07 GD825A-2 Shop Manual
07 GD825A-2 Shop Manual
01-l
0
GENERAL SPECIFICATION DIMENSION DRAWINGS
-I
c
0
c
0
-
SWG00332
01-2
0
GENERAL SPECIFICATION DIMENSION DRAWINGS
c
0
c
a
-
P
01-3
0
GENERAL SPECIFICATIONS
SPECIFICATIONS
Load on front wheel kN {kg1 78.9 {8,040) 78.9 (8,040) 78.9 (8,040)
Load on rear wheel kN (kg1 212.2 121,640) 212.2 (21,640) 212.2 (21,640)
Gradeability deg 24 24 24
01-4
0
GENERAL SPECIFICATIONS
Machine
Serial
model
No.
1 G D825A-2
Model 3
q
5 Type Fully hydraulic type (Orbit-roll)
ij
t Steering angle
z deg 50 50 50
q
ii
Max. articulating angle deg 25 25 25
Y
01-5
0
GENERAL SPECIFICATIONS
(min.) deg 25 25 63
01-6
0
GENERAL WEIGHT TABLE
WEIGHT TABLE
a Thus
. weight table is for use when handling components or when transporting the machine.
Unit: kg
Steering cylinder 15 x2 15 x 2 15 x2
Articulate cylinder 72 72 72
Transmission pump 12 12 12
01-7
0
GENERAL FUEL, COOLANT AND LUBRICANTS
+
Transmission case 25
Engine
Final drive case oil 63 57
Diesel
Fuel tank 500
fuel
NOTE:
(I) When fuel sulphur content is less than 0.5%, (2) When starting the engine in an atmospheric
change oil in the oil pan every periodic main- temperature of lower than OC, be sure to
tenance hours described in this manual. use engine oil of SAEIOW, SAEIOW-30 and
Change oil according to the following table SAE15W-40, even though an atmospheric
if fuel sulphur content is above 0.5%. temperature goes up to 10C more or less in
the day time.
Change interval of oil in (3) Use API classification CD as engine oil and if
Fuel sulphur content API classification CC, reduce the engine oil
engine oil pan
change interval to half.
0.5 to 1.0% l/2 of regular interval
Specified capacity: Total amount of oil including oil for components and oil in piping.
Refill capacity: Amount of oil needed to refill system during normal inspection and maintenance.
01-8
0
GENERAL FUEL, COOLANT AND LUBRICANTS
Transmission case 35 25
Engine
Final drive case oil 63 57
c
Tandem case (each) 120 95
Fuel tank
Cooling system
Diesel
fuel
78.5
t
L
s ASTM D975 No.1
NOTE:
(I) When fuel sulphur content is less than 0.5%, (2) When starting the engine in an atmospheric
change oil in the oil pan every periodic main- temperature of lower than OX, be sure to
tenance hours described in this manual. use engine oil of SAEIOW, SAEIOW-30 and
Change oil according to the following table SAE15W-40, even though an atmospheric
if fuel sulphur content is above 0.5%. temperature goes up to 10C more or less in
the day time.
Change interval of oil in (3) Use API classification CD as engine oil and if
Fuel sulphur content API classification CC, reduce the engine oil
engine oil pan
change interval to half.
)
ASTM: American Society of Testing and Material
SAE: Society of Automotive Engineers
API: American Petroleum Institute
Specified capacity: Total amount of oil including oil for components and oil in piping.
Refill capacity: Amount of oil needed to refill system during normal inspection and maintenance.
10 STRUCTURE AND FUNCTION
10-l
0
GENERAL
4 5 El
F23507003
1o-2
POWER TRAIN DIAGRAM
F23501004
1. Engine
2. Joint
3. PTO (Power Take Off)
4. HYDROSHIFT transmission
5. Transfer
6. Parking brake
7. Drive shaft
8. Final drive
9. Tandem drive
10. Tire
P, Hydraulic pump
P, Transmission pump
P, Differential lock pump
1o-3
0
JOINT
Engine
f
-..
T
---2
13
F23501007
1. Engine flywheel
2. Plate
3. Tube
4. PTO input shaft
1o-4
c----q r-n
I YI
_-_--_$ 2 r-.
- - _.- - __i--i_~.-=&
f /l- - - *_-,-y_
1. Transfer
2. HYDROSHIFT transmission
3. Transmission control valve
4. Transmission filter
5. Transmission pump
6. Engine
7. Radiator
8. Oil cooler
1o-5
HYDRAULIC CIRCUIT FOR POWER TRAIN
Engine running, gear shift lever in NEUTRAL
Serial No.: 11001 - 12012, 12016 - 12018
235FO2001
1O-6
0
STRUCTURE AND FUNCTION HYDRAULIC CIRCUIT DIAGRAM FOR POWER TRAIN
0. 29-3 04HPa
13-3lks/cm'l
t----t-------
6
4th
1. OGMPa 3rd
(10. Bka/cm'i
II
I
!________
i
)I(
LL
0 29HPa
_ ,;!
1o-7
0
STRUCTURE AND FUNCTION HYDRAULIC CIRCUIT FOR POWER TRAIN
SWG00336
1o-7- 1
0
STRUCTURE AND FUNCTION HYDRAULIC CIRCUIT DIAGRAM FOR POWER TRAIN
0.29-3.04HPa
13-3lka/cm'l
1 47HPa
&
il5ks/cm'l
L--J t--j
I.OGMPa
(IO Bkefcm'l
-___p~-~-~-----------__
9 I--_-dI II
)I(
LL
0 49MPa
15ks/cm'l
SWG00335
10-7-2
0
PTO (Power Take Off)
2
B-B
235FO2003
1, 1. Input shaft
2. Idler gear
3. Pump drive gear
4. Transmission pump
5. Transmission control valve
1 O-8
STRUCTURE AND FUNCTION HYDROSHIFT TRANSMISSION AND TRANSFER
B-B
A-A
c-c
235FO2004
2
10-10
0
TRANSMISSION CONTROL VALVE
Serial No.:11001 - 12012,12016-12018
235coo2039
10-16
0
UPPER VALVE
r-71 -iid
1. Housing
2. Inching valve
3. . huick return valve
4. Modulating valve
235CDO2040
5. Priority valve \
1 4
6. Oil cooler bypass valve Y-Y
OUTLINE
l The oil from the transmission pump enters port A, l The other oil line flows to modulating valve (4)
and passes through priority valve (5). It is then and quick return valve (3). The action of modulat-
divided into two lines: one to the clutch pistons, ing valve (4) and quick return valve (3) raises the
and the other to pilot reducing valve (12). Priority clutch pressure smoothly. This reduces the shock
valve (5) acts to control the two lines so that pilot when actuating the FORWARD, REVERSE and Ist,
reducing valve (12) is the priority circuit. 2nd, 3rd, 4th, High and Low speed clutches to
l The oil flowing to pilot reducing valve (12) con- change gear.
trols the pilot pressure used to actuate the direc- . Lubrication valve (14) controls the lubrication oil
tional and speed spools. The oil regulated by pilot inside the transmission.
reducing valve (12) presses through the orifice in
each spool and fills the spool.
10-17
LOWER VALVE
235CD02041
lo-18
SOLENOID VALVE
\ I I
6 7 8 9
\
11 Section X-X
10
F23501302
10-19
PRIORITY VALVE
Function
. Priority valve (1) ensures the minimum oil press-
ure required for pilot reducing valve (2) and sends
oil to pilot reducing valve (2) with priority over
any other circuit.
Operation
To modulating valve To each transmission spool
l When the oil pressure is below 1.47 MPa (15 kg/
cm2), the oil from pump flows to port A on the
priority valve and also into port B on the pilot re-
ducing valve. Since the oil pressure on port A is
lower, the priority valve moves to the left, causing
the flow to ports A and C to be shut off. As a re-
sult, the oil from the pump is delivered only to the
pilot reducing valve circuit.
423FO33
l When the oil pressure is more than 1.47 MPa (15 To modulating valve To each transmission spool
kg/cm2), the hydraulic pressure and force of pop-
pet spring (3) push back spring (4) and move
priority valve (1) to the right. When this happens,
port A and port C are connected,
from port C to the clutch spool.
and the oil flows
-
Pi lot
oil filter
423FO34
1O-20
PILOT REDUCING VALVE
Function
l The pilot reducing valve acts to control the press-
ure needed to actuate the transmission spools.
Operation
l The oil from the pump passes through the pilot fil-
ter and enters port A of pilot reducing valve (1).
The oil passes through port B and enters through
the orifice of transmission spool (2) to fill the in-
side of port C.
valve
423 FO30
423FO29
10-21
Function of pilot circuit drain
This pilot valve functions as a reducing valve primary
pressure: 1.47 MPa (15 kg/cm*); secondary pressure:
1.06 MPa (10.8 kg/cm2). If the reducing valve does not
have drain port a at the secondary side, it is im-
possible to obtain the specified reducing pressure.
For example, at the Neutral position, if there is no sec-
ondary pressure at drain port a, theoretically the
pressure generated at the secondary side is the same
pressure as the primary pressure. (Actually, it is not as
high as the primary side because of leakage from the
valve spool.)
F23501306
1o-22
MODULATING VALVE AND QUICK RETURN VALVE
Function
l The modulating valve and quick return valve act (kg/cm) C
together to raise the transmission clutch pressure Shifting gear I
smoothly. In this way. they reduce the shock
when shifting speed range, and prevent the gen-
eration of peak torque in the power train. As a
result, operator fatigue is reduced, and at the
same time, operator comfort and the durability
of the power train are increased.
Time (Set)
423FO35
11 Immediately after shifting gear (Point A on Fig. 423FO35)
To pilot reducing
F23501303
Operation
l The oil sent from the pump flows from priority difference in pressure between port B and port
valve (I) through port A, passes through C. The quick return valve moves to the right and
modulating valve (21, and enters port B of quick the oil flows to clutch (5). In addition, when quick
return valve (3). The oil passes through orifice return valve (3) moves to the right, drain port D
a of quick return valve (3) and flows to the is opened, and the pressurized oil at the rear of
clutch pistion, which has been actuated. Howev- piston (4) flows to the drain circuit.
er when it passes through orifice a it creates a
1 O-23
2) Clutch pressure rising (Point B on Fig. 423FO35)
pilot reducing
Ive
To oil cooler
F23501304
Operation
l As the pressure at the clutch piston rises, the At the same time, pressurized oil also passes
pressure at port C also rises. Quick return valve through the orifice and enters poppet (7) of
(3) is pushed back to the left and drain port D is modulating valve (2). It moves modulating valve
closed. The oil from the pump flows from port C (2) to the left and some of the oil at port A flows
to the clutch piston, and at the same time it to port G.
flows from orifice b through quick return valve
(3) and enters port E.
The oil at port E acts on the modulating piston
(4). It pushes back spring (61 and moves piston
(4) to the rig ht.
1 O-24
3) Completion of rise in clutch pressure (Point C on Fig. 423FO35)
pilot reducing
Ive
To oil cooler
To inching valve
235FO2005
Operation
l The oil entering port E continues to push piston
(4). When the piston reaches the end of its stroke,
the rise in pressure stops. When this happens, the
pressure reaches the set pressure of the modulat-
ing valve. In addition, port F and port G are closed
by piston (4), so the oil at port A passes through
port G and flows to the oil cooler.
l The oil at port E is connected to the inching valve
through the throttle (the modulating valve is inter-
connected with the inching valve).
1 o-25
OIL COOLER BYPASS VALVE
FUNCTION
l The oil cooler bypass valve acts to maintain the To each transmission spool
pressure of the oil entering the oil cooler at a con-
stant pressure. It drains the oil if it goes above
the specified pressure.
OPERATION
l The oil from the pump passes through priority
valve (I) and actuates modulating valve (2). It
then enters port A and flows to the oil cooler. -2
-1
l If the oil at port A goes above the specified To each transmission spool
pressure, it passes through orifice a of oil
cooler bypass valve (3) and enters port B. It then
moves oil cooler bypass valve (3) to the left. As a
result, the oil from port A is drained, and the oil
flowing to the oil cooler is maintained at the
specified pressure.
1 O-26
TRANSMISSION SOLENOID VALVE
Function
. There is one solenoid valve installed for each
directional and speed spool in the transmission
valve.
When the gear shift lever in the operators com-
partment is operated, the solenoid valve is
actuated, and oil is drained to actuate the direc-
tional and speed spools.
Operation
1) Solenoid valve OFF
The oil of spool (1) enters port A. However, valve
(2) shuts off the oil, so directional and speed
spool (I ) does not move.
423FO31
8
4
8
2) Solenoid valve ON
When the gear shift lever is operated, the sole-
noid valve is pulled up.
The oil from directional and speed spool (I)
enters port A and flows from port B to the drain
circuit. Therefore, port A becomes the low pres-
sure circuit, and directional and speed spool (1)
is moved to the right. As a result, the oil from
quick return valve flows to the piston.
Fr
reducing valve
423 F032
1 O-27
Function
l If there is any failure in the electrical circuit of the
transmission control system, and the solenoid
valve does not work, the emergency spool is
used. This spool is attached to each directional
and speed spool and is used to operate the trans-
mission valve mechanically. (It is used to drive
the machine to a place where it can be repaired.)
* Particular attention must be paid for when
using this spool.
Operation
1. When solenoid valve is normal:
(Emergency spool is at normal position)
When the solenoid valve is working normally, the
spool is maintained in this position.
Oil from directional and speed spool (I) enters
port A, but it is shut off by solenoid valve (2).
From. ~
reducing valve 423 F044
reducing valve
423 F045
From
reducing valve 423 F046
1 O-28
INCHING VALVE (INCHING VALVE WITH MODULATING VALVE)
OPERATION
1. When inching valve is not depressed;
The oil from the pump passes through ports A
and B, goes through the F-R spool and is sent to
the F-R clutch.
The return spring of the inching pedal pushes To quick return
valve spool (2) and collar (3). These push valve (1)
to the right. The oil passing through orifice D en- Modulating
valve
ters chamber C, and produces force to push valve
(I) to the left. However, the tension of the return
spring prevents valve (1) from moving.
The oil in chamber E of the modulating valve is To oil cooler From pump
shut off by spool (2), so it does not flow to drain bypass valve
port F.
235FO2007
3. When inching valve is fully depressed;
Valve spool (2) moves completely to the left, so
the tension of spring (5) is further reduced. As a 2 F zin 5 From pump
result, the hydraulic pressure of the F-R clutch
drops to 39 kPa - 49 kPa (0:4 - 0.5 kg/cm2), and
the clutch is completely disengaged.
The oil at port E of modulating valve (7) is con-
nected to drain circuit F, so the main pressure is
kept reduced.
235FO2008
1 O-29
STRUCTURE AND FUNCTION TRANSMISSION CONTROL VALVE
SWG00338
10-29-l
0
STRUCTURE AND FUNCTION TRANSMISSION CONTROL VALVE
LOWER VALVE
z-z SWG00339
1O-29-3
STRUCTURE AND FUNCTION TRANSMISSION CONTROL VALVE
SOLENOID VALVE
II 12 13 I4 15 Ifi 17 18
A-A SWG00340
10-29-4
0
STRUCTURE AND FUNCTION TRANSMISSION CONTROL VALVE
PRIORITY VALVE
Function
. Priority valve (1) ensures the minimum oil press-
ure required for pilot reducing valve (2) and sends
oil to pilot reducing valve (2) with priority over
any other circuit.
423FO33
. When the oil pressure is more than 1.47 MPa (15 To modulating valve To each transmission spool
kg/cm), the hydraulic pressure and force of pop-
pet spring (3) push back spring (4) and move
priority valve (1) to the right. When this happens,
port A and port C are connected, and the oil flows
from port C to the clutch spool.
Pilot
oil filter
423FO34
1 O-29-5
0
STRUCTURE AND FUNCTION TRANSMISSION CONTROL VALVE
Function
. The pilot reducing valve acts to control the
pressure needed to actuate the transmission
spools.
Operation
. The oil from the pump passes through the
pilot filter and enters port A of pilot reduc-
ing valve (I). The oil passes through port B
and enters through the orifice of transmis-
sion spool (2) to fill the inside of port C.
* To Priority valve
SWG00421
To Priority valve
SWG00422
10-29-6
0
STRUCTURE AND FUNCTION TRANSMISSION CONTROL VALVE
1 O-29-7
0
STRUCTURE AND FUNCTION TRANSMISSION CONTROL VALVE
Function
. The modulating valve and quick return valve act (kg/cm*)
together to raise the transmission clutch pressure 40 - Shlftlng gear
smoothly. In this way, they reduce the shock
when shifting speed range, and prevent the gen-
30 -
eration of peak torque in the power train. As a F
5
result, operator fatigue is reduced, and at the Z
k 20-
same time, operator comfort and the durability .=
of the power train are increased. 0
Trne (Set)
F23501303
Operation
l The oil sent from the pump flows from priority difference in pressure between port B and port
valve (1) through port A, passes through C. The quick return valve moves to the right and
modulating valve (21, and enters port B of quick the oil flows to clutch (5). In addition, when quick
return valve (3). The oil passes through orifice return valve (3) moves to the right, drain port D
a of quick return valve (3) and flows to the is opened, and the pressurized oil at the rear of
clutch pistion, which has been actuated. Howev- piston (4) flows to the drain circuit.
er when it passes through orifice a it creates a
10-29-8
0
STRUCTURE AND FUNCTION TRANSMISSION CONTROL VALVE
pilot reducing
lve
F23501304
Operation
l As the pressure at the clutch piston rises, the At the same time, pressurized oil also passes
pressure at port C also rises. Quick return valve through the orifice and enters poppet (7) of
(3) is pushed back to the left and drain port D is modulating valve (2). It moves modulating valve
closed. The oil from the pump flows from port C (2) to the left and some of the oil at port A flows
to the clutch piston, and at the same time it to port G.
flows from orifice b through quick return valve
(3) and enters port E.
The oil at port E acts on the modulating piston
(4). It pushes back spring (61 and moves piston
(4) to the right.
1 O-29-9
0
STRUCTURE AND FUNCTION TRANSMISSION CONTROL VALVE
It reducing
To inching valve
235FO2005
Operation
The oil entering port E continues to push
piston (4). When the piston reaches the end
of its stroke, the rise in pressure stops. When
this happens, the pressure reaches 3.04 MPa
I31 kg/cm) as a set pressure of the modulat-
ing valve. In addition, port F and port G are
closed by piston (4), so the oil at port A
passes through port G and flows to the oil
cooler.
The oil at port E is connected to the inching
valve through the throttle (the modulating
valve is interconnected with the inching
valve).
10-29-10
0
STRUCTURE AND FUNCTION TRANSMISSION CONTROL VALVE
FUNCTION
l The oil cooler bypass valve acts to maintain the To each transmission spool
OPERATION
l The oil from the pump passes through priority
valve (1) and actuates modulating valve (2). It
then enters port A and flows to the oil cooler.
l If the oil at port A goes above the specified To each transmission spool
10-29-11
0
TRANSMISSION SOLENOID VALVE
Function
l There is one solenoid valve installed for each From quick
return valve
directional and speed spool in the transmis-
sion valve.
When the gear shift lever in the operators
compartment is operated, the solenoid valve
is actuated, and oil is drained to actuate the
directional and speed spools.
Operation
I) Solenoid valve OFF From pilot
reducing valve SWG00423
The oil of spool (I) enters port A. However,
valve (2) shuts off the oil, so directional and
speed spool (I) does not move.
2) Solenoid valve ON
When the gear shift lever is operated, the From quick
return valve
solenoid valve is pulled up.
-8
The oil from directional and speed spool (I)
enters port A and flows from port B to the
drain circuit. Therefore, port A becomes the
low pressure circuit, and directional and
speed spool (I) is moved to the right.
As a result, the oil from quick return valve
flows to the piston.
2?
From oilot
reducing valve
10-29-12
0
EMERGENCY SPOOL
Function
. If there is any failure in the electrical circuit
of the transmission control system, and the
solenoid valve does not work, the emergency
spool is used. This spool is attached to each
directional and speed spool and is used to
operate the transmission valve mechanically.
(It is used to drive the machine to a place
where it can be repaired.)
* Particular attention must be paid for
when using this spool.
Operation
1. When solenoid valve is normal:
From quick
(Emergency spool is at normal position) return valve
When the solenoid valve is working normally,
the spool is maintained in this position.
Oil from directional and speed spool (1) en-
ters port A, but it is shut off by solenoid
valve (2).
5/t,
:
Kh : A
% 3
From Pilot
reducing valve
SWG00425
From oilot
reducina valve SWG00427
10-29-13
0
INCHING VALVE (INCHING VALVE WITH MODULATING VALVE)
OPERATION
1. When inching valve is not depressed;
The oil from the pump passes through ports A
and B, goes through the F-R spool and is sent to
the F-R clutch.
The return spring of the inching pedal pushes
valve spool (2) and collar (3). These push valve (1)
Modulating
to the right. The oil passing through orifice D en-
valve
ters chamber C, and produces force to push valve
(1) to the left. However, the tension of the return
spring prevents valve (I) from moving.
The oil in chamber E of the modulating valve is To oil cooler From pump
shut off by spool (2), so it does not flow to drain bypass valve
port F.
235FO2006
235FO200:
3. When inching valve is fully depressed;
Valve spool (2) moves completely to the left, so
the tension of spring (5) is further reduced. As a 2 F D:i 5 From pump
235FO2008
10-29-14
0
STRUCTURE AND FUNCTION TRANSMISSION CONTROL
TRANSMISSION CONTROL
Serial No.: 11001 - 11030
lIn
II
I..l
r-
d
235COO2002
1O-30
0
STRUCTURE AND FUNCTION TRANSMISSION CONTROL
l-l
A-A 6-B lJ
235CD02003
Outline
l The control system of this machine is used the . Press button switch (5) on the gear shift lever only
electrical type. So, the operation is easy and the when moving the gear shift lever 5 .+ 6 or 6 + 7
operating force and stroke are small. (for both forward and reverse).
l When operating gear shift lever (6), the F-R If gear shift lever (6) is placed at the N position
switching is used F-R switch (3), (4) and the speed and shift lock lever (2) is placed at the LOCK posi-
range is used rotary switch (7), and the current tion, bolt (1) holds gear shift lever (6) and keeps
signal is sent to each solenoid valve so that the the gear shift lever in the N position.
transmission control valve operates.
10-31
0
TRANSMISSION CONTROL
STRUCTURE AND FUNCTION
10-31-l
0
STRUCTURE AND FUNCTION TRANSMISSION CONTROL
A-A c-c
SDGOOOO
1
Outline
l The transmission control is an electrical type. l When shift lever (6) is at the N or P position,
When the shift lever is operated, an electri- and shift lock lever (2) is set to the LOCK
cal signal is sent to the transmission sole- position, bolt (I) holds shift lever (6) and
noid valve from F and R switches (4) and (3) prevents it from moving back from the N
when switching direction, and from rotary position (1st and other drive positions).
switch (7) for the gear ranges, and the con-
trol valve is actuated.
. To prevent mistaken operation, when the
shift lever is operated 5 + 6 or 6 + 7 (both
forward and reverse) and when it is oper-
ated N tf P, button (5) installed to shift lever
(6) must be pressed to move the shift lever.
10-31-2
0
STRUCTURE AND FUNCTION TRANSMISSION CONTROL
SWG00350
Outline
. The transmission control is an electrical type.
When shift lever (1) is operated, an electrical
signal is sent to the transmission controller
from F and R switches (3) and (2) when
switching direction, and from potentiometer
(5) for the gear ranges.
The drive for the transmission solenoid valve
is carried out by the transmission controller
to protect the transmission from mistaken
operation or failure in the control system.
l To prevent mistaken operation, when shift
lever (1) is operated N ++ P, button (4) in-
stalled to the shift lever must be pressed to
move the shift lever.
10-31-4
0
INCHING CONTROL
_--_I@ !! e !
:I ^ :
2-
A-A
T
D
l-
F
---
235CDO2004
1. Inching pedal
2. Brake pedal
3. Brake valve
4. Transmission control valve
1 O-32
DRIVE SHAFT
-I6 -
-
-
-
p
:::
d-
----.
\
_
h
:- F23501019
P -
1. Drive shaft
1o-33
STRUCTURE AND FUNCTION FINAL DRIVE, DIFFERENTIAL LOCK AND UNLOCK PIPING
c
A=========3 ii
II I
SWG00351 +
1o-34
0
STRUCTURE AND FUNCTION FINAL DRIVE, DIFFERENTIAL LOCK AND UNLOCK PIPING
SWG00352
[A
SWG00353
1o-35
0
FINAL DRIVE
i
16 15 14 13 12 11
A-A 235COO2006
1O-36
0
235CD02007
Outline
When motor graders carry out operations with
the blade angled to the front or the chassis at
an angle, there is a reaction to this. It applies a
force in a sideways direction from the front, and
the machine tries to turn to the left or right.
It is necessary to give the machine the ability to
resist this and travel in a straight line, so gener-
ally speaking, motor graders are not designed
to be equipped with a differential.
However, the GD825A is an articulated type, so
when the machine is articulated, the rear wheels
tend to slip to the side. For this reason, the
machine is equipped with a differential to im-
prove the wear resistance of the rear tires. Con-
trol of the differential can be carried out simply
by pressing a switch in the operators compart-
ment.
Operation
The power transmitted from the engine to the
whee
transmission is then transmitted by the mesh-
To front wheel
ing of bevel pinion (IO) and bevel gear (7), and
is sent from shaft (6) -+ (I) + sprocket (2). \
1o-37
0
TANDEM DRIVE
F23501025
The motive power from the final drive turns sprocket 1. Chain 8. Gear (105 teeth)
(14) and its rotation is transmitted to right and left 2. Breather 9. Plate (138 teeth)
sprockets (4) by chains (1). Then the motive power is 3. Shaft 10. Disc
transmitted to the tires through shaft (3). As to the 4. Sprocket 11. Tandem case
disc brake (piston (6), spring (7), disc (10) and plate 5. Cage 12. Oil level gauge
(9)), refer to DISC BRAKE. 6. Piston 13. Drain plug
7. Spring 14. Sprocket
1o-39
STEERING PIPING SWING CIRCLE
STEERING PIPING
10-41
0
STEERING CIRCUIT SYSTEM
L ,
I
235FO2011
1 O-42
STEERING CIRCUIT DIAGRAM
From hydraulic
-c--
control valve
To hydraulic
control valve
235FO2012
1o-43
STRUCTURE AND FUNCTION STEERING VALVE
STEERING VALVE
ORBIT-ROLL
A-A
10
11
SEW01234
1o-44
0
STRUCTURE AND FUNCTION STEERING VALVE
Outline
l The steering valve is connected directly to
the shaft of the steering wheel. It switches
the flow of oil from the steering pump to the
left and right steering cylinders to determine
the direction of travel of the machine.
. The orbit-roil valve, broadly speaking, con-
sists of the following components: rotary
type spool (9) and sleeve (81, which have the
function of selecting the direction, and the
Girotor set (a combination of rotor (5) and
stator (IO)), which acts as a hydraulic motor
during normal steering operations, and as a
hand pump (in fact, the operating force of
the steering wheel is too high, so it cannot
be operated) when the steering pump or
engine have failed and the supply of oil has
stopped.
SLWO1980
Structure
l Spool (9) is directly connected to the drive
shaft of the steering wheel, and is connected
to sleeve (8) by center pin (7) (it does not
Connected to
contact the spool when the steering wheel steerlnu
is at neutral) and centering spring (2). wheel shaft
1o-45
0
STRUCTURE AND FUNCTION STEERING VALVE
SBWOO725
SBWW726
1O-46
0
STRUCTURE AND FUNCTION STEERING VALVE
1o-47
0
DOUBLE RELIEF VALVE
(For Steering)
1. Relief valve
2. Body
3. Poppet(B)
4. Sleeve
5. Relief valve
6. Poppet (A)
7. Sleeve
FL?3501389
ll4-n
F238098
OPERATION
F23BOSS
1 O-48
CHECK VALVE
1 1. Nipple
2. Joint
3. Spring
4. Valve
235FO2013
235FO2014
--
8
FJJ
__-
I
1.
2.
3.
4.
Joint
Spring
Valve
Nipple
*I
ZJ
I
I
I I 1
I I
@
+-
+---~\,L-__--------
f I
1 rX- A ---------
x 1
LI
1
,
_Jk
,
*
235FO2015
F23501391
1o-49
EMERGENCY STEERING SYSTEM
235FO2017
235FO2016
1O-50
STRUCTURE AND FUNCTION FRONT AXLE
FRONT AXLE
235CDO2009
1o-51
0
WHEEL
Serial No.: 11001 - 12000
*\
3A 1.
2.
Side
Rim
ring
3. Tire
F23501039 F23501040
=23501041 042
Air pressure 0.25 MPa i2.60 kg/cm21 Air pressure 0.24 MPa 12.46 kg/cm21
1o-52
0
Serial No.: 12001 and up
*\
l-----
1. Side ring 8H
2. Rim
3. Tire
F23501040 :23501039
Air pressure 0.24 MPa f2.46 kg/cm*} Air pressure 0.25 MPa t2.60 kg/cm3
Air pressure 1 0.24 MPa 12.46 kg/cm? Air pressure 1 0.25 MPa I2.60 kg/cm?
10-52-l
0
DISC BRAKE
STRUCTURE OF DISC BRAKE
1234 5
Final drive
I II
F23501056
Disc brakes are fitted on the four rear wheels and are 1. Hub shaft
actuated by air pressure. 2. Gear
The motive force from the final drive rotates hub 3. support
shaft (I), gear (2) and disc (4). This rotation is trans- 4. Disc
mitted to the tires which are fixed to the hub. 5. Plate
Each brake consists of discs (4) which are meshed 6. Spring
with gear (2). plates (5) which are meshed with cage 7. Cage
(7) and piston (8). The discs are cooled by the oil 8. Piston
inside the tandem case. 9. Nut
IO. Bolt
1o-53
OPERATION
1. Brake applied
When the brake pedal is depressed, the air circuit
is connected to chamber A of the disc brake.
When the air pressure is greater than the pushing
force of spring (6), piston (8) moves to the left,
and pushes discs (41 and plates (5). Friction is
generated between the discs (meshed with gear
(2)) and the plates (meshed with cage (7)). This
slows down the rotation of the discs and finally
stops it. In other words, the brake is applied.
* 8
F23501057
2 Brake released
When the brake pedal is released, the air in
chamber A is released. Spring (6) moves piston
4 5 8
(8) back to the right, so the pushing force is
reduced. This removes the friction between
discs (4) and plates (5), and allows them to
rotate freely. In other words, the brake is
released.
To air tank
F23501058
1o-54
PARKING BRAKE
Section A -A
F23501061
Outline 1. Disc
l The parking brake is a disc type and is installed 2. Plate
on the transmission output shaft. 3. Disc
l The force of the spring inside the spring cylinder 4. Piston
(7) is used to apply the brake mechanically; it is 5. Shaft
released by air pressure. 6. Adjuster
l When spring cylinder (7) yoke is moved out, ad- 7. Spring cylinder
juster (6) and shaft (5) turn and piston (4)
moves. So discs (3) and plate (2) are forced in
contact and the parking brake is applied.
1o-55
STRUCTURE AND FUNCTION BRAKE AIR PIPING
II
1. Brake valve
2. Disc brake housing 7. Parking brake valve
3. Safety valve 8. Air tank
4. Air governor 9. Air drier
5. Check valve 10. Air compressor
6. Parking brake 11. Automatic drain valve
1o-57
0
BRAKE AIR CIRCUIT SYSTEM
235FO2018
1 O-58
BRAKE AIR CIRCUIT DIAGRAM
SllG00003
1o-59
0
AIR DRIER
F23501047
The function of the air drier is to remove the moisture 1. Purge tank
from the compressed air in the circuit. In this way it 2. Check valve
protects the components of the equipment and pre- 3. Spring
vents problems with operation in cold areas. 4. Drier cylinder
5. Drying agent
6. Body
To Brakevalve 7. Valve body
8. Valve
9. Oil filter
A. Air compressor
8. Air drier
C. Air governor
D. Air tank
235FO2019
lo-60
OPERATION
1. Drying
When the compressor is working, air from the
compressor enters port A of the air drier. It is
then cooled by the outside of drier cylinder (4). To air tank
and water and oil collect in the bottom of body
(6). The air then passes through oil filter (9)
which is fitted with an oil mist separator. Here
the fine drops of oil and particles of dust are re-
moved before the air enters drier cylinder (4).
Any water still included in the air is removed by
drying agent (5). When the air reaches the top of
drier cylinder (4). it is completely dry. This dry air
From air compressor
then passes through check valve (2) and purge
tank (1) to the air tank.
F23501048
F23501049
10-61
AIR TANK
1. Plate
2. Plate
3. Plate
4. Boss
SAFETY VALVE
1. Valve seat
2. Ball
3. Release pin
4. Spring
5. Spring cage
6. Lock nut
7. Adjusting screw
238FO67
1 O-64
AUTOMATIC DRAIN VALVE
! 2 3
I. Retainer
2. Filter
3. Body
4. Plug
5. Valve guide
6. Inlet-Exhaust valve
7. Cover
238FO72
OPERATION
1. When there is no air pressure inside the air tank,
inlet-exhaust valve (6) is closed.
238FO73
1O-65
2. When air pressure enters the air tank, inlet-
exhaust valve 16) opens even when the pressure
is low. Air and water then enter chamber A. The
inlet-exhaust valve stops open until the pressure
inside the air tank reaches the maximum pressure
(until the governor is cut off).
238FO74
238FO75
238FO78
1O-66
CHECK VALVE
1 2 3 4
1. Body
PI PZ 2. Disc valve
3. Spring
4. Screw cap
238FO64
OPERATION
When air flows into the check valve from the left,
valve (2) leaks its seat and the air flows freely to the
various ports.
When air flows into the check valve from the right,
valve (2) is pushed back into its seat by spring (3)
and the air pressure. This shuts off the air flow.
238FO65
1 O-67
BRAKE VALVE
--. /ix
4L
1, ,I--, I
/i / :
\ 0, ii
l\ 0 i
\__, ._. (
l--r---___--_____r_~_
I
F23501050
1. Brake pedal
2. Plunger
3. Piston
4. Inlet valve
5. Piston
t 6. Inlet valve
7. Rubber spring
235FO2020
1O-68
OPERATION
1. Brake operating
Upper part
l When brake pedal (1) is depressed, the
operating force pushes plunger (2) and
rubber spring (71, and these transmit the
operating force to piston (3).
l When piston (3) moves down, it closes ex-
haust outlet (9). At the same time, it pushes
down inlet valve (4) and air flows from air
tank A to right relay valve C.
Lower part
l When inlet valve (4) opens, air flows to
chamber a of piston (5).
l The air pressure pushes piston (5) down and
this closes exhaust outlet (I 0). At the same
time, it pushes down.inlet valve (6) and air
flows from air tank B to left relay valve D to
actuate the brake.
l Only a small amount of air pressure is
needed to move piston (51, so the movement
of the lower valve occurs at almost the same
time as the movement of the upper valve.
F23501051
F23501052
lo-69
3. Brake operation when upper side breaks down
. If there is any leakage of air at the upper
side, piston (5) is pushed down mechanically
when the brake pedal is depressed. Because
of this, the lower side operates normally but
the upper side does not actuate the brake.
F23501053
4. Balancing operation
Upper part
. If the air pressure in relay valve C and the
space below piston (3) becomes high, piston
(3) will push rubber spring (7) and move up
to close inlet valve (4).
l When this happens, exhaust outlet (9) re-
mains closed, so the air pressure in the relay
valve is maintained. As a result, the brake re-
mains applied. 3
Lower part
l When the air pressure at the top and bottom
of piston (5) becomes the same, the piston 4
moves down slightly under the force of the
spring at the top of the piston and closes
inlet valve (6). The exhaust valve is closed so
the air pressure is maintained. As a result,
9
the brake remains applied. 5
l The pressure in the space in the upper part
balances with the operating force of the
pedal, and the pressure in the space in the
lower part balances with the air pressure in
t-i
the space in the upper part.
F23501054
1O-70
l When piston (3) and (5) move their whole
stroke inlet valves (4) and (6) are completely
opened. As a result, the air pressure in the
spaces in the upper part and lower part, and
in the right and left relay valves is the same
as the air pressure in the air reservoir.
l Therefore, until the piston its full stroke
down, the braking effect is controlled by the
amount the brake pedal is depressed.
5. Pedal released
Upper part
l If the pressure on the pedal is reduced, and
the operating pressure is removed from the
top of the piston, the piston moves up be-
cause of the air pressure at the bottom of
the piston and the force of the piston return
spring. As a result, the passage to exhaust
port (9) is opened and the compressed air in
the relay valve is released to the atmosphere.
Lower part
l If the pressure on the pedal is reduced, and
the compressed air at the top of piston (5) is
released, the air pressure at the bottom of
piston (5) pushes piston (5) up. Exhaust port
(10) is opened and the compressed air in the
relay valve is released to the atmosphere.
F23501055
10-71
PARKING BRAKE SYSTEM
235CD02012
235FO2022
235FO2021
1 O-72
PARKING BRAKE SOLENOID VALVE
1. Coil
2. Body
3. Inlet valve
4. Outlet valve
A. Inlet port
B. Outlet port
C. From air tank
423F119
Function
l The parking brake solenoid valve is a valve to
switch air to the parking brake spring cylinder.
1o-73
EXHAUST VALVE
Section A-A
z
4
2
F23501060
1. Body
2. Rubber valve
3. Valve
4. Cap
A. To spring cylinder
B. Exhaust port
C. From solenoid valve
1o-74
SPRING CYLINDER
423F I 24
1. Rod OUTLINE
2. Boot l The air pressure from the parking brake so-
3. Cylinder lenoid valve pushes spring (4) and com-
4. Spring presses it to release the parking brake.
5. Piston Usually the parking brake is kept applied by
spring (4), so the machine is prevented from
moving.
1o-75
0
STRUCTURE AND FUNCTION HYDRAULIC CONTROL PIPING
A-A
1O-76
0
STRUCTURE AND FUNCTION HYDRAULIC CONTROL PIPING
1o-77
0
STRUCTURE AND FUNCTION HYDRAULIC CONTROL PIPING
4 -___
: :
y I i
--__-
Z
1 O-78
0
STRUCTURE AND FUNCTION HYDRAULIC CONTROL PIPING
Ii SWGOO
359
11. Pilot check valve (for blade lift) R.H. 16. Swivel joint
12. Shuttle valve 17. Drawbar side shift cylinder
13. Circle rotation motor 18. Blade side shift cylinder
14. Power tilt cylinder
15. Circle rotation gear
1o-79
0
STRUCTURE AND FUNCTION HYDRAULIC CONTROL PIPING
II IO
SWGOO 1360
10-79-l
0
STRUCTURE AND FUNCTION HYDRAULIC CONTROL PIPING
18 SWG00361
10-79-2
0
STRUCTURE AND FUNCTION HYDRAULIC CONTROL PIPING
i i i i ii ii
235COO2013
1. Return filter
2. Suction filter
3. Hydraulic pump
1o-79-3
0
STRUCTURE AND FUNCTION HYDRAULIC CONTROL PIPING
RIPPER PIPING
I :
__----
235COO2016
1. Ripper cylinder
2. Pilot check valve
1o-79-4
0
STRUCTURE AND FUNCTION HYDRAULIC CIRCUIT SYSTEM
I 1x1 x3 1x4
235FO2023
1O-80
0
STRUCTURE AND FUNCTION HYDRAULIC CIRCUIT DIAGRAM
L.lI!ii
I/ 12 113
L___ _-
I
----II--
II
-1
I
t-- 1---1p
2
2:
r
1 O-80-2
0
STRUCTURE AND FUNCTION HYDRAULIC CIRCUIT DIAGRAM
II II II II I
3 -7+Q
4
I
I
I
------------7
!I
i
I / ,
5I < i I
/
I 24.5MPa
I i250ko/cm*i
I I
; ---------------~~~_____-----__~_~--------_--------______---_________
I
SWG00363
10-80-3
0
STRUCTURE AND FUNCTION HYDRAULIC CIRCUIT DIAGRAM
1. Hydraulic tank
2. Breather
3. Strainer
4. Hydraulic pump (VXD70-IF)
5. Priority flow divider valve
6. Surge pressure absorbing valve
7. L.H. hydraulic control valve (5-spool)
7A. Blade lift (L.H.) control spool
7B. Ripper control spool
7C. Blade side shift control spool
7D. Power tilt control spool
7E. Circle rotation control spool
7F. Relief valve
8. R.H. hydraulic control valve (5-spool)
8A. Drawbar shift spool
8B. Articulate control spool
8C. Leaning spool
8D. Service spool
8E. Blade lift (R.H.) control spool
8F. Relief valve
9. Blade lift cylinder (L.H.)
10. Accumulator
11. Blade float solenoid valve
12. Ripper cylinder
13. Blade side shift cylinder
14. Power tilt cylinder
15. Swivel joint
16. Circle rotation motor
17. Drawbar shift cylinder
18. Articulate cylinder
19. Leaning cylinder
20. Blade lift cylinder (R.H.)
21. Pilot check valve
22. Check valve
23. Steering valve
24. Double relief valve
25. Steering cylinder
26. Pressure switch
27. Filter
28. Hydraulic filter
29. Emergency pump
1 O-80-4
0
STRUCTURE AND FUNCTION HYDRAULIC CIRCUIT DIAGRAM
24.5MPa
(250Wcm~l
2
--i-___ 3
I ! / I
4
---i---.__.i..-.__.i.._..__i--__-_~j
ILS
.*+-m-------
22 27
1 O-80-6
0
STRUCTURE AND FUNCTION HYDRAULIC CIRCUIT DIAGRAM
24.5MPa
3------
4
5 Il
SWG00365
10-80-7
0
STRUCTURE AND FUNCTION HYDRAULIC CIRCUIT DIAGRAM
1. Hydraulic tank
2. Breather
3. Strainer
4. Hydraulic pump (VXD70-IF)
5. Priority flow divider valve
6. Surge pressure absorbing valve
7. L.H. hydraulic control valve (5-spool)
7A. Blade lift (L.H.) control spool
78. Ripper control spool
7C. Blade side shift control spool
7D. Power tilt control spool
7E. Circle rotation control spool
8. R.H. hydraulic control valve (5-spool)
8A. Drawbar shift spool
8B. Articulate control spool
8C. Leaning spool
8D. Service spool
8E. Blade lift (R.H.) control spool
9. Blade lift cylinder (L.H.)
10. Accumulator
11. Blade float solenoid valve
12. Ripper cylinder
13. Blade side shift cylinder
14. Power tilt cylinder
15. Swivel joint
16. Circle rotation motor
17. Drawbar shift cylinder
18. Articulate cylinder
19. Leaning cylinder
20. Blade lift cylinder (R.H.)
21. Pilot check valve
22. Check valve
23. Steering valve
24. Double relief valve
25. Steering cylinder
26. Pressure switch
27. Filter
28. Hydraulic filter
29. Emergency pump
30. Relief valve
1O-80-8
0
STRUCTURE AND FUNCTION HYDRAULIC CIRCUIT DIAGRAM
24.5MPa
A4 -_83 -.__-____
A3 82 -._______
A2 Bl _
7; > I
25
_-
r i P
As
!*-@L------- _,
L
22 27 :--
10-80-10
0
STRUCTURE AND FUNCTION HYDRAULIC CIRCUIT DIAGRAM
L_
24.5MPa
,-
id27
27
i
IO
, , __-------_j@_
12
10-80-11
0
STRUCTURE AND FUNCTION HYDRAULIC CIRCUIT DIAGRAM
1. Hydraulic tank
2. Breather
3. Strainer
4. Hydraulic pump (VXD70-IF)
5. Priority flow divider valve
6. Surge pressure absorbing valve
7. L.H. hydraulic control valve (5-spool)
7A. Blade lift (L.H.) control spool
7B. Ripper control spool
7C. Blade side shift control spool
7D. Power tilt control spool
7E. Circle rotation control spool
8. R.H. hydraulic control valve (5-spool)
8A. Drawbar shift spool
8B. Articulate control spool
8C. Leaning spool
8D. Service spool
8E. Blade lift (R.H.) control spool
9. Blade lift cylinder (L.H.)
10. Accumulator
11. Blade float solenoid valve
12. Ripper cylinder
13. Blade side shift cylinder
14. Power tilt cylinder
15. Swivel joint
16. Circle rotation motor
17. Drawbar shift cylinder
18. Articulate cylinder
19. Leaning cylinder
20. Blade lift cylinder (R.H.)
21. Pilot check valve
22. Check valve
23. Steering valve
24. Double relief valve
25. Steering cylinder
26. Pressure switch
27. Filter
28. Hydraulic filter
29. Emergency pump
30. Relief valve
31. Relief valve
10-80-12
CLOSED CENTER LOAD SENSING SYSTEM (CLSS)
This machine uses the CLSS in the hydraulic system This system consists of the following components.
to supply an oil flow to each actuator to match the l Variable displacement piston pump with
characteristics of the work equipment at a pressure servo-valve
corresponding to the actuating load. l Selector valve with proportional flow control
This increases the working performance and saves function
the fuel consumption. l Reducing type pressure compensating valve
Advantages
1o-:-1
(3) Excellent fine control performance
The oil flow to each actuator is proportional to
area E of the gap between the valve body and
the selector spool of the control valve. It is not in-
fluenced by the load, so the fine control range is
a large 60 - 70%. Therefore, it is possible to
move each part of the work equipment at a
medium speed to enable more precise
operations.
F23501073
- To actuator
Reducing type pressure Selector valve with
compensating valve proportional flow
Variable displacement control function
piston pump - From actuator
++
Pump delivery pressure
I
I t
I
_-_-__c---- A f
Actuating pressure
Return
_ Oil flow
c
CLSS Gear pump CLSS Gear pump
F
(1
Uunderno load)
The pump delivery The pump delivery The hydraulic servo acts to All the oil delivered from
pressure is kept low, so the pressure depends on the prevent the pump delivery the pump is wasted, so the
power loss is small. load, so the power loss is pressure from going above power loss is extremely
small. the relief pressure, so the large.
oil flow is reduced and the
power loss is imall.
P: Pressure
0: Oil quantity
m Power loss
HYDRAULIC PUMP
VXD70-1 F
!
\
Suction port
Section A-A
1. Servo valve assembly 6. Swash plate 11. Coupling 16. Dummy spool
2. Pump assembly 7. Front shaft 12. Housing 17. Yoke
3. Cylinder block 8. Front cover 13. Swash plate 18. Servo piston
4. Piston 9. Housing 14. Rear shaft 19. Guide
5. Shoe 10. Center section 15. Rear cover 20. Stopper pin
1O-82
0
PRINCIPLE OF OPERATION OF PISTON PUMP
FUNCTION
. It converts the rotation torque transmitted by the
pump shaft into hydraulic energy, and discharges
pressurized oil corresponding to the load.
. It is possible to vary the amount of oil discharged
by changing the angle of the swash plate.
OPERATION
Input shaft (2) is fitted with a spline and rotates cylin-
der block (I ). The nine pistons (4) contained inside
the cylinder block move in a reciprocal motion. The
distance moved in and out by the pistons is controlled
by the angle of swash plate (3) of the pump. This
swash plate is supported by trunnion (5). The only
parts that rotate are the input shaft and the cylinder
block. The input shaft does not contact the swash
plate of the pump. Therefore, when the directional
lever is at the Neutral position, and the sliding surface
of the pump swash plate is flat and vertical, there is 262F0 I6
no movement of oil to the motor, so no rotation is
given to the motor. The transmission speed can be
controlled steplessly by changing the angle of the
swash plate with the pump control lever.
262F0 IS
262FO20
1 O-83
OPERATION OF HYDRAULIC PUMP
FUNCTION
l This is a variable displacement swash plate type
piston pump with servo which can control the
amount discharged to match the pressure and oil
flow needed for the work equipment and steering
circuit.
l The pump assembly consists of the pump and
servo portion (servo valve and servo piston).
OPERATION
1. When engine is stopped
l No hydraulic pressure is generated, so servo
piston (1) is pushed fully to the left by the
force of spring (2).
l Swash plate (3) of the pump is interconnected
with servo piston (I), so it is at the maximum
swash plate angle.
235FO2024
2. Immediately after engine starts (work equipment
control lever, steering not operated)
1) The pump rotates at the maximum swash
plate angle, and oil is discharged from dis-
charge port P. The oil discharged from P is
sent to the main control valve and steering
valve, but the valves are closed, so the press-
ure in the circuit rises.
This circuit is connected with servo valve
chamber A, and the hydraulic pressure that is
generated overcomes the force of spring (5),
so spool (4) moves to the right.
When spool (4) moves to the right, servo
valve chamber A and servo piston chamber B
are connected, and servo piston (1) is pushed
to the right.
In addition, discharge port P is also connected
with servo piston chamber C, but the area of
chamber B is larger than the area of chamber
C, so servo piston (1) overcomes the force of
spring (2) and the pushing force of chamber
C, and moves to the right. This pushes back
swash plate (3) to a position where the dis-
charge amount is 0. (Servo piston chamber C
is a feedback pressure chamber. It is used to
improve the response and stabilize the oper-
ation of the servo piston, regardless of the 235FO2025
1 O-84
2) In the condition in Section I), if the pressure
in the circuit drops, spool (4) of the servo
valve is pushed back to the left by spring (5),
and the oil in servo piston chamber B passes
through chamber E and is drained to the
case.
The pressure in chamber B drops, and the
force pushing servo piston (1) to the right is
removed, so servo piston (1) is moved to the
left by spring (2), and the angle of swash
plate (3) is changed to increase the discharge
of oil from the pump. The pump pressure
rises again, and piston (4) moves to the right
to a position where it balances with the push-
ing force of spring (5), and it then stays in this
position.
When this happens, the difference in balance
pressure is determined by the force of spring
(5), and is approx. 2.0 MPa (20 kg/cm2). In
other words, the pump is at the maximum
swash plate angle before the engine is
started, and provides the maximum discharge
immediately after the engine is started, but
the swash plate angle is immediately returned
235FO2026
to reduce the discharge amount to nearly the
minimum.
235FO2027
1 O-85
4. When work equipment and steering are relieved
When the cylinder reaches the end of its stroke,
the relief pressure transmitted through the LS line
is sent to chamber D of the servo valve.
The servo valve is balanced by control differential
pressure approx. 2.0 MPa (20 kg/cm2) + load
pressure P2 of the LS line. Therefore, the pump
pressure is equal to the relief pressure + approx.
2.0 MPa (20 kg/cm2).
The cylinder has reached the end of its stroke and
the flow of the oil has stopped, so if the swash
plate is kept at the same angle, the pump press-
ure will rise further. If the pump pressure rises
further, the balance of the servo valve will be lost
and the pressure in servo piston chamber B will
rise. This pushes servo piston (I) to the right and
reduces the amount discharged by the pump.
In other words, at relief, the relief pressure is
maintained while the discharge amount is re-
duced (minimization of power loss).
235FO2028 8
4
8
1O-86
PRIORITY FLOW DIVIDER VALVE
8 7 6 235FO2029
1. Relief valve
2. Strainer
3. Spool
4. Body
5. PLUG, damping orifice
6. PLUG, flow control orifice
7. Orifice (for high response actuation)
, 17.2MPa
8. Spring
235FO2030
1 O-87
FUNCTION
l When the hydraulic systems for both the work
equipment and steering are covered by one
pump, if the work equipment and steering are
operated at the same time, there is danger that
the flow of oil to the steering circuit may be insuf-
ficient, making it impossible to operate the steer-
ing. This condition is extremely dangerous, so to
prevent this, the oil flow to the steering circuit is
given priority and is maintained by this priority
valve.
l This valve is a load sensing type and ensures only
the necessary flow of oil to the steering when the
steering is operated. When the steering is at neu-
tral, if a large amount of oil flows to the steering
circuit, the flow of oil to the work equipment cir-
cuit will drop, and the operating efficiency will
become poor. To prevent this and to ensure quick
response when the steering is operated, the flow
of oil to the steeering circuit is kept to the mini-
mum when the steering at neutral (approx. 1 Q/
min), and all the rest of the oil flows to the work
equipment circuit.
l The relief pressure of the steering circuit is set as
a different relief pressure from the relief pressure
for the work equipment circuit. It also has the
function of preventing any abnormal pressure in
the circuits.
OPERATION
1. When engine is stopped
Spool (1) is pushed to the right by spring (2).
In this condition, port CF is opened to the maxi-
mum and port EF is closed.
235FO2031
1O-88
2. When engine is started (steering and main con-
trol valves at neutral)
The oil from the pump flows to the steering valve,
but the steering valve is closed, so the pressure in
steering circuit CF rises.
The oil from the pump passes through orifice a
in spool (I), enters chamber B, and pushes spool
(1) to the left. At the same time, the oil passing
through orifice b of spool (1) enters chamber C,
passes from orifice c to the LS circuit, and is
drained to thetank through the steering valve (the
flow in the LS circuit is normally 1 Urnin.)
When this flow passes through orifice lb, a dif-
ference in pressure of approx. 1.0 MPa (IO kg/
cm*) is formed on both sides of orifice b. The
pressure in chamber B is the pressure in chamber
C + 1.0 MPa (10 kg/cm2), so spool (1) is pushed
to the left and tries to close portion d of spool
(1). If the area of the opening at portion d
becomes smaller, the oil flow in the drain circuit
passing through orifice b becomes smaller, SO 235FO2032
1 O-89
0
3. Steering operated (main control valve at neu-
tral)
When the steering wheel is turned, the steering
valve is switched, and port CF and port LS are
connected to the steering cylinder. When this
happens, the pressure in chamber C becomes
higher, and spool (1) is pushed to the right by
spring (2). The area of the opening of portion d
of spool (1) becomes larger, so the oil from the
pump passes through port CF when the steering
wheel is being turned, and the necessary oil flow
goes from the steering valve to the steering cylin-
der.
If the steering wheel is turned quickly, and the
area of the variable throttle in the steering valve
becomes larger, the difference in pressure on
both sides of the variable throttle inside the steer-
ing valve becomes smaller, and the pressure in
the LS circuit rises. (The pressure in chamber 6
drops)
At the same time, the oil pressure in chamber C 235FO2033
also rises, so.spool (1) is moved further to the
right, and the area of the opening of portion d
also becomes larger. This sends a large oil flow to
the steering cylinder. On the other hand, if the
steering wheel is turned slowly, the differential
pressure on both sides of the variable throttle in-
side the steering valve becomes larger, and the
pressure in chamber B becomes larger than the
pressure in chamber C, so spool (1) is pushed to
the left, and the area of the opening of portion d
becomes smaller to match the flow of oil needed
for the steering valve. It becomes balanced in this
position.
In other words, spool (1) moves in accordance
with the flow of oil needed for port CF to maintain
the differential pressure between chamber B and
chamber C at 1.0 MPa (10 kg/cm2), and adjusts
the opening of portion Id. (In this way, all the oil
not needed for the steering can be used at port
EF.)
When the oil from port CF enters the steering cy-
linder and load is applied, the pressure in the cir-
cuit rises. This signal forms the PLS circuit and is
fed back to the pump servo valve. The angle of
the swash plate in the pump changed to increase
the discharge amount, and to increase the press-
ure in the circuit. In this way, the EL circuit acts to
detect the hydraulic load on the steering and
feeds back this information to the pump.
1O-90
4. Steering cylinder at end of stroke
When the steering cylinder reaches the end of its
stroke, and the operator continues to turn the
steering wheel, the flow of oil to the cylinder is
stopped regardless of the opening of the steering
valve.
There is no flow of oil, so the CF and LS press-
ures rise together with the pressure at pump port
P, and at the same time, pressures PB and PC
also rise, and spool (I) is moved to the right.
If pressure PC goes above 17.2 MPa (175 kg/cm2),
relief valve (3), which is being pushed to the right
by spring (4), opens and drains the oil in chamber
C.
Because of this flow of oil, a difference in press-
ure on both sides of orifice b is created, and
pressure PC becomes lower than pressure PB. As
a result, spool (1) moves to the left to a position
where the oil flow inside the spool is 1 Q/min.
Spool (1) remains at a position where portion d
of the spool is throttled, and this prevents the 235FO2034
large loss when the oil is drained if the circuit is
relieved.
If spool (1) moves too far to the left, portion d is
closed and the oil stops flowing. The flow of oil
through orifice b stops, so pressure PC and
pressure PB become the same, and spool (I) is
moved again to the right by spring (2) to open
portion d. Because of this repeated action, the
pressure in the steering circuit is maintained at a
maximum of 17.2 MPa (175 kg/cm2).
235FO2035
10-91
6. Steering, work equipment operated simulta-
neously
1) When load on steering circuit is higher than
load on work
The actuation
as in Section
equipment
condition
3 When
circuit.
is basically
steering
the same
is operated
e 63
A 1
235FO2036
235FO2037
1 O-92
SURGE PRESSURE ABSORBING VALVE
B-B
A-A 235FO2038
1o-93
FUNCTION
. If the control lever is moved from an operating
position to neutral, the circuit between the pump
and the control valve is closed, but the pump
swash plate is prevented from returning to the
minimum swash plate angle by the inertia, so the
pump continues to discharge oil. As a result,
there is high pressure in the pump circuit (surge
pressure). This valve is installed to prevent this
high pressure.
. In order to obtain the necessary amount of oil dis-
charged from the pump when the work equip-
ment or steering are operated, it is necessary to
detect the highest pressure from the three inde-
pendent valves (left, right, main control valve,
steering valve), and to send this information to
the pump servo valve.
This valve also has the function of detecting the
highest pressure.
OPERATION
I. Control lever or steering operated
If we take the comparative size of the pressures
of the right control valve, left control valve, and
steering valve as PXI > PX3 > PX4, hydraulic
pressure PXI, which is the highest pressure, is
sent to chamber B by two shuttle valves (3) and
(4). At the same time, the pump discharge press-
ure is connected to port A.
The following forces are acting on spool (1).
Pressure to right from chamber A:
PXI + 2.0 MPa (20 kg/cm*)
[2.0 MPa (20 kg/cm*) is the differential press-
ure of the pump control pressure for the
valve.]
Pressure to left from chamber B:
PXI i- 2.4 MPa (24 kg/cm2) A. 1
[2.4 MPa (24 kg/cm2) is the converted hy-
draulic pressure for spring (2)]
The pressure in chamber B is larger, so valve (I)
is at the left and closes the drain port.
TO
priority flow 6
divider valve
235FO2039
1o-94
2. When operation of control lever or steering is
stopped
The moment the operation of the control lever or
steering is stopped, the circuit between the pump
and the valve is closed. However, because of iner-
tia, the pump swash plate does not return im-
mediately to the minimum swash plate angle, and
the pump continues to discharge oil, so there is
high pressure in the pump discharge circuit.
As a result, the pressure in chamber A rises
momentarily, and when it exceeds the pressure in
port B, valve (1) is moved to the right. This re-
leases the pressure in chamber A to the drain cir-
cuit and prevents the generation of surge press-
ure.
divider valve
235FO2040
1o-95
STRUCTURE AND FUNCTION HYDRAULIC CONTROL VALVE
12345
1-G H - H, J - J
K-K,L-L
F-F
B-B C-C.D--D
A-A
\
io
1O-96
0
STRUCTURE AND FUNCTION HYDRAULIC CONTROL VALVE
R.H. VALVE
(Right blade lift, Leaning, Articulate, Drawbar and Service)
G-G
8 9
J
A-A,B-B,C-C D-D E-E
\
10
235FO2042
1o-97
0
STRUCTURE AND FUNCTION HYDRAULIC CONTROL VALVE
H-H
G-G SWG00366
10-97-l
0
STRUCTURE AND FUNCTION HYDRAULIC CONTROL VALVE
R.H. VALVE
(Right blade lift, Leaning, Articulate, Drawbar shift and Service)
I 2 3 4 5
F-F
A-A, E-0
c-c. D-D
E-E
7
H-H
G-G SWG00369
10-97-2
0
PRESSURE COMPENSATING MECHANISM OF
HYDRAULIC CONTROL VALVE
Serial No.: 11001 - 12022
OPERATION
1. Control lever at neutral (immediately after en-
gine is started)
The oil discharged from the pump enters .cham-
C b B A 2
ber B from chamber A of pressure compensation
spool (2), and enters chamber C through orifice
b. The pressure in chamber C becomes greater
than the force of spring (3), so pressure compen-
sation spool (2) moves to the right.
When pressure compensation spool (2) moves to
the right, chamber A and chamber B are closed,
and control pressure 0.6 MPa (6 kg/cm2), which
balances with the force of spring (3), is supplied
to chamber B.
The hydraulic pressure from the pump does not
flow to the work equipment because the work
equipment circuit is closed by work equipment
spool (1).
235FO2043
1 O-98
0
2. When control lever is operated.
1) If the control lever is operated and work
equipment spool (1) moves to the left, the oil
from the pump enters chamber F from cham-
ber E of work equipment spool (I), passes
through chamber G, and is sent to the work
equipment.
The pressure in chamber G is transmitted to
spring chamber D through orifice a, and is
applied to the right end of pressure compen-
sation spool (2). When the pressure in cham-
ber D rises, pressure compensation spool (2)
moves to the left, pump circuit chamber A is
connected to chamber B, and the pressure in
chamber B rises.
The pump pressure passes through orifice b
and is applied to the left end of pressure com-
pensation spool (2), so the pressure in cham-
ber C rises. As the pressure rises, the force in
the left direction becomes greater, and when
it overcomes the sum of the pressure in
chamber D (load pressure) + the force of 235FO2044
spring (3), pressure compensation spool (2) is
pushed back to the right. At this point, the
force acting on pressure compensation spool
(2) is as follows.
Force in right direction = pump pressure
Force in left direction = load force f
force of spring (3)
In this condition, pressure compensation
spool (2) is balanced,,so the pressure on the
left and right sides is equal.
Pump pressure = load pressure + force of
spring (3)
The differential pressure on both sides of por-
tion H (chamber F, chamber G), which con-
trols the flow of oil for work equipment spool
(1) is determined and kept constant by the
force of spring (3) (approx. 0.6 MPa (6 kg/
cm2)).
1o-99
2) When the pressure for the work equipment
rises, the pressure in chamber G goes to
chamber D through orifice a, and the bal-
ance at pressure compensation spool (2) is
lost. Pressure compensation spool (2) is
pushed to the left and opens control corner
J at the bypass end, so the oil from the
pump passes from chamber A through cham-
ber B and flows to chamber G of work equip-
ment spool (1).
The pressure in chamber G rises, so the
pump pressure and the pressure in chamber
B also rise.
The pressure in chamber B passes to cham-
ber C through orifice b, so pressure com-
pensation spool (2) is pushed back to the
right, and pressure compensation spool (2)
again becomes balanced. The pressure dif-
ference on both sides of flow control portion
H (chamber F, chamber G) is taken as the
force of spring (3).
235FO2045
10-100
Serial No.: 12023 and up
OPERATION
The control valve acts to start, accelerate, decel- 1. Control lever at neutral (immediately after
erate, and stop actuators. engine is started)
A feature which is typical of these functions is The oil discharged from the pump enters
the metering function (the relationship between chamber B from chamber A. The pressure in
the control flow of the valve and the spool stroke chamber C becomes greater than the force
of the selector valve). This feature is obtained of spring (3), so pressure compensation spool
by controlling the throttle installed in the selec- (2) moves to the right.
tor valve by the amount the lever is controlled. When pressure compensation spool (2)
However, it has the disadvantage that it is the moves to the right, chamber A and chamber
influenced by the load pressure, so even if the B are closed, and control pressure, which
valve stroke is the same, it is fast when the load balances with the force of spring (31, is sup-
pressure is low and slow when the load pres- plied to chamber B.
sure is high. The hydraulic pressure form the pump does
To overcome this problem, it is necessary to not flow to the work equipment because the
keep the pressure difference on either side of work equipment circuit is closed by work
the control (throttle) constant to obtain a con- equipment spool (I ).
stant control flow regardless of the load pres-
sure. The pressure compensating mechanism is
used to perform this function.
- SWG00428
10-100-1
0
2. When work equipment lever is operated Pressure pushing to right = pump pressure
1) When work equipment spool (1) is The force pushing to the left = load pres-
moved up, the oil in chamber B passes sure + force of spring (31, so pressure
through chamber C of work equipment compensation spool (2) is kept in bal-
spool (1) and is sent to the actuator. ance in this condition.
At the same time, the pressure in cham- The forces to the left and right are equal.
ber C is transmitted from small hole a to Pump pressure = load pressure + force
spring chamber D and is applied to the of spring (31, so the difference in pres-
right side of pressure compensation sure at the front and rear sides of the
spool (2). flow control portion of work equipment
When the pressure in chamber D rises, spool (I) (chamber B and chamber C) is
spool (2) moves to the left. Pump circuit determined by the force of spring (3) and
chamber A is connected to chamber B, is kept constant.
and the pressure in chamber B rises. The
pressure in chamber B is applied to the
left end of pressure compensation spool
(2), so as the pressure in chamber B rises,
and the force to the right increases. When
it overcomes the combined force of the
pressure in chamber D (load pressure) +
force of spring (31, spool (2) moves to
the right. When this happens, the force
acting on pressure compensation spool
(2) is as follows:
1o- 100-2
0
2) When the pressure for the work equip- 3) When the pressure in the work equip-
ment rises, the pressure in chamber C ment goes down, the pressure in cham-
goes to chamber D through orifice a, ber C goes to chamber D through orifice
and the balance at pressure compensa- a I, and the balance at pressure com-
tion spool (2) is lost. Pressure compen- pensation spool (2) is lost. Pressure com-
sation spool (2) is pushed to the left and pensation spool (2) is pushed to the right
opens control corner E at the bypass and flow of oil through control corner
end, so the oil from the pump passes E at the bypass end is reduced.
from chamber A through chamber B and Because of this, pressure in chamber B
flows to chamber C of work equipment and chamber C goes down, so pressure
spool (I). compensation spool (2) is pushed back
The pressure in chamber C rises, so the to the left and pressure compensation
pump puressure and the pressure in spool (2) again becomes balanced. At
chamber B also rise. the point where the pressure difference
The pressure in chamber B pushes back on both sides of flow control portion
pressure compensation spool (2) to the (chamber B, chamber C) becomes the
right, and pressure compensation spool force of spring (3).
(2) again becomes balanced. The pres- In this way, pressure differnce AP on both
sure difference on both sides of flow sides of flow control portion is kept con-
control portion (chamber B, chamber C) stant, so if area S of the opening of flow
is taken as the force of spring (3). control portion is constant, oil flow Q
which passes through it remains con-
stant regardless of the load.
-
QOC (proprotional) S X liAP
SWG00429
1o- 100-3
0
BLADE LIFT SPEED ADJUSTMENT MECHANISM
Serial No.: 11001 - 12022
OUTLINE
. If there is a great difference in the blade lift speed
on the left and right, or if it is desired to reduce
the left and right blade speeds, it is possible to
adjust with the adjustment bolt.
l The adjustment bolt has an adjustment range of
4.8 turns, and if the adjustment bolt is loosened,
the cylinder speed will become slower.
FUNCTION
l When adjustment bolt (1) is loosened, the force of 2 3 1
spring (3) is reduced, so the force in the left direc-
tion is also reduced.
. In this condition, the differential pressure AP on
both sides of flow control portion H (chamber F,
chamber G) is reduced to balance pressure con-
trol spool (2).
l Therefore, oil flow Q passing through oil flow con-
trol portion H is reduced, and the blade lift cylin-
der speed becomes slower.
l On the other hand, if adjustment bolt (1) is
screwed in, oil flow Q increases, and the speed of
the blade lift cylinder becomes faster.
Q CC (proportional) S X p
(S = Area of opening at portion H)
235FO2047
1o- 100-4
0
Serial No.: 12023 and up
Outline
. If there is a great difference in the blade lift
speed on the left and right, or if it is desired
to reduce the left and right blade speeds, it
is possible to adjust with adjustment bolt
(I).
. If adjustment bolt (I) is loosened, the cylin-
der speed will become slower.
Operation
. When adjustment bolt (I) is loosened, the
force of spring (3) is reduced, so the force in
the left direction is also reduced.
In this condition, the differential pressure AP
on the front and rear sides of flow control
portion F (chamber B and chamber C) is re-
duced to balance pressure compensation
spool (2). Therefore, the oil flow passing
through oil flow control portion F is reduced,
and the blade lift cylinder speed becomes
slower. On the other hand, if adjustment bolt
(I) is screwed in, oil flow Q increases, and
the speed of the blade lift cylinder becomes
faster.
QOC (proprotional) S X m
(S = Area of opening at portion F)
SWG00431
PILOT CHECK VALVE
(For Blade lift R.H.)
1. Pilot valve
2. Check valve
F23501093
F23501092
OPERATION
When the control valve is operated to lower the
blade, pressure is generated at the bottom end of the
blade lift cylinder. This pressure passes through a
throttle and pushes pilot valve (1). This opens pilot
check valve (2), and the oil in chamber C at the
cylinder head returns to the tank. The blade hold
pressure is acting on the head end of the blade lift
cylinder. When it pushes open check valve (21, the oil
in chamber C suddenly escapes to chamber A, and
the pressure at the bottom drops.
When this happens, if there is no throttle at the pilot
valve, the check valve will always open and close ac-
cording to the changes in the pressure at the bottom
and head ends. This will cause blade chattering. To E
prevent this, a throttle is installed at E which acts as
a damper, so even if the pressure at the bottom end
drops, the check valve will not close immediately.
I F23501094
1o-1 02
PILOT CHECK VALVE
(For Articulate, Leaning and Drawbar)
1. Check valve
2. Piston
3. Body
4. Plug
,5
5. Plug
6. Check valve
Al A2
_ -
F23BH1115
F23BH1116
OPERATION
When the control valve is operated, the oil from the
pump enters port A,, opens check valve (61, and
flows into port B,. When a pressure is generated, the
oil from orifice E pushes up piston (2) and opens
check valve (1). so the oil connecting port B, and
port A, flows into the drain port.
Hunting occurs because check valve (1) opens and
closes in accordance with the fluctuations in pressure
at the bottom side and head side, but because of ori-
fice E, a damper effect is provided so that check
valve (1) will not close immediately even if the pres-
sure at port A, goes down.
F23BH1117
10-103
PILOT CHECK VALVE (WITH SAFETY VALVE)
(For Blade lift L.H.)
1. Check valve
2. Plug
3. Body
4. Piston
5. Relief valve
.-.
-----
.-.
'-1
hydraulic
cylinder
force.
R
I-
A2
L
Al
F23501099
OPERATION
When the lever is operated to retract the cylinder, oil
from the pump enters chamber AI and pushes check
valve (1). It then passes through chamber BI and
flows to the chamber at the head of the cylinder to
push the cylinder piston. The oil at the cylinder
bottom end flows back through chamber Bz and
chamber AZ and returns to the tank.
When the lever is operated to extend the cylinder,
the oil from the pump enters chamber A2 and flows
through chamber B2 to the cylinder bottom end. As
the pressure in chambers A2 and B2 rises, piston (4)
is pushed. This pushes open check valve (I ), and the
oil at the cylinder head flows from chamber BI
through the throttle of check valve (1). It then flows
from chamber AI hack to the tank.
If there is any shock to the work equipment during
operations, and the pressure in chamber BI rises to
an abnormal pressure of 280 kg/cm2 or more, relief
valve (5) is pushed open and the oil flows to chamber
B2. This raises the work equipment and relieves the
shock. 235F247
10-104
(For Ripper and Power tilt)
1. Check valve
2. Piston
3. Body
4. Check valve
5. Relief valve
-5
OPERATION
When the lever is.operated to extend the cylinder, oil
from the pump enters chamber A, and pushes piston
(2) and check valve (4). It then passes through cham-
ber B, and flows to the chamber at the bottom end
of the cylinder. The oil at the cylinder head flows
back through the chamber B, and chamber A, and
returns to the tank.
When the lever is operated to retract the cylinder, the
oil from the pump enters chamber A,. As the pres-
sure in chamber A, rises, check valve (I) is pushed.
This pushes open check valve (I), and the oil flows
to the cylinder head from chamber B,.
If shock causes abnormal pressure of over 280
kg/cm2 in chamber B,, it pushes open relief ,valve (5)
and oil flows to chamber B, to relieve the shock.
10-105
0
CIRCLE ROTATION MOTOR
Serial No.: 11001 - 12050
ME300-FTS
F23501104
1. Cover
2. Bearing
3. Thrust plate
4. Slipper retaining ring
5. Slipper
6. Spring
7. Piston
8. Bearing
9. Thrust retainer plate
10. Timing plate
1 1. Cylinder block
12. Shaft
13. Casing
lo-106
0
4
F23501105
1o-1 07
Serial No.: 12051 and up
ME150203AAAA
1. Housing
2. Key
3. Coupling shaft
4. Drive shaft
5. Wear plate
6. Rotor set
7. Manifold
8. Commutator ring
9. Commutator
IO. End cover
lo-108
0
BLADE ACCUMULATOR SYSTEM
235FO2048
i Iii 3
1.
2.
3.
Solenoid
Solenoid
valve
valve
Pilot check valve
(for blade float)
(for accumulator)
---- 4. Accumulator
5. Blade lift cylinder
6. Blade lift control valve
235FO2049
10-109
0
ACCUMULATOR
1. Cap
2. Shell
3. Bladder
4. Valve
5. Plug
6. Slow return valve
A: Nitrogen gas
B: Pressure oil (from blade cylinder)
C: From solenoid valve
t
C
SWG00004
FUNCTION
When oil pressure is applied to the blade cylin- shell (2) sends to the blade cylinder until the oil
der, the pressure oil flows to the accumulator pressure in the shell balances to that in blade
through the solenoid valve and pushes valve cylinder circuit. At this time, valve (5) closes
(6). This pushes valve (4), and the oil flows into throttling the return oil. This prevents the oil in
shell (2). Thereby, bladder (3) is compressed. shell (2) from flowing out abruptly and prevents
Consequently, the shock imposed on the blade the bladder from striking against the inside of
cylinder is reduced by the compressible amount the shell.
of the bladder. When the oil pressure in the The flow of oil in the accumulator hydraulic cir-
blade cylinder drops, the bladder expands by cuit is repeated smoothly to reduce the shock
the gas pressure in bladder (31, and the oil in imposed on the blade.
10-110
0
BLADE FLOAT SYSTEM
235FO2050
OUTLINE
l When the blade lift lever is at the N position, and
blade float switch (6) is turned ON, solenoid valve
(1) is actuated, and the bottom and head ends of
blade lift cylinder (3) are connected to the drain
circuit. This sets the blade in a floating condition. 2
l When blade float switch (6) is ON, and the blade
lift lever is operated to the RAISE or LOWER posi-
tions, switch (5) turns blade float switch (6), and
the blade returns to the normal RAISE or LOWER
condition, and this condition is maintained.
If the blade lift lever is returned to the N position,
the blade is placed in a floating condition.
t If the blade float switch is turned ON with the
blade raised, the blade will suddenly drop.
235FO2051
10-111
0
STRUCTURE AND FUNCTION DRAWBAR AND LIFTER
==- -==
==v -_==
i
__--
235CD02018
OUTLINE 1. Circle
The drawbar is an important piece of equipment 2. Drawbar
which supports the circle and blade. If ball joint (6) is 3. Blade lift cylinder
worn, use shim (5) to adjust the clearance at the joint 4. Drawbar side shift cylinder
so that there is no excessive play. When adjusting the 5. Shim
clearance at the contact portions of guides (8) and 6. Ball joint
(II), adjust with shims (7) and (IO), and adjustment
bolt (9).
10-112
0
STRUCTURE AND FUNCTION DRAWBAR AND LIFTER
114
F-F G-G
235CD02019
There are two cylinders installed in the lifter for mov- 7. Shim
ing the blade device. Brackets (14) and (16) are in- 8. Guide
stalled by the guide which is welded to the main 9. Adjustment bolt
10-113
0
STRUCTURE AND FUNCTION DRAWBAR AND LIFTER
OUTLINE 1. Circle
The drawbar is an important piece of equip- 2. Drawbar
ment which supports the circle and blade. If ball 3. Blade lift cylinder
joint (6) is worn, use shim (5) to adjust the clear- 4. Drawbar side shift cylinder
ance at the joint so that there is no excessive 5. Shim
play. 6. Ball joint
When adjusting the clearance at the contact por-
tions of guides (20) and (17), adjust with shims
(16) and (191, and adjustment bolt (15).
10-113-l
0
STRUCTURE AND FUNCTION DRAWBAR AND LIFTER
B-B
I8 5
G-G
17 F-F
SWG00376
There are two cylinders installed in the lifter for 7. Lifter bracket (Upper)
moving the blade device. Brackets (7) and (9) 8. Shim
are installed by the guide which is welded to 9. Lifter bracket (Lower)
the main frame. They can be revolved by re- 10. Yoke
volving the guide by extracting a pin (13) con- 11. Bolt
trolled from the operators seat. There are two 12. Pin
insertion holes altogether for the pin stopping 13. Pin
revolution. Holes b and c are used for the blade 14. Bushing
to make a bank cut to left or right. At other 15. Adjustment bolt
times, holes a are used. 16. Shim
These a get use much more than other holes 17. Guide
and bushing (14) is used in it to make the clear- 18. Bolt
ance between the pin and the hole at a mini- 19. Shim
mum. (This clearance amplifies the up and down 20. Guide
movement of the blade.) Also, the clearance
between the bracket and the guide welded to
the frame can be adjusted with shims (8). Pin
(12) combined with bolt (11) tightening force
prevents bracket up and down slippage.
10-113-Z
0
STRUCTURE AND FUNCTION BLADE
BLADE
V
\ \
6 1
Y
235CO02020
FUNCTION 1. Bracket
Side edge (5) installed to the blade is designed so that 2. Blade shift cylinder
it can be used twice by turning it upside-down and 3. Support
moving it to the other (left or right) side. 4. Blade
A power tilt device is installed to adjust the cutting 5. End bit
angle of the blade. Adjustment can be made freely be- 6. Bolt
tween 25 and 84 using a single lever. 7. Nut
The guide acts as a bushing for the sliding parts when 8. Cutting edge
shifting the blade to the side. If the clearance from the 9. Adjuster
sliding parts is too large and the finishing accuracy 10. Shaft
cannot be obtained, replace the guide.
10-l 13-3
0
STRUCTURE AND FUNCTION BLADE
FUNCTION 1. Bracket
Side edge (5) installed to the blade is designed 2. Blade shift cylinder
so that it can used twice by turning it upside- 3. support
down and moving it to the other (left or right) 4. Blade
side. 5. Side edge
A power tilt device is installed to adjust the cut- 6. Bolt
ting angle of the blade. Adjustment can be made 7. Nut
freely between 25 and 84 using a single lever. 8. Cutting edge
The guide acts as a bushing for the sliding parts 9. Adjuster
when shifting the blade to the side. If the clear- 10. Shaft
ance from the sliding parts is too large and the
finishing accuracy cannot be obtained, replace
the guide.
10-113-4
0
LIFTER BRACKET CONTROL PIPING
235CD02021
Detail A
F23501114
The lifter bracket is fixed by pin (3). When setting in the 1. Air tube
bank cutting position, operate control lever. This uses 2. Bank-lock valve
compressed air to push piston (4). The pin can be 3. Pin
removed and the bracket can then be rotated. 4. Piston
5. Spring
6. Bushing
10-114
CIRCLE ROTATION GEAR,
Serial No.: 11001 - 12050
6 7 8
F23501400
Outline 1. Cover
The circle rotation gear is driven by an oil motor 2. Spring
connected to worm gear shaft (17). 3. Disc
When the control valve is operated, disc (14) and 4. Plate
plate (15) are separated by pressurized oil, and the 5. Shaft
motive force is transmitted to pinion gear (9). If the 6. Case
control valve is not operated, disc (14) and plate 7. Worm wheel
(15) are pressed together by spring (13) and act as 8. Plug
a brake. Pinion gear (9) has a clutch mechanism, 9. Pinion gear
and if an abnormal rotating force is transmitted 10. Shim
from the blade, disc (3) slips to prevent breakage 11. Nut
of the blade. 12. Bolt
The clutch pressure of this clutch mechanism is ad- 13. Spring
justed by the thickness of shim (IO). 14. Disc
15. Plate
16. Drain plug
17. Worm gear shaft
10-115
0
Serial No.: 12051 and up
lo-116
0
REAR MOUNT RIPPER
-7 III
Section A-A
Section B-B
Section G-G
Section E-E
Section F-F
Section C-C Section D-D
F23501118
Ripper lifting height and digging depth can be con- 1 Ripper cylinder
trolled with ripper cylinder (1). Since the point tips 2. Pin
cut into the ground under the load of the rippers 3. Bracket
heavy weight, the ripper easily performs heavy-duty 4. Shank pin
digging work which cannot be done by the scarifier. 5. Shank
Two kinds of points are selectively used: A short 6. Point
point for heavy-duty work and a long point for ordi-
nary work.
10-l 17
0
HYDRAULIC CONTROL LINKAGE
1234 7 8 9 10
235FO2052
l Steering wheel and instrument panel tilting mech- 1. Blade lift R.H. lever
anism: 2. Service lever
Rotate tilt lever (11) to loosen the lock, move to a 3. Leaning lever
suitable position, then tighten the lever. 4. Articulate lever
The tilting angle can be adjusted steplessly 20. 5. Drawbar shift lever
l Console box tilting mechanism: 6. Circle rotation lever
Depress pedal (12) to remove the dowel pin, and 7. Power tilt lever
the console box can be adjusted in five stages. 8. Blade shift lever
In this way, the steering wheel and console box can 9. Ripper lever
be set to the optimum position for the operator. 10. Blade lift L.H. lever
11. Tilt lever
12. Pedal
lo-118
0
A-A
B-B
F-F
E-E
G-G
H-H 235FO2053
10-119
0
MAIN FRAME
1,//__-_____-_ ---
A-A
I. Main frame
2. Articulate cylinder
3. Center pin
4. Pin
5. Grease fitting
The main frame can be articulated 25to the left and right The front frame is made of one piece, so there is a good
from the center by the articulate cylinder (the articulat- view of the work equipment.
ing stopper is on the frame side). This is useful in reduc- In this mechanism, main frame center pin (3) and articu-
ing the turning radius, carrying out offset operations, es- late cylinder pin (4) are greased by grease coming from
taping from mud, and operating at corners. grease fitting (5) at the central greasing point.
10-120
0
STRUCTURE AND FUNCTION AIR CONDITIONER
AIR CONDITIONER
AIR CONDITIONER PIPING
(Refrigerant: for R-12)
SYSTEM DIAGRAM
swc00419
10-120-l
0
STRUCTURE AND FUNCTION AIR CONDITIONER
SYSTEM DIAGRAM
SWG00419
1o- 120-2
0
ELECTRICAL WIRING DIAGRAM
(l/3)
235CDO2025
10-121
0
ri
r--i
r7
l!lL
14
A-A
--- J Y
X
Z
235CDO2026
5. Final drive oil temperature sensor 12. Engjne oil pressure sensor
1o-1 22
0
(3/3)
I5
IO
14
11
13
I2
SDG00008
lo-123
0
Serial No.: 12013 - 12015, 12019 and up
lo-124
0
MONITOR PANEL, CLUSTER GAUGE AND PILOT LAMP
27 235CD0202B
23
10-125
0
Serial No.: 11031 and up
,22
23
27 26 25 24 SDG00009
10-126
0
(1/2)
Serial No.: 12013 12015, 12019 12098
023502
10-134
4
(2/2)
Serial No.: 12013 12015, 12019 12098
023502
10-135
4
(2/2)
Serial No.: 12099 and up
023502
10-136-1
4
STRUCTURE AND FUNCTION ELECTRICAL CIRCUIT DIAGRAM
CN-TO1 Rotary
Diode
______
I Transmission
; solenoid valve
SWG00437
10-137
0
STRUCTURE AND FUNCTION ELECTRICAL CIRCUIT DIAGRAM
CN-RPB
Relay
(parking
brake1
iJJ Diode
SWG00438
lo-138
0
STRUCTURE AND FUNCTION ELECTRICAL CIRCUIT DIAGRAM
FR detect
Caution buzzer Cautlan buzzer
CN-RDI
I
yifferential
ock relay
lamp
used)
Inching
CN_TM,, Potentio mete
,.___________
#- SWG00440
STRUCTURE AND FUNCTION ELECTRICAL CIRCUIT DIAGRAM
10-141-2
4
STRUCTURE AND FUNCTION ELECTRICAL CIRCUIT DIAGRAM
Blower unit
i______d L_______-__d
/ L----i 4L. P S H.P S
Air conditioner Blower switch Thermostat
switch SWG00441
10-143
0
STRUCTURE AND FUNCTION ELECTRICAL CIRCUIT DIAGRAM
CN-AI
CN-AL
Blower high
relay CN-A9
Blower main
relay CN-A8
20
21
ii
24
25
Magnet ic
clutch
relay CN-A12
Blower Ml
SWG00442
10-144
0
STRUCTURE AND FUNCTION ELECTRICAL CIRCUIT DIAGRAM
r-k
If--!
CN-A6
I
Damper ~ ComPressor
Air
-
conditioner I 4
CN-A3 unit I-
CN-27
Pressure
II
From
Lisnt switch
Fuse box
CN-
SWG00443
10-145
0
STRUCTURE AND FUNCTION ELECTRONIC VEHICLE MONITORING SYSTEM (EVMS)
-4A
2A
5A
ii 5c 5D 5E 5F 235COO2032
10-147
0
STRUCTURE AND FUNCTION ELECTRONIC VEHICLE MONITORING SYSTEM (EVMS)
3E 30 3C 38 3A 6 7 6
4A
2A 48
9
IO
4c
5B
10-148
0
STRUCTURE AND FUNCTION ELECTRONIC VEHICLE MONITORING SYSTEM (EVMS)
Cate-
Symbol Indication item Indication range Description
gory
Below specified
Engine oil pressure
pressure
Below specified
Air pressure
pressure
--
-0 High beam When operated
Displays when starting switch is turned ON;
4D
Lights up when operated
Turn signals (right, left) When operated
0 Service meter indicator When operated Flashes when service meter is operating
10-149
0
STRUCTURE AND FUNCTION ELECTRONIC VEHICLE MONITORING SYSTEM IEVMS)
Cate-
Symbol Indication item Indication range Description
gory
Red 115OC
102.3-C
97OC
Coolant temperature ;reen
90C One lamp lights up to indicate level
80C
67C
White
FULL
Red EMPTY
L
10-150
0
STRUCTURE AND FUNCTION ELECTRONIC VEHICLE MONITORING SYSTEM (EVMS)
Cate-
Symbol Indication item Indication range Description
gory
al s0c000!8
Coolant level Below low mark
Below specified
Engine oil pressure
pressure
@I~
SDP00957
Coolant temperature Above 105C
Below specified
Air pressure
pressure
--
--
- High beam When operated
Service meter indicator When operated Flashes when service meter is operating
0
SKD00632
10-151
0
STRUCTURE AND FUNCTION ELECTRONIC VEHICLE MONITORING SYSTEM (EVMS)
Cate-
Symbol Indication item Indication range Description
gory
El
Red 115c
lOZf3'C
97-c
al
SDP00957
Coolant temperature Green 90"c
80"c
One lamp lights up to indicate level
67C
White
SWG00461
FULL
;reer
Fuel level All lamps light up below indicated level
SAD00712
led EMPTY
SWG00462
10-152
0
STRUCTURE AND FUNCTION TRANSMISSION CONTROL SYSTEM
TRANSMISSION CONTROLLER
1. Display window
2. Connector
CNl cN2
2 SWCOO388
Outline
The transmission controller controls the system, 2) Prevention of overrun of engine or trans-
and has a built-in computer. When the operator mission
operates the shift lever, this is transmitted to When the transmission is shifted down, it
the controller, and the controller observes the judges if there is overrun of the engine or
condition of the machine and shifts to the speci- transmission, and does not shift down until
fied speed range. In this way, it is possible to the travel speed will not cause any overrun.
prevent excessive load on the transmission and If the machine is accelerated with the clutch
engine caused by any failure or mistaken opera- still partially engaged (acceleration caused
tion by the operator. by the weight of the machine when traveling
down hill), it shifts up at above the travel
Protective functions of transmission speed that is dangerous for the speed range
1) Observing disconriections or short circuits for the lever position.
It judges if there is any abnormality in the 3) Observing excessive inching load
transmission switch signals and uses a dou- It calculates the temperature of the clutch
ble system to prevent damage to the trans- and plate from the length of time that the
mission clutches. clutch is partially engaged, and warns of
If there is any abnormality, it carries out con- overheating of the clutch.
trol to prevent the clutch for that speed range
from being meshed.
10-154
0
STRUCTURE AND FUNCTION TRANSMISSION CONTROL SYSTEM
F R 1 2 3 / 4 / L / H j ST 1 FB 1 DF 1 PB 1 PL 1
Parking lamp
Parking brake
Backup buzzer
Starting motor
Differential lock solenoid
Transmission H clutch solenoid
Transmission L clutch solenoid
Transmission 4 clutch solenoid
Transmission 3 clutch solenoid
Transmission 2 clutch solenoid
Transmission 1 clutch solenoid
Transmission R clutch solenoid
Transmission F clutch solenoid
10-155
0
STRUCTURE AND FUNCTION SENSORS
SENSORS
1. Sub-tank
I 2. Float
3. Sensor
4. Connector
Construction of wrcuit
lo-156
0
STRUCTURE AND FUNCTION SENSORS
1 2 3 4 5 6
1. Plug
2. Contact ring
3. Contact
4. Diaphragm
5. Spring
6. Terminal
Function
. The engine oil pressure switch is installed to
the engine cylinder block. It uses a dia-
phragm to detect the oil pressure, and when
it goes below the specified pressure, the
switch is turned ON. The engine oil pressure
indicator lamp lights up to warn of the ab-
normality.
@&- 1.
2.
3.
Connector
Plug
Thermistor
@%!I
Composition of circuit
SBPO0379
Function
. The engine water temperature sensor is in- the final drive case. They send a signal to
stalled to the right side of the engine. the monitor panel. If the temperature goes
Thermistor (3) detects the temperature and above the specified temperature, the warn-
sends a signal to the monitor panel. The ing lamp flashes and the alarm buzzer
monitor panel displays the water tempera- sounds to warn of the abnormality.
ture according to that signal. If the tempera- The transmission oil temperature sensor is
ture goes above the specified temperature, installed to the transmission oil piping and
the warning lamp flashes and the alarm sends a signal to the transmission control-
buzzer sounds to warn of the abnormality. ler. If the temperature goes above the speci-
. The hydraulic oil temperature sensor is in- fied temperature, the warning lamp flashes
stalled to the hydraulic tank and the final and the alarm buzzer sounds to warn of the
drive oil temperature sensor is installed to abnormality.
STRUCTURE AND FUNCTION SENSORS
SPEEDOMETER SENSOR
ENGINE SPEED SENSOR
I c1
20 a
1 2 3 4
I --?
F9 5
ii 0.85fG 1
._. 0.85fG 2
0 c
b Structure of circuit
SEW00289
1. Magnet Function
2. Terminal . The speedometer sensor is installed to the
3. Case transmission output gear. A pulse voltage is
4. Boot generated by the rotation of the gear teeth,
5. Connector and the signal is sent to the machine moni-
tor to display the travel speed.
. The engine speed sensor is installed to the
ring gear portion of the flywheel housing.
A pulse voltage is generated by the rotation
of the gear teeth, and a signal is sent to the
transmission controller.
Function
. The air pressure sensor is installed to the air
tank. Any change in the air pressure inside
the air tank is converted to a change in the
1. Connector resistance, and a signal is sent to the air
2. Frame pressure gauge to display the air pressure.
lo-158
0
STRUCTURE AND FUNCTION SENSORS
1. Plug
2. Diaphragm
3. Switch
4. Wire
5. Connector
Function
. The air pressure switch is installed to the air
tank. The diaphragm detects the air pres-
sure, and when it goes below the specified
pressure, it shuts off the electric current from
the machine monitor. The warning lamp then
flashes, and the alarm buzzer sounds.
1. Connector
2. Bracket
3. Sensor
4. Switch
Composition of
circuit
SBPOO376
10-159
0
STRUCTURE AND FUNCTION SENSORS
1. Float
2. Switch
3. Plug
4. Connector
m
Construction of
1
circuit SWG00448
Function
. The hydraulic oil level switch is installed to
the hydraulic tank, and the float moves up
and down according to the oil level. If the oil
goes below the specified level, the switch is
turned OFF, the warning lamp flashes, and
the alarm buzzer sounds.
FUEL LEVEL SENSOR
1. Connector
2. Float
3. Arm
4. Body
5. Spring
6. Contact
7. Spacer
Structure
of circuit
Function A-A SBD02295
. The fuel level sensor is installed to the
center of the front face of the fuel tank.
Float (2) moves up and down according
to the fuel level.
As the float moves up and down, arm (3)
actuates a variable resistance, and this
sends a signal to the sub monitor to dis-
play the fuel level.
10-160
0
STRUCTURE AND FUNCTION SENSORS
SHIFT POTENTIOMETER
INCHING POTENTIOMETER
1. Lever
2. Sensor
3. Connector
Construction of circuit
//
!
ua
I
i,, SWG00449
Function
. The shift potentiometer is installed to the
shift lever, and sends a signal to the trans-
mission controller according to the amount
that the lever is operated. The transmission
controller controls the speed range of the
transmission according to this signal.
The inching potentiometer is installed to the
inching linkage at the transmission end, and
sends a signal to the transmission controller
according to the amount that the inching
pedal is depressed. It is used to detect inch-
ing overload.
lo-161
0
STRUCTURE AND FUNCTION ENGINE STARTING CIRCUIT
Engine
staD
lnator
relay
Monitor module
\
Non-continui
port ion
(hatched DO,
Parking End
brake lamp
_
start Ina Alternator
motor
Fuse box
Transmission
control box
CN-RST
Start ins
Rotary motor relay
switch
SWG00450
10-162
0
STRUCTURE AND FUNCTION ENGINE STARTING CIRCUIT
Function
Starting motor terminal E is separated from the
ground only when the shift lever is at the neu-
tral position, the parking switch is ON, and the
starting relay coil is energized. If it is not in this
condition, it is impossible to start the engine.
Operation
1. When the starting switch is turned to the 7. If the parking brake switch is turned to the
ON position, electricity flows from battery ON position, electricity flows from battery
+ starting switch terminals B - BR + en- relay + fuse + parking switch terminals 1 -
gine stop motor relay terminals 1 - 2 + 2 + starting motor relay (CN RST) terminals
ground, and the relay coil is energized. 1 - 2 + ground, and the relay coil is ener-
gized.
2. The electric current from the battery flows
from engine stop motor terminals A - B + 8. In this condition, if the starting switch is
relay terminals 5 - 3 + motor, and rotates turned to the START position, electric cur-
the motor. rent flows from starting switch terminals B -
C + starting motor terminal S + terminal E
3. When the motor rotates, terminal D also ro- + starting motor relay (CN RST) terminals 5
tates at the same time. When the non-con- - 3 + starting motor relay (CN RST) termi-
tinuous portion of terminal D reaches termi- nals 3 - 5 + ground.
nal B, the circuit from terminal A to B opens,
and the current from the battery to the mo- 9. A circuit is formed from the battery + bat-
tor is shut off. The motor attempts to con- tery relay + starting motor terminal B, so
tinue rotating under inertia, but when the the engine starts.
continuous portion of terminal D contacts
terminal B, both poles of the motor are con- If the shift lever is not at the N position,
nected to the ground, and the motor stops electricity is not supplied to terminal 1
rotating. of the starting motor relay (CN RST).
Terminals 3 and 5 of the relay remain
4. In this condition, the engine stop motor ca- open, so the circuit in Item 6 is not
ble is completely extended, and the fuel in- formed, and the engine does not start.
jection pump lever is set to the FULL posi-
tion to place it in the operating condition. In addition, if the parking switch is not
ON, electricity is not supplied to termi-
5. In addition, the current flows from starting nal 1 of the starting motor relay (CN
switch terminal BR + battery relay coil -+ RPST). Terminals 3 and 5 of the relay
ground, and the battery relay switch is remain open, so the circuit in Item 7 is
closed. not formed, and the engine does not
start.
6. Furthermore, if the shift lever is at the neu-
tral position, electric current flows from the
battery relay + fuse + starting motor relay
(CN RST) terminals 1 - 2 + rotary switch
terminals 2 - 11 + ground, and the relay
coil is energized.
10-163
0
STRUCTURE AND FUNCTION ENGINE STARTING CIRCUIT
Engine
stop
motor
relay
Monitor module II
I I
CN-25
- 4 I
CN-PL
Parkine
End
brake IamP
Service meter
StartIn Alternator
motor
Fuse box
Transmission
control box
Startin
Rotary motor rel
switch
Parklna
brake rel
SWG0045 I
lo-164
0
STRUCTURE AND FUNCTION ENGINE STARTING CIRCUIT
Function
Starting motor terminal E is separated from the
ground only when the shift lever is at the park-
ing position and the starting relay coil is ener-
gized. If it is not at the parking position, it is
impossible to start the engine.
Operation
1. When the starting switch is turned to the 6. Furthermore, if the shift lever is at the park-
ON position, electricity flows from battery ing position, electric current flows from the
--f starting switch terminals B - BR + en- battery relay + fuse -+ starting motor relay
gine stop motor relay terminals 1 - 2 -+ terminals 1 - 2 + rotary switch terminals 1 -
ground, and the relay coil is energized. 11 + ground, and the relay coil is energized.
2. The electric current from the battery flows 7. In this condition, if the starting switch is
from engine stop motor terminals A - B + turned to the START position, electric cur-
relay terminals 5 - 3 + motor, and rotates rent flows from starting switch terminals B -
the motor. C -+ starting motor terminal S + terminal E
-+ starting motor relay terminals 3 - 5 +
3. When the motor rotates, terminal D also ro- ground.
tates at the same time. When the non-con-
tinuous portion of terminal D reaches termi- 8. A circuit is formed from the battery + bat-
nal B, the circuit from terminal A to B opens, tery relay + starting motor terminal B, so
and the current from the battery to the mo- the engine starts.
tor is shut off. The motor attempts to con-
tinue rotating under inertia, but when the . If the shift lever is not at the parking
continuous portion of terminal D contacts position, electricity is not supplied to ter-
terminal B, both poles of the motor are con- minal 1 of the starting motor relay. Ter-
nected to the ground, and the motor stops minals 3 and 5 of the relay remain open,
rotating. so the circuit in Item 6 is not formed,
and the engine does not start.
4. In this condition, the engine stop motor ca-
ble is completely extended, and the fuel in-
jection pump lever is set to the FULL posi-
tion to place it in the operating condition.
lo-165
0
STRUCTURE AND FUNCTION ENGINE STARTING CIRCUIT
Function
Starting motor terminal E is separated from the
ground only when the transmission controller
recognizes the parking command and the start-
ing relay coil is energized. If the shift lever is not
at the parking position, it is impossible to start
the engine.
Operation
1. When the starting switch is turned to the 6. Furthermore, if the shift lever is at the park-
ON position, electricity flows from battery ing position, electric current flows from the
+ starting switch terminals B - BR -+ en- transmission controller + starting motor re-
gine stop motor relay terminals 1 - 2 -+ Jay terminals 1 - 2 -+ ground, and the relay
ground, and the relay coil is energized. coil is energized.
2. The electric current from the battery flows 7. In this condition, if the starting switch is
from engine stop motor terminals A - B + turned to the START position, electric cur-
relay terminals 5 - 3 + motor, and rotates rent flows from starting switch terminals B -
the motor. C + starting motor terminal S + terminal E
+ starting motor relay terminals 3 - 5 +
3. When the motor rotates, terminal D also ro- ground.
tates at the same time. When the non-con-
tinuous portion of terminal D reaches termi- 8. A circuit is formed from the battery -+ bat-
nal B, the circuit from terminal A to B opens, tery relay + starting motor terminal B, so
and the current from the battery to the mo- the engine starts.
tor is shut off. The motor attempts to con-
tinue rotating under inertia, but when the . If the shift lever is not at the P position,
continuous portion of terminal D contacts electricity is not supplied to terminal 1
terminal B, both poles of the motor are con- of the starting motor relay. Terminals 3
nected to the ground, and the motor stops and 5 of the relay remain open, so the
rotating. circuit in Item 7 is not formed, and the
engine does not start.
4. In this condition, the engine stop motor ca-
ble is completely extended, and the fuel in-
jection pump lever is set to the FULL posi-
tion to place it in the operating condition.
lo-167
0
STRUCTURE AND FUNCTION ENGINE STOPPING CIRCUIT
CN-53 CN-15
Engine
stop
motor
relay
Monitor module
Service meter
CN-SH
w
StartIne Alternator
motor
t
______.._.__ ~__._ -.-..-.- ------ -~~ 7 _.__.__ ~_
Transmission
z
control box
CN-RST
Start ine
Rotary motor relay
switch
SWG00453
lo-168
0
STRUCTURE AND FUNCTION ENGINE STOPPING CIRCUIT
CN-53 CN-15
Engine
stop
motor
relay
Monitor module
II
CN-25
ir Engine
stop motor
\
Non-continuity
port ion
(hatched portion)
Parking End
brake IamP
Startin
snitch
Service meter
Transmission
control box
Start ino
motor relay
Rotary
switch
Parking
brake relay
SWG00454
1O-l 69
0
20 TESTING AND ADJUSTING
TROUBLESHOOTING . . _. 20-39
20-l
A When carrying
pins, block the wheels,
out testing
and apply
and adjusting,
the parking
or troubleshooting,
brake.
stop the machine on level ground, fit safety
A When
thorized
carrying
person
out operations
near the machine.
with two or more workers, always use signals, and do not allow any unau-
A When checking the water level, if the radiator cap is removed when the engine is hot, boiling water will
spurt out and may cause burns, so always wait for the engine to cool down before checking the water
level.
A Be extremely careful not to get caught in the fan or any other rotating parts.
A When
release
removing
the internal
the plugs
pressure
or caps
first.
from
Fit the
places
measuring
under hydraulic
tools securely
pressure,
before
water
carrying
pressure,
out any
or air pressure,
testing, adjust-
ing, or troubleshooting.
* When using the standard values table for judgement in testing, adjusting, or troubleshooting, it is necessary to
be careful of the following points.
1. The standard values for the new machines in the standard values table are values given as reference from the
standards for new machines and machines shipped from the factory. They should be used as values for esti-
mating wear during operation or as target values when carrying out repairs.
2. The failure judgement standard values in the standard value table are values using estimated values based on
the results of various tests and standard values for machines shipped from the factory. Use these values for ref-
erence together with the repair and operation history of the machine when judging failures.
3. Do not use this standard values table as a standard for judging claims.
20-2
TESTING AND ADJUSTING STANDARD VALUE TABLE FOR ENGINE
Engine I S6D140-1
Classifi
cation
Item Condition Unit Standard value Permissible value
Quick acceleration
Bosch scale Max. 5.0 7.0
(Low idling + High idling)
Exhaust gas color
At high idling Bosch scale Max. 1.5 2.5
Compression Oil temperature: 40 - 60C VlPa {kg/cm? Max. 3.1 I321 2.2 (22)
pressure
(SAE30 oil) (Engine speed) (rpm) (160 - 200) (160 - 200)
+ The values given in the TESTING AND ADJUSTING DATA are NOT for adjustment of the output.
Do not use these values as a guide to change the setting of the fuel infection pump.
20-3
0
TESTING AND ADJUSTING STANDARD VALUE TABLE FOR ENGINE
Engine S6D140E-2
Classifi-
cation Item Condition Unit Standard value Iermissible value
ga,
PC
0 Engine
High idling speed mm 2,350 f 50 2,350 + 50
-
tm
a
Low idling speed mm 650 +;
Quick acceleration
Bosch scale Max. 4.0 6.0
(Low idling + High idling)
Exhaust gas color
At high idling Bosch scale Max. 1.0 2.0
Compression Oil temperature: 40 - 60C MPa {kg/cm? Max. 3.8 139) 2.7 f27)
pressure
(SAE30 oil) (Engine speed) (rpm) (160 - 200) (160 - 200) 8
z
zz
(Water temperature inside
Blow-by pressure operating range)
tPa ImmH,O) Max. 0.98 UOO) 1.96 1200)
(SAEBO oil)
At rated output
At high idling (SAE 30) MPa (kg/cm? 0.3 - 0.5 (3.0 - 5.0) 0.2 (2.0)
Oil pressure
(SAE30 oil) At high idling (SAE IOW) MPa Ikg/cm*) 3.25 - 0.44 (2.5 - 4.5)t 0.18 (1.8)
At low idling (SAE 30) MPa Ikg/crr+) 0.12 (1.2) 0.07 (0.7)
At low idling (SAE IOW) MPa {kg/cm? 0.10 (1.0) 0.07 (0.7)
Oil temperature All speed (Oil in oil pan) C 80- 110 120
Alternator belt
13- 16
tension
Deflects when pushed with
mm
a force of 58.8 N 16 kg)
Fan belt tension 17 - 19
* The values given in the TESTING AND ADJUSTING DATA are NOT for adjustment of the output.
Do not use these values as a guide to change the setting of the fuel infection pump.
20-3-l
STANDARD VALUE TABLE FOR TESTING AND
TESTING AND ADJUSTING ADJUSTING, FAILURE JUDGMENT OF CHASSIS
Compo
nent
-
- TOGO0001
Operating effort
. Engine stopped 127.5 5 19.6 127.5 f 49.0
. Max. value to just before end of travel {I3 rt 2) {13 + 51
Operating effort
. Engine stopped
. Max. value to just before end of travel
&I 13.0
29.4 +f 0.51
4.9 13.0
29.4 *f 0.5)
4.9
. Engine stopped
Travel . Travel at tip of lever for each mm 27f 10 27+ 12
speed range
Lubrication oil
I 1.1 f 0.1
{II f I} I
-
20-4
0
STANDARD VALUE TABLE FOR TESTING AND
TESTING AND ADJUSTING ADJUSTING, FAILURE JUDGMENT OF CHASSIS
Camber
I
-----I
Toe-in . Flat, paved road surface
Leaning angle
I I deg 19.5 + 1.5
I
19.5 rt 1.5
N H Left
Leaning N H Right 30 + 5 30 f 10.0
N H Left
Articulating N H Right 35 + 5 35 + 10.0
. Engine: N tf Left
F Blade side shift Stopped N tf Right 30 + 5 30 * 10.0
2 . . Measure at mm
I= Drawbar side tip of lever N tf Left
shift N ti Right 30 f 5 30 + 10.0
N ++ Left
Circle rotation N tf Right 30 * 5 30 + 10.0
N ti Tilt forward
Power tilt N H Tilt back 35 f 5 35 f 10.0
N t;, RAISE
Ripper N tj LOWER 35 f 5 35 * 10.0
20-5
0
STANDARD VALUE TABLE FOR TESTING AND
TESTING AND ADJUSTING ADJUSTING, FAILURE JUDGMENT OF CHASSIS
T
-
Compc
Item Measurement conditions Standard value Service limit value
nent LJnit for new machine
Leaning
N t)
N t)
Left
Right I 19.6 - 34.3
{2 - 3.5) I
Max. 39.2
{Max. 4.0)
Articulating
N
N tf
H Left
Right I 14.7 - 29.4
{I .5 - 3.0) I
Max. 39.2
{Max. 4.0)
. Engine: N tf Left
Blade side shift
Stopped N H Right
. Max. value ~ -
Drawbar side to end of N tf Left 19.6 - 34.3 Max. 39.2
shift travel N tf Right {2 - 3.5) {Max. 4.0)
20-6
0
STANDARD VALUE TABLE FOR TESTING AND
TESTING AND ADJUSTING ADJUSTING, FAILURE JUDGMENT OF CHASSIS
20-7
0
STANDARD VALUE TABLE FOR TESTING AND
TESTING AND ADJUSTING ADJUSTING, FAILURE JUDGMENT OF CHASSIS
Standard value
Item Measurement conditions Unit for new machine Service limit value
Engine
water
cooling
I Max.102
I
Max. 102
Engine oil
8 temperature . Oil and water levels are normal
E Transmission oil
. Air temperature 40C
. Continuous traction IF-21
2 C
. On a concrete road surface
z . Using thermistor
z! Performed with thermostat
open
20-7-l
0
TOOL LIST FOR TESTING AND ADJUSTING
For engine
Water temperature,
Digital temperature
oil temperature, B 799-l 01-l 502 -99.9 - 1,299c
Gauge
exhaust temperature
1 799-l 01-5002 Analog hydraulic Pressure gauge: 2.5, 5.9,39.2, 58.8 MPa
tester (25, 60,400,600 kg/cm2)
Compression pressure
20-8
0
For chassis
No. Testing and measuring item Tool Name Part No. Remarks
Pressure gauge:
Analog hydraulic 2.5, 5.9, 39.2, 58.8 MPa
3 Oil pressure 799-l 01-5002
tester (25,60,400,600 kg/cm2)
Commercially 2 m
5 Measuring travel Convex scale
available
Commercially
6 Tire runout Dial gauge 0.1 - 5 mm
available
Commercially
7 Tire inflation pressure Tire gauge 0 - 1 .O MPa (0 - 10 kg/cm2)
available
I
I I I
Commercially
SI 8 Camber Camber gauge
available
%
2
Commercially
10 Wear of brake lining Vernier calipers 150 mm - 200 mm
available
Commercially
11 Brake distance Tape measure
available
30 m
I I I I
20-9
TESTING AND ADJUSTING VALVE CLEARANCE
0.43 mm I 0.80 mm
I TDD00714
20-l 0
0
5. Then rotate the crankshaft in the normal direction by
one turn and adjust the valve clearance for the re-
maining valves marked o.
* After adjusting No. 1 cylinder at compression
top dead center, it is also possible to turn the
crankshaft 120 each time and adjust the valve
clearance of each cylinder according to the firing
order.
l Firing order: 1 - 5 - 3 - 6 - 2 - 4
MEASURING COMPRESSION
PRESSURE
235FO2057
20-l 1
0
TESTING AND ADJUSTING FUEL INJECTION TIMING
Serial No.: 11001 - 12000
20-12
0
3. Remove spring (9) and delivery valve (10) from the
delivery valve holder (8), and reassemble the de-
livery valve holder (8).
20-l 3
TESTING AND ADJUSTING TESTING AND ADJUSTING FUEL INJECTION TIMING
1. Testing
1) Procedure for fixing crankshaft in position
i) Pull out pin (I), and remove nut (2).
ii) Rotate the crankshaft in the normal di-
rection and align pointer (4) with the fuel
injection line on top of damper (3).
* When doing this, check that line (5)
on the injection pump camshaft is
near the line on the pump case. If it
cannot be seen, rotate the crankshaft
one more turn.
iii) Push in lock pin (7) towards the engine
and rotate the crankshaft to insert pin
(7) into the hole in gear (8).
2) In this position, check the position of line (5)
on the injection pump camshaft and line (6)
on the pump case.
Note: In this condition, do not start the engine
or try to crank it by force.
2. Adjusting
If the line in Step l-2) is not aligned, adjust as
follows.
I) Loosen coupling bolts (9) and nuts (IO) at
two places.
2) Rotate camshaft (11) to align line (5) on the EEP01138
camshaft completely with line (6) on the in-
jection pump case.
3) Tighten bolts (9) and nuts (IO).
w Nut :
61.25 + 2.45 Nm t6.25 f 0.25 kgm}
BEPOll
20-13-l
0
MEASURING BLOW-BY PRESSURE
2 3
235FO2059
20-14
4) In the condition in Step 3), measure the blowby
pressure.
A The blade moves during the measurement,
so be careful to avoid the contact shown in
the diagram, and stop operation of the
lever before there is any contact.
A: A Be careful not to let the work
equipment hit the main frame.
b: AB e careful not to let the blade hit
the tire.
235FO2060
A When
rotating
measuring,
parts.
be careful not to get caught in
20-15
MEASURING EXHAUST GAS COLOR
Fl RM02216A-K
20-l 6
MEASURING EXHAUST GAS
A When removing
_
or installing measuring equip-
ment, be caretul not to touch any hot parts.
the tire.
235FO2060
20-17
MEASURING INTAKE AIR PRESSURE (BOOST PRESSURE)
Note:
Run the engine at a mid-range speed or above, then
use the self-seal portion of the gauge to remove oil
from inside the hose.
* Insert the gauge about half-way and repeat the
movement to open the self-seal and remove the
oil.
* If there is any oil inside the hose, the gauge will
not move, so always be sure to remove the oil.
235FO2059
20-l 8
4) In the condition in Step 3), measure the boost
pressure. I
A The blade moves during the measurement,
so be careful to avoid the contact shown in
the diagram, and stop operation of the
lever before there is any contact.
A: A Be careful not to let the work
equipment hit the main frame.
B: AB e careful not to let the blade hit
the tire.
AA BA
235FO2060
1. Fan belt
1) Testing
Check that the deflection of the belt is within
the standard range when central portion a be-
tween fan pulley (2) and belt tension adjustment
pulley (1) is pressed with a force of approx.
58.8 N (6 kg). If it is not within the standard
value, adjust the belt tension.
* Standard belt tension: 5 - 9 mm
2) Adjusting
Use adjustment bolt (3) to adjust the belt ten-
sion as follows.
If deflection is too LARGE, TIGHTEN bolt
b
If deflection is too SMALL, LOOSEN bolt
2. Alternator belt
1) Testing
Check that the deflection of the belt is wihin the
standard range when central portion b be-
tween alternator (4) and accessory pulley (5) is 235FO2062
pressed with a force of approx. 58.8 N (6 kg). If
it is not within the standard value, adjust the
belt tension.
* Standard belt tension: 8 - 12 mm
2) Adjusting
i) Loosen belt tension adjustment bolt (6) and
mount bolt (7) of alternator (4).
ii) Using a bar, pull alternator (4) up to adjust
the belt tension, then tighten adjustment bolt
(6) and mount bolt (7).
20-l 9
0
Serial No.: 12001 and up
1. Fan belt
1) Testing
Check that the deflection of the belt is within
the standard range when central portion a
between fan pulley (2) and belt tension ad-
justment pulley (I) is pressed with a force of
approx. 98 N {IO kg}. If it is not within the
standard value, adjust the belt tension.
* Standard belt tension: 17 - 19 mm
2) Adjusting
If the deflection of the belt is too loose, a
tighten adjustment bolt (3); if the tension is
too tight, loosen adjustment bolt (3).
TEGOOOOZ
2. Alternator belt
1) Testing
Check that the deflection of the belt is within
the standard range when central portion a
between alternator pulley (I) and accessory
pulley (2) is pressed with a force of approx.
98N {IO kg}. If it is not within the standard
value, adjust the belt tension.
Ir Standard belt tension: 13 - 16 mm
2) Adjusting
i) Loosen mounting bolt (3) of the alterna-
tor assembly and locknut (4) of the belt
tension adjustment bolt.
ii) Turn adjustment nut (5) to move the al-
ternator assembly and adjust the tension
of belt (6). After adjusting, tighten locknut
(41, adjustment nut (5), and alternator as-
sembly mounting bolt (3).
iii) After adjusting the belt tension, check
again that deflection a of the belt is
within the standard value.
TLD00026
20-19-l
0
PROCEDURE FOR ADJUSTING THE ENGINE STOP
MOTOR CABLE
20-20
ADJUSTING ACCELERATOR CONTROL
A-A
235FO2064
20-2 1
INCHING PEDAL TRAVEL AND OPERATING FORCE
i
235FO2065
20-22
0
CHECKING DIFFERENTIAL LOCKING DEVICE OIL PRESSURE
Special tool
*
ure.
One turn of the set screw adjusts the hydraulic
n
pressure by 0.4 MPa (4 kg/cm*).
/ \
1 2
235FO2068
20-24
CHECKING STEERING WHEEL PLAY
20-25
CHECKING TIRE RUNOUT
1. Start the engine and raise the front wheels off the
ground, using the blade or scarifier as a jack.
2. Use dial gauge @ to measure the tire runout while
rotating the tire (I 1 by hand.
1. Put jacks under the left and right tandem cases, and
raise the rear wheels off the ground.
2. Put stand @ under the tandem case.
3. Start the engine and lower the blade to the ground.
20-26
CHECKING TOE-IN
CHECKING TOE-IN
-I
235FO2069
Standard of toe-in: B - A
235FO207'
1
TOE-IN ADJUSTMENT
* When toe-in is outside standard value, adjust it ac-
cording to following procedure.
Loosen mounting nuts (I), apply wrench to the notch
section (2), turn left and right turn buckle, and adjust
to within standard value.
* Toe-in increases when turn buckle is turned in the di-
rection of the arrow, and decreases when it is turned
in the opposite direction. (one revolution: 6 mm)
20-27
Insert the front frame in the rear frame.
Insert center pins (1) and (2), adjust with bottom nut
(4) so that all clearance A are equal, then tighten
the nut.
20-28
CHECKING WEAR OF BRAKE DISC
Checking hole
F23EC030
CHECKING PARKING BRAKE
CHECKING PARKING BRAKE
1. Place the gear shift lever at the P position.
2. Check that slack adjuster (I) works smoothly.
3. Check that the angle between push rod (2) of the
brake chamber and slack adjuster (1) is greater than
90.
20-29
CHECKING WORK
EQUIPMENT CONTROL LEVER
TRAVEL AND OPERATING
FORCE
CHECKING HYDRAULIC
OIL TEMPERATURE
Special tool
A When
slowly
removing
to release
cap, loosen the oil filler cap
the remainingoil pressure
in the hydraulic tank.
20-30
CHECKING WORK EQUIPMENT HYDRAULIC PRESSURE
Special tool
tank.
/ -
235FO2077
ADJUSTING WORK
EQUIPMENT HYDRAULIC
PRESSURE
If the hydraulic pressure is not the standard value
[24.5 MPa (250 kg/cm*)], adjust as follows.
Remove cap (2). loosen nut (3), then turn adjustment
screw (4) to adjust the pressure of internal spring (5).
* To INCREASE pressure, turn screw CLOCKWISE.
* To DECREASE pressure, turn screw
COUNTERCLOCKWISE.
, I.
235F0207E
20-32
CHARGING BLADE ACCUMULATOR WITH GAS
Special tool
If pressure gauge (5) does not reach 2.4 MPa (24 kg/
SI
z cm*), loosen valve (3) gradually, and charge with
z gas from the cylinder until pressure gauge (5)
reaches 2.4 MPa (24 kg/cm*).
If the pressure gauge registers above 2.4 MPa (24
kg/cm*), remove hose (6). Then gradually loosen ,_______j____,
valve (3) to release gas from the accumulator into I I \.
the atmosphere and adjust to 2.4 MPa (24 kg/cm*).
Ii. Accu;;;;iator
A 234F114E
Accumulator joint
Gasket
\ r-i-
! t-7
5/8-18UNi /
TV8 234F1146
TESTING AND ADJUSTING ADJUSTING BLADE LIFT SPEED
20-34
0
BLEEDING AIR FROM HYDRAULIC PUMP
z
R 10. Run the engine at high idling, and raise and lower
8 the left and right blade lift cylinders 2 - 3 times.
1
12. Run the engine at low idling, and raise the left and
right blade lift cylinders to the end of their stroke.
* Relieve the hydraulic pressure and bleed the air
completely.
20-35
TESTING AND ADJUSTING ADJUSTING SLIP LOAD OF CIRCLE ROTATION CLUTCH
INSPECTION
1. Remove plug (I).
1 F23501402
F23501401
20-36
0
TESTING AND ADJUSTING ADJUSTING SLIP LOAD OF CIRCLE ROTATION CLUTCH
slippage limit.
* If a shim is added, the pushing force of
the belleville spring becomes smaller,
and it is easier for the clutch to slip. If a
shim is removed, the pushing force of
the belleville spring becomes larger, and
it is difficult for the clutch to slip.
BREAKING IN CLUTCH
. When the clutch disc is replaced with a new
part, break in the clutch as follows.
i) Adjust in Steps 1 and 2 above to align to the
slippage limit point.
2) Make the clutch slip for 3.5 - 4.0 seconds. [Order of tightening bolts] F23501407
. Run the engine at full throttle
. The clutch disc will rotate one turn when
it slips for 3.5 - 4.0 seconds. Shim thickness that slips
3) Repeat Step 2) 20 - 25 times at three min- (Slipoaae limit Point)
(Alien to this shim
utes intervals. c thickness)
* Precautions
a) If the clutch housing temperature ex-
ceeds 5OC, stop the breaking-in opera-
tion until it cools down to the normal
temperature.
b) If the clutch stops slipping during the
operation, add one shim of 0.2 mm to Shim thickness
make the clutch slip.
Shim thickness that
4) Adjust again to the slippage limit point. does not slip TWG00243
* Wait for the clutch housing to cool down
to the normal temperature before adjust-
ing.
20-37
TESTING AND ADJUSTING ADJUSTING SLIP LOAD OF CIRCLE ROTATION CLUTCH
Testing
1. Remove bolt (I), then remove cover (2).
2. To prevent the circle from rotating, push the
blade against the ground and raise the front
wheels or secure the ends of the blade.
. Method of raising front wheels
I) Lower the work equipment to the ground,
then extend the blade lift cylinder fur-
ther to jack up the front wheels.
2) Apply the parking brake.
A Put a block under the frame at the center
of the front axle.
3. Operate the circle rotation lever and check that
the clutch slips.
. When it starts to slip, there will be a sliding
noise and the holder at the tip of the shaft
will rotate. After checking, return the circle
rotation lever to the neutral position.
However, if the slippage stops immediately,
judge that it is not slipping.
I TWG00300
Adjusting
t Adjust the pushing force of belleville spring (6)
by adjusting the number of shims (5).
INCREASE shims to DECREASE pushing force
and make it EASY to slip
DECREASE shims to INCREASE pushing force
and make it DIFFICULT to slip
w Mounting bolt :
110.5 f 12.5 Nm Ill.25 f 1.25 kgm)
3) Repeat the testing procedure to check if the
clutch slips. I + Shim
(Slivvaae
thickness
Ilmlt
that
Point)
slips
Chim thickness
I
I
Shim
(Al
thickness
ian to this
that
shim
does
thickness)
not SIIP
TWG00302
I
20-38
0
TESTING AND ADJUSTING ADJUSTING SLIP LOAD OF CIRCLE ROTATION CLUTCH
Breaking in clutch
. When the clutch disc is replaced with a new
part, break in the clutch as follows.
1) Adjust in Steps 1 and 2 above to align to the
slippage limit point.
2) Make the clutch slip for 3.5 - 4.0 seconds.
. Run the engine at full throttle
. The clutch disc will rotate one turn when it
slips for 3.5 - 4.0 seconds.
z 3) Repeat Step 2) 20 - 25 times at three minutes
z intervals.
2 * Precautions
a) If the clutch housing temperature exceeds
5OC, stop the breaking-in operation until it
cools down to the normal temperature.
b) If the clutch stops slipping during the opera-
tion, add one shim of 0.2 mm to make the
clutch slip.
20-39
0
TESTING AND ADJUSTING ADJUSTING CLEARANCE OF F AND R SWITCHES
ADJUSTING CLEARANCE OF
F AND R SWITCHES
Adjusting
1. Set the shift lever to the neutral position and
operate to the REVERSE position.
20-40
0
TESTING AND ADJUSTING ADJUSTING SHIFT POTENTIOMETER
ADJUSTING SHIFT
POTENTIOMETER
. Adjust the output voltages of shift potentiometers
(1) and (2) so that they are as shown in Table 1
when the shift lever is at the 8 and @ positions.
TM5 TM4
+ Turn the starting switch off before removing or
I
installing any connector.
8 4.08 + 0.08
@ 0.84 f 0.08
TWG00257
II1 TWG00258
20-41
0
TESTING AND ADJUSTING ADJUSTING INCHING POTENTIOMETER
20-42
0
ADJUSTING SPEEDOMETER MODULE OF MACHINE
MONITOR
Adjustment procedure
Remove the machine monitor, and adjust at the back
of the speedometer.
1. Remove rubber caps II and Ill at the back of the
speedometer.
2. When the rubber caps are removed, a rotary
switch can be seen inside. Check the part
number of the speedometer, then turn this
switch with a screwdriver to adjust as shown in
the table below.
Switch11 1 3 / 3 1 3 1 3 i 7
Screwdriver 423F336
Switch III 121213131E b
423F337
20-43
0
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.
AL 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 If the radiator cap is removed when the engine is hot, hot water may spurt out and cause burns, so wait for
the engine to cool down before starting troubleshooting.
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 (-) 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,
sembled. and judge whether to handle it as a real fail-
. It will become impossible to find the cause ure or as a problem with the method of op-
of the failure. eration, etc.
It will also cause a waste of manhours, parts, or * When operating the machine to reenact
oil or grease, and at the same time, will also lose the troubleshooting symptoms, do not
the confidence of the user or operator. carry out any investigation or measure-
For this reason, when carrying out troubleshoot- ment that may make the problem worse.
ing, it is necessary to carry out thorough prior 5. Troubleshooting
investigation and to carry out troubleshooting in . Use the results of the investigation and in-
accordance with the fixed procedure. spection in Items 2 - 4 to narrow down the
2. Points to ask user or operator causes of failure, then use the troubleshoot-
1) Have any other problems occurred apart from ing flowchart to locate the position of the
the problem that has been reported? failure exactly.
2) Was there anything strange about the ma- * The basic procedure for troubleshooting
chine before the failure occurred? is as follows.
3) Did the failure occur suddenly, or were there 1) Start from the simple points.
problems with the machine condition before 2) Start from the most likely points.
this? 3) Investigate other related parts or in-
4) Under what conditions did the failure occur? formation.
5) Had any repairs been carried out before the 6. Measures to remove root cause of failure
failure? . Even if the failure is repaired, if the root cause
When were these repairs carried out? of the failure is not repaired, the same failure
6) Has the same kind of failure occurred be- will occur again.
fore? To prevent this, always investigate why the
3. Check before troubleshooting problem occurred. Then, remove the root
1) Check the oil level cause.
2) Check for any external leakage of oil from
the piping or hydraulic equipment.
3) Check the travel of the control levers.
20-46
0
TROUBLESHOOTING SEQUENCE OF EVENTS IN TROUBLESHOOTING
Office, shop
TFWnOl RO &Q TFWIIII(I Jobsite
eP 1
IExamination, confirmation of symptoms 1
1) When a request for repairs is received, first ,, II
ask the following points. R ins! Ring!
* Name of customer
- Type, serial number of machine
- Details of jobsite, etc.
21 Ask questions to gain an outline of the prob-
Ien%
- Condition of failure
- Work being carried out at the time of the TEW00182
failure
. Operating environment
. Past history, details of maintenance, etc.
eP 2 TEP01348
Determining probable location of cause
Step 6
&-enacting failure]
20-47
0
TROUBLESHOOTING POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE
To maintain the performance of the machine over a long period, and to prevent failures or other
troubles before they occur, correct operation, maintenance and inspection, troubleshooting, and 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).
TEP01352
I TEP01353
20-48
0
TROUBLESHOOTING POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE
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.
20-49
0
TROUBLESHOOTING POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE
l 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- TEP0135' 1
nectors apart.
Ir Never pull with one hand.
TBW00484
TBP01355
TEW00198
20-50
0
TROUBLESHOOTING POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE
l Connecting connectors
0 Check ;he connector visually.
I) 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- Cliks into Position
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. II TEP01356
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.
L
the connector until the stopper clicks into
position.
EWOOZOO
Correct any protrusion of the boot and any
misalignment of the wiring harness
For connectors fitted with boots, correct any
protrusion of the boot. In addition, if the
wiring harness is misaligned, or the clamp
is out of position, adjust it to its correct po-
sition.
* If the connector cannot be corrected eas-
ily, remove the clamp and adjust the
position.
Transmission
solenoid valve end
TWG00248
20-51
TROUBLESHOOTING POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE
TEW00202
TEP01357
20-52
0
TROUBLESHOOTING POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE
TEW00204
TEW00205
ii TEW00206
20-53
0
TROUBLESHOOTING POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE
TEW00207
3) Sealing openings
After any piping or equipment is removed, the
openings should be sealed with caps, tapes, or
vinyl bags to prevent any dirt or dust from 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.
TEW00208
TEW00209
20-54
0
TROUBLESHOOTING POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE
Flushing operations
After disassembling and assembling the equip-
ment, or changing the oil, use flushing oil to
remove the contaminants, sludge, and old oil oi I
TEP01358
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~) particles that the filter
built into the hydraulic equipment cannot re-
move, so it is an extremely effective device.
TEWOOZII
20-55
0
Other check items Item Checks before starting
Hydraulic. Electrical
Electrical components mechamcal Lubricating oil, cooling water
compoetS equipment
8
A A A
P 0 13 .
023502
TROUBLESHOOTING ELECTRICAL CIRCUIT SYSTEM DIAGRAM
Engine oil
pressure switch
[r/i iii/i1 IF
Radiator water
level sensor
CN PL
e *ensor
Accumulator
Fl0a1 (Left
Parking
To flasher relay
Warning To turn signal lamp
To head lamp
I watertemperature
II lllll Startina 62
I ST
Electrical Intake
u --- . ,-,
235FO2079
20-57
0
TROUBLESHOOTING ELECTRICAL CIRCUIT SYSTEM DIAGRAM
Y
PleSSle
switch
Winker 125W)
Parking 13W)
Winker (25W)
Electrical intake
air heater
20-59
0
TROUBLESHOOTING ELECTRICAL CIRCUIT SYSTEM DIAGRAM
Proximity Proximity
switch(F) switch(R1 Relay
(XtYPe) IXtYPe) (Starting
GND
lWG00244
20-60
0
TROUBLESHOOTING ELECTRICAL CIRCUIT SYSTEM DIAGRAM
Relay Relay
(BAck-uD (Diffe-
buzzer) rent lall Relay (RI Relav(F)
Rotary
Print board circus CN-TO 1 switch
I
Diode
q :Startina motor
q iDifferential lock solenoid
q LTransmission R clutch solenoid
TWG00245
20-60- 1
0
TROUBLESHOOTING ELECTRICAL CIRCUIT SYSTEM DIAGRAM
Transmission
-.._._-__-__-.._-.-._-___ solenoid valve
2nd
4th
1st
LO
Hi
3rd
F
R
TWG00246
20-60-2
0
TROUBLESHOOTING ELECTRICAL CIRCUIT SYSTEM DIAGRAM
Rotary
int board circuit CN-TO I sxich
(SWP type1 ISIP type1
! p 0. 68rR -m P
- Diode
q
r-Y
;Startino motor
:Different al lock solenoid
;Transmlss on R clutch solenoid
;Transmlss on F clutch solenoid
:Transmiss on 4th clutch solenoid
:Transmiss on 3th clutch solenoid
:Transmiss on 2th clutch solenoid
:Transmiss on Ith clutch solenoid
:Transmiss on low clutch solenoid
:Transmlss on hioh clutch solenoid
TWG00247
20-60-3
023502
CN-FRError memo,~
reset
0 drift
CN-SWF
a-n
-a
:a
--m
3-
m
CN-SWR :;I:
------1
TROUBLESHOOTING ELECTRICAL CIRCUIT SYSTEM DIAGRAM
(2/2)
1 CN-E2 Transmission
controller
Power source far
transmission clutch +24V ----v
solenoid
Ground
:Parkino brake
:Back buzzer
:Starting mot0 r
20-60-6
0
TROUBLESHOOTING CONNECTOR TYPES AND MOUNTING LOCATIONS
CN14 1 SWP 1 8 1 I ntermediate connector (inside of R.H. console box) 1A4. G9. 14.M51
CN15 SWP 12 Intermediate connector (next to L.H. battery) D2
20-60-7
0
TROUBLESHOOTING ELECTRICAL WIRING DIAGRAM
CN-37 CN-36
CN-38 CN-63
CN-32 CN-
CN- 82
X CN-36 Y
CN-40
CN-28
\ ,PL
/ I
RPST RPB cN!lo d-63 c\N-61 7.-----
.21
i / \
14
I::4
63
91
20-60-11
0
TROUBLESHOOTING ELECTRICAL WIRING DIAGRAM
(3/3)
RIL R,CB
TM5
RBB
\ \
SWF
CN-14
TM13
TM14
FR
TiC
CN-30
TWG00299
20-60-12
0
TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
TEW00222
TEW00223 TEW00224
1 3
3 1
2 4 4 2
TEW00225 TEW00226
20-60- 13
0
TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
4 8
n
8 4
5 1 BLWOO54
BLPOOO53
6 12 12 6
ELW0056
8 ?8
16 8
16
BLPO0057 TEW00232
10 20
20
B 1' ii
BLWOO56 TEW00234
20-60-14
0
TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
I 4
TLG00099 TLGOOlOO
7 12
12
TLGOOlOl TLG00102
16
TLG00103 TLG00104
TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
No.
of
T MIC connector
H BLPWO45 BLP00046
BLPOoO47 BLPM)O48
13
8
13
H BLmoo49
9
BLPCOO50
17
17
I 1 BLPOoo51 BLPOO052
21
1 1 TEW00259 TEW00260
20-60-16
0
TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
3 6
TEW00235
4 s
8 4
TEW00237
BLPOOO34 BLPOOO35
1 4 8 11 11 8 4 1
3 i io 14
14 IO 7
TEW00239 TEW00240
4 1
ELF00036
20-60-17
0
TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
No.
of
T M type connector
1
BLP00038 BLPcoO39
TEW00243 TEW00244
2 4 4 2
TEW00245 TEW00246
4 1
6 6 3
TEW00247 TEW00248
20-60-l 8
0
TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
TEZOQZZO
I
TKL00295 TKL00296
TKL00297 TKL00298
5 2 1 3
TKLOOZSS TKL00300
12
6 2 I 3 TKL00302
TKL00301
20-60-19
0
TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
No.
of
T Automobile connector
FB BLPOO063
I
BLPOO064
3 2
I 2
3 4
BVLOll43
3 1
BLPoOO69
5 8
BLPOO071 BLPOoO72
20-60-20
0
TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
:
I
TLG00048
TLG00049
6
2
5
1 4
TLG00050 TLG00051
20-60-21
0
TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
1 3 6
BLPOOO73 BLPO0074
6 5
BLFuOO75 BLFQ0076
20-60-22
0
TROUBLESHOOTING CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
/I;K
2 I I
H 2
TLG00034
TLC00035
3
m 2
2
1, 3
y
I
TLG00036
TLG00037
1 3
4 lx 0
6
TLG0003.3 TLG00039
20-60-23
0
TROUBLESHOOTING METHOD OF USING TROUBLESHOOTING CHARTS
20-60-24
0
TROUBLESHOOTING METHOD OF USING TROUBLESHOOTING CHARTS
<Example>
(I) E-l Engine does not start (starting motor works).
(4) * Before carrying out troubleshooting, check that all the related connectors are prop-
erly inserted.
j, Always connect any disconnected connectors before going on the next step.
Sr Check that the coolant is at the specified level before carrying out troubleshooting
20-60-25
0
TROUBLESHOOTING METHOD OF USING TROUBLESHOOTING CHARTS
[Questions]
Sections @ + @ in the chart on the right corre-
sponds to the items where answers can be ob-
tained from the user. The items in @ are items
that can be obtained from the user, depending
on the users level.
[Check items1
The serviceman carries out simple inspection to
narrow down the causes. The items under @ in
the chart on the right correspond to this.
The serviceman narrows down the causes from
information @ that he has obtained from the
user and the results of @ that he has obtained
from his own inspection.
[Troubleshooting]
Troubleshooting is carried out in the order of
probability, starting with the causes that have
been marked as having the highest probability
from information gained from [Questions] and
[Check items].
20-60-26
0
TROUBLESHOOTING METHOD OF USING TROUBLESHOOTING CHARTS
20-60-27
TROUBLESHOOTING METHOD OF USING TROUBLESHOOTING CHARTS
20-60-28
0
TROUBLESHOOTING METHOD OF USING TROUBLESHOOTING CHARTS
Five causes
+ Step 1
Clarify the relationship between the three
symptoms in the [Questions] and [Check items]
section and the five Cause items in the vertical
column.
Three symptoms
t t A
Step 2
Step 3
20-60-29
0
TROUBLESHOOTING OF ENGINE
(S MODE)
S-l Starting performance is poor (Starting always takes time) .............................................................. 20-62
s-3 Engine does not pick up smoothly (Follow-up is poor) .................................................................... 20-66
S-8 Oil consumption is excessive (or exhaust gas is blue) ..................................................................... 20-71
S-l 1 Oil is in cooling water, or water spurts back, or water level goes down ............................................ 20-74
s-12 Oil pressure lamp lights up (drop in oil pressure) ........................................................................... 20-75
20-61
0
TROUBLESHOOTING TABLE
. The specific gravity should exceed the value for the charging rate
of 70% in the above table.
. In cold weather the specific gravity must exceed the value for the
charging rate of 75% in the above table.
20-62
S-2 Engine does not start
0 Engine does not turn
Legend
0 : Possible causes (judging from Questions and check items]
G : Most probable causes (judging from Questions and Check items)
* : Possible causes due to length of use (used for a long period)
0 : Items to confirm the cause.
switch IS turned ON
20-63
@ Engine turns but no exhaust gas comes out
(Fuel is not being injected)
Ambient temperature
Diesel fuel
Legend
0 : Possible causes (judging from Questions and check items1
6,:) : Most probable causes (judging from Questions and Check items)
A : Possible causes due to length of use (used for a long period)
0 : Items to confirm the cause.
20-64
0 Exhaust gas comes out but engine does not
start
(Fuel is being injected)
Legend
0 : Possible causes (judging from Ouestions and check items)
0 : Most probable causes (judging from Questions and Check items)
A : Possible causes due to length of use (used for a long period)
l : Items to confirm the cause.
Legend
0 : Possible causes (judging from Questions and check items)
I Replacement of filters has not been carried out according to operation IllI I Ill III
20-66
S-4 Engine stops during operations
General causes why engine stops during operations
. Seized parts inside engine
- Insufficient supply of fuel
. Overheating
* If there is overheating and insufficient
output, carry out troubleshooting for over-
heating.
. Failure in power train
* If the engine stops because of a failure in
the power train, carry out troubleshooting
for the chassis.
:gend
0 : Possible causes (judging from Questions and check items)
a : Most probable causes (judging from Questions and Check items)
A : Possible causes due to length of use (used for a long period)
0 : Items to confirm the cause.
stopped
to be clogged
20-67
S-5 Engine does not rotate smoothly (hunting)
General causes why engine does not rotate smoothly
. Air in fuel system
. Defective governor mechanism
. Defective electric goyernor machanism (electric
governor type)
* If there is no hunting when the electric governor
rod is disconnected, carry out troubleshooting
for the electrical system.
Legend
0 : Possible causes (judging from Questions and check items)
0 : Most probable causes (judging from Questions and Check items)
A : Possible causes due to length of use (used for a long period)
l : Items to confirm the cause.
Condition of hunting
epacemen 0
20-68
S-6 Engine lacks output (no power)
General causes why engine lacks output
. Insufficient intake of air
. Insufficient supply of fuel
. Improper condition of fuel injection
. Improper fuel used
(if non-specified fuel is used, output drops)
. Lack of output due to overheating
* If there is overheating and insufficient
output, carry out troubleshooting for over-
heating.
Legend
0 : Possible causes (judging from Questions and check items)
: Most probable causes (judging from Questions and Check items)
: Possible cau e to length of use (used for a long period)
en va ve c earance IS c
20-69
S-7 Exhaust gas is black (incomplete combustion)
General causes why exhaust gas is black
. Insufficient intake of air
. improper condition of fuel injection
* Excessive injection of fuel
Legend
0 : Possible causes (judging from Questions and check items)
@ : Most probable causes (judging from Ouestions and Check items)
a : Possible causes due to length of use (used for a long period)
0 : Items to confirm the cause.
V
Dust indicator is red \?
standard value
20-70
S-8 Oil consumption is excessive (or exhaust gas is blue)
* Do not run the engine at idling for more than
20 minutes continuously. (Both low and high
idling)
General causes why oil consumption is excessive
. Abnormal combustion of oil
. External leakage of oil
. Wear of lubrication system
Legend
0 : Possible causes (judging from Questions and check items)
20-7 1
S-9 Oil becomes contaminated quickly
General causes why oil becomes contaminated
quickly
. Intake of exhaust gas due to internal wear
. Clogging of lubrication passage
. Improper combustion
. Improper oil used
. Operation under excessive load
Legend
0 : Possible causes (judging from Questions and check items)
6 : Most probable causes (judging from Questions and Check items)
A : Possible causes due to length of use (used for a long period)
0 : Items to confirm the cause.
20-72
S-l 0 Fuel consumption is excessive
General causes why fuel consumption is excessive
. Leakage of fuel
. Improper condition of fuel injection
. Excessive injection of fuel
of same model
Condition of fuel consumption
to be incorrect
20-73
S-l 1 Oil is in cooling water, or water spurts back, or water level goes down
General causes why oil is in cooling water
* Internal leakage in lubrication system
. Internal leakage in cooling system
LegC!O
ssible causes (judging from Questions and check items)
_____. , _
2 Oil level
0 Graduallv increased
20-74
S-12 Oil pressure lamp lights up (drop in oil pressure)
General causes why oil pressure lamp lights up
. Leakage, clogging, wear of lubricating system
* Defective oil pressure control
* Improper oil used (improper viscosity)
. Deterioration of oil due to overheating
Type of oil
I Selection of oil SAE number
to ambient temperature
according
I
-22 -4 14 32 50 68 86 104 122F
-30 -20 -10 0 10 20 30 40 5oc
!gend
: Possible causes (judging from Questions and check items)
: Most probable causes (judging from Questions and Check items)
gth of use (used for a long period1
20-75
S-13 Oil level rises
t If there is oil in the cooling water, carry out
troubleshooting for Oil is in cooling water.
General causes why oil level rises
. Water in oil (cloudy white)
. Fuel in oil (diluted, and smells of diesel fuel)
. Entry of oil from other component
I I
Legend
20-76
S-14 Water temperature becomes too high (overheating)
General causes why water temperature becomes
too high
. Lack of cooling water (deformation, damage of
fan)
. Drop in heat dissipation efficiency I I
. Defective cooling circulation system
. Rise in oil temperature of power train
* Carry out troubleshooting for chassis.
Legend
0 : Possible causes (judging from Questions and check.items)
: Most probable causes (judging from Questions and Check items)
a : Possible causes due to length of use (used for a long period)
l : Items to confirm the cause.
20-77
S-l 5 Abnormal noise is made
* Judge if the noise is an internal noise or an
external noise.
General causes why abnormal noise is made
. Abnormality due to defective parts
. Abnormal combustion noise
* Air sucked in from intake system
Legend
0 : Possible causes (judging from Questions and check items)
Q : Most probable causes (judging from Questions and Check items)
A : Possible causes due to length of use (used for a long period)
0 : Items to confirm the cause.
Degree of use
z 1 Gradual1 y occurred 0 0
Condition of abnormal noise
.g
Suddenly occurred 0 0 0
5
Non-specified fuel is being use d 0 0
2
Engine oil must be added more __._.... 1-1 I, I, / I I I I I
1 Blue under liaht load @ I 1
Color or exhaust gas
20-78
S-l 6 Vibration is excessive
* If there is abnormal noise together with the
vibration, carry out troubleshooting for Abnor-
mal noise is made.
General causes why vibration is excessive
. Defective parts (abnormal wear, breakage)
* Improper alignment
* Abnormal combustion
Legend
0 : Possible causes (judging from Questions and check items)
: Most probable causes (judging from Questions and Check items)
: Possible causes due to length of use (used for a long period)
20-79
TROUBLESHOOTING CHART FOR ELECTRONIC
VEHICLE MONITORING SYSTEM
(M MODE)
M-l. When starting switch is turned ON, monitor panel display does not appear . . .. 20-82
M-2. When starting switch is turned ON, monitor panel display does not go out . . . 20-82
M-3. When starting switch is turned ON (engine stopped), check items flash . .. 20-83
M-4. Preheating operation is not being used but preheating display lights up . . . 20-85
M-5. When starting switch is turned ON and engine is started, caution items flash
(but there is no abnormality with engine or CHECK items ) . . . _. . 20-86
M-6. Buzzer does not sound for 1 minute when starting switch is turned ON (engine stopped) 20-91
M-7. There is no abnormality displayed on monitor, but buzzer sounds . _. . . . 20-91
M-8. Monitor panel lighting does not light up . . . . . 20-92
M-9. . Service meter does not move after engine is started
. Service meter continues to move when engine is stopped ..... 20-93
M-10. Coolant temperature gauge displays abnormally low temperature 20-94
M-l 1. Coolant temperature gauge does not give a display ............. 20-95
M-12. Fuel level gauge always displays FULL .......................... 20-96
M-13. Fuel gauge does not give any display ........................... 20-96
M-14. Speedometer display does not work normally ................... 20-97
M-15. Turn signal indicator pilot lamp does not light up ................ 20-98
M-16. High beam pilot lamp does not Ilight up ......................... . . 20-99
20-81
0
M-l WHEN STARTING SWITCH IS TURNED ON, MONITOR PANEL
DISPLAY DOES NOT APPEAR.
* When disconnecting connectors to connect the T-adapter (or socket adapter), always turn the starting switch OFF.
* When connecting the T-adapter, connect the male and female to the socket specified in ( ).
* After checking, connect the disconnected connectors again immediately.
2 YES
Defective monitor module Replace
YES Is voltage behveen
, - CN18 (female) (I) - Defective contact, or discon-
and (2) 20 - 30 V? section in wiring harness After inspec-
Jetween CN18 (female) (1) tion, repair
Is voltage between
1) Connect T-adap- NO - CN25 (4) - CN13 (3) -fuse (clean) or re-
chassis ground and -
ter to CN18 (fe- 13, or between CN18 (fe- place
fuse 13 20 - 30 V?
male). male) (2) - chassis ground
2) Turn starting switch ON.
1) Turn starting 3lown fuse After finding
switch ON. case, check for
short circuit in
wiring harness
Tester
Troubleshooting
tools T-adapter or socket adapter
(for DLl)
Monitor
module
Fl
2
235FO2088
20-82
M-3 WHEN STARTING SWITCH IS TURNED ON (ENGINE STOPPED),
CHECK ITEMS FLASH.
* When disconnecting connectors to connect the T-adapter (or socket adapter), always turn the starting switch OFF.
* When connecting the T-adapter, connect the male and female to the socket specified in ( 1.
* After checking, connect the disconnected connectors again immediately.
a)
sl 8 (COOLANT LEVEL) FLASHES.
Cause Remedy
3 YES
Defective monitor module Replace
YESI I
Disconnection in wiring
After inspec-
1) Connect CN39 harness, or defective con-
tion, repair
tact between CN39 (fe-
(clean)-or re-
male) (3) - CN25 (7) -
place
2) Connect - disconnect CN39 (female) (3) CN18 (female) (7).
2) Turn starting
Disconnection in wiring
After inspec-
harness, or defective con-
(or socket adapter) NO tion, repair
tact between CN39 (fe-
to CN39 (female). (clean) or re-
male) (2) - CN25 (3) -
place
chassis ground.
Table
CN39
Continuity
(3) - (2)
Connect 1 Yes
Disconnect 1 No
Does q go out? - NO
2 YES
Defective monitor module Replace
_ Is there continuity
1) Connect CN35 (fe- _ between CNI 8 (fe-
Defective contact, or dis-
male) (engine oil male) (6) - (Z)?
connection in wiring har- After inspec-
level sensor) to (See table)
ness between CN35 (fee- tion, repair
chassis ground. male) (1) - CN15 (1) - (clean) or re-
1) Connect T-adapter NO
2) Turn starting place
to CN18 (female). CN26 (2) - CN18 (female)
switch ON.
2) Connect - discon- Table (6).
nect CN35 (fe-
male) and chassis CN35 -
Continuity
ground. chassis ground
Connect Yes
Disconnect No
20-83
cl
El b (hydraulic oil level) flashes.
Cause Remedy
Does @j go out
r-l
when short con-
nector is con-
nected?
After inspec-
male) (hydraulic as shown in table? ness between CN36 (fe-
, tion, repair
oil level sensor). male) (1) - CN25 (8) -
1) Connect T-adaoter NO (clean) or re-
2) Turn starting CN18 (female) (5). or be-
to CN18 (femaie). place
switch ON. tween CN36 (female) (2) -
2) Connect * discon- Table CN25 (3) - chassis ground
nect CN36 (fe- ^,. ,.
male) and short- anorr SOCKBT:
Continuity
connector. adapter
Monitor
module Coolant level sensor
235FO2089
235FO2090
235FO2091
20-84
M-9 l Service meter does not move after engine is started
l Service meter continues to move when engine is stopped
* When disconnecting connectors to connect the T-adapter (or socket adapter), always turn the starting switch OFF.
* When connecting the T-adapter, connect the male and female to the socket specified in ( ).
* After checking, connect the disconnected connectors again immediately.
YES
Go to M5 a)
1
- Is voltage between
1) Turn starting - CN19 (female) (1) -
switch ON. NO and (4) 20 - 30 V?
Disconnection in wiring hap
After inspec-
2) Start engine. tion, repair
ness between CN19 (female)
1) Connect T-adapter NO (clean) or re-
(4) and CN25 (male) (5)
to CN19. place
2) Turn starting
switch ON.
3) Start engine.
Tester
Troubleshooting
tools T-adapter or socket adapter
lfor DLI)
20-93
M-9 Related electrical circuit drawing
Engine oil
pressure relay
Monitor
module
Service meter
(speedometer
module)
CN32
A 0
Engine oil
* pressure sensor
235FO2101
8
R
M-IO COOLANT TEMPERATURE GAUGE DISPLAYS ABNORMALLY s1
LOW TEMPERATURE
* When disconnecting connectors to connect the T-adapter (or socket adapter), always turn the starting switch OFF.
* When connecting the T-adapter, connect the male and female to the socket specified in ( ).
t After checking, connect the disconnected connectors again immediately.
Cause Remedy
to CN17.
2) Connect CN17 (1)
to chassis ground.
3) Turn starting
switch ON.
20-94
M-II COOLANT TEMPERATURE GAUGE DOES NOT GIVE A DISPLAY
* When disconnecting connectors to connect the T-adapter (or socket adapter), always turn the starting switch OFF.
* When connecting the T-adapter, connect the male and female to the socket specified in ( 1.
* After checking, connect the disconnected connectors again immediately.
F
Cause Remedy
CNIE
235FO2094
20-95
M-12 FUEL LEVEL GAUGE ALWAYS DISPLAYS FULL
* When disconnecting connectors to connect the T-adapter (or socket adapter), always turn the starting switch OFF.
* When connecting the T-adapter, connect the male and female to the socket specified in ( ).
* After checking, connect the disconnected connectors again immediately.
YES
Defective fuel level sensor Replace
1 I
Wiring harness between
After inspec-
CN17 (female) (3) - CN26
2 YES tion, repair
(4) - CN7 (9) - CN33 (1)
(clean) or re-
(female) short circuiting
Does fuel level place
1) Disconnect CN33 with chassis ground
(fuel level sensor). - gage dispav go -
out?
2) Turn starting
switch ON. Defective monitor module Replace
3) Wait for approx. 1 1) Disconnect CN17. NO
min. 2) Turn starting
switch ON.
3) Wait for approx. 1
min.
ES
Defective fuel level sensor Replace
235FO2102
20-96
M-14 SPEEDOMETER DISPLAY DOES NOT WORK NORMALLY
* When disconnecting connectors to connect the T-adapter (or socket adapter), always turn the starting switch OFF.
* When connecting the T-adapter, connect the male and female to the socket specified in ( ).
* After checking, connect the disconnected connectors again immediately.
Cause Remedy
setting of speed
sensor 0.5 - 1.5
0
It It contacts
.,. _
turn.
gggi$gj (2)
Replace
NO
sor) (male).
Troubleshooting
tools T-adapter or socket adapter T-adapter or socket adapter
(for DLI) (for Econoseal)
CN20 CN 26 CN30
Monitor
3
Speedometer sensor
module
235FO2103
20-97
M-15 TURN SIGNAL INDICATOR PILOT LAMP DOES NOT LIGHT UP
t The turn signal indicator lamp itself lights up.
Tester
Troubleshooting
tools T-adapter or socket adapter 1 I
I 1 (for Dil, I
CN40
To To
turn signal turn signal
lamp (L.H.) lamp (R.H.)
235FO2104
20-98
TROUBLESHOOTING CHART FOR ELECTRONIC
(ENGINE, PARKING BRAKE, TRANSMISSION CONTROL)
(E MODE)
* If the controller displays an error on machines mounting a transmission controller (Serial No.:
12013 - 12015, 12019 and up), carry out troubleshooting for the transmission system first.
* When disconnecting or connecting the T-adapter (or socket adapter) or short socket adapter, or
when disconnecting the connector for checking, turn the starting switch OFF to prevent accidents.
* When connecting T-adapter (or socket adapter), connect to the connector specified. (CNxx( 1)
* When disconnecting connectors or connecting T-adapters, return them to the original condition
immediately after checking, then go to the next check.
* If the diagnosis indicates a defect in the shift controller, replace the sensor assembly (a diode and
relay are assembled on the print board, so use the input from the rotary switch to output the signal
voltage to drive the solenoid valve inside the transmission), the F-R switch assembly and the
rotary switch assembly, do not disassemble the assemblies, otherwise dust or other impurities
may get inside and cause secondary failures.
20-101
0
TROUBLESHOOTING E-l
Cause Remedy
2 YES
lefective engine stop qeplace
notor.
Sjg-jH-
Is voltage of
CN51 (4) 20 -
3OV? Iefective relay, or Repair or
. Turn starting NO lefective contact, or replace.
- Starting switch switch ON. lisconnection in wiring
at both ON and * Disconnect rarness.
OFF. CN51
Iefective contact, or Repair
U jisconnection in wiring
rarness between battery
elay and CN51 (4).
1
- Defective contact, or Repair or
- Turn starting disconnection in wiring replace.
Is voltage switch ON. harness between start in
between CN14 * Turn parking 1 motor (E)_ - CN14 (5).
switch ON. . Defective relay or RPST.
s Connect T- Iefective contact, or Repair
adapter (or - Turn starting NO iisconnection in wiring
socket) to CN 14 switch ON. larness between parking
- Turn starting
(female) (male). rwitch and tarting motor
switch ON. * Turn parking
switch ON. clay.
. Turn parking
switch ON. i Defective fuse (No. 14), or Repair
. Connect T- NO fefective power circuit.
adapter (or
socket) to CN14
(female).
20-l 02
0
TROUBLESHOOTING E-2
Cause Remedy
Disconnection in wiring
2 YES harness between starting
Repair
motor (E) and CN14 (5)
Is there continuity
YES between CN14 (5) _ Failure of starting motor Replace
and chassis relay or rotary switch or
ground? disconnection in wiring
harness between CN14 Repair
CN14 (famale) (1) I) Turn starting NO (male) (5) -starting
and chassis ground switch ON. motor relay- rotary
2) Place shift lever at P. switch -chassis ground
3) Connect T-adapter to CN14 (male) (female)
1) Turn starting
Defective power source -
switch ON. IO wiring
Cause Remedy
Disconnection in wiring
controller warning
3 YES harness between starting Repair
r
lamp flash and is Is there continuity motor(E) and CN14 (5)
NL!Ft5&J
gg%_..
,p
wiring harness between
switch ON.
CN14 (male) (5) -starting Repair
motor relay -chassis
ground
3) Connect T-adapter to CN14 (male) (female Defective power source -
seconds after NO wiring
starting switch
is turned ON
20-l 03
0
TROUBLESHOOTING E-2
CN15
3
Cbj27
1 3
ctq55 Start ina
motor
3 CNST
Start ine CN8 73 0422 3
-3 I 3
From battery
CN9 CN14 Battery
relay
Rotary -
switch
TWCOO307
20-104
0
TROUBLESHOOTING E-5
4) Transmission shifts to 1st to 4th (F and RI but not to 5th to 8th Cause Remedy
(F and R).
2 YES
Defective transmission Replace
Is voltage between high solenoid valve.
YES CNT03 (4) - CNTOI
- (11) -ground
1 connection 20 -
- 3OV?
* Defective contact, or Repair or
Is voltage
between CNTO3 - * Turn starting No disconnection in wiring replace.
switch ON. harness.
(1 j - (4) 20 - 3OV?
* Place shift lever - Defective print board
between 5th and 8th. circuit.
* Turn starting Iefective contact, or Repair
switch ON. NO iisconnection in wiring
- Place shift >arness between CNT03
lever between and transmission
5th and 8th. solenoid valve.
. Connect T-
adapter (or
socket) to
CNT03 (male).
SerialNo.:11001-12012,12016- 12018
2 YES
Iefective transmission Replace
Is voltage ow solenoid valve.
YES between CNT03
_ I3)-CNTOl (II)- _
1 ground
- connection 20 -
Is voltage 3OV?
Defective contact, or Repair or
between CNT03 NO disconnection in wiring replace.
(I) and (3) 20 - harness.
3OV? Defective print board
I circuit.
. Turn starting Reoair
Iefective contact, or
switch ON.
iisconnection in wiring
- Place shift iarness between CNT03
lever between
Ind transmission
1st and 4th.
solenoid valve.
* Connect T-
adapter (or
socket) to
CNT03 (male).
20-113
0
TROUBLESHOOTING E-6, E-7, E-8
Cause Remedy
2 YES
Defective inside rotary Repair or
Is voltage switch. reolace.
YES between CNTO~
1 - (3) and (11) 20- -
- 3OV?
Is voltage between
CNTOZ 14) and Defective contact, or
CNTOl 13). CNT02 - Turn Startig No disconnection in siring
(6) and CNTOI (3) switch ON. harness of rotary switch.
20 - 3OV? * Place shift lever
at 1st.
* Turn starting 1 * Defective print board Replace
switch ON. NO circuit.
* Place shift lever - Defective contact, or
at 1st. Repair
disconnection in wiring
harness between print
board and connector.
E-7 Transmission does not shift to 2nd (F and R).
Serial No.: 11001 - 12012, 12016 - 12018
20-114
0
TROUBLESHOOTING E-S, E-10, El1
2 YES
Defective inside rotary
Is voltage switch.
YES between CNTOI
1 - (6)and (11) ZO- -
- 3OV?
Is voltage
between CNTOZ ~ Defective contact, or
(4) and CNTOI (6), _ * Turn starting NO disconnection in wiring
CNT02 19) and switch ON. harness of rotary switch.
CNTOl (6) 20 -
3OV? - Place shift levr
at 4th.
. Turn starting 1 - Defective print board
switch ON. NO circuit.
- Place shift lever - Defective contact, or
at 4th. disconnection in wiring
harness between print
20-115
0
TROUBLESHOOTING E-12, E-13
Cause
,EiZ
Defective inside rotary Repair or
switch. replace.
ES between CNTOl
* Turn starting
*Defective print board Replace
switch ON.
circuit.
* Place shift lever - -Defectivecontact, or
at 7th. Repair
disconnection in wiring
harness between print
board and connector.
E-13Transmission does not shift to 8th (F and R).
Serial No.: 11001 - 12012, 12016 - 12018
2 YES
Iefective inside rotary Repair or
Is voltage switch. replace.
mz between CNTOI
1 (IO) and (11) 20- -
- 3OV?
Is voltage between
CNTOZ(5) and Iefective contact, or Repair
CNTOl(lO), CNTOP - ' Turn starting No disconnection in wiring
19)and CNTOI (IO) switch ON. larnss of rotary switch.
20-3OV? * Place shift lever
at 8th.
* Turn starting 1
switch ON. * Defective print board Replace
NO circuit.
- Place shift lever Repair
at 8th. * Defective contact, or
disconnection in wiring
harness between print
board and connector.
20-l16
0
TROUBLESHOOTING LED DISPLAY FOR TRANSMISSION CONTROLLER
1) Self-diagnostic display
The error code is displayed by LEDs using a 2-digit code. If an abnormality is detected, the warning
lamp and alarm buzzer are actuated.
2) Method of displaying error codes and abnormal operation codes again
Turn the starting switch OFF + ON and the error code and abnormal operation code will be
displayed in the following order:
[CHECK.SUMl + [Past failures] + [Existing failures] + [Abnormal operation]
When the [Abnormal operation] display finishes, the [Existing failure] display is repeated.
I I Error
code
Al 1 Short
Abnormal
circuit
system
in 1st clutch
and content
solenoid
of abnormality
20-152
0
TROUBLESHOOTING LED DISPLAY FOR TRANSMISSION CONTROLLER
2
z
2
16 Engine speed above 2350 rpm 0 0 -
17 Acceleration to dangerous speed with inching pedal depressed 0 0 -
Transmission lubricating oil temperature above 120C
18
continued for more than 30 seconds 0 0 -
With transmission at neutral, travel speed above 4 km/h and - -
19
engine speed above 1400 rpm continued for more than 10 seconds -
With transmission in F or R and inching pedal depressed,
IA travel speed above 4 km/h and engine speed above - - -
1400 rpm continued for more than 10 seconds
I------
0 : Clutch temperature below 200C
1 : Clutch temperature 200 - 230C
2 : Clutch temperature 230 - 260C
3 : Clutch temperature 260 - 290C
4 : Clutch temoerature above 290C
20-153
0
TROUBLESHOOTING LED DISPLAY FOR TRANSMISSION CONTROLLER
Display time
Display item (order of display) LED display
(se4
4) CHECK.SUM display
5) Trouble data
Z .Y 0.5
5 6) Error codes
Z
2 d4: Abnormality in engine speed sensor
Y-J $ c( 3
I? 7) If there are any other failures in memory,
Steps 5) and 6) are repeated.
8) Existing failures
* If there are no existing failures, t3.E is f-u 0.5
Z
L
=I displayed for 3 seconds.
Z
2 9) Error codes
F4: Disconnection in backup buzzer F 1-i
.-P 3
Z system, short circuit in power source
X
LLI IO) If there are any other failures, Steps 8) and
9) are repeated.
20-154
0
TROUBLESHOOTING LED DISPLAY FOR TRANSMISSION CONTROLLER
(1) Turn the starting switch to the ON position, and after completing the display for all the past
failures in memory, check that the display returns to 17 17 .
(2) Take the connector (color of wiring harness: green) cor%zed to connector number [FRI inside the
right console box, and ground it to the chassis. (When doing this, make sure that the starting
switch is at the ON position.)
. After grounding the connector, install the blind connector to the FR connector in the original
way.
(3) Turn the starting switch OFF, then turn it ON again and check that the past error codes have been
deleted from memory.
. If the past error codes have been deleted from memory, CHECK.SUM is displayed, then E.!l
is displayed immediately. (If there are any abnormal operation items saved in memory, the
display will start to show the abnormal items.)
20-155
0
TROUBLESHOOTING ET-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 connec-
tor to its original position, if the error code for [Existing failure] is no longer displayed on the LED
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
3 YES
GotoA
1Is voltage
H
II
11[ZFn
y$ijiij!;;;g.
Repair or
between 1st (female) (2)
YES replace
and E2 (female) (17)
Transmission controller
I
E2 1st 1st solenoid
TWG00317
20-156
0
TROUBLESHOOTING ET-2
Ir 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 connec-
tor to its original position, if the error code for [Existing failure] is no longer displayed on the LED
display, the problem has been removed.
* 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.
Cause Remedy
3 YES
GotoA
Is voltage
YES between 2nd
Short circuit with power
2 (female) (2) and
source in wiring harness Repair or
When 2nd is chassis normal? between 2nd (female) (2) replace
YE disconnected, is and E2 (female) (18)
* Max. 0.1 V NO
resistance between -
E2 (female) (81 and -Turn starting switch OFF. Short circuit in wiring
1
(18) normal? * Disconnect 2nd and E2. harness between E2
* Min. 1 MR - Turn starting switch ON. (female) (8) and 2nd Repair or
*Turn startina (female) (1) and wiring replace
hln
(male) (1) and (2) harness between E2
switch OFF.- *
(female) (18) and 2nd
. Disconnect 2nd (female) (2)
-5-20Q and E2.
-Turn starting Defective 2nd solenoid Replace
switch OFF. 0
- Disconnect 2nd.
Transmission controller
I I
E2 2nd 2nd solenoid
20-157
0
TROUBLESHOOTING ET-3
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 connec-
tor to its original position, if the error code for [Existing failure] is no longer displayed on the LED
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
3 YES GotoA
Is voltage
YES between 3rd
Short circuit with power
2 - (female) (2) and -
source in wiring harness Repair or
When 3rd is chassis normal?
between 3rd (female) (2) replace
disconnected, is
YE * Max. 0.1 V NO and E2 (female) (19)
- resistance between -
* Turn starting switch OFF. Short circuit in wiring
1 E2 (female) (9) and
119) normal?
* Disconnect 3rd and E2. harness between E2
* Min. 1 MC2 *Turn starting switch ON. (female) (9) and 3rd Repair or
(female) (1) and wiring replace
* Turn starting NO
(male) (1) and (2) harness between E2
switch OFF.
(female) (19) and 3rd
* Disconnect 3rd (female) (2)
*5-20R and E2.
. Turn starting ,h Defective 3rd solenoid Replace
switch OFF. IV
s Disconnect 3rd.
Transmission controller
I
TWG00319
20-l 58
0
TROUBLESHOOTING ET-4
+ 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 connec-
tor to its original position, if the error code for [Existing failure] is no longer displayed on the LED
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
3 YES GotoA
Is voltage
YES between 4th Short circuit with power
2 - (female) (2) and - source in wiring harness Repair or
I When 4th is chassis normal? between 4th (female) (2) replace
YES disconnected, is * Max. 0.1 V and E2 (female) (20)
NO
- resistance between -
*Turn starting switch OFF. Short circuit in wiring
1 E2 (female) (101and
* Disconnect 4th and E2.
p (201normal? _ harness between E2
Is resistance *Turn starting switch ON. (female) (IO) and 4th Repair or
* Min. 1 MCI
between 4th (female) (I) and wiring replace
- *Turn starting NO
(male) (1) and (2) harness between E2
switch OFF. (female) (20) and 4th
normal?
* Disconnect 4th (female) (2)
-5-20R and E2.
* Turn starting Defective 4th solenoid Replace
switch OFF. NO
* Disconnect 4th.
* Max. 0.1 V
* Turn starting
NO
source in wiring harness
between 4th (female) (1)
and E2 (female) (10)
Repair or
replace
switch OFF.
- Disconnect 4th and E2.
- Turn starting switch ON.
Transmission controller
I
E2 4th 4th solenoid
TWC00320
20- 159
0
TROUBLESHOOTING ET-5
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 connec-
tor to its original position, if the error code for [Existing failure] is no longer displayed on the LED
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
6 YES
GotoB
When Hi is
YES disconnected, is
Short circuit in wiring
- resistance between - harness between E2
5
- E2 (female) 121and
(female) (2) and Lo
Is resistance (14) normal? Repair or
(female) (I) and wiring
YES between Hi (male) _ *Min. 1 MR NO harness between E2 replace
(1) and (2) *Turn starting switch (female) (13) and Lo
~ 4 normal? OFF. (female) (2)
Is voltage * Disconnect Hi and E2.
*5-20R
A between Lo Defective Hi solenoid Replace
- -Turn starting NO
(female) (1) and switch OFF.
chassis normal?
. * Disconnect Hi.
* Max. 0.1 V Short circuit with power
source in wiring harness Repair or
* Turn starting
NO between Lo (female) (1) replace
switch OFF.
and E2 (female) (2)
* Disconnect Lo and E2.
-Turn starting switch ON.
a YES Defective transmission Repair or
controller replace
20-160
0
TROUBLESHOOTING ET-5
Lo solenoid
ransmission controller
Lo solenoid (+I
id
Hi solenoid (+I
Lo solenoid (+I
I I TWG00321
20-161
0
TROUBLESHOOTING ET-6
-+ 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 connec-
tor to its original position, if the error code for [Existing failure] is no longer displayed on the LED
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
3 YES
GotoA
6 YES
GotoB
L-t
between RE (female) (I) replace
B between RE Max. 0.1 V NO
and E2 (female) (5)
(female) (2) and * Turn starting switch OFF.
chassis normal? - Disconnect RE and E2. Short circuit with power
f Max. 0.1 V I *Turn starting switch ON. source in wiring harness Repair or
-Turn starting between RE (female) (2) replace
switch OFF. and E2 (female) (16)
* Disconnect RE
and E2.
* Turn starting
switch ON.
20- 162
0
TROUBLESHOOTING ET-6
FORWARD
solenoid
Transmlsslon controller
FORWARD solenold(-1
TWG00322
20-163
0
TROUBLESHOOTING ET-7
* 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.
*
4YES1 Defective transmission Repair or
Is resistance between
controller replace
YES E2 (female) (17).1st
Short circuit with ground
3 ifemale) 12)and
in wiring harness Repair or
~ chassis normal?
When 1st (female) (2) between 1st (female) (2)
YES isgroundedto chassis, ~ - replace
* Min. 1 MR NO and E2 (female) (17)
- is resistance between -
* Turn starting
2 E2 (female)(17)and Defective contact or
~ chassis n~~m.g switch OFF. disconnection in wiring
When 1st(female) (1) . Disconnect 1st and E2. 1 harness between 1st
* Max. 1 R Repair or
YI ; Is groundedto chassis, replace
- ISresistancebetween - - Turn starting NO (female) (1) and E2
E2 (female1 (71 and switch OFF. (female) (17)
1 chassisnormal? - Disconnect 1st and E2.
- Max. 1 R Defective contact or
* Ground 1st (female) (2) to chassis. Repair or
-Turn starting disconnection in wiring
harness between 1st replace
(male) (I) and (2) switch OFF. NO
+ Disconnect 1st and E2. (female) (I) and E2
* Ground 1st (female) (1) (female) (7)
*5-20R
* Turn starting to chassis. Defective 1st solenoid Reolace
switch OFF. \I0 (internal disconnection)
* Disconnect 1st.
Transmission controller
1
E2 1st 1st solenoid
TWG00317
20- 164
0
TROUBLESHOOTING ET-8
Ir 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.
I Cause Remedy
Transmission controller
I
g)
I TWG00318
20- 165
0
TROUBLESHOOTING ET-9
* 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
Defective contact or
* Ground 3rd (female) (2) to chassis. Repair or
disconnection in wiring
harness between 3rd replace
(male) (I) and (2) switch OFF. NO
* Disconnect 3rd and E2. (female) (1) and E2
* Ground 3rd (female) (1) (female) (9)
*5-20n
. Turn starting to chassis. Defective 3rd solenoid Replace
switch OFF. JO (internal disconnection)
* Disconnect 3rd.
Transmission controller
I
E2 3rd 3rd solenoid
TWG00319
20-166
0
TROUBLESHOOTING ET-10
+ 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
harness between 4th Repair or
YE replace
(female) (2) and E2
(female) (20)
1
1
chassis normal?
* Disconnect 4th and E2.
resistance * Max. 1 R Defective contact or
* Ground 4th (female) (2) to chassis. Repair or
between 4th * Turn starting disconnection in wiring
harness between 4th replace
(male) (I) and (2) switch OFF. NO
normal? * Disconnect 4th and E2. (female) (I) and E2
. Ground 4th (female) (1) (female) (IO)
5-20R
* Turn starting to chassis. Defective 4th solenoid Replace
switch OFF. 0 (internal disconnection)
* Disconnect 4th.
Transmission controller
I TWG00320
20-167
0
TROUBLESHOOTING ET-l 1
Ir Before carrying out troubleshooting, check that ail the related connectors are properly inserted.
* Always connect any disconnected connectors before going on to the next step.
Cause Remedy
Transmission controller
I
E2 Lo Lo solenoid
Lo solenoid (+I 3
Lo solenoid (-1 3
TWG00323
20-168
0
TROUBLESHOOTING ET-12
+ 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
Transmission controller
I
E2 Hi Hi solenoid
Hi solenoid (+I @
Hi solenoid (-1
TWG00324
20-169
0
TROUBLESHOOTING ET-13
* 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
FORWARD
YE2 FW solenoid
FORWARD solenoid(-)
I I TWG00325
20- 170
0
TROUBLESHOOTING ET-14
* Before carrying out troubleshooting, check that all the related connectors are properly inserted.
-)r Always connect any disconnected connectors before going on to the next step.
Cause Remedy
Defective contact or
- Ground RE (female) (2) to chassis. Repair or
disconnection in wiring
harness between RE replace
normal? * Disconnect RE and E2. (female) (1) and E2
. Ground RE (female) (1) (female) (5)
*5-20R
* Turn starting 1 to chassis. Defective REVERSE Replace
switch OFF. NO solenoid (internal
* Disconnect RE. disconnection)
Transmission controller
REVERSE
E2 solenoid
REVERSE solenoid(t) 5
REVERSE solenold(-) 16
it
I TWG00326
20-171
0
TROUBLESHOOTING ET-15
+ 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 connec-
tor to its original position, if the error code for [Existing failure] is no longer displayed on the LED
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.
* Check that the inching potentiometer mount is normal.
Cause Remedy
3 YES
GotoA
[When TM11 (female) 12) 1 7
Defective contact or
disconnection in wiring Repair or
harness between TM11 replace
YES (female) (2) and E3
1
r (female) (4)
GND
I \ I \ /
1 I
TWG00327
ZO-172
0
TROUBLESHOOTING CHART FOR HYDRAULIC SYSTEM
(H MODE)
STANDARDS FOR MEASURING HYDRAULIC PRESSURE, AND JUDGEMENT VALUES ................................. .20-202
TABLE OF FAILURE MODES AND CAUSES ............................................................................................................ 20-204
HYDRAULIC PRESSURE MEASUREMENT AND FILTER MOUNTING POSITIONS.. ............................................ 20-206
H-l Abnormal noise is made (from around pump) ............................................................................................. 20-208
H-2 Relief sound is heard (when not operating) .................................................................................................. 20-208
H-3 Hydraulic oil overheats (when not operating) .............................................................................................. .20-208
H-4 Work equipment does not move when control lever is operated (steering at neutral). .......................... 20-209
H-5 Work equipment is slow, lacks power ........................................................................................................... 20-210
H-6 There is excessive hydraulic drift of work equipment ................................................................................. 20-21 1
H-7 Steering wheel does not turn
(work equipment at neutral) ............................................................................................................................ 20-21 1
H-8 Turning speed is slow, lacks power
(work equipment at neutral) ............................................................................................................................ 20-212
H-9 Feeling when operating steering wheel is strange.. ..................................................................................... 20-212
20-201
0
STANDARDS FOR MEASURING HYDRAULIC
TROUBLESHOOTING PRESSURE, AND JUDGEMENT VALUES
*a=
*
l All work equipment
Min. 1.0 (IO), Min. 2.0 (201,
at standard position. and
and Max. 2.0 (20)
l Work equipment + 2.5 + 251
Pp+ 1.0 ( + 101
not operated.
235FO21025
:Hm 235FO2107
l Steering cylinder relief.
16.2 - 18.1
(165 - 185)
Vlax. Ps + 2.5
(25)
235FO2108
n
l Right blade lift cylinder %I 23.0 - 26.0
relief. PSI + 1.0 (IO) (235 - 265)
235FO2109
To steer ir
valve
I
I 235COO2220
20-202
0
TROUBLESHOOTING TABLE OF FAILURE MODES AND CAUSES
Surge
Parts causing failure pressure Priority flow
Pump
absorb- divider valve
Failure mode
20-204
0
023502
0 0 o
Wrk equipment control link
0 0 Slip clutch
I I I I I I
io do 4 Q z 2 z Troubleshooting code
in A
HYDRAULIC PRESSURE MEASUREMENT AND
TROUBLESHOOTING FILTER MOUNTING POSITIONS
235CD02221
Fia 2
l Pilot pressure measuring port (PP).
Surge Dressure
l LS line filter (3). absorbing valve
1 b@-+@A 235COO2222
Fig 3
. Pump filters (I), (2).
I
Fig 4
0 Filters (41, (5), (6) on top of surge pressure absorbing
valve.
absorbing valve
235CDO2044
20-206
0
HYDRAULIC PRESSURE MEASUREMENT AND
TROUBLESHOOTING FILTER MOUNTING POSITIONS
Fig 5
0 Control valve filters (71, (8).
235C00204E
Fia 6
l Steering valve LS line filter (9).
Fig 7
Measuring port for brake piston (circle) pressure.
(Serial No.: 11001 - 12050)
20-207
0
TROUBLESHOOTING H-l, H-2, H-3
Cause Remedy
YES Is strainer
clogged? YES
_ooseness of piping Tighten
3 :lamp.
- Is problem
corrected when
- piping between -
NO tank and pump is 4YE
Iefective pump. Replace
tightened?
~ Are metal
I; raulic tank particles found
Y
el normal? NO w,hen hydraulic
011 IS drained?
Natch for a short time to Inspect again
N( ;ee if there is any change [according to
n the condition. change in
condition).
H
Zlogged orifice. Clean
Is LS port orifice
clogged?
20-208
0
TROUBLESHOOTING H-A
H-4 Work equipment does not move when control lever is operated (steering
at neutral).
Cause Remedy
I) No work equipment moves.
YES
Go to Item 2). -
1
Is hydraulic
pump main pre- _ YES
Ssure normal? Pump filter (1) or (2) is Clean
2 clogged. (See Fig. 3)
Is surge pressure
absorbing valve
filter clogged? 2 YES
Clogged filter. Iean
2 YES
Defective operation of Repair or
control valve. replace.
20-209
0
TROUBLESHOOTING H-5
Cause Remedy
io to H-4.
GotoA
1 * Engine: Rated
Is work
equipment
control linkage
normal?
. Check
([i%$Thift ) Whenthereisnopower~ 1
operation of
linkage.
sot0 H-4.
Is there defect
From IA inside cylinder? 4 YES
Defective pilot check Repair or
valve. replace.
i!ic$q1-
20-210
0
TROUBLESHOOTING H-6, H-7
1 YES
Damaged cylinder, Replace
Are cylinder, piston, seal.
piston, seal
damaged?
YES Ilean
Clogged pump filters (I),
) I
(2). (See Fig.3)
- 17.2 + 1.0 MPa
(175 + 10 kg/cm).
I Is pilot pressure
, normal?
- Steering oil
at top and bottom
of surge pressure
YES
Clogged filter Clean
pressure
: _$$ Nm
k.
r
- Check filters
(3),(5). (See
Fig.2.4)
YES Defective shuttle valve. Repair or
reolace.
1 pees condition 5[ [
From A
Defective servo valve. Repair or
replace.
20-211
0
TROUBLESHOOTING H-8, H-9
Cause Remedy
YES
Go to H-7
4 YE:
Defective steering Repair or
cylinder. replace.
move normally?
Is relief pressure
- 20.6 MPa , Defective double relief Adjust or
(210 kg/cm? NO valve. replace.
2) There is kickback.
20-212
0
30 DISASSEMBLY AND ASSEMBLY
1
of piston
Blade lift
790-I 02-I 320 Socket (70 mm) 1 Drawbar shift ~~~~~~~~
3 Blade shift installation
Power tilt of nylonnut
790-I 02-I 330 Socket (75 mm) 1
Articulate
30-2
0
Nature of work Symbol Parts No. Part Name Oty Remarks
790-702-1000 Expander 1
Disassembly, assembly
of circle rotation gear
and hydraulic motor
B 791-560-1520 Floating seal installer Installation of floating seal
assembly
(Serial No.: 12051 and
up)
30-3
0
REMOVAL OF STARTING MOTOR
ASSEMBLY
A Disconnect the
minal of the battery.
cable from the negative (-) ter-
INSTALLATION OF STARTING
MOTOR ASSEMBLY
l Carry out installation in the reverse order to remo-
val.
REMOVAL OF ALTERNATOR
ASSEMBLY
Serial No.: 11001 - 12000
INSTALLATION OF
ALTERNATOR ASSEMBLY
Serial No.: 11001 - 12000
l Carry out installation in the reverse order to remo-
val.
30-4
0
DISASSEMBLY AND ASSEMBLY ALTERNATOR
REMOVAL OF ALTERNATOR
ASSEMBLY
Serial No.: 12001 and up
INSTALLATION OF
ALTERNATOR ASSEMBLY
Serial No.: 12001 and up
m
t After installing the V-belt, adjust the tension
of the belt.
For details, see TESTING AND ADJUSTING,
Testing and adjusting of belt tension.
30-4- 1
0
REMOVAL OF NOZZLE HOLDER
ASSEMBLY
INSTALLATION OF NOZZLE
HOLDER ASSEMBLY
l Carry out installation in the reverse order to remo-
val.
12
m Mounting bolt: 4.9 + 1.0 Nm (0.5 i 0.1 kgm)
m
m Locknut: 36.8 12.5 Nm (3.75 k 0.25 kgm)
m
w Connector: 36.8 + 2.5 Nm (3.75 + 0.25 kgm)
30-4-2
0
REMOVAL OF FUEL
INJECTION PUMP ASSEMBLY
2. Remove oil gauge pipe (I), hose flange (2), and ro-
tation guard (3).
* When removing the rotation guard, be careful
not to let the spacer on the inside fall out.
5. Disconnect fuel hoses (9), (IO), and (II), and fuel re-
turn hoses (12) and (13).
g
kc
: INSTALLATION OF FUEL
INJECTION PUMP ASSEMBLY
l Carry out installation in the reverse order to remo-
val.
30-6
0
DISASSEMBLY AND ASSEMBLY WATER PUMP
INSTALLATION OF WATER
PUMP ASSEMBLY
30-7
0
REMOVAL OF ENGINE OIL
COOLER CORE ASSEMBLY
235FO2204
REMOVAL OF TURBOCHARGER
ASSEMBLY
INSTALLATION OF
TURBOCHARGER ASSEMBLY
8
4
z l Carry out installation in the reverse order to remo-
val.
m
* Fit the gasket with UP mark facing up.
3%9
REMOVAL OF AIR COMPRESSOR
ASSEMBLY
INSTALLATION OF AIR
COMPRESSOR ASSEMBLY
l Carry out installation in the reverse order to remo-
val.
30-&o
REMOVAL OF CYLINDER
HEAD ASSEMBLY
8. Intake manifold
Remove bracket mounting bolts (28), then remove
mounting bolts (29) and intake manifold assembly
(30). m
3022
9. Turbocharger, exhaust manifold assembly m
Disconnect turbocharger oil supply hose (31)
and drain tube (32).
Remove mounting bolts (33) of exhaust man-
ifold, leaning 2 - 3 bolts in position.
Sling turbocharger and remove remaining bolts.
Then remove turbocharger and exhaust manifold
assembly (34) as one unit.
z
4
2
14. Connection m
Loosen lock nut (46), then remove connection (47)
and pull out.
18. Crosshead m
Remove crosshead (52).
3064
INSTALLATION OF CYLINDER
HEAD ASSEMBLY
1 21 17 13 9 5 1 4 8 12 16 20 24
235FO2205
I 566FO6352
m
* Clean the oil hole of the mounting bolt and install.
* Check that the ball of the adjustment screw is fitted se-
curely in the socket of the push rod.
w Rocker arm mounting bolt:
98.1 k 4.9 Nm (10 + 0.5 kgm)
w Adjustment screw locknut:
48.0 k 2.9 Nm (4.9 + 0.3 kgm)
* Adjust the valve clearance.
For details, see TESTING AND ADJUSTING, Adjusting
valve clearance.
30-&w
m Connection: 37.2 + 2.9 Nm (3.8 + 0.3 kgm)
pi?icJ
* Adjust the crosshead as follows.
i) Loosen locknut and turn back adjustment screw.
ii) Hold down top surface of crosshead lightly and
tighten adjustment screw.
iii) When adjustment screw contacts valve stem,
tighten a further 20.
iv) Tighten locknut to hold in position.
302 6
m
* Check that there is no dirt or dust on the cylin-
der head mounting surface or inside the cylin-
der.
* Check that the grommet does not come out
when installing the gasket.
* Coat the bolt threads and seat surfaces com-
pletely with molybdenum disulphide (LM-P).
* Screw in the cylinder head mounting bolts 2 -
3 turns by hand, then tighten as shown in the
diagram.
621 OF301
& Mounting bolt: Anti-friction compound
(LM-P)
F621201061
3027
DISASSEMBLY AND ASSEMBLY ENGINE
REMOVAL OF ENGINE
ASSEMBLY
(Incl. TRANSMISSION)
2. Radiator assembly
Remove radiator assembly.
For details, see REMOVAL OF RADIATOR AS-
SEMBLY.
3. Lift up cabin.
For details, see METHOD FOR LIFTING UP ROPS
CAB.
30-18
0
DISASSEMBLY AND ASSEMBLY ENGINE
30-18-l
0
6) Remove cables (13) and (14) from starting
motor.
I,
235FO2207
235FO2208
335FO72OC
30&l 9
10) Remove hoses (19A) and (19B).
w 19A 235FO221C
I 235FO2212
32
2) Remove engine front mounting bolts (34).
* Check the number and positions of the
shims,(37) which were removed.
9. Engine assembly
Remove engine assembly (32) from main frame.
J
235FO2213
3022
INSTALLATION OF ENGINE ASSEMBLY
(Incl. TRANSMISSION)
1. Engine assembly
Sling engine assembly (32) and set to main
frame.
30623
3) Adjust shim
J I .._.-.=-,,--/--~+=-
235COO2053
G
i) Insert shims at portions BL, BR, and A so iv) Finally, check that the misalignment between
that the center line of the crankshaft is par- the transmission and the propeller shaft is
allel to the final drive and propeller shaft within 3 mm.
when supported by portions BL, BR, and A. m Tightening torque:
When doing this, the standard shim thick- D: 235.4 - 411.9 Nm (24 - 42 kgm)
ness at portions BL and BR shall be 3.8 E: 245.2 - 308.9 Nm (25.0 - 31.5 kgm)
mm. F: 490.3 - 608.0 Nm (50.0 - 62.0 kgm)
ii) Decide the shim thickness so that the clear- G: 245.2 - 284.4 Nm (25 - 29 kgm)
ance at portion C is 0 mm. H: 823.8 - 872.8 Nm (84 - 89 kgm)
iii) Raise the engine and transmission, and add
0.7 mm of shim to portion C. Next, remove
0.7 mm of shim from portions BL and BR,
add 0.5 mm of shim to portion A, then as-
semble.
30624
2. Drive shaft
Using dial gauge, check-again that radial runout and
face runout of coupling face at transmission end
and coupling face at final drive end are within per-
missible value, then install drive shaft (30) with bolts
(31).
* If they are not within the permissible value, ad-
just the engine mount shims again.
m Mounting bolt: 98.1 - 122.6 Nm
(10.0 - 12.5 kgm)
8 235FO2.212
30625
4) Connect hoses (23), (24), and (25) to compress-
ors (21) and (22).
1
25
23
24
235FO2210
8) Connect air hose (19C).
235FO22Oi
12) Install tank and mounting bracket (12) to
rear frame, then connect connectors (IO) and
(II), and hose (9A) to sub-tank (8) and
washer tank (9).
FW, RE, HI, LO, Ist, 2nd, 3rd, 4th Serial No.: 11001 - 12012, 12016 - 12018
Connector (39): TM1 1
Connector (40): TM10
Connector (41): TM95
7. Radiator assembly
Install radiator assembly.
For details, see INSTALLATION OF RADIATOR
ASSEMBLY.
30-28
0
8. Refilling with oil
1) Tighten drain plug.
2) Add engine oil through oil filler (29) to the
specified level.
Q Transmission case: 35 e
30-28-l
0
REMOVAL OF RADIATOR,
:
u Coolant: 58 P
235FO221
30629
Sling radiator assembly (13). and remove mounting
bolts.
1) Loosen front mounting bolts (14).
13
L
235COO2056
23x002057
30630
INSTALLATION OF RADIATOR
Y
13 14
i,
Y
235C00205t
I
I
235COO205i
235CDO205E
30531
4. Install piping and electric wiring
1) Install fan guard (7).
2) Connect hose (6) to sub tank (6A).
3) Install radiator inlet hose (3), outlet hose (4) and
aeration hose (5) to engine.
4) Connect heater tubes (8) and (9) to radiator (10).
Q Coolant: 58 Q
235FO2215
30632
REMOVAL OF FUEL TANK
ASSEMBLY
2. Open drain valve (1) and drain fuel from fuel tank
(2).
235FO2216
235FO2217
-I
235F0221E
30633
INSTALLATION OF FUEL
TANK ASSEMBLY
1. Raise fuel tank (2) with jack 0, then pass shaft (16)
through rear frame and fuel tank.
235FO227C
frame
235FO2221
30634
9. Connect fuel hoses (4) and (5) to injection pump (6).
235FO2217
11. Close drain valve (I), then add fuel through fuel fil-
ler.
30-35
0
DISASSEMBLY OF PTO ASSEMBLY
1. Cover, tube
1) Remove tube (2).
2) Disconnect tube (3).
2. PTO assembly
Using plate, sling PTO assembly (4), remove mount-
ing bolts, then lift off PTO assembly.
* The center gravity of the PTO assembly is high,
and .it will fall over to the front, so use a lever
block to. keep it parallel to the mounting face
when lifting.
235COO2060
3. O-ring, gear
1) Remove O-ring (5).
2) Remove gear (6) from transmission case.
3) Remove bearing (7) from gear.
P2350 D 205
4. Tube
Remove tube (8).
5. Gear assembly
I) Screw in forcing screw and remove gear assem-
bly (9).
30636
2i Remove snap ring (IO), then pull out gear from
cage.
3) Remove bearing (1 1) from gear (12).
4) Remove snap ring (13), then pull out bearing
(14) from cage (15).
P23505207 P2350f208
6. Cover, holder
1) Using forcing screw 0 (Thread dia. = 12 mm,
Pitch = 1.75 mm), remove cover (17).
2) Remove holder (18).
7. Gear assembly
1) Screw in forcing screw and remove gear assem-
bly (1 9).
8. Lubrication tube
I) Turn over PTO case.
2) Remove lubrication tubes (28) and (29).
3020
ASSEMBLY OF PTO ASSEMBLY
Preparatory work
l Clean the lubrication oil circuit thoroughly.
l Apply engine oil to sliding portion of each part before
installing.
2. Shaft assembly
I) Set bearing and gear (43) to case.
2) Press-fit bearing (41) to shaft then install spacer
(42).
z
kc
2
3. Bearing cover
I) Press fit bearing (40).
2) Temporarily install cover (I 7).
4. Holder
Fit dowel pin and install holder (38).
6. Lubrication tube
Fit O-rings and install tubes (29) and (28).
30642
7. Gear assembly
I) Press fit bearing (27) to case.
2) Install shaft (25) to gear (26).
8. Cover holder
1) Screw in forcing screw 0 (Thread dia. = 12
mm, Pitch - 1.75 mm) and remove cover (17).
2) Fit dowel pin and install holder (18).
w Mounting bolt: 112.8 + 9.8 Nm
(11.5 + 1.0 kgm)
3) Fit O-ring and install cover (17).
9. Gear assembly
1) Press fit bearing (I 6) to case.
10. Tube
Install tube (8)
235COO2061
13. Tube
1) Connect tube (3)
2) Install tube (2).
DISASSEMBLY AND ASSEMBLY TRANSMISSION
REMOVAL OF TRANSMISSION
ASSEMBLY
(AS INDIVIDUAL PART)
1. Remove ROPS cab.
For details, see REMOVAL OF ROPS CAB.
- : Transmission case : 25 e
I k DEG00007
30-45-l
0
DISASSEMBLY AND ASSEMBLY TRANSMISSION
-------_.--._-=-~ ($_
DEG00008
9. Piping, control
1) Remove inching control rod (8) from trans-
mission.
OEGOOOIO
30-45-2
0
DISASSEMBLY AND ASSEMBLY TRANSMISSION
30-45-3
0
DISASSEMBLY AND ASSEMBLY TRANSMISSION
\ \ \ \,\ DEGOOOl6
DEG00017
DEG00301
30-45-4
0
DISASSEMBLY AND ASSEMBLY TRANSMISSION
INSTALLATION OF
TRANSMISSION ASSEMBLY
(AS INDIVIDUAL PART)
1. Raise transmission assembly (17) and set main
frame.
DEGO0019
I 18 DEG00017
DFG00009
30-45-5
0
DISASSEMBLY AND ASSEMBLY TRANSMISSION
4. Piping, control
I) Install air hose (15).
DEG00013
DDGOOOI 1
30-45-6
0
DISASSEMBLY AND ASSEMBLY TRANSMISSION
DEGOOOIO
.P OEG00007
30-45-7
0
DISASSEMBLY AND ASSEMBLY TRANSMISSION
30-45-8
0
DISASSEMBLY OF TRANSMISSION
ASSEMBLY
. Preparatory work
* Sling transmission assembly (I), then set it on block
@ (Height = 470 mm).
1. PTO assembly
Sling PTO assembly (2), remove mounting bolts (3),
then remove PTO assembly from transmission as-
sembly.
235CDO2061
5. Sleeve
Remove sleeve (8).
* Using eyebolt (Thread dia. = 16 mm, Pitch =
2.0 mm), remove sleeve.
6. Transmission case
1) Using eyebolts @ (Thread dia. = 12 mm, Pitch
= 1.75 mm), sling transmission case.
2) Remove mounting bolts, then remove transmis-
sion case (9).
7. Tie bolt
+ Using tool C check operating condition of piston
before disassembling.
Remove tie bolts (10).
8. Cage and reverse carrier assembly
Using eyebolts @ (Thread dia. = 16 mm, Pitch =
2.0 mm), sling cage and reverse carrier assembly
(1 11, then remove it.
14. Spring
Remove spring (20).
19. Spring
Remove spring (31).
26. Spring
Remove spring (40).
49
30650
30. No. 3 housing, 2nd speed piston
Using eyebolts @ (Thread dia. = 16 mm, Pitch =
2.0 mm), sling No. 3 housing and 2nd speed piston
(50) and remove them.
* Hold piston by hand to prevent it from falling.
31. Spring
Remove spring (5 1).
39. Spring
Remove spring (63).
s1
4
_-_,\\\\s, ,,,:,,,,i\,,,~&\ zf
2. No. 5 housing, low speed piston
1) Fit seal rings (71) and (721, then install piston to
No. 5 housing.
* Assemble with the seal ring groove facing
the housing side.
* Install seal ring without twisting.
3024
3. Ring gear
Install ring gear (68)
4. Guide pin
Install guide pin (67).
t Guide pin (67) is different in length from guide
pin (35).
6. Spring
Install spring (63).
7. Cage assembly
Using eyebolts @ (Thread dia. = 16 mm, Pitch =
2.0 mm), sling cage assembly (62) and install it.
* Confirm that spring (63) is firmly installed in
groove of cage and piston.
10. Spring
Install spring (57).
11. No. 4 housing, 1 st speed piston
I) Fit seal ring and install 1 st piston to No. 4
housing.
Sr When installing seal ring, refer to 2.-l 1.
2) Using eyebolts @ (Thread dia. = 16 mm, Pitch
= 2.0 mm), sling No. 4 housing and 1 st speed
piston (56) and install them.
+ Hold piston by hand to prevent it from falling.
+ Confirm that spring (57) is firmly installed in
groove of piston and housing.
14. Spring
Install spring (5 I).
lg. Spring
Install spring (40).
21. Sleeve
Install sleeve (73).
P2350E273
27. Spring
Install spring (3 1).
3028
42. Seal ring
Install 2 seal rings (78).
44. Cage
1) Install ball to cage and install caller (81).
2) Press fit bearing (82) and fix it with snap ring
(83).
3) Fit O-ring and install cage (6).
c3
@
@
235COO206:
L
30$2
DISASSEMBLY OF CAGE AND REVERSE
CARRIER ASSEMBLY
3. Shaft
Remove shaft (5).
4. Cage
Remove cage (6).
5. Cage assembly
1) Remove snap ring (7).
2) Remove cage assembly (8).
1. Cage assembly
1) Install spacer (10) to reverse carrier assembly
(9).
2) Press fit bearing (11) to cage assembly (8).
3) Install seal ring (12). install cage assembly (8)
and fix it with snap ring (7).
2. Cage
Install seal ring (13) and install cage (6).
3. Shaft
Install shaft (5).
4. Shaft assembly
1) Remove snap ring (IO) from shaft (9) and
remove 1 st speed sun gear (11).
2) Remove spacer (12).
F23EC019A
P23EC I 56 P23EC I 55
30664
ASSEMBLY OF 1 ST SPEED AND 2ND SPEED
CARRIER ASSEMBLY
1. Shaft assembly
I) Install spacer (12) to shaft (9).
2) Install 1st speed sun gear (1 1) and fix it with
snap ring (10).
3) Install seal ring (13) to spacer (12).
P23EC I 56
P23EC f 53
DISASSEMBLY OF HIGH ROTATING CLUTCH
ASSEMBLY
1. Shaft assembly
Remove mounting bolt and remove shaft assembly
(1).
3. Sun gear
1) Remove snap ring (5).
2) Remove sun gear (6).
4. Cage assembly
I) Put punch mark on cage (7) and carrier (8).
2) Remove bearing (9) together with cage.
5. Planetary gear
Remove planetary gear (10).
* For details, see DISASSEMBLY OF PLANETARY
GEAR.
ASSEMBLY OF HIGH ROTATING CLUTCH
ASSEMBLY
1. Planetary gear
Install planetary gear (IO).
* For details, see ASSEMBLY OF PLANETARY
GEAR.
2. Cage assembly
1) Press fit bearing (9) to cage (7).
2) Align the punch mark stamped during disassem-
bly and install cage assembly (8).
3. Sun gear
1) Install sun gear (6).
2) Turn carrier assembly over and fix it with snap
ring (5).
30667
DISASSEMBLY OF PLANETARY GEAR
1. Transmission assembly
Remove transmission assembly from transfer case.
For details, see DISASSEMBLY OF TRANSMISSION
ASSEMBLY.
3029
5. Cover, brake assembly
I) Remove mounting bolts, then remove cover (I 0).
2) Remove mounting bolts, then remove brake as-
sembly (I I).
6. Coupling assembly
I) Remove mounting bolts (I 2) then remove holder
(I 3).
30670
3) Remove oil seal (21) from cage (20).
4) Put tool (inside diameter: 90 mm; height: 150
mm) in contaot with bearing (221, push out
shaft, and remove bearing (23). spacer (24). 39 21
gear (251, and spacer (26) from shaft (27). 22
5) Remove cover (28). bearing (22) from cage (29).
29
6) Remove bearing (3 I) from case.
40 26
28
25
24 23
31
P23508300
9. Strainer
Remove connector (38) and strainer.
DISASSEMBLY OF TRANSMISSION CONTROL VALVE
ASSEMBLY
UPPER VALVE
235FO2225
LOWER VALVE
235FO2226
30-&76
UPPER VALVE LOWER VAVE
1. Remove covers (2) and (3) from body (1). 1. Remove cover (50) from body (49).
7. Spacer
Remove plug (47), then remove spacer (48).
30677
ASSEMBLY OF TRANSMISSION CONTROL VALVE ASSEMBLY
UPPER VALVE
235FO2225
LOWER VALVE
235FO2226
REMOVAL OF HYDROSHIFT
TRANSMISSION PUMP ASSEMBLY
2. Remove inlet and outlet tube (1) and hose (2) from
transmission pump.
INSTALLATION OF HYDROSHIFT
TRANSMISSION PUMP ASSEMBLY
Install transmission pump assembly (4) to PTO (5)
and tighten mounting bolts (3).
Install inlet and outlet tube (1) and hose (2) to trans-
mission pump.
30680
REMOVAL OF TANDEM AND
FINAL DRIVE ASSEMBLY
1. Cover
Remove cover (IA) and (1 B) from final drive.
:
U Final drive case: 57 II
235FO2227
4. Hanger
Loosen bolts (4), disconnect hanger (5) and main
frame.
3
235FO2228
5. Brake hose
Disconnect brake hoses (6) and (7) from joint (8).
6. Drive shaft
Loosen bolts (IO), then remove drive shaft (9) be-
tween transmission and final drive.
30A8 1
7. Cap
Support final drive and main frame mounting cap
(11) with jack 0, and remove.
* Distinguish between L.H. and R.H. caps.
30$2
INSTALLATION OF TANDEM
AND FINAL DRIVE ASSEMBLY
\\\ / 235FO2231
2. Cap
Adjust shims of final drive and main frame mount-
ing cap (II), then support with jack 0, and install.
l Adjusting shims
1) Tighten bolt (B).
a Tighten bolt (A) and measure clearance.
3) Loosen bolt (A) and insert shim (13) (thickness
= clearance above) in (A) end.
4) Loosen bolt (B).
5) Tighten bolt (A).
6 A 13
235FO223;
3. Drive shaft
Using dial gauge, check that radial runout and face
runout of coupling face at transmission end and
coupling face at final drive end are within per-
missible value, then install drive shaft (9) with bolts
(IO).
* For details of the method of measuring and the
permissible values for the radial runout and face
runout, see INSTALLATION OF ENGINE ASSEM-
BLY.
* If they are not within the permissible value, ad-
just the engine mount shims.
w Mounting bolt: 110.3 + 12.3 Nm
(11.25 i 1.25 kgm)
30683
Hanger
Install hanger (5) on main frame by bolts (4).
a Hanger mounting bolt: Thread tightener (LT-2)
w Hanger mounting bolt: 926.7 - 103.0 Nm
(94.5 k 10.5 kgm)
235FO2227
3A
235FO2228
7. Brake hose
Connect brake hoses (6) and (7) to joint (8).
30684
DISASSEMBLY OF FINAL DRIVE
ASSEMBLY
Special tool
:
u Final drive case: Approx. 63 Q
2. Cover
Remove covers (5)
Chain
I) Turn the pinion and align connection part of
chain to access position.
5. Drive shaft
Remove bolts (111, then remove drive shaft (I 2)
from coupling.
3026
6. Coupling
Pull out coupling (13) from pinion shaft.
7. Tube
Remove tube (I 4) together with O-ring.
235FO2233
8. Strainer
Remove spring (15) and strainer (I 6) from pipe.
9. Cover, pipe
1) Remove pipe (17) together with O-ring.
2) Remove cover (18).
10. Tube
Remove tubes (19) and (20) then remove flanges
(21) and (22).
P2350 I325 ti
0
I2350 1326
12. Plate
Remove bolt (26) then remove plate (27).
P2350 I327
13. Carrier assembly
Sling and remove carrier assembly (28).
63kg
Carrier assembly: 1 10 kg
16. Sprocket
Remove sprocket (36) from shaft.
17. Bearing
Remove bearing (37) from shaft.
lg. Plate
Remove bolts (39). washer (40) and plate (41).
21. Flange
Sling and remove flange (45).
Flange: 74 kg
30692
2) Remove bolts (65), then remove cages (62) and
(63).
30693
ASSEMBLY OF FINAL DRIVE
ASSEMBLY
Special tool
3) Measuring preload
Install @ and bolt @ (16 mm x 2 mm -
locknut
120 mm) to bevel pinion assembly, then measure
starting torque with torque wrench 0.
* Adjust so that the starting torque at the bevel
pinion is 0.68 - 1.0 Nm (0.07 - 0.10 kgm)
greater than the torque for the bevel pinion
alone 9.8 - 12.8 Nm (1 .O - 1.3 kgm).
When doing this, measure the starting torque
at the outside circumference of the bevel gear
alone.
Starting force (bevel gear alone):
9.8 - 12.8 N (1.0 - 1.3 kg)
4. Testing and adjusting
Adjust preload to taper roller bearing, backlash and
tooth contact of bevel gear and bevel pinion.
Adjust bevel pinion assembly for starting force
of 9.8 to 12.8 Nm (1.0 to 1.3 kgm) as a single
assembly.
Install bevel pinion assembly on case with the
same shims as those before removal.
Perform adjustment of preload, backlash and
tooth contact in parallel.
Measure starting torque of bevel gear assembly
while bevel gear is in mesh with bevel pinion.
When adjusting the preload of the bearing,
change the amount of shims inserted in the
cages at the left and right sides of the center
case. a=20to33mm
b = 13to26mm
end side
Small
23F032
v 23FO50
30697
6. Shaft
Install axle shaft (56) to center case.
6. Sungear
Install sun gear (55) and collar (54) to axle shaft, and
fix them with snap ring (53).
7. Ring-gear
Install ring-gear (52) to center case.
8. Shaft, bearing
Press fit bearing (51) to shaft (50).
* When doing this, position it so that the distance
from the end face of the shaft to the tip of the
bearing is distance A (1 15 mm).
30698
9. Side case
i) Assemble washer (49) to side case (48) (with
bearing and oil seal) so that end of washer is as
shown in diagram on right.
#TIJ= Washer (contact surface) :
Anti-friction compound (LM-P)
10. Flange
Fit O-ring to side case, then sling and install flange
(45).
ks Flange: 74 kg
C?J
14. Bearing
Install bearing (37) to shaft.
15. Sprocket
Install sprocket (36) to shaft.
* Assemble the sprockets so that the long ribs are
alinged.
30-A00
ii) Install 3 gears (33) to carrier with pin (32), plate
(31) lock plate (30), and bolts (29).
P2350 B328
P2350 I327
18. Tube
Install flanges (22) and (2 I) then connect tubes (20)
and (1 9).
21. Tube
Fit O-ring and install tube (14).
235FO2233
22. Coupling
Install coupling (13) to pinion shaft.
3. Remove bearing (6) and seal ring (7) from cage (5).
11. Remove pinion assembly (18, 18A, 19, 19A, 19B, 19C,
and 19D) from cross joint (17).
12. Remove nut (18A) from sleeve (18), then remove pi-
nion (19) and bearing assembly (19A, 19B. 19C, and
19D).
13. Remove gear (20) and thrust washer (21) from dif-
ferential case A (4).
30208
ASSEMBLY OF BEVEL GEAR
ASSEMBLY
8. Install seal ring (9) to piston (8) and install to cage (5).
30210
9. Install bearing (6), seal ring (7) to cage (5) and install
them by bolts and lock plate.
10. Stop bevel gear (3) with dowel pin of differential case
A (4),. then install with lock plate (2) and bolt (1).
30211
DISASSEMBLY OF BEVEL PINION
ASSEMBLY
2. Use press fit tool @ (I.D. 4200 mm) and set cage (5)
in press. Press pinion (6). pull it out from cage to
separate pinion and cage.
* It is possible to remove bearing (7) and pull out
pinion at the same time.
30212
ASSEMBLY OF BEVEL PINION
ASSEMBLY
P2350t366
2. Using press fit tool, press fit outer races (8) (upper
and lower: 2 PCS.) in cage (5).
5. Set the pinion in a vice and install nuts (3), (2) and
lock plate (4).
P2350t363
REMOVAL OF FRONT AXLE
ASSEMBLY
kg
r6?l Front wheel assembly: 530 kg
36
:
I Front axle housing: 1.8 11
1. Steering cylinder
1) Loosen bolt (I) and pull out pin (2), remove
steering cylinder (3) bottom end from front axle
(4).
2) Loosen locknut (5) and remove steering cylinder
head end from hub shaft assembly (6).
Leaning rod: 50 kg
30218
2) Loosen bolt (16) and pull out pin (17). then
remove leaning cylinder bottom end from front
axle.
Leaning cylinder: 26 kg
& kg
4. Kingpin
Loosen bolt (18) and pull out king pin (191, then
remove hub shaft assembly.
5. Bracket
Loosen nut (201, pull out shaft (211, then remove
bracket (22) from front axle.
& Bracket: 29 kg
iI 235FO2238
3. King pin
1) Assemble hub shaft assembly (6) and bearing
(33) to bracket (22), then insert king pin (19).
2) Measure clearance 0.
* Standard clearance: 6 mm
3) Select one thrust washer of a thickness closest
to 0 - 0.2 mm.
* Types of thrust washer:
t = 4.5 mm, t = 5.5 mm, t = 6.5 mm
4) Pull out king pin (19), and assemble selected
thrust washer (32) to bracket (22).
5) Insert king pin into hub shaft assembly and
bracket, insert bolt into hole 0 and secure.
-'35F0223E
30222
4. Leaning rod, leaning cylinder
1) install leaning cylinder (14) bottom side to front
axle then fix pin (17) and lock to bolt (16).
30-123
5. Tie rod assembly
1) Install joint (35) and ball joint (36) to shaft (34).
* . Toe-in adjustment is carried out on joint (35)
after completion of assembly, so coat it with
thread tightener when adjusting.
* When adjusting
6. Steering cylinder
1) Install steering cylinder (3) bottom side to front
axle, fix pin (2) and tighten bolt (1) with lock
(37).
2) Install steering cylinder head end to hub shaft
assembly and tighten nut (5).
30224
DISASSEMBLY OF STEERING
VALVE
23EFO I lOi
I 23EFOI 109
302 25
8. Remove drive (7).
Control End
I 23EFOI I I I
I 23EFOI I I2
13. Remove quad ring seal (13) from seal gland bush-
ing.
I 23EFOI I13
15. Remove 2 bearing races (15) and the needle thrust
bearing (16) from spool and sleeve assembly.
23EFOI II4
17. Push pin (18) from spool and sleeve assembly (17).
Control end
* a . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Spring slot
* b . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Identification marks.
30228
7. Bring spring slots of both parts in line and stand
parts on end of bench. Insert spring (21) installation
tool through spring slots of both parts. Tool is avail-
able as part No. 600057. Position 3 pairs of center-
ing springs (or 2 sets of 3 each) on bench so that
extended edge is down and arched center section is
together. In this position, insert one end of entire
spring set into spring installation tool.
8
4
si 23EFOI 121
23EF0 I I23
14. Install dust seal (14) in seal gland bushing (12), flat
or smooth side of dust seal must face down to-
wards bushing.
f==b 11
15. Install dry quad ring seal (13) in seal gland bushing
(12).
Smooth seal in place with your finger. Do not use
any seal that falls freely into pocket of buhisng.
16. Install seal gland bushing over the spool end with a
twisting motion. Tap the bushing in place with a
rubber hammer. Make sure that bushing is flush
23EFO I I.24
against the bearing race.
23EF 01 125
23EF0 I I26
23EF0 I I27
21. Rotate spool and sleeve assembly until pin (18) is
parrallel with port face a. Install drive (7), make
sure you engage drive with pin. To assure proper
alignment, mark drive. Note relationship between
slotted end of drive to splined end of drive when
marking.
I 23EFOI 129
I 23EF0 I I30
23EFOI I31
F23EH01212
30-G31
ASSEMBLY
10. Pull out bearing (18) and spacer (19) from shaft
assembly.
P2350 1,406
30-l 33
0
ASSEMBLY OF WHEEL BRAKE
ASSEMBLY
30234
6. Install 4 springs (14) and 4 bolts (I 3).
ATL Mounting bolt: Thread tightener (LT-2)
Cage assembly: 80 kg
& kg
302 36
DISASSEMBLY AND ASSEMBLY AIR TANK
To transmission DWG00233
REMOVAL OF HYDRAULIC
TANK
:
w Hydraulic oil: 108 Q
1235FO2244 / /I
6. Disconnect hydraulic hoses (5), (6), (7), (8), and (9).
INSTALLATION OF HYDRAULIC
TANK
235COO2
REMOVAL OF HYDRAULIC
PUMP ASSEMBLY
:
I Hydraulic tank: 108 Q
4. Disconnect hoses (3), (4), (5), (6), and (7) from hy-
draulic pump (2).
235CD0207t
INSTALLATION OF HYDRAULIC
PUMP ASSEMBLY
Reartram 235CDO2074
30- 140
0
BLEEDING AIR FROM HYDRAULIC PUMP
A When
replaced
the
or
hydraulic
removed,
pump
always
or piping
bleed
have
the air
been
as
follows.
Q Oil: 3.5 - 4 Q
Special tools
:
W Hydraulic pump: Approx. 3 S?
* The drained oil cannot be used again.
235CDO2076
2. Seal assembly
1) Remove snap ring (5), then remove seal assem-
bly (6) from front cover.
* The stationary seal and O-ring cannot be
used again.
235FO2246
5. Front pump
1) Loosen 8 bolts (16), then remove bolts leaving 2
bolts marked % remaining in position.
2) Loosen 2 bolts marked % in turn, and separate
pump and center section.
* The mounting surface of the servo valve is
easily scratched, so put a rubber mat under
the pump when carrying out the operation.
Ll
F23501333
6. Rear pump
Remove rear pump in the same way as Item 5.
Front pump.
30244
3) Remove bearing plate (27) with screwdriver 0.
* The mating surface of the cylinder block and
bearing plate is lapped precisely, so be care-
ful not to scratch it.
8
k=G
P23501541
8
30- 146
a
15) Loosen 3 bolts (39), then tap bottom of trunnion
with hammer X, and remove trunnion assembly
(40).
* Make match marks to indicate the mounting
position of the trunnion.
P23508547
30-&48
5) Set bolt 0 in vice, insert cylinder block (51) and
spacer @ , then tighten nut 0 slightly, and
remove snap ring (52).
235COO2078
3
8
:
O\dL
-\
235CW2CBZ 235FO2247
A Remove
from
the
flying
cover
off under
carefully
the
to prevent
pressure of the
it
spring.
30250
7) Remove spring (63).
235CDO2084
235CDO2086
235CD02087
66 71 u
235FO2248
12) Remove link (76)
Long-nosed pliers
235F0224E
17) Remove sleeve (64) from cover (61). -
I
6432
\l\ 235COO2096
::!2
0
J
--
77
--
-A -
235CD02097
235CD02098
Mating surface
T-4 235FO2251
235FO2252
302 54
4) Remove plug (85).
t If it is necessary to use a vice, clamp with
the vice at the position shown by the arrow.
Mating surface
235FO2251
235CD0210(
235FO225L
ASSEMBLY OF HYDRAULIC PUMP ASSEMBLY
Special tools
c I 790-445-6550 1 Guide I 1
A. The gasket,
used again.
O-ring, and backup ring cannot be
4. Assembly of trunnion
Press fit bearing (62) in trunnion (40) with press.
66
_,?2350 i 665
P2350 I566
P.2350 I567
30-A60
8. Assembly of pump (common for F and R pumps)
1) Install pin (46) to swash plate (43), and secure
with snap ring (45).
2 disassembled.
% The shim thicknesses are distinguished by
8 color.
Colors and shim thicknesses Unit: mm
Color Thickness
Amber 0.025
Green 0.075
Blue 0.127
Brown 0.254
Yellow 0.508
F23501338
F23501338
3op
7) Install pilot (28).
8) Install pin (29).
9) Install bearing plate (27).
* Align pin (29) and the mounting hole when
installing the bearing plate.
* Coat with grease (G2-LI) when installing to
P2350 L 585
30265
3) Install guide (32).
P23501588
F23501340
F23501342
302 68
Method of tightening bolts
@ Tighten in turn 2 bolts marked % in diagram on
right until center section (18) is in close contact.
@ If bolt becomes difficult to tighten but center section
is still not in close contact, loosen bolts and tighten
again.
@ Install remaining 6 bolts and screw them in.
F2350134:
F23501344 F23601345
F23501346
3oi!70
7) Coat bearing plate (27) with engine oil (EO
SAEI OW).
F23501343
F23501345
9) Measure shaft end play of front pump
i) Set tool C to front shaft, and measure end
play with dial gauge.
Standard end play: 0.15 - 0.41 mm
ii) If measurement is outside standard range,
adjust shim (23) again in Item 12.1).
End play too large: Add shims
End play too small: Remove shims
235CD02096
302 72
4) Install plug (68A) to housing.
66 71 LJ
235FO2248
235COO2087
235CDO2OBe
I 235CDO2084
30274
12) Install O-ring (72) and back-up ring (73).
2?5COO2083
235COO210;
235COO2103
235CDO21OL
16) Fit O-ring to plug (69) and install to housing.
235COO2078
-- F23501348
F23501349
15. LS valve (common for F and R pump)
1) Install 3 plugs (68).
235FO2251
5 3
235FO2256
17. Plugs
Install 3 plugs (8).
:
w Hydraulic tank: 108 Q
j235FO2244 / /I
35FO2257
DISASSEMBLY OF MAIN CONTROL VALVE
* Be careful to check that there is no dirt or 8. Loosen 2 bolts (18), and remove plate (19).
scratches on any part.
* Be careful not to damage the sliding surface 9. Pull out spool (16) from spring cap.
and the mating surface.
* When disassembling the spools, shuttle valves, 10. Remove oil seal (20) with a screwdriver.
or any other parts, mark with tags to distin-
guish the location. 11. Removal of pressure compensation valve
When assembling, be sure to assemble in the (without adjustment screw)
same valve case. 1) Remove cap (21), then remove spring (22).
* Be careful not to let the spring fly. off.
1. Hold nuts (1) and (2) with a box wrench, and 2) Remove plug (23), then pull out spool (24).
loosen nuts (3) and (4).
* Leave nuts (1) and (2) fitted to the stud 12. Removal of pressure compensation valve (with
bolts. adjustment screw)
Remove cap (25).
2. Pull out each valve body assembly from stud Remove locknut (26) and adjustment screw
bolts (5) and (6). (27) from cap (25).
* Make match marks on the mating surface Remove collar (28), o-ring (29), backup ring
of each valve body. (30), and spring (31).
Remove plug (32), then pull out spool (33).
3. Remove O-rings (7) and (8) from valve body.
13. Disassembly of pilot relief valve
4. Pull out shuttle valve assembly (9). 1) Remove pilot relief valve assembly (34).
2) Loosen cap nut (35) and nut (36), then re-
5. Loosen 2 bolts (IO), and remove cap (11). move adjustment screw (37) and 2 seal
washers (38).
6. Loosen bolt (12), and remove 2 collars (13), * Be careful not to let the spring fly off.
spring (14), and plate (15). 3) Remove spring (40), valve (41), o-ring (42),
* When removing bolt (12), be careful not to and backup ring (43) from valve body (39).
let the spring fly off.
235F501
30; 83
ASSEMBLY OF MAIN CONTROL VALVE
case.
11. Install O-rings (7) and (8) to each valve body.
m Plug: 78.5 & 9.8 Nm (8 k 1 kgm)
2) Install backup ring (30) and O-ring (29) to
12. Insert valve body in stud bolts (5) and (6) in
collar (28).
the same order as for disassembly.
3) Tighten adjustment screw (27) and locknut
* Be careful not to bend the shuttle valve or
to cap (25) temporarily, and insert collar
let the O-ring protrude.
(28) and spring (31) in cap.
4) Fit O-ring (46) to cap (25) and install to
13. Tighten nuts (2) and (3).
valve case.
m Nut (2): 58.8 Nm (6 kgm)
m Cap: 78.5 f 9.8 Nm (8 k 1 kgm)
* Tighten the locknut fully after adjusting w Nut (3): 98.1 Nm (10 kgm)
3Oi.84
LO
27/
34
235F501
302 85
DISASSEMBLY OF CIRCLE ROTATION MOTOR
Serial No.: 11001 - 12050
Special tools
A, 1 790-445-6210 1 * Stand I 1
A, 1 790-445-6220 / . Stud bolt I 1
A, 1 790-445-6230 / * Stud bolt I 1
A., / 790-445-6240 I * Handle I 2
A, / 790-445-6250 ) . Nut I 2
A, 1 01010-31045 1 - Bolt I 4
A, 1 01643-31032 1 * Washer I 4
F23501351
A, 1 04025-00332 I . Spring pin I 2
B I 790-445-6260 I Plate I 1
B, / 790-445-6270 I . Plate I 1
B, 1 01010-31030 1 - Bolt I 5
4 01643-31032 * Washer 5
F23501353
30-186
0
* Be careful not to damge oil seal (IO) with the
shaft when removing the cover.
6. Loosen bolts (ll), (12), and (13), and pull out case
(9) from top.
13. Remove timing plate (18), spring (19), and pin (20).
15. Loosen bolts (22) from retainer plate (3) and swash
plate (14), then remove retaining rings (23), retaining
plates (24), and slippers (25).
L F23501355
F23501356
17. Remove O-ring (28) and backup ring (29) from
sleeve (27) fitted to retainer plate (3).
* Do not remove sleeve (27) except when replac-
ing it.
F23501356
F23501357
ASSEMBLY OF CIRCLE ROTATION MOTOR
Serial No.: 11001 - 12050
Special tools
E2 01010-31035 . Bolt 1
B, 01643-31232 . Washer 1
* Shim adjusting ,
F, 790-445-6460
tool
F, 1 01010-31055 1 . Bolt I 4
F, 1 01643-31032 1 * Washer I 4
F, 1 01050-31030 1 . Bolt I 3
C, 04205-00835 . Pin 1
C 10 04205-01038 * Pin 1
30-189
0
1. Fit O-ring (26) to retainer plate (3).
F23501358
* When assembling timing plate (18), set it sym-
metrically to the left and right of the line joining
the high side and low side of the angled surface
of retainer plate (3).
13. Fit stud bolt (A*), and secure cylinder block (4) and
retainer plate (3).
* Align slipper (25) with the position of the bore
of the cylinder block.
18. Using inserting tools (D,) and (D,), insert piston (16)
at swash plate (14) end, then stop piston with stop-
per (C,).
F23501359
F23501360
19. Install slippers (25), retaining plate (24), and retain-
ing ring (23) to swash plate (14) with bolts (22).
21. Set top hat (E,) over shaft, then screw bolt (E2) and
washer (EJ into bolt hole in end face of shaft to
tighten top hat (E,). F23501361
24. Set case (9) over cylinder block (4), then secure
case (9) and retainer plate (3) with bolt (13).
25. Fit seal washers (31) to bolts (11) and (12), then
tighten case (9) and swash plate (14).
27. Shrink fit inner race of bearing (15) to shaft, then in-
stall.
F23501362
* Shrink-fitting temperature: Max. 130C
F23501363
28. Knock outer race of bearing (15) into case (9).
F23501366
30. Knock oil seal (10) into cover (6).
F23501367
F23501368
F23501352
30294
DISASSEMBLY AND ASSEMBLY CIRCLE ROTATION MOTOR
\I
J DWG00277
30-194-l
0
DISASSEMBLY AND ASSEMBLY CIRCLE ROTATION MOTOR
DWG00278
30-194-2
0
DISASSEMBLY AND ASSEMBLY CIRCLE ROTATION MOTOR
DWGO
30-194-3
0
DISASSEMBLY AND ASSEMBLY CIRCLE ROTATION MOTOR
=, DWG00287
30-194-4
0
DISASSEMBLY AND ASSEMBLY CIRCLE ROTATION MOTOR
30-194-5
0
DISASSEMBLY AND ASSEMBLY CIRCLE ROTATION MOTOR
DWG00277
30- 194-6
0
DISASSEMBLY AND ASSEMBLY CIRCLE ROTATION MOTOR
=, DWG00287
DISASSEMBLY AND ASSEMBLY CIRCLE ROTATION MOTOR
9. Install seal ring (4) to rotor set (8), then put wear
plate (9) on it.
* Install with the seal ring side at the bottom.
* Replace seal ring (4) between stators (8B)
and (8D) of the rotor set with a new part.
& Bearing : Grease (G2-LI)
30-194-8
0
DISASSEMBLY AND ASSEMBLY CIRCLE ROTATION MOTOR
/ I II ---lJ--- I\ DWG00296
_=;i=;_ 1 DWG00297
3 DWG00298
30-194-9
0
DISASSEMBLY AND ASSEMBLY CIRCLE ROTATION MOTOR
DWG00300
16. Install shaft key (12A), bolt (12D), washers (12E) B port
and (12C), and retaining ring (12F). /
I DWG00278
30-194-10
0
REMOVAL OF DRAWBAR SHIFT CYLINDER,
BLADE LIFT CYLINDER, LIFTER GUIDE
A Stop
times
the engine.
the remaining
Operate
pressure
control
from
lever several
the hydraulic
piping.
P2350 F424
P2350 i 425
A
m Lower lifter guide: 550 kg
P2350 I427
INSTALLATION OF DRAWBAR SHIFT CYLINDER,
BLADE LIFT CYLINDER, LIFTER GUIDE
P2350 I425
P2350 I430
3. Blade lift cylinder
1) Temporarily sling blade lift cylinder (4) and insert
in upper lifter guide hole.
INSTALLATION OF ARTICULATE
CYLINDER ASSEMBLY
30?A99
REMOVAL OF REAR MOUNT
RIPPER CYLINDER ASSEMBLY
2. Remove lock plate (2) at head end and remove pin (3).
A If it is difficult
residual pressure
to remove
in the
the
cylinder,
pin because
loosen
of
the
sleeve nut of the hose to discharge the residual
pressure.
INSTALLATION OF REAR
MOUNT RIPPER CYLINDER
ASSEMBLY
5. Install head pin (13) and fix with lock plate (2).
30200
DISASSEMBLY OF HYDRAULIC
CYLINDER ASSEMBLY
iii-_ 235FO2259
Ripper 27 mm
/ 123&02261
I I
235FO2263
Piston head assembly
1) Set piston rod assembly (6) to tool Al.
2) Using tool A3, remove nut (7).
Steering 46 mm
Leaning I 50 mm
Blade shift I 70 mm
Blade lift I 70 mm
Articulate 75 mm
Power tilt I 75 mm
Ripper I 80 mm
235FO2265 235FO2266
15 235FO226;
ASSEMBLY OF HYDRAULIC
CYLINDER ASSEMBLY
a
* Be careful not to damage the packings, dust seals,
and O-rings when assembling.
235FO2272 235FO2273
,
235FO2274 235FO2275
15 235FO2267
2. Assembly of piston assembly
Using tool A6, expand piston ring (11).
f Set the piston ring on the expander and
turn the handle 8 - IO times to expand the
ring.
Remove piston ring (11) from tool A6, and in-
stall to piston.
Using tool A7, retract piston ring (11).
Install wear ring (12).
262FO548: 7 205F2338P
If?
235FO2265 235FO2266
w Piston nut
/ 1 14OF13758
_. .._.
mm
7 Steering
mm
Blade lift
mm Drawbar shift
I
/ I__- _
26.5)
i0
235FO2264
30204
4. Piston rod assembly
l Steering, blade shift, leaning cylinder
1) Set cylinder to tool Al.
w Cylinder head
Cylinder I Nm (kv-4
Steering 1 441.3 i 44.1 (45 * 4.5)
3 i ,
235FO226:
Blade shift 1 784.5 + 78.5 (80 k 8)
Leaning 1 676.7 & 67.6 (69 I 6.9)
111111111111111111111
Cylinder
(kNgmm)
;35F0226;
1 235FO2259
REMOVAL OF CIRCLE ROTATION GEAR AND
HYDRAULIC OIL MOTOR ASSEMBLY
Serial No.: 11001 - 12050
:
I Hydraulic tank: 108 P
235FO2244
4. Remove mount bolt (8), and tap dowel pin (9) from
bottom to remove.
+ Dowel pin: 2 places
235FO227t
30-206
0
INSTALLATION OF CIRCLE ROTATION GEAR AND
HYDRAULIC OIL MOTOR ASSEMBLY
Serial No.: 11001 - 12050
2. Align dowel pin (9) with pin hole, and tighten mount / 7
bolt (8).
235COO2106
235CDO2107
235FO2244
30-207
0
DISASSEMBLY AND ASSEMBLY CIRCLE ROTATION GEAR, HYDRAULIC MOTOR
REMOVAL OF CIRCLE
ROTATION GEAR, HYDRAULIC
MOTOR ASSEMBLY
Serial No.: 12051 and up
I
I
k DWG00248
DWG00249
30-207-l
0
DISASSEMBLY AND ASSEMBLY CIRCLE ROTATION GEAR, HYDRAULIC MOTOR
INSTALLATION OF CIRCLE
ROTATION GEAR, HYDRAULIC
MOTOR ASSEMBLY
Serial No.: 12051 and up
DWG00249
4
DWG00248
L
DWG00247
30-207-2
0
DISASSEMBLY OF CIRCLE ROTATION GEAR AND
HYDRAULIC OIL MOTOR ASSEMBLY
Serial No.: 11001 - 12050
1. Draining oil
1) Remove plug (I) and drain oil
3. Key
Remove key (6) from hydraulic oil motor assembly
z
P2350 1483
z
4. Clutch
1) Remove cover (9A).
2) Loosen locknut (7) and remove bolt (8).
3) Remove cover (9).
30-208
0
4) Remove discs (13) and plates (14) in order.
* Disc: 6 PCS, plate: 5 PCS.
Ej
+ziiib
18H - 18J
F235014OI
6. Cover
Remove collar (2 1)
7. Housing
Remove housing (22) and shim (23).
$2350 I466
P23503468
DISASSEMBLY AND ASSEMBLY CIRCLE ROTATION GEAR AND HYDRAULIC OIL MOTOR
ASSEMBLY OF CIRCLE
ROTATION GEAR AND
HYDRAULIC OIL MOTOR
ASSEMBLY
Serial No.: 11001 - 12050
P2350 I468
P2350 9 469
3. Housing
1) Attach shim (23) to housing (22) and install
it in case.
Sr Fix O-ring in housing.
* Adjust rotating torque with shim.
Ir Rotating torque:
4.9 to 15.7 Nm {0.5 to 1.6 kgm)
& O-ring groove: Grease (G2-LI)
P23501470
30-211
0
DISASSEMBLY AND ASSEMBLY CIRCLE ROTATION GEAR AND HYDRAULIC OIL MOTOR
Lubricant (LM-P)
4) Install shims (18N), holder (18M), and lock
plate (18L) to shaft with bolt (18K).
* Adjust so that clearance A of the shim is
1 mm.
5) Assemble end plate (18G) and springs (18F),
then install shims (18E) and collar (18C) with
bolt (18A).
.lUJ
F23501409
F235014
30-212
0
DISASSEMBLY AND ASSEMBLY CIRCLE ROTATION GEAR AND HYDRAULIC OIL MOTOR
5. Cover i
$
Using push tool kit (o95), press fit bushing (33) i:
to cover (21), then install to case. Q
$
Ir Install an O-ring to the cover. 8
6 O-ring groove: Grease (G2-LI) $
i
6. Clutch
1) Press fit oil seal (34).
7. Key
Install key (6) to hydraulic oil motor assembly
(5).
P2350 1483
30-214
0
DISASSEMBLY AND ASSEMBLY CIRCLE ROTATION GEAR AND HYDRAULIC OIL MOTOR
30-214-l
0
DISASSEMBLY AND ASSEMBLY CIRCLE ROTATION GEAR, HYDRAULIC MOTOR
DISASSEMBLY OF CIRCLE
ROTATION GEAR, HYDRAULIC
MOTOR ASSEMBLY
Serial No.: 12051 and up
1. Draining oil
I) Remove drain plug (I) and drain oil.
3. Clutch
1) Remove 8 bolts (61, then remove cover (7).
2) Remove 3 bolts (8), then remove holder (9)
and shims (IO).
* Check the number and thickness of the
shims, and keep in a safe place.
3) Remove collar (II), spring (12), and plate
(13).
4) Remove clutch discs (14) and plates (15) in
order, then remove washer (16).
Clutch disc (14) : 11
Clutch plate (15) : 10
30-214-2
0
DISASSEMBLY AND ASSEMBLY CIRCLE ROTATION GEAR, HYDRAULIC MOTOR
4. Housing
Remove nut (171, then remove housing (18).
Ir Check the number and thickness of shims
(191, and keep in a safe place.
5. Worm wheel
Install eyebolts (Thread = 6 mm, Pitch = 1 mm) to
worm wheel (20), then remove worm wheel.
Ir The % mark in the diagram shows the eyebolt
hole.
-
-
OWC
7. Pinion gear
1) Remove 8 bolts (231, then remove cover (24).
23
24
1 DWG00256
30-214-3
DISASSEMBLY AND ASSEMBLY CIRCLE ROTATION GEAR, HYDRAULIC MOTOR
DWG00257
I DWG00258
33
32 DWGO
30-214-4
0
DISASSEMBLY AND ASSEMBLY CIRCLE ROTATION GEAR, HYDRAULIC MOTOR
ASSEMBLY OF CIRCLE
ROTATION GEAR, HYDRAULIC
MOTOR ASSEMBLY
Serial No.: 12051 and up
3. Pinion gear
I) Press fit bushing (31) to housing (30).
30-214-5
0
DISASSEMBLY AND ASSEMBLY CIRCLE ROTATION GEAR, HYDRAULIC MOTOR
DWG00262
30-214-6
0
DISASSEMBLY AND ASSEMBLY CIRCLE ROTATION GEAR, HYDRAULIC MOTOR
33
32
28
30
29
is 25 DWG00261
4. Worm wheel
Fit eyebolt to worm wheel (201, and install to
shaft (36).
* Remove the housing of the worm gear. Mesh
it with the worm gear, then install the worm
gear housing again.
DWG00254
5. Clutch
1) Insert washer (16) in worm wheel, then in-
sert discs (14) and plates (15) in order.
Discs (14): 11
Plates (15): 10
2) Install plate (II), spring (12), and collar (13).
3) Insert shim (IO) on top end of shaft (36),
then install holder (9) with bolt (8).
6. Cover
Install cover (7) to case (5).
* Install the O-ring to the cover.
a O-ring : Grease (G2-LI)
30-214-7
0
DISASSEMBLY AND ASSEMBLY CIRCLE ROTATION GEAR, HYDRAULIC MOTOR
Case : Approx. 10 e
2 DWG00250 1
30-214-8
0
REMOVAL OF BLADE ASSEMBLY
A Start engine,
work equipment
operate the control
(approx. 200 mm).
lever to raise the
2. Loosen bolts (3) and (4), pull out pin (5) and remove
bracket (6).
kg
C!?J Blade assembly: approx. 1540 kg
INSTALLATION OF BLADE
ASSEMBLY
Serial No.: 11001 - 12050
z
% 1. Sling center of blade (2) and set to adjuster.
P2350 B43,
2
2. While sliding the wire, operate the control lever to
extend the cylinder piston rod (1) and push it in until
it reaches a position where it can be connected.
4. Set cylinder rod to bracket (6) fix with pin (5) and
tighten bolts (3) and (4).
P2350 I437
5. Raise blade and pull out block from under the circle.
30-2 15
0
REMOVAL OF BLADE
ASSEMBLY
Serial No: 12051 and up
INSTALLATION OF BLADE
ASSEMBLY
Serial No.: 12051 and up
30-215-l
0
REMOVAL OF CIRCLE AND
DRAWBAR ASSEMBLY
INSTALLATION OF CIRCLE
AND DRAWBAR ASSEMBLY
30-216
0
DISASSEMBLY OF CIRCLE AND
DRAWBAR ASSEMBLY
Serial No.: 11001 - 12050
1. Ball joint
Loosen nut (1) and remove ball joint (2) and cover
(3) from drawbar top end.
P2350 I445
/,
Circle guide
1) Loosen nut (6) and remove circle guides (5),
then separate drawbar and circle assembly.
5 5 5
235FO2281
P2350 t 448
30-217
0
5. Power tilt cylinder
I) Remove power tilt cylinder (12) head bolt (131,
lock plate (I 4) and pin (151, then remove it from
center bracket (16).
2) Remove power tilt cylinder (12) bottom bolt (I 7)
and cap (181, then remove it.
6. L.H. adjuster
Loosen nuts (20), (21) and (221, and remove L.H.
adjuster.
7. Shaft
Loosen nut (23) and pull out shaft (24).
Shaft: 20 kg
& kg
kg
CII?T?? Power tilt center bracket: 82 kg
9. R.H. adjuster
Loosen nuts (27) and (28), and remove R.H. adjuster
(29).
1. R.H. adjuster
Install R.H. adjuster (29) to circle (30) and tighten
nuts (27) and (28).
3. Shaft
Insert shaft (24) to R.H. adjuster and center bracket
and fix with nut (23).
30-219
0
4. L.H. adjuster
Install adjuster (19) to circle and shaft and fix with
nuts (201, (21) and (22).
,, ,,, _,,
I ,, I
6. Blade side shift cylinder
Install blade side shift cylinder (1 1) to R.H. adjuster
and fix with pin (91, washer (8) and snap ring (7).
P2350 t 448
'35FO2282
DDG00027
30-221
0
3) Adjusting clearance of circle guide.
i) Raise blade so that drawbar and ground
are parallel, and so that dimension E at
tip of blade edge and ground surface is
approx. 90 mm.
E 235FO2287
L 9
3
If-
ii- 10
I 2 I 4 !-
A-A DOG000 30 H
235FO229
30-222
0
vi) Check that clearance L between tip of
teeth of pinion gear (9) and root of teeth
of circle (IO) is 3.86 mm.
vii) Check clearance H between pinion gear
(9) and circle (IO) again, loosen locknut
(14), then tighten pusher bolt (15) of
center circle guide (3), and set clearance
C between center circle guide (3) and
circle (5) to 0.7 mm, then tighten locknut
(14).
viii)Adiust with pusher bolt (8) so that clear- I 3
ante R between rear circle guide (4) and B-B DDG00031
9. Ball joint
I) Install ball joint (2) and cover (3) to drawbar
top end.
P2350t445
30-223
DISASSEMBLY AND ASSEMBLY CIRCLE, DRAWBAR
DISASSEMBLY OF CIRCLE,
DRAWBAR ASSEMBLY
Serial No.: 12051 and up
1. Ball joint
Loosen bolt (I), and remove ball joint (2) and
cover (3).
3. Circle guide
Remove 16 bolts (8) and 2 bolts (8A), then re-
move circle guides (51, (61, (7) and (7A), and
disconnect drawbar and circle assembly.
5 s 7 DWGOO266
DWG00267
I DWC00266
30-223-l
I?\
DISASSEMBLY AND ASSEMBLY CIRCLE, DRAWBAR
6. Adjuster
I) Remove cotter pin (20) and nuts (21) and
26 15 23
(22).
DWG00169
Adjuster : 300 kg
30-223-2
0
DISASSEMBLY AND ASSEMBLY CIRCLE, DRAWBAR
ASSEMBLY OF CIRCLE,
DRAWBAR ASSEMBLY
Serial No.: 12051 and up
1. Adjuster
1) Insert adjuster (12) in circle.
I DWGOO270
I DWG00266
30-223-3
0
DISASSEMBLY AND ASSEMBLY CIRCLE, DRAWBAR
5. Circle guide
1) Set wear plate (281, put circle assembly on
drawbar, lay out shims (29), then temporar-
ily tighten guides (5), (6), (7) and (7A) with
bolts.
* Lay out 2 wear plates (28) each.
-k Install wear plate (27) to each circle
guide.
. Standard shim thickness : 5.5 mm
. Bolt length
l (8) : 175 mm (16 bolts)
l (8A) for circle guide (7A): 155 mm (2 7 DWG00271
bolts)
32 DWG00302
30-223-4
0
DISASSEMBLY AND ASSEMBLY CIRCLE, DRAWBAR
3d 3i 29 28 27
B-B DWG00275
2i
c-c DWG002:6 I
7. Ball joint
Install ball joint (2) and cover (3) to drawbar,
and tighten bolt (I).
w Bolt : 534.5 + 73.5 Nm I54.50 2 7.50 kgml
I bWG00265 1
30-223-5
0
REMOVAL OF REAR MOUNT RIPPER
ASSEMBLY
2. Raise shank (2) with a crane, pull out pin (3). then
remove shank (2).
4. Raise body (lj, pull out pin (71, then disconnect rod
(8).
5. Hold rod (9) with jack, pull out pin (IO), then discon-
nect link (1 I).
kg
CE?l Body: 1390 kg
30-224
0
INSTALLATION OF REAR MOUNT
RIPPER ASSEMBLY
P2350 I475
30225
METHOD FOR LIFTING UP ROPS
I 235CD02108
235COO210<
DWG00224
235CD02111 235COO2112
30-226
0
* When lifting up the cab, the operators seat and I
air conditioner stand are lifted at the same time,
so remove only the 15 mounting bolts of the
cab mount shown in the diagram.
1235FO2293
1235FO2294
235FO2295
30-227
0
9. Remove lock pin (13) installed to cab.
10. Wind up chain block and raise cab until ROPS and
hole of cab lock pin are aligned.
30-228
0
DISASSEMBLY AND ASSEMBLY ROPS CAB
30-229
0
DISASSEMBLY AND ASSEMBLY
ROPS CAB
DWG00225
I DWG00224
DECO0037
30-230
0
DISASSEMBLY AND ASSEMBLY ROPS CAB
s-i-4 -
-XT+---
DEG00039
FWD+
DWG00234
DEG00042
DEG00043
30-231
DISASSEMBLY AND ASSEMBLY ROPS CAB
DWG00235
DECO0046
OEG00047
30-232
0
DISASSEMBLY AND ASSEMBLY ROPS CAB
DEG00046
m
Adjusting cab vibration stopper
1) Front-to-rear direction
Mounting dimensions of stopper
Unit: mm
Ll 45 40 5
ROPS/FOPS roof Plate
i) Set mounting dimension Ll of stopper
(5) to 45 mm.
ii) Put brackets (1) and (3) in light contact
with stopper (51, then tighten bolts (4)
temporarily.
iii) Tighten adjustment bolt @ six turns, then
tighten bolts (4).
Adjustment bolt 0: 235-950-5440
iv) Remove adjustment bolt 0.
L2 47 42 5
30-233
0
DISASSEMBLY AND ASSEMBLY ROPS CAB
m
Installation of ROPS roof
m ROPS roof mounting bolt (6) :
277 f 32 Nm (28.25 f 3.25 kgm}
v, Rail guide
Adjust rail guide to front or rear so that rail
at rear of cab is at center of rail guide.
2) Roller
Adjust roller bracket to front or rear so that
clearance between roller and ROPS column DWG00238
is 4 + 1 mm.
Length of
Bolt No. Bolt length
tube to use
19 30 -
20 60 -
Roller bra
21 I 465 I 400
22 365 300
23 25 -
Tube
EL
i
o cabin
DWG00240
30-234
0
DISASSEMBLY AND ASSEMBLY ROPS CAB
1. Removal
1) It is unnecessary to remove plates (15) and
(17) and mounting bolts (14) and (16) in Items
6 and 7.
2) It is unnecessary to disconnect coupler (18)
in Item 8. DWG00226
2. Installation
. 21 (White)
Carry out installation in the reverse order to
removal.
22IWhite)
116
w Cab mounting bolt : I
(Wh
110.5 2 12.5 Nm (11.25 = 1.25 kgm}
31 (Red)
Unit : mm
Length of
Bolt No. Bolt length 22 (White)
tube to use
19 30 - Ig(White) j[(White) DWG00241
20 60 -
21 465 400
22 365 300
31 270 200
Tube
b
1
To cabin
DWG00303
30-235
0
DISASSEMBLY AND ASSEMBLY ROPS CAB
1. Removal
1) It is unnecessary to remove plates (15) and
(17) and mounting bolts (14) and (16) in Items
6 and 7.
2) It is unnecessary to disconnect coupler,(l8)
in Item 8.
DEG00055
30-236
0
DISASSEMBLY AND ASSEMBLY ROPS CAB
22fWhite)
2. Installation
. Carry out installation in the reverse order to
removal.
a
w Cab mounting bolt :
110.5 + 12.5 Nm Ill.25 f 1.25 kgml
Unit: mm
Length of
Bolt No. Bolt length
tube to use I
19 I
I
30 I
To cabin
DWC00303
20 60 -
21 465 400
22 365 300
31 I 270 I 200
30-237
0
40 MAINTENANCE STANDARD
40- 1
0
LOWER VALVE
Serial No.: 11001 - 12012.12016-12018
40-8
0
Unit: mm
Tolerance
Standard size
Ist,2nd,3rd,4th speed
40-9
Serial No.: 12013 - 12015, 12019 and up
/ 5
/
9
4 9
9 2
IO
IO
11
13
12
8
SWG00398
40-9-l
0
Unit: mm
I 22 -0.045
-0.035 +0.013
0 0.035
0.058
- 0.08 I
-
2
Clearance between 1st spool and body 22 -0.045
-0.035 0
+0.013 0.058
0.035 0.08 I
-
3 Clearance between 2nd spool and body 22 -0.035 f0.013 0.035 0.08
-0.045 0 0.058
Replace
-
4 Clearance between 3rd spool and body 22 -0.035 +0.013 0.035 0.08
-0.045 0 0.058
-
5
Clearance between 4th spool and body 22 -0.045
-0.035 0
+0.013 0.058
0.035 0.08 I
-
6
Clearance between L spool and body 22 -0.045
-0.035 0
f0.013 0.058
0.035 0.08 I
-
-
Clearance between H spool and body 22 -0.045
-0.035 0
+0.013 0.058
0.035 0.08 I
-
Clearance between pilot reducing -0.035 +0.013 0.035 -
a valve spool and body 25 -0.045 0 0.058 0.08
-
Standard size Repair limit
5.7 N 5.4 N
12 Pilot reducing valve spring (inner) 26 19 25.2
I / (0.58 kg) (0.55 kg)
13 Thickness of pilot reducing valve 3 mm [Pressure per each shim: 0.03 MPa (0.26 kg/cm?)] Adjust
I
40-9-2
0
MAINTENANCE STANDARD TRANSMISSION SOLENOID VALVE
1st
LOW
Hioh
3rd
F
R
40-10
0
MAINTENANCE STANDARD TRANSMISSION SOLENOID VALVE
4th
1st
LOW
A-A
SwG00400
40-10-l
0
FINAL DRIVE
235CDO2033
Unit: mm
1 Preload of bevel pinion bearing Starting torque: 9.8 - 12.7 Nm (I .O - 1.3 kgm)
2 Preload of shaft bearing Starting torque: 9.8 - 12.7 Nm (1.0 - 1.3 kgm)
40-l 1
MAINTENANCE STANDARD DIFFERENTIAL LOCK-UP PUMP
- Unit: mm
I I
-
No Check item
I
Criteria
I Remedy
40-12
0
TANDEM DRIVE
F23501032
Unit: mm
1 Preload of hub bearing Drag starting torque of shaft (a) + 19.6 - 24.5 Nm (2.0 - 2.5 kgm) Adjust
40-13
STEERING CYLINDER
F23501044
I I I I I
-
3
Clearance between cylinder bottom
support shaft and bushing I 35
- 0.025
- 0.064
+0.039
0
0.025 -
a 103 0.6 -1
40-16
DISC BRAKE
F23501062
Unit: mm
247.1 N
71 52 67 -
(25.2 kg)
40-17
PARKING BRAKE
Section A -A
F23501063A
40-18
MAINTENANCE STANDARD SPRING CYLINDER
SPRING CYLINDER
277*31_9Nm
{28.25*3.25bml
SWG00413
Unit: mm
Standard size
40-19
0
MAINTENANCE STANDARD HYDRAULIC CONTROL VALVE
L.H. VALVE
(Left blade lift, Ripper, Blade side shift, Power tilt and Circle rotation)
1.5Nm
0.15!+3
A-A
40-20
0
MAINTENANCE STANDARD HYDRAULIC CONTROL VALVE
R.H. VALVE
(Right blade lift, Leaning, Articulate, Drawbar side shift and Service)
SWG00403
40-21
MAINTENANCE STANDARD HYDRAULIC CONTROL VALVE
L.H. VALVE
(Left blade lift, Ripper, Blade side shift, Power tilt and Circle rotation)
F-F
00.3*9.8Nm 68.3*9.8Nm
'S*llaml S*lkPml
/
c-c. D-D
I SWG00404
40-21-l
0
MAINTENANCE STANDARD HYDRAULIC CONTROL VALVE
R.H. VALVE
(Right blade lift, Leaning, Articulate, Drawbar side shift and Service)
88.3i9.8Nm
(9*lkpml
SWG00405
40-2 1-2
0
HYDRAULIC CYLINDER
F23501109
Unit: mm
T
No Check item
l- Criteria Remedy
Clearance
limit
Ripper 0.6
- i
40-22
0
Unit: mm
-
Blade lift 100 -0.05 +O.l 0.05 1.0
-0.15 0 0.25
Blade side -0.030 +0.174 0.130 -
shift 55 -0.076 +O.lOO 0.250 1.0
Clearance
between
Drawbar -0.05 +O.l 0.05 -
piston rod shift 100 -0.15 0 0.25 1.0
support shaft
(ball joint) -
Learning 55 -0.030 +0.174 0.130 1.0
and bushing -0.076 +O.lOO 0.250
(rod end)
Replace
-
Blade lift 75 -0.100 +0.074 0.100 1.0
-0.174 0 0.248
I Rippar
(if equipped) go
-0.120
-0.207
+0.207
+0.120
0.240 -
0.414
1.0
Blade lift 3.3 5 0.3 kNm 1340 e 34 kgm1 (Width across flats: 70 mm)
Blade side
shift 2.3 2 0.2 kNm 1230 2 23 kgm} (Width across flats: 70 mm)
Drawbar
shift 2.6 + 0.3 kNm (265 + 26.5 kgm1 (Width across flats: 70 mm)
Tightening
torque of Learning 912 2 91.2 Nm {93.0 + 9.3 kgm1 (Width across flats: 50 mm) Retighten
piston nut
Articulate 3.1 2 0.3 kNm {320 2 32 kgm} (Width across flats: 75 mm)
Power tilt 2.8 2 0.3 kNm (290 2 29 kgm1 (Width across flats: 75 mm)
Ripper
(if equipped) 4.0 + 0.4 kNm 1405.0 2 40.5 kgm) (Width across flats: 80 mm)
I
40-23
0
HYDRAULIC CYLINDER
F23501109
Unit: mm
NC Check item
T Criteria Remedy
-
Leaning 50 -0.025 +0.152 0.032 0.6
-0.087 -l-o.007 0.239
-
Ripper 70 -0.100 +0.271 0.175 0.6
-0.174 +0.075 0.445
40-23- 1
0
Unit: mm
-
Nc3.
- T Check item
1 Standard
Criteria
Blade lift -
110 -0.05 +O.l 0.05 1.0
-0.15 0 0.25
Blade side -0.030 +0.174 0.130 -
Clearance shift 1.0
55 -0.076 +O.lOO 0.250
between
Drawbar -0.05 +O.l 0.05 -
piston rod 1.0
shift 110 -0.15 0 0.25
i support shaft
(ball joint) Learning -
55 -0.030 +0.174 0.130 1.0
and bushing -0.076 +O.lOO 0.250
(rod end)
Articulate 65 -0.030 -
+0.174 0.130 1.0
-0.076 +O.lOO 0.250
hl
0
Fi
0 - ~~ Replace
Blade lift 3.3 + 0.3 kNm (340 + 34 kgm1 (Width across flats: 70 mm)
4
Tightening
torque of
piston nut
)l 2.3 2 0.2 kNm
I180 2 18 kgm}
(Width
(Width
(Width
across
across
across
flats:
flats:
flats:
70 mm)
70 mm)
60 mm)
Ret,ghten
Articulate 3.1 k 0.3 kNm {320 2 32 kgm} (Width across flats: 75 mm)
Power tilt 2.8 2 0.3 kNm (290 2 29 kgm} (Width across flats: 75 mm)
Ripper
(if equipped) 4.0 2 0.4 kNm 1405.0 + 40.5 kgm} (Width across flats: 80 mm)
40-23-2
0
MAINTENANCE STANDARD HYDRAULIC PUMP
HYDRAULIC PUMP
FOR WORK EQUIPMENT
VXD70-1 F
-
98* 9.8Nm I
(lO*lbml amI
I
SWG00406
40-24
0
MAINTENANCE STANDARD DRAWBAR AND LIFTER
\
m 981+49Nm
~100~5koml
SDG00029
Unit: mm
40-26
0
MAINTENANCE STANDARD DRAWBAR AND LIFTER
A-A 0-B
\ \ \
m 981*49Nm
(100*5bml
m 981*49Nm
~100*5kPml
Unit: mm
If it is impos-
sible to adjust
8 Wear of lifter bracket Standard shim thickness: 2 with shims,
replace lifter
bracket
40-27
0
MAINTENANCE STANDARD DRAWBAR AND LIFTER
40-27-l
0
MAINTENANCE STANDARD DRAWBAR AND LIFTER
7
981*49Nm
G-G ~100~5koml
F-F f SWG00408
Unit: mm
-
40-27-2
0
MAINTENANCE STANDARD BLADE
BLADE
Serial No.: 11001 - 12050
SDG00031
Unit: mm
Side face 25
Wear of side edge Repair limit: Replace
Within 10 mm from blade holder
Height 85
Wear of blade rail Repair limit:
Thickness 35
40-28
0
MAINTENANCE STANDARD BLADE
Xl
------;~5------.
!it SWG00409
Unit: mm
Height 85
3 Wear of blade rail Repair limit:
Thickness 35
40-29
0
CIRCLE ROTATION GEAR
Serial No.: 11001 - 12050
.
\
-
\7
L.3 F23501412
Unit: mm
40-29- 1
0
MAINTENANCE STANDARD CIRCLE ROTATION GEAR
swcoo4 I I
Unit: mm
40-29-2
0
RIPPER
Section A-A
Section E-E
F23501124
Unit: mm
Tolerance
Standard Standard Clearance
Clearance between pin and size clearance limit
1 Shaft Hole Replace
bushing
- 0.025 +0.174
60 0.125 - 0.229 0.5
-0.055 +0.100
40-30
0
FRAME
Y
Bottom Din
235COO2038
Unit: mm
40-3 1
Komatsu America international Company
440 North Fairwav Drive I 1
Vernon Hills, IL 66061-8112 U.S.A.
Attn: Technical Publications PROPOSAL FOR MANUAL REVlslON
Fax No. (847) 970-4186
: PHONE NO:
:
S DEPARTMENT: DATE:
E
R NAME:
MANUAL NAME:
MANUAL NO:
MACHINE MODEL:
S/N IF APPLICABLE:
PAGE NO:
PROBLEM:
PFMRl 081696