) - HR3 (female) (1).
*Turn atatting between MONA(female) (7) -
switch OFF. HR12 (female) (1). and
* Disconnect M02A. U7, HR3, bsrween MONA(female) (8) -
HR4, HR12, and HR13 HR13 (female) (1) with each
other
37
Bucket dump
switch
Wor
con Bucket tilt
switch
Boom raise
switch
TXW0247 1
* 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.
Cause Remedy
* 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.
Remedy
Transmission
_ R fill switch
TXW0’2456
f Before carrying out troubleshooting, check that all the related connectors are properly inserted.
t Always connect any disconnected connectors before going on to the next step.
Remedy
Table 1
RPM-SET IDLE- RESUMEJDLE-
UP switch ON DOWN switch ON
Between LllO (female) (1) - (2) Min. 1 MR Max. 1 R
Between LllO (female) (3) - (2) Max. 1 R Min. 1 MR
Modulated clutch
.
4-j 2 000
TXW02473
+ 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.
Modulated clutch
controller OUANTUM
NO1 (NIC21) LRI (HD-95066)
)ELc.0”.*01 W1..1 1355( I
TXW02479
Modulated clutch
rnntrnlIPr
__ . _ _ MOO/C f i II
RT2 (HD-85086) T10 (011) switch
11’1711 =FE
- __-
lLLl
TXWO2480
Cause Remedy
i TXW0248 I
* Before carrying out troubleshooting, check that all the related connectors are properly inset-ted.
* Always connect any disconnected connectors before going on to the next step.
Modulated clutch
M02A (04020) . Speed set
switch
Cause Remedy
Defective modulated
YES
clutch controller Replace
Is voltage between
YES (female) (3)
M02B Short circuit with chassis
Nodu RPM-SET
cant
* 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.
d
1and chassis r
clutch controller
Shon circuit with chassis
ground, disconnection,
Replace
I (7)
Modulated clutch
con
VHMS controller
Work eauiDment
controller L28 1040 16)
TXW02484
I Cause Remedy
Disconnection or
defective contact in
wiring harness between Repair or
MO1 (female)(8),(17). replace
(18)-MO1 W,M02A(9)
Disconnection or
defective contact in Repair or
- Max. 1R NO wiring harness between replace
. Turn starting MO1 (female) (91, M02A
switch OFF. (female) (9) - chassis
- Disconnect MO1 ground
and M02A.
Modulated clutch
con
TXW02485
* See “T-39 Fl (Forward 1st gear) signal system” in troubleshooting for transmission controller
system.
Judgement table for work equipment control system related parts ............................................... .20-602
Operations of controller against abnormality and conditions of machine caused
by abnormality ................................................................................................................................. 20-604
Electrical circuit diagram for joystick steering system ..................................................................... .20-608
J- 1 Error code I551 (Abnormality in travel speed sensor system) is displayed.. ....................... 20-609
J- 2 Error code 1561 (Disconnection or short circuit with chassis ground in
caution buzzer relay system) is displayed ....................................................................... 20-610
J- 4 Error code [581 (Deviation of steering lever angle sensor and frame
angle sensor potentiometer signals ................................................................................. 20-612
J- 9 Short circuit with chassis ground in travel speed sensor system ......................................... 20-617
J-10 Steering speeds in both directions are different ..... ................................................................ 20-618
Location of failure
Failure mode
63
Refer to
1 1 Engine cannot be started G mode
2 1 Steering speed is heightened -
1) Resistance between travel speed sensor T15 Turns off steering Steering speed is
(male) (1) - (2): 500 - 1,OOOQ main pressure control heightened even at
EPC solenoid. high travel speed.
J-l
11 Voltage between relay L65 (1) - chassis ground Does not operate at Caution buzzer does
when caution buzzer is turned on: 20 - 30 V all. not sound or keeps
2) Resistance between work equipment controller sounding.
L28 (15) - chassis ground, caution buzzer relay:
200 - 4OOQ
3) Resistance between work equipment controller J-2
L28 (female) (15) - L65 (female) (1): Max. 1 R
4) Resistance between caution buzzer relay L65
(female) (2) - chassis ground: Max. 1 R
I) Voltage between work equipment controller L27 1) Turns off steering Steering speeds in
(20) - (9): 0.5 - 4.5 v main pressure both directions are
!I Resistance between steering lever angle sensor control EPC different.
JS2 (male) (1) - (2): 0 - 5 kS2 solenoid output.
2) Controls steering
J-3
lever angle sensor
signal voltage as
input voltage.
I) Voltage between work equipment controller L27 Turns off steering Steering speeds in
(20) - (9): 0.5 - 4.5 v main pressure control both directions are
2) Voltage between work equipment controller L28 EPC solenoid output. different.
(1) - L27 (9): 0.5 - 4.5 V
3) Resistance between steering lever angle sensor
JS2 (male) (1) - (2): 0 - 5 kQ
4) Resistance between frame angle sensor L30 J-4
(male) (1) - (2): 0 - 5 kD
1) Voltage between work equipment controller L28 1) Turns off steering Steering speeds in
(1) - L27 (9): 0.5 - 4.5 V main pressure both directions are
2) Resistance between frame angle sensor L30 control EPC different.
(male) (1) - (2): 0 - 5 kQ solenoid output.
2) Controls frame
J-5
angle sensor signal
voltage as input
voltage.
Voltage between work equipment controller L27 Turns on caution (In case of
(female) (1) - chassis ground: buzzer. disconnection}
l When steering lock lever is in LOCK: 20 - 30 V I) Transmission is
. When steering lock lever is in FREE: Max. 1 V kept in N.
2) Steering system is
operable normally.
Voltage between work equipment controller L26 Does not operate at 1) Engine can be
(female) (21) - chassis ground: all. started while
l When steering lock lever is in NEUTRAL: Max. 1 V machine is steered.
2) Machine is steered
suddenly after J-7
engine is started
3) Engine cannot be
started.
Current flowing between work equipment controller Turns off steering I) Response of
L26 (2) - (16): 600 & 80 mA main pressure control steering system is
(Check on CGC monitor.) EPC solenoid output. lowered.
2) Steering speed is
lowered.
3) Response of J-8
steering system is
heightened
4) Steering speed is
heightened
TXW02486
WA1 200-3
TROUBLESHOOTING J-l
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.
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.
Cause Remedy
TXW02453
WA1 200-3
TROUBLESHOOTING J-2
J-2 Error code [56] (Disconnection or short circuit with chassis ground
in caution buzzer relay 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.
* Before carrying out troubleshooting, check that all the related connectors are properly inserted.
* When the joystick steering lever is not being used, leave it at the neutral position.
* Always connect any disconnected connectors before going on to the next step.
Replace
- l;;ha;ground 11 withc&as$sis;md&
Is rssistance Repair or
yes between I.28 replace
- (female) (15) and - * Mi”-’ MC2 NO L28 (female) (15) - L66
* Turn starting (female) (1)
2 L65 Ifemale) (1)
-
Is resistance normat? . D~~~~nor.U8 and L65. Disconnection or defective
YES between L65 - Max. 1 R contact in wiring harness Repair or
- (female) (2) and - -Turn starting NO between L28 (female) (15) - replace
chassis ground switch OFF. L65 (female) (1)
1
- - normal? - Disconnect L28
Is resistance Disconnection or defective
* Max. 1 R and L65.
between L65 contact in wiring harness Repair or
_ * Turn starting between L65 &male) f21-
(male) (1) and (2) NO replace
switch OFF. chassis ground
normal? * Disconnect LG.
1
.200-400R
‘Turn starting Lo 1r caution buzzer Rep,ace
switch OFF.
* Disconnect L65.
I
L65
OlOAV 0.5fB 6 Jovst ick
Work eauipment~
controller 124AB 0.5fL : taut ion
L28 (04016) OIOAU 0.5fB buzzer
252 0.5fY :
J/S caution relay 252 15 ” 5fY relay
m
m
TXW024137
J-3 Error code [57] (Disconnection or short circuit with chassis ground
in steering lever angle sensor 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.
* Before carrying out troubleshooting, check that all the related connectors are properly inserted.
* When the joystick steering lever is not being used, leave it at the neutral position.
* Always connect any disconnected connectors before going on to the next step.
Remedy
Replace or
adjust neutral
position
neutral position)
Disconnection, defective
(female) (20) and contact,short circuitwith
chassis ground, or short circuti Repair or
with power source in wiring replace
harnessbetween L27 ffemale)
(20) - JS2 (female)(1)
left (0.5 - 4.5 V) Defective steerintg lever
(female) (10) and Replace
* Lean steering angle sensor
lever to right or
left (0.2 - 5 kc11
Replace
Work eauiwnent
Pontentionetcl
TXWO.2488
J-5 Error code 1591 (Disconnection or short circuit with chassis around
in frame angle sensor 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.
Before carrying out troubleshooting, check that all the related connectors are properly inserted.
When the joystick steering lever is not being used, leave it at the neutral position and turn the
joystick steering selector switch ON.
Always connect any disconnected connectors before going on to the next step.
CaUSe Remedy
Improper installation of
Replace or
frame angle sensor
adjust neutral
(Deviation of neutral
position
position)
Disconnection, defective
contact short circuit with
chassis ground, or short circuit Repair or
with power source in wiring replace
harness between LZ8 (female)
(1) - WO (female) 11)
Defective frame angle
Replace
l Change frame NO sensor
I J angle
-4.9-5.1 v
(0.2 - 5 kQ)
*Turn starting switch
Defective work
ON. Replace
IO equipment controller
Work eauiDment
Pontentioncter
rotentiometer
Txw024aa
J-6 Error code [611 (Disconnection or short circuit with chassis ground
in steering lever lock pressure switch system) is displayed
f 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.
* Before carrying out troubleshooting, check that ail the related connectors are properly inserted.
Ir Always connect any disconnected connectors before going on to the next step.
cause Remedy
, fZ!Z&-H
Disconnection or defective
contact in wiring harness Repair or
YES between STL (1) between L27 (female) (2) - replace
.dl”““““h chassis ground
L
ground normal? Disconnection or defective
Is voltage contact in wiring harness Repair or
lo-2v
YES between L27 (1) between L27 (female) (1) - replace
- . Turn starting
and chassis STL (female) (1)
switch OFF.
_1 ground normal?
. Disconnect L27 Short circuit with chassis
~20-3ov and STL Repair or
ground in wiring harness
_ lTurn starting between L27 (female) (1) replace
(male) (1) and (2) switch ON. NO
- STL (female) (1)
lTurn steering lock
* Max. 1 R pressure switch ON.
Defective steering lock
* Disconnect STL Replace
NO pressure switch
Start engine.
l
When steering
lock lever is in FREE:
Max. 1 R
When steering
lock lever is in LOCK:
Min. 1 MR
ry
WA1 200-3
TROUBLESHOOTING J-7
J-7 Error code 1621 (Disconnection or short circuit with chassis ground
in steering neutral interlock relay system) is displayed
j, 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.
* 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.
F
Cause Remedy
Work equipment
controller L26 (MIC21) L127
573 0.5fY
J/S neutral lock relay 573 21 ‘. 5fY
OlOBT 0.5fB ; Steer ins
m
nr) 3 neutral
< 5
6 relay
0
TXW02490
WA 1200-3 20-615
0
TROUBLESHOOTING J-8
J-8 Error code [631 (Disconnection, short circuit with chassis ground,
or short circuit with power source in steering main pressure
control EPC solenoid 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.
+ Before carrying out troubleshooting, check that all the related connectors are properly inserted.
f Always connect any disconnected connectors before going on to the next step.
* When the joystick steering lever is not being used, leave it at the neutral position.
CalIS Remedy
4YE! 5
GotoA.
Is resistance
YES between L26 Short circuit of wiring
3 (female) (6) and harness betwean I_26
pIs resistance (16) normal? (female) (6) - L2S (female) Repair or
y~5 betweenl.26 (2) with wiring harness replace
- (female) (16) and - * Min* ’ MR NC1 between U6 (female) (16)
i! chassis gmund * Turn starting and L29 (female) (1)
1Is resistance - normal? switch OFF.
Short circuit with chassis
* Min. 1 MD * Disconnect L26. Repair or
ground in wiring harness
lfamalelf6l and - * Turn starting NO between L26 (female) (16) - replace
I
switch OFF- US (female) (1)
* Disconnect I_26
Short circuit with chassis
* Min. 1 MQ and l29.
ground in wiring harness Repair or
*Turn starting
NO between L26 (female) (6) - replace
switch OFF.
US (female) (2)
. Disconnect l-26
*Turn starting and US. Defective steering main
switch OFF. pressure control EPC Replace
* Replace with solenoid
other same EPC
solenoid.
*Turn starting 5 YES Defective work
switch ON. is resistance Replace
equipment controller
between L26
From A - (female) (6) and -
chassisground Short circuit with power
normal? source in wiring harness rlepair or
* Max. 1 V NO between l.26 (female) (6) aplace
. Disconnect L26 - L29 (female) (2)
and l-29.
*Turn starting
switch ON.
TJW02491
J-9 Short circuit with chassis ground in travel speed sensor system
* Before carrying out troubleshooting, check that all the related connectors are properly inserted.
Ir Always connect any disconnected connectors before going on to the next step.
Cause Remedy
Transmission
TXW02453
Cause
Deviation of steering
lever angle sensor or Repair or
frame angle sensor replace
potentiometer
* 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.
Remedy
Work equipment
controller L27 (04020)
Cons0 I
Transmission h joystick
steering controller
* Before carrying out troubleshooting, check that all the related connectors are properly inserted.
* Check that fuse I (10) is normal.
J, When the joystick steering lever is not being used, leave it at the neutral position.
j: Always connect any disconnected connectors before going on to the next step.
I Cause Remedy
0
TROUBLESHOOTING OF WORK EQUIPMENT
CONTROLLER (REMOTE BOOM POSITIONER
CONTROL) SYSTEM
(W MODE)
Judgement table for work equipment controller related parts ......................................................... 20-652
Action taken by controller when abnormality occurs and problems on machine.. ....................... 20-654
Electrical circuit diagram for work equipment controller system ..................................................... 20-656
w- 1 Failure code [431 (Shot-t circuit, disconnection in damping solenoid) is displayed.. ........ 20-658
w- 2 Failure code 1441 (Short circuit in power source at hot end of damping
solenoid) is displayed ......................................................................................................... 20-659
w- 3 Failure code [451 (Short circuit in power source at return end of damping
solenoid) is displayed ......................................................................................................... 20-659
w- 4 Failure code [491 (Short circuit, disconnection in boom lever kick-out relay
system) is displayed ........................................................................................................... 20-660
w- 5 Failure code 1511 (Disconnection in boom RAISE, LOWER detection pressure
switch) is displayed ............................................................................................................ 20-661
W- 6 Failure code 1521 (Short circuit, disconneciton in boom angle potentiometer
system) is displayed ........................................................................................................... 20-662
w- 7 Sensor cannot be adjusted ...................................................................................................... 20-663
W- 8 Abnormality in engine speed signal system .......................................................................... 20-663
w- 9 Remote positioner RAISE, LOWER LEDs do not light up ..................................................... 20-664
W-IO Remote positioner RAISE stop lamp (CGC monitor) does not flash
(for 2.5 seconds) ................................................................................................................. 20-665
w-11 Remote positioner LOWER stop lamp KGC monitor) does not flash
(for 2.5 seconds) ................................................................................................................. 20-665
w-12 Buzzer for switch operation does not sound ......................................................................... 20-666
w-13 Shock when stopping boom (abnormality in boom lever detent switch) ......................... 20-667
w-14 Short circuit in boom RAISE, LOWER pressure detection switch.. ...................................... 20-668
Location of failure
Failure mode
Voltage between work equipment controller L26 Damping solenoid There is shock when
(female) (5) and chassis ground: Less than 1 V output: OFF stopping boom in
remote positioner w-2
mode
Voltage between work equipment controller L26 Damping solenoid There is shock when
(female) (15) and chassis ground: Less than 1 V output: OFF stopping boom in
remote positioner w-3
mode
1) Resistance of relay coil: 200 - 400 R Boom lever kickout Boom does not stop at
2) Resistance of wiring harness between work output: OFF desired position in
equipment controller L26 (female) (20) - boom remote positioner
relay L45 (1): Less than 1 R mode (boom lever
3) Resistance of wiring harness between boom relay detent is not canceled) w-4
L45 (female) (2) and chassis ground:
Less than 1 R
1) When boom lever is at neutral, resistance Damping solenoid There is shock when
becomes as follows. output: OFF stopping boom in
2) Resistance between work equipment controller remote positioner
L26 (female) (5) and chassis ground: mode
Less than 1 R
and resistance between work equipment
w-5
controller L26 (female) (3) and chassis ground:
Less than 1 R
Voltage between work equipment controller L26 Remote positioner Remote positioner
(female) (19) and L27 (9): 0.3 - 4.8 V function: OFF function does not
work
W-6
Fuse (I)
FS2 (S12Xeluel
Fuse M
Positioner
raise
indicator
(Green1
Bucket
positioner
solenoid
FLI (HD-26086)
Bucket
sositioner
Boom angle
sensor
Boom lever
I detent switch
Boom lower
switch
R20
I// Boom dump
solenoid
Boom dumv
solenoid
TXW02495
* 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.
* Before carrying out troubleshooting, check that all the related connectors are properly inserted.
f Always connect any disconnected connectors before going on to the next step.
f Always turn the starting OFF before disconnecting any connector to connect the T-adapter (or
socket adapter).
Cause Remedy
I
between L26
* Disconnect HR9. NO solenoid wiring harness
(female) (5) and
(15) normal? t l Min. 1 MR Short circuit, defective
contact. or disconnection
* Disconnect L26. 4 YES in wiring harness Repair or
l15-2552
Is resistance between L26 (female) (5). replace
between HR9 (15) - HR9 (female) (1).
N (female) (1) and (2)
(2) normal?
Defective damping
* Disconnect HR9. solenoid
.15-25R
Work equipment
cant rol ler
DUMP ins
solenoid
TJW02496
W-2 Failure code [441 (Short circuit in power source at hot end of
damping 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.
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.
Always turn the starting OFF before disconnecting any connector to connect the T-adapter (or
socket adapter).
Cause Remedy
Defective work
Replace
Is voltage between equipment controller
L26 (female) (5)
Short circuit with power
source in wiring harness Repair or
* Disconnect L26. NO between L26 (female) (5) replace
l Turn starting and HR9 (female) (1)
switch ON.
- Max. 1 V
Defective work
Replace
equipment controller
L26 (female) (15)
l Disconnect U6.
1
NO
Short circuit with power
source in wiring harness
between L26 (female)
Repair or
replace
* Turn starting (15) and HRg (female) (2)
switch ON.
- Max. 7 V
Work equipment
cant
Dumping
solenoid
TJW02496
W-4 Failure code [491 (Short circuit, disconnection in boom lever kick-
out relay 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.
* 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.
* Always turn the starting OFF before disconnecting any connector to connect the T-adapter (or
socket adapter).
Cause Remedy
Defective work
Replace
equipment controller
Disconnection in wiring
harness between U6 Repair or
(female) (20) - L45’
(female) (1)
Work equipment
coni Booim
kit k-out
SOI enoid
R20 TJW02497
20-660 WA 1200-3
0
TROUBLESHOOTlNG w-5
socket adapter).
Cause Remedy
Work eauipment
pressure switch
Pressure switch
* 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.
* 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.
* Always turn the starting OFF before disconnecting any connector to connect the T-adapter (or
socket adapter).
F
Remedy
Work eauipment
cant
JL24 (DT2)
Boom angle
Potentiometer
TJWO2499
Remote positioner
RAISE, LOWER
1
Is remote
ZYES
L Defective work
equipment controller
Replace
_ positioner set _
LEDS does not signal system
light up of flash Defective remote
normal?
positioner RAISEROWER RezaFeor
* Turn remote l See trouble- NO set switch or LED s&em
’I
positioner shooting W-10.
RAISEAOWER
set switch ON.
* 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.
* Always turn the starting OFF before disconnecting any connector to connect the T-adapter (or
socket adapter).
Cause Remedy
Defective work
Replace
euqipment controller
D&connectionor defective
contactin wiring harness
betweenI26 (female)(61- Repair or
Ll37 (male) (1). or betweenL28 recdace
(female)(14) - L13S(male)(1)
Short circuitwith chassis
,____.___.. groundin wiring harness
male) (1). - Disconnect L28, betweenU8 (female)(8) - Repair or
nale) (1) L137, and L139. NO Ll37 (male) (1). or betweenI26
1and chassis ground H * Min. 1 MR (female)(141-LES (male)(1)
normal7 II I Diinnection, defective
-2O-30V contact.or short circuitwith Repair or
* ~isxnn L136 NO chassisground in wiring
harnessbeween fuse I (11) -
- Turn starting L136(female) (1). L136
switch ON. (female)(1)
Positioner
LOWER
indicator
(green)
TJW02501
W-IO Remote positioner RAISE stop lamp (CGC monitor) does not
flash (for 2.5 seconds)
Cause Remedy
W-II Remote positioner LOWER stop lamp (CGC monitor) does not
flash (for 2.5 seconds)
Cause Remedy
Repair or
Defective CGC
replace
* Check that the main monitor and alarm buzzer work properly.
* 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.
* Always turn the starting OFF before disconnecting any connector to connect the T-adapter (or
socket adapter).
Cause Remedy
Defective work
Is resiincebetween euqipment controller Replace
R20
TJW02502
cause Remedy
Work
uipment Boom
Intro1 ler L27 (04020)
I ever
detent
3 (HD-76086) (DTt) switch
JL21 (DTIE)
JR13 (DTlB)
A7
TJW02503
* Before carving out troubleshooting, check that all the related connectors are properly inserted.
* Always connect any disconnected connectors before going on to the next step.
cause Remedy
i/OE,,i
and (9) normal? betweenL27 (female)(6) -
- - Disconnect L27 and HR13(female)(1) and betweer
* Min. 1 MR HRl l27 (female)(6) - HR12 Repair or
Yl
l Turn starting NO (female)(l), or between l27 replace
(female)(5) and HR13(female)
1 switch OFF. (11,HR12 (female)(1)
l Disconnect K7, Shortdr& withchassisgrow,
between HFi12 l Min. 1 MR HR12, and HR13. in wiringharnessbetweenL27
Repair or
(male) 11) and HR73 l Turn starting (female)(5) - HRl3 (female)(1)
;0 or betwell L27wemale)(6)- replace
(male) (1) -chassis switch OFF. HRl2 (female)(1). or between
* Disconnect U7, I27 Ifemale (9)- HR13(female)
l Min. 1 M~z HR12, and HR13. (2). HR12(female)12)
*Turn starting Defective boom RAISE Replace
switch OFF. NO switch or boom LOWER
* Disconnect HR12 switch
and HR13.
Work esuipment
cant
Dressure switch
Dressure switch
TJW02498
Trouble data display ,.................................,................ ,.................. ........ .... ... ............i .................. ......... . 20-703
Electrical circuit diagram of main monitor system .......... .......... ................... ....... ...... .......... .............. 20-704
M- 1 Main monitor does not work ..................................................................................................... 20-706
M- 2 When starting switch is turned ON (within 3 seconds) and engine is started
(PRE-LUBE) immediately, all lamps stay lighted up ................................................................ 20-707
M- 3 Speedometer display does not work properly ......................................................................... 20-708
M- 4 Abnormality in shift indicator .................................................................................................... 20-709
a) Displays N even when directional lever is at F ................................................................. 20-709
b) Displays N even when directional lever is at R. ................................................................ 20-709
c) Does not display N even when FNR (Forward-reverse) switch is set in N ................... 20-710
d) Does not display F even when FNR (Forward-reverse) switch is set in F.. ................... 20-710
e) Does not display R even when FNR (Forward-reverse) switch is set in R .................... 20-710
M- 5 Turn signal display does not light up ....................................................................................... 20-712
a) L.H. turn signal display does not light up.. ....................................................................... .20-7X?
b) R.H. turn signal display does’not light up ......................................................................... 20-712
M- 6 Abnormality in parking display .................................................................................................. 20-713
a) Parking lamp display does not light up ............................................................................ .20-713
Parking lamp display stays lighted up ..............................................................................
b) -20-713
M- 7 Night lighting does not light up ................................................................................................ 20-714
M- 8 Abnormality in front working lamp. .......................................................................................... 20-715
a) Neither monitor display nor front working lamp light up.. ............................................. .20-715
b) Working lamp lights up but monitor display does not light up.. ................................... .20-715
c) Monitor display lights up but front working lamp does not light up ............................ 20-715
M- 9 Abnormality in rear working lamp ............................................................................................ 20-717
a) Neither monitor display nor rear working lamp light up.. .............................................. .20-717
b) Rear working lamp lights up but monitor display does not light up ............................ 20-717
Monitor display lights up but working lamp does not light up ..................................... .20-717
c)
M-10 Abnormality in transmission cut-off.. ........................................................................................ 20-719
a) When monitor switch (transmission cut-off switch) is pressed, cut-off function is
not switched and display does not change . ... ................ .. .. .......... ...... .. .............. .............. . 20-719
b) When monitor switch (transmission cut-off switch) is OFF, monitor display
goes out but cut-off function is actuated when pedal is depressed .. .. ............ ....._...... 20-719
c) When monitor display is turned off (transmission cut-off switch turned OFF),
cut-off function is always actuated ... ....... ...... .. ................ ... ..................... ........................... 20-719
d) Cut-off function is always actuated regardless of monitor display
(transmission cut-off switch ON or OFF) .... .. ... .. ................. ............ ...... .............................. 20-719
Monitor display lights up (transmission cut-off switch turned ON),
e)
but cut-off function is not actuated .... ............. ...........**..*.................***............................... 20-720
M-l 1 Abnormality in emergency steering normal display ............................................................... 20-721
Emergency steering normal display does not light up ........................................................... 20-721
M-12 Abnormality in emergency steering actuation display ........................................................... 20-722
a) Emergency steering actuation display does not light up ................................................. 20-722
b) Emergency steering actuation display stays lighted up .................................................. .20-722
l-l-% I
-~~-~~-~~-_~-~~-_________=
z
z
z
0
WA1 200-3
TROUBLESHOOTING M-l
Ir 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.
YES
Defective main monitor Replace
1
Bat terv
Bat tery~Battery/A~ relay
/I
TJW02506
1
YES
I I Defective PRE-LUBE
HOLD relay (L114)
Replace
If L114 is
replaced, do
lamps operate 2YEs
Defective main monitor Replace
normally? When engine is
- tined, is voltage
* Turn starting Disconnection or
L between LO5 14) and -
switch OFF. NO chassisground defective contact in
* Replace Ll14 normal? wiring harness between Repair or
with normal relay .20-30V NO LO5 (female) (4) - JL15 replace
of same type. l Start engine. (4). (3) - SJ2 (female) (3)
* Turn starting - L57 (female) (1)
switch ON.
;;;;;;;g
re I ay
PRE-LUBE
hold relay
Neutral
relay
a Rear frame
ENG
TJW02507
20-707
WA1 200-3
0
TROUBLESHOOTING M-3
Cause Remedy
1 YES
Defective main monitor Replace
Is resistance
between LO7
Defective contact or
(female) (1) - (2) -
disconnection in wiring
normal? Repair or
harness between LO7
.500-lktl NO replace
(female) (1). (2) -115
-Turn starting (female)(11, (2)
switch OFF.
* Disconnect L07.
Work ewiment
controller
128 hl4016)
Modulated clutch
Transmission I
Main monitor
TXW02453
Cause
1 YES
Defective main monitor
Is voltage
between LO8 (7)
Defective contact or
and chassis
disconnection in wiring
ground normal? Repair or
harness between LO8
-2O-30V NO replace
(female) (7) and JSl
* Turn starting (female) (2)
switch ON.
* Directional lever: F
1 YES
Defective main monitor Replace
Is voltage
between LO8 63)
and chassis Defective contact or
ground normal? disconnection in wiring
Repair or
harness between LO8
*20-30V NO replace
(female) (8) and JSl
l Turn starting (female) (4)
switch ON.
* Directional lever: R
1 YES
Defective main monitor
Is voltage
between LO8 (7) Short circuit with power
or (8) and chassis source in wiring harness
ground normal? between LO8 (female) (7)
Repair or
and JSl (female) (2) or
- Max. 1 V NO replace
harness between LO8
* Turn starting [female) (8) and JSl
switch ON. (female) (4)
* Set FNR (Forward-
Reverse) switch in
N.
Cause Remedy 1
f
YES
r
1
Defective main monitor Replace
Is voltage betvveen I
LO8 (female) (7)
and chassis Defective contact or
ground normal? disconnection in wiring
Repair or
harness between LO8
*20-30V NO (female) (7) - JL16 (4). (3) replace
* Turn starting and JSl (female) (2)
switch ON.
. Set FNR (Fotward-
Reverse) switch in
F.
1
Defective main monitor Replace
Is voltagebetween
LO8 (female) (8)
and chassis
ground normal?
Repair or
*20-30V
l Turn starting
switch ON.
* Set FNR (Forwarcf-
Reverse) switch in
R.
Transmissi on
JLl8 (DT2l
controller
Dn d-l
JL16 (DT2)
i TJWO2508
* 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.
* Before starting troubleshooting, check that the lamp bulb of the turn signal indicator on the
monitor is not blown. T
Cause Remedy
al L.H. turn signal display does not light up
1 YES
Defective main monitor Replace
Is voltage
between LO6 (14)
Defective contact or
and chassis
disconnection in wiring
1ground normal? harness between LO6
Repair or
* Repeats 0 V and NO replace
(female) (14) and L144
20-30V. (male) (1)
* Turn starting switch ON.
-Turn L.H. turn signal ON.
Cause Remedy
b1 R.H. turn signal display does not light up
R. H. turn L. H. turn
signal signal
I amp(25W) I amp (25W)
-
F20 TJW02509
0
TROUBLESHOOTING M-6
* Before carwing out troubleshooting, check that all the related connectors are properly inserted.
* Always connect any disconnected connectors before going on to the next step.
3 YES
Defective main monitor Replace
Is resistance
YES between T18
r (female) (2) and - Defective contact or
.B
L. 1gyfrl9rc”hc 11 disconnection in wiring
harness between T18 Repair or
Is voltage
- Max. (female) (2) - JMl (21, (7) replace
YES between LO6 (11) 1R NO
and chassis * Turn starting and chassis ground
1 ground normal? switch OFF.
_ Defectivecontact or
Is resistance P - Disconnect Tl8. disconnectionin wiring Repair or
-2O-30V
between T18 harness between LO6 replace
- * Turn starting NO
(male) (1) and (2) (fernale)(FR2ill)-RT2
switch ON. (N) and T18 (female) (1)
normal? * Turn parking
* Max. 1 R switch ON. Defective parking brake Replace
* Disconnect T18. NO indicator switch
*Turn starting
switch ON.
* Turn parking
switch ON.
Ma i n
Parking
RT2 (HO-85086)
brake
indicator
Tl TJW02510
1 YES
Defective main monitor
I Is valtaae
between LO5 (16)
and chassis Defective contact or
ground normal?
*20-3ov
I
NO
disconnection in wiring
harness between LO5
Repair or
replace
(female) (16) and FSZ
* Turn starting (female) (5)
switch ON.
* Turn small lamp
switch ON.
Main
monitor LO5 (04020)
0.5fY
Small
lamp
relay
I”0
rance
(5W)
G14
TJW02511
Cause Remedy
Defective contact or
disconnsction in wiring
YES harness between L60 Repair or
(female) (1) - LO5 (female) replace
117). L75 (female) (5). CL6
(female) (1)
1
between L60 (1)
YE S between L66 (6)
1
Defective main monitor Replace
l Max. 1 V
2
-Turn starting Max. 1 V between LO6 (1)
l
Defective contact or
switch ON. Is voltage between
disconnection in wiring
L60 f2), (4), (5) and
switch ON. harness between LO6 Repair or
NO chassis ground I
normal? l20-30V (female) (1) and L60 replace
4 * Turn starting (female) (6)
.20-30V
switch ON. Defective contact or
* Turn starting
switch ON. disconnection in wiring Repair or
N harness between L60 replace
(female) (21, (4), (5) and
FS5 (female) (1)
Is voltage
between LO5 (17)
3 Defective main monitor Replace
Ma i n
eht
r
In onito r Fuse (II,
I amp
3 eft
amp
FL1 (HD-26066)
I.25fBr
I. 25fY I
I I
a
FZO
L60
Front
working
lam0
relay
Rear
L61
working
I amp
relay
Front
working
lamp
relay
D
!34
lamp
(R. H. 1
I amp
(L. H. )
ine
--
Working
I amp
TJW02512
0
TROUBLESHOOTING M-9
I CaUSe Remedy
Defective contact or
disconnection in wiring
harness between L61 Repair or
(female) (1) - LO5 replace
(female) (18). LRI
(female) (13)
YES
I Defective rear working Replace
3 lamp relay
between L61 (I ) Is voltage
YES between L61 (6)
and chassis 4YES
ground normal? - Is voltage - Defective main monitor Replace
*20-30V
2
*Turn starting , * Max. 1 V between LO6 (2)
Defective contact or
switch ON. Turn starting NO and chassis
l
disconnection in wiring
switch ON. ground normal?
harness between LO6 Repair or
*Max.lV NO (female) (2) and L61 replace
I t
-Turn starting (female) (6)
l20-30V
switch ON. Defective contact or
* Turn starting
switch ON. disconnection in wiring Repair or
NO harness between L61 replace
(female) (2). (41, (5) and
FS5 (female) (2)
b) Rear working lamp lights up but monitor display does not light up
CaUSe Remedy
I YES
Defective main monitor Replace
Is voltage
between LO5 (18)
and chassis Defective contact or
ground normal? disconnection in wiring
Repair or
harness between LO5
.20-30v NO replace
(female) (18) and L61
- Turn starting (female) (1)
switch ON.
Main
monito r Fuse (II) aht
7 iamp
I-88-b eft
L J lamp
LRI MD-95086)
FLItHO-26066)
Im lr
”
Y
0
a
c
i 34 0
* worklna
worixlna worklna
Worki ne It
lamp lamp IamP lamp k
lamp
relay relay relay (L. H. ) lamp
(R. H. )
TJWO2512
* 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.
Defective contact or
disconnection in wiring
2 YES harness between L12 Repair or
(female) (1) and C3A replace
(female) (10)
(female) (‘2)and
Defective contact or
disconnection in wiring Repair or
harness between L12 replace
(female) (2) and chassis
ground
switch OFF.-
* Disconnect L12. Defective transmission
*Max.152 Replace
* Turn starting NO cut-off switch
switch OFF.
+ Disconnect L12.
Cause Remedy
Defective transmission
Replace
cut-off switch
function work
YES
r)
‘
I Defective main monitor
disconnected?
* Disconnect L12.
1Does cut-off II
-Turn starting N
Defective transmission
switch ON. Replace
controller
Transmission I
controller
Transmission
cut-off switch
(OPEN at left
brake dePressed)
TJW02513
* 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.
*
1 YES Defective main monitor Replace
Is voltage
between LO5 (10)
and chassis Defective contact or
ground normal? disconnection in wiring Repair or
harness between LO5 replace
*20-30V NO
(female) (10) -chassis
- Turn starting
switch ON.
Main
LR2 (HD-85086)
TJW02514
* Before carrying out troubleshooting, check that all the related connectors are properly inserted.
* Always co&e6t any disconnected connectors before going on to the next step.
2 YES
Defective main monitor
Is resistance
YES between LO5
, r Wemale)(11) and
Short circuit with chassis
ground in harness Repair or
* Min. 1 MS2 NO between Lo5 (female) replace
(male) (1) and Rll -Turn starting switch OFF. (11) and Rll (female) (1)
* Disconnect LO5 and R12.
Defective emergency
* Min. 1 MD I
steering indicator switch
* Turn starting NO
switch ON.
lDisconnect Rll,
R12.
I
l Turn starting ground
(male) (2) normal? 1 switch ON.
I.
Defective emergency
-Max.lR Replace
steering indicator switch
- Start engine. NO
- Disconnect Rll,
R12.
Main
l-h?
TJW02514
R20
* 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.
al When parking brake is applied, buzzer sounds (intermittently) and CAUTION lamp flashes even
when directional lever is at N
I
F
Cause Remedy
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
Ir Check that the synchronous flash is normal.
CaUSe Remedy
YES
Defective main monitor Replace
Joust ick
Transmission lever
controller JSl LsWP12) switch
TJW02515
* 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.
a1 When parking brake is applied, buzzer sounds (intermittently) and CAUTION lamp flashes even
when directional lever is at N
:
See troubleshooting of
1 YES
transmission controller
system CTmode)
Is S-NET has any
trouble?
Repair or
Defective main monitor
*20-30V NO replace
*Turn starting
switch ON.
*Joystick lever
switch: N
bl 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
* Check that the synchronous flash is normal.
Remedy
See troubleshooting of
1 YES transmission controller
Repair or
replace
system CT mode)
Is S-NET has any
trouble?
Work Modulated
VHMS esuipment clutch Transm ission Main Jovst ck
controller controller controller contra I ler monitor lever switch
a a _I I
. JLI 5 (IIT
I 1:
TJW02516
f Before carrying out troubleshooting, check that all the related connectors are properly inserted.
-k Always connect any disconnected connectors before going on to the next step.
a) Actuated continuously
Cause Remedy
YES
Defective main monitor Replace
1
b) Not actuated
Cause Remedy
Defective VHMS
Replace
controller
Main VHMS
TJW02517
* 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.
a) Buzzer does not sound when starting switch is at ON (for 3 seconds) (during self-check)
cause Remedy
Defective contact or
disconnection in wiring
Repair or
harness between LO6
replace
(female) (8) and L43
(male) (1)
Does buzzer
sound? 2 YES
Defective buzzer Replace
Is voltage between
* Turn starting L42 (female) (1)
Defective contact or
switch ON. NO and chassis
ground nonnat? disconnection in wiring
* Contact L43 Repair or
harness between L42
(female) to *20-30V replace
NO (female) (1) and FS2
chassis ground. Turn starting
l
(female) (9)
switch ON.
YES
Defective main monitor
1
If LO6 is II
Defective caution buzzer
relay Replace
Defective emergency
parking brake reset Replace
3
switch
If L89 is I
* Turn starting
switch OFF.
* Disconnect L99. ’ Defective buzzer
0
TROUBLESHOOTING M-16
Emergency
Darkins brake
cancel switch
VHMS
I-#7 TJW02518
* 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.
cause Remedy
Battery relay
Main monitor LO7 (04012)
Starting switch 66AC 10 0.5fY -
R03 (DT2)
JR3 (DTl)
0
TROUBLESHOOTING M-18
1 YES
Defective main monitor Replace
Is voltage
between LO5 (5)
Defective contact or
and chassis
disconnection in wiring
ground normal?
harness between LO5 Repair or
*20-30V NO (female) (5) -alternator replace
* Start engine. terminal L, or defective
alternator
I Cause I Remedy
1 YES
Defective main monitor Replace
Is voltage
between LO5 (5)
Short circuit with power
and chassis
source in wiring harness
ground normal?
between LO5 (female) (5) Repair or
*o-5v NO -alternator terminal L, or replace
* Turn starting defective alternator
switch ON.
Alternator psg~
TJW02520
A
YES
Defective main monitor Replace
1
Is voltage Defective contact or
between LO8 (5) disconnection in wiring
and chassis 2 YES harness between LO8 Repair or
ground normal?
_ Is voltage
’ (female) (5) and GREl replace
(female) (2)
l20-3ov between GREl
-Turn starting NO (2)and chassis - See “Handling auto-
switch ON. ground normal? greasing system” in -
.20-3ov NO Operation and
* Turn starting Maintenance Manual
switch ON.
Main
m
TJW025.22
TWW02601
WA1200-3 20-801
2
(8)
V-107 [E824] (Communication with CGC and engine controller is impossible)
is displayed in history .............................................................................................................. 20-859
V-108 [E825] (Abnormality in S-NET communication between VHMS – transmission
controller) is displayed in history ............................................................................................ 20-860
V-109 [E826] (Abnormality in S-NET communication between VHMS – modulated
clutch controller) is displayed in history ................................................................................ 20-862
V-110 [E827] (Abnormality in S-NET communication between VHMS – work
equipment controller) is displayed in history ........................................................................ 20-864
V-111 [E828] (Abnormality in S-NET communication between VHMS – main monitor)
is displayed in history .............................................................................................................. 20-866
V-113 [E841] (Short circuit with power source in buzzer output system)
is displayed in history .............................................................................................................. 20-869
V-114 [E843] (Short circuit with power source in check lamp system)
is displayed in history .............................................................................................................. 20-870
V-115 [E844] (Short circuit with power source in flash synchronizing signal system)
is displayed in history .............................................................................................................. 20-871
V-116 [E861] (Disconnection or short circuit with chassis ground in
boom bottom pressure sensor system) is displayed in history ........................................... 20-872
V-117 [E862] (Disconnection or short circuit with chassis ground in
boom head pressure sensor system) is displayed in history............................................... 20-874
V-118 [E863] (Disconnection or short circuit with chassis ground in
rear brake oil pressure sensor system) is displayed in history ........................................... 20-876
V-119 [E864] (Disconnection or short circuit with chassis ground in
work equipment relief pressure sensor system) is displayed in history ........................... 20-878
V-120 [E865] (Disconnection or short circuit with chassis ground in
front brake oil pressure sensor system) is displayed in history .......................................... 20-880
V-121 [E866] (Disconnection or short circuit with chassis ground in
transmission main relief pressure sensor system) is displayed in history ........................ 20-882
V-122 [E867] (Disconnection or short circuit with chassis ground in
steering relief pressure sensor system) is displayed in history ........................................... 20-884
V-123 [E868] (Disconnection or short circuit with chassis ground in
torque converter outlet oil pressure sensor system) is displayed in history .................... 20-886
V-124 [E871] (Disconnection or short circuit with chassis ground in
transmission modulation pressure sensor system) is displayed in history....................... 20-888
V-125 [E872] (Disconnection or short circuit with chassis ground in
transmission lubricating oil pressure sensor system) is displayed in history .................. 20-890
V-126 [E874] (Short circuit with chassis ground in torque converter oil temperature
sensor system) is displayed in history ................................................................................... 20-892
V-127 [E875] (Short circuit with chassis ground and with power source in hydraulic
oil temperature sensor system) is displayed in history ........................................................ 20-893
V-128 [E875] (Short circuit with chassis ground in ambient temperature
sensor system) is displayed in history ................................................................................... 20-894
20-802 WA1200-3
2
(8)
v-129 IE8781 (Disconnection or short circuit with chassis ground in
PPC relief pressure sensor system) is displayed in history ................................................ .20-896
v-130 IE8841 (Disconnection or short circuit with chassis ground
in torque converter inlet oil pressure sensor system) is displayed in history.. ................ 20-898
v-201 Disconnection or short circuit with power source in 24-V system
of sensor power supply ............................................................................................................ 20-900
v-202 Disconnection or short circuit with power source in 12-V system
of sensor power supply ............................................................................................................ 20-902
V-203 Disconnection or short circuit with power source in 5-V system
of sensor power supply ............................................................................................................ 20-903
V-204 Disconnection or short circuit with chassis ground in buzzer output system.. ................. 20-904
V-205 Disconnection or short circuit with chassis ground in check lamp system.. ..................... 20-905
V-206 Disconnection or short circuit with chassis ground in
flash synchronizing signal system .......................................................................................... 20-906
V-207 Short circuit with power source in boom bottom pressure sensor system ...................... 20-907
V-208 Short circuit with power source in boom head pressure sensor system .......................... 20-908
v-209 Short circuit with power source in rear brake oil pressure sensor system.. ..................... 20-909
v-210 Short circuit with power source in front brake oil pressure sensor system ..................... 20-910
v-21 1 Short circuit with power source in work equipment relief pressure sensor system.. ...... 20-911
v-212 Short circuit with power source in transmission relief pressure sensor system.. ............ 20-912
V-213 Short circuit with power source in steering relief pressure sensor system ...................... 20-913
V-214 Short circuit with power source in torque converter outlet oil pressure sensor system 20-914
V-215 Short circuit with power source in transmission modulation pressure sensor system.. . 20-915
V-216 Disconnection or short circuit with power source in
torque converter oil temperature sensor.. .............................................................................. 20-916
V-217 Disconnection in hydraulic oil temperature sensor system ................................................. 20-917
V-218 Disconnection in ambient temperature sensor system ......................................................... 20-918
v-219 Short circuit with power source in PPC relief sensor system ............................................. .20-919
v-220 Short circuit with chassis ground in fuel level sensor system ............................................ 20-920
v-221 Short circuit with power source in battery fluid level sensor “1” ....................................... 20-921
v-222 Short circuit with power source in battery fluid level sensor “2” ....................................... 20-922
V-223 Short circuit with power source in battery fluid level sensor “3”. ..................................... .20-923
V-224 Short circuit with chassis ground or power source in brake fluid level sensor.. ............. 20-924
V-225 Short circuit with power source in coolant level sensor ...................................................... 20-925
V-226 Short circuit with chassis ground or power source in
transmission oil filter clogging sensor ................................................................................... 20-926
V-227 Short circuit with power source in air cleaner clogging (I) relay system ......................... 20-927
V-228 Short circuit with power source in air cleaner clogging (2) relay system ......................... 20-928
v-229 Short circuit with power source in air cleaner clogging (3) relay system ......................... 20-928
V-230 Short circuit with power source in air cleaner clogging (4) relay system.. ....................... 20-929
V-231 Abnormal charge by alternator ............................................................................................... 20-930
Resistance (between
T24 (1) – (2)) Gauge keeps indicating 130°C. V-7
Normal temperature ––– ––– fi Alarm screen is output When left is V-8
wrongly. not satisfied.
(25°C): Approx. 40 kΩ V-126
130°C: Approx. 1.7 kΩ
Gauge keeps indicating 25°C.
––– ––– ––– Alarm screen cannot be ––– V-216
output.
Resistance (between
HS (1) – (2))
100°C: Gauge keeps indicating 130°C. When left is V-9
Approx. 3.5 – 4.0 kΩ ––– ––– fi Alarm is output wrongly. not satisfied. V-127
25°C:
Approx. 37 – 50 kΩ
WA1200-3 20-805
2
(8)
OPERATIONS OF VHMS CONTROLLER AGAINST ABNORMALJTY
TROUBLESHOOTING AND CONDITIONS OF MACHINE CAUSED BY ABNORMALITY
Short circuit 1)Shon circuit with power source in wiring harness between
7 Brake oil __-
with power --- --- V2A (female) (7) - HR15 (female) (3)
pressure (F) 2) Defective VHMS controller
source
1) Low rear brake oil pressure (E912, E915)
2) Defective rear brake oil pressure sensor
3) Defective joint connector JR14, JL?, or JR13
Disconnec-
E912 41 Disconnection or defective contact In wiring harness between
Input voltage
E915 --- Vl (female) (2) - HR16 (female) (2)
tion < 0*5V
E863 5) Disconnection or defective contact in wiring harness between
V2A (female) (8) - HR 16 (female) (3)
6) Defective VHMS controller
+ For E912 and E915, see alarm items displayed on CGC monitor
1) Low rear brake oil pressure (E912, E915)
Brake oil
2) Defective rear brake oil pressure sensor
a pressure (R)
Short circuit E912 3) Short circuit with chassis ground in wiring harness between
Vl (female) (2) - HR16 (female) (2) Input
with chassis Eg15 - _ _
4) Short circuit with chassis ground in wiring harness between < o 5v voltage
ground E863 V2A (female) (8) - HR16 (female) (3)
5) Defective VHMS controller
* For E912 and E915, see alarm items displayed on CGC monitor
Short circuit 1) Short circuit with power source in wiring harness between
with power --- --- WA (female) (8) - HR16 (female) (3) -_-
source 2) Defective VHMS controller
1)Defective battery fluid level sensor (1) or inscfricientcharge of battery
2) Disconnection or defective contact in wiring harness between 6-v cel,
Disconnec-
E916 --- WA (female) (1) - RA7 (female) (1)
tion 3) Defective VHMS controller voltage c 2 V
f See alarm items displayed on CGC monitor
1) Defective battery fluid level sensor (1) or insufficientcharge of battery
g Battery fluid Short circuit 2) Short circuit with chassis ground in wiring harness between 6-v cell
level (1) with chassis E916 - - - WA (female) (1) - RA7 (female) (1)
voltage < 2 V
ground 31 Defective VHMS controller
+ See alarm items displayed on CGC monitor
Short circuit 1) Short circuit with power source in wiring harness between
Sensing is
with power --- --- V2B (female) (1) - RA7 (female) (1)
2) Defective VHMS controller impossible.
source
1) Defective battery fluid level sensor (2) or insufficientcharge of battery
2) Disconnection or defective contact in wiring harness between 6V cell
Disconnec-
E917 --- V2B (female) (2) - RA6 (female) (1) voltage < 2 V
tion
3) Defective VHMS controller
t See alarm items displayed on CGC monitor
1) Defectivebatteryfluidlevelsensor(2) or insufficientcharge of battery
Battery fluid Short circuit 2) Short circuit with chassis ground in wiring harness between 6-V cell
lo level (21 with chassis E917 - - - V2B (female) (2) - RA6 (female) (1) voltage < 2 V
ground 3) Defective VHMS controller
f See alarm items displayed on CGC monitor
Short circuit 1) Short circuit with power source in wiring harness between
Sensing is
with power --- --- V2B (female) (2) - RA9 (female) (1)
impossible.
source 2) Defective VHMS controller
1) Defective battery fluid level sensor (3) or insufficientcharge of bsttery
2) Disconnection or defective contact in wiring harness between 6-V cell
Disconnec-
tion E918 --- V2B (female) (3) - RA9 (female) (1) voltage < 2 V
3) Defective VHMS controller
* See alarm items displayed on CCC monitor
1) Defective battery fluid level sensor (3) or insufficientcharge of battery
11 Banery fluid Short circuit 2) Short circuit with chassis ground in wiring harness between 6-V cell
level (3) with chassis E918 - - - V2B (female) (3) - RA9 (female) (1) voltage < 2 V
ground 3) Defective VHMS controller
rt See alarm items displayed on CGC monitor
Short circuit 1) Short circuit with power source in wiring harness between Sensing is
with power --- --- V2B (female) (3) - RA9 (female) (1) impossible.
source 2) Defective VHMS controller
1) Low front brake fluid level or defsctive front brake fluid level sensor
2) Low rear brake fluid level or defective rear brake fluid level sensor
3) Disconnection or defective contact in wiring harness
Disconnec- E925 between V3A (female) (5) - HR6 (female) (1) Sensing is
tion E926 - - - 4) Disconnection or defective contact in wiring hamess between impossible.
V3B (female) (5) - HRlO (female) (1)
5) Defective VHMS controller
t See alarm items displayed on CGC monitor
Brake fluid 1) Short circuit with chassis ground in wiring harness between
Short circuit V3A (female) (5) - HR6 (female) (1)
l2 level Sensing is
with chassis - - - - - - 2) Short circuit with chassis ground in wiring harness between
impossible.
ground V3B (female) (5) - HRlO (female) (1)
3) Defective VHMS controller
1) Short circuit with power source in wiring harness between
Short circuit V3A (female) (5) - HR6 (female) (1) Sensing is
with power - - - - - - 2) Short circuit with power source in wiring harness between impossible.
source V3B (female) (5) - HI?10 (female) (1)
3) Defective VHMS controller
Voltage (between
;;A (;)3-J3)):
. - . Real-time monitor is displayed.
Min. pressure is always v-10
--_ --_ 0 sensed. When left is
not satisfied. v-12
Alarm is sensed wrongly. V-118
(Max. 0 MPa {O kg/cm%
Voltage (between
RA7 (1) - chassis): -__ __- When left is
0 Alarm is output wrongly.
not satisfied. v-13
5.5 - 6.5 V
Voltage (between
RA8 ( 1) - chassis): --- Alarm is output wrongly. When left is v-14
0
5.5 - 6.5 V not satisfied.
Voltage (between
E (;)5-;hassrs): _-- _-_ 0 When left is v-15
Alarm is output wrongly.
. - . not satisfied.
1)Clogging of transmission oil filter or defective transmission oil filter sensor (ROl)
2) Cl ging of transmission oil filter or defective transmission oil filter sensor (ROZ)
Disconnec- E931 --- 31 Dzective joint connector JR7 Sensing is
tion 4) Disconnection or defective contact in wiring harness between impossible.
Differential V3A (female) (11) - V2A (female) (1)
pressure on 5) Defective VHMS controller
14 transmission Short circuit 1)Short circuit with chassis ground in wiring harness between
oil filter V3A (female) (11) - R02 (female) (1) Sensing is
with chassis - -- ---
(clogging) ground 2) Defective VHMS controller impossible.
Short circuit 1) Short circuit with power source in wiring harness between
Sensing is
with power --- --- V3A (female) (11) - R02 (female) (1)
2) Defective VHMS controller impossible.
source
1)Ciogging of air cleaner (1) or defective dust indicator (1)
2) Defective dust indicator relay (1)
Disconnec- 3) Disconnection or defective contact in wiring harness between Sensing is
E932 ---
tion V3B (female) (1) - L132 (female) (6) impossible.
4) Defective VHMS controller
* See alarm items displayed on CGC monitor
!5 Clogging of
air cleaner (1) Short circuit 1) Short circuit with chassis ground in wiring harness between Sensing is
withchassis --- --- V36 (female) (1) - L132 (female) (6)
ground 2) Defective VHMS controller impossible.
Short circuit 1) Short circuit with power source in wiring harness between
Sensing is
with power --- --- V3B (female) (1) - L132 (female) (6)
2) Defective VHMS controller impossible.
source
1) Clogging of air cleaner (2) or defective dust indicator (2)
2) Defective dust indicator relay (2)
Disconnec- 3) Disconnection or defective contact in wiring harness between Sensing is
E933 ---
tion V36 (female) (2) - L133 (female) (6) impossible.
4) Defective VHMS controller
6 C!ogging of *See alam items displayed on CGC monitor
air cleaner (2) Short circuit 1)Short circuit with chassis ground in wiring harness between
V3B (female) (2) - L133 (female) (6) Sensing is
withchassis --- ---
ground 21 Defective VHMS controller impossible.
Short circuit 1) Short circuit with power source in wiring harness between
V3B (female) (2) - L133 (female) (6) Sensing is
with power --- ---
2) Defective VHMS controller impossible.
source
1) Clo ging of air cleaner (3) or defective dust indicator (3)
. dust indicator relay (3)
2) De 3ectlve
Disconnec- 3) Disconnection or defective contact in wiring harness between Sensing is
ES34 ---
tion V3B (female) (3) - L134 (female) (6) impossible.
4) Defective VHMS controller
f See alarm items displayed on CGC monitor
,, Clogging of
air cleaner (3) Short circuit 1) Short circuit with chassis ground in wiring harness between Sensing is
withchassis --- --- V3B (female) (3) - L134 (female) (6)
2) Defective VHMS controller impossible.
ground
Short circuit 1) Short circuit with power source in wiring harness between Sensing is
with power --- --- V3B (female) (3) - L134 (female) (6)
2) Defective VHMS controller impossible.
source
1) Clogging of air cleaner (4) or defective dust indicator (4)
2) Defective dust indicator relay (4)
Disconnec- 3) Disconnection or defective contact in wiring harness between Sensing is
E935 --- impossible.
tion V3B (female) (4) - 1135 (female) (6)
4) Defective VHMS controller
,8 Clogging of f See alarm items displayed on CGC monitor
air cleaner (4) Short circuit 1) Short circuit with chassis ground in wiring harness between Sensing is
with chassis --- - -- V3B (female) (4) - L135 (female) (6)
impossible.
ground 2) Defective VHMS controller
Short circuit 1) Short circuit with power source in wiring harness between Sensing is
with power --- --- V3B (female) (4) - L135 (female) (6)
impossible.
source 2) Defective VHMS controller
1) Defective alternator signal relay L152
2) Defective alternator
Disconnec- 3) Disconnection or defective contact in wiring harness between _ _ _
E937 ---
tion V2A (female) (4) - L152 (female) (6)
4) Defective VHMS controller
Alternator * See alarm items displayed on CGC monitor
9 terminal R
Short circuit 1) Short circuit with chassis ground in wiring harness between
voltage withchassis --- --- V2A (female) (4) - L152 (female) (6) ___
ground 2) Defective VHMS controller
Short circuit 1)Short circuit with power source in wiring harness between V2A
with power --- --- (female) (4) - L152 (female) (61 - El4 (female) (2). El5 (female) (2) - - -
source 2) Defective VHMS controller
Voltage (between
V3A (11) - (9))
Filter normal: Max. 1 V Low coolant level alarm is not __ _
Filter clogged: 17 - 30 V --- --- --- output. V-226
Voltage (between
V3B (1) - chassis)
Filter normal: Max. 1 V --- -__ --_
Filter clogged: 17 - 30 V --- - -- Alarm cannot be sensed.
Voltage (between
V3B (3) - chassis)
Filter normal: Max. 1 V
--- --- --- Alarm cannot be sensed. _-- _--
Filter clogged: 17 - 30 V
Voltage (between
V3B (4) - chassis)
Filter normal: Max. 1 V
Alarm cannot be sensed. -__ ___
Filterclogged: 17-30V --- --- ---
20-810 WA1200-3
2
(8)
OPERATIONS OF VHMS CONTROLLER AGAINST ABNORMALITY
TROUBLESHOOTING AND CONDITIONS OF MACHINE CAUSED BY ABNORMALITY
Voltage (between ––– ––– ––– Fuse may be broken. ––– –––
V1 (6), (7) – chassis):
20 – 30 V
––– ––– ––– When left is V-101
Failure does not occur. not satisfied.
Hold until
Voltage (between Abnormal value of power turning
V1 (4), (5) – chassis): Stops outputting. ––– fi source sensor starting V-104
4–6V switch OFF.
WA1200-3 20-811
2
(8)
OPERATIONS OF VHMS CONTROLLER AGAINST ABNORMALITY
TROUBLESHOOTING AND CONDITIONS OF MACHINE CAUSED BY ABNORMALITY
20-812 WA1200-3
2
(8)
OPERATIONS OF VHMS CONTROLLER AGAINST ABNORMALITY
TROUBLESHOOTING AND CONDITIONS OF MACHINE CAUSED BY ABNORMALITY
Voltage (between
V3A (8), (18) – chassis): ––– ––– fi Display of real-time monitor When left is V-111
4–8V does not change. not satisfied.
WA1200-3 20-813
2
(8)
OPERATIONS OF VHMS CONTROLLER AGAINST ABNORMALITY
TROUBLESHOOTING AND CONDITIONS OF MACHINE CAUSED BY ABNORMALITY
-7
Buzzer Short circuil 1) Short circuit with chassis ground in wiring harness between
3i with chassis --- _-- Vl (female) (16) - L99 (female) (2) _--
output
ground 2) Defective VHMS controller
Short circuii 1) Short circuit with power source in wiring harness between
with power E841 -__ Vl (female) (16) - L99 (female) (2) Overcurrent
2) Defective VHMS controller
-
1) Disconnection or defective contact in wiring harness be&veer
Disconnec- --_ --_ Vl (female) (14) - LO6 (female) (10) --_
tion 2) Defective VHMS controller
Check lamp Short circuit 1) Short circuit with chassis ground in wiring harness between
33 (For main with chassis --_ --_ Vl (female) (14) - LO6 (female) (10) ___
monitor) ground 2) Defective VHMS controller
Short circuit 1) Short circuit with power source in wiring harness between
with power E843 _-- Vl (female) (14) - LO6 (female) (10) Overcurrent
source 2) Defective VHMS controller
-
1) Disconnection or defective contact in wiring harness between
Disconnec- --- --_ Vl (female) (13) - LO7 (female) (6) -__
tion 2) Defective VHMS controller
Flash
synchronizing Short circuit 1)Short circuit with chassis ground in wiring harness between
34 signal (For with chassis ___ Vl (female) (13) - LO7 (female) (6) _-_
main moni- ground 2) Defective VHMS controller
tor) Short circuit 1) Short circuit with power source in wiring harness between
with power E644 --_ Vl (female) (13) - LO7 (female) (6) Overcurrent
source 2) Defective VHMS controller
-
1)Defective boom bottom oressure sensor
2) Defective joint connector JF3 Sensed
Disconnec- _--
E861 3) Disconnection or defective contact in wiring harness between voltage is
tion
Vl (female) (1) - F06 (female) (3) below 0.5 V
4) Defective VHMS controller
Boom bonom
1) Defective boom bottom pressure sensor Sensed
35 pressure Short circuit
sensor with chassis __- 2) Short circuit with chassis ground in wiring harness between
voltage is
Vl (female) (1) - F06 (female) (3)
ground below 0.5 V
3) Defective VHMS controller
Short circuit 1) Short circuit with power source in wiring harness between
with power ___ Vl (female) (1) - F06 (female) (3)
source 2) Defective VHMS controller
-
I) Defective boom head oressure sensor
2) Defective joint connector JF3 Sensed
Disconnec- -__
E862 3) Disconnection or defective contact in wiring harness between voltage is
tion
Vl (female) (10) - F14 (female) (3) below 0.5 V
1) Defective VHMS controller
Boom head
II Defective boom head pressure sensor Sensed
36 Dressure Short circuit
sensor with chassis E862 --_ 2) Short circuit with chassis ground in wiring harness between voltage is
Vl (female) (10) - F14 (female) (3)
ground below 0.5 V
3) Defective VHMS controller
Short circuit I) Short circuit with power source in wiring harness between
with crower -__ e-m Vl (female) (10) - F14 (female) (3) -__
!) Defective VHMS controller
-
I) Defective work equipment relief pressure sensor
!I Defective joint connector JR14, JL2, JR16, or JR13
3) Disconnection or defective contact in wiring harness between
hzonnec- E864 --_ nput voltage
Vl (female) (2) - HS2 (female) (2)
: 0.5 v
1) Disconnection or defective contact in wiring harness between
V2A (female) (18) - HS2 (female) (3)
j) Defective VHMS controller
Nork equip-
nent relief I) Defective work equipment relief pressure sensor
37 Short circuit !) Short circuit with chassis ground in wiring harness between
xessure nput voltage
with chassis IE864 -em
Vl (female) (2) - HS2 (female) (2)
sensor $1Short circuit with chassis ground in wiring harness between : 0.5 v
ground
WA (female) (18) - HS2 (female) (3)
1)Defective VHMS controller
Short circuit I) Short circuit with power source in wiring harness between Sensing is
with power --- _-- WA (female) (18) - HS2 (female) (3) mpossible
source !I Defective VHMS controller
-
1) Defective transmission main relief pressure sensor
2) Defective joint connector JT2, JU, JT3, or JLll
3) Disconnection or defective contact in wiring harness between Input voltage
Disconnec-
E866 -__ Vl (female) (2) - MT2 (female) (2)
tion c 0.5 v
4) Disconnection or defective contact in wiring harness between
V2A (female) (6) - MT2 (female) (3)
5) Defective VHMS controller
Transmission
main relief 1) Defective transmission main relief pressure sensor
38 2) Short circuit with chassis ground in wiring harness between
pressure Short circuit
Vt (female) (2) - MT2 (female) (2) Input voltage
sensor with chassis E866 m-m
--_ _-- _-- Check lamp does not light up. - - - v-205
doltage (between
;~j”:;:‘“: --- -_- Load measured by load meter When left is
. . 0 V-116
is always 0 ton. not satisfied.
Joltage (between
;;2 $-$1)): Real-time monitor is displayed.
. - . --- Min. pressure is always When left is v-119
0 not satisfied.
sensed.
(0 MPa (0 kg/cm%
Voltage (between
;;A (;13-;3)): Real-time monitor is displayed.
. - . _-_ --- Min. pressure is always When left is v-121
0 not satisfied.
sensed.
(0 MPa f0 kg/cm%
WA I 200-3 20-8 15
0
OPERATIONS OF VHMS CONTROLLER AGAINST ABNORMALITY
TROUBLESHOOTING AND CONDITIONS OF MACHINE CAUSED BY ABNORMALITY
20-816 WA1200-3
2
(8)
OPERATIONS OF VHMS CONTROLLER AGAINST ABNORMALITY
TROUBLESHOOTING AND CONDlTlONS OF MACHINE CAUSED BY ABNORMALlTY
Voltage (between
;-;A ‘263’; (12)):
- . Real-time monitor is displayed
___ --_ Min. pressure is always When left is
0 v-122
sensed. not satisfied.
(0 MPa {O kg/cm31
Voltage (between
V2A (5) - (3)): Real-time monitor is displayed
0.7 - 5.3 v -__ --- Min. pressure is always When left is
0 V-123
sensed. not satisfied.
(0 MPa f0 kg/cm%
Voltage (between
;‘A_‘;_53’ ; (12)): Real-time monitor is displayed.
Min. pressure is always When left is V-124
sensed. not satisfied.
(0 MPa IO kg/cm%
Resistance (between
V2A (10) - (12)): PM Clinic display is abnormal When left is
Ambient temperature ___ ___ 0 V-128
(held at 100°C). not satisfied.
20% Approx. 12 kQ
0°C: Approx. 4 kQ
___ _-- PM Clinic display is abnormal When left is V-128
0
(held at -30°C). not satisfied.
PM Clinic is displayed.
Voltage (between Min. oressure is alwavs When left is
‘J2p_‘;‘3-Vf12”:
--- 0 sensed. not satisfied.
v-129
. . (0 MPa IO kg/cm?)
PM Clinic
_-- __- Min. pressure is always When left is
0 v-129
Voltage (between sensed. not satisfied.
;‘p (;)3-$12)): (0 MPa {O kg/cm%
. - .
PM Clinic
_-- --_ ___ Max. pressure is always --_ v-219
sensed.
Voltage (between
V2B (8) - chassis):
Small lamp ON:
Fuse is broken.
Load measurement
-__ _-- -__ Trigger is not applied and load ___ __ _
!!?l!g: OPEN meter does not calculate load.
__- ___ -_- Trigger is not applied and load ___ ___
meter does not calculate load.
2 Engine oil pressure Below specified Refer to Engine Shop Manual ––– fi 2 When left is not satisfied.
pressure
Engine coolant
3 temperature Above 105°C Above 105°C fi fi 10 When left is not satisfied.
5 Fuel level Below specified level Below 1 segment of gauge (11%) fi ––– 10 When left is not satisfied.
6 Below specified level Below 1 segment of gauge (11%) ––– fi 10 When left is not satisfied.
7 Torque converter Above 120°C Above 120°C fi fi 2 When left is not satisfied.
oil temperature but 130°C alarm is not detected
8 Above 130°C Above 130°C fi fi 2 When left is not satisfied.
Hydraulic oil
9 temperature Above 105°C Above 105°C fi fi 10 When left is not satisfied.
2
Brake oil Below 14.7 MPa Below 14.7 MPa {150 kg/cm }
10 pressure (F) {150 kg/cm2} and within 60 sec after engine starts ––– fi ––– When left is not satisfied.
2
(Cut-in/Cut-out Below 14.7 MPa {150 kg/cm }
11 pressure) and after 60 sec after engine starts ––– fi 5 When left is not satisfied.
Brake oil Below 14.7 MPa Below 14.7 MPa {150 kg/cm2}
13 pressure (F) {150 kg/cm2} and within 60 sec after engine starts ––– fi ––– When left is not satisfied.
25 Clogging of air
cleaner (2)
Above specified
negative pressure OPEN = 24 V (When clogged) ––– fi 2 When left is not satisfied.
26 Clogging of air
cleaner (3)
Above specified
negative pressure OPEN = 24 V (When clogged) ––– fi 2 When left is not satisfied.
27 Clogging of air
cleaner (4)
Above specified
negative pressure OPEN = 24 V (When clogged) ––– fi 2 When left is not satisfied.
20-820 WA1200-3
2
(8)
TROUBLESHOOTING LIST OF ALARM ITEMS DISPLAYED ON CGC MONITOR
Alarm output
Main monitor Display of message
output (CGC)
Alarm Saving of Sensor Normal Real-time
Screen Cancel Check Caution Error detecting display Remarks
display on color switch lamp lamp Buzzer monitor, PM
No. failure history component (Reference) Clinic
CGC Saved: fi (Reference)
918 fi
Abnormal Yellow Installed Flashing ––– ––– 925 fi VHSM
––– –––
Abnormal Red Not installed ––– Flashing ON 926 fi ––– –––
Abnormal Yellow Installed Flashing ––– ––– 927 fi ––– –––
VHSM
Abnormal Red Not installed ––– Flashing ON 928 fi ––– –––
Abnormal Yellow Installed Flashing ––– ––– 931 fi VHMS ––– –––
Abnormal Yellow Installed Flashing ––– ––– 937 fi VHMS ––– –––
WA1200-3 20-821
2
(8)
FOR VHMS SYSTEM
-TR(3UBLESHOOTlNG ELECTRICAL CIRCUIT DIAGRAM
Cause Remedy
Cause Remedy
Engine coolant
Check or see
temperature above 105°C
Service
or defect related to
Manual of
CUMMINS engine
CUMMINS
controller (CENSE)
20-824 WA1200-3
2
(8)
TROUBLESHOOTING V-5
V-5 EE9051 [Fuel level below specified level (before engine starts)] 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 CGC monitor display, the
problem has been removed.
* 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.
* This failure code is displayed before the engine starts.
Cause Remedy
Table 1
Fuel level 1 Resistance
1 FULL (100%) 1 Approx. 10 R 1
VHM
JR2 (DTI)
RAlO (DTHD4)
TJW02526
V-6 [E906] [Fuel level below specified level (While engine is running)]
-
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 CGC monitor display, the
problem has been removed.
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.
This failure code is displayed before the engine starts.
Cause Remedy
Defective VHMS
Replace
controller
I
I I * Disconnect VZA
* See Table 1. and R05. Insufficient fuel or Supply fuel or
l Disconnect R05. defective fuel level replace fuel
NO sensor level sensor
Table 1
Fuel level Resistance
II Fuel level
sensor
TJW02526
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 CGC monitor display, the
problem has been removed.
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.
1
2 YES Defective VHMS
Replace
1Is resistancebetwen II controller
I
YES WA Ifemale)(3). T24
, r (female)11)and Short circuit with chassis
_ chassisground ground in wiring harness
normal? Repair or
Is resistance between V2A (female) (3) replace
between T24 Imale) _ - Min. 1 MR NO -T24 (female) (1)
(1) and (2) as shown . Turn starting
in Table 17 Torque converter oil
switch OFF.
temperature is above Repair or
* Disconnect VZA and T24.
- See Table 1. 120°C or defective torque replace
* Turn starting NO converter oil temperature
switch OFF. sensor
* Disconnect T24.
Table 1
*j
Totsue converter
v-7 Related electrical circuit diagram oil temDerature
sensor bon i tar)
VHMS
l!
TJW02527
A- 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 CGC monitor display, the
problem has been removed.
* 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.
Cause Remedy
Tome carlverter
V-B Related electrical circuit diagram YI II tmmmr
ni L*,llr*l,ature
sensor bon i tar)
VHMS
LR7 (0
m .*
RAlO [DTHD4)
TJW02527
0
TROUBLESHOOTING v-9
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 CGC monitor display, the
problem has been removed.
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.
Cause Remedy
Table 1
Temperature Resistance
VHMS
controller V2A(07018)
0. 5’Y JR16 (DTl)
Hydraulic oi I
LR2 (HD-85086) sensor
TJW02528
* 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 CGC monitor display, the
problem has been removed.
* Before carrying out troubleshooting, check that all the related connectors are properly inserted.
* This failure code is displayed when the brake cut-out oressure is below 14.71 MPa (150 kg/cm? (for
60 seconds after the engine starts).
* Perform the following troubleshooting when the cut-out pres- Cause Remedy
sure is normal.
* Always connect any disconnected connectors before going
on to the next step. Low front brake oil
YES pressure or defective Check or
I front brake oil pressure replace
1 sensor
If HR15 is II
Low rear brake oil
Check or
pressure or defective rear
replace
brake oil pressure sensor
L
J--
. Turn starting
If HRlr ‘-
switch OFF. GotoA -
discon
Disconnect HRlS.
l
SC+=raiiure code
NO dr--
Start engine.
l
di
Contact of wiring harness
* Turn starting between V2A (female) (8) Repair or
switch OFF. - HR16 (female) (3) with replace
. Disconnect HR16. chassis ground
* Start engine. h _.
round normal? * DisconnectVZA and Contact of wiring harness
HR16. between V2A (female) (7) Repair or
* Min. 1 MD
VO - HR15 (female) (3) with replace
- Turn starting
chassis ground
switch OFF.
l Disconnect V2A
and HR15. 7 YES -
Go to 8.
YF
6 Disconnection or defective
OFF.
I if WA (female) 17) is I * DisconnectJR14 Disconnection or defective
contact in wiring harness Repair or
From A between WA Ifemaie) (8) - replace
HR16 (female) (3)
Disconnection or defective
l Max. 1 R and HR16. contact in wiring harness Repair or
-Turn starting between WA (female) (7) - replace
NO
switch OFF. HR15 (female) (3)
l Disconnect V2A
and HR15.
Defective VHMS
Replace
Is resistance bet- controller
YES ween JR14 (female)
- (5). HR16(female)(2) -
-
9 and chassisground Contact of wiring harness
Is resistance bat- normal? between JR14 (female) (5) Repair or
yfcS ween JR14 (female) _ - HR16 (female) (2) with replace
* Min. 1 MQ NC
- (6), HR15 (female) - -Turn starting switch chassis ground
a (2) and chassis OFF.
IfJR14 ground - normal? - DisconnectJR14 Contact of wiring harness
gmundedto chz Min. 1 MD
l
and HR16. between JR14 (female) (6) Repair or
From S _ is resistancebetween - HR15 (female) (2) with replace
HR16 (female)(2) and - * Turn start@ NO
chassisground chassis ground
switch OFF.
normal?
* Disconnect JR14 Disconnection or defective
- Max. 1 R and HR15 contact in wiring harness Repair or
-Turn starting between JR14 (female) (5) replace
NO
switch OFF. - HR16 [female) (2)
. Disconnect JR14
and HR16.
VHMS
JR13 (DTIB)
Front brake
oi I Pressure
Rear brake
oil Pressure
RAlO(DTHD4)
TJW02529
Remedy
. .-
IYF!
-
GotoA
Disconnection or defective
contact in wiring harness Repair or
d
- Min. 1 MR
).~$m?ct
ii14 and Contact of wiring harness
between V2A (female) (7) - Repair or
Yl
*Turn starting NO HRt5 (female) (31 with replace
switch OFF. chassis ground
- Disconnect V2A
* Max. 1 D and HR15. contact in wiring harness Repair or
replaced with rear . Turn starting NO
between WA (female) (7) - replace
switch OFF. HR15 (female) (3)
- Disconnect V2A
and HR15. Low front brake oil
- Turn starting
pressure or defective Check or
switch OFF.
IO front brake oil pressure replace
* Replace with
sensor
(normal) rear
brake oil
pressure sensor. Defective VHMS
Replace
*Start engine. controller
JL21fDTlBl
Front brake
oi I Pressure
RA5 (LITI)
RAlU(DTHD4)
qmp
TJW02530
* 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 CGC monitor display, the
problem has been removed.
* Before carrying out troubleshooting, check that all the related connectors are properly inserted.
* This failure code is displayed when the cut-in/cut-out pressure of the rear brake is below 14.71 MPa
(150 kg/cm21 (60 seconds after the engine starts).
* Perform the following troubleshooting when the rear brake cut-in/cut-out pressure is normal.
* Always connect any disconnected connectors before going on to the next step.
cause Remedy
Gotok -
VH
e
ure
TJW02531
* 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 CGC monitor display, the
problem has been removed.
-)r Before carrying out troubleshooting, check that all the related connectors are properly inserted.
f Always connect any disconnected connectors before going on to the next step.
* Perform the following troubleshooting when the battery fluid level is normal.
F=-
Remedy
VHMS
RA2 (DTP/DT 1)
TJW02532
* 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 CGC monitor display, the
problem has been removed.
* Before carrying out troubleshooting, check that all the related connectors are properly inserted.
Ir Always connect any disconnected connectors before going on to the next step.
* Perform the following troubleshooting when the battery fluid level is normal.
*
3 YES Defective VHMS
Replace
Is resistancebet- controller
YES ween VZB (female)
- (2). RA8 (female) (1) - Short circuit with chassis
2 and chassisground
If V26 (fern ground in wiring harness Repair or
normaI?
between V2B (female) (2) replace
YES gs$:: EC;:;, _ *Min.lMR NO
RA6 (female) (1) and - RAB (female) (1)
1 chassisground l Turn starting switch OFF.
- normal? - Disconnect V2B and RAB. Disconnection or defective
Is voltage bet- contact in wiring harness Repair or
- Max. 1 Q
ween RAB (male) between VZB (female) (2) - replace
- - Turn starting NO
(1) and chassis RA6 (female) (1)
switch OFF.
ground normal?
Disconnect VZB
l
Defective battery fluid
- 5.5 - 6.5 V and RAB. level sensor ‘2’ or Charge or
- Disconnect RAB. NO
I insufficient battery replace
charge
VHMS
Battery
TJW02532
* 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 CGC monitor display, the
problem has been removed.
* 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.
* Perform the following troubleshooting when the battery fluid level is normal.
ChJSe Remedy
_ MS
3 ._- Defective VHMS
Replace
Is reskance bet- controller
YES wee” V2B (female)
- 131.RA9 (female) (1) - Short circuit with chassis
_ 2 and chassisground
If V2B (female)(3) is ground in wiring harness Repair or
normal?
ES grourjdedtochassis, - - between VZB (female) (3) replace
_ Is re%tance between _ . Min. f MD NO
- RA9 (female) (1)
RA3 (female)11)and
1 chassisground * Turn starting switch OFF.
- normal? * Disconnect VZS and FiA9. Disconnection or defective
Is voltage bet- Repair or
* Max. 1 R contact in wiring harness
ween RA9 (male) between V26 (female) (3) - replace
- * Turn starting NO
(1) and chassis RA9 (female) (1)
switch OFF.
ground normal?
* Disconnect VZB Defective battery fluid
.5.5-6.5V and RA9. Charge or
level sensor ‘3’ or
- Disconnect RA9. ’ replace
NO insufficient battery
charge
VHMS
TJW02532
V-16 [E9251 [Brake fluid level below specified level (before engine
starts)] 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 CGC monitor display, the
problem has been removed.
* 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.
* This failure code is displayed before the engine starts.
CaUSe Remedy
H
switch OFF. Defective VHMS
_ groundedto Replace
- Ground HRlO controller
dwsfailure
(female) (1) to No :~~~~s
appear?
chassis.
* Turn starting *Turn starting Disconnection or defective
switch ON. switch OFF. contact in wiring harness Repair or
- ___..__I
urouno
ll”C
“no Ie -.-.ce between _ -Max.lQ NO between V3A (female) (5) - replace
. Turn aarting HR6 (female) (1)
(female) (1) to
switch OFF.
chassis. * DisconnectV3A and HR6. Disconnection or defective
* Turn starting - Max. 1 Q contact in wiring harness Repair or
switch ON. * Turn starting NO between V3B (female) (5) - replace
switch OFF. HRlO (female) (1)
* Disconnect V3B
and HRlO.
Front brake
oil level
VHMS controller
ake
el
TJW02533
V-17 [E926] [Brake fluid level below specified level (While engine is
running)] 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 CGC monitor display, the
problem has been removed.
+I 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.
* This failure code is displayed while the engine is running.
Cause Remedy
Front brake
oil level
VHM
ake
el
,,,I
TJW02533
V-18 [ES271 [Coolant level below LOW level (before engine starts] 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 CGC monitor display, the
problem has been removed.
* 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,
* This failure code is displayed before the engine starts.
CaUSe Remedy
I.,
If GO6 (female) (1)
and 12) are shorted $j%j$jz~
to each other, does Disconnection or
failure code - IS resistance
IL
ground normal? defective contact in
wiring harness between
Repair or
- 0)
disa ear?
MS between JR2 Imale) replace
. Max. 1 R N( GO6 (female) (2) -chassis
* Turn starting and (1) and
* Turn starting switch
switch OFF. I iI between JR7 (male) ground
- (2) and (1) normal? OFF.
* Short GO6
* Disconnect G06.
(female) (1) and * Max. 1 R Defective JR2 or JR7 Replace
l Turn starting NO
- Turn starting switch OFF.
switch ON. Disconnection or
* Disconnect JR2
- Max. 1R and JR7.
defective contact in
Repair or
. Turn starring wiring harness between
NO replace
switch OFF. V3A (female) (10) - GO6
* Disconnect V3A
and G06.
VHMS
RAlO (DTHD4)
000 1
--I
GO6CDT11
Coolant level
sensor
TJW02534
V-19 [E9281 [Coolant level below LOW level (While engine is running)]
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 CGC monitor display, the
problem has been removed.
* 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. .
* This failure code is displayed while the engine is running.
Cause Remedy
Disconnection or
defective contact in Repair or
I
wiring harness between replace
* Turn starting N?
GO6 (female) (2) -chassis
* Turn starting switch
switch OFF. ground
* Short GO6
(female) (1) and . Disconnect G06.
Defective JR2 or JR7 Replace
(2) to each other. NO
mTurn starting
switch ON. Disconnection or
- Max. 1R
I
defective contact in
Repair or
s Turn starting wiring harness between
NO replace
switch OFF. V3A (female) (10) - GO6
l Disconnect V3A (female) (1)
and G06.
VHMS
Coolant level
TJW02534
* 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 CGC monitor display, the
problem has been removed.
-k Before carrying out troubleshooting, check that all the related connectors are properly inserted.
Sr Always connect any disconnected connectors before going on to the next step.
Cause Remedy
Clogging of transmission
oil filter or defective Check or
transmission oil filter replace
sensor (ROl )
Clogging of transmission
and (2) are shorted
YES oil filter or defective Check or
to each other, does
transmission oil filter replace
sensor (R02)
- Turn starting If ROZ(female)
switch OFF. and (2) are shorted 4YE
Gotok -
Is resistance
disappear? YES between R02
(female) (1) and 3 (female) (2) and ROl Disconnection or defective
(2) to each other. * Turn starting PIf v3A (female)I11 I is (female) (1) normal? contact in wiring harness Repair or
switch OFF. groundedto chassis, p - between R02 (female) (2) - replace
. Disconnect ~02. _ is resistancebetween _ -Max.lQ NI
ND RO2Uynale) (1) and . Turn starting ROl (female) (1)
- Short R02 chassrsground switch OFF.
(female) (1) and normal? Disconnection or defective
*Disconnect
ROl and AOi
contact in wiring harness Repair or
(2) to each other. - Max. 1 R
* Turn starting between V3A (female) Ill) replace
NO
switch OFF. - RO2 (female) (1)
* Disconnect V3A
and R02. 6 YES Defective VHMS
Replace
Is resistancebet- controller
YES ween ~101(female)
5 (2) and chassis Disconnection or
- ground normal? defective contact in
Is resistance Repair or
wiring harness between
From A _ between JR7 * Max. 1 R NO replace
ROl (female) (I) - chassis
(male) (3) and (1) * Turn starting
ground
normal? switch OFF.
* Disconnect ROl. Defective joint connector
l Max. 1 R Replace
* Turn starting NO (JR71
switch OFF.
l Disconnect JR7.
VHMS
TJW02535
+ 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 CGC monitor display, the
problem has been removed.
* 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.
ChUSe Remedy
Replace
If connector B06
Y ES Defective dust indicator
does failure code Replace
relay 1
* Turn starting
switch OFF. 4 YE:
-I- Gotok -
* Disconnect B06.
n Is resistance bet-
* Turn starting
MS ween V3B (female) _
switch ON. 3 (1) and L132 Disconnection or defactivc
. Turn starting - Is resistance bet- (female) (61 normal? contact in wiring harness Repair or
switch OFF. ween B06 (female)
-Max.lQ NC behnreen V3B (female) (1) replace
l Replace with N- (1). 1132 (female) (2) -
*Turn starting L132 (female) (6)
another relay. 0 and chassis ground
switch OFF.
l Turn starting normal? Contact of wiring harness
p * DisconnectV3B and L132
switch ON. . Max. 1 R between 606 (female) (1). Repair or
* Turn starting NO L132 (female) (2) with replace
switch OFF. chassis ground
* Disconnect B06 and L132.
Defective VHMS
controller Replace
Is resistance bet-
From A _ ween L132 (female) _
Disconnection or
(3) and chassis
ground normal? defective contact in
Repair or
wiring harness between
* Max. 1 $2 NO replace
L132 (female) (3) -
* Turn starting chassis ground
switch OFF.
- Disconnect L132.
VHMS
C
Dust
indicator
I relay
Dust
indicator
2 relay
Dust
indicator
3 relay
Dust
indicator
4 relay
TJW02536
0
TROUBLESHOOTING V-22
* 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 CGC monitor display, the
problem has been removed.
f 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.
ChJSe Remedy
1
If connector 807
is disconnected, Y ES Defective dust indicator
Replace
does failure code I relay 2
disappear?
I 2
-Turn starting
switch OFF. relay 2 is replaced 4 YE5 -
-r Gotok
. Disconnect 807. with another relay, Isresistamcebet-
P
. Turn starting YES ween ~38 (femaw
switch ON. 3 - (2) and L133 Disconnection or defective
* Turn starting - (female) 16) normal?
Is resistancebet- contact in wiring harness Repair or
switch OFF. ween 807 (female) between V3B (female) (2) - replace
Replace with NC
l
L133 (female) (6)
another relay. and chassisground
switch OFF.
Turn starting normal? Contact of wiring harness
l
- * DisconnectV3E and L136
switch ON. - Max. 1 R between 807 (female) (1) - Repair or
-Turn starting NO L133 (female) (2) with GND replace
switch OFF. harness or chassis ground
lDisconnect 807 and L133.
5 YES Defective VHMS
Replace
controller
Is resistance bet-
From A _ ween L166 (female) _ Disconnection or
(3) and chassis
defective contact in
ground normal? Repair or
wiring harness between
NO replace
l Max. 1 R L133 (female) (3) -
-Turn starting chassis ground
switch OFF.
. Disconnect L133.
* The related electrical circuit diagram is the same as that for V-21. See V-21.
Cause Remedy
‘ES
Defective dust indicator 3
I
If connector B08
is disconnected, Y FS Defective dust indicator
does failure code Replace
relay 3
disappear?
I
*Turn starting
switch OFF. relay 3 is replaced 4 YE!
Ir GotoA. -
- Disconnect 808.
h Is resistance bet-
* Turn starting
YES ween ~36 (female) _
switch ON.
3 (3) and L134 Disconnection or defective
*Turn starting - bat-
Is resistance (female) (6) normal? contact in wiring harness Repair or
switch OFF. ween Bo8 (female) P _
-Max.lQ between V3B (female) (3) - replace
l Replace with - (1). L134 (female) (2) - N(
*Turn starting L134 (female) (6)
another relay. h10 and chassisground
switch OFF.
* Turn statting normal? Contact of wiring harness
. Okconnect V3B and L136
switch ON. * Max. 1 D between 808 (female) (1) - Repair or
-Turn starting NO L134 (female) (2) with GNC replace
switch OFF. harness or chassis ground
. Disconnect BOB and L134.
Defective VHMS
Replace
controller
From A Disconnection or
[groundnormal? 1i defective contact in
c I qepair or
I
wiring harness between
- Max. 10 NO 1134 (female) (3) -
* Turn starting chassis ground
switch OFF.
- Disconnect L134.
* The related electrical circuit diagram is the same as that for V-21. See V-21.
j, 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 positio& if the error code is no longer displayed on the CGC monitor display, the
problem has been removed.
* 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.
cause Remedy
GotoA. -
Is resistance bet-
disaopear?
yEs wee” V3B (female) _
switch ON. 3 (4)and Ll35 Disconnection or defective
- Turn starting - Is resistance bet- (female1(6) normal? contact in wiring harness Repair or
mritch OFF. wsen 609 (female) between V3B (female) (4) - replace
.Msx.lR NC
. Replace with - 11).L135 (female) (2) - L135 (female) 16)
*Turn starting
another relay. NO and chassis ground
switch OFF.
. Turn starting normal? Contact of wiring harness
- . DisconnectV3B and L135
switch ON. * Max. 1 R between B69 (female) (1) - Repair or
* Turn starting NO L135 (female) (2) with GND replace
switch OFF. harness or chassis ground
- Disconnect BO9 and L135.
5 YES Defective VHMS
Replace
controller
1
Is resistance bet- 11
wen L135 (female)
From A -
(3) and chassis Disconnection or defective
ground normal? contact in wiring harness Repair or
between L135 (female) (3) - replace
0 Max. 1 R NO
chassis ground
*Turn starting
switch OFF.
. Disconnect L135.
* The related electrical circuit diagram is the same as that for V-21. See V-21.
* 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 CGC monitor display, the
problem has been removed.
* Perform the following troubleshooting when fuse 1410) is not broken. If fuse IO is broken, check
the wiring harness between the fuse and L152 for short circuit with the chassis ground.
* 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.
Cause Remedy
Gotok -
/ES
Disconnection or defective
contact in wiring harness Repair or
-Max.ln ._
NI between L152 (female) 12) replace
. Turn starting - ERl (female) 6)
switch OFF.
- Disconnect L152 and Disconnection or defective
ERl contact in wiring harness Repair or
between FS2 (male) (9) am replace
IO
L152 (female) (1). (3)
Defective alternator
alternator terminal I Seplace
NO signal relay fL152)
R and chassis
.28t2V
qepair or
* Start engine. Defective alternator
NO rplace
6 YES Defective VH MS
qeplace
Is resistance II controller
YES bstweenV2A
r; l-l (female) (4) and Disconnection or defective
contact in ti!ing harness qepair or
between V2A (female) (4) - aplace
L152 (female) (6)
srenal relay
TJW07.537
Cause Remedy
VHMS controller
\
ROI R02.B
TJWO2538
Remedy
Defect of sensor,
YES
disconnection of which
turns off failure code
1
If MT 2,3.4, and 5
are disconnected Defect of sensor,
YES
one by one, does - disconnection of which
failure code turns off failure code
-Turn starting
I Short circuit with chassis
ground in wiring harness
4 YES between JT~ (female) (2). Repair or
If JT2 is (3). 14). (5) -MT 5 (female) replace
(2). MT4 (female) (2). MT3
turn starting codedisappear? 1disconnected, (female), (2)) MT2 (female)
switch OFF. When does failure code (2)
* Turn starting
disconnecting disappear?
switch ON. between pins of JT2 Go to A. -
each connector, -When connecting i - Turn startina NO
turn starting each connector, switch ON. -
switch ON. turn starting I
switch OFF. When *Turn starting ,. 1 Eective JT2, JR14, or Replace
disconnecting
.switch
. ._ON.
Repair or
replace
Transmission
main relief
Pressure sensor
Torque converter
outlet oil
VHMS Con t ro I ler v, ~07020~ Pressure sensor
Torque converter
inlet oil
Pressure sensor
Transmission
modulated oil
Pressure sensor
J T2 (DT2)
Steering relief
oil Pressure sensor
Pressure sensor
TJW02533
Cause Remedy
0.75fG
)OUtPUt (t24v)]307/ 3 E 307 1 307
TJW02540
V-104 [E814] (Short circuit with chassis ground in 5-V circuit of sensor
power supply)
* Before carrying out troubleshooting, check that all the related connectors are properly inserted.
f Always connect any disconnected connectors before going on to the next step.
Remedy
1
Y ES Defective transmission
lubricating oil pressure Replace
sensor
If R05 is
YES disconnected,
disappear? does failure code
I Gotok -
disappear?
* Turn starting - between R05
switch ON. 2 * Turn starting Ne (female) (1) and -
Is resisrance switch ON. chassis ground Short circuit with chassis
between Vl ll0rmal7 ground in wiring harness Repair or
- (female) (5) and - * Min. 1 MR Nf between R05 (female) (1) replace
ND chassis ground - Turn starting - RES3 (female) (2)
normal? switch OFF.
* Disconnect R05 and Short circuit with chassis
- Min. 1 MR
RES3. ground in wiring harness Repair or
* Turn starting
NO between Vl (female) (5) - replace
switch OFF.
MT1 (female) (2)
. Disconnect Vl
and MTl.
5 YES Defective VHMS
Replace
controller
between Vl
From A (femaie) (4) and
~&ahaground 11 Short circuit with chassis
ground in wiring harness Repair or
NO between Vl (female) (4) - replace
l Min. 1 MR
RES3 (female) 1
* Turn starting
switch OFF.
* Disconnect Vl
and AES3
VHMS controller
TJW0254 I
Cause Remedy
Table 1
V2A (9) – chassis ground V2A (12) – chassis ground V3A (9) – chassis ground V3B (12) – chassis ground
20-858
20-858 WA1200-3
2
(8)
TROUBLESHOOTING v-107
* 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.
Cause Remedy
uamaw,z
d 01 Uemde, K m *
*Min.lMQ
* Turn starting
nnritch OFF.
1
NO
Short circuit with chassis
,ground in wiring harness
Ihaving abnormal value
Repair or
replace
VH
TJW02543
* 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.
* If E826, E827, and E828 occur simultaneously, disconnection, defective contact, short circuit with
chassis ground, or short circuit with power source has occurred in the VHMS controller or in the
wiring harness between V3A (8) and JL22 (1).
CallSo Remedy
Go to A. -
NO
l
and C3B.
(female) (4)
Disconnect JL22.
- Max. 1D
* Turn starting I Defective joint connector
Replace
switch OFF. NO (JL17)
-Disconnect JL17.
Go to B. -
I Is resistance II
Replace
- Max. 1V
* Disconnect V3A
and C3B.
11
NO
switch OFF.
* Disconnect JL18. Short circuit with power
source in wiring harness
between V3A (female) (8)
- C3B (female) (4)
Repair or
replace
*Turn starting
switch ON.
10 YE: Defective transmission
Replace
Is voltage between controller
YES ~38(female) 112)
9 and chassis Short circuit with power
1s resrstancebe- ground normal? source in wiring harness Repair or
YES tween VW (female) replace
* Max. 1 V NI between V3A (female)
- (18). C3B (female) -
(12) and chassis . DisconnectV3A (18) - C3B (female) (12)
8 and US.
- ground normal? Short circuit with chassis
Is resistance *Turn starting switch ON
betweenV3A * Min. 1 MR ground in wiring harness Repair or
From B -) (female) (18) and - l Turn starting NO between V3A (female) replace
r.Z3;.Z;,male)112) switch OFF. (18) - C3B (female) (12)
- l Disconnect V3A Disconnection or
= Max. 2 R and C3B defective contact in Repair or
. Turn starting NO wiring harness between replace
switch OFF. WA (female) (18) - C3B
* Disconnect V3A (female) (12)
and C3B.
Cause Remedy
4YE!
IC Gotok
Is voltage between
YES MO1 (female) It)
3 and chassis Short circuit with power
Is resistancebet-- ground normal? source in wiring harness Repair or
ween V3A (female) between V3A (female) (8) replace
. (81,MO1(female) (1) - -Max.lV
. DisconnectV3A
NC
- MO1 (female) (11
and chassisground
and Mol.
normal? Short circuit with chassis
- *Turn starting switch ON
l Min. 1 MD ground in wiring harness Repair or
l Turn starting NO between V3A (female) (8) replace
switch OFF. - MO1 (female) (1)
* Disconnect V3A Disconnection or defective
and Mol. contact in wiring harness Repair or
between JU2
between V3A (female) (8) - replace
(male) (1) and (7)
MO1 (female) (1)
. Disconnect V3A
7 YE:
Go to B. -
Is resistancebet-
YES ween WA (female)
- (18). M01 (female) -
6 (12) and chassis Short circuit with chassis
Is resistance ground normal? ground in wiring harness Repair or
YE between V3A between V3A (female) replace
* Min. 1 MR NC
(female) (181and - (18) - MO1 (female) (12)
. Turn starting
5 MO1(female) (12)
switch OFF.
normal?
Is resistance I - * DisconnectWA and MO1
sMax.2R contact in wiring harness Repair or
between JU3
From A * Turn starting NO betvveen V3A (female) (18) replace
(male) (1) and (7)
switch OFF. - MO1 (female) (12)
-I normal7 t
* Disconnect V3A
- Max. 1R and Mol. Defective joint connector
-Turn starting Replace
0 (JL23)
switch OFF.
. Disconnect JL23.
a MS Defective modulated
Replace
clutch controller
Isvoltage between
MO1 (female) (12) _
From 0 -
and chassis Short circuit with power
ground normal? source in wiring harness Repair or
- Max. 1 V NO between V3A (female) replace
l Disconnect V3A (18) - MO1 (female) (12)
and Mol.
l Turn starting
switch ON.
TWW02601
* 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.
* If E825, E826, and E828 occur simultaneously, disconnection, defective contact, short circuit with
chassis ground, or short circuit with power source has occurred in the VHMS controller or in the
wiring harness between V3A (8) and JL22 (I).
Cause Remedy
4YE! -
6 I c Gotok
$SZ&~H
Short circuit with chassis
I Is resistancebet- I ground in wiring harness Repair or
IL
y~z ween V3A Ifemale) between V3A (female) (8 replace
-Max.lV NC
- (8). L26 (female) (1) -
- DisconnectV3A - l.26 (female) (1)
2 and chassisground
and LZ6.
- normal? Disconnaction or defective
Is resistance - . Turn starting switch ON
* Min. 1 MD contact in wiring harness Repair or
YES betweenV3A
- (female) (8) and LZ6 - * Turn starting NO between V3A (female) (8) - replace
(female) (1) normal? switch OFF. L26 (female) (1)
1
* Disconnect V3A Disconnaction or defective
Is resistance *Max.2!.2 and L26. contact in wiring harness Repair or
between JL22 _ *Turn starting
between V3A (female) (8) - replace
(male) (1) and (2) switch OFF. NO
U6 (female) (1)
normal? * Disconnect V3A
- Max. 1R and L26.
. Turn starting Defective joint connector
Replace
switch OFF. NO (JU2)
. Disconnect JL22.
7 YE! -
Is resurtancebet-
Go to 0.
YES wee” V3A (female)
- (181.L26 (female) -
_ 6 (121and chassis Short circuit with chassis
Is resistance ,ground normal? ground in wiring harness Repair or
Y ; betweenV3A between V3A (female) replace
. Min. 1 MQ N(
- (female) (18) and -
*Turn starting (18) - L26 (female) (12)
L26 (female) (12)
switch OFF.
“o”nal? Disconnection or defective
I Is resistance I * DisconnectV3A and LZ6
lMax.2R contact in wiring harness Repair or
between JL23
From A . Turn starting NO between V3A (female) (181 replace
-I (male) (1) and (2) I switch OFF. - L26 (female) (12)
normal?
I l Disconnect V3A
- Max. 1R and L26. Defective joint connector
-Turn starting Replace
IO (JK3)
switch OFF.
. Disconnect JL23.
II II II
TWW02601
* 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.
* If E825, E826, and E827 occur simultaneously, disconnection, defective contact, short circuit with
chassis ground, or short circuit with power source has occurred in the VHMS controller or in the
wiring harness between V3A (8) and JL22 (1).
CaUSS! Remedy
GotoA. -
7 YE -
Go to 8.
Is resistance
YES between JL23
6 (male) (1) and (8) -
normal? Defective joint connector
Is resistance qeplace
YES_ between JL18 _ * Max. 1 R NC (JL23)
(male) (1) and (6) -Turn starting
5
- normal? switch OFF.
Is voltage between * Disconnect JU3. Defective joint connector
- Max. 1 D ?eplace
Lo8 (female) (1) (JL18)
From A -c * Turn starting NO
and chassis
ground normal? switch OFF.
- Disconnect JL18. Short circuit with power
. Max. 1 V source in wiring harness qepair or
* Disconnect V3A between V3A (female) (8) aplace
NO
and L08. - Lo8 (female) (1)
* Turn starting
switch ON.
10 YE!
Defective main monitor Replace
Is voltage between
YES LO8 (female) (3)
9 and chassis Short circuit with power
Is reswance bet- - ground normal? source in wiring harness Repair or
yes waen WA (female) between V3A (female) replace
*Max.lV N(
- (181. LO8(female) (3) -
s DisconnectV3A (18) - Lo8 (female) (3)
8 and chassisground
and L08.
- normal? Short circuit with chassis
Is resistance - * Turn starring switch ON
. Min. 1 MR ground in wiring harness Repair or
betweenV3A
From 6 -) (female) (18) and - . Turn starting NO betwean V3A (female) replace
LO8(female) (3) switch OFF. (18) - Lo8 (female) (3)
_normal? _ * Disconnect V3A Disconnection or
* Max. 2 R and LO8 defective contact in Repair or
-Turn starting wiring harness between replace
NO
switch OFF. V3A (female) (18) - Lo8
* Disconnect V3A (female) (3)
and L68.
Transmission
ontroller
TWW02601
* Before carrying out troubleshooting, check that all the related connectors are properly inserted.
f Always connect any disconnected connectors before going on to the next step.
Emergency
Parking brake
cancel switch
Fues (I)
VHMS controller Vl (07020) FS2 (S12 Blue)
Caution
Caution buzzer buzzer
relay
TJW02518
V-114 [E843] (Short circuit with power source in check lamp system)
is displayed in history
* Before carrying out troubleshooting, check that all the related connectors are properly inserted.
J, Always connect any disconnected connectors before going on to the next step.
Cause Remedy
Defective VHMS
Replace
controller
Is voltage between
Vl (female) (14)
Short circuit with power
source in wiring harness Repair or
between Vl (female) (14) replace
* Max. 1 V NO
- LO6 (female) (10)
-Turn starting
switch OFF.
. Disconnect VI
and L06.
* Turn starting
switch ON.
TJW02545
* Before carrying out troubleshooting, check that all the related connectors are properly inserted.
Ir Always connect any disconnected connectors before going on to the next step.
Cause Remedy
Cause Remedy
4YES
* .I Go to A.
Is resistance
YES between JF3
3 r (male) (1) and (4)
Is resistance bet- Defective joint connector
YES ween ~06 (female) _ l Max. 10 NO (JF3)
(31 and chassis * Turn starting switch
_ 2 ground normal? OFF. Short circuit with chassis
If F06 (female) (3) is
YES groqded to chassis, * Min. 1 MR - Disconnect JF3. ground in wiring harness Repair or
_ IS resonancebetween _ between Vl (female) (1) -
Vl (female1 (1) and l Turn starting NO replace
1 switch OFF. FfE (female) (3)
ck%?grc”“d
n 1 * Disconnect Vl
Disconnection or defective
*Max.10 and F06. contact in wiring harness Repair or
of boom head l Turn starting between Vl (female) (1) -
NO replace
pressure switch, is switch OFF. F06 (female) (3)
* Disconnect Vl
. Turn starting and F06.
switch ON. Defective boom bottom
NO pressure sensor
From A Disconnection or
- Max. 1 Q
-Turn starting
NO
defective contact in
wiring harness between
Fo6 (female) (2) - Vl
(female) (81, (9)
Repair or
replace
switch OFF.
. Disconnect F06
and Vl.
VHMS
Boom
bottom
pressure
sensor
TWW02602
* Perform the following troubleshooting when fuse II-9 is not broken. If fuse II-9 is broken, check the
wiring harness between the fuse, VHMS controller, and F14 (female) (2) for short circuit with the
chassis ground.
* 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.
Cause Remedy
4YES -
Gotok
Is resistance
ez betweenJF3
8 (male) (1) and (5)
normal? Defective joint connector
Replace
_ .Max.lR NO (JF3)
*Turn starring switch
&_ ground normal? OFF. Short circuit with chassis
If F14 (female) (31 if
yES groundedto chasrx * Disconnect JF3. ground in wiring harness Repair or
* Min. 1 MD
_ I* resistancebetween _ between Vl (female) (10) replace
- Turn starting NO
Vl (female) (10) and
chassisground switch OFF. - F14 (female) (3)
lDisconnect Vl Disconnection or
replaced with that and F14. defective contact in Repair or
of boom bottom *Turn starting NO wiring harness between replace
pressure switch, is switch OFF. Vl (female) (10) - F14
l Disconnect Vl (female) (3)
*Turn starting and F14.
Defective boom head
switch ON. Replace
NO pressure sensor
-
From A Disconnection or
defective contact in
Repair or
i---- wiring harness between
NO replace
Max. 1 Q F14 (female) (2) - Vl
* Turn starting (female) (81, (9)
switch OFF.
* Disconnect F14
and Vl.
0
TROUBLESHOOTING v-102
VHMS
controller
TJW02548
* 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.
* If E864, E865, E867, and E868 occur simultaneously, disconnection, defective contact, or short
circuit with chassis ground has occurred in the wiring harness between VI (female) (2) and JR14
(female) (1).
Cause Remedy
I
Replace
pressure sensor
4YE
Ir
1 GotoA. -
1 If rear brake oil 1 Ilf HR16 (female) (2) is
1 pressuresensor is 1
VH
JRl3tDTlB)
RAlO (DTHD4)
Battery 8L
TJW02531
Cause Remedy
MS Defective work
equipment relief Replace
pressure sensor
l
sensor is replaced
with normal one,
system normal?
. Turn starting
switch OFF.
Replace
pressure sensor
wth normal
one. (steering
oil pressure
is
I r
I
YI
2
If HSZ Ifemale I31 is
grounded to chassis, is
resistance between WA
(181 and
Ifemale)
chassis
switch OFF.
round normal?
* Disconnect HS2
YES
3
1If HS2
*Turn
NO
OFF.
Vl.
Ifemale)
round normal?
- Max. 1 R
starting
* Oisconnect
(2) is
grounded to chassis, is
resistance between Vl
bnale) (2) and chassis
switch
HS2 and
NI
Gotok
Disconnection or defective
contact in wiring harness
between Vl (female) (2) -
HS2 (female) (2)
Disconnection or defective
contact in wiring harness
behveen V2A (female) (18)
- HS2 (female) (3)
Repair or
replace
Repair or
replace
VHMS
ipment
ii
e sensor
RAlO [DTHDI)
Bat terv
000 I
TJW02550
Cause Remedy
4YES
GotoA -
tf HR15 (female) CZ! is
YES groupded to chassis,
_ IS resistance between _
3 ;f;;kNand Disconnection or defective
If HR15 (female)(3) is normal? contact in wiring harness Repair or
groundedto chassis.
* Turn starting
n is resistancebetween _ aMax.lC.2 NC between Vl (female) (2) - replace
WA (female)(7) and * Turn starting switch HRl5 (female) (2)
switch OFF. 2 f;~~7ground OFF.
- Replace Is resistance between - DisconnectHRlS Disconnection or defective
‘I,,,
pressure sensor JR14 (male) (1) and * Max. 1 R and Vl. contact in wiring harness Repair or
(6). between JLZ between VZA (female) (7) -
with normal * Turn starting NO replace
~0 (male) (3) and (51, or
one. (rear brake betwean JR13 (male) switch OFF. HRl5 (female) (3)
oil pressure 1 and 6 normal?
. Disconnect HR15
sensor) -Max.1 R Joint connector having
and V2A.
. Turn starting -Turn starting improper resistance Replace
switch OFF. IO (JR14, JL2, or JR131
switch ON.
l Disconnect JR14,
JL2, or JR13.
7 YES
1r
Defective VHMS
1IS resistance bat- Replace
controller
VHMS
JR13tDTIB1
Fran t brake
oi I Pressure
TJW07.530
Cause Remedy
Defective transmission
main relief pressure Replace
sensor
4YEI
Go to A. -
If MT2 (female)(2) is
MS groundedto chassis,
_ 1sresistancebetween _
sensor is replaced 3 Vl (female)(2) and
- chassisground Disconnection or defective
If MT2 (female)(3) is normal? , contact in wiring harness Repair or
groundedto chassis,
Yl is resistancebetween _ .Max.lQ NC between Vl (female) (2) - replace
* Turn starting
*Turn starting switch MT2 (female) (2)
switch OFF. OFF.
. Replace pressure , * DisconnectMT2 and Disconnsction or defective
sensor with Imale)
(1)and12).kwaen * Max. 1 Q Vl. contact in wiring harness Repair or
normal one. JLZImaW(31and (0. between V2A (female) (6) -
*Turn starting NO replace
- Turn starting switch OFF. MT2 (female) (3)
switch ON. . Disconnect MT2
* Max. 1 n and WA. Joint connector having
l Turn starting improper resistance (JTZ, Replace
switch OFF. 0 JK, JT3, or JLll)
* Disconnect JTZ,
JL2, JT3, or JLll.
7 YES Defective VHMS
Replace
controller
Yl
iS[
6 Short circuit with chassis
1Is resistancebet- 1 ground in wiring harness Repair or
YE . Min. 1 MQ NO between Vl (female) (2) - replace
*Turn starting switch MT2 (female) (2)
6 OFF.
I Is resistance - DisconneciVl and Short circuit with chassis
1
ground in wiring harness Repair or
From A -f%$%~ . Min. 1 MR
- Turn starting
switch OFF.
between VZA (female) (6)
- MT2 (female) (3)
replace
VHMS
.._ Transmission
main relief
ensor
TJWO2552
* Before carrying out troubleshooting, check that all the related connectors are properly inserted.
f Always connect any disconnected connectors before going on to the next step.
* If E863, E864, E865, and E878 occur simultaneously, disconnection, defective contact, or short
circuit with chassis ground has occurred in the wiring harness between VI (female) (2) and JR14
(female) (1).
Cause Remedy
1 GotoA. -
1 If steering relief 1
VHMS
Steering
relief oil
sensor
TJW02553
* 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.
* If E868, E871, and E884 occur simultaneously, disconnection, defective contact, or short circuit with
chassis ground has occurred in the wiring harness between VI (female) (2) and JT2 (female) (1).
Cause Remedy
Defective torque
YES Replace
converter outlet oil
pressure sensor
4YE! -
1 Gotok
If MT3 Wemale)(2) is
rlf tOmu 000v.3-ter
YES grounded to chassis,
outlet oil pressure _ ts resistancebetween _
sensor is replaced 3 Vl (female)(2) and Disconnection or defective
chassis,ground
If MT3 (female)(3) is contact in wiring harness Repair or
; gmundedto chassis, * Max. 1 n
-gfUMf.
between Vl (female) (2) - replace
. ISresistancebetween _ NC
* Turn starting *Turn starting switch MT3 (female) (2)
WA (female)(5) and
switch OFF. &&siiTground OFF.
* Replace pressure - - DisconnectMT3 and Disconnection or defective
sensor with ImaId and(4). betwen . Max. 1R Vl. contact in wiring harness Repair or
JKlmabJfllaed(41, *Turn starting between ‘&!A (female) (5) - replace
normal one. NO
- Turn starting switch OFF. MT3 (female) (3)
switch ON. . Disconnect MT3
lMax.lR Joint connector having
and V2k
*Turn starting improper resistance (JT2, Replace
switch OFF.
IO JU, JT3, or JLll)
l Disconnect JT2,
Jl.2, JT3, or JLl 1.
7 YE! Defective VHMS
Replace
Is resistance bet- controller
yEs ween Vl (female)
- (2). MT3 (female) (2) -
6 Short circuit with chassis
- and chassis ground
Is resistancebet- normal? ground in wiring harness Repair or
wean WA (female) --Min. 1 MS2 - between Vl (female) (2) - replace
YI NC
(5).MT3(female) (31 - * Turn starting switch MT3 (female) (2)
5 and chassisground OFF.
normal? - * DisconnectVl and Short circuit with chassis
I Is resistance I
* Min. 1 MR MT3. ground in wiring harness Repair or
From A ~~~rr?.~~ * Turn starting NO between V2A (female) (5) replace
switch OFF. - MT3 (female) (3)
* Disconnect WA Disconnection or defective
*MaxlR and MT3. contact in wiring harness Repair or
* Turn starting between MT3 (female) (1) - replace
switch OFF. chassis ground
- Disconnect MT3.
0
TROUBLESHOOTING v-123
Tome converter
VHMS outlet oil
ensor
TJW02554
f 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.
* if E864, E865, E867, and E878 occur simultaneously, disconnection, defective contact, or short
circuit with chassis ground has occurred in the wiring harness between VI (female) (2) and JT2
(female) (I 1.
Cause Remedy
Defective transmission
YES Replace
modulation pressure
sensor
4YE -
If MT5 (female) (2) is
yEs gryded to chassis,
_ IS resistance between _
3 Vl (female) (2) and
Disconnection or defective
If MT5 (femalejob ~o~$ground contact in wiring harness Repair or
; groundedto chassis,
n . ISresistancebetween - Max. 1 Q between Vl (female) (2) - replace
* Turn starting v2A (female)(151and - ‘$ starting switch N’ MT5 (female) (2)
switch OFF. i FoEi&ground
- Replace pressure - Disconnact MT5 and Disconnection or defective
- Max. 1 R Vl. contact in wiring harness Repair or
sensor with
JL2 (male) 13)and(4). between V2A (female) (15) replace
normal one. - Turn starting NO
I bshwnJT3lmakl~1lad
U. orbetwen JLll ImaW switch OFF. - MT5 (female) (3)
l Turn starting
switch ON. * Disconnect MT5
Joint connector having
.Max.lR and WA.
improper resistance (JT2, Replace
. Turn starting
JO JL2, JT3, or JLll)
switch OFF.
mDisconnect JT2,
JL2, JT3, or JLll.
7 YE Defective VHMS
Replace
Is resistance bet- fr controller
- Max. 1 R
* Turn starting
. Disconnect V2A
and MT5
Disconnection or defective
contact in wiring harness
between MT5 (female) (1) -
Repair or
replace
switch OFF. chassis ground
. Disconnect MT5.
I
sor
TJW02555
WA 1200-3 20-889
0
TROUBLESHOOTING v-125
* 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.
Cause Remedy
Defective transmission
lubricating oil pressure Replace
sensor
1 4YE!
Gotok -
transmlsslon If MT1 (female) (2) is
lubricatingoil yEs younded to chassis,
pressure sensor is _ u.resistancebetween_
replaced with 3 Vl (female1(5) and Diaconnaction or defective
normal one, is It MT1 &zmale)(3) is chassisgmund
contact in wiring harness Repair or
1:. em normal? YES youndedtochassis, RQRMR between Vl (female) (5) -
_ 1sresisrancebenueen _ -Max.lQ NC replace
* Turn starting VZA (female)(14) and *Turn starting switch MT1 (female) (2)
switch OFF. 2 r;h%&s$ground OFF.
* Replace pressure Is resistance bet- - - DisconnectMT1 and Disconnection or defective
sensor with ween .JT5 (male) (1) * Max. 1 R Vl. contact in wiring harness Repair or
and (5) and between - Turn starting between V2A (female) (14) replace
normal one. l
NO
NIO JLll (male) (1) and - MT1 (female) (3)
* Turn starting switch OFF.
switch ON. r4) “orr”a’L . Disconnect MT1
* Max. 1 R and VZA. Joint connector having
* Turn starting improper resistance (JT3 Replace
NO orJRl1)
switch OFF.
* Disconnect JT3
and JR11
BYE: Defective VHMS
Replace
controller
Transmission
VHMS lubricating
oil pressure
sensor
1
rb7 TJW02556
WA 1ZOO-3 20-891
0
TROUBLESHOOTING V-126
V-126 [E874] (Short circuit with chassis ground in torque converter oil
temperature sensor system) is displayed in history
Ir Before carrying out troubleshooting, check that all the related connectors are properly inserted.
-k Always connect any disconnected connectors before going on to the next step.
Torque convert er
V-126 Related electrical circuit diagram oil temperatur e
I_--.__
sensor unon I Ior)
VHMS kUKl
controller
V-127 [E8751 (Short circuit with chassis ground and with power
source in hydraulic oil temperature sensor system) is displayed
in history
* Before carrying out troubleshooting, check that all the related connectors are orooerly inserted.
* Always connect any disconnected connectors before going on to the next stei. ’
Cause Remedy
VHMS
roller
V2A(07018)
Hrdraul ic oi I
LR2 (HO-85086) sensor
8 2801
TJW02528
* Before carrying out troubleshooting, check that all the related connectors are properly inserted.
J, Always connect any disconnected connectors before going on to the next step.
-
Cause Remedy
VHMS
rol ler VZA (070 I81
.
temperature
LR2 (~~-85086)
0.76fE
TJWO2557
* 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.
Ir If E863, E864, E865, and E867 occur simultaneously, disconnection, defective contact, or short
circuit with chassis ground has occurred in the wiring harness between VI (female) (2) and JR14
(female) (1).
Cause Remedy
1 4 YE? -
Gotok
If HS4 (female)(2) is
If PPC relief pressure MS groundedto chassrs,
sensor is replaced rsresotance between _
3 - Vl (female)(2) and Disconnection or defective
with normal one, is - ;has$ground
system normal? If HS4 (female)(3) is o a contact in wiring harness Repair or
El groundedto chassis,
YI is r&stance betwean _ - Max. 1 Q N( between Vl (female) (2) - replace
* Turn starting V2A (female)(11and -Turnstarting switch HS4 (female) (2)
switch OFF. 2 chassisground OFF.
l Replace pressure normal? * Disconnect HS4 and
sensor with * Max. 1 R Vl. contact in wiring harness Repair or
normal one. * Turn Starting NO between V2A (female) (1) - replace
switch OFF. HS4 (female) 13)
-Turn starting
switch ON. * Disconnect HS4
-Max. 1R and V2A.
Joint connector having
improper resistance Replace
* Turn starting
IO (JR14, JU, or JR71
switch OFF.
* Disconnect JR14
JL2, or JR7.
7 YE: Defective VHMS
Replace
Is resistance bet- controller
yfzs ween Vl (female)
- (2). HS4 (female) 12) -
_ 6 and chassis ground Short circuit with chassis
Is resistancebet- normal? ground in wiring harness Repair or
YES ween VZALfemale) P
* Min. 1 MR - between Vl (female) (2) - replace
NC
- (1). HS4Jfemale) (3) - *Turn starting switch HS4 (female) (2)
5 and chassisground OFF.
-
Is resistance ~ normal? . DisconnectVl and Short circuit with chassis
between HS4 * Min. 1 MR I ground in wiring harness Repair or
From A - (female) (1) and - -Turn starting NO between V2A (female) (1) replace
chassisground _. . .
Switch ncF - HS4 (female) (3)
normal?
*Discon lnect V2A Disconnection or defective
- Max. 1 Q and HS4. contact in wiring harness Repair or
. Turn starting between HS4 (female) (1) - replace
NO
switch OFF. chassis ground
. Disconnect HS4.
VHMS
JR14tDT2)
RA5 (DTt)
RAlO(DTHD4)
000 I
* 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.
+ If E866, E868, and E871 occur simultaneously, disconnection, defective contact, or short circuit with
chassis ground has occurred in the wiring harness between VI (female) (2) and JT2 (female) (1).
Cause Remedy
iS -
Gotok
1 .~.
YES ground&dtc chassis,
_ IS reststance between _
3 Vl (female) (2) and
Disconnection or defective
If chassis wo”“d contact in wiring harness
svstem normal?. Repair or
YES gmu?ded to chassis, .normal)
_ IS resmance between _ - Max. 1 R N IO between Vl (female) (2) - replace
- Turn starting VZB (female) (10) and * Turn starting switch MT4 (female) (2)
switch OFF. 2 ;has$is,ground OFF.
- Replace pressure kresatancebetwenJT2 - o a _ *Disconnect MT4 and Disconnection or defective
sensor with (male)(1) ard (3). between - Max. 1 Q ‘ VI. contact in wiring harness Repair or
_ JK Imale) Ill and (3). between V2B (female) (10)
normal one. NO replace
NO bSweenJT3Imale)~l)and - -Turnstarting
- Turn starting (3).orbetween JLll (male) switch OFF. - MT4 (female) (3)
(11and I21normal? - Disconnect MT4
switch ON.
- Max. 1 R and V2B. Joint connector having
Turn starting
l
improper resistance (JT2 Replace
NO JL2, JT3, or JLll)
switch OFF.
* Disconnect JT2,
JL2, JT3, or JLll.
7YE S Defective VHMS
Replace
1 Is resistance bet- II controller
VHMS
Tome t:onverter
inlet oi I Dressure
sensor
Cl
TJW02559
CaUSe Remedy
Transmission
main relief
Pressure sensor
Toraue converter
outlet oil
Pressure sensor
Torque converter
inlet oil
Pressure sensor
Transmission
modulated oil
Pressure sensor
FRZIHD-46082) RT2 (HD-85086)
LR2(HD-85086) JRl4tOT2)
A 5OOC o'75f8
Steering relief
oil Pressure sensor
Pressure sensor
TJW02539
I CaUSe 1 Remedy
Wheel rotation
VHMS controller
sensor
VI (07020) FL2 (HD-25086) F 15 (DT2)
TJW02540
0
TROUBLESHOOTING V-203
* Before carrying out troubleshooting, check that all the related connectors are properly inserted.
-k Always connect any disconnected connectors before going on to the next step.
* Since the GND line harness of VHMS cannot be disconnected b
its disconnection is not taken up as a cause.
4YEs
rk voltage between fA GotoA. -
l-l
between Vl .Max.lV and RES3. source in wiring harness Repair or
(female) (4) and . Turn starting between Vl (female) (4) -
NO replace
REs3 (female) (1) switch OFF. RES3 (female) (1)
normal? l Disconnect Vl and RES3.
s Max. 1 Q * Turn starting switch ON. Disconnection or defective
* Turn starting contact in wiring harness Repair or
switch OFF. NO between Vl (female) (4) - replace
* Disconnect Vl FiES3 (female) (1)
and RESJ.
Defective VHMS
Replace
controller
Transmi ss ion
lubrica tina oil
Dressur e sensor
TJW02541
*
2 YES Defective VHMS
Replace
Is resistance bet- controller
MS Wee” Vl (female)
- (16). LSS (female1 (2) -
1 ~ Short circuit with chassis
If Vl (female) (16) is _ a”d chassis ground ground in wiring harness Repair or
normal?
grounded to chassis,
between Vl (female) (16)
is resiRance between _ * Min. 1 MC? NO replace
L99 @male) (2) and l Turn starting - L99 (female) (2)
ckzssztground
switch OFF. Disconnection or
l Disconnect Vl and L99. defective contact in Repair or
* Max. 1 R
* Turn starting NO wiring harness between replace
switch OFF. Vl (female) (16) - L99
. Disconnect Vl (female) (2)
and L99.
Emergency
parking brake
cancel switch
ion
er
A TJW02516
* Before carrying out troubleshooting, check that all the related connectors are properly inserted.
Jc Always connect any disconnected connectors before going on to the next step.
Main monitor
TJW02545
* 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.
Cause Remedy
TJW02546
f 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.
Cause Remedy
TJW0.2547
V-208 Short circuit with power source in boom head pressure sensor
system
* Before carrying out troubleshooting, check that all the related connectors are properly inserted.
j, Always connect any disconnected connectors before going on to the next step.
Cause Remedy
VHMS
TJW02548
0
TROUBLESHOOTING v-209
V-209 Short circuit with power source in rear brake oil pressure
sensor system
Ir Before carrying out troubleshooting, check that all the related connectors are properly inserted.
f Always connect any disconnected connectors before going on to the next step.
I cause I Remedy
JR13 (DTlB)
JR14 (DT2)
e
oil wessure
RA5 CDT11
RAt 0 (DTHD4)
Bat terv OL
TJW02531
V-210 Short circuit with power source in front brake oil pressure
sensor system
Sr 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.
JR13 (DTIB)
LR7 (DTI)
RAI 0 (DTHD4)
000 I
TJW02530
0
TROUBLESHOOTING v-21 1
Ir 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.
Remedy
t-=
1 YES Defective VHMS
ISvoltage between Replace
controller
V2A (female) (18).
HS2 (female) (3) and -
chassis ground Short circuit with power
IllJmlal? source in wiring harness Repair or
NO between V2A (female) replace
* Max. 1 V
(18) - HS2 (female) (3)
* Turn starting
switch OFF.
. Disconnect V2A
and HS2.
-Turn starting
switch ON.
VHMS
con
JR/6 (DTII
Work esuiment
relief oil
.e sensor
TJW02550
* 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.
Cause Remedy
Defective VHMS
Replace
controller
I
MT2 (female)(3)
and chassisground Short circuit with power
nO~~l7 source in wiring harness Repair or
NO between WA (female) (6) replace
* Max. 1 V
- MT2 (female) (3)
-Turn starting
switch OFF.-
* Disconnect WA I I
and MT2.
*Turn starting
switch ON.
Transmission
VHMS nain relief
cvessure sensor
l-l
TJWO2552
Cause
--I
Remedy
VHMS
con ol ler VI (07020)
il
sensor
TJW02553
WA1 ZOO-3
TROUBLESHOOTING v-214
V-214 Short circuit with power source in torque converter outlet oil
pressure sensor system
* Before carrying out troubleshooting, check that all the related connectors are properly inserted.
It Always connect any disconnected connectors before going on to the next step.
Cause Remedy
lortoe converter
VHMS outlet oil
Dressure sen t.or
* 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.
Cause Remedy
Transmission
VHMS modulated oil
&roller VI fO70201 wassure sensor
TJWO2555
* 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.
CallSe Remedy
Torsue converter
V-216 Related electrical circuit diagram oil temperature
or)
VHMS
-44
aa J4
aa
41
TJW02527
0
TROUBLESHOOTING V-217
t Before carrying out troubleshooting, check that all the related connectors are properly inserted.
f Always connect any disconnected connectors before going on to the next step.
I Cause I Remedy
Defective VHMS
Replace
controller
Disconnection or
defective contact in Repair or
wiring harness between replace
* 3.5 - 4.0 kQ at
No
- Disconnect V2A and HSI.
I
I
V2A (female) (11) - HSl
(female) 11)
VHMS
TJW02528
* 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.
Cause Remedy
VHMS
JR13 (DTIB)
TJW02557
0
TROUBLESHOOTING v-219
V-219 Short circuit with power source in PPC relief sensor system
or 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.
ReDlace
Repair or
replace
switch OFF.-
- Disconnect V2A
and HS4.
- Turn starting
switch ON.
VHMS
JR7 (DTl)
LR7 (DTI)
TJW02558
V-220 Short circuit with chassis ground in fuel level sensor system
* 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.
CaUSe Remedy
Table 1
Resistance
Between (1) - (2) Between (1) - chassis grouncI
FULL (100%) Approx. 10 Q
l/2 (50%) Approx. 32 R
Min. 1 MP
l/4 (25%) Approx. 49.5 Q
1 EMPTY (0%) 1 Approx. 85 R
VHM
LR2 (HD-85086)
TlW02526
V-221 Short circuit with power source in battery fluid level sensor “1”
* 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.
Cause Remedy
1
Bat terv
RAl (DTZ/DTl)
TJW02532
V-222 Short circuit with power source in battery fluid level sensor “2”
* 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.
Cause Remedy
VHMS
RA2 (DT2/DTI)
RA7 (DTl)
Battery
Jevel sensor TJW02532
V-223 Short circuit with power source in battery fluid level sensor “3”
* 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.
Cause Remedy
RAl(DTZ/DTl)
TJW02532
V-224 Short circuit with chassis ground or power source in brake fluid
level sensor
* 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.
cause Remedy
. Turn starting
switch OFF. 4YE
* Disconnect HRlO.
ween HR6 (female)
1Isresktance
bet- 1r Gotok -
. Measure vccl ween V3A (female) I I
resistance when 1 ‘A IS). HR6 (female) (1) I-l
front brake tank Short circuit with chassis
. Turn starting
ground in wiring harness Repair or
is empty. switch OFF.
between V3A (female) (5) replace
* Disconnect HR6
h
*Turn stanina switch - HR6 (female) (‘1)
(female). 1and chassis OFF. -
* Measure ?I? * DisconnectV3A and Short circuit with chassis
II
resistance when * Min. 1 MQ ground in wiring harness Repair or
rear brake tank is * Turn starting between V3B (female) (5) replace
empty. switch OFF.- _- -HRlO (female) (1)
- Disconnect V3B
and HRIO.
6 YES Defective VHMS
Replace
_1Is voltage between 1 1 controller
VHMS controller
ake
el
-n%-
TJW02533
0
TROUBLESHOOTING V-225
* 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.
Cause
IS voltage between
V3B ~fermle) 110).
GO6 (female) (1) and
chassis ground
*Max. 1 V
* Turn starting
switch OFF.
* Disconnect V36
and G06.
* Turn starting
switch ON.
1 YES
NO
Defective VHMS
controller
IReplace
Repair or
replace
VHMS
RAlO (DTHD4)
Coolant level
TJW02534
ChJSt? Remedy
Defective transmission
2 YES
oil filter or VHMS Replace
Is voltage between
MS V3A (female) (11). controller
, r R02 (female) (1) and
_ chassisground Short circuit with power
Is resistancebat- normal? source in wiring harness Repair or
ween V3A (female) between V3A (female) replace
- ’ Max* ’ ” NO
(111, R02 (female)
*Turn starting switch OFF. (11) - R02 (female) (1)
(1) and chassis
around normal? . Disconnect V3A and R02.
- Turn starting switch ON. Short circuit with chassis Repair or
l Min. 1 MR
- Turn starting NO ground in wiring harness replace
switch OFF. between v3A (female)
- Disconnect (11) - R02 (female) (1)
V3A and R02.
VHMS
Transmission
TJW02535
V-227 Short circuit with power source in air cleaner clogging (1) relay
system
* 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.
Cause Remedy
VHMS
controller
DUS t
ind icator
I r clay
Dus t
ind icator
2 r clay
-vindicator 31
-vindicator
141
-IDust
TJW02536
V-228 Short circuit with power source in air cleaner clogging (2) relay
system
* 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.
Cause Remedy
* The related electrical circuit diagram is the same as that for V-227. See V-227.
V-229 Short circuit with power source in air cleaner clogging (3) relay
system
* 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.
Cause Remedy
* The related electrical circuit diagram is the same as that for V-227. See V-227.
V-230 Short circuit with power source in air cleaner clogging (4) relay
system
* 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.
Cause Remedy
1 MS Defective VHMS
Replace
Is voltage between controller
V3B (female) (4)
and L135 (female) Short circuit with power
(6) normal? source in wiring harness Repair or
NO between V3B (female) (4) replace
* Max. 1 V
- L135 (female) (6)
* Turn starting
switch OFF.
mDisconnect V36
and L135.
* Turn starting
switch ON.
* The related electrical circuit diagram is the same as that for V-227. See V-227.
j, 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.
1 Is resistance bet-
1ween WA (female) I
1 YES
VHM
Alternator
signal relay
-
Fuse (I)
FS2 (SlZBlue)
-___ m--l
TJWO7.537
0
TROUBLESHOOTING OF HYDRAULIC AND
MECHANICAL SYSTEM
(H MODE)
I Transmission
No. Problems
8
Relief pressure at torque converter too low
(Items 5 and 7 normal)
0
Ir 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.
No. Problems I I I
I Turning, response of steering is poor in both directions (left and right) IO/O 10 10 I()( 0 /
, .. .. .
10101 l0l0l0J
5 ( Work equipment moves
.
. equipment
_ .worn --- I I I -
6 also speed IS slow oww 0
7 Abnormal noise comes from around PTO 0
8 Abnormal noise comes from around steering pump or hydraulictank 0 0
9 Abnormal noise comes from around switch pump or hydraulictank 00
I
Oil pressure is low or there is no pressure in o(-j(-Jooonlnl I InI
--I
10 When steering
relief pressure
is measured
both directions (left and right)
* 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.
Remedy/+/
No. Problems /x/x x
1 Steering is heavy when turned in both directions (left and right) 000
No. Problems
1 Steering wheel shakes or jerks in both directions (left and right) lO[OlOj~
No
1
6 When air bleed plug is loosened, a large amount of oil flows out 0 ()
H-13 Boom moves slowly or does not have sufficient lifting power
Checks before troubleshooting
. Is the travel of the boom control lever
and also the spool of the work equip-
ment control valve correct?
l Seizure of work equipment linkage bush-
ing.
(Does emits abnormal noise)
l If the boom speed lowers when it is
loaded, it must be overloaded. Check the
load meter in this case.
Fault check
There is a strong relationship between faults
involving lifting force and lifting speed. Such
faults appear initially in the from of insuffi-
cient lifting speed. Measure the lifting speed
of the lift arm when loaded and refer to the
standard value table to determine whether
or not there is a fault.
2 Bucket tilt back force and speed are normal but boom lifting
speed is slow. 0 00
Cause
l Swollen or internally damaged boom cylinder tube.
* Regarding other faults occurring during boom rise, refer to item “H-13 Boom moves slowly or
does not have sufficient lifting power”.
Refer to item “H-13 Boom moves slowly or does not have sufficient lifting power”.
Cause
. Defective boom cylinder rod side suction valve seat of work equipment control valve
. Oil leakage from boom cylinder piston seal
During excavation or ground leveling when the boom control lever is in the “HOLD” position, the
bucket and boom move up and down in accordance with the terrain.
The boom drops momentarily under its own weight when the boom control lever is gradually
shifted from the “HOLD” position to the “RAISE” position while the engine is at low idling. When
the control lever is put completely into the “RAISE” position, the boom moves normally.
Cause
l Defective seating of work equipment control valve or boom spool check valve.
Fault checks
l Check deficient tilt back force by per-
forming actual work.
. Measure the operating speed of the
bucket and check it against the standard
value table to determine whether or not
it is normal.
Boom lifting force and lifting speed are abnormal and also
1 0000 0
bucket tilt force and tilt speed are abnormal.
Boom lifting force and lifting speed are normal but bucket tilt
2 0 ooc
force and tilt speed are abnormal.
Cause
l Swollen or internally damaged bucket cylinder tube.
l As to other faults which occur when operating bucket, refer to item “H-20 Bucket moves
slowly or has insufficient tilt back power”.
Cause
l Defective seat of safety valve (with suction valve) of the rod side of bucket cylinder of work
equipment valve.
l Oil leakage from seal of bucket cylinder piston.
Fault check
. Use the standard value table to check whether or not the hydraulic drift of the bucket is
actually large.
Cause
l Oil leakage in bucket cylinder
l Defective seating of safety valve (with suction valve) at bottom side.
Defective oil sealing of bucket spool.
l Defective check valve between pipings.
Cause
l Defective piston seal of bucket cylinder.
. Defective safety valve (with suction valve) for the head side of bucket cylinder.
If the above symptoms occur together, refer to the troubleshooting items corresponding to
each fault. _ .
The bucket dumps momentarily under its own weight when the bucket control lever is gradually
shifted from the “HOLD” position to the “TILT” position while the engine is at low idling.
When the control lever is put completely into the “TILT” position, the bucket moves normally.
Cause
. Defective seating of bucket spool check valve of work equipment valve.
作業時の注意事項 ………………………………………………………… 30-003 コンバータ Ass’y ………………………………………………………… 30-071 フロア/プラットフォームサポート,A/Cカバー Ass’y ……………… 30-112
PRECAUTIONS WHEN CARRYING OUT OPERATION CONVERTER Ass’y FLOOR/PLATFORM SUPPORT, A/C COVER Ass’y
塗布剤リスト ……………………………………………………………… 30-005 トランスミッション Ass’y ……………………………………………… 30-077 コンソール/ダッシュ Ass’y …………………………………………… 30-113
COATING MATERIALS TRANSMISSION Ass’y CONSOLE/DASH Ass’y
特殊工具一覧表 …………………………………………………………… 30-006 バルブ Ass’y ……………………………………………………………… 30-080 作動油タンク Ass’y ……………………………………………………… 30-115
SPECIAL TOOL LIST VALVE Ass’y HYDRAULIC TANK Ass’y
特殊工具略図 ……………………………………………………………… 30-007 トルコン,トランスミッションライン Ass’y ………………………… 30-081 ステアリング油圧配管 Ass’y …………………………………………… 30-116
SKETCHES OF SPECIAL TOOLS T/C, T/M LINE Ass’y STEERING HYDRAULIC LINE Ass’y
DTコネクタピンの取り外し,取り付け ………………………………… 30-050 プロペラシャフト Ass’y ………………………………………………… 30-086 ローダリンケージ Ass’y ………………………………………………… 30-117
REMOVAL AND INSTALLATION OF DT CONNECTOR PIN PROPELLER SHAFT Ass’y LOADER LINKAGE Ass’y
HDコネクタピンの取り外し,取り付け ………………………………… 30-051 センタサポート Ass’yの分解・組立 ………………………………… 30-086-1 キックアウトポジショナ Ass’y ………………………………………… 30-120
REMOVAL AND INSTALLATION OF HD CONNECTOR PIN DISASSEMBLY AND ASSEMBLY OF CENTER SUPPORT Ass’y KICKOUT POSITIONER Ass’y
ハーネスの補修要領 ……………………………………………………… 30-051 フロントアクスル Ass’y ………………………………………………… 30-087 ロップッスキャノピ Ass’y ……………………………………………… 30-121
REPAIR PROCEDURE OF HARNESS FRONT AXLE Ass’y ROPS CANOPY Ass’y
エンジンマウント Ass’y ………………………………………………… 30-052 リヤーアクスル Ass’y …………………………………………………… 30-089 エマージェンシステアリング Ass’y …………………………………… 30-122
ENGINE MOUNT Ass’y REAR AXLE Ass’y EMERGENCY STEERING Ass’y
クーリングシステム Ass’y ……………………………………………… 30-055 デフキャリア Ass’y ……………………………………………………… 30-091 ステアリングシリンダ Ass’y …………………………………………… 30-124
COOLING SYSTEM Ass’y DIFFERENTIAL CARRIER Ass’y STEERING CYLINDER
フューエルタンク Ass’y ………………………………………………… 30-058 ファイナル&ブレーキ Ass’y …………………………………………… 30-096 リフトシリンダ Ass’y …………………………………………………… 30-126
FUEL TANK Ass’y FINAL & BRAKE Ass’y LIFT CYLINDER Ass’y
エアコン Ass’y …………………………………………………………… 30-062 J/S & アームレスト Ass’y ……………………………………………… 30-100 ダンプシリンダ Ass’y …………………………………………………… 30-128
AIR CONDITIONER J/S & ARM-REST Ass’y DUMP CYLINDER Ass’y
エアコンパイピング Ass’y ……………………………………………… 30-064 ブレーキシステム Ass’y ………………………………………………… 30-103 MESABIオイルクーラ Ass’y ……………………………………………… 30-131
AIR CONDITIONER PIPING Ass’y BRAKE SYSTEM Ass’y MESABI OIL COOLER Ass’y
WA1200-3 30-001
(9)
DISASSEMBLY AND ASSEMBLY STANDARD TIGHTENING TORQUE
11
2. TABLE OF TIGHTENING TORQUES FOR SPLIT FLANGE BOLTS 22 54 – 93 {5.5 – 9.5} 74 {7.5} – – 16UN 17.5
03 16
fl In the case of split flange bolts for which there is no special instruction, tighten to the torque
given in the table below. 24 59 – 98 {6.0 – 10.0} 78 {8.0} 18 – –
13
Thread diameter Width across flat Tightening torque 04 27 84 – 132 {8.5 – 13.5} 103 {10.5} 22 – 16UN 20.6
16
mm mm Nm kgm 05 32 128 – 186 {13.0 – 19.0} 157 {16.0} 24 1 – 14UNS 25.4
10 14 59 – 74 6 – 7.5 3
12 17 98 – 123 10 – 12.5 06 36 177 – 245 {18.0 – 25.0} 216 {22.0} 30 1 – 12UN 30.2
16
16 22 235 – 285 23.5 – 29.5
(10) 41 177 – 245 {18.0 – 25.0} 216 {22.0} 33 – –
30-002 WA1200-3
(9)
DISASSEMBLY AND ASSEMBLY PRECAUTIONS WHEN CARRYING OUT OPERATION
Nominal Flange (hose end) Sleeve head (tube end) Split flange 4. Precautions when completing the operation
number • If the coolant has been drained, tighten the drain valve, and add water to the specified level. Run
04 07379-00400 07378-10400 07371-30400 the engine to circulate the water through the system. Then check the water level again.
05 07379-00500 07378-10500 07371-30500 • 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.
3) If the part is not under hydraulic pressure, the following corks can be used. • If the piping or hydraulic equipment have been removed, always bleed the air from the system
Nominal Dimensions after reassembling the parts.
Part Number fl For details, see TESTING AND ADJUSTING, Bleeding air.
number D d L
06 07049-00608 6 5 8 • Add the specified amount of grease (molybdenum disulphide grease) to the work equipment parts.
08 07049-00811 8 6.5 11
10 07049-01012 10 8.5 12
12 07049-01215 12 10 15 Taper 1/8
øD
ød
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 L
24 07049-02430 24 20 30
27 07049-02734 27 22.5 34 DEW00401
WA1200-3 30-003
(9)
DISASSEMBLY AND ASSEMBLY PRECAUTIONS WHEN CARRYING OUT OPERATION
Disconnection
1) Release the residual pressure from the hydrau-
lic tank. For details, see TESTING AND AD-
JUSTING, Releasing residual pressure from hy-
draulic tank.
Disassembly
fl Do not hold rubber cap portion (4).
Connection
30-004 WA1200-3
(9)
DISASSEMBLY AND ASSEMBLY COATING MATERIALS
COATING MATERIALS
fl The recommended coating materials such as adhesives, gasket sealants and greases used for
disassembly and assembly are listed below.
fl For coating materials not listed below, use the equivalent of products shown in this list.
Category Komatsu code Part No. Q’ty Container Main applications, features Category Komatsu code Part No. Q’ty Container Main applications, features
• Used to prevent rubber gaskets, rubber • Used as lubricant for sliding portion
LM-G 09940-00051 60 g Can
LT-1A 790-129-9030 150 g Tube cushions, and cock plug from coming Molybdenum (to prevent from squeaking).
out. disulphide • Used to prevent seizure or scuffling of the
• Used in places requiring an immediately lubricant LM-P 09940-00040 200 g Tube thread when press fitting or shrink fitting.
effective, strong adhesive. Used for plas- • Used as lubricant for linkage, bearings, etc.
20 g Polyethylene
LT-1B 790-129-9050 tics (except polyethylene, polyprophylene, SYG2-400LI • General purpose type
(2 pcs.) container
tetrafluoroethlene and vinyl chloride), rubber, SYG2-350LI
metal and non-metal. G2-LI SYG2-400LI-A Various Various
• Features: Resistance to heat and chemicals SYG2-160LI
Polyethylene
LT-2 09940-00030 50 g • Used for anti-loosening and sealant pur- SYGA-160CNLI
container
pose for bolts and plugs. SYG2-400CA • Used for normal temperature, light load
Adhesive: • Used as adhesive or sealant for metal, SYG2-350CA bearing at places in contact with water or
790-129-9060
1 kg glass and plastic. G2-CA SYG2-400CA-A Various Various steam.
(Set of adhesive
LT-3 Hardening Can SYG2-160CA
and hardening
agent: SYGA-160CNCA
Adhesives agent)
500 g Molybdenum • Used for heavy load portion
SYG2-400M 400 g ✕ 10 Bellows type
Polyethylene • Used as sealant for machined holes. disulphide
LT-4 790-129-9040 250 g SYG2-400M-A 400 g ✕ 20 Bellows type
container Grease grease
SYGA-16CNM 16 kg Can
Holtz • Used as heat-resisting sealant for repairing LM-G (G2-M)
790-126-9120 75 g Tube
MH 705 engine. Hyper White • Seizure resistance and heat resistance
SYG2-400T-A
• Quick hardening type adhesive Grease G2-T higher than molybdenum disulfide grease
SYG2-16CNT 400 g Bellows type
Three bond Polyethylene • Cure time: within 5 sec. to 3 min. G0-T (*) • Since this grease is white, it does not
790-129-9140 50 g SYG0-400T-A (*) 16 kg Can
1735 container • Used mainly for adhesion of metals, *: For use in stand out against machine body.
SYG0-16CNT (*)
rubbers, plastics and woods. cold district
• Quick hardening type adhesive Biogrease G2B • Since this grease is decomposed by bacteria
SYG2-400B
Aron-alpha Polyethylene • Quick cure type (max. strength after 30 minutes) G2-BT (*) in short period, it has less effects on
790-129-9130 2 g SYGA-16CNB 400 g Bellows type
201 container • Used mainly for adhesion of rubbers, *: For high microorganisms, animals, and plants.
SYG2-400BT (*) 16 kg Can
plastics and metals. temperature
SYGA-16CNBT (*)
and large load
Polyethylene • Resistance to heat, chemicals
Loctite SUNSTAR • Used as primer for cab side
79A-129-9110 50 cc • Used at joint portions subject to high Glass
648-50 container PAINT PRIMER 20 ml (Using limit: 4 months)
temperatures. container
580 SUPER
• Used as adhesive or sealant for gaskets Primer
LG-1 790-129-9010 200 g Tube SUNSTAR • Used as primer for glass side
and packing of power train case, etc. Glass
GLASS PRIMER 20 ml (Using limit: 4 months)
container
WA1200-3 30-005
(9)
DISASSEMBLY AND ASSEMBLY SPECIAL TOOL LIST
30-006 WA1200-3
(9)
DISASSEMBLY AND ASSEMBLY SPECIAL TOOL LIST
Ne- New/
Component Symbol Part No. Part Name ces- Q’ty re– Sketch Nature of work, remarks
sity model
• 793-890-2510 • Shaft ■ 1 N
• 793-890-2520 • Nut ■ 1 N
• 793-890-2530 • Sleeve ■ 1 N
• 793-890-2540 • Sleeve ■ 1 N
• 793-890-2550 • Plate ■ 1 N
• 793-890-2560 • Plate ■ 1 N
• 793-890-2580 • Guide ■ 1 N
• 793-890-2590 • Ring ■ 1 N
• 793-890-2610 • Bolt ■ 6 N
• 04530-11222 • Eyebolt ■ 2
• 793-890-2710 • Sleeve ■ 1 N
• 793-890-2720 • Sleeve ■ 1 N
• 793-890-2730 • Shaft ■ 1 N
• 793-890-2750 • Guide ■ 1 N
• 793-890-2760 • Ring ■ 1 N
• 793-890-2770 • Bolt ■ 4 N
• 01580-02016 • Nut ■ 4
• 04530-11222 • Eyebolt ■ 2
792-525-3000 Micrometer ■ 1
Adjustment of side bearing
2 790-425-1670 Adapter ■ 1 preload
Disassembly,
assembly of axle · 790-425-1660 Wrench ■ 1
final drive · brake W
SMT-890-3100 Tool assembly ■ 1
assembly
SMT-890-3110 • Cylinder
Adjustment of hub bearing
3 SMT-890-3120 • Piston preload
SMT-890-3130 • Shaft
SMT-890-3140 • Plate
WA1200-3 30-006-1
(9)
!J3B*sm !#33lca~~
DISASSEMBLY AND ASSEMBLY SKETCHES OF SPECIAL TOOLS
$~a-~y~~i~~~Bl
St AJ-U70-007
#3 k&T&,
lii8CMli
co.5tm R0.64.2mIo:tl
Thisspaceris eauivalentto one in jigdrawingNo. AJ-U70-007
#3 of KomatsuEC .
Chamferoutsidecornersto CO.5and roundinsidecornersto R0.6 - RI.2
unlessotherwisespecified. #AmI 1
V mWll?fA R’l?
1 ; HEAT TREATMENT 1 CASE DEPTH MATERIAL
pI,;mj- . ss4cJo
PAMT CM
MASS (kg1 PART NAME
SJFACE mAT.arz
1 SPACER
SCALE
NONE
V . I
I HEAT TREATMENT CASE DEPTH MATERIAL
/ .
I HEAT TREATMENT CASE DEPTH MATEATAL p(AT&
tiIOl! #A#WL /Idenim andtmerinn HRC26-32 s45c MASS (kg) PART NAME RDJTOFI
PAMT (R SJmcE
TE4r.coK
MASS (kg) PART NAME
sJ?=da
TREIT.lm PUSH TOOL
12 SLEEVE
SCALE
NONE
:d) *~t=~~~~~~~~~~Wt~~~~~~~~~-~~~~~~~~~~.
1 B2/B3 1 NOTE: Komatsu cannot accept any responsibility for special tools manufactured according to these sketches.
” A ” $38 ” A ” $3 $jJ
r-;-5------
y-+_
‘=Q
\‘::\,_ _----
111
1.4,ik, t-4 I I III I
L” I . .
ti ---
--._---
____ ‘#lBA
LF-~j-------
WA
1200(31 1 WA1200
(31 1
APPLICATION Q’TY APPLICATION B’TY
I HEAT TREATMENT 1 CASE OEPTH MATERIAL I HEAT TREATMENT CASE DEPTH MATER IAL
.
ss400
I
SCALE SCALE
( NOTE: Komatsu cannot accept any responsibility for special tools manufactured according to these sketches.
-‘- --
:‘p q.$
co \ ;f
oocc; 0-J
a* 0
8 / .
-- 1
1, -
.----------
--L
V
I
:
I q I r-7-Y
k/ It: ,f
I _-------I
’ i
86. 67
I I I.
\ i
‘,
I ‘.
I
l I
a-------
1 1
WA1200131
I
I I
APPLICATION
1 Q’TY
: HEAT TREATMENT
I
I $~l;t’Z~I&%Q!~o”oi 40-85155-OOA #l3i~t16. [. ; CASE DEPTH MATERIAL
I KflTICti!
r
I
( ---f I
Thissocketis equivalent
to one in ii9drawing MASS Ik g)
8.8
PART NAME
ASS'Y-DRAW
PAMT
(R
SURFACE
TREAT.coDE
i i- No. 40-85155-OOA
AwazuPlant. I I
-7 i SCALE
NONE
WA1 200-3
33l#*%l2t mIE!81$m
DISASSEMBLY AND ASSEMBLY SKETCHES OF SPECIAL TOOLS
NOTE: Komatsu cannot accept any responsibility for special tools manufactured according to these sketches.
1 Cl (2/3) 1
It)
‘7 1.47 0.15
77
WAi200131 1
175 .. APPLICATIONQ’TY
I HEAT TREATMENT 1 CASE DEPTH MATERIAL
&423295311301 HRC5863 SCM415H
MASS (kg1 I PART NAME PAINTOR
SURFACE
lREAT.cooE
Thissocketis eauivalent
to one in jigdrawingNo. 40-85t55-001
AwazuPlant. 5.7 1 SOCKET
SCALE
NONE
-&I *~t~kb~~~~~~~~Wt~~l~~~~~~-~~~ff~~~~~~.
I Cl (3/3) I NOTE:Komatsu cannot accept any responsibility for special tools manufactured according to these sketches.
_ 8
-9 _ 170 I
6 66 *
_,4 ~
7v z G
(r0
1 0
as
W 00 / n1wJ 44
o- --- .
2 __&__-_-___ J5,driIled g
hole g
Thissocketis ecmivalent
to one in iio drawingNo. 40-85155-002
AwazuPlant.
SUEFACE
TREU.CODE
YC .I. I
WA1 200-3 11
5H#*mi !fs33cm~~
DISASSEMBLY AND ASSEMBLY SKETCHES OF SPECIAL TOOLS
-w *iTlcd: t3~~~~-fi~~ll~~-~~~-C~~f;flt-Wlo)~ff~~~~~1.
I c2 NOTE: Komatsu
cannot accept any responsibility for special tools manufactured according to these sketches.
------__-_
------
\
Thissocketis eauivalent
to one in jig drawingNo. 40-85161-001
AwazuPlant.
w *lzlt-.k ~~~~~~~~LWl~~~~~~~~~-~~~~~~~~~~.
1 C3(1/2) 1 NOTE: Komatsu cannot accept any responsibility for special tools manufactured according to these sketches.
I I I
!3 BOSS SS4O”P ’ ’ ’ n f
01 GEAR 543
PART NAME
SYM.
1
I HEAT TREATMENT 1 CASE DEPTH IAPPLICATIONI Q’TY
rIIJNi / HRC20-30 m
! Thermal%/!t!of material,
c ‘__. . . -
1
u -PA-RT NAME
- SAE~~;lr"h-En?fdd
MASS (kg1 PAINT Cfl
(NONE)
TJ
ss -p-t-/ I SWFACE,,IREAT.COE
fi 4 A jij
. 42C-.13-15120 1.56 T!~I/~J I
DETAIL OF SAE I NVOLUTE SPL I NE SH,AT
SCALE PART NO.
11
NONE ?!S,MT,89.0: 124,O.d
WA1 200-3 30-013
0
%#*%I3 CINCH
DISASSEMBLY AND ASSEMBLY SKETCHES OF SPECIAL TOOLS
2s:) *~t~~~~~~~~~~l~t~~~~~~~~~-~~~~~~~~~~.
NOTE: Komatsu cannot accept any responsibility for special tools manufactured according to these sketches.
Thissocketis euuivalent
to one in jigdrawing
No. 40-85228-001
AwazuPlant.
inioiutespline
60X22X2. 5
!iiOo”1 “10.19;
I
_iHAtI- s43c 1 1 '$.
I 1 E3lA
Pressureangle 20” 00 I PART NAME MATERIAL UV!3$ffs~ REMARKS
4‘/;r;‘Jr Ex774‘/ti3Yk
J f Thermal refining of material
SWACE TiEAT.CODE
Detail of involute spline shaft
125.o.L
30-O 14 WA1 200-3
0
53l!#*+Jlz DIZZY
DISASSEMBLY AND ASSEMBLY SKETCHES OF SPECIAL TOOLS
NOTE: Komatsu cannot accept any responsibility for special tools manufactured according to these sketches.
d
-
c
-- -------_--_ k
,= z
z
y _-co.5
++
\
A
i ),
/\ A
/'
co.5
-22-l
- 218
(240)
d
&00
A-A
‘\
WA1 200-3
!&%*a2 ~71~~H
DISASSEMBLY AND ASSEMBLY SKETCHES OF SPECIAL TOOLS
l__!L-l NOTE: Komatsu cannot accept any responsibility for special tools manufactured according to these sketches.
------
100 I
This socket is equivalent to one in jig drawing No. 40-85159-001 Awazu Plant.
WdPOO131 1
I HEAT TREATMENT CASE DEPTH APPLICATION O’TY
04 BAR /SS4OOP2 10.051. MATERIAL
I s53c
7 b-L#i.hh
PI ATF 1 I 1.5 I. AIlTmi
s53c
I Flame hardening
I
02 PiPE ~TKMI~Ai l6.1 i$lOOXt6 j MASS (kg1 PART NAME PAINTL-R
I
I s53c 1 i-2.2 I. SURFACETAEAT.WOE
SYM. PART NAME j MATER[AL[UY~~f;~j REMARKS ]
9.9 SOCKET
SCALE
NONE
30-016 WAl200-3
0
33fR*$m 6v.%IE%H
DISASSEMBLY AND ASSEMBLY SKETCHES OF SPECIAL TOOLS
1 D2(1/3) -1 NOTE: Komatsu cannot accept any responsibility for special tools manufactured according to these sketches.
120 *
204 WAlXtO131 1
1
APPLICATION Q’TY
I HEAT TREATMENT CASE DEPTH MATERIAL
. I
$o"old
I$!l&WBirsbti40-85154-OOA ME&H, FumB!
MASS (kg) PART NAME PAINT(R
SUR?Q
TREAT.COOE
13.2 ASS'Y-DRAW
Thissocketis eauivalent
to one in jigdrawingNo. 40-85154-OOA
AwazuPlant.
SCALE
NONE
%&I *~t~~d~~~~~~~~Wt~~~~7~~~~-~~~~~~~~~~.
1 D2 (2/3) 1 NOTE: Komatsu cannot accept any responsibility for special tools manufactured according to these sketches.
m *Iat-k bQ~:~~M~~~FG-~,t~~~~~b-Wlo)~~~~~~~~.
NOTE: Komatsu cannot accept any responsibility for special tools manufactured according to these sketches.
1 D2(3/3) 1
154 r’
27. 5 66 m
16. 5 -
C-
S%
7v 4:’
OD
r
_--- ----- u
I 145 I
__J
WAlX)O
I31 1
I HEAT TREATMENT 1 CASE DEPTH APPLICATION Q’JY 4
MATERIAL
RTM[
m' ztiy$igzk I HRC30-36
I after f inishiw
MASS (kg) PART NAME PAINT (El
Thissocketis euuivalent to one in jig drawing SUFFACE TREAT.COoE
NO. 40-85154-002
AwazuPlant. 4.9 GUIDE
SCALE
NONE
Y
v
40 I I i I
93. 5 83
* 196. 5 N
131 ) 1
f WA1200
r ; HEAT TREATMENT 1 CASE DEPTH /APPLICATION I ~‘17
$o”,IL!
WI#%WBrnSI 40-85153-001 I!ama.
Thissocketis eouivalent
to one in jig drawingNo. 40-85153-001
AwazuPlant.
q@@
,li\ ~#ll~ltf~
V
May be finished
with latheafterheattreatment .___ ,_.
WAlZCU131 I 1
t HEAT TREATMENT CASE DEPTH APPLICATION O’TY
%&~XF? L MATERIAL
K&N; Hardening and tefiwering
! after finishing
HRC36w42 SEE DWG
03 i GUIDF I s53c II 12.2. MASS (kg) PART NAME PAINT OR
WIFACE lFEAT.cooE
1 OCKFT I s53c II 16.9. 9.1 SOCKET
WM. PART NAME 1MATER I AL ]UlY/¶j@$~ REMARKS SCALE
NONE
WA1 200-3
30-02 1
0
53-#+*#i42 !4+3s#IE?sl$rn
DISASSEMBLY AND ASSEMBLY SKETCHES OF SPECIAL TOOLS
,&) *~lt-~13~~:~~~~~~tt-7~~~~~~t-Wle>-ff~~~~~~.
NOTE: Komatsu cannot accept any responsibility for special tools manufactured according to these sketches.
-__ i,\. / j
_
,d /,A&;.L
I,
q.k===J= j
I
I
t---
1’
!
--._ f----i ‘\
-3 i
I
i
8
/
I
a--
j 1
/
; c__-__-__-__-__-ji_”
~_______________~ \
c 5 drilled hole
U70-OP/TF-85156-2 $I@
/ / Stamp
/ / 40 20 z:_:
1’ -=----,“I v / /
ii5-T“
I
I;\‘
---_-- _--- III \ / / L
---__ __-__-__-__
/ii /
t t I .
I I I /I I I!I !I I
I__-__-__-__-__-_i
- May be finished wi th lathe after heat tr eatment
ii ” i_______________J
1 WAiZOO(3) 1 I
is..) *~t~~$~~~~~~~~Wt~~L~7~~~~-~~~ff~~~~L~.
D6 NOTE: Komatsu cannot accept any responsibility for special tools manufactured according to these sketches.
6-13. 5Zfy
6-13.5. drilled hole
I /
j /
I
-_-
1 I/,
40- ,85157-00
This socket is ewivalent to onein ii47 drawing No. 40-85157-001 AwazuPlant.
v I31 (
1 WA1200 1
-I
02 I HEAT TREATMENT CASE DEPTH APPLICATION Q’TY
01 ;
01353-32335i BOLT $%i Standardoart 6 1 !. II 7z&itARiz L MATERIAL
,rj-_-
JLL--
1
_ $228.6
31 I -clYu
t;’
2150
07-k‘/:j
yyIck;I:p
Lowerhinge
Upperh irwe
I
SCALE
NONE
WA1 200-3
30-024
0
53s*wi $333aw3~
DISASSEMBLY AND ASSEMBLY SKETCHES OF SPECIAL TOOLS
1 Kl(Wi’) 1 NOTE: Komatsu cannot accept any responsibility for special tools manufactured according to these sketches.
*,“,I% %Yc/ZS%%WHrn
I@3 AJ-lJ70-004 #Z $?lS&:ap&a.
~~Xit$%$Plt CO.5 3-?%!YtRO. 6-l. Zlz-c~nra,L I:
Thismater is euuivalerrt
to one in jig
drawingNo. AJ-U70-004
#2 of KomatsuMEC
Chamferoutsidecornersto CO.5and round
insidecornersto R0.6 -Rf.2unless
I
PART Ntd4E
23.4 GUIDE
PART NO.
ISURFACE ilEAT.CUIE
16
SCALE
I
GUIDE
!iUFAIX lEAT.COE
-
SCALE PART NO.
-
; I
NONE I$M,T, tj9,0, 2 1,2Q ,A
I NONE I
I
-2
$M,T, - Ej 9,0,
WA1 200-3 30-025
0
!iMf+*BE +$3zKls~~
DISASSEMBLY AND ASSEMBLY SKETCHES OF SPECIAL TOOLS
*w *~t~~~~~~~~~~IWt~~t~~~~~~-~~~~~~~~~~.
NOTE: Komatsu cannot accept any responsibility for special tools manufactured according to these sketches.
\/
Chamfer outside corners to CO.5 and round inside This spacer is equivalent to one in jig drawing
corners to R0.6 - R1.2 unless otherwise specified. No. AJ-U70-004 #3 of Komatsu MEC .
WAiZOO
I31 1
.
I . ; HEAT TREATMENT 1 CASE DEPTH 1 mum 1Q’TY II-IEAT TREATMENT -CASE DEPTH R~PUCA~~’
Q’T~
I
-El *~t~~~~~~~~~~l~t~~~~~~~l~-~~~~~~~~~~.
NOTE: Komatsu cannot accept any responsibility for special tools manufactured accordingto these sketches.
MIN
MIN 4
(31
WA1200 1
APPLICATION Q’TY ! HEAT
v
TREATMENT CASE DEPTH
I HEAT TREATMENT CASE DEPTH MATERIAL . I
. I P@llI@lf
PuITrm’ ss400 I HRC30*36
MASS (kg) PART NAME FAINT 08 MASS (kg) PART NAME PAINTOR
SURAIX
lFFAT.CWE SUIFACZ
PLATE
TlEAT.CCOE
1.2 17.5 GUIDE
SCALE SCALE
NONE NONE
Q9
02 01
MIN -----+
MIN
0-W
++
R z
A
---_- -8- 2 P
I
-- 5
C
_ _c1
+
80
t-
v<4 PLACES
SURFACE
TFlEAT.CC#lE
18.54 1 GUIDE
SCALE
NONE
1 K1(6/7) 1 NOTE: Komatsu cannot accept any responsibility for special tools manufactured according to these sketches.
MIN
36X3
\ WAi2ooI31 1
I HEAT TREATMENT 1 CASE DEPTH 1APPLICATION O'TY
MATERIAL
Fal;lolj E$Ai%c;R
L HB248~285
Hardening and tempering s45c
M&S (kg) PART NAME PllINl
OR
SWdCE ~~.CODE
6 GUIDE I
1 K1(7/7) 1 NOTE: Komatsu cannot accept any responsibility for special tools manufactured according to these sketches.
PLACES
V
HEAT TREATMENT CASE DEPTH
01I
RlFmq #iAm L
, Hardening and tempering
I
m *~t~~~~~rh~~~l~t~~~~~~~~~-~~~ff~~~~~~.
NOTE: Komatsu cannot accept any responsibility for special tools manufactured according to these sketches.
--- I_---
-y----- “-- 1
II
J
:: ii :
l__-Ll-_____ I _-_-u-__
t--
HA1200
(31 1
APPLICATION Q’TY
I HEAT TREATMENT CASE DEPTH MATERIAL
. I
PmTl
MASS (kg) PART NAME PAINT WI
WFACI lHEAT.COOE
. PUSH TOOL
SCALE
NONE 230.0.A
WA1 200-3 30-03 1
0
1 Q(N) 1 NOTE: Komatsu cannot accept any responsibility for special tools manufactured according to these sketches.
NOTE: Komatsu cannot accept any responsibility for special tools manufactured according to these sketches.
I
t I
.&I *~t~~~~~~~~~~~~c~~~~~~~~~-~~~ff~~~~~~.
NOTE: Komatsu cannot accept any responsibility for special tools manufactured according to these sketches.
'his spacer is equivalent to one in jig This spacer is equivalent to one in jig
Irawing No. AJ-U70-006-C of Komatsu MEC . drawing No. AJ-U70-006-B of Komatsu MEC _
Chamfer outside corners to CO.5 and round Chamfer outside corners to CO.5 and round
inside corners to R0.6 - R0.8 unless inside corners to R0.6 - R0.8 unless
” A ” +j-jFJ$@
Detai I of “A” Detai I of “A”
30-034 WA1200-3
0
5m*mc 433?DxBH
DISASSEMBLY AND ASSEMBLY SKETCHES OF SPECIAL TOOLS
m *ixllt:‘k ~~~~~~~~~Wt~~/l~~~l~-~~~~~~~~~~.
1 Vl (l/8) 1 NOTE: Komatsu cannot accept any responsibility for special tools manufactured according to these sketches.
---2
\ \
1 tlA1200
(31 1 1
APPLICATION1 Q’TY
, HEAT TREATMENT CASE DEPTH MATERIAL
. I
mum!
MASS (kg) PART NAME PAINT OR
SIBFACE
TREAT.CCllE
I
PUSH TOOL I
SCALE
NONE
-1
‘8V m40
Threaddepth:40
IHEAT TREATMENT
I
m *~jl-~:13~~~;ht;~~~~t-31,~~~~t~.-wl~a~~~~~~~.
NOTE: Komatsu cannot accept any responsibility for special tools manufactured according to these sketches.
#2 ill3~rrnai v
This spacer is equivalent to one in jig drawing No. AJ-U70-001 #2 of Komatsu MEC . . I idEAT TREATMENT CASE XJEPTH
wRTrar;
PART
HRC26*32
NAME
MATERIAL
s45c
PAINT OR
unlessotherwisesmcified. SlFAcE TFEAT. COE
NUT .
SCALE PART NO.
NONE 1 z9,3,Ej9,0,25,2Q ,A
WA1200-3
30-037
0
53R*wL !l+iSKLEsl$B
DISASSEMBLY AND ASSEMBLY SKETCHES OF SPECIAL TOOLS
1 VI (4/8) 1 NOTE: Komatsu cannot accept any responsibility for special tools manufactured according to these sketches.
ItAJ-U70-001
#4~~ir;b3t
This spacer is equivalent to one in jig
drawing No. AJ-U70-001 #4 of Komatsu MEC .
Chamfer outside corners to CO.5 and round inside Chamfer outside corners to CO.5 and round inside
corners to R0.6 - R1.2 unless AMIWIM 0 ’ TY corners to R0.6 - R1.2 unless MPLIWIJN Q’TY
I I
. I HEAT. TREATMENT CASE DEPTH MATERIAL I I HEAT TREATMENT 1 CASE DEPTH MATERIAL
I %ma L HRC26*32 s45c I 1 HRC26?32 s45c
mI@( Hardening and tempering MiI@( Harder?$%kempering
MASS (kg) PART, NAME PAINTOR MASS (kg) PART NAME PAINT OR
WFKETREAT. COOE SWFACE TEAT.CUE
9 SLEEVE 17.5 I
SLEEVE .
SCAiE SCALE PART NO.
NONE NONE
.&I *~t~k$~~~~~~~I~~~~1~~~~~~-~~~~~~~~~~.
NOTE: Komatsu cannot accept any responsibility for special tools manufactured according to these sketches.
%B.i)
mls-bc ~~~~~fi~~I~c~7ts~~~m-~~~ff~~~~~~.
NOTE: Komatsu cannot accept any responsibility for special tools manufactured according to these sketches.
(EquaI I Y spaced)
41
[ 9% Outside diameter Cm) 1 32 /
1 ojB@ Wire diameter Cum) 1 3 2 1
1 I&X* Freeheight W 1 46 1
/.x5- I
A-A
8&U ?f~x;ctf$ H#i!$~1bUla $!;8$ A32-03 ~~,",~~a.
This spring is equivalent to compressivecoil spring,product
No. A32-03, manufacturedby SANESU Co.,Ltd.
$88~TNM#J~ hl#
AJ-801-024
tr3
I%tbh
This spacer is equivalent to one in jig drawing No. AJ-801-024 #3 of Komatsu MEC
WAl200(31 4
v
APPLICATION Q’TY
(wAi200131
_ 1 HEAT TREATMENT CASE DEPTH MATERIAL
, HEAT TREATMENT CASE OEPTH ~~UTIM 0.n I
wirm~ wmz L FaiLor SEE DWG
~~~30-36 MATERIAL
1 Hardening and tempering s45c MASS (kg) PART NAME PUNT [R
MASS (kg1 PART NAME PAM IBI SRdCE TIBT.wDE
SIFUI TR5AT.W SPRING
39.9 GUIDE SCALE ’ PART NO.
SCALE
NONE NONE
30-040 WA1200-3
0
53lB-ala
!f?3?#IE!sr$B
DISASSEMBLY AND ASSEMBLY SKETCHES OF SPECIAL TOOLS
:w *Ht-k ~~~~~fi~~~~t~~~~~~~l~-~~~~~~~~~~.
NOTE: Komatsu cannot accept any responsibility for special tools manufactured according to these sketches.
t
WAVOOi31 1
M’lICllTIM Q’ TY
,HEAT TREATMENT CASE DEPTH MATERIAL
A-A
,mim~ . . ss400
MASStkg) PART NAME PAINT
OR
SW&E TREAT .COOE
$8 bi3SfAitWl~ Iii AJ-801-024
#4131~&3, 7.8 RING .
This spacer is equivalent to one in jig drawing No. AJ-801-024 #4 of Komatsu MEC _ SCALE PART NO.
NONE j ‘7y9,3,89,0,25,90 ,A
WA1 200-3
30-04 1
0
53?#*$Im %3%7IE@O
DISASSEMBLY AND ASSEMBLY SKETCHES OF SPECIAL TOOLS
22) *~c~k~~~~h~~~LW~~~1~~~~~~-~~~ff~~~~~~.
NOTE: Komatsu cannot accept any responsibility for special tools manufactured according to these sketches.
Q/5
.&Ii)*l.ac-k ~~~~~~~~I~l~~/l~~~~~-~~~~~~~~~~.
NOTE: Komatsu cannot accept any responsibility for special tools manufactured according to these sketches.
WA1200
131 1
AfJFtICATI~ Q’TY
I HEAT TREATMENT CASE DEPTH’ MATERIAL
lxlli,i
MASS (kg) PART NAME PUNTIIF!
SWACE TWJ.CWE
PUSH TOOL
SCALE
NONE
m *~t~~~~~~~~~~~Wt~~l~~~~~~-~~~~~~~~~~.
NOTE: Komatsu cannot accept any responsibility for special tools manufactured according to these sketches.
RO.5QT /
RO.5 max.
MATERIAL
s45c
PAINT OA
SIRFdCE TREAT.UXE
I I
This spacer is ivalent to one in jig drawing No. AJ-801-002#501 of Komatsu MEC . L
SCALE
-.-.. . .._ -_
NONE
30-044 WA1200-3
0
33lB*sm $-333=W~~
DISASSEMBLY AND ASSEMBLY SKETCHES OF SPECIAL TOOLS
1 V2(3n) 1 NOTE: Komatsu cannot accept any responsibility for special tools manufactured according to these sketches.
hT?l\tsPhdld
CO.5 tmi%Pld
R0.6-1.2 k~~oIo:t,
Chamfer outside corners to CO.5 and round inside corners to R0.6 - R0.8 unless
This spacer is equivalent to one in jig drawing No. AJ-801-002 #401 of Komatsu MEC . SCALE
NONE
30-046 WA1200-3
0
33-$T*sm !#+!s?kiI~~rn
DISASSEMBLY AND ASSEMBLY SKETCHES OF SPECIAL TOOLS
m *~t~kb~~~~~~~~Wt~~l~~~~~~-~~~~~~~~~~.
I v2(5/7) I NOTE: Komatsu cannot accept any responsibility for special tools manufactured according to these sketches.
t-lb
tually positioned on part
This spacer is equivalent to one in jig drawing No. AJ-801-002 #7 of Komatsu MEG .
.
I
lHEAT TREATMENT
v CASE DEPTH
$$iu;r~318$Z%iB6
It AJ-801-002#402 RiirQh
This spacer is equivalent to one in jig drawing No. AJ-801-002 #402 of Komatsu MEC .
SCALE
NONE
WA1200-3 30-047
0
m *Bll-dr $~~~~~~~~~t~~l~~~nl~-~~~~~~~~~~.
NOTE: Komatsu cannot accept any responsibility for special tools manufactured according to these sketches.
- I
v
I
A-A
1 I
-83 ~~t-~c3~~:~;pl_fi~~~~t-~,1~~~~~zS-~Je)~it~~~~~~.
NOTE: Komatsu cannot accept any responsibility for special tools manufactured according to these sketches.
4 - ZZ+'J
--
A-A
\ I WA
12Oi[31 1
V APWUfIa( Q’ TY
AJ-801-002#4 lll%M
SiItrr38fiMMi110 .
‘IHEAT TREATMENT CASE DEPTH MATERIAL
This spacer is equivalent to one in jig drawing No. AJ-801-002 #4 of Komatsu MEC . ~RiHM! . . ss400
MASS (kg) PART NAME PAINTOR
~dM#t CO. 5 MN R0.6d.2 M114):ts 13 RING
SWACE TEAT. CmlE
.
Chamfer outside corners to CO.5 and round inside corners to R0.6 - R1.2 unless
otherwise specified. SCALE PART NO.
NONE I7,9,3,@9,0, 7,6Q tA
WA1200-3
30-049
0
53s*$!E !f33?kIErs$H
DISASSEMBLY AND ASSEMBLY SKETCHES OF SPECIAL TOOLS
-&I *~t~~~~~~~~~~~~r~~t~~~~l~-~~~ff~~~~~~.
NOTE: Komatsu cannot accept any responsibility for special tools manufactured according to these sketches.
This tool assembly is equivalent to one in jig drawing No.AJ-00193P Mooka Plant.
2%) *~t~~~~~~~fi~~LWI~~L~~~~~~-~~~ff~~~~~~.
NOTE: Komatsu cannot accept any responsibility for special tools manufactured according to these sketches.
This cylinder is equivalent to one in jig drawing No.AJ-00193P-02 Mooka Plant. SCALE
NONE t szi";"" 8 !4 0 -?I 1 1 0 n
WA1 200-3 30-049-2
0
53#f*%B ~1~~~
DISASSEMBLY AND ASSEMBLY SKETCHES OF SPECIAL TOOLS
*&) *~t~kd~~~h~~~LWt~~t~~~~~~-~~~~~~~~~~.
NOTE: Komatsu cannot accept any responsibility for special tools manufactured according to these sketches.
3-52f’J
I 240 I
This Piston is equivalent to one in jig drawing No.AJ-00193P-01 Mooka Plant. SCALE
NONE f S;";"" 8 9 0 - 3 1 2 0 A
WA1 200-3
30-049-3
0
53-?%*4!m +33?kIE%El
DISASSEMBLY AND ASSEMBLY SKETCHES OF SPECIAL TOOLS
-83 *~t~~~~~~~~~~r~t~~t~~~~l~-~~~~~~~~~~.
NOTE: Komatsu cannot accept any responsibility for special tools manufactured according to these sketches.
This shaft is esuivalent to one in .iis drawing No.AJ-00193P-04 This Plate is equivalent to one in jig drawing No.AJ-00193P-03
Mooka Plant. Mooka Plant.
cwwo4997
1. Using needle-nose pliers, tweezers, or pulling tool 1. Hold wire (4) at 30 mm on rear side of crimped part
Xl from DT connector, pull out wedge (I). (Photo of contact.
shows male side)
__
i :
2. Separating contact fixing claw (2) in connector from 2. Insert wire (4) on grommet side of connector.
contact with flat-head screwdriver, tweezers, or pull- Ir Insert contact at end of wire (4) straight in
ing tool Xl, pull out wire to reset fixing claw. grommet hole until it clicks.
* Insert the wire until you catch a click (a sound ,
made when the contact passes the fixing claw)
and feel the contact collide with the end wall.
Ir Pull the wire a little in the pull-out direction to
confirm that the contact at the end of the wire
is not removed.
3. Holding shield rubber (grommet) (3), pull out wire 3. After inserting all wires, install wedge (1).
(4).
1. Select tool matched to wire size of pin to be re- Remove cover of wire.
moved from “Special Tools List”, and install it to * For the length of cover to be removed, see the
wire. following table.
2. Insert tool Xl in clearance between wire and con- I 15.0 / 6AWG 1 10.9 - 12.5 I
nector seal driver (1) until it is stopped by contact.
t Use a tool a little larger than the wire.
* Take care not to break the wire and connector
pin. Remove pin (1) of crimping tool X2.
3. Pull out wire (2) together with tool Xl. Raise and turn knob (2) to select a size matched to
wire size. (AWG sizes in above table are indicated
on tool X2.)
2. Insert wire on grommet side of connector. 6. Insert wire (6) in contact (5).
* Insert contact straight in grommet hole until it
clicks. 7. Grip handles to crimp contact.
* Insert the wire until you catch a click (a sound * Grip the handles to the stroke end, and they
made when the contact passes the fixing claw) open automatically.
and feel the contact collide with the end wall.
t Pull the wire a little in the pull-out direction to
confirm that the contact at the end of the wire
is not removed.
WA1 200-3
aE#*mi ri-;;‘iT?i bAss’y
DISASSEMBLY AND ASSEMBLY ENGINE MOUNT Ass’y
/'
WA1 200-3
mR*sm r>-;i’iT’9i bAss’y
DISASSEMBLY AND ASSEMBLY ENGINE MOUNT Ass’y
Ii-);‘iTrfi t+Ass’y(2/3)
ENGINE MOUNT Ass’y (2/3)
16.2-6. 9kom
llGHTEN,Nt TORD”f TlGniEWlltTORPUE
fi - C 'I7 :j
il%Lh7 45-49.5Nm IffIJI 24-28Nm
(4. 6-5. Okom) (2. 5-2. 6kom)
(33.1-37. Okomi
_-.-__-__-_.-__-__---I
--.
l-
CWW04867
Ii-;;‘>?‘3 i bAss’y(3/3)
ENGINE MOUNT Ass’y(3/3)
Unspecified tightening torque shall be as follows.
(1) Bolts: Conform to KES 04. 123. 1
1. #%?Q)&LGGVX#Wlrf-t? i-JL3wctzha. Impact wrench
(1)%x. b KES 04. 123. 1 4 >I\“3 b L>f (2) Hose clamps: Conform to KES D 07281, D 07289
(3) PT thread: Conform to KES 04. 123. 3
(2)*-X:3427” D 07281, D 07289
Change direction of hose clamp 180” each for double
(3)Fr;taC KES 04. 123. 3
clamp portion.
Engine oil
Total volume: 290 .r? PATTERN
Exchange volume: 260 e MUFFLER OUTLET
Oil grade: E015-40CD cwwo4931
Meet API CE or CF grade
-__-k:=::
-----__-__
WA1 200-3
33%*siil~ 3-‘J ig>X?&Ass’y
DISASSEMBLY AND ASSEMBLY COOLING SYSTEM Ass’y
3-11 i?-iX5-&Ass’y(2/3)
COOLING SYSTEM Ass’y (213)
-
-_
-
3
;Nm
Skem)
X--
CWWO4869
3‘ - ‘/ i 9-i Xf&Ass’y(3/3)
COOLING SYSTEM Ass’y (3/3)
,i_~~~+Ig$LI~~
-__-_____-
___
________------j----- __
____-----
,______------ ,fL&$
” &A (I :z)
-_-
(FROM Ctwo4868~
77%. (2)
HTC?P'1-SIN /
RADIATOR
v (FROM ~~~04868) (FROM ~~~048681 '_'
CWWO4870
7 ZL--JI~ i?Ass’y(1/4)
FUEL TANK Ass’y(l/4)
A 1
-__-_____-_____-______------
z:
-3\
----__ ---_ @____ ’ ‘%\
I”4 (
’ lb-4ib
‘m’ !
-_ -
--_
+_x
(TO CWWO4874)
‘--_-_/i ,,,,F’
A- =-+!
CWW04871
7.1--MO~Ass’y(2/4)
FUEL TANK Ass’y (2/4)
Z(G2-Ll)XttKt.
:%?-I.,,
II “ATICED
AREA
/
i
‘-1
“1
cwwo4872
7 ~--~l&i3Ass’y(3/4)
FUEL TANK Ass’y (3/4)
(25-31. 5kem)
H-H II :2. 5)
7 x--h9 i?Ass’y(4/4)
FUEL TANK Ass’y (4/4)
'~77-Pi~17owx4 '1?3>t'i'/l
REARCOYBINITIOH
LAYP
FULL 3681.9L
(FROM CWWO4871)
c-c t1:2. 5)
(FROM ~~~04873)
D-D (1:2)
(FROM ~~~04873)
B-B (1:2. 5)
(FROM CWWO4872)
E-E (1:2. 51
(FROM ~~~04873)
F-F (1:2. 51
PTl/2
P (1:2. 5)
(FROM CWWO4872)
&_________ __-__-__;________
-_____&-------i------n__
________-))
/
CWWO4874
717’1 iAss’y(V2)
AIR CONDITIONER Ass’y(l/2)
TltHTEYinG TOPDUE
fi#Ek9 3.43~4.4lNm
(0. 35-O. 45kam)
B-B
(FROM CWWO4876)
F-F
/PH :2.5)
J-J (TO
D-D
(FROM CWWO4876)
17=1 iAss’y(2/2)
AIR CONDITIONER Ass’y (212)
r B (TO CWWO4875)
~~&_-+L-~~~!l~ c c i
I ___-i-“________________
I T
i--B i A
A mi
CWW04876
--<__
ii/ ,_-----* r-7 ._> ______L_L________L
____-__Ld_-______
“y
‘:
“,
ii__
-_-
“Yy._
_-__-__-________
“1 4
.
_ ---____
- -____
i
_‘_‘____-__-__T_
(1) Keep the ambient temperature above 3°C (since the system does not work if the ambient temperature
1. Attention to connection of piping is below 3°C).
(1) Coat ND-OIL8 (Compressor oil for non-freon) on O-ring. (2) Use Freon gas (R134a) as refrigerant.
Be sure not to use oil of sniso base and liquid lubricants of CRC (mineral oil).
(3) Before filling the air conditioner with refrigerant, be sure to evacuate the air conditioner by repetitive
(2) Remove the plugs of the air conditioner parts (devices and hoses) just before connecting those parts evacuation method. (The degree of vacuum must be above 750 mmHg.1
(to prevent dust and water from entering those parts).
(4) The standard quantity of refrigerant to be supplied is 1.3 - 1.5 kg.
(3) Connect each hose securely by using two spanners.
(Hold the device side with one spanner and tighten only the flare nut of the hose with another (5) Take care not to supply liquid Freon to the refrigerant system by holding the refrigerant can upside
spanner.) down or handling it wrongly.
(4) Do not connect the ports of receiver conversely. (6) Do not operate the compressor before filling the air conditioner with refrigerant.
(5) Tightening torques of the following parts must be as shown, unless other specified. 3. Inspection after assembly
1) Bolt: Conform to KES 04. 123. 1 Impact wrench
2) Taper thread: Conform to KES 04. 123. 3 (I) Check that proper quantity of refrigerant was supplied to the air conditioner.
3) Nut: Conform to KES DO1597 Judge and adjust the quantity of refrigerant by the following method.
4) Pipe connecting parts
Operating pressure of Number of bubbles passing
Remedy
compressor through receiver sight glass I
Bubbles pass sometimes or Discharge refrigerant through
0.1 MPa Il.0 kg/cm*}
do not pass at all. pressure valve to proper level.
0.06 - 0.1 MPa -
Proper Bubbles pass continuously.
CONDI out IO.6 - 1.0 kg/cm*)
0 Ml6 x 1.5
-
12 - 15
{I18 1471 CONDZ out a Insuffi- Connect charging hose to compressor
ret to unit in cient 0.06 MPa to.6 kg/cm*} Bubbles pass continuously. and supply refrigerant to proper level.
Nut type D l/2 G M22 x 1.5 20 - 25 CONDl in b (2) Check the air conditioner starting normally.
24 I196 - 2451 CONDZ in
4. Precautions for discharging gas
D 518 0 M24 x 1.5
30 - 35 Unit out
27 (294 - 343) (1) Before discharging gas, perform the oil return work (work to return compressor oil in the piping to the
compressor).
. Oil return procedure: Set the fan switch to the MAX position and run the engine at low idling
and operate the air conditioner for 5 minutes.
Block joint (2) Be sure to discharge the gas through the high-pressure valve.
~~
5. Precautions for repair work
(1) If a defective part is installed and the refrigerant needs to be discharged to repair that part, perform
the oil return work, then discharge the refrigerant gradually through the valve rubbers installed to the
. After tighten up, if the gas shall leak, clean and apply ND-OIL8 to the flares. And tighten as high-pressure and low-pressure valves of the compressor. (It is very dangerous to disconnect the
mentioned above. piping without reducing the pressure in the cooling system. Never do that.)
6) Tube joint to click as assembly. (2) When repairing the air conditioner, be sure to put on protective goggles. (If refrigerant enters your
eyes, you may lose your eyesight.)
(4) Once refrigerant is discharged and supplied again for a repair work, check the compressor oil.
(Specified quantity of oil: 130’~* cc, ND-OIL81
9kfAss’y(l/2)
DAMPER Ass’ y (l/2)
TlC”TENlNG TOROUE
ti#bJid 245-309Nm
16x2
\/
cwwo487a
3 =/ I- II --/LI\‘/I, j'Ass'y
E-E
TlGHTEnIYG TOlO”
OQik5’ Zll-240Nm
(?.I.+24.5komI
Ok81
30-068
0
53%*%lZ b IL3 7 El -Ass’y
DISASSEMBLY AND ASSEMBLY TORQFLOW Ass’v
b/L? 7 q -Ass’y(l/2)
TORQFLOW Ass’y(1
Y
(TO CWWO
WA1 200-3
mf#*mz b IL3 7 II -Ass’y
DISASSEMBLY AND ASSEMBLY TORQFLOW Ass’y
F /td’ 7 q -Ass’y(2/2)
TORQFLOW Ass’y (2/2)
P (1 :2. 5)
Y
(FROM
cwwo4879) CWWO4880
cwwo4950
3 x\“- 9Ass’y(l/6)
CONVERTER Ass’y (l/6)
i f=fl
_+,q
GG(i:i) E-E (I : I)
T/Clild-t
PDRT PF T/C EXlT
TlGHTENlWC TDROUE
913th944.1553.9Nm
(4. 5--5. 5 kern)
- .
‘1
\\I?4
‘1. t
N-N
'ti (TO CWWO4884) “;/
AC- AC
CWWO4881
=I id- 9Ass’y(3/6)
CONVERTER Ass’y (3/6)
(FROM cwwo48811
LT-2@b
A h
TlG”iENlNG TOROUE
h?lb9 58.6-73. 5Nm
(6-7. Skeml
A-A
(FROM CWWO4881) (FROM cwwo4881)
cwwo4883
1 id- gAss’y(4/6)
CONVERTER Ass’y (4/6)
LT-PM
(2%31.5koml
3uat1'I WC- 1
(42C-13-172603
Ilctxt. SEE NOTE I
J-J
(FROM CWWO4881)
LT-Ptt
LT-2ltle
I
c-c
(FROM CWWO4881)
CWW04884
=I id - 9Ass’y (5/6)
CONVERTER Ass’y (5/6)
z- --_
(TO 214)
-I+!
,CWWO4866. CWWO466;)
CWW04885
ZI id- 9Ass’y(6/6)
CONVERTER Ass’y (6/6) _ When assembling oil seal (07012-50110), coat with LG-
5 on fitting face of the housing (42G13-15250) lightly
and after assembling, wipe off the rest completely.
Assembly procedure 4. Modulated clutch ECMV assembly 9. Breather and breather hose
1. Torque converter assembly and PTO and I) Fit the O-ring and install modulated 1) Install elbow (3).
transfer assembly clutch ECMV assembly (25) with the 4 2) Install breather (2) with the 2 bolts.
I) Install coupling (30) to torque converter bolts. 3) Install breather hose (I).
assembly (28). * Secure the hose with the hose clamp.
2) Fit the O-ring to the connecting parts of &I ks Mounting bolt:
torque converter assembly (28) and PTO 27.4 - 34.3 Nm f2.8 - 3.5 kgm}
and transfer assembly (29). 2) Install cover (24) with the 3 bolts.
& O-ring: Grease (G2-LI) 5. Torque converter regulator valve assembly
3) Install torque converter assembly (28) to I) Fit the O-ring and install valve block as-
PTO and transfer assembly (29) with the sembly (23) with the 4 bolts.
19 bolts. w Mounting bolt:
* Since the outer race and inner race 44.1 - 53.9 Nm (4.5 - 5.5 kgm1
of the tapered roller bearing are 2) Fit the O-ring and install torque converter
coupled with each other, drop about regulator valve assembly (22) with the 4
6 cc of engine oil (E030-CD or EOIO- bolts.
CD) onto the sliding surfaces of the w Mounting bolt:
rollers. 44.1 - 53.9 Nm 14.5 - 5.5 kgml
3) Fit the O-ring and install block (21) and
63ks Torque converter assembly: cover (20) with the 4 bolts.
430 kg 4) Fit the O-ring and install sleeve (19).
!I+ks PTO and transfer assembly: & O-ring: Grease (G2-LI)
800 kg 5) Fit the O-ring and install block (18) with
2. Modulated clutch assembly 4 bolts.
Fit the O-ring and install modulated clutch 6. Main relief valve and torque converter relief
assembly (27) with the 10 bolts. valve assembly
6 O-ring: Grease (G2-LB Fit the gasket and install main relief valve
* Since the outer race and inner race of and torque converter relief valve assembly
the roller bearing are coupled with each (17) with the 9 bolts.
other, drop about 6 cc of engine oil m Mounting bolt:
(E030-CD or EOIO-CD) onto the sliding 58.8 - 73.5 Nm j6.0 - 7.5 kgm}
surfaces of the rollers and insert the 7. Lubrication tubes and blocks
modulated clutch assembly horizontally, 1) Fit the O-ring and install block (16) with
taking care not to tilt it. the 3 bolts.
2) Install bracket (15) and block (14) with
r+lkg Modulated clutch assembly: 220 kg the 2 bolts.
3) Fit the gasket and install lubrication tubes
3. Rotation sensor (131, (121, (II), and (IO) with the 2 joints
Install rotation sensor (26) and secure it with each.
the locknut. w Joint:
& Threaded part of sensor: 44.1 - 53.9 Nm 14.5 - 5.5 kgm1
Gasket sealant (LG-51 4) Fit the gasket and install lubrication tube
* Put the rotation sensor tip lightly against (9) with the 3 joints.
the gear tooth tip in the modulated clutch w Joint:
and return by l/2 - 1 turn and secure 44.1 - 53.9 Nm 14.5 - 5.5 kgm1
with the locknut. 8. Lubrication hoses and block
m Locknut: 49.0 - 68.6 Nm (5 - 7 kgm1 Install lubrication hose (8).
* Secure the hose with the hose clamp.
Install block (7) with the 4 bolts.
Fit the O-ring and install lubrication hose
(6) with the 4 bolts and the flange.
Install lubrication hoses (5) and (4).
* Secure the hoses with the hose
clamps.
cwwo4955
CWWO4956
0
DISASSEMBLY AND ASSEMBLY
CONVERTER ASSEMBLY
20
\ /
CWWO4982
WA1 200-3
30-076-7
0
DISASSEMBLY AND ASSEMBLY CONVERTER ASSEMBLY
Disassembly procedure Modulated clutch gear (Gear E) Assembly procedure Install cage (31) with the 17 bolts.
Rotation sensor 1) Remove the 8 mounting bolts, cage (211, 1. Case A Threaded parts of mounting bolt:
Loosen the locknut and remove rotation sen- and shims (22). Install the outer races of tapered roller bear- Liquid adhesive (LT-2)
sor (1). * Check the thickness and quantity of ings (201, (151, and (IO) to case (39). w Mounting bolt:
Cover the shims. f Push each outer race with a press until 245 - 309 Nm (25.0 - 31.5 kgm1
Remove the 12 mounting bolts and cover 2) Remove the outer races of tapered roller its end touches the shoulder of the case. Using a push-pull scale, check that the
(2). bearings (23) and (24) from cage (21). 2. Input gear (Gear A) rotational force at the gear tooth tip is
PTO gear 1 (Gear D) * Use a bearing puller and a press to I) Install the outer race of tapered roller within the standard range.
1) Remove the 6 mounting bolts, cage (31, pull out the outer races. bearing (36) to cage (37). j, Rotational force of gear:
and shims (4). 3) Remove gear (25). * Push the outer race with a press un- 0 - 1.08 N (0 - 0.11 kg}
Ir Check the thickness and quantity of 4) Remove snap ring (26), then remove the til its end touches the shoulder of Ir If the rotational force is out of the
the shims. outer race of roller bearing (27) from gear the cage. standard range, adjust it by chang-
2) Remove the outer race of tapered roller (25). 2) Fit the O-ring and install shims (38) and ing the shim thickness.
bearing (5) from cage (3). * Use a bearing puller to pull out the cage (37) with the 8 bolts. * Adjustment range of shim thickness:
* Use a bearing puller to pull out the outer race. + The shims are of 2-piece split type. 1.3 - 2.7 mm
outer race. 5) Remove the inner races of tapered roller Set them to the standard thickness * Types of shims:
3) Remove coupling (6). bearings (23) and (28) from gear (25). temporarily on each side. 0.15 mm, 0.2 mm, 0.5 mm
4) Remove snap ring (7) from coupling (6). * Use a bearing puller to pull out the * Standard thickness of shims: 2.0 mm IO) Fit the O-ring and install coupling (30).
5) Remove gear (8). inner races. 3) Install the inner races of tapered roller 11) Install holder (29) with the mounting
6) Remove snap ring (9) from gear (8). Input gear (Gear Al bearings (36) and (33) to gear (35). bolts.
7) Remove the inner races of tapered roller I) Remove the mounting bolts and holder * Push each inner race with a press a Threaded parts of mounting bolt:
bearings (5) and (IO) from gear (8). (29). until its end touches the shoulder of Liquid adhesive (LT-2)
* Use a bearing puller to pull out the 2) Remove coupling (30). the gear. m Mounting bolt:
inner races. 3) Remove the 17 mounting bolts and cage 4) Install gear (35). 824 - 1,030 Nm I84 - 105 kgm1
PTO gear 2 (Gear C) (31). 5) Install spacer (34). 3. Modulated clutch gear (Gear El
I) Remove the 8 mounting bolts, cage (1 I), 4) Remove oil seal (32) from cage (31). 6) Install the outer race of tapered roller 1) Install the inner races of tapered roller
and shims (12). 5) Remove the outer race of tapered roller bearing (33) to cage (31). bearings (28) and (23) to gear (25).
+ Check the thickness and quantity of bearing (33) from cage (31). * Push the outer race with a press un- * Push each inner race with a press
the shims. * Use a bearing puller to pull out the til its end touches the shoulder of until its end touches the shoulder of
2) Remove the outer race of tapered roller outer race. the cage. the gear.
bearing (13) from cage (1 I). 6) Remove spacer (34). 7) Using tool Cl, press fit oil seal (32) to 2) Install the outer race of roller bearing
+ Use a bearing puller to pull out the 7) Lift off gear (35). cage (31). (27) to gear (25) and secure it with snap
outer race. 8) Remove the inner races of tapered roller * Thinly apply gasket sealant (LG-5) to ring (261.
3) Remove gear (14) bearings (33) and (36) from gear (35). the oil seal fitting part of the cage. Ir Push the outer race with a press un-
4) Remove the inner races of tapered roller * Use a bearing puller to pull out the After fitting the oil seal, wipe off the til its end touches the shoulder of
bearings (13) and (15) from gear (14). inner races. projected sealant. the gear.
* Use a bearing puller to pull out the 9) Remove the 8 mounting bolts, cage (37), f Press fit the oil seal until the flange 3) Install gear (25).
inner races. and shims (38). of tool Cl touches the cage. * Drop about 6 cc of engine oil tE030-
5. PTO gear 3 (Gear BI * Check the thickness and quantity of & Oil seal lip: Grease (G2-LI) CD or EOIO-CD) onto the sliding parts
I) Remove the 8 mounting bolts, cage (161, the shims. of the bearing and rotate the bearing
and shims (17). IO) Remove the outer race of tapered roller 10 turns to spread the oil.
Ir Check the thickness and quantity of bearing (36) from cage (37). 4) Install the outer races of tapered roller
the shims. * Use a bearing puller to pull out the bearings (24) and (23) to cage (21).
2) Remove the outer race of tapered roller outer race. j, Push each outer race with a press
bearing (18) from cage (16). Case until its end touches the shoulder of
Ir Use a bearing puller to pull out the Remove the outer races of tapered roller the cage.
outer race. bearings (IO), (15), and (20) from case (39). 5) Install shims (22) and cage (21) with the
3) Remove gear (19) * Use a bearing puller to pull out the outer 8 bolts.
4) Remove the inner races of tapered roller races. * Drop about 6 cc of engine oil (E030-
bearings (18) and (20) from gear (19). CD or EOIO-CD) onto the sliding parts
f Use a bearing puller to pull out the CWWO4958 of the bearing and rotate the bearing
inner races. 10 turns to spread the oil.
* The shims are of 2-piece split type. 4) Fit the O-ring and install shims (17) and 6. PTO gear 1 (Gear D)
Set them to the standard thickness cage (16) with the 8 bolts. I) Install the inner races of tapered roller
temporarily on each side. * The shims are of 2-piece split type. bearings (IO) and (5) to gear (8).
* Standard thickness of shims: Set them to the standard thickness * Push each inner race with a press
2.0 mm temporarily on each side. until its end touches the shoulder of
6) Using a push-pull scale, check that the * Standard thickness of shims: 2.0 mm the gear.
rotational force at the gear tooth tip is 5) Using tool C3 (2/2), check that the rota- 2) Install snap ring (9) to gear (8).
within the standard range. tional force at the center of the gear is 3) Install gear (8).
* Rotational force of gear: within the standard range. 4) Install snap ring (7) to coupling (6).
0 - 1.08 N (0 - 0.11 kg} * Rotational force of gear: 5) Install coupling (6).
* If the rotational force is out of the 0 - 2.16 Nm IO - 0.22 kgm} 6) Press fit the outer race of tapered roller
standard range, adjust it by chang- * If the rotational force is out of the bearing (5) to cage (3).
ing the shim thickness. standard range, adjust it by chang- + Push the outer race with a press un-
* Adjustment range of shim thickness: ing the shim thickness. 3) Install the outer race of tapered roller til its end touches the shoulder of
1.3 - 2.7 mm * Adjustment range of shim thickness: bearing (13) to cage (II). the cage.
* Types of shims: 1.3 - 2.7 mm * Push the outer race with a press un- 7) Fit the O-ring and install shims (4) and
0.15 mm, 0.2 mm, 0.5 mm * Types of shims: til its end touches the shoulder of cage (3) with the 6 bolts.
4. PTO gear 3 (Gear BI 0.15 mm, 0.2 mm, 0.5 mm the cage. & O-ring: Grease (G2-LII
I) Install the inner races of tapered roller 4) Fit the O-ring and install shims (12) and Ir The shims are of 2-piece split type.
bearings (20) and (19) to gear (19). cage (I I) with the 8 bolts. Set them to the standard thickness
* Push each inner race with a press * The shims are of 2-piece split type. temporarily on each side.
until its end touches the shoulder of Set them to the standard thickness * Standard thickness of shims: 2.0 mm
c312 /2)
the gear. temporarily on each side. 8) Using tool C3 (l/2), check that the rota-
2) Install gear (19). \ Ir Standard thickness of shims: 2.0 mm tional force at the center of the gear is
* PTO gear 2 and PTO gear 3 are dif- 5) Using tool C3 (2/2), check that the rota- within the standard range.
ferent parts and they must be in- tional force at the center of the gear is * Rotational force of gear:
stalled in the correct directions re- within the standard range. 0 - 5.40 Nm 10 - 0.55 kgm)
spectively. There are 2 identification Rotational force of gear: * If the rotational force is out of the
grooves on the end of gear (19). In- 0 - 3.24 Nm (0 - 0.33 kgm) standard range, adjust it by chang-
stall gear (19) with those identifica- CWWO4960 If the rotational force is out of the ing the shim thickness.
tion grooves on the cage side (torque standard range, adjust it by chang- * Adjustment range of shim thickness:
converter side). (The following fig- 5. PTO gear 2 (Gear Cl ing the shim thickness. 1.3 - 2.7 mm
ure is the gear seen from the torque 1) Install the inner races of tapered roller Adjustment range of shim thickness: * Types of shims:
converter side.) bearings (15) and (13) to gear (14). 1.3 - 2.7 mm 0.15 mm, 0.2 mm, 0.5 mm
f Push each inner race with a press Types of shims:
Ii 14
until its end touches the shoulder of 0.15 mm, 0.2 mm, 0.5 mm
the gear.
2) Install gear (14).
* PTO gear 2 and PTO gear 3 are dif-
ferent parts and they must be in-
stalled in the correct directions re-
spectively. There is 1 identification
groove on the end of gear (14). In-
stall gear (14) with those identifica-
tion grooves on the cage side (torque
converter side). (The following fig- CWWO4961
7. Cover
Fit the gasket and install cover (2) with the
12 bolts.
8. Rotation sensor
Install rotation sensor (I) and secure it with
the locknut.
& Threaded parts of sensor:
Gasket sealant (LG-5)
* Put the rotation sensor tip lightly against
the side of the input gear in the PTO and
transfer assembly and return by l/2 - 3/
4 turns and secure with the locknut.
m Locknut: 49.0 - 68.6 Nm (5 - 7 kgml
F jiX 5 Y 2 3 >Ass’y(l/3)
TRANSMISSION Ass’y (l/33)
GP-Llrt GZ-LIB8
+,-*[ %$gg\
\__-----_____--M )--- -
CWWO4686
-__-&I:=IT=II
----__----__-__
-_-_-_-_-_-4
b 3 i it : Y -i EI i Ass’y (3/3)
TRANSMISSION
8#6ff 2861Ni293.
Bkal R#Rlf 1562N(l59.3kal
l”ITlLLED LOAD lHSTlLLE0 LOlO
WA1 ZOO-3
DISASSEMBLY AND ASSEMBLY TRANSMISSION ASSEMBLY
Assembly procedure assembly (19) with the 3 bolts. * The mounting bolts are classified into
1. Preparation work * The mounting bolts are classified into 3 2 lengths. When installing them,
Support the transfer with blocks, etc. so that lengths. When installing them, check check their respective locations by
it will be vertical. their respective locations by the match the match marks made when they
2. Strainer marks made when they were removed. were removed.
1) Fit the O-ring and install 4 cases (32). w Mounting bolt: w Mounting bolt:
& Periphery of O-ring: 58.8 - 73.5 Nm 16.0 - 7.5 kgml 27.4 - 34.3 Nm 12.8 - 3.5 kgm}
Grease (G2-LI) 7. Gear speed control valve assembly 9. Oil filter
2) Install 4 magnets (31) and 4 springs (30). f The ECMV assembly for gear speed con- 1) Fit the O-ring and install cover (11) and
3) Fit the O-ring and secure 4 covers (29) trol and that for forward-reverse control oil filter assembly (IO) with the 3 bolts.
with 4 bolts each. are different from each other. The cover m Mounting bolt:
4) Fit the O-ring and install drain plug (28) of the ECMV assembly for gear speed 58.8 - 73.5 Nm IS.0 - 7.5 kgml
with the 2 bolts. control is secured with hexagon bolts. 2) Install the 3 stud bolts, then install the 4
& O-ring: Grease (G2-LI) 1) Fit the O-rings and install the 2 sets of spacers (9) and cover (8) with the 1 bolt
3. Transmission assembly and transfer and park- the 3rd clutch ECMV assembly and 2nd and 3 nuts.
ing brake assembly clutch ECMV (18) with the 4 bolts each. 10. Lubrication tube
1) Fit the O-ring to the connecting parts of * The mounting bolts are classified into I) Install block (7) with the 2 bolts.
transmission assembly (26) and transfer 2 lengths. When installing them, 2) Install block (6) with the 2 bolts.
and parking brake assembly (27). check their respective locations by 3) Fit the gasket and install lubrication tubes
6 O-ring: Grease (G2-LI) the match marks made when they (51, (41, (31, (21, and (I) with 2 joints each.
2) Sling transmission assembly (26) and in- were removed. w Joint:
stall it to transfer assembly (27) with the w Mounting bolt: 44.1 - 53.9 Nm I4.5 - 5.5 kgm}
23 bolts. 27.4 - 34.3 Nm 12.8 - 3.5 kgm)
A When installing the transmission, 2) Fit the O-ring and install bypass fill valve
take care extremely so that the trans- assembly (17) and 1st clutch ECMV as-
fer and parking brake assembly will sembly (16) with the 4 bolts.
not fall down. * The mounting bolts are classified into
* After installing the transmission, sup- 2 lengths. When installing them,
port it with blocks, etc. check their respective locations by
4. Breathers the match marks made when they
1) Install flange (25) with the 4 bolts. were removed.
& Mating faces of flange and case: w Mounting bolt:
Gasket sealant (LG-51 27.4 - 34.3 Nm (2.8 - 3.5 kgm}
2) Install 2 elbows (24) and 2 breathers (23). 8. Forward-reverse control valve assembly
& Elbow and breather: The ECMV assembly for forward-reverse
Gasket sealant (LG-5) control and that for gear speed control
5. Valve seat are different from each other. The cover
1) Fit the O-ring and install valve seat (22) of the ECMV assembly for forward-re-
with 14 bolts. verse control is secured with hexagon
w Hexagon socket head bolts (6 socket head bolts.
pieces): Fit the O-rings and install the bypass fill
58.8 - 73.5 Nm IS.0 - 7.5 kgm} valve assembly (15) and forward clutch
2) Fit the O-ring and install valve seat (21). ECMV assembly (14) with the 4 bolts.
3) Fit the O-ring and install valve seat (20) + The mounting bolts are classified into
with the 4 bolts. 2 lengths. When installing them,
* The mounting bolts are classified into check their respective locations by
2 lengths. When installing them, the match marks made when they
check their respective locations by were removed.
the match marks made when they m Mounting bolt:
were removed. 27.4 - 34.3 Nm {2.8 - 3.5 kgm}
w Mounting bolt: Fit the O-ring and install bypass fill and
58.8 - 73.5 Nm IS.0 - 7.5 kgm} drain valve assembly (13) and reverse
6. Lubrication relief valve assembly clutch ECMV assembly (12) with the 4
Fit the O-ring and install lubrication valve bolts.
Il/2 27
40
Lk
\ -55 ”
54
Disassembly procedure 5. Reverse clutch plates and discs 13. Forward clutch and 3rd clutch carrier assem- 2) Remove piston (83) from housing (82).
1. Preparation work 1) Remove 6 springs (27). bly 3) Remove seal ring (84) from housing (82).
Set the transmission assembly on blocks, * The length of the springs depends 1) Remove the 4 mounting bolts and collar 4) Remove seal ring (85) from piston (83).
etc. with the input shaft side up. on the clutch. Put tags, etc. to the (54). lg. 2nd clutch sun gear
2. Case springs to indicate their respective 2) Remove 2 seal rings (55) from collar (54). Remove gear (86).
1) Remove 7 sleeves (1). locations. 3) Lift off forward clutch and 3rd clutch car- 20. 2nd clutch carrier and 1st clutch assembly
* Apply a bearing puller, etc. to the 2) Remove 8 plates (28), 7 discs (29), and rier assembly (56). 1) Remove 2nd clutch carrier and 1st clutch
groove on the inside wall of the 48 springs (30) alternately. 4) Remove snap ring (57), ball bearing (58), assembly (87).
sleeve to pull out the sleeve. 6. Reverse clutch ring gear and gear (59). * Utilizing the bolt holes of the carrier,
2) Remove the 3 mounting bolts and case Remove ring gear (31). * Use a press to pull out above parts. pull out the assembly with a puller.
(2). 7. Reverse clutch housing and piston 5) Remove collar (60) from ball bearing (61). 2) Remove the 30 mounting bolts and cage
3. Housing 1) Remove housing (32). * Use a press to pull out the bearing. (88).
Remove the 24 long bolts, 6 short bolts, and * Remove the housing and piston as 1 6) Remove shaft (62) and ball (63) from car- 3) Remove snap ring (89) and spacer (90)
housing (3). unit. rier (64). from cage (88).
4. Input shaft, reverse clutch carrier and reverse 2) Remove piston (33) from housing (32). * Remove the 4 sets. * Remove the snap ring, compressing
sun gear assembly 3) Remove seal ring (34) from housing (32). 7) Remove 2 gears (65) each, 4 needle roller the spring with a press.
1) Sling the input shaft end and remove 4) Remove seal ring (35) from piston (33). bearings (66) each, and 4 thrust washers 4) Remove 3 springs (91) from cage (88).
the input shaft, reverse clutch carrier and 8. Connecting ring gear (67) each. 5) Remove piston (92) from cage (88).
reverse sun gear assembly (4). 1) Remove the 8 mounting bolts and plate * Remove the 4 sets. 6) Remove seal ring (93) from piston (92).
* Sling the input shaft vertically so that (36). 8) Remove the outer race of roller bearing 7) Remove snap ring (94) and ball bearing
the inner race and outer race of the 2) Remove ring gear (37). (26) from carrier (64). (95) from cage (88).
taper roller bearing under the carrier 3) Remove snap ring (38) from ring gear * Use a bearing puller to pull out the * Use a bearing puller to pull out the
will not be tilted when they are dis- (37). outer race. ball bearing.
connected from each other. 9. Forward clutch plates and discs 14. 3rd clutch ring gear 8) Remove snap ring (96) and collar (97)
2) Remove snap ring (5) and spacer (6). 1) Remove 6 pins (39) and 12 pins (40). 1) Remove the 8 mounting bolts and plate from cage (88).
3) Remove cage (7). Ir The length of the pins depends on (68). 9) Remove ball bearing (98) from cage (88).
Ir Use a puller to remove the cage. the clutch. Put tags, etc. to the pins 2) Remove ring gear (69). * Use a bearing puller to pull out the
4) Remove ball bearings (8) and (9) from to indicate their respective locations. 3) Remove snap ring (70) from ring gear ball bearing.
cage (7). 2) Remove 6 springs (41). (69). 10) Remove seal rings (99) and (100) from
Jr Use bearing puller to pull out the * The length of the springs depends 15. 3rd clutch housing and piston cage (88).
bearings. on the clutch. Put tags, etc. to the 1) Remove housing (71). 11) Remove hub (101).
5) Remove the 8 mounting bolts and cage springs to indicate their respective * Remove the housing and piston as 1 12) Remove 2 seal rings (102) from hub (101).
(IO). locations. unit. 13) Remove 9 discs (103), 8 plates (104), and
* Pull out the cage with forcing screws. 3) Remove 9 plates (42), 8 discs (43), and 2) Remove piston (72) from housing (71). 9 springs (105) alternately.
6) Remove 2 seal rings (11) from cage (IO). 72 springs (44). 3) Remove seal ring (73) from housing (71). 14) Remove snap ring (106) from carrier
_
7) Remove snap ring (12) and gar (13). 10. Forward clutch ring gear 4) Remove seal ring (74) from piston (72). (107).
8) Remove snap ring (14). Remove ring gear (45). 16. 2nd clutch plates and discs 15) Remove shaft (108) and ball (109) from
9) Remove shaft (15). 11. Forward clutch housing and piston 1) Remove 6 springs (75). carrier (107).
+ Use a press to pull out the shaft. 1) Remove housing (46). * The length of the springs depends * Remove the 4 sets.
10) Remove seal ring (16) from shaft (15). * Remove the housing and piston as 1 on the clutch. Put tags, etc. to the 16) Remove gear (IIO), 2 needle bearings
11) Remove snap ring (17) and gear (18). unit. springs to indicate their respective (111) each, and 2 thrust washers (I 12)
12) Remove ball bearing (19) from shaft (15). 2) Remove piston (47) from housing (46). locations. each.
* Use a press to pull out the ball bear- 3) Remove seal ring (48) from housing (46). 2) Remove 6 pins (76) and 12 pins (77). * Remove the 4 sets.
ing. 4) Remove seal ring (49) from piston (47). Ir The length of the pins depends on 21. Output shaft assembly and housing
13) Remove shaft (20) and ball (21) from car- 12. 3rd clutch plates and discs the clutch. Put tags, etc. to the pins 1) Remove 6 mounting bolts and output
rier (22). 1) Remove 6 springs (50). to indicate their respective locations. shaft assembly (113) from housing (114).
* Remove the 4 sets. f The length of the springs depends 3) Remove 4 plates (78), 3 discs (79), and * Pull out the output shaft with forcing
14) Remove gear (23), 2 needle bearings (24) on the clutch. Put tags, etc. to the 24 springs (80). screws.
each, and 2 thrust washers (25) each. springs to indicate their respective 17. 2nd clutch ring gear 2) Remove snap ring (115) and cage (116)
* Remove the 4 sets. locations. Remove ring gear (81). from shaft (I 17).
15) Remove the inner race of roller bearing 2) Remove 5 plates (51), 4 discs (52), and 18. 2nd clutch housing * Use a press to pull out the cage.
(26). 30 springs (53) alternately. I) Remove housing (82). 3) Remove seal ring (I 18) from cage (I 16).
* Use a bearing puller to remove the * Remove the housing and piston as 1 4) Remove snap ring (119) and ball bearing
inner race. unit. (120) from shaft (I 17).
* Use a press to pull out the ball bear- 7) Install seal rings (100) and (99) to cage 15) Install cage (88) to carrier (107) with the 2) Install 12 pins (77) and 6 pins (76).
ing. 038). 30 bolts. * The length of the pins depends on
5) Remove seal ring (121) from shaft (117). & Seal ring: Grease (G2-LI) & Threaded parts of mounting bolt: the clutch. Before installing each pin,
* Install seal ring (100) as shown be- Liquid adhesive (LT-2) check its length.
low. w Mounting bolt: * Pin length:
98 - 123 Nm (IO.0 - 12.5 kgml (77); 208 mm, (76); 223 mm
16) Install 2nd clutch carrier and 1st clutch 3) Install 6 springs (75).
assembly (87) to the output shaft. * The length of the springs depends
Ir Push the assembly with a press until on the clutch. Before installing each
the end of the inner race of the ball spring, check its length.
bearing touches the shoulder of the * Free length of spring: 56.9 mm
shaft. 7. 3rd clutch housing and piston
3. 2nd clutch sun gear 1) Install seal ring (74) to piston (72).
Assembly procedure Install gear (86). & Seal ring: Grease (G2-LI)
1. Output shaft assembly and housing 4. 2nd clutch housing * The seal ring must be installed in
1) Install seal ring (121) to shaft (117). I) Install seal ring (85) to piston (83). the correct direction. When install-
6 Seal ring: Grease (G2-LI) & Seal ring: Grease (G2-LI) ing it, check its direction (Install it as
2) Install ball bearing (120) to shaft (117) * Install the seal ring as shown below. in the 2nd clutch).
and secure it with snap ring (119). 8) Install ball bearing (98) to cage (88). 2) Install seal ring (73) to housing (71).
J, Push the bearing with a press until * Push the ball bearing with a press & Seal ring: Grease (G2-LII
the end of its inner race touches the until the end of its outer race touches f The seal ring must be installed in
shoulder of the shaft. the shoulder of the cage. the correct direction. When install-
3) Install seal ring (118) to cage (116). 9) Install collar (97) to cage (88) and secure ing it, check its direction (Install it as
6 Seal ring: Grease (G2-LI) it with snap ring (96). in the 2nd clutch).
4) Install cage (116) to shaft (117) and se- IO) Install ball bearing (95) to cage (88) and 3) Install piston (72) to housing (71).
cure it with snap ring (115). secure it with snap ring (94). 4) Install housing (71).
* Push the outer race of the bearing * Push the ball bearing with a press 8. 3rd clutch ring gear
with a press until it touches the until the end of its outer race touches 1) Install snap ring (70) to ring gear (69).
shoulder of the cage. the shoulder of the cage. 2) Install ring gear (69).
5) Install output shaft assembly (113) to 11) Install seal ring (93) to piston (92). CWWO4967 3) Install plate (68) with 8 bolts.
housing (114) with the 6 bolts. & Seal ring: Grease (G2-LI) & Threaded parts of mounting bolt:
& Threaded parts of mounting bolt: * Install the seal ring as shown below. 2) Install seal ring (84) to housing (82). Liquid adhesive (LT-2)
Liquid adhesive (LT-2) a Seal ring: Grease (G2-LI) m Mounting bolt:
m Mounting bolt: f Install the seal ring as shown below. 98 - 123 Nm (IO.0 - 12.5 kgml
98 - 123 Nm (10.0 - 12.5 kgml 9. Forward clutch and 3rd clutch carrier assem-
2. 2nd clutch carrier and 1st clutch assembly bly
I) Set 2 thrust washers (112) each and 2 Install the outer race of roller bearing
needle bearings (I 1 I) each to gear (I IO), (26) to carrier (64).
then install them to carrier (107). j, Push the outer race with a press un-
* When installing, take care not to til its end touches the shoulder of
bruise the thrust washers. the carrier.
* Install the 4 sets. Set 2 thrust washers (67) each and 2
2) Set ball (109) to shaft (1081, then install needle bearings (66) to gear (65), then
them to carrier (107). CWW04966 install them to carrier (64).
* Match the ball to the cut of the car- * When installing, take care not to
rier and push the shaft with a press 12) Install piston (92) to cage (88). CWW04968 bruise the thrust washers.
until it is flush with the carrier. 13) Install 3 springs (91) to cage (88). * Install the 4 sets.
* Install the 4 sets. 14) Install spacer (90) and secure it with snap 3) Install piston (83) to housing (82). Install ball (63) to shaft (62), then install
3) Install snap ring (106) to carrier (107). ring (89). 4) Install housing (82). them to carrier (64).
4) Install 9 discs (103), 8 plates (1041, and 9 * Install the snap ring, compressing the 5. 2nd clutch ring gear * Match the ball to the cut of the car-
springs (105) to carrier (107) alternately. spring with a press. Install ring gear (81). rier and push the shaft with a press
5) Install 2 seal rings (102) to hub (101). * Installed load of spring: 6. 2nd clutch plates and discs until it is flush with the carrier.
6 Seal ring: Grease (G2-LI) 1,697 N {I73 kg1 1) Install 4 plates (781, 3 discs (791, and 24 * Install the 4 sets.
6) Install hub (101) to carrier (107). springs (80) alternately. Install gear (59) to carrier (64).
5) Press fit collar (60) to ball bearing (58). 3) Install 12 pins (40) and 6 pins (39). 3) Set ball (21) to shaft (201, then install 19. Housing
* Push the collar with a press until its j, The length of the pins depends on them to carrier (22). Install housing (3) with 24 long bolts and 6
shoulder touches the end of the in- the clutch. Before installing each pin, * Match the ball to the cut of the car- short bolts.
ner race. check its length. rier and push the shaft with a press 6 Threaded parts of short mounting
6) Install bearing (58) to carrier (64) and * Pin length: until it is flush with the carrier. bolt: Liquid adhesive (LT-2)
secure it with snap ring (57). (40); 315 mm, (39); 315 mm * Install the 4 sets. w Long bolt:
Ir Push the bearing with a press until 14. Connecting ring gear 4) Install ball bearing (19) to shaft (15). 353 - 392 Nm I36 - 40 kgm1
the end of its outer race touches the 1) Install snap ring (38) to ring gear (37). * Push the ball bearing with a press Short bolt:
shoulder of the carrier. 2) Install ring gear (37). until the end of its inner race touches 98 - 123 Nm {IO.0 - 12.5 kgml
7) Install forward clutch and 3rd clutch car- 3) Install plate (36) with 8 bolts. the shoulder of the shaft. 20. Case
rier assembly (56). & Threaded parts of mounting bolt: 5) Install gear (18) and secure it with snap 1) Install case (2) with the 3 bolts.
8) Install 2 seal rings (55) to collar (54). Liquid adhesive (LT-2) ring (17). m Mounting bolt:
& Seal ring: Grease (G2-LII w Mounting bolt: 6) Install shaft (15) to carrier (22). 490 - 608 Nm (50 - 62 kgml
9) Install collars (54) with 4 bolts. 98 - 123 Nm {IO.0 - 12.5 kgm} + Push the outer race of the ball bear- 2) Fit the O-ring and install 7 sleeves (I).
& Threaded parts of mounting bolt: 15. Reverse clutch housing and piston ing with a press until its end touches
Liquid adhesive (LT-2) 1) Install seal ring (35) to piston (33). the shoulder of the carrier.
w Mounting bolt: 6 Seal ring: Grease (G2-LI) 7) Install snap ring (14).
98 - 123 Nm I10.0 - 12.5 kgm} * The seal ring must be installed in 8) Install gear (13) and secure it with snap
10. 3rd clutch plates and discs the correct direction. When install- ring (12).
I) Install 5 plates (511,. 4 discs (521, and 30 ing it, check its direction (Install it as 9) Install 2 seal rings (I I) to cage (IO).
springs (53) alternately. in the 2nd clutch). & Seal ring: Grease (G2-LI)
2) Install 6 springs (50). 2) Install seal ring (34) to housing (32). IO) Install cage (IO) to carrier (20) with the 8
* The length of the springs depends 6 Seal ring: Grease (G2-LI) bolts.
on the clutch. Before installing each * The seal ring must be installed in & Threaded parts of mounting bolt:
spring, check its length. the correct direction. When install- Liquid adhesive (LT-2)
* Free length of spring: 68.8 mm ing it, check its direction (Install it as w Mounting bolt:
11. Forward clutch housing and piston in the 2nd clutch). 98 - 123 Nm {IO.0 - 12.5 kgm}
1) Install seal ring (49) to piston (47). 3) Install piston (33) to housing (32). 11) Install ball bearing (9) to cage (7).
& Seal ring: Grease (G2-LI) 4) Install housing (32). * Push the ball bearing with a press
* The seal ring must be installed in 16. Reverse clutch ring gear until the end of its inner race touches
the correct direction. When install- Install ring gear (31). the shoulder of the cage.
ing it, check its direction (Install it as 17. Reverse clutch plates and discs 12) Install cage (7) to cage (IO).
in the 2nd clutch). I) Install 8 plates (281, 7 discs (291, and 48 * Push the cage with a press until the
2) Install seal ring (48) to housing (46). springs (30) alternately. end of the inner race touches the
& Seal ring: Grease (G2-LI) 2) Install 6 springs (27). shoulder of the cage.
* The seal ring must be installed in * The length of the springs depends 13) Install ball bearing (8) to cage (7).
the correct direction. When install- on the clutch. Before installing each * Push the inner race and outer race
ing it, check its direction (Install it as spring, check its length. of the ball bearing simultaneously
in the 2nd clutch). * Free length of spring: 133 mm with a press until the end of the outer
3) Install piston (47) to housing (46). 18. Input shaft, reverse clutch carrier and reverse race touches the shoulder of the
4) Install housing (46). sun gear assembly cage.
12. Forward clutch ring gear I) Install the inner race of roller bearing 14) Install spacer (6) and secure it with snap
Install ring gear (45). (26) to carrier (22). ring (5).
13. Forward clutch plates and discs * Push the inner race with a press un- 15) Install seal ring (16) to shaft (15).
I) Install 9 plates (421, 8 discs (431, and 72 til its end touches the shoulder of & Seal ring: Grease (G2-LII
springs (44) alternately. the carrier. 16) Sling the input shaft end and install the
2) Install 6 springs (41). 2) Set 2 thrust washers (25) and 2 needle input shaft, reverse clutch carrier and
* The length of the springs depends bearings (24) to gear (231, then install reverse sun gear assembly (4).
on the clutch. Before installing each them to carrier (22). * Sling the input shaft vertically so that
spring, check its length. * When installing, take care not to the inner race and outer race of the
* Free length of spring: 168 mm bruise the thrust washers. taper roller bearing under the carrier
Ir Install the 4 sets. will not be tilted when they are
coupled with each other.
29
28
27 \
32
WA1 200-3
30-079-8
0
DISASSEMBLY AND ASSEMBLY TRANSMISSION ASSEMBLY
Disassembly procedure Pull out the assembly evenly with Remove the outer race of roller bearing Assembly procedure
Ir When removing only the parking brake as- forcing screws. After it is pulled out (30) from cage (29). * When installing only the parking brake as-
sembly from the TORQFLOW assembly or to the shaft end, lift it off. * Use a bearing puller to pull out the sembly to the TORQFLOW assembly or ve-
vehicle body, see REMOVAL, INSTALLATION For the disassembly procedure of the out races. hicle body, see REMOVAL, INSTALLATION
OF PARKING BRAKE ASSEMBLY. parking brake assembly, see DISAS- Remove gear (31). OF PARKING BRAKE ASSEMBLY.
1. Front coupling SEMBLY, ASSEMBLY OF PARKING * Pull out the gear straight so that the 1. Case
I) Remove the mounting bolts and holder BRAKE ASSEMBLY. inner race and outer race of the roller Install the outer races of roller bearings (24)
(I). 5. Output shaft and gear assembly bearing will not be tilted when they and (32) to case (33).
2) Remove coupling (2). I) Remove the 8 mounting bolts and cover are disconnected from each other. * Push each outer race with a press until
2. Cage (14). Remove the inner races of roller bear- its end touches the shoulder of the case.
1) Remove the 6 mounting bolts, cage (31, 2) Remove output shaft and gear assembly ings (30) and (32) from gear (31). 2. Input gear
and shims (4). (15). * Use a bearing puller to pull out the 1) It-&all the inner races of roller bearing
* Check the thickness and quantity of 3) Remove spacer (16) and gear (17) from inner races. (32) and (30) to gear (31).
the shims. shaft (IS). 8. Case * Push each inner race with a press
2) Remove dust seal (5) from cage (4). * Use a press to pull out the spacer 1) Remove the outer races of roller bear- until its end touches the shoulder of
3) Remove oil seal (6) from cage (4). and gear simultaneously. ings (24) and (32) from case (33). the case.
3. Rear coupling 6. Idler gear * Use a bearing puller to pull out the 2) Install gear (31).
I) Remove the bolts and holder (7). I) Remove the 2 mounting bolts and plate outer races. * Insert the gear straight so that the
2) Remove coupling (8). (19). 2) Remove tapered roller bearing (34) from inner race and outer race of the roller
4. Parking brake assembly 2) Remove the 18 mounting bolts and cage case (33). bearing will not be tilted when they
I) Remove 2 mounting bolts and flange (9). (20). Ir Use a bearing puller to pull out the are coupled with each other.
2) Remove sleeve (IO). * Pull out the cage with forcing screws bearing. 3) Install the outer race of roller bearing
* Screw a hanging bolt (12 mm) in the (12 mm). (30) to cage (29).
sleeve to pull out the sleeve. * Pull out the cage straight so that the * Push the outer race with a press un-
3) Remove 2 plugs (11) and 2 sets of bolt inner race and outer race of the roller til its end touches the shoulder of
and washer (12). bearing will not be tilted when they the cage.
* Any bolts and washers may be re- are disconnected from each other. 4) Install cage (29) with the 18 bolts.
moved, since they will be used to 3) Remove the outer race of roller bearing * Insert the cage straight so that the
secure the parking brake. Do not re- (21) from cage (20). inner race and outer race of the roller
move any of the 4 hexagon socket * Use a bearing puller to pull out the bearing will not be tilted when they
head bolts. outer race. are coupled with each other.
4) Install the removed 2 sets of bolt and 4) Remove gear (22). 5) Install joint (28) and secure it with snap
washer (12) in the plug holes. * Pull out the gear straight so that the ring (27).
* Screw in the 2 sets of bolt and washer inner race and outer race of the roller 6) Fit the O-ring and install cage (26) with
alternately and slowly to pull the pis- bearing will not be tilted when they the 6 bolts.
ton in the packing brake toward the are disconnected from each other. & O-ring: Grease (G2-LI)
housing. 5) Remove the 4 mounting bolts and joint 7) Fit the O-ring and install plate (25) with
(23) from gear (22). the 2 bolts.
6) Remove the inner races of roller bear- 3. Idler gear
ings (21) and (24) from gear (22). Press fit the inner races of roller bear-
* Use a bearing puller to pull out the ings (24) and (21) to gear (22).
inner races. -Lr Push each inner race with a press
7. Input gear until its end touches the shoulder of
Remove the 2 mounting bolts and plate the gear.
(25). Install joint (23) to gear (22) with the 4
Remove the 6 mounting bolts and cage bolts.
(26). Install gear (22).
* Pull out the cage straight so that the * Insert the gear straight so that the
inner race and outer race of the roller inner race and outer race of the roller
bearing will not be tilted when they bearing will not be tilted when they
5) Remove the remaining 10 mounting bolts are disconnected from each other. are coupled with each other.
and parking brake assembly (13). Remove snap ring (27) and joint (28).
* Do not remove the 4 hexagon socket Remove the 18 mounting bolts and cage
head bolts. (29).
4) Install the outer race of roller bearing 5. Parking brake assembly 6. Rear coupling iii) Calculate shim thickness c.
(21) to cage (20). 1) Fit the O-ring and set the parking brake I) Install coupling (8). l c = (a -b) - (0.05 to 0.10)
* Push the outer race with a press un- assembly (13) in position, then tighten 2) Install holder (7) with the bolts. * The bearing is pushed in by 0.05
til its end touches the shoulder of the 10 bolts temporarily. & Threaded parts of mounting bolt: to 0.10 mm with the cage.
the cage. 2) Remove the 2 sets of bolt and washer Liquid adhesive (LT-2) * Standard shim thickness (Refer-
5) Fit the O-ring and install cage (20) with (12) from parking brake assembly (131, w Mounting bolt: ence): 0.8 to 2.0 mm
the 18 bolts. then install parking brake assembly (13) 2,059 - 2,354 Nm (210 - 240 kgml * Types of shims: 0.15, 0.20 mm
6 O-ring: Grease (G2-LI) with the 12 bolts in total. 7. Cage
* Insert the cage straight so that the * Loosen the bolts and washers alter- 1) Using tool D2, press fit oil seal (6) to
inner race and outer race of the roller nately and slowly so that the piston cage (3).
bearing will not be tilted when they in the parking brake will not be tilted. Sr Thinly apply gasket sealant (LG-5) to
are coupled with each other. & Threaded parts of mounting bolt: the oil seal fitting part of the cage.
w Mounting bolt: Liquid adhesive (LT-2) After fitting the oil seal, wipe off the
245.0 - 308.7 Nm I25.0 - 31.5 kgm} m Mounting bolt: projected sealant.
6) Fit the O-ring and install plate (19) with 205.9 - 269.7 Nm I21.0 - 27.5 kgml f Push the oil seal until the flange of
the 2 bolts. the tool touches the cage.
4. Output shaft and gear assembly & Oil seal lip: Grease (G2-Lll
I) Install tool D6 to case (31).
cwwo4974
8. Front coupling
I) Install coupling (2).
2) Install holder (1) with the bolts.
& Threaded parts of mounting bolt:
Liquid adhesive (LT-2)
w Mounting bolt:
2,059 - 2,354 Nm 1210 - 240 kgm1
MR : S43C-D
MateriaI:S43C-D CWWO4984
I I CWWO4986 1
CWW04983
5) Using output shaft (8) as a guide, slide Installation procedure m Mounting bolt:
off parking brake assembly (7) to the rear 1. Install parking brake assembly (7) according 205.9 - 269.7 Nm (21.0 - 27.5 kgm}
of the vehicle body. to the following procedure and tighten the
IO mounting bolts temporarily.
1) Install shackles @ as shown in the fig-
ure.
2) Sling parking brake assembly (7) from
both sides of the transmission and slide
it toward the transfer until it is placed on
output shaft (8) perfectly.
CWW04986
CWW04987
3. Install 2 plugs (5) to parking brake assembly
(13).
4. Fit the O-ring and install sleeve (4).
& Sleeve: Grease (G2-LI)
5. Fit the O-ring and install flange (3) with 2
bolts.
CWW04988 6. Install coupling (2).
7. Install holder (1) with the bolts.
3) Remove shackles @ and install 3 guide f When using a booster wrench to tighten
bolts @ as shown in the figure. the mounting bolts, hold it securely with
4) Push parking brake assembly (7) toward a rope or a band from above so that it,
the transfer to set it to the position for bolts, and wrench adapter will not come
installation. Off.
5) Tighten the 10 bolts temporarily and re- & Threaded parts of mounting bolt:
move guide bolts 0. Liquid adhesive (LT-2)
w Mounting bolt:
2,059 - 2,354 Nm I210 - 240 kgm)
CWW04989
Assembly procedure
1
Disassembly procedure
1. Plate 1. Housing
IO Remove snap ring (1) and plate (2). 1) Using tool D2, install oil seal (20) to hous-
6 I 2. Plates and discs
Remove 9 plates (3),8 discs (41, and 8 springs
ing (19).
+ Thinly apply gasket sealant (LG-5) to
(5). the oil seal fitting part of the hous-
3. Drum 1 ing. After fitting the oil seal, wipe off
Remove drum (6). the projected sealant.
4. Spacer * Press fit the oil seal until the flange
Remove spacer (7). of the tool touches the housing.
5. Drum 2 & Oil seal lip: Grease (G2-LI)
I) Remove 2 sets of bolt and washer (8).
* These are the bolts moved when the
parking brake assembly was re-
moved.
+ Loosen the 2 sets alternately and
slowly, checking that the piston is
coming out toward the drum.
2) Remove the 4 bolts and drum (9).
3) Remove snap ring (IO) from drum (9).
6. Piston
I) Remove piston (II).
2) Remove seal rings (12) and (13) from
piston (11).
7. Springs 2) Using tool D3, install dust seal (18) to
Remove 14 springs (14) and 14 springs (15). housing (19).
8. Bearing * Press fit the dust seal until the flange
Remove snap ring (16) and bearing (17). of the tool touches the housing.
* Use a bearing puller to pull out the bear- & Dust seal lip: Grease (G2-LI)
ing. 1
9. Housing
1) Remove dust seal (18) from housing (19).
2) Remove oil seal (20) from housing (19).
Ii CWW04978 1
2. Bearing
Install bearing (17) and secure it with snap
ring (16).
* Push the bearing with a press until its
end touches the shoulder of the hous-
ing.
CWWO4976
3. Springs 6. Spacer
Install 14 springs (15) and 14 springs (14). Install spacer (7).
4. Piston Jr Insert the spacer vertically, since it is
I) Install seal rings (13) and (12) to piston used as the inner race of the roller bear-
(II). ing, too.
* Install the seal rings as shown in the 7. Drum 2
following figure. Install drum (6).
I I 8. Plates and discs
I 1 I Remove 9 plates (3), 8 discs (41, and 8 springs
(5) alternately.
d Plate
Install plate (2) and secure it with snap ring
(I).
I - cwwo4979
I
2) Place piston (I 1) on the spring.
* Match the dowel pin of the housing
to the pin hole of the piston.
5. Drum 2
I) Install snap ring (IO) to drum (9).
2) Place drum (9) over piston (11) and se-
cure it with the 4 bolts.
* Tighten the bolts slowly so that the
piston will not be tilted in the hous-
ing.
3) Tighten the 2 sets of bolt and washer (8)
in the plug holes.
* Use the bolts and washers for the
parking brake assembly temporarily.
Do not remove them until the park-
ing brake assembly is installed to the
transfer.
* Tighten the 2 sets alternately and
slowly, checking that the piston is
moving toward the housing.
VALVE Ass’y
_-_-_-_-_
_________---
_-_-_-_
_________-__
-
1i
L-J AA f?l ll7-h
I I
d‘-_________!_______-_____-__-
D-D
-__r__-__7____ .-~_-._-__r__-__-_-
B-B(1 :2)
___--- _-----_-____ --__
_------_______
>.:---
F-F
-_--__-__-___
-__-__-__-__-__-__
_-__
._-__3
Y<
I’ ,/
,‘,, 3
5,’
0
_&_ 0
CWW04889
IdLO, ~~jsc~8~~~i~~iAss’y(2/5)
T/C, T/M LINE Ass’y(2/5)
/--1
--_,
\
‘\
\ n
(TO CW'w;892)
r\
_Ip-__ L--r_ ___-;_-__-__h_ . ,' \ '\\
A__-_ -________ __-__-__-__
I “\ '\\
I:0 CWWO48921
\( \
r
CWWO4890
___-______ 1
it-
c-c (1 :2)
(FROM CWWO48921 E-E
Y
(FROM CWWO4889)
CWW0489 1
WA1 200-3
30-083
0
33B+*?im t+Jb=I>, b?iX<-~_iz;5_I;Ass’y
DISASSEMBLY AND ASSEMBLY T/C, T/M LINE Ass’y
(FROM CtWO4890)
PC1 2)
CWW04892
6. Use oil
E03@CD . .. Atmospheric temperature 0°C Min.
EOIO-CD . ..Atmospheric temperature +lO”C
Max.
I
L__~~______I_~__-__-__-_; 4 i ’L_~I_-___-LI__I_-__-__-_~ 4
TlGWTEHlWG TDLPUE
343-427Nm
I ilG”TEYlYG TORPUE
8fiClb9 iiIth7 343-427Nm
(35-43. 5kaml
CWW04893
6. Housing
2. Coupling Remove outer race (12) from housing
1) Turn over the center support assembly.
2) Remove bolt (3), then remove holder (4),
coupling (5), and shim (6). 3) Remove bearing (10) and retainer (1) from
fl Check the number and thickness of the shaft.
shims.
3. Retainer
Remove retainer (7).
WA1200-3 30-086-1
(9)
DISASSEMBLY AND ASSEMBLY CENTER SUPPORT
ASSEMBLY 3. Shaft 4. Retainer 7) Using dial gauge [1], check that the end
1. Housing 1) Install retainer (1) to the shaft. 1) Install retainer (7). play is within the standard range.
1) Install outer race (12) to the housing. 2) Using the push tool, install bearing (10) to fl Fill internal space (c) with grease (G2-LI). • End play: 0.05 – 0.15 mm
2) Install the O-rings to both ends of the housing. the shaft. 3 Mounting bolt: 98 – 123 Nm
{10 – 12.5 kgm}
30-086-2 WA1200-3
(9)
53lB*Bl3 7Ui bP//XlLAss’y
DISASSEMBLY AND ASSEMBLY FRONT AXLE ASS’Y
7 q i I\ ;i7// XIbAss’y(l/Z)
FRONT AXLE Ass’y (l/2)
CWW04894
7ni b73JWAss’y(2/2)
FRONT AXLE As&y (2/2)
NW04895
1 Disassembly procedure
1. Draining oil
Assembly procedure
1. Breather
1) Remove 3 level plugs (I ). Install breather (13).
2) Remove 3 drain plugs (2) and drain the 2. Tubes
oil from the axle. 1) Install 6 connectors (12).
2) Install tubes (II), (IO), and (9).
- : Quantity of drained oil: 670 e w Tube nut:
15.7 - 23.5 Nm (1.6 - 2.4 kgm}
&I kg Axle assembly: 3. Shaft
16,100 kg (Without oil) Fit the O-ring and install shaft (8) with the 2
Sensor assembly bolts.
1) Remove the mounting bolts and clip (5). 4. Sensor assembly
2) Remove the 2 mounting bolts, sensor I) Assemble the sensor assembly accord-
assembly (61, and shims (7). ing to the following procedure.
* Check the thickness and quantity of i) Insert the sensor until its tip touches
the shims. the flange of the axle.
Shaft ii) Measure the clearance between the
Remove the 2 mounting bolts and shaft (8), sensor fitting faces of the flange and
Tubes housing.
Remove tubes (91, (IO), and (11) and 6 con- iii) Adjust the shims so that the clear-
nectors (12). ance between the sensor tip and the
Remove breather (13). housing in the axle will be as fol-
lows.
* Clearance at sensor tip:
0.6 -C 0.1 mm
* Types of shims: 0.2, 0.3, 1.0 mm
* Combine the shims so that the
number of them will be mini-
mized.
2) Fit selected shims (7) and the O-ring and
install sensor assembly (6) with the 2
bolts.
w Bolt: 98 - 123 Nm {IO - 12.5 kgml
3) Install clip (5) with the bolts.
5. Supplying oil,
I) Fit the O-ring and install 3 drain plugs
(2).
w Drain plug:
127 - 176 Nm I13 - 18 kgm)
2) Fit the O-ring and supply oil into the axle
and install 3 level plugs (1).
w Level plug:
127 - 176 Nm (13 - 18 kgml
CWW02772
‘H’-P%WAss’y(l/2)
REAR AXLE Ass’y (l/2)
I. M94fV4l. ‘IL\V4l
STD. OPT.
94f ttll 165/65-57155.5/80-57
cwwo4902
‘/ +‘--B3XJLAss’y(2/2) _
WA1 200-3
fffR*wi REAR AXLE ASSEMBLY
w Level plug:
127 - 176 Nm I13 - 18 kgm}
cwwo2773
?7 + -v ‘I PAss’y(F) (l/5)
DIFFERENTIAL CARRIER Ass’y (F) (l/5)
CWWO4896
CLEARANCE
i LT-2Lf
APPLY LT-2 ON THREAD
Z-2413 4-24X3
/
I
c1w04904
WA1 200-3
30-093
0
53-?s*$Im 77 + P 'I JAss’y
DISASSEMBLY AND ASSEMBLY DIFFERENTIAL CARRIER Ass’y
?7 + -v ‘I PAss’y(R) (4/5)
DIFFERENTIAL CARRIER Ass’y (R) (4/5)
to.2 to.3 t1.0
CLEARANCE
4 5
4
3
‘\
‘\
-1
“\ -” /
‘\.(J
‘\
13
‘\ .\ Ii j
-_-.-_
cwwo2774
Removal procedure Disassembly procedure 8) Disassemble the pinion gear assembly Assembly procedure
1. Differential carrier assemblv 2. Cover according to the following procedure. 1. Differential assembly
1) Remove the 13 mounting bolts and cover Remove the 2 mounting bolts and cover (8). i) Secure pinion gear assembly (34) I) Install bevel gear (44) to case (41) with
assembly (3). Ir Front differential carrier only with a press and remove locknut (35) the 20 bolts.
2) Remove gear (4). 3. Flange with wrench WI. & Mounting bolt:
3) Remove shaft assembly (5). Remove snap ring (9) and flange (IO). ii) Using a press, remove sleeve (37) Liquid adhesive (LT-2)
4) Remove the mounting bolts and t-piece * Front differential carrier only from pinion gear (36). w Mounting bolt:
(7). 4. Lock plate iii) Remove inner race (38A) from pin- 824 - 1,030 Nm (84 - 105 kgml
5) Remove 23 mounting bolts and differen- Remove the 4 mounting bolts and 2 lock ion gear (36). 2) Install 2 bushings (43) to case (41).
tial carrier assembly (6). plates (I I). iv) Remove spacer (38B) and inner race * Front differential carrier only
5. Cage assembly (38C) from sleeve (37). 3) Install tube (42) to case (41).
kg
&?I Differential carrier assembly: 1) Remove the 2 mounting bolts and * Front differential carrier only
1,570 kg bracket (12). 4) Install the inner race of bearing (27) and
2) Remove the 22 mounting bolts and cage thrust washer (40) to case (41).
assembly (13). & Contact faces of thrust washer
3) Remove shims (14) from cage (15). (40) and side gear (39):
* Check the thickness and quantity of Axle oil (AX075).
the shims. 5) Install side gear (39) to case (41).
4) Remove the mounting bolts, holder (16), 6) Assemble the pinion gear assembly ac-
and shims (17). cording to the following procedure.
* Check the thickness and quantity of i) Using a press, install collar (38E) and
the shims. outer race (38F) to pinion gear (36).
5) Remove coupling (18). * Push the outer race until its end
6) Remove the 4 mounting bolts and cage touches the pinion gear.
(19). v) Using a press, remove outer race ii) Using a press, install outer race (38D)
7) Remove dust seal (20) from cage (19). (38D) from pinion gear (36). to pinion gear (36).
8) Remove oil seal (21) from cage (19). vi) Using a press, remove collar (38E) * Push the outer race until its end
9) Remove pinion (22) from cage (15). and outer race (38F) from pinion gear touches the pinion gear.
IO) Remove the inner race of roller bearing (36).
(23) from cage (15).
11) Remove the inner race of roller bearing
(24) from pinion (22).
* Use a press to pull out the inner race.
12) Remove the outer races of roller bear-
ings (23) and (24) from cage (15).
+ Use a bearing puller to pull out the
outer races.
6. Differential assembly
I) Remove the 4 mounting bolts and 2 caps
(25). I cwwo4991
2) Remove 2 nuts (26).
3) Remove differential assembly (28) and 2 iii) install inner race (38C) and spacer
outer races of bearing (27) from carrier 9) Remove side gear (39). (38B) to sleeve (37).
(29). IO) Remove the inner race of bearing (27) iv) Install sleeve (37) to pinion gear (36).
4) Remove the 8 mounting bolts and case and thrust washer (40) from case (41). VI Install inner race (38A) to pinion gear
(30). 11) Remove tube (42) and 2 bushings (43). (36).
5) Remove the inner race of bearing (27) Ir Front differential carrier only
and thrust washer (31) from case (30). 12) Remove the 20 bolts and bevel gear (44).
6) Remove side gear (321, then remove spi-
der shaft (33) and pinion gear assembly
(34) as one unit.
7) Remove 4 pinion gear assembly (34)
from spider shaft (33).
vi) Secure pinion gear assembly (34) just it into the following range with becomes 15.7 Nm Il.6 kgml. 9) Install cage (19) to cage (15) with the 4
with a press and tighten nut (35) with the adjustment nut. iv) Measure distance b between the bolts.
wrench WI. * Rotational force: holder and pinion end. w Mounting bolt:
m Nut: 20.6 - 23.5 N (2.1 - 2.4 kg} v) Calculate shim thickness c. 157 - 196 Nm (16 - 20 kgml
882 - 1,080 Nm I90 - 110 kgn f The rotational force may be mea- . c = (b - a) - (0 to 0.04) 10) Install coupling (18) to pinion (22), then
35 sured by winding a string onto * Select shims so that their thick- fit the O-ring.
plane half part b. (79.4 - 95.1 N ness will be 0 to -0.04 mm less 6 Yoke end, shaft spline:
/ ,38A
I8.1 - 9.7 kg)) than the clearance. Lubricant (LM-G)
* Types of shims: 11) Install the selected shims and holder (16)
0.05, 0.2, 0.3, 1.0 mm with the bolts.
* Combine the shims so that the & Mounting bolt:
number of them will be mini- Liquid adhesive (LT-2)
mized. w Mounting bolt:
vi) Install the selected shims and tighten 2,450 - 3,040 Nm (250 - 310 kgml
the bolt. 12) Fit the O-ring to cage (15).
vii) Rotate cage (15) to fit the bearing, 13) Adjust the shim thickness for the differ-
then check that the starting torque is ential carrier according to the following
15.7 - 52.0 Nm (I.6 - 5.3 kgm). procedure.
7) Install the assembly of 4 pinion gear as- * If the starting torque is out of the * After the bearing, pinion gear, bevel
semblies (34) and spider shaft (33) to above range, adjust the shims gear, etc. is replaced, adjust the
case (41). again. shims.
8) Install side gear (32). iv) After adjusting, check that the ad- b a
i) Measure distance a between carrier
* Move the side gear to check that the justment nut groove on the plain half (29) and pinion gear (22).
pinion gear rotates lightly. side is at the position where the lock
9) Install the inner race of bearing (27) and plate is inserted.
thrust washer (31) to case (30). 2. Cage assembly
& Contact faces of thrust washer 1) Install the outer races of roller bearings a
(31) and side gear (32): (24) and (23) to cage (15).
Axle oil (AX075). * Push each outer race until its end
IO) Install case (30) to case (41) with the 8 touches the shoulder of the cage.
bolts. 2) Install the inner race of roller bearing
m Mounting bolt: (24) to pinion (22).
824 - 1,030 Nm (84 - 105 kgml * Push the inner race until its end CWW02777
11) Install the 2 outer races of bearing (27) touches the pinion.
to cases (41) and (30). 3) Install pinion (22) to cage (15). 6) Fit the O-ring to cage (19). cwwo2778
12) Install differential assembly (28) to car- & Bearing: Axle oil (AX0751 7) Install oil seal (21) to cage (19).
rier (29). * Press fit the bearing, rotating the 8) Install dust seal (20) to cage (19). ii) Calculate standard value b.
13) Tighten 2 nuts (26) onto carrier (29) tem- cage. Stop press fitting when a load * Fitting dimension c of dust seal: l b=(427+c)-(121.69id)
porarily. is applied. 4 mm from cage end * Dimensions c and d are indicated
* Check that the carrier can be rotated * Limit the press fitting force to the & Fitting part of oil seal: at the end of the pinion shaft on
lightly with the hand. minimum load to insert the bearing. Gasket sealant (LG-I) or (LG-5) the unit of l/100 mm. (Take care
14) Install 2 caps (25) to carrier (29) with the 4) Install the inner race of roller bearing & Seal lip: Grease (G2-LI) of plus and minus.)
4 bolts. (23) to pinion (22).
15) Adjust the preload on the differential side 5) Adjust the thickness of the shim for the
bearing according to the following pro- input bearing according to the following
cedure. procedure.
i) Bring the lock groove of the nut on the i) Measure thickness a of the holder.
bevel gear side to the position where ii) Install coupling (18) to pinion (22),
the lock plate is inserted. then install holder (16) temporarily
ii) Rotate the bevel gear until it rotates with the bolts.
smoothly. Sr Do not install the shims at this
iii) Measure the rotational force of the time.
bevel gear at large end a, then ad- iii) Fitting the bearing, loosen the bolt
gradually until the starting torque CWWO7776 cwwo2787
(146) mm
I-_
kg--63mml 169~83mA
I3 CII
cwwo2779
548’
f!d
\0_-_-_
_ 1, ‘_
/’
/’
-_
‘\
‘\’ r
0 \‘;:
P (I :I1 0(1:1)
2 PLACES
(84-105Kaml CWWO4898
J-J
il6HTENl”G TORDUE
PUbAd 245-309Nn
(25~31.5Komi
M
-I_____
__-__-__-
CWWO4899
TiCHTEWlNt TORDUE
PtkAd 34.3-44.
(3.5~4.5K
(21 I21
H-H E-E
cww04900
36
---.-__
\ ,------ \ /I
L
80
/ -i____/- CWWO2780 )
-L
Disassembly procedure 8. Hub ring-- gear assembly 12. Tube Assembly procedur
1) Remove the 8 mounting bolts, retainer 1) Remove plug (70) and O-ring from tube 1. Gear
&I kg Final drive and brake assembly: 5,450 kg (34), and shims (35). (74). 1) Fit the O-ring and install guide (82) to
* Check the thickness and quantity of 2) Remove the inner race from roller bear- gear (75).
1. Cover assembly the shims. ing (50). 2) Fit the O-ring to shaft (84).
I) Install the 16 mounting bolts and cover 2) Remove hub ring gear assembly (36). 3) Remove retainer (72) and 3 washers (73). 3) Insert shaft (84) in gear (75). Pass guide
assembly (3). 3) Remove the O-ring from tube (74). 4) Remove the 34 mounting bolts and gear (82) and lever (83) onto the shaft in or-
2) Remove the O-ring from cover (4). 4) Remove the 2 mounting bolts and 2 (75). der, then install spring pin (80).
3) Remove spacer (5). plates (37). 13. Gear 4) Fit the O-ring and install plug (79).
4) Remove the 3 mounting bolts and shaft 5) Remove retainer (38) and O-ring. 1) Remove plugs (76) and (77) and O-rings. w Plug: 58.8 - 78.4 Nm 16 - 8 kgm)
(6). 6) Remove seal (39) and O-ring. 2) Remove plugs (78) and (79) and O-rings. 5) Install plug (78).
2. Sun gear 7) Remove ball (40). 3) Remove spring pin (80). 6) Fit the O-ring and plug (77).
Remove gear (7). 8) Remove the inner race of roller bearing 4) Remove cap (81) and guide (82). 7) Fit the O-ring and install plug (76) to gear
3. Carrier assembly (Large) (41) from hub (42). 5) Remove lever (83) and shaft (84). (75).
1) Remove the 4 cap bolts and carrier as- 9) Remove the 16 mounting bolts and 8 w Plug:
sembly (8). plates (43). 44.1 - 53.9 Nm 14.5 - 5.5 kgm)
2) Remove the O-ring from carrier assem- 10) Remove ring gear (44) from hub (42). 2. Tube
bly (8). 9. Wheel hub assembly 1) Fit the O-ring to tube (74).
3) Remove 4 shafts (10) from carrier (9), 1) Remove 61 stud bolts (45) from wheel & Fitting part of O-ring:
then remove 4 balls. (11). hub assembly (46). Grease (G2-LI)
-k Remove the 4 sets. 2) Remove the outer race of roller bearing 2) Install gear (75) to tube (74) with the 34
4) Remove 4 gears (12) from carrier (9). (41) from hub (51). bolts.
* Remove the 4 sets. 3) Remove seal (47) and O-ring. m Mounting bolt:
5) Remove the bearing (13) from gear (12). 4) Remove retainer (48) and seal (49). 824 - 1,030 Nm (84 - 105 kgml
Jr Remove the 4 sets. 5) Remove the O-ring from seal (49). 3) Fit 3 washers (73) and install retainer
6) Remove snap ring (14) from gear (12). 6) Remove the O-ring from hub (51). (72).
* Remove the 4 sets. 7) Remove the outer race of roller bearing 4) Install the inner race of roller bearing
4. Ring gear (50) from hub (51). (50) to tube (74).
I) Remove the 16 mounting bolts and 8 10. Cylinder and piston assembly 5) Fit the O-ring and install plug (70).
plates (15). 1) Remove the 16 mounting bolts and cyl- 3. Wheel hub assembly
2) Remove ring gear (16). inder (52). 1) Press fit the outer races of roller bear-
5. Shaft assembly 2) Remove the O-ring from cylinder (52). ings (41) and (50) to hub (51).
I) Remove shaft assembly (17). 3) Remove oil seal (53) and seal (54). * Press fit each outer race until its end
2) Remove snap ring (19) and gear (20). 4) Remove the O-ring from seal (54). touches the shoulder of the hub.
3) Remove spacer (21) from shaft (18). 5) Remove plug (55) and O-ring. 2) Fit the O-ring to hub (51).
6. Carrier assembly (Small) 6) Remove bleeder (56). a O-ring: Grease (G2-LI)
I) Remove carrier assembly (22). 7) Remove plug (57) and O-ring. 3) Install retainer (48) to hub (51).
2) Remove spacer (24) from carrier (23). 8) Remove 3 plugs (58). 4) Fit the O-ring to seal (49).
3) Remove snap ring (25) and pin (26). 9) Remove 2 plugs (59) and 2 O-rings. a Seal: Engine oil (EOIO-CD)
* Remove the 3 sets. 10) Remove 2 plugs (60) and 2 O-rings. * Before fitting the O-ring, remove the
4) Remove 3 balls (27). 11) Push in guide (61) and remove 8 dowel blooming white powder from its sur-
5) Remove 3 gears (28) from carrier (23). pins (62) and 8 plates (63). face with engine oil (EOIO-CD).
6) Remove 2 bearings (29) and spacer (30). 12) Remove 8 guides (61) and 8 springs (64). * Before fitting the O-ring, check that
* Remove the 3 sets. 13) Remove piston (65) from cylinder (52). it is not skewed.
7) Remove snap ring (31) from gear (28). 14) Remove seals (66) and (67) from piston
* Remove the 3 sets. (65).
7. Hub and brake assembly 11. Discs and plates
1) Sling hub and brake assembly (32) tem- 1) Remove 10 plates (68) and 9 discs (69)
porarily, then remove the 36 mounting alternately.
bolts and the assembly. 2) Remove gear (71).
2) Remove the O-ring and plate (33).
5) Install seal (49) to retainer (48). 8) Install 61 stud bolts (45) to hub (51). * After installing the seal, check that 8) Remove wheel hub assembly (46) and
& Retainer: Engine oil (EOIO-CD) * Tighten each stud bolt to the incom- the O-ring is not skewed. hub rina aear assembly (36).
* Check the O-ring contact face of the plete thread portion. * After installing the seal, measure di-
retainer is free from flaw, dust, etc. * Check that each stud bolt has an mension a at 4 places on the periph-
* Use a push jig to install the seal. identification mark. ery and reduce the dimensional dif-
* After installing the seal, check that * Tightening dimension (Reference): ference below 1 mm (similarly to seal
the O-ring is not skewed. 139 mm (49)).
* After installing the seal, measure di- w Stud bolt: IO) Fit the O-ring to tube (74).
mension a at 4 places on the periph- 441 - 883 Nm I45 - 90 kgm} & O-ring: Grease (G2-LI)
ery and reduce the dimensional dif- II) Install hub ring gear assembly (36).
ference below 1 mm. & Fitting face of bearing seal:
Engine oil (EOIO-CD)
5. Adjustment of preload on wheel bearing
1) Install wheel hub assembly (46) and hub
ring gear assembly (36).
& Bearing: Axle oil (AX075)
2) Install preload adjustment jig W3 with
the 3 bolts.
3) Checking the oil pressure with oil pres-
sure gauge 0, apply the following speci-
CWW02784 fied hydraulic pressure to preload ad-
justment jig W3 with a hydraulic pres-
cwwo4993 4. Hub ring gear assembly sure pump.
I) Press fit the inner race of roller bearing * Specified hydraulic pressure:
6) Fit the O-ring to seal (47). (41) to hub (42). 40.8 MPa (400 kg/cm*)
& Seal: Engine oil (EOIO-CD) 2) Install ring gear (44) to hub (42). 4) Close needle valve @ and remove the
t Before fitting the O-ring, remove the 3) Install 8 plates (43) with the 16 bolts. coupler.
blooming white powder from its sur- & Mounting bolt: 5) Rotate the hub wheel assembly suffi-
face with engine oil (EOIO-CD). Liquid adhesive (LT-21 ciently to fit the bearing. 6. Discs and plates
* Before fitting the O-ring, check that w Mounting bolt: * Check that the hydraulic pressure is Remove gear (71).
it is not skewed. 245 - 309 Nm 125 - 31.5 kgm} about 38.8 MPa (380 kg/cm*}. If it is Install 10 plates (68) and 9 discs (69) al-
7) Install seal (47) to hub (51). 4) Install ball (40). below that level, raise it again ac- ternately.
& Hub: Engine oil (EOIO-CD) 5) Fit the O-ring to retainer (38). cording to step 3). Install the 9 plates from the tube side,
Check the O-ring contact face of the 6) Install retainer (38) to hub (42). 6) Measure dimension b between cylinder matching the centers of their cuts to the
hub is free from flaw, dust, etc. 6 Retainer fitting part: upper face and piston upper face with a centers of the cuts of the indicator
Use a push jig to install the seal. Grease (G2-LI) depth micrometer. mounting part of the gear.
After installing the seal, check that 71 Install 2 plates (37) with 2 bolts. * Measure the dimension at 3 places Install the 1 plate from the piston side,
the O-ring is not skewed. & Mounting bolt: and obtain the average. matching its tooth to the cut of the indi-
After installing the seal, measure di- Liquid adhesive (LT-2) 7) Calculate shim thickness d. cator mounting part of the gear.
mension a at 4 places on the periph- w Mounting bolt: l d = (a - b - c) + (0 to 0.1) 7. Cylinder and piston assembly
ery and reduce the dimensional dif- 98 - 123 Nm {IO - 12.5 kgm} * a: 86.99 mm, c: 40.09 mm 1) Install seals (67) and (66) to piston (65).
ference below 1 mm (similarly to seal 8) Fit the O-ring to seal (39). * Types of shims: 0.2, 0.3, 1.0 mm & Periphery of seal: Grease (G2-LB
(49)). 6 Seal: Engine oil (EOIO-CD) * Combine the shims so that the num- * Before installing the seals, check the
* Before fitting the O-ring, remove the ber of them will be minimized. piston grooves for flaw and foreign
blooming white powder from its sur- matter.
face with engine oil (EOIO-CD). 2) Install piston (65) to cylinder (52).
Sr Before fitting the O-ring, check that & Piston surface: Grease (G2-LI)
it is not skewed. 3) Install 8 springs (64) and 8 guides (61).
9) Fit the O-ring and seal (39) to retainer 4) Push in guide (61) and install 8 dowel
(38). pins (62) and 8 plates (63).
6 Retainer: Engine oil (EOIO-CD) 5) Fit the O-ring to cylinder (52).
* Check the O-ring contact face of the
retainer is free from flaw, dust, etc.
* Use a push jig to install the seal.
6) Install cylinder (52) to gear (75) with the iii) Install cap (81) to guide (82). 10. Carrier assembly (Small) 14. Sun gear
16 bolts. m Cap: I) Install snap ring (31) to gear (28). Install gear (7).
w Mounting bolt: 117.6 - 161.7 Nm (12 - 16.5 kgm) * Install the 3 sets. 15. Cover assembly
824 - 1,030 Nm (84 - 105 kgml 2) Install spacer (30) and 2 bearings (29). Install shaft (6) with the 3 bolts.
7) Fit the 2 O-rings and install 2 plugs (60) * Install the 3 sets. 6 Mounting bolt:
to cylinder (52). 3) Install 3 gears (28) to carrier (23) with 3 Liquid adhesive (LT-2)
m Plug: 58.8 - 78.4 Nm (6 - 8 kgm) balls (27) and 3 pins (26). m Mounting bolt:
8) Fit the 2 O-rings and install 2 plugs (59) 4) Install 3 snap rings (25). 245 - 309 Nm (25 - 31.5 kgml
to cylinder (52). 5) Install spacer (24) and carrier assembly Install spacer (5).
w Plug: (22). Fit the O-ring and install cover assembly
9.8 - 12.7 Nm Il.0 - 1.3 kgm1 11. Shaft assembly (3) with the 16 bolts.
9) Install 3 plugs (58). I) Install spacer (21) to shaft (18). w Mounting bolt:
IO) Fit the O-ring and install plug (57). 2) Install gear (20) and snap ring (19) to 245 - 309 Nm I25 - 31.5 kgm}
11) Install breather (56) to cylinder (52). shaft (18).
& Threaded parts of breather: 3) Install shaft assembly (17).
Gasket sealant (LG-51 12. Ring gear
12) Fit the O-ring and install plug (55) to cyl- 15) Fit the O-ring to seal (54). 1) Install ring gear (16) to ring gear (44).
inder (52). 6 Seal: Engine oil (EOIO-CD) 2) Install 8 plates (15) with the 16 bolts.
m Plug: * Before fitting the O-ring, remove the & Mounting bolt:
34.3 - 44.1 Nm I3.5 - 4.5 kgml blooming white powder from its sur- Liquid adhesive (LT-2)
13) Check the brake seal according to the face with engine oil (EOIO-CD). m Mounting bolt:
following procedure. f Before fitting the O-ring, check that it 245 - 309 Nm 125 - 31.5 kgml
i) Install an oil pressurizing connector is not skewed. 13. Carrier assembly (Large)
to pressurizing port a. 16) Install seal (54) to cylinder (52). I) Install snap ring (14) to gear (12).
ii) Supply oil through pressurizing port & Cylinder: Engine oil (EOIO-CD) * Install the 4 sets.
a and bleed air through bleeder b. * Check the O-ring contact face of the 2) Install bearing (13) to gear (12).
iii) Keep the piston operating hydraulic cylinder is free from flaw, dust, etc. * Install the 4 sets.
pressure at 175 MPa (178 kg/cm*] and * Use a push jig to install the seal. 3) Install 4 gears (12) to carrier (9) with 4
close the hand valve. * After installing the seal, measure di- balls (II) and 4 shafts (IO).
iv) Check that the pressure does not fall mension a at 4 places on the periph- 4) Fit the O-ring to carrier assembly (81, then
more 0.29 MPa (3 kg/cm*) in 5 min- ery and reduce the dimensional dif- install them with the 4 cap bolts.
utes. ference below 1 mm (similarly to seal m Mounting bolt:
b (49)). 123 - 157 Nm I12.5 - 16 kgm}
17) Install oil seal (53) to cylinder (52). Ir When installing the carrier assembly
& Oil seal fitting part: LOCTITE 648 to the hub, match through tap hole a
& Oil seal lip: Grease (G2-LI) of the hub to hole b under the drain
Wheel hub assembly and hub ring gear assem- plug of the carrier.
a bly
I) Install wheel hub assembly (46).
6 Bearing: Axle oil (AX0751
2) Install hub ring gear assembly (36).
& Bearing: Axle oil (AX0751
3) Install the selected shims (35) and retainer
CWWO.2781 (34) with the 8 bolts.
& Mounting bolt:
14) Adjust the disc wear indicator according Liquid adhesive (LT-2)
to the following procedure. w Mounting bolt:
i) Apply pressure to the brake. 1,520 - 1,910 Nm I155 - 195 kgm}
ii) Rotate guide (82) with shaft (84) Hub and brake assembly I 6 CWWO2785 1
pushed in and adjust the shaft end Fit the O-ring and plate (33) to tube (74).
flush with the guide end, then se- Install hub and brake assembly (32) with
cure the shaft with the nut. ’ the 36 bolts.
w Nut: w Mounting bolt:
237.7 - 321 Nm I24 - 33 kgm} 2,450 - 3,040 Nm (250 - 310 kgm}
D-D (1~2)
CWWO4906
WA1 200-3
53lE*sm J/S & P--41/X bAss’y
DISASSEMBLY AND ASSEMBLY J/S & ARM-REST Ass’v
OF FRAME ANGLE
DIRECT "ARNESS
TOWARD RIGHT-FRONT
Z(l:l)
7b-b%KT>L3P@
DETAILS OF POTENT10 METER
OF FRANE ANGLE
CWWO4906
cwwoh4g06
cwwo4907
WA1 200-3
53s*%I& i‘k3XZf~Ass’y
DISASSEMBLY AND ASSEMBLY BRAKE SYSTEM Ass’y
i’k-+>X%Ass’y(1/2)
BRAKE SYSTEM Ass’y (l/2)
r__-_i
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WA1 200-3
5m*%Z i’t-+F-_j?AAss’y
DISASSEMBLY AND ASSEMBLY BRAKE SYSTEM Ass%
TIGHTENING TOI(O”E
l)+tEJ!d 9. 8-l 3Nm
(I. O--l. 3kom) /
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q-$hII bU--ILAss’y
LOADER CONTROL Ass’y
SHIM
I-I.0
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18850
151
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r’-i -‘i’_
/I i ii F-F (I : I)
E-E (I:11
WA1 200-3
5m*%a 7 I/ - &Ass’y
DISASSEMBLY AND ASSEMBLY FRAME Ass’y
7 I/-LAss’y(V4)
FRAME Ass’y(l/4)
E-E (1:l)
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cwwo4912
7 I/ - LAss’y (2/4)
FRAM E Ass’ y (2/4)
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WA1 200-3
53l!s*%l~ 7 I/--Ass’y
DISASSEMBLY AND ASSEMBLY FRAME Ass’y
LM-Pflb /----- I
*PPL* U-P
A-A (1:2. 5)
IFROM CWWO4913)
cwwo4914
7 I, - LAss’y (4/4)
FRAME Ass’y(4/4) pin head 3 to 5 times with copper head ham-
WA1 200-3
53?%#*mi fj:- F&7- FAss’y
DISASSEMBLY AND ASSEMBLY GUARD & HOOD Ass’y
jr--.---l L__,
,y.._-__-2 ‘\__O
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cwwo4915
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(FROM Cwwo4915)
w (1:2. 5)
(FROM CWWO49151
x (1:2. 51
(FROM cwwo4915)
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c-c (1:51 (FROM cwwo4915)
B-B (1 :2. 5)
(FROM cwwo4915) (FROM cwwo4915)
WA1 200-3
30-l 11
0
m#*i#Rsr 7RP/7’5~ b7%-.L+t&‘- b, AAX/\“-Ass’y
DISASSEMBLY AND ASSEMBLY FLOOR/PLATFORM SUPPORT, A/C COVER Ass’y
i__.___.-----,_-
I I Jj
UPPER SURFACE OF
REM FINE
\, 'IP7lPkkrn
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cwwo4917
a i ‘1 --Ib/3f Y -i z~Ass’y(l/2)
CONSOLE/DASH Ass’y(V2)
F-F l1:2. 5)
D-4
B-B (1:2. 5)
s(l:2.51 /
E-E (I :2. 5)
P (1:ll (PPLACES)
x (I :2. 5)
d=-t=h A-A
\ LT-lAUBt(tl)
"SE L1-l* TO GLUE
,1YIRIS,
w D-D
1760
(1 :2. 5)
INS TcmlE
19.6-29.4Nm
(2-3kem)
3.43--4.41Nm(0.35--0.45Kom)0~t.
1. TtGHiEWlYGTOPdUE OF LlSTED PARTS APWE SHALL BE
1.43‘1.4,H. co. 35-o. 16kI.l
CWWO4918
=I i’/-Jb/+~ _ixAss’y(2/2)
CONSOLE/DASH Ass’y (2/2)
K-K (I:I)
c---.--__-__-_____
I c CT
\.
i OPEN
H-H
)IK9’J71?3;t.
i:390nm)
w
G-G
WA1 200-3
53-fB*%m #aa 9 i 3Ass’y
DISASSEMBLY AND ASSEMBLY HYDRAULIC TANK Ass’y
fG&& 9 i 3Ass’y
HYDRAULIC TANK Ass’y
TlC”TEHlNG iORD”E
illtbh9 9.8s13Nm
(I. O-l. Jksml
A-A (I :2. 5)
-1
ilG”iENl”G TORDUE B-B (1:2. 5)
Ofi1M 79-93Nm
(8. l-9.5kgn)
BREATHER SET PRESS
I'l-7FYb.E 0.14MPa
(I. 4ke/cm')
WA1 200-3
5f-liB*sE X f 7’ ‘J i 5%i~E$$Ass’y
DISASSEMBLY AND ASSEMBLY STEERING HYDRAULIC LINE Ass’y
.--
,’
/
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Ii
cwwo4921
II-Sf’l i+-‘;i’Ass’y(l/3)
LOADER LINKAGE Ass’y(li3)
cwwo4922
WA1 200-3
30-117
0
alR*%R.a q - $2’‘J i 3_- ';;‘Ass' y
DISASSEMBLY AND ASSEMBLY LOADER LINKAGE Ass’y
q-Sf’J i++Ass’y(2/3)
LOADER LINKAGE Ass’y(2/3)
(FROM CWWO4922)
(FROM cwwo4922)
91.3*.O.lI J ! 91.3iO.l
E-E (I:51
(FROM cwwo4922)
(FROM cwwo4922)
+d7+ ~~_;;‘-i~fAss’y
KICKOUT POSITIONER Ass’y
Y
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A-A (I : 1) -’
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ROPS CANOPY Ass’y
-(501
8V779 (4PLACES)
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cwwo4925
r~--~I:i~~TP’~irAss’y(l/2)
EMERGENCY STEERING Ass’y(V2)
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cwwo4927
WA1 200-3
30-123
0
m?#*%aI XT7 r/ i9-i ‘I XfAss’y
DISASSEMBLY AND ASSEMBLY STEERING CYLINDER Ass’y
00
7 0
00
Z
TlGHTEHlNG TOilDUE
li#Ckl 157-l 96Nm
(16~20kgml
CWWO4928
‘J 7 F -i ‘I iYAss’y(l/2)
LIFT CYLINDER Ass’y(l/2)
cwwo4929
WA1 200-3
30- 126
0
T)l%*aE ‘I 7 b 9 ‘I i 9’Ass’y
DISASSEMBLY AND ASSEMBLY LIFT CYLINDER Ass’y
gi7“‘j ‘J XfAss’y(l/2)
DUMP CYLINDER Ass’y(V2)
cwwo4930
WA1200-3 30-131
6
DISASSEMBLY AND ASSEMBLY OIL COOLER
30-132 W1200-3
6
DISASSEMBLY AND ASSEMBLY OIL COOLER
2. Specifications, points
The overall dimensions are extremely large: approximately length 2162 mm x width 2880 mm x
depth 143 mm. The total number of tubes is 912. The tubes have a top-bottom two- stage structure
and there are four tubes to each line.
1) When mounted on the machine, it is difficult to pinpoint the location of any leakage. It is only
possible at the front face at places where there are no ribs.
2) There is a top-bottom two-stage structure. To remove the tubes at the bottom (bottom core),
first remove the tubes at the top (top core), then remove the tubes at the bottom. (Even if the
top retainer clip is removed, it is still difficult to move.)
fl When assembling, assemble the tubes at the bottom first, then assemble the tubes at the
top.
For the above reasons, carry out repairs or replacement when mounted on the machine only at the
front where it easy. For other locations, take the machine to the repair shop and set the machine
horizontal.
Note: The pressure is high, so a blind plug cannot be used. For this reason, no blind plug is available
as a supply part.
WA1200-3 30-133
6
DISASSEMBLY AND ASSEMBLY OIL COOLER
Disassembly
30-134 W1200-3
6
DISASSEMBLY AND ASSEMBLY BOTTOM DUMP
OIL
CYLINDER
COOLER
2. Removal of tubes
fl When removing the tubes, start from the
top core.
WA1200-3 30-135
6
DISASSEMBLY AND ASSEMBLY OIL COOLER
30-136 W1200-3
6
DISASSEMBLY AND ASSEMBLY OIL COOLER
WA1200-3 30-137
6
DISASSEMBLY AND ASSEMBLY OIL COOLER
Assembly
1. Installation of tubes
1) Install the rubber seal by hand.
fl If it is cold and the rubber seal is stiff,
warm it up in hot water before install-
ing.
fl An oil film will cause leakage of oil, so
do not use lubricating oil on the seal.
fl Tap with a flat hammer to bring portion
a of the rubber seal into tight contact.
30-138 W1200-3
6
DISASSEMBLY AND ASSEMBLY OIL COOLER
WA1200-3 30-139
6
DISASSEMBLY AND ASSEMBLY OIL COOLER
30-140 W1200-3
6
DISASSEMBLY AND ASSEMBLY OIL COOLER
WA1200-3 30-141
6
DISASSEMBLY AND ASSEMBLY OIL COOLER
Pressurizing test
30-142 W1200-3
6
40 MAINTENANCE STANDARD
ENGINE MOUNT
n n
i56* 6koml
SWWO4865
TRANSMISSION MOUNT
z-__
B-0
A-A
SWWO4666
A3~_.____________
--r---r------ ,---,-=jqpqy
SWW04667
Unit: mm
Tolerance
Standard Standard Clearance
Clearance between trunnion and size clearance limit
1 Shaft Hole
torque converter case
DAMPER
__-
j__-_
,c--
,i_-_ /
112*9.8Nm
111.5* l.Okrrml
ii il
1
____
__-
i
111.5* l.Okoml
SJWO4868
Unit: mm
WA1 200-3
TORQUE CONVERTER, TRANSMISSION,
MAINTENANCE STANDARD BRAKE COOLING AND BRAKE PUMP
SWWO3285
Unit: mm
SARl3) 71 13 I 4.5
O I - I
-
SAR(2) 28 1 - 1 - I-l
4 Rotating torque of spline shaft 29.4 - 48.1 Nm f3.0 - 4.9 kgm} I
-
Revolution
Model
tram)
Discharge
Oil: EOlO-CD
Temperature: 45 - 55°C 2,000
All IHt
9JBOO110
Unit: mm
Standard size
0.15 - 0.32
MODULATED CLUTCH
7
110.3*12.3Nm 353*39.2Nm
II 1,l)cI 1 rlEl,__l ,*c,,, 1
93800111
Unit: mm
No
WA1 200-3
MAINTENANCE STANDARD TORQUE CONVERTER
TORQUE CONVERTER
\ I i
‘66.2* 7.35Nm
(6.75* 0.75kom 1
9JBOO112
Unit: mm
0
Width 5.95 5.45
Wear of seal ring of -0.1
3
retainer
Thickness 6.3 *o. 1 5.67
Replace
4 Thickness of plate 9 20.1 8.5
-
TRANSMISSION
--_---
0 -----_
i 110.3*12.3Nm
~ll.25*1.25knmI
110.3*~2.3Nm 110.3~12.3Nm
(11.25*1.25kaml (11.25*1.25kPml
9JBOO113
Unit: mm
357.9 N 304.0 N
3 No. 3 clutch spring (6 PCS.) 68.8 55 64.67 t31.0 kg}
136.5 kg}
42.7 N 358.9 N
4 No. 4 clutch spring (6 PCS.) 56.9 43 t43.0 kg} 53.49 l36.6 kg}
! I I I
-0.01
Wear of seal ring of Width 4 -0.03 3.6
16 transmission output
shaft
Thickness 4.6 eo.12 4.45
Unit: mm
sun
18 Backlash between No. 1, 2, 3 0.16 - 0.40
gear and planetary pinion
19
I Backlash between No. 1 planetary
pinion and inside teeth of ring gear I
0.18 - 0.43
I
Backlash between No. 2, 3 planetary
20 0.19 - 0.47
I pinion and inside teeth of ring gear I I Replace
4
21 Backlash between No. sun gear 0.17 - 0.39
and planetary pinion
TRANSFER
277 *31.%m
-{Z&25* 3.25kml
17*147.lNm 2207*147.lNm
1u5f15 km1 {225*15 kern1
,_*,.
(24.;
9JBOO114
Unit: mm
66.2*7.35Nm
4 ‘3 ‘0 (6.75*0.75koml
\
A-A
9JB00115
Unit: mm
49*4.9Nm
5 * 0.5 kern)
A-A
Unit: mm
-
040 -0.035 +0.016 0.035 0.081
-0.045 0 0.061
156.9 N
155.6 116.0 kg}
Unit: mm
Standard Clearance
size &I ~;Z limit
Clearance between by-pass fill valve
spool and valve body
63.7 N 60.8 N
33.4 17.3 32.4
(6.5 kg} f6.2 ka}
H 4.9 f 1 Nm
(0.5*0.1 koml
I’ ?t 1 ; tL,8,b 4.9 * f 1 Nm
(0. 5 0. I knm1
9JBOOl18
Unit: mm
Replace
ECMV
(For modulated clutch)
30. 9 *3. 43 Nm
13. 15 *O. 35kam)
9JBOOl 19
Unit: mm
-
No Check item Criteria Remedy
Standard
3
Replace
5
-
(For transmission)
30. 9 *3. 43 Nm
(3. 15 *O. 35komI
9JBOO120
Unit: mm
66.2*7.35Nm
1 6.75i 0.75 kam]
A-A
SJBOO121
Unit: mm
Tolerance
Standard Standard Clearance
Clearance between lubricating oil size clearance limit
1 Shaft Hole
relief valve spool and valve body
I I I
-
022 -0.035 +0.013 0.035 0.078
-0.045 0 0.058
-
Replace
Standard size I Repair limit
2
Valve
valve
spring of lubricating oil relief
,I:
WA1 200-3 40-25
MAINTENANCE STANDARD DRIVE SHAFT
DRIVE SHAFT
176.5*19.6Nm
~l8.0*2.0hl
1
I I I
fl
367.8*24.5Nm 367.8*24.5Nm
{37.5*2.5kPmI
SJWO4869
CENTER SUPPORT
Unit: mm
No.
2
-
DIFFERENTIAL (I/Z)
A-A
Unit: mm
-
No
shaft bearing
7
_
11
12
13
-
WA1 200-3
MAINTENANCE STANDARD DIFFERENTIAL
DIFFERENTIAL (2/2)
927* 103Nm
(94.5* 10.5koml
2746 i294Nm
~260-t30ko.1
SJWO4872
Unit: mm
9.0 8.5
Replace
2 Thickness of pinion gear washer
sleeve 10.8 10.3
FINAL DRIVE
277131.4Nm
~28.3~3.2ksmI 277*31.4Nm
(28.3*3.2ksml
277*31.4Nm
,(28.3*3.2bml
1715*195Nm
-~175*2Okaml
\
12
\
152*24.5Nm
~15.5~2.5kivnl
i5 i IO II 2 3 13 4
SJWO4873
Unit: mm
No.
I Check item
I
Criteria Remedy
Tolerance
Standard Standard Clearanc
size clearance limit
, Clearance between planetary shaft
Shaft Hole
and bearing
+0.018 0 -0.038- 0 _
90
0 -0.020
6 I Clearance
bearing
between wheel hub and
I 679.45
+0.076
0
-0.050
-0.130
-0.206 -
-0.050
AXLE MOUNT
19.6Nm
176.5-t 2746*294Nm
~l8.0*2.0hl (280~30koml
2746*294Nm
(280~3Okp.l
B-B
SJW04874
Unit: mm
- 1
Tolerance
Standard Standard Clearance
size clearance limit
Clearance of shaft and hole
1 (Front support side) Shaft Hole
(Before press-fit bushing)
8 kO.2
-0.21
6 Thickness of thrust plate 53
-0.35
-
927*103Nm
{94.5*10.5kml
53.9
15.52
17
5’ Ii \ '2746*294Nm
A-A B - B 5000*4QONm (280*3Okml
(510*50kaml
sxwo4935
Unit: mm
-
No. Check item
I Criteria
I Remedy
I 228.6 -0.079
-0.050 +0.078
0 0.050
0.157- I
Clearance between lower hinge pin -0.050 +0.072 0.050 -
2 and (small) 228.6 -0.079 0 0.151 1.0
spacer
3
-
and bearingbetween
Clearance lower hinge pin I 228.6 -0.079
-0.050 0
+0.025 0.104-
0.050 I
upper
7 and rear frame -0.079
Clearance between hinge pin I 187.325 -0.050 0
+0.072 0.151-
0.050 I
Clearance between upper hinge pin -0.050 +0.025 0.050 -
8 and bearing 187.325 -0.079 0 0.129
- Replace
Clearance between front frame and +0.025 -0.093 -0.175 -
9 lower hinge bearing 355.6 0 -0.150 -0.093
17
Thickness
retainer
for lower hinge and
I
45
I kO.8
I
Shim thickness for lower hinge and
18 3.0
retainer I I
Shim thickness for lower hinge and Adjust
19 2.52
retainer I I
Shim thickness for upper hinge and
retainer 2.62
STEERING PUMP
(HPF160 + 160)
66*6.9Nm
{6.73~0.7kml
68.j*9.81Nm
i7.0*l.Obd
9JYOO286
SWITCH PUMP
(HPV160 + HPF160)
34.3*4.9Nm
~3.5*0.5l@ml
24.5*4.9Nm 66*6.9Nm
~2.5*0.5koml {6.73*0.7bml
\
l-----l
9JYOO287
7 C
A --I
2 I
A-A
svwo3soo
Unit: mm
Remedy
WA1 200-3
MAINTENANCE STANDARD DIVERTER VALVE
DIVERTER VALVE
A-A SEW01614
Unit: mm
-
No. Check item Criteria Remedy
I I
A-A
SJWO4876
Unit: mm
-
No. Check item Criteria Remedy
I Tolerance I I
Replace
Connection of steering cylinder and
3
front frame
120 -0.25
O
I
135 +;
I 0 - 3.25
7.0 to.5
A-A
‘2
SWWO3661
Unit: mm
WA1 200-3
MAINTENANCE STANDARD BRAKE VALVE
(RIGHT)
SWWO4877
Unit: mm
-
2 Clearance between roller and pin 10 -0.025 +O.l 0.175 0.25
-0.075 0 0.025
-
4.6 N
34 33.5 33
IO.47 kg)
-
11.8 N
5 Control spring 46.3 46.0 45.3
Il.2 kg}
60.8 N
6 Return spring 86.2 58 78
16.2 ka1
17.7 N
7 Spring 17 16.5 16.2
- I (1.8 kg}
16.7 N
8 Return spring 31.5 19.5 28
(1.7 kg}
-
(LEFT)
7.3Nm
0.75kom
152*24.5Nm /
~15.5*'2.5koml
Unit: mm
-
10 -0.025 +O.l 0.175 0.25
-0.075 0 0.025
-
-
2 Clearance between roller and pin 10 -0.025 +O.l 0.175 0.25
-0.075 0 0.025
Replace
4 Control spring
5 Control spring
I 46.3 34.3
45.9 N
(4.7 kg}
45.3
N
6 Return spring 86.2 58 60.8 78
(6.2 kg}
WA1 200-3
MAINTENANCE STANDARD SLACK ADJUSTER
SLACK ADJUSTER
55.9* 6.9Nm
(5.7*0.7kml
1 I2*9.8Nm
(1 1.5* l.Okml
SXW04878
Unit: mm
-
No. Check item Criteria Remedy
Tolerance
Standard Standard Clearance
size clearance limit
1 Clearance between body and piston Shaft Hole
117.7 N
246 88
I12 kg}
123.6 N
3 Check valve spring 44.8 38 112.6 kg} -
-
BRAKE
\
i’ I I \
\
\
I_------%_/ 7 G
927i-98 Nm
194.5*IO km1 SXWO4879
Unit: mm
Wear of surface
in contact with
in contact with
839.5
I +0.140
0
+0.140
I
piston seal 864 0
I
Standard Repair limit
Deformation of friction surface of I
plate
Max. 0.5
PARKING BRAKE
237. 8 f 31.9 Nm
(24.25 f 3.25 kern)
9JBOO122
Unit: mm
No. 2 Clutch spring (14 PCS.) 111 77.4 1,313 N 99.9 1,182 N
2 1133.9 kg} 1120.5 kg}
5 Brake disc
Lining groove
depth (One side)
0.45
+0.7
0 I 0.235
Lining thickness
0.7 20.16
(One side) I I I
626.6 N ~176.5 N 405 N
6 Load on wave spring (Height: 3.2 mm) 163.9 kg} {*I8 kg) 141.3 kg}
66* 6.9Nm
(6.73*0.7kp.l
24.5i4.9Nm
~2.5*0.5kPml
30.5*3.5Nm
~3.11*0.36bml
34.3*4.9Nm
~3.5*0.5lwnI
9JYOO288
34.3i4.9Nm
(3.5*0.5kp.l
24.554.9Nm
30.9*3.43Nm
{3.15*0.35bml
66.2*7.35Nm
16.75*0.75kml
\
66.7*9.81Nm
(7.0*l.O!all
9JYooza9
PPC VALVE
SVWO3605
Unit: mm
Standard size
I Repair limit
I
Centering spring Free Installation Installation Free Installation
1 (Bucket dump, boom lower) length length load length load
5.4 N
39.9 34.5 iO.55 kg} - Replace if
damaged or
Centering spring 21.1 N deformed
2 56.7 34.5 i2.15 kg} -
(Bucket tilt, boom raise)
1
33.3 N
3 Metering spring 33.5 29.4 c3.4 kg) -
14.7 N
4 Return spring 26.2 17.5 (1.5 kg} -
34.3ik.SNm
13.5*0.5kml
SJWO4897
Unit: mm
WA1 200-3
MAINTENANCE STANDARD PUMP CONTROL RELIEF VALVE
34.3+4.9Nm
13.5*0.5!Qml
SJW04897
Unit: mm
-
No Check item Criteria Remedy
-
Standard size Repair limit
36.9 N 29.5 N
Poppet spring 31.0 26.7
13.77 kg} - i3.0 kg}
WA1 200-3
MAINTENANCE STANDARD MAIN CONTROL VALVE
152.0*24.5Nm
\
A-A c-c
3
68.7*9.8Nm 304+9.8lNm
(7.0*I.Okaml 131.0*I.Obml
9JYOO290
Unit: mm
HYDRAULIC CYLINDER
BOOM CYLINDER
2450*250Nm
(250*25kml
SJWO4898
Unit: mm
-
240 -0.050 +0.247 0.084 0.669
-0.122 +0.034 0.369
Replace
Clearance between piston rod -
2 240 -0.050 +0.519 0.471 1.0
mounting pin and bushing -0.122 +0.421 0.641
1
4 Cylinder bore
+0.2
360 0
BUCKET CYLINDER
SJW04899
Unit: mm
I
T Remedy
Clearance
limit
Clearance between bucket cylinder
1
rod and bushing
0.622
- Replace
Clearance between piston rod
2 1.0
mounting oin and bushing
1
Standard size Tolerance Repair limit
4 Cylinder bore
+0.2
300 n
STEERING CYLINDER
i I
SJWO4900
Unit: mm
2
17.2*2.5Nm
(1.75*0.25kPml
A-A -1
SJWO4901
Unit: mm
BUCKET LINKAGE
20
II
20
18
\
I!
SJWO4902
d e
d’
b c
I7
A-A B-0 c-c
n n
d
d e
b b
14
d
d
b b la C b
13’ a I2
G-G H-H J-J
SJWO4903
Unit: mm
-
180 -0.043 +0.401 0.352 1.0
-0.106 +0.309 0.507
-0.050 -
240 +0.519 0.471 1.0
2 Clearance parts of bushing
connecting between boom andandbucket
pin at -0.122 +0.421 0.641
-0.056 - Replace
280 +0.605 0.549 1.0
3 connecting parts of bushing
Clearance between boom andandframe
pin at -0.137 +0.493 0.742 (Replace
when pin
4 Clearancebetweenbushingand pin at connecting 180 -0.043 +0.401 0.352 -
1.0 has scuff
parts of bucketcylinder rod and bellcrank -0.106 +0.309 0.507
mark, too)
5 Clearancebstwas~ bushing and pin at connecting 180 -0.043 +0.401 0.352 -
-0.106 +0.309 0.507 1.0
parts of bucket cylinder bottom and frame
IO
I
Connecting parts of boom and frame 655 2 0.3 304.5 + 0.1 / 174.7+0.1-
II Connecting parts of boom and bucket 594 -c 0.3 349.4 t 0.1 121.8 + 0.1 121.8 f 0.1
I If clearance
ofd+e
I2 Connecting parts of bucket link and becomes
bucket 461 f 0.3 259.5 f 0.1 91.3 + 0.1 109.3 f 0.1
2.5 mm,
replace
I3 Connecting
bucket link parts of bellcrank and 443 f 0.3 259.5 f 0.1 91.3 * 0.1 91.3 f 0.1 bushing
and collar.
I4 Connecting parts of boom cylinder
and frame 580.5 * 0.3 274.4 + 0.1 121.8 + 0.1 183.3 + 0.1
I5 I Connecting
boom
parts of bellcrank and
I
594 * 0.3 349.4 * 0.1 121.8 + 0.1 121.8 * 0.1
504 340
WA1 200-3
90 OTHERS
90-2 WA1200-3
6
OTHERS TRANSMISSION HYDRAULIC CIRCUIT DIAGRAM
1. Transmission case
2. Strainer
3. Transmission and torque converter
charging pumps
4. Torque converter charging pump
5. Oil filter
6. Main relief valve
7. Torque converter relief valve
8. Torque converter
9. Torque converter regulator valve
10. Oil cooler
11. Transmission lubricating circuit
12. Transfer lubricating circuit
13. PTO and input transfer lubricating circuits
14. Modulated clutch lubricating circuit
15. Lubricating oil relief valve
16. Brake circuit (see brake circuit diagram)
17. Parking brake pilot lamp switch
18. Parking brake (Builtin transmission)
19. Clutch No. 1 (Reverse) ECMV
20. Clutch No. 1 (Reverse) by-pass fill valve
and by-pass drain valve
21. Clutch No. 1 (Reverse)
22. Clutch No. 2 (Forward) ECMV
23. Clutch No. 2 (Forward) by-pass fill valve
24. Clutch No. 2 (Forward)
25. Clutch No. 3 (3rd speed) ECMV
26. Clutch No. 3 (3rd speed)
27. Clutch No. 4 (2nd speed) ECMV
28. Clutch No. 4 (2nd speed)
29. Clutch No. 5 (1st speed) ECMV
30. Clutch No. 5 (1st speed) by-pass fill valve
31. Clutch No. 5 (1st speed)
32. Pilot oil filter
33. Modulated clutch ECMV
34. Modulated clutch
35. Transmission control valve oil temperature
sensor
WA1200-3 90-3
6
OTHERS BRAKE CIRCUIT DIAGRAM
90-4 WA1200-3
6
OTHERS BRAKE CIRCUIT DIAGRAM
WA1200-3 90-5
6
ELECTRIC CIRCUIT DIAGRAM (1/7)
WA1200-3 90-11
(7)
ELECTRIC CIRCUIT DIAGRAM (2/7)
90-13
(7)
ELECTRIC CIRCUIT DIAGRAM (3/7)
WA1200-3 90-15
(7)
ELECTRIC CIRCUIT DIAGRAM (4/7)
WA1200-3 90-17
(7)
ELECTRIC CIRCUIT DIAGRAM (5/7)
WA1200-3 90-19
(7)
ELECTRIC CIRCUIT DIAGRAM (6/7)
WA1200-3 90-21
(7)
ELECTRIC CIRCUIT DIAGRAM (7/7)
WA1200-3 90-23
(7)
DataKom Publishing Corporation
440 North Fairway D&e _
Vernon Hills, IL 60061-8112 U.S.A.
Attn: Service Publications PROPOSAL FOR MANUAL OR CSS REVISION
Fax No. (847) 970-4186
I DEPARTMENT:
STATE OR PROVINCE::
COUNTRY:
NAME:
OOK DESCRIPTION
ACHINE MODEL 8 S/N:
ROBLEM:
PROPFRN.WF’D 071: