D275A-2

MACHINE D275A-2 MODEL SERIAL NUMBER 10001 and up

.
This shop manual area. Please Materials may contain attachments and optional without equipment notice. that are not available you may require. in your

KOMRdbU

consult

your local Komatsu are subject

distributor to change

for those items

and specifications mounts

D275A-2

the S6D170-1

and S6D170-2

engine. and 6D170-2 Series Engine Shop Manual.

For details

of the engine,

see the 6D170-1

Series

@ 1996 KOMAl%U All Rights Reserved

02-96(03)02951

oo1
@

CONTENTS
No. of page

01

GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..*..................

01-l

10 STRUCTURE AND FUNCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10-l

20

TESTING AND ADJUSTING

. . . . . . . ..-...............................

20-l

30

DISASSEMBLY AND ASSEMBLY . . . . . . . . . ..*................n......

30-l

40

MAINTENANCE

STANDARD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

40-l

00-2 0

The affected pages are indicated by the use of the following marks. Itis requested that necessan/ actions must be taken to these pages according to the list below. 0 Page Mark Indication Action required

to be newly added
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00-2-3 @

SAFETY

SAFETY

NOTICE

SAFETY
SAFETY NOTICE
SAFETY
and repair

IMPORTANT
Proper service

NOTICE
is extremely important for safe machine operation. The

service and repair techniques are both effective designed To prevent manual. by Komatsu

recommended

by Komatsu

and described

in this manual

and safe. Some of these techniques for the specific purpose.

require the use of tools specially

injury to workers,

the symbol a

is used to mark safety precautions should always be followed

in this care-

The cautions

accompanying situation

these symbols

fully. If any dangerous take the necessary

arises or may possibly arise, first consider

safety, and

actions to deal with the situation.

GENERAL Mistakes carefully

PRECAUTIONS in operation are extremely and dangerous. Manual

6. Decide

a place

in the

repair

workshop correct

to keep

keep tools and removed Read the Operation Maintenance the machine. or repairs, Always

parts. Always

the tools and parts in their

places.

keep the work area clean and make for smok-

BEFORE operating

sure that there is no dirt or oil on the floor. Smoke only in the areas provided ing. Never smoke while working.

1. ,Before carrying which 2. When

out any greasing

read all the precautions

given on the decals

are fixed to the machine. carrying out any operation, always PREPARATIONS 7. Before FOR WORK oil or making or tracks any repairs, and the

wear safety shoes and helmet. loose work clothes, missing. . Always . Always wear wear

Do not wear adding park the machine on hard, level ground, to prevent

or clothes with buttons hitting grind-

safety glasses when safety glasses etc. always carry when

block the wheels machine 8. Before ground. equipment

parts with a hammer. ing parts with a grinder, 3. If welding trained, ways

from moving. starting If this work, lower blade, ripper, to the the

bucket or any other work equipment have a out the work, alhand is not possible,

repairs are needed, experienced carrying welding welder gloves,

insert

safety pin or use blocks to prevent the work from falling. In addition, be sure to lock all the control ing signs on them. 9. When disassembling or assembling, blocks, jacks support or stands levers and hang warn-

work. When wear

out welding

apron,

shield, cap and other clothes suited for welding work. 4. When ating carrying procedure out any operation always before starting. with two Always in-

the

machine

with

or more workers,

agree on the operbefore starting any work,

before starting IO. Remove

work.

all mud and oil from the steps or use the handrails, ladders or

form your fellow workers step of the operation. hang UNDER in the operators 5. Keep all tools

other places used to get on and off the machine. Always steps when Never jump impossible getting on or off the machine. If it is or ladders

Before starting

REPAIR signs on the controls compartment. and learn

on or off the machine. to use the handrails,

in good condition

the correct way to use them.

steps, use a stand to provide

safe footing.

00-3

SAFETY

SAFETY

NOTICE

PRECAUTIONS 11 When or

DURING

WORK

19. Be sure to assemble original places. Replace any damaged . When installing

all parts again

in their

removing

the oil filler cap, drain plug pressure measuring plugs, to prevent the oil from compofirst the from

parts with new parts. be sure is beby contact

hydraulic out.

hoses and wires,

loosen them spurting Before remove circuit. 12. The when Wait water

slowly

that they will not be damaged ing operated. 20. When sure installing that they high pressure are

with other parts when the machine or removing completely or air circuits,

disconnecting the pressure

nents of the oil, water

hoses, make Damaged careparts

not twisted.

tubes are dangerous, and oil in the circuits are hot ful when circuits. installing Also, the engine is stopped, so be careful to cool before

so be extremely connecting

tubes for high pressure

check that installed.

not to get burned. for the oil and water out any work carrying circuits. 13. Before starting work, remove the leads from the battery. the negative Always remove first. use a hoist the lead from (-1 terminal on the oil or water

are correctly

21. When assembling use the specified installing or parts which high speed,

or installing tightening

parts, always torques. When

protective vibrate

parts such as guards, violently correctly. or rotate at careful to check

be particularly

that they are installed 22. When fingers fingers 23. When which has aligning caught

14. When raising heavy components, or crane.

two holes, never insert your Be careful not to get your in a hole. hydraulic pressure, check assem-

or hand.

Check that the wire rope, chains and hooks are free from damage. Always ample Install places. slowly use lifting equipment capacity. the lifting to prevent equipment at the correct and operate from hitany Use a hoist or crane

measuring

that the measuring

tool is correctly

bled before taking any measurements. 24. Take care when When removing removing the track, or installing the track the sepa-

the component

tracks of track-type rates suddenly,

machines.

ting any other

part. Do not work with

part still raised by the hoist or crane. 15. When ternal spring, removing pressure always covers which or under leave two are under infrom a

so never let anyone stand at

either end of the track.

pressure

bolts in position release the pres-

on opposite

sides. Slowly

sure, then slowly loosen the bolts to remove. 16. When wiring 17. When removing components, be careful fires. not

to break

or damage

the wiring.

Damaged

may cause electrical removing piping,

stop the fuel or oil Fuel or oil

from spilling out. If any fuel or oil drips onto the floor, wipe it up immediately. on the floor even start fires. 18. As a general mum parts. rule, do not use gasoline when washing to can cause you to slip, or can

wash parts. In particular, of gasoline

use only the minielectrical

00-4

FOREWORD

GENERAL

FOREWORD
GENERAL
This shop serviceman manual has been prepared as an aid to improve the quality of repairs by giving the an accurate understanding of the product and by showing the contents him the correct way to perform of this manual and use it to full

repairs and make judgements. effect at every opportunity.

Make sure you understand

This shop manual service workshop. chapters are further

mainly

contains

the necessary

technical

information is divided

for operations

performed chapters;

in a these

For ease of understanding, divided

the manual

into the following

into the each main group of components.

STRUCTURE

AND

FUNCTION the structure and function of each component. It serves not only to give for troubleshooting. of the structure, but also serves as reference material

This section explains an understanding TESTING This

AND ADJUSTING section explains checks to be made before and after performing repairs, as well as to be made at completion charts correlating of the checks and repairs. to Causes are also included in this section.

adjustments

Troubleshooting DISASSEMBLY This section assembling MAINTENANCE

Problems

AND ASSEMBLY explains the order to be followed when removing, installing, disassembling or each component, STANDARD standards when inspecting disassembled parts. as well as precautions to be taken for these operations.

This section gives the judgement

NOTICE
The time with specifications and the without latest date. contained any advance in this notice. shop manual are subject to change given in the at any book Use the specifications

00-5

FOREWORD

HOW TO READ THE SHOP MANUAL

HOW TO READ THE SHOP MANUAL

VOLUMES Shop manuals are issued as a guide to carrying out repairs, They are divided as follows: Chassis volume: Issued for every machine model Engine volume: Issued for each engine series Electrical volume: Attachments volume: Each issued as one volume to cover all models REVISED When pages. EDITION MARK is revised, an edition bottom mark of the

a manual

(@@@....)

is recorded

on the

REVISIONS Revised pages are shown in the LIST OF REVISED PAGES next to the CONTENTS page.

These various volumes are designed to avoid duplicating the same information. Therefore, to deal with all repairs for any model , it is necessary that chassis, engine, electrical and attachment volumes be available. DISTRIBUTION AND UPDATING

SYMBOLS So that the shop manual can be of ample practical use, important safety and quality portions are marked with the following symbols.

Any additions, amendments or other changes will be sent to KOMATSU distributors. Get the most up-to-date information before you start any work. FILING METHOD 1. See the page number on the bottom of the page. File the pages in correct order. 2. Following examples show how to read the page number. Example 1 (Chassis volume): 10 -3 Item number (IO. Structure and Function) Consecutive page number for each item. Example 12 - 5 Unit number (I. Engine) Item number (2. Testing and Adjusting) Consecutive page number for each item. 2 (Engine volume):

Symbol

Item

Remarks Special safety precautions are necessary when performing the work.
I I

A
*

Safety

/ 1
Caution

Special technical precautions or other precautions for preserving standards are necessary when performing the work. Weight of parts of systems. Caution necessary when selecting hoisting wire, or when working posture is important, etc. Places that require special attention for the tightening torque during assembly. Places to be coated with adhesives and lubricants, etc. Places where oil, water or fuel must be added, and the capacity. Places where oil or water quan-

Weight

Tightening w torque

&

Coat

Oil, water

3. Additional

pages:

Additional

pages are indiafter the

& b & Drain

cated by a hyphen page number. Example:

1 o-4

(-1 and number

File as in the example.

m;yob,

dd:,ii,,d. and

1
12-203

10-4-I > 1O-4-2 IO-5

Added

pages -1:

~~~~~I~ 12-204

00-6

FOREWORD

HOISTING

INSTRUCTIONS

HOISTING
HOISTING

INSTRUCTIONS

Heavy parts (25 kg or more) must be lifted with a hoist, etc. In the DISASg every part weighing 25 kg or more indicated clearly with the symbol & is

Slinging near the edge of the hook may cause the rope to slip off the hook during hoisting, and a serious accident can result. Hooks have maximum strength at the middle portion.

If a part cannot be smoothly removed from the machine by hoisting, the following checks should be made:
I) Check

for removal

of all bolts fastening parts. part causthe part to be reof another

100%

88%

79%

71%

41%
SAD00479

the part to the relative 2) Check for existence ing interference moved. with

WIRE ROPES I) Use adequate ropes depending on the to weight of parts to be hoisted, referring

3) Do not sling a heavy load with one rope alone, but sling with two or more ropes symmetrically wound onto the load. Slinging with one rope may cause turning of the load during hoisting, untwisting of the rope, or slipping of the rope from its original winding position on the load, which can result in a dangerous accident. 4) Do not sling a heavy load with ropes forming a wide hanging angle from the hook. When hoisting a load with two or more ropes, the force subjected to each rope will increase with the hanging angles. The table below shows the variation of allowable load KN (kg) when hoisting is made with two ropes, each of which is allowed to sling up to 9.8 KN (1000 kg) vertically, at various hanging angles. When two ropes sling a load vertically, to 19.6 KN (2000 be suspended. hanging angle. kg) of total weight becomes This weight up can 9.8

the table below: Wire ropes (Standard Z or S twist ropes without galvanizing) Rope diameter mm 10 11.2 12.5 14 16 18 20 22.4 30 40 50 60 *

Allowable KN 9.8 13.7 15.7 21.6 27.5 35.3 43.1 54.9 98.1 176.5 274.6 392.2

load tons 1.0 1.4 1.6 2.2 2.8 3.6 4.4 5.6 10.0 18.0 28.0 40.0

KN (1000 kg) when two ropes make a 120 On the other hand, two force ropes are subjected to an excessive

as large as 39.2 KN (4000 kg) if they sling a 19.6 KN (2000 kg) load at a lifting angle of 150. 6 0 ~~~~~ 44 0

The allowable load value is estimated to be one-sixth or one-seventh of the breaking strength of the rope used. portion

2) Sling wire ropes from the middle of the hook.

30
Lifting

60
mole

90
(degree)

120

150
SAD00480

00-7

FOREWORD

COATING

MATERIALS

COATING

MATERIALS
coating materials prescribed in Komatsu Shop Manuals are listed below.

The recommended

Category

Komatsu code
LT-1A

Part No.
790-129-9030

Qty 150 g

Container
Tube

Main applications, features

*
*

Used to prevent rubber gaskets, rubber out and cork plugs from coming

cushions,

LT-1B

790-129-9050

20 g (x2)

Plastic container * *

effecan immediately Used in places requiring Used for plastics (except tive, strona adhesive. tetrafluoroethylene, polypropylene, polyethylene, rubber, metal, and non-metal. and vinyl chloride), to heat, chemicals Features: Resistance for and sealant purposes Used for anti-loosenina bolts and plugs. Used as adhesive or sealant for metal, glass, plastic

LT-2 Adhesive

09940-00030

50 g Adhesive :I Kg Hardening I agent: :500 g 250 g

Plastic container

LT-3

790-129-9060 (Set of adhesivs and hardenginc

*
Can

agent)
LT-4 790-129-9040

Plastic container -

* . . *

Used

as sealant

for machined

holes

Loctite

646-50)

79A-129-9110 790-129-9010

50 cc

to heat, chemicals Features: Resistance subject to high Used at joint portions ture Used as adhesive packings of power for or sealant train case, etc.

temperaand

LG-1

200 g

gaskets

Tube

*
LG-3 790-129-9070

1 Kg

Can

* * *

to heat Features: Resistance Used as sealant for flange surfaces and bolts at used to prevent seilocations, high temperature zure Used as sealant for heat resistant gasket for high locations such as engine precombustion temperature exhaust pipe chamber, to water, oil Features: Resistance Used as sealant for flange surface, thread Also possible to use as sealant for flanges large clearance Used as sealant for mating surfaces of final case case, transmission Used as sealant flanges Used as sealant ples of hydraulic Features: Used as Used as Features: Used as fold, oil for various for tapered piping threads, plugs,

LG-4

790-129-9020

200 g

Tube

with drive

pipe joints, elbows, nip-

I
I
Rust prevention lubricant Molybdenum Iudisulphide bricant

LG-5

790-129-9080

1 Kg

Plastic container

09940-00011 250 g Tube * * * . * * LM-P 09940-00040 SYG-350LI SYG-400LI SYG-400LI-A SYG-16OLI SYGA-IGOCNL SSG2-400CA SYG2350CA SYG2-4OOCA-A SYG2-160CA SYGA-IGCNCA SYG2-400M 200 g Tube * . Various Various

LG-7

09920-00150

150 g

Tube

to heat, cold Silicon based, resistance sealant for flange surface, thread sealant for oil pan, final drive case, etc. type Silicon based, quick hardening housing, intake manisealant for flywheel etc. housing, pan, thermostat

LM-G

09940-00051

60 g

Can

parts (to prevent for sliding Used as lubricant squeaking) of the thread Used to prevent seizure or scuffing when press fitting or shrink fitting etc. for linkage, bearings, Used as lubricant General purpose type

Lithium grease

G2-LI

Various Various

light load Used for normal temperature, at places in contact with water or steam

bearing

Calcium grease

G2-CA

400 g (IOpercas

Used for places with heavy

load

?)

I3ellows

type

00-8

FOREWORD

STANDARD

TIGHTENING

TORQUE

STANDARD
STANDARD

TIGHTENING
TORQUES

TORQUE
OF BOLTS AND tightening NUTS torques of bolts and nuts. Exceptions are given

TIGHTENING

The following in section

charts give the standard

of DISASSEMBLY

AND ASSEMBLY. 1 Kgm = 9.806 Nm

Thread diameter of bolt mm

6 8 IO 12 14 16 18 20 22 24 27 30 33 36 39

Width across flats mm IO

13 17 19 22 24 27 30 32 36 41 46 50 55 60

T
Nm 13.2+ 1.4 31.4f2.9 65.7 * 6.8 112k9.8 177If: 19 279*29 383k39 549 k 58 745f78 927f98 1320f 1720* 140 190

SAD00481

SAD00482

1.35f0.15 3.2kO.3 6.7kO.7 11.5fl.O 18.0f2.0 28.5f3 39f4 56f6 76+8 94.5f 135f 10 15

175f20 225+25 280+30 335f35

2210f240 2750+290 3280 + 340

This torque table does not apply to the bolts with nonferrous metal washers are to be used, or which specified torque.

which nylon packings or other require tightening to otherwise

00-9

FOREWORD

STANDARD

TIGHTENING

TORQUE

TIGHTENING

TORQUE

OF SPLIT FLANGE for split flange bolts.

BOLTS

Use these torques

Thread diameter of bolt mm 10 12 16

Width across flats mm 14 17 22

I
Nm 65.7f6.8 112f9.8 279k29

Tightening

torque kgm 6.7kO.7 11.5+1 28.5f3

TIGHTENING

TORQUE

FOR FLARED NUTS for flared part of nut.

SAD00483

Use these torques

Thread diameter of nut part mm 14 18 22 24 30 33 36 42

Width across flats of nut part mm 19 24 27 32 36 41 46 55

T
Nm 24.5+ 4.9 49k 19.6 78.5f 19.6 137.3f29.4 176.5f29.4 196.1+49 245.2 f 49 294.2 f 49

Tightening

torque

Mm
2.5f0.5 5f2 8+2 1453 18k3 20+5 25+5 30+5

00-10

FOREWORD

ELECTRIC WIRE CODE

ELECTRIC WIRE CODE

In the wiring diagrams, various colors and symbols are employed to indicate the thickness of wires. This wire code table will help you understand WIRING DIAGRAMS. 5WB indicates a cable having a nominal number 5 and white coating with black stripe. Example:

CLASSIFICATION

BY THICKNESS

Applicable circuit

17.6

230

Starting

CLASSIFICATION

BY COLOR AND CODE

Color

Red & Blue

Yellow&White

Green

& Blue

FOREWORD

CONVERSION

TABLE

CONVERSION
METHOD details OF USING

TABLE
THE CONVERSION Table in this section TABLE is provided to enable simple conversion of figures. For Table, see the example given below.

The Conversion

of the method

of using the Conversion

EXAMPLE . 1. Method Convert (I) of using the Conversion Table to convert from millimeters to inches 55 mm into inches. Locate the number 50 in the vertical column at the left side, take this as @, then draw a horizontal line from @. (2) Locate the number down from @. (3) Take the point where the two lines cross as @J. This point 0 from millimeters to inches. Therefore, 55 mm = 2.165 inches. 2. Convert 550 mm into inches. gives the value when converting 5 in the row across the top, take this as @, then draw a perpendicular line

(I) The number 550 does not appear in the table, so divide by IO (move the decimal point one place
to the left) to convert it to 55 mm.

(2) Carry out the same procedure as above to convert 55 mm to 2.165 inches.
(3) The original value (550 mm) was divided by 10, so multiply 2.165 inches by 10 (move the decimal point one place to the right) to return to the original value. This gives 550 mm = 21.65 inches.

Millimeters

to inches 0 0 IO 20 30 40 0 0.394 0.787 1.181 1.575 .. . . . . . . .1.969. .. 2.362 2.756 3.150 3.543 1 0.039 0.433 0.827 1.220 1.614 . . .. . . . .2.008. . . 2.402 2.795 3.189 3.583 2 0.079 0.472 0.866 1.260 1.654 3 0.118 0.512 0.906 1.299 1.693 4 0.157 0.551 0.945 1.339 1.732 5 0.197 0.591 0.984 1.378 1.772 6 0.236 0.630 1.024 1.417 1.811 2.205 2.598 2.992 3.386 3.780 7 0.276 0.669 1.063 1.457 1.850 2.244 2.638 3.032 3.425 3.819

1 mm = 0.03937

in

8 0.315 0.709 1.102 1.496 1.890 2.283 2.677 3.071 3.465 3.858

9 0.354 0.748 1.142 1.536 1.929 2.323 2.717 3.110 3.504 3.898

@-

... . . . 50. .. . . 60 70 80 90

. . .. .. . . .. . . . . . . . . .. . .2.047. . . . .2.087. ..I ..2.126 . . EE& 2.480 2.441 2.520 2.874 2.913 2.953 2.835 3.268 3.346 3.307 3.228 3.701 3.661 3.740 3.622
..I

00-l 2

FOREWORD

CONVERSIONTABLE

Millimeters to Inches
1 mm = 0.03937 in

0 10 20 30 40

0 0.394 0.787 1.181 1.575

0.039 0.433 0.827 1.220 1.614

0.079 0.472 0.866 1.260 1.654

0.118 0.512 0.906 1.299 1.693

0.157 0.551 0.945 1.339 1.732

0.197 0.591 0.984 1.378 1.772

0.236 0.630 1.024 1.417 1.811

0.276 0.669 1.063 1.457 1.850

0.315 0.709 1.102 1.496 1.890

0.354 0.748 1.142 1.536 1.929

50 60 70 80 90

1.969 2.362 2.756 3.150 3.543

2.008 2.402 2.795 3.189 3.583

2.047 2.441 2.835 3.228 3.622

2.087 2.480 2.874 3.268 3.661

2.126 2.520 2.913 3.307 3.701

2.165 2.559 2.953 3.346 3.740

2.205 2.598 2.992 3.386 3.780

2.244 2.638 3.032 3.425 3.819

2.283 2.677 3.071 3.465 3.858

2.323 2.717 3.110 3.504 3.898

Kilogram

to Pound

1 kg = 2.2046 lb 1 2.20 24.25 46.30 68.34 90.39 4 5 11.02 33.07 55.12 77.16 99.21 7 8 17.64 39.68 61.73 83.78 105.82

2 4.41 26.46 48.50 70.55 92.59

3 6.61 28.66 50.71 72.75 94.80

6 13.23 35.27 57.32 79.37 101.41

\
0 10 20 30 40 0 22.05 44.09 66.14 88.18 8.82 30.86 51.91 74.96 97.00 15.43 37.48 59.53 81.57 103.62 19.84 41.89 63.93 85.98 108.03

50 60 70 80 90

110.23 132.28 154.32 176.37 198.42

112.44 134.48 156.53 178.57 200.62

114.64 136.69 158.73 180.78 202.83

116.85 138.89 160.94 182.98 205.03

119.05 141.10 163.14 185.19 207.24

121.25 143.30 165.35 187.39 209.44

123.46 145.51 167.55 189.60 211.64

125.66 147.71 169.76 191.80 213.85

127.87 149.91 171.96 194.01 216.05

130.07 152.12 174.17 196.21 218.26

00-13

FOREWORD

CONVERSIONTABLE

Liter to U.S. Gallon

It = 0.2642 U.S. Gal

0 IO 20 30 40

0 2.642 5.283 7.925 10.567

0.264 2.906 5.548 8.189 10.831

0.528 3.170 5.812 8.454 11.095

0.793 3.434 6.076 8.718 11.359

1.057 3.698 6:340 8.982 11.624

1.321 3.963 6.604 9.246 11.888

1.585 4.227 6.869 9.510 12.152

1.849 4.491 7.133 9.774 12.416

2.113 4.755 7.397 10.039 12.680

2.378 5.019 7.661 10.303 12.944

50 60 70 80 90

13.209 15.850 18.492 21.134 23.775

13.473 16.115 18.756 21.398 24.040

13.737 16.379 19.020 21.662 24.304

14.001 16.643 19.285 21.926 24.568

14.265 16.907 19.549 22.190 24.832

14.529 17.171 19.813 22.455 25.096

14.795 17.435 20.077 22.719 25.361

15.058 17.700 20.341 22.983 25.625

15.322 17.964 20.605 23.247 25.889

15.586 18.228 20.870 23.511 26.153

Liter to U.K. Gallon

It = 0.21997 U.K. Gal 2 3 5 6

7

0 10 20 30 40

0 2.200 4.399 6.599 8.799

0.220 2.420 4.619 6.819 9.019

0.440

0.660 2.860 5.059 7.259 9.459

0.880 3.080 5.279 7.479 9.679

1.100 3.300 5.499 7.969 9.899

1.320 3.520 5.719 7.919 10.119

1.540 3.740 5.939 8.139 10.339

1.760 3.950 6.159 8.359 10.559

1.980 4.179 6.379 8.579 10.778

2.640 4.839 7.039 9.239

50 60 70 80 90

0.998 3.198 15.398 17.598 19.797

11.281 13.418 15.618 17.818 20.017

11.438 13.638 15.838 18.037 20.237

11.658 13.858 16.058 18.257 20.457

11.878 14.078 16.278 18.477 20.677

12.098 14.298 16.498 18.697 20.897

12.318 14.518 16.718 18.917 21.117

12.528 14.738 16.938 19.137 21.337

12.758 14.958 17.158 19.357 21.557

12.978 15.178 17.378 19.577 21.777

00-14

FOREWORD

CONVERSIONTABLE

kgm to ft. lb
1 kgm = 7.233 ft. lb

\\
0 10 20 30 40 0 72.3 144.7 217.0 289.3 7.2 79.6 151.9 224.2 296.6 14.5 86.8 159.1 231.5 303.8 21.7 94.0 166.4 238.7 311.0 28.9 101.3 173.6 245.9 318.3 36.2 108.5 180.8 253.2 325.5 43.4 115.7 188.1 260.4 332.7 50.6 123.0 195.3 267.6 340.0 57.9 130.2 202.5 274.9 347.2 65.1 137.4 209.8 282.1 354.4

50 60 70 80 90

361.7 434.0 506.3 578.6 651.0

368.9 441.2 513.5 585.9 658.2

376.1 448.5 520.8 593.1 665.4

383.4 455.7 528.0 600.3 672.7

390.6 462.9 535.2 607.6 679.9

397.8 470.2 542.5 614.8 687.1

405.1 477.4 549.7 622.0 694.4

412.3 484.6 556.9 629.3 701.6

419.5 491.8 564.2 636.5 708.8

426.8 499.1 571.4 643.7 716.1

100 110 120 130 140

723.3 795.6 868.0 940.3 1012.6

730.5 802.9 875.2 947.5 1019.9

737.8 810.1 882.4 954.8 1027.1

745.0 817.3 889.7 962.0 1034.3

752.2 824.6 896.9 969.2 1041.5

759.5 831.8 904.1 976.5 1048.8

766.7 839.0 911.4 983.7 1056.0

773.9 846.3 918.6 990.9 1063.2

781.2 853.5 925.8 998.2 1070.5

788.4 860.7 933.1 1005.4 1077.7

150 160 170 180 190

1084.9 1157.3 1129.6 1301.9 1374.3

1092.2 1164.5 1236.8 1309.2 1381.5

1099.4 1171.7 1244.1 1316.4 1388.7

1106.6 1179.0 1251.3 1323.6 1396.0

1113.9 1186.2 1258.5 1330.9 1403.2

1121.1 1193.4 1265.8 1338.1 1410.4

1128.3 1200.7 1273.0 1345.3 1417.7

1135.6 1207.9 1280.1 1352.6 1424.9

1142.8 1215.1 1287.5 1359.8 1432.1

1150.0 1222.4 1294.7 1367.0 1439.4

00-l 5

FOREWORD

CONVERSIONTABLE

kg/cm*

to lb/in*
1 kg/cm* = 14.2233 lb/id

\
0 10 20 30 40

0 142.2 284.5 426.7 568.9

14.2 156.5 298.7 440.9 583.2

28.4 170.7 312.9 455.1 597.4

42.7 184.9 327.1 469.4 611.6

56.9 199.1 341.4 483.6 625.8

71.1 213.4 355.6 497.8 640.1

85.3 227.6 369.8 512.0 654.3

99.6 241.8 384.0 526.3 668.5

113.8 256.0 398.3 540.5 682.7

128.0 270.2 412.5 554.7 696.9

50 60 70 80 90

711.2 853.4 995.6 1138 1280

725.4 867.6 1010 1152 1294

739.6 881.8 1024 1166 1309

753.8 896.1 1038 1181 1323

768.1 910.3 1053 1195 1337

782.3 924.5 1067 1209 1351

796.5 938.7 1081 1223 1365

810.7 953.0 1095 1237 1380

825.0 967.2 1109 1252 1394

839.2 981.4 1124 1266 1408

100 110 120 130 140

1422 1565 1707 1849 1991

1437 1579 1721 1863 2005

1451 1593 1735 1877 2020

1465 1607 1749 1892 2034

1479 1621 1764 1906 2048

1493 1636 1778 1920 2062

1508 1650 1792 1934 2077

1522 1664 1806 1949 2091

1536 1678 1821 1963 2105

1550 1693 1835 1977 2119

150 160 170 180 190

2134 2276 2418 2560 2702

2148 2290 2432 2574 2717

2162 2304 2446 2589 2731

2176 2318 2460 2603 2745

2190 2333 2475 2617 2759

2205 2347 2489 2631 2773

2219 2361 2503 2646 2788

2233 2375 2518 2660 2802

2247 2389 2532 2674 2816

2262 2404 2546 2688 2830

200 210 220 230 240

2845 2987 3129 3271 3414

2859 3001 3143 3286 3428

2873 3015 3158 3300 3442

2887 3030 3172 3314 3456

2901 3044 3186 3328 3470

2916 3058 3200 3343 3485

2930 3072 3214 3357 3499

2944 3086 3229 3371 3513

2958 3101 3243 3385 3527

2973 3115 3257 3399 3542

00-l 6

FOREWORD

CONVERSION

TABLE

Temperature
Fahrenheit-Centigrade Conversion ; a simple way to convert a Fahrenheit temperature These figuresrefer to the temperature in eitherFahrenheitor Centigrade degrees. Ifitis desired to convert from Fahrenheitto Centigrade degrees, consider the center column as a table of Fahrenheit temperatures and read the corresponding Centigrade Ifitis desired to convert from Centigrade and read the corresponding Fahrenheit temperature
temperature in the column at the left. to Fahrenheitdegrees,considerthecenter column as a table of Centigradevalues,

reading intoa Centigradetempera-

ture reading or vice versa isto enter the accompanying table in the center or boldfacecolumn of figures.

on the right. 1C = 33.8"F

C
-40.4 -37.2 -34.4 -31.7 -28.9 -28.3 -27.8 -27.2 -26.7 -26.1 -25.6 -25.0 -24.4 -23.9 -23.3 -22.8 -22.2 -21.7 -21.1 -20.6 -20.0 -19.4 -18.9 -18.3 -17.8 -17.2 -16.7 -16.1 -15.6 -15.0 -14.4 -13.9 -13.3 -12.8 -12.2 -40 -35 -30 -25 -20 -19 -18 -17 -16 -15 -14 -13 -12 -11 -10 -9 -8 -7 -6 -5 -4 -3 -2 -1 0 1 2 3 4 5 6 7 8 9 10

F
-40.0 -31.0 -22.0 -13.0 -4.0 -2.2 -0.4 1.4 3.2 5.0 6.8 8.6 10.4 12.2 14.0 15.8 17.6 19.4 21.2 23.0 24.8 26.6 28.4 30.2 32.0 33.8 35.6 37.4 39.2 41.0 42.8 44.6 46.4 48.2 50.0

C
-11.7 -11.1 -10.6 -10.0 -9.4 -8.9 -8.3 -7.8 -7.2 -6.7 -6.1 -5.6 -5.0 -4.4 -3.9 -3.3 -2.8 -2.2 -1.7 -1.1 -0.6 0 0.6 1.1 1.7 2.2 2.8 3.3 3.9 4.4 5.0 5.6 6.1 6.7 7.2 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45

F
51.8 53.6 55.4 57.2 59.0 60.8 62.6 64.4 66.2 68.0 69.8 71.6 73.4 75.2 77.0 78.8 80.6 82.4 84.2 86.0 87.8 89.6 91.4 93.2 95.0 96.8 98.6 100.4 102.2 104.0 105.8 107.6 109.4 111.2 113.0

C
7.8 8.3 8.9 9.4 10.0 10.6 11.1 11.7 12.2 12.8 13.3 13.9 14.4 15.0 15.6 16.1 16.7 17.2 17.8 18.3 18.9 19.4 20.0 20.6 21.1 21.7 22.2 22.8 23.3 23.9 24.4 25.0 25.6 26.1 26.7 46 47 46 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72 73 74 75 76 77 78 79 80

F
114.8 116.6 118.4 120.2 122.0 123.8 125.6 127.4 129.2 131.0 132.8 134.6 136.4 138.2 140.0 141.8 143.6 145.4 147.2 149.0 150.8 152.6 154.4 156.2 158.0 159.8 161.6 163.4 165.2 167.0 168.8 170.6 172.4 174.2 176.0

C
27.2 27.8 28.3 28.9 29.4 30.0 30.6 31.1 31.7 32.2 32.8 33.3 33.9 34.4 35.0 35.6 36.1 36.7 37.2 37.8 40.6 43.3 46.1 48.9 51.7 54.4 57.2 60.0 62.7 65.6 68.3 71.1 73.9 76.7 79.4 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96 97 98 99 100 105 110 115 120 125 130 135 140 145 150 155 160 165 170 175

F
117.8 179.6 181.4 183.2 185.0 186.8 188.6 190.4 192.2 194.0 195.8 197.6 199.4 201.2 203.0 204.8 206.6 208.4 210.2 212.0 221.0 230.0 239.0 248.0 257.0 266.0 275.0 284.0 293.0 302.0 311.0 320.0 329.0 338.0 347.0

00-l 7

01

GENERAL

............... General assembly drawing .......................... Specifications Weight table ........................... ............... List of lubricant and water

Ol- 2 01- 3 Ol- 8 01-10

D275A-2

01-l

GENERAL ASSEMBLY DRAWING

SEMI U-DOZER WITH VARIABLE MULTIPLE RIPPER

17MF02001

01-2

D275A-2

SPECIFICATIONS

Machine

model 10001 - 10167

D275A-2 10168 and up

Serial numbers Operating weight

l

Bare tractor With semi U-dozer Semi U-dozer with variable multiple ripper Semi U-dozer with variable multiple ripper + with ROPS cab assembly

37200 44180

kg

48830 50000

Minimum turning radius Grade ability Stabilitiy (Front, rear, left, right)
7

m degree degree 0km/h 0-

3.9 30 35 3.8 6.7

1st 2nd 3rd

$ 2

O-11.8 0km/h 04.9 8.7

$ 1st & 2 2nd cT 3rd Bare tractor With Semi U-dozer

0 - 14.9 8.63 IO.881 10.29 (1.05) 11.37 11.16) 11.67 {1.19}

kPa Semi U-dozer with variable multiple ripper Semi U-dozer with variable multiple ripper (kg/cm*} + with ROPS cab assembly Bare tractor With Semi U-dozer Semi U-dozer with variable multiple ripper Bare tractor Wtih Semi U-dozer To top of exhaust pipe Except exhaust pipe, operatiors seat Track gauge Length of track on ground Show width Minimum ground clearance mm mm mm mm mm

5445 7085 9055 2935 4300 3875 2880 2260 3450 610 507

01-3 @

Machine

model
10001 - 10167

D275A-2
10168 and up

Serial numbers
Engine Type model

S6D170-1 4-cycle, water-cooled, in-line vertical, direct injection type with turbocharger x stroke mm cc kW/rpm :HP/rpmI Nm/rpm cgmlrpm rpm rpm ration g/kWh {glpshl 6-170x170 23150

S6D170-2 $-cycle, water-cooled, in-line vertical, direct injection type with turbocharger 6-170x170 23150

No. of cylinders-bore Piston displacement

Flywheel

horsepower

302/l ,800 141 O/l ,800) 2,079/l ,300 (2 12/l ,300) 2,000 630 214 {I581

302/I ,800 (41 O/l ,800) 2,079/l ,300 (2 12/l ,300) 2,000 630 224 {I651

Max. torque High idling speed Low idling speed Min. fuel consumption Starting Alternator Battery Radiator Torque core converter motor

24V, 7.5kw x 2 24V, 50A 12V, 170Ah x 2 ZG D type 3-element, l-stage, single phase (with lock-up clutch) 2 ;;

Transmission

Planetan/ gear, multiple disc clutch, hydraulically actuated, force-feed lubrication pump, forward B-speed, reverse 3-speed Spiral bevel gear, splash type lubrication Wet type, multiple clutch disc, spring boosted, hydraulically actuated (manual type), interconnected with brake Wet type, multiple clutch disc, spring boosted, hydraulically actuated (pedal operated, manual type), interconnected with clutch Spur gear l-stage, planetary gear l-stage reduction, splash type lubrication Semi-rigid balancing beam type 2 (each) 8 (each) Assembly type, single grouser 39 (each) mm mm 260.35 610

Bevel gear Steering clutch

Steering

brake

Final drive Suspension Carrier roller

Track roller Track shoe type

l

No. of shoes Pitch Width

01-4 @

Machine

model

D275A-2

Serial numbers
Relief valve setting Hydraulic Delivery pump type (at engine speed 1,800 rpm) L?/min

f
RPafkglcm:

10001

- 10167

I
20.6 (210)

10168

and

up

Gear type, 2 tandem 288

x 2EARlOO

+ 050)

. Blade

lift control

valve and ripper low valve

Single spool type with demand spool 3-tandem spool type 2-tandem pilot spool type

. Blade tilt control

l

Ripper

high valve

Hydraulic

cylinder bore

type

Reciprocal, piston type 130

Cylinder Outside

diameter

of Piston rod mm

80 1,420 2,365 945 200

Piston stroke Max. distance Min. distance Cylinder Outside bore diameter of Piston rod between between Pins Pins

100 mm 190 1,555 1,365 200

Piston stroke Max. distance between between Pins Pins

Min. distance Cylinder Outside bore

diameter

of Piston rod mm

100 465 1,565 1,100

Piston stroke Max. distance Min. distance between between Pins Pins

01-5 @

ork.equipment W Dozer equipment Jin puller cylinder Dual tilt cylinder Gpper tilt cylinder efformance limension

Hydraulic cylinder

21
D L

017M02

Machine

model
10001 - 10167

D275A-2 10168

Serial numbers Type

Weight Beam length No. of shanks Ripping Ripping angle depth depth mm mm (standard) degree

and up
type

Variable angle type, parallelogram

kg
mm

4,490 2,495 3 51.7 (Possible to adjust steplessly 36.9 - 61.2) P-stage selection possible 900 955 Variable angle type, parallelogram type

Max. digging

Max. lifting height Type Weight Beam length No. of shanks Ripping Ripping angle depth depth height (standard)

kg
mm

3,640 1,252 1

degree

52.7 (Possible to adjust steplessly 39.7 - 62.2) 3-stage selection possible

Max. digging Max. lifting

mm mm

1.300 870

01-7 @

WEIGHT TABLE

This weight table is a guide for use when transporting or handling components. Machine model
Serial numbers

Unit: kg

D275A-2

10001 and up

Engine and damper assembly

l

2810 2580 160 70 350 100 390 (1150)

Engine assembly Damper assembly Engine mounting parts

Radiator assembly Oil cooler assembly Fuel tank assembly (Full) Power train unit Power train assembly Torque converter and PTO assembly Transmission Transmission assembly control valve assembly

3360 740 890 35 1600 60 1940 4200 4100 1200 340 110 120 70 6800 145 255 195 350 56 47

Steering clutch and brake assembly Steering control valve assembly Final drive assembly (each side) Main frame assembly Track group assembly (each side) Track frame Idler assembly Track roller assembly (single) (each) Track roller assembly (double) (each) Carrier roller assembly (each) Track shoe assembly (width 610 mm) Pivot shaft (each side) Equalizer bar Bolster Hydraulic tank assembly
l

Blade lift control valve assembly Blade tilt and ripper low valve assmebly

01-8

D275A-2

Unit: kg Machine model Serial numbers D275A-2

10001 and up 6330 2980 780 780 220

Semi-U dozer assembly

l

Blade L.H. straight frame R.H. straight frame Tilt cylinder assembly

Variable multiple shank ripper assembly

l

Shank assembly (each) Lift cylinder assembly Tilt cylinder assembly

350 205 185 3600 500 205 185 1700 750 210 330 260 330 90 300 320 500 580 320 490 70

Variable giant ripper assembly

l

Shank assembly Lift cylinder assembly Tilt cylinder assembly

Radiator guard assembly (with cylinder yoke)

l

Radiator guard Blade lift cylinder assembly (each side)

Front guard (with grille) Engine under guard Power train under guard Engine hood L.H. fender R.H. fender ROPS mount assembly ROPS assembly Floor frame assembly Cab assembly Operators seat assembly

D275A-2

01-9

TABLE OF FUEL, COOLANT AND LUBRICANTS

RESERVOIR

KIND OF FLUID

AMBIENT TEMPERATURE
-22 -4

Engine oil pan

Power train oil pan (Incl. torque converter, transmission and bevel gear case) Engine oil

Hydraulic tank

*I

Gear oil

Fuel tank

Diesel fuel

Cooling system

Coolant

Add antifreeze

136

ASTM D975 No. 1

NOTE: (1) When fuel sulphur content is less than 0.5 %, change oil in the oil pan every periodic maintenance hours described in this manual. Change oil according to the following table if fuel sulphur content is above 0.5 %.

Above 1 .O %

l/4 of regular interval

ASTM: SAE: API:

American Society of Testing and Material Society of Automotive Engineers American Petroleum Institute

(2) When starting the engine in an atmospheric temperature of lower than OC, be sure to use and SAEIOW-30 oil of SAEIOW, engine even though an atmospheric temSAEl5W-40 perature goes up to 10C more or less in the day time. (3) Use API classification CD as engine oil and if API classification CC, reduce the engine oil change interval to half. (4) There is no problem if single grade oil is mixed with multigrade oil (SAEIOW-30, 15W-40), but be sure to add single grade oil that matches the temperature in the table on the left. Komatsu genuine oil which (5) We recommend has been specifically formulated and approved for use in engine and hydraulic work equipment applications.

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.

01-10 @ .*-

10 STRUCTURE AND FUNCTION

Z Z Z

General ...................................................... Power train ............................................... Power train unit.. ...................................... Power train unit mount ........................... Power train piping ................................... Power train hydraulic circuit diagram ... Damper and universal joint .................... Torque converter - PTO ........................... Torque converter valve ........................... Transmission ............................................ Transmission control ............................... Transmission control valve ..................... Transmission lubrication relief valve.. ... Scavenging pump .................................... Oil strainer ................................................ Power train oil filter and lubrication oil filter.. ....................... Steering unit ............................................. Transfer, bevel pinion.. ............................ Bevel gear, steering clutch and steering brake ................................. Steering control.. ...................................... Steering control valve ............................. Final drive ................................................. Main frame ............................................... Track group.. ............................................. Recoil spring ............................................. Suspension ............................................... Hydraulic piping ....................................... l Blade .................................................... l Variable multiple shank ripper .......... l Variable giant ripper.. ......................... Hydraulic control ...................................... l Blade control ....................................... l Blade control (for dual tilt dozer). ..... 0 Kipper control ..................................... Hydraulic circuit system .......................... Hydraulic circuit diagram ........................ Hydraulic tank.. .........................................

IO- 2 IO- 3 IO- 4 IO- 5 IO- 7 IO- 8 IO-IO IO-12 IO-16 IO-24 IO-29 IO-30 IO-37 IO-38 IO-39 IO-40 IO-42 IO-44 IO-46 IO-51 IO-52 IO-60 IO-63 IO-64 IO-65 IO-66 IO-69 IO-69 IO-70 10-70-I IO-71 IO-71 IO-72 IO-73 IO-74 IO-75 IO-77

Blade lift control valve ............................. Blade tilt control and ripper low valve.. . Ripper high valve ................................... Ripper tilt suction valve.. ....................... Piston valve ............................................ Quick drop valve .................................... Cylinder stay ........................................... Semi U-dozer .......................................... Ripper ...................................................... l Variable multiple shank ripper ........ l Variable giant ripper.. ....................... Pin-puller solenoid valve ....................... Electrical circuit diagram ....................... l Chassis electrical circuit diagram.. .. l Cab electrical circuit diagram .......... l Air conditioner electrical circuit diagram ............... EVMS (Electrical vehicle monitoring system) ... APS control system ............................... Torque converter lock-up control system ......................................

IO- 78 IO- 82 IO- 84 IO- 86 IO-104 IO-105 IO-106 IO-108 10-l 10 IO-I IO IO-I 12 IO-I 12-2 10-l 14 IO-I 14 10-118-4 10-l 18-6 10-l 19 IO-132 IO-133

10-l @

GENERAL

1. Engine (S6D170) 2. Damper 3. Universal joint 4. Torque converter 5. TORQFLOW transmission

6. 7. 8. 9. 10. 11.

Transfer Steering clutch Steering brake Final drive Sprocket Track

F19702001

The power produced by diesel engine (1) goes from the engine flywheel to torque converter (4) through damper (2) and universal joint (3). The torque converter (4) transmits the power to transmission (5) by converting the mechanical energy - fluid energy mechanical energy. The transmission (5), with a planetary gear mechanism and a hydraulic control unit combined, allows an easy selection of three forward speeds and three reverse speeds. Through the drive shaft, the power is transmitted from transmission (5) to transfer drive gear (6) on the rear of the machine body. The transfer gears reduce the speed and, then, the power is transmitted to bevel pinion. Bevel pinion and bevel gear direct the power to the right and left, and the power is transmitted to the left and right steering clutches (7) and final drives (9).

The steering clutch connects and disconnects the power from the bevel gear shaft to final drive (9). SO that the traveling direction of the machine is controlled (steering). For example, when the R.H. steering lever is pulled, the steering control valve linked to the lever is operated, the power is disconnected, and the machine turns to the right. Steering brake (8) is installed between steering clutch (7) and final drive (9). It is the same type as the steering clutch. Steering brake (8) not only stops the machine, but also controls the turning radius of the machine. Final drive reduces the revolution speed by spur gear single reduction and planetary gear system, and the revolution speed is transmitted to sprocket (10). Sprocket (10) drives track (11).

1 o-2

D275A-2

POWER TRAIN

17 M F02002A

1. 2. 3. 4. 5.

Engine (S6D170) Damper Universal joint Torque converter Transmission

6. 7. 8. 9. 10.

Transfer Steering clutch Steering brake Final drive Sprocket

11. 12. 13. 14. 15.

Track shoe PTO Power train pump (BALI 00 + 140) Scavenging pump (BAR63 + 200) Hydraulic pump (SAR(3)lOO + (2)50)

10-3 0

POWER TRAIN UNIT

I4
D275A-2 10061 and up

SI

A
6
1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. PTO Torque converter Torque converter valve Transmission control valve Transmission Steering clutch and brake Steering control valve Power train pump Power train oil filter Power train oil strainer Scavenging pump Power train oil tank

OUTLINE 0 The power train unit can be broadly divided

into the torque converter and transmission unit and the steering unit. Therefore, after removing the power train as a unit, it can be disassembled into the torque converter and transmission unit and the steering unit. The steering unit consists of the transfer, bevel gear shaft, steering clutch, and steering brake.
17MF02003B

POWER TRAIN UNIT MOUNT

9 10 11

A-A 17MF02004

1. 2. 3. 4. 5. 6.

Main frame PTO Torque converter Transmission Steering clutch and brake Cage

7. 8. 9. 10. 11.

Clamp Seal Cover Coupling Cap

D275A-2

1o-5

Oil cooler Power train lubrication oil filter Power train oil filter Torque converter valve Transmission control valve Steering control valve Oil tank Power train oil strainer Power train pump Scavenging pump

D275A-2

1 o-7

setpressure
2.7 kg/cm2

!
r
pressure i--J Se 1!7I f 1 kg/cm2 :racking ,VZSE

!t

Cracking pressw 1.4 kg/cm2

ir
i

1:

.4 kg/cm*

;
46
F17M02001A

Plug for transmission main relief pressure Plug for torque converter relief pressure Plug for torque converter regulator pressure Plug for torque converter stator clutch modulating pressure Plug for torque converter lock-up pressure Plug for transmission reducing pressure Plug for R.H. steering clutch pressure Plug for R.H. brake pressure Plug for L.H. brake pressure Plug for L.H. steering clutch pressure

1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24. 25. 26. 27. 28. 29. 30. 31. 32. 33. 34. 35. 36. 37. 38. 39. 40. 41. 42. 43. 44. 45. 46.

Oil tank Power train oil strainer Power train pump (BALI401 Power train lubrication pump (BALIOO) Power train oil filter Main relief valve Modulating valve Quick return valve Reducing valve Transmission F-R valve Transmission speed valve Reverse clutch Forward clutch 3rd speed clutch 2nd speed clutch 1st speed clutch Power train lubrication oil filter PTO lubrication Transmission lubrication valve Transmission lubrication Transmission case Torque converter relief valve Torque converter case Torque converter Torque converter lock-up modulating valve Torque converter lock-up clutch Stator clutch modulating valve Stator clutch Torque converter lock-up selector valve Torque converter lock-up solenoid valve Stator and clutch lubrication R.H. steering clutch valve R.H. brake valve L.H. brake valve L.H. steering clutch valve Pin puller solenoid valve Pin puller cylinder Steering clutch and brake lubrication R.H. Steering clutch R.H. Brake L.H. Brake L.H. Steering clutch Steering case Scavenging pump (BAR63 + 200) Oil cooler Oil filler

E
6

1 O-8 0

DAMPER AND UNIVERSAL JOINT

r-7

17MF02007

10-10

D275A-2

OUTLINE The damper acts as a cushion to prevent the vibration of the engine from being transmitted directly to the torque converter and transmission. The power from the engine is transmitted to damper outer body (1) through flywheel (9). The power is absorbed the engine vibration by rubber coupling (7), and is transmitted to shaft (8) and universal joint (4), and then is transmitted to the torque converter. As the damper uses rubber, it absorbs the vibration by the vibration-reducing effect of rubber, and the twist by the friction-reducing effect of the deformation of the rubber. The number of part is fewer than the friction plate type damper.

I. 2. 3. 4. 5. 6. 7. 8. 9.

Outer body Oil level gauge Coupling Universal joint Flange Cover Rubber coupling Output shaft Engine flywheel

D275A-2

10-11

TORQUE CONVERTER

PTO
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17

C.

17MF02008

A. B. C.

Mount of hydraulic pump Mount of power train pump Mount of scavenging pump

1. Coupling 2. Seal cage 3. Input shaft [PTO drive gear (61 teeth)] 4. Front housing 5. Idler gear (77 teeth) 6. Idler gear shaft 7. Clutch housing 8. Drive case 9. Turbine IO. Rear housing 11. Stator 12. Pump

13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24. 25.

Stator shaft Bearing cage Retainer Shaft Transmission input shaft Stator shaft boss Stator clutch housing Return spring Stator clutch plate Stator clutch disc Stator clutch piston Turbine boss Lock-up clutch disc

26. 27. 28. 29. 30. 31. 32. 33. 34. 35. 36. 37.

Lock-up clutch plate Lock-up clutch piston Scavenging pump gear (63 teeth) Scavenging pump boss Seal seat Spacer Cover Hydraulic pump gear (57 teeth) Power train pump gear (57 teeth) Drive shaft Cover Cover

37'

z-z

17MF02009

10-12

D275A-2

OUTLINE 0 The torque converter is a 3-element, singlestage, l-phase torque converter, and it forms a single structure with the transmission. To improve the fuel consumption and ease of operation and to reduce consumption of the engine horsepower, a wet-type, multiple-disc clutch type torque converter lock-up device and a wettype, double-disc stator clutch device are assembled inside it. 0 When the machine is carrying out continuous low-load dozing or grading operations, it is more efficient if the motive power of the engine is transmitted directly to the transmission input shaft. To achieve this, a lock-up clutch actuated by hydraulic pressure is assembled inside the torque converter. When the torque converter is locked up (the pump and turbine form one unit), the oil supplied from the torque converter relief valve does not stop, so the oil leaving the turbine from the pump is given unneeded direction by the stator, and this resists the rotation of the pump and turbine (the oil is churned). To prevent this, a stator clutch similar to the lock-up clutch is built in. This allows the stator to rotate freely when the torque converter is locked up. The oil then moves together with rotation of the pump and turbine; it is discharged from the pump and turbine with little resistance, and is returned to the pump. * The condition for the torque converter to enter the lock-up range and torque converter range are as follows. 0 Lock-up range When both of the following conditions are fulfilled: Torque converter output shaft speed: Above 1170 rpm Transmission set pressure: _ Above 19.5 kg/cm2 0 Torque converter range When either of the following conditions are fulfilled. Torque converter output shaft speed: Below 1110 rpm Transmission set pressure: Below 15 kg/cm2

STRUCTURE 0 Pump (12) forms one unit with coupling (I), shaft (3), clutch housing (7), and drive case (8); and is rotated by the motive force from the engine. l Turbine (9) forms one unit with turbine boss (24) and transmission input shaft (turbine shaft) (17), and is rotated by oil from the pump. 0 Stator (11) forms one unit with stator shaft (13) and stator shaft boss (18), and is locked to rear housing (10) by the stator clutch. 0 The lock-up clutch consists of three parts: clutch plate (26) (meshed with drive case (8)), clutch disc (25) (meshed turbine boss (24)), and clutch piston (27) (that slides inside housing (7) that forms one unit with the drive case). l The stator clutch consists of three parts: clutch disc (22) (meshed with boss (18) that is connected by a spline to stator shaft (13)), clutch plate (21) (supported by a pin to clutch housing (19) and rear housing (IO)), and clutch piston (23) (that slides inside the rear housing). 0 The PTO consists of a drive gear forming one unit with input shaft (3), idler gear (5), scavenging pump drive gear (28), hydraulic pump drive gear (33), and power train pump drive gear (34).

D275A-2

10-13

PATH OF TRANSMISSION

OF MOTIVE

FORCE

1. Lock-up clutch OFF, stator clutch ON When the lock-up clutch is OFF, the connection between drive case (8) and turbine (9) is cut; and when the stator clutch is ON, rear housing (IO) and stator shaft (13) are connected, so stator (11) is locked and the torque converter provides the normal functions of a torque converter. The motive force generated by the engine passes through the damper and universal joint, and is transmitted to coupling (1). Input shaft (3), clutch housing (7), drive case (8), and pump (12) rotate as one unit. The motive force from the pump uses oil to rotate turbine (9), and is transmitted to transmission input shaft (17), that forms one unit with the turbine.

10

11

12

13

17

Lock-up clutch

Stator Clutch 17MF02010

2. Lock-up clutch ON, stator clutch OFF When the lock-up clutch is ON, drive case (8) and turbine (9) are connected to form one unit; and when the stator clutch is OFF, the connection between rear housing (10) and stator shaft (13) is cut, so stator (11) follows the rotation of pump (12) and turbine (9). The motive force generated by the engine passes through the damper and universal joint, and is transmitted to coupling (1). Input shaft (3), clutch housing (7), drive case (8), and pump (12) rotate as one unit. In addition, the drive case and turbine (9) _ are connected by the clutch, so the oil is 4 not used. The motive force is transmitted directly to the turbine and transmission input shaft (17).

3!3

110 ,,,I

11

12

13

Lock-up clutch

Stator clutch 17MF02011

10-14

D275A-2

FLOW OF OIL 0 Oil set to within Max. 10 kg/cm2 by the torque converter relief valve flows from port A, passes through the oil hole inside rear housing (IO), and enters pump (12). The pump is always being rotated by the motive force from the engine, so the oil entering the pump is given centrifugal force, and enters turbine (9). The turbine is rotated by the centrifugal force of the oil. The turbine forms one unit with transmission input shaft (17), so the motive force received by the turbine is transmitted to the transmission. The oil leaving the turbine is sent to stator (11) and enters the pump again, but some of the oil passes from the stator through port B and is sent to the oil cooler.

D275A-2

10-15

TORQUE CONVERTER VALVE

A-A Pl \

17MF02013

1. 2. 3. 4. 5. 6. 7. 8. 9. IO. 11. 12. 13. 14. 15. 16. 17.

Valve body Torque converter relief valve Valve spring Valve spring Main relief valve Cover Piston Piston spring Piston Stator clutch modulating valve Lock-up clutch modulating valve Cover Piston Piston spring (Small) Piston Valve spring (Outer) Valve spring (Inner)

18. Stopper 19. Load piston 20. Cover 21. Cover 22. Valve spring 23. Valve body 24. Lock-up selector valve 25. Piston 26. Cover Lock-up solenoid valve assembly 27. Push pin 28. Valve seat 29. Return spring 30. Valve body 31. NO valve 32. Return spring 33. Cap

Stator clutch pressure pickup port P,: Torque converter relief pressure pickup port P. Lock-up clutch pressure 3 pickup port P,: Main relief pressure pickup port P10' Lock-up clutch initial . pressure pickup port P11'* Stator clutch initial pressure pickup port P:

lo-16

D275A-2

E-E

E
6

17MF02014

OUTLINE 0 The torque converter valve is installed at the top of the rear housing of the torque converter and consists of the following six types of valves. 1. Main relief valve Main relief valve (5) sets the hydraulic pressure to 25.4 28.0 kg/cm2 in the transmission, steering clutch, brake and torque converter lock-up clutch, and stator clutch circuits. 2. Torque converter relief valve Torque converter relief valve (2) sets the inlet pressure of the torque converter to within 8.7 kg/cm2 to protect the torque converter from abnormally high pressure. 3. Torque converter lock-up valve Lock-up selector valve (24) acts to switch the lock-up clutch and stator clutch ON * OFF.

4. Torque converter lock-up solenoid valve Solenoid valve receives an electrical signal from the lock-up controller and switches the pilot pressure to lock-up selector valve (24). It operates lock-up selector valve (24) and switches the two clutches ON * OFF. 5. Stator clutch modulating valve Modulating valve (10) sets the clutch pressure to 26 - 28 kg/cm* to protect the stator clutch from abnormally high pressure and acts to raise the pressure of oil from lock-up selector valve (24) gradually until it reaches the set pressure. 6. Lock-up clutch modulating valve Modulating valve (11) acts in the same way as stator clutch modulating valve (IO) and sets the clutch pressure to 13 - 14 kg/cm* to protect the stator clutch from abnormally high pressure.

10-17 0

OPERATION OF MAIN RELIEF VALVE The oil from the power train pump passes through the oil filter, and enters port A of the main relief valve. It then passes through orifice a and enters port B. When the oil from the pump fills the circuit, the pressure starts to rise. When the pressure in the circuit rises, the oil entering port B pushes piston (9). The reaction force compresses spring (4), moves main relief valve (5) to the left in the direction of the arrow, and opens ports A and C. When this happens, the oil from the pump is relieved from port A to port C, and flows port C to the torque converter. The pressure in the circuit at this point is 25.4 - 28.0 kg/cm*.

To torque converter

To oil tank

Q
From pump F19702004

To torque converter

To oil tank

OPERATION OF TORQUE CONVERTER RELIEF VALVE The oil relieved from the main relief valve flows into the torque converter from port C, and at the same time passes through orifice b and enters port D. When the oil fills the torque converter, the pressure starts to rise. If the pressure in the torque converter rises abnormally high, the oil entering port D pushes piston (9). The reaction force compresses spring (3), moves relief valve (2) to the right in the direction of the arrow, and opens ports C and E. When this happens, the oil at port C is relieved to port E, and is drained to the oil tank. The pressure in the circuit at this point is below 8.7 kg/cm*.
To torque converter

From pump F19702005 To oil tank

From pump

F19702006

lo-18

D275A-2

OPERATION OF TORQUE CONVERTER LOCK-UP VALVE, SOLENOID VALVE The torque converter lock-up valve supplies oil to switch the lock-up and stator clutch built.into the torque converter ON - OFF. The lock-up valve is actuated by the pilot pressure from the solenoid valve that is actuated when it receive an electrical signal from the lock-up controller. When the lock-up switch on the switch panel at the side of the operators seat is pressed ON (the indicator lamp inside the switch lights up), the auto-lock-up system is actuated, and when the torque converter reaches the lock-up range, the lock-up controller, that has received signals from the two sensors, connects the solenoid to the ground and current flows. The hydraulic circuit is switched and pilot pressure is sent to the lock-up valve to lock up the torque conveter.
0

E
6

The diagram on the right shows the electrical circuit for the torque converter lock-up system. (For details, see the electrical circuit diagram) The electricity from the battery flows from the relay box to the panel switch. When the lock-up switch is pressed ON, the switch is connected to the ground, and this actuates the relay inside the relay box. The electricity from the battery passes through the pilot lamp and acts as the power source for the lockup controller. In this condition, if both the torque converter output shaft speed detected by the speed sensor is above 1170 rpm, and the transmission modulating pressure detected by the hydraulic sensor is above 19.5 kg/cm* (AND circuit), the controller connects the pilot lamp and solenoid to the ground, and they light up or are excited respectively. If either the torque converter output shaft speed Transm,ss,o is below 1110 ram or the modulating pressure is pressure sens below 15 kg/cm* (OR circuit), the controller cuts the circuit connecting the pilot lamp and solenoid to the ground, and they go out or are deactivated respectively. In other words, when the torque converter %% comes close to the stall range or tries to shift gear, the machine changes to torque converter drive, and when there is continuous light operation, the machine changes to direct drive.

LOC~.P power LocL-pgrod

197FO26

10-19 0

1. Travel in torque converter

drive

:lutch

197FO2023

When the machine is in the torque converter range, the solenoid valve is deactivated, so valves (28) and (31) are pushed to the right in the direction of the arrow by the tension of spring (29). Ports N and M close and ports N and P open.

When this happens, oil from the pump flows ports P and N into port L of the lock-up valve. When the pressure inside the circuit rises, piston (25) is pushed to the left in the direction of the arrow, and the piston pushes out lock-up selector valve (24) to the left.

197FO2024

When lock-up selector valve (24) moves to the left in the direction of the arrow, ports F and G and ports H and K close, and ports F and H and ports G and J open. When this happens, the oil from the pump flows from port F to port H, and becomes the back pressure of the stator clutch piston. When the pressure

in At of to

the circuit rises, the stator clutch is engaged. the same time, the oil that is the back pressure the lock-up clutch piston is drained from port G port J, and the lock-up clutch is disengaged.

1O-20

D275A-2

2. Travel in direct drive

197FO2025

When the machine is in the direct drive range, the solenoid valve is excited, so push pin (27) is pushed to the left in the direction of the arrow and valves (28) and (31) are moved. Ports N and P close and ports N and M open. When this happens, oil from the pump stops at P. The high-pressure oil at port L is drained from port N to port M. When the pilot pressure at port L is lost, piston (25) and lock-up selector valve (24) are returned to the right in the direction of the arrow by the tension of spring (22).

Ports F and H and ports G and J close, and ports F and G and ports H and K open. When this happens, the oil from the pump flows from port F to port G, and becomes the back pressure of the lock-up clutch piston. When the pressure in the circuit rises, the lock-up clutch is engaged. At the same time, the oil that is the back pressure of the stator clutch piston is drained from port H to port K, and the stator clutch is disengaged.

D275A-2

10-21

Operation of stator clutch, lock-up clutch modulating valve 0 The modulating valves are in the circuit between the lock-up selector valve and the inlet ports of the two sets of clutches. When the clutch is switched ON, the modulating valve acts to raise the pressure on the piston gradually until it reaches the set pressure so that the clutch is engaged smoothly, thereby reducing any shock to the torque converter or transmission. j, The following explanation of operation takes the stator clutch as the example, but the operation of the lock-up clutch is the same. However, the oil flow to the clutch during direct drive or torque converter drive is the reverse. 1. Travel in direct drive When the machine enters the direct drive range, the oil at port L of lock-up selector valve (24) returns to the solenoid valve and is drained. When this happens, lock-up selector valve (24) is pushed to the right in the direction of the arrow by the tension of spring (22). Ports F and H close, and ports H and K open, and the oil at port H is drained from port K. When the hydraulic pressure at port H is lost, modulating valve (10) is returned to the right in the direction of the arrow by the tension of spring (16), and ports H and 0 open fully. At this point, the actuating pressure of the stator clutch is drained from port H to port K, and the clutch is disengaged.

Frompump

TO solenoid valve

197FO2026

1o-22

D275A-2

2. Travel in torque converter drive When the machine is in the torque converter drive range, the oil from the solenoid valve enters port L of lock-up selector valve (24) and moves the lock-up selector valve to the left in the direction of the arrow. Ports F and G, and ports H and K close, and ports F and H open. A circuit is then formed from port F through modulating valve (10) to the stator clutch. The oil from the pump flows from port F to the stator clutch, and the pressure in the circuit starts to rise. As the hydraulic pressure in the circuit rises, the oil passing through orifice d in modulating valve (IO) pushes piston (13), and the reaction force moves the modulating valve to the left in the direction of the arrow to throttle ports Q and H. Port Q is connected with port S that applies back pressure to load piston (19), and moves the load piston to the right in the direction of the arrow to compress spring (16). The tension of the spring opens ports Q and H. This operation is repeated intermittently to increase the load of spring (16). While this is happening, the hydraulic pressure gradually increases, and finally stops at the position where ports Q and H are closed to complete the rise in hydraulic pressure. The hydraulic pressure at this point is 26 - 28 kg/cm2. The hydraulic pressure of the lock-up clutch is 13 - 14 kg/cm2.

From pump

To solenoid valve

_ II

197FO2027

From pump

To solenoid valve

//I
D275A-2

197FO2028

1 O-23

TRANSMISSION

17MF02015

OUTLINE The D275A-2 bulldozer is equipped with a planeand 3-reverse speed transtary type, 3-forward mission which is a combined structure of a planetary gear mechanism and disc clutches. of the direction and the revolution The rotational output shaft is selected by fixing two transmission disc clutches out of five disc cluthes by means of control valve operation.

No. 1 clutch is fixed in reverse, No. 2 clutch in forward, No. 3 clutch in third speed, No. 4 clutch in second speed, and No. 5 clutch in first speed. Any speed can be selected from three forward speeds and three reverse speeds by fixing either No. 1 or No. 2 clutch and one clutch among No. 3, No. 4 and No. 5 clutches and by combining two of the above.

1 O-24

D275A-2

8 \

9 \

1,s

17

l,B

;2

/23

f4

;5

36

1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24. 25. 26. 27. 28. 29. 30. 31. 32. 33. 34. 35. 36. 37. 38. 39. 40. 41.

Input shaft Transmission valve Front case Rear case Front cover Reverse sun gear (34 teeth) Reverse ring gear (91 teeth) Pinion shaft Reverse planetary pinion (25 teeth) Reverse ring gear (84 teeth) Forward sun gear (41 teeth) Forward planetary pinion (25 teeth) Forward ring gear (91 teeth) Pinion shaft 3rd speed ring gear (91 teeth) 3rd speed planetary pinion (25 teeth) 3rd speed sun gear (41 teeth) 2nd speed ring gear (93 teeth) 2nd speed planetary pinion (23 teeth) Pinion shaft 2nd speed sun gear (47 teeth) No. 5 gear (1 st speed gear) No. 5 clutch piston No. 5 clutch piston housing Output shaft Spacer Block No. 5 clutch spring Seal seat No. 4 carrier Plate No. 2, 3 carrier No. 2, 3 piston housing No. 1 carrier No. 1 piston housing Clutch piston Clutch spring Clutch plate Clutch disc Tie bolt Reverse carrier gear (91 teeth)

Speeds and operating

clutches

Speed Neutral First speed Forward Second Third Neutral First speed Reverse Second Third speed speed speed speed

Operating No. 5 clutch No. 2 and

clutch

No. 5 clutches

No. 2 and No. 4 clutches No. 2 and No. 3 clutches No. 5 clutch No. 1 and No. 5 clutches No. 1 and No. 4 clutches No. 1 and No. 3 clutches

Number of discs and plates on each clutch

Clutch

No.

Number

of plates

Number

of discs

No. 1 clutch No. 2 clutch No. 3 clutch No. 4 clutch No. 5 clutch

5 4 2 3 4

5 5 3 3 5

40 /////I 39

38

37

36

35

I 34

/ 33

I 32

I 31

I 30

I 29

I 28

I 27

17MF02016

D275A-2

1 o-25

FUNCTION

OF PISTON 3.7 4.2 3.! 38 36 35

To lock ring gear (7), the discs (39) and plates (38) are brought into close contact. The clutch consists of a clutch piston (36), clutch plates (38), clutch discs (39), pins (42) and piston return springs (37). The discs internal teeth engage with the ring gears external teeth. The plates, whose notch on the outside diameter engage with pins (42) on housing (35), are locked against the rotating direction. Piston (36) also is locked against the rotating direction.

Clutch engaged (oil pressure is acting) Oil from the control valve flows under pressure through the port in housing (35) to the piston (36). The piston presses clutch plates (38) and clutch discs (39) together, and the frictional force developed stops clutch discs (39) revolution, thus ring gear (7) meshing with the discs internal teeth is locked.

39

3p

36C

?5

Clutch disengaged (oil pressure is not acting) When the supply of pressure oil from the control valve is shut off, piston (36) returns to the initial position by the force of piston return spring (37), thus relieving the frictional force between plates (38) and discs (39), making the ring gear (7) free.

F19702010

1 O-26

D275A-2

POWER FIRST

TRAIN FORWARD

OF TRANSMISSION SPEED

30
17MF02017

For FORWARD Ist, No. 2 clutch and No. 5 clutch are engaged. The motive force transmitted from the torque converter to input shaft (1) is transmitted to output shaft (25). No. 2 clutch is actuated by the hydraulic pressure applied by the clutch piston and locks ring gear (13) in position. No. 5 clutch is actuated by hydraulic pressure applied by the clutch piston and engages No. 5 gear (22) and No. 4 ring gear (18) in position. The motive force from the torque converter is transmitted to the input shaft. The rotation of the input shaft is transmitted through sun gear (11) to planet gear (12).

Ring gear (13) is locked in position by No. 2 clutch, so planet gear (12) rotates carrier (32), which is on the inside of ring gear (13). No. 5 clutch is also engaged, so the No. 5 gear (22), sun gears (17) and (21), planet gears, ring gears (15) and (18), and No. 4 carrier (30) form one unit, and carrier (32) rotates as one unit with the gears of No. 3, 4 and 5 clutches to rotate output shaft (25). Output shaft (25) rotates at the same speed as carrier (32).

D275A-2

1 O-27

10

11

12

13

15

17

18

21

22

25

17MF02018

For REVERSE Ist, No. 1 clutch and No. 5 clutch are engaged. The motive force transmitted from the torque converter to input shaft (1) is transmitted to output shaft (25). No. 1 clutch is actuated by the hydraulic pressure applied by the clutch piston and locks carrier (34) in position. No. 5 clutch is actuated by hydraulic pressure applied by the clutch piston and engages No. 5 gear (22) and No. 4 ring gear (18) in position. The motive force from the torque converter is transmitted to the input shaft (1). The rotation of the input shaft is transmitted through sun gear (6) to planet gear (9).

Carrier (34) is locked in position by No. 1 clutch, so the rotation of planet gear (9) rotates ring gear (IO). Ring gear (IO) rotates in the opposite direction from the input shaft, and it rotates carrier (32). No. 5 clutch is engaged, so the No. 5 gear, sun gears, planet gears, ring gears, and No. 4 carrier form one unit, and carrier (32) rotates as one unit with the gears of No. 3, 4 and 5 clutches to rotate output shaft (25).

1 O-28

D275A-2

TRANSMISSION

CONTROL

1. 2. 3. 4. 5.

Gear shift lever Safety lever F-R spool linkage Speed spool linkage Transmission control

17MF02019

valve

D275A-2

1 O-29

TRANSMISSION

CONTROL VALVE

E-E

17MF02020

Modulating pressure Reducing pressure

26-28 20.5 22.5

A B C D E F G H J K

From power train pump To speed valve G To speed valve J To forward clutch port (No. 2) To reverse clutch port (No.1) To 1st speed clutch port (No. 5) From reducing valve B To 2nd speed clutch port (No. 4) From reducing valve C To 3rd speed clutch port (No. 3)

1O-30

D275A-2

A-A

18

J
B-B

19
11. 12. 13. 14. 15. 16. 17. 18. 19.

17MF :02021

1. 2. 3. 4. 5. 6. 7. 8. 9. 10.

Piston Modulating valve Modulating valve load piston Modulating valve spring (Inner) Modulating valve spring (Outer) Quick return valve Cover Piston spring Piston Piston

Reducing valve Stopper Reducing valve spring Stopper Modulating sleeve spring (Small) Stopper Piston F-R valve Speed valve

D275A-2

10-31

MODULATIING

VALVE

OUTLINE l The modulating valve consists of a modulating relief valve and a quick return valve, and acts to modulates the pressure. l When the gear shift lever is operated to shift gear, the clutch is pushed into close contact by the piston. However, if high pressure is suddenly applied, the piston will suddenly engage the clutch. This will make the machine suddenly start, and it will receive an excessive shock. To prevent this, the modulating valve is installed. When the gear shift lever is operated to shift gear, the pressure on the piston gradually rises to the set pressure and the clutch is engaged smoothly. This allows the machine to start without any shock, thereby improving the durability of the power train and at the same time providing a comfortable ride for the operator. l The figure shows the relationship between the time and the increase in the hydraulic pressure of the modulating valve. For example, when the gear is shifted from Fl and F2, the oil from the pump passes through the speed valve spool, flows to the second clutch and fills the circuit up to the clutch piston port. The time taken for the circuit to be filled up to the clutch piston port is called the filling time, and the oil pressure during this time is 0 - 3 kg/cm2. When the circuit up_to the clutch piston port is filled with oil, the oil pressure starts to rise. The time taken for the pressure to rise to the set pressure is called the built-up time. The filling time and build-up time together are called the modulating time.

Modulating

time

(kg/cm? 30 27 (Set pressure)

2 .? 2 5i is

20-

10 -

0 0

(Sec.)
1 I I , , , ,

0.5 Time

1.0

1JMF02022

1 O-32 0

Operation 1. Immediately after shifting When the transmission shift lever is operated and the clutch is engaged, the passage from the pump to the clutch piston port is opened and the oil flows to the clutch piston port. When this happens, the passage between port B and port D is restricted by orifice b, so a difference in pressure is generated, and quick return valve (6) is moved to the left in the idrection of the arrow by the pressure at port B. This connects port E and drain port F, and removes the back pressure of load piston (3). 2. Pressure starting to rise, during rise When the oil sent under pressue from the pump fills the circuit from port A to the clutch piston port, the hydraulic pressure starts to rise. When this happens, the difference in pressure on the two sides of orifice b of quick return valve (6) is lost, and the quick return valve is moved to the right in the direction of the arrow to close the passage between port E and drain port F. The oil flows form orifice a of modulating valve (2) to port C, and pushes piston (1). Because of the reaction force, the modulating valve compresses springs (4) and (5), and moves to the right in the direction of the arrow to drain the oil from port A to port G. At the same time, the oil flowing from orifice e in quick return valve (6) through the central port passes through orifice d and enters port E. It becomes the back pressure of load piston (3), moves the load piston to the left in the direction of the arrow and compresses springs (4) and (5).

From pump

TO clutch cylinder

Drain

6
A From pump

17MF02023

,E

17MF02024

To clutch cylinder

Drain

\ 6 17MF02025

D275A-2

1o-33

During rise in oil pressure, completion of rise As the pressure rises, the back pressure of load piston (3) increases. When the movement of the load piston to the left increases, modulating valve (2) closes the passage between port A and port G because of the tension of springs (4) and (5). As the pressure at port C pushing piston (1) increases, modulating valve (2) moves to the right in the direction of the arrow due to the reaction force, compresses springs (4) and (5), and opens the passage between port A and port G. By repeating this operation intermittently, the load of springs (4) and (5) increases and the pressure rises slowly. Finally, load piston (3) contacts the valve body and does not move any further. When this happens, modulating valve (2) stops at the position where the passage from port A to port G is closed, and the rise in hydraulic pressure is completed. The hydraulic pressure at this point is 26 0 kg/cm2. The oil frbm the pump is relieved through the main relief valve assembled to the torque converter assembly.

A
\

From pump

G \

17MF02026

\From / PumA

To

clutchcylinder
17MF02027

1o-34

D275A-2

REDUCING

VALVE

OUTLINE The reducing valve is in the circuit between the modulating valve and the 1st speed valve spool. It reduces the pressure applied to the 1st clutch to 20.5 - 22.5 kg/cm*. The hydraulic pressure in the circuit as a whole is set to 26 - 28 kg/cm* by the modulating valve.

From modulating valve

OPERATION 1. Valve OPEN The oil from the modulating valve flows from port A. Some passes through port B and flows to the 1st valve spool and clutch, and at the same time, passes through orifice a and enters port D. The oil also flows from port A through port C, and flows to the 2nd and 3rd spools and the directional spool. When the circuit up to the clutch that has been shifted becomes filled with oil and the pressure rises according to the operation of the modulating valve, the oil entering through orifice a of reducing valve (11) pushes piston (12). The reaction force compresses spring (13) and moves reducing valve (11) slowly to the left in the direction of the arrow in accordance with the rise in the hydraulic pressure, and starts to throttle port B. C

To F-R spool To 2nd & 3rd spool

To 1st spool 17MF02028

From modulating valve

13
1

To F-R s;ool To 2nd & 3rd spool

To 1;t spool 17MF02029

2. Valve CLOSED When the pressure in the whole circuit rises further because of the action of the modulating valve, reducing valve (11) moves further to the left and closes the circuit from the modulating valve, so the pressure in the 1st clutch circuit stops rising. The pressure at this point is 20.5 - 22.5 kg/cm*.

From modulating

To F-R spool To 2nd & 3rd spool

To 1st spool
17MF02030

D275A-2

10-35

If the pressure in the 1st clutch circuit drops because of leakage from the transmission Iubrication or seal ring, the reaction force of the spring of reducing valve (11) opens the circuit. This raises the pressure to the set pressure of reducing valve (11) and maintains the set pressure. Except for the 1st clutch circuit, the pressure in all the circuits continues to rise to the set pressure of the modulating valve. The 1st clutch is farthest from the control valve, and the piping to the cylinder is longer, so it takes a longer time for the oil to fill the piping. For this reason, even when the gearshift lever is in neutral, oil still flows to the 1st clutch. Therefore, when moving the gearshift lever from neutral to Fl, it is only necessary for the oil from the pump to fill the FORWARD clutch. When the gearshift lever is moved from Fl to F2, the FORWARD clutch is already filled with oil, so the oil from the pump only needs to fill the 2nd clutch. By using the oil in this way, the time lag when shifting gear is reduced.

From reducing valve

1st clutch piston 17MF02031

1 O-36

D275A-2

TRANSMISSION

LUBRICATION

RELIEF VALVE

A-A

561 FO3032

1. Valve body 2. Lubrication relief spool a. Lubrication pressure measurement

plug

FUNCTION l This valve is installed to the right transmission and prevents abnormal the transmission lubrication circuit. Cracking pressure: 2.7 kg/cm2

side of the pressure in

D275A-2

1o-37

SCAVENGING
(BAR63 + BARZOO)

PUMP

197 F058A

A. Discharge port B. Small pump suction C. Large pump suction 1. Small pump 2. Large pump

port port

OUTLINE This pump is installed on the lower of the PTO l case, and consists of a small pump and a large
l

pump. The small pump sucks the torque converter case oil and the large pump sucks the steering case oil, and this oil is returned to the oil tank.

Discharge

pressure (kg/cm2) (rpm)

At rated speed

1 O-38 0

OIL STRAINER

17MF02032

1. 2. 3. 4. 5.

Cover Spring Magnet Screen Case

A. From oil tank B. TO power train pump and lubrication

pump

OUTLINE l The strainer is installed on the front and left of the power train unit. l Open the fender located at the front of operators seat, and maintain the strainer. l The oil from the oil tank is filtered by screen (4), and is sucked by the power train pump and the lubrication pump.

Passage flow Screen mesh

600 a/min 80

D275A-2

1o-39

POWER TRAIN

OIL FILTER AND LUBRICATION

OIL FILTER

z
17MF02033

1. 2. 3. 4. 5.

Cover Element Body Valve (Setting Spring

pressure:

I.4 kg/cm*)

A. Inlet B. Outlet

OUTLINE The two filters are the same part, and are installed on the front of power train unit. Open the fender located at the right and front of operators seat, and maintain the filter. The oil from the oil tank is sucked by the power train pump and the lubrication pump through the strainer, and is sent to each filter. If element (2) is clogged or the oil temperature is low, the oil pressure increase, so valve (4) is installed to prevent the filter from breaking.

Cracking

pressure

1.4 kg/cm* 273 Illmin. 30 microns

Passage flow Filter ability

1O-40

D275A-2

STEERING

UNIT

II%
= 0 --

---

----

17MF02034

OUTLINE The steering unit consists of the transfer, bevel gear shaft, steering clutch, and steering brake.

1 O-42

D275A-2

A-A

F-F

E-E D-D 17MF02035

1. 2. 3. 4.

Transmission Breather Steering unit Torque converter

output

shaft speed sensor

A. Mount of steering control valve B. Center of bevel gear shaft C. Center of crank shaft D. Center of bevel pinion

D275A-2

1o-43

TRANSFER,

BEVEL PINION

17MF02036

1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13.

Input shaft Drive shaft Drive gear (33 teeth) Rear cover support Torque converter output Bearing cage Drum Cover Bearing cage Driven gear (34 teeth) Bevel pinion Bevel gear

shaft speed sensor

OUTLINE l The transfer and bevel pinion are installed at the rear inside the steering case and receive the motive force from the transmission output shaft with input shaft (1). The transfer consists of drive gear (3) and driven gear (11). It reduces the speed of the motive force from input shaft (1) and transmits it to bevel pinion (12). Drive shaft (2) rotates drum (8), which sends a pulse signal to torque converter speed sensor (6).

1o-44

D275A-2

OUTLINE Bevel gear shaft The motive force from the engine - torque converter -+ transmission -, transfer enters the bevel gear system. The bevel pinion and bevel gear are meshed and act both to reduce the speed of rotation and to send to the power at right angles to the left and right. The bevel gear system uses spiral bevel gears for the bevel pinion and bevel gear, and a splash-type lubrication system is employed that uses the oil from the power train oil cooler. The bevel gear system consists of the following: bevel gear (17) that meshes with the bevel pinion, bevel gear shaft (16). two steering shafts (15) that are connected to the bevel gear shaft by a spline, the bearing that supports the bevel gear shaft, and bearing cages (14) and (18). Steering clutch l The steering clutches are connected by a spline to the left and right steering shafts, and act to engage or disengage the motive force to the final drive, thereby changing the direction of travel of the machine. l The steering clutches are wet, multiple-disc clutches with a spring booster. They are interconnected with the brakes and are hydraulically actuated by a steering valve that is actuated when the steering lever is operated. A forced lubrication system is employed in which the oil from the power train oil cooler passes through the passage inside the steering case, enters the housing and cage, and is then sent to the discs and plates. l The steering clutch consists of the following: hub (19) that is connected with the steering shaft by a spline, disc (23) that meshes with the hub, plate (22) and housing (27) that are mated at the outside circumference with torque pin (24), piston (25) that presses the discs and plates together, spring (26) and stopper (20), and cage (28) that supports these parts. Housing (27) and cage (28) are connected with brake hub (12), and send the motive force from the bevel gear through the brake hub to output shaft (1). Steering brake l The steering brakes are connected with the left and right steering clutches, and act to brake the machine or change the direction of travel by braking or connecting the motive force from the steering clutches to the final drive. l The steering brakes are wet, multiple-disc clutches with a spring booster. They are interconnected with the brakes and are hydraulically actuated by a steering valve that is actuated when the brake pedal and steering lever are operated. A forced lubrication system is employed in which the oil from the power train oil cooler passes through the passage inside the steering case, enters the housing and cage, and is then sent to the discs and plates. The steering brakes are designed so that when the engine has stopped, the back pressure of the brake piston drops and the brake are applied without the brake pedal being depressed. However, when the engine is started again, the brake is released as the hydraulic pressure inside the circuit rises, so the brake pedal must always be locked. l The steering brakes consist of the following: clutch housing (27), hub (12) that is connected with cage (28) and output shaft (I), disc (10) that is meshed with the hub, plate (8) and housing (5) that are mated at the outside circumference by torque pin (7), piston (6) that presses the discs and plates together, spring (4) and stopper (II), and cage (3) that supports these parts. Housing (5) and cage (3) are secured to the steering case.

D275A-2

1o-47

OPERATION

OF STEERING

CLUTCH

1. When steering clutch is engaged When the steering lever is at the neutral position, the steering valve is also at the neutral position, so no back pressure is applied to piston (25). In this condition, the piston is pushed to the right by the tension of spring (26), and disc (23) and plate (22) are brought into close contact with stopper (20). The stopper is connected with housing (27) by torque pin (24). Therefore, the motive force from steering shaft (15) is transmitted from hub (19) to housing (27) through the discs and plates that are held together. The motive force is then transmitted from brake hub (12), which forms one unit with the housing, through the output shaft (1) to the final drive.

12

27 26

25

24

23

22

20

19

15

F19702025

2. When steering clutch is disengaged When the steering lever is pulled, the steering valve is switched and oil enters the area behind piston (25). When the hydraulic pressure rises, it pushes the piston to the left, and compresses spring (26) to release the pressure holding disc (23) and plate (22) together. When this happens, the motive force from steering shaft (15) rotates only hub (19) and the disc, so the motive force is not transmitted beyond housing (27) and does not go to the final drive. When the steering lever is released, the steering valve opens the drain circuit, and the tension of spring (26) pushes piston (25) back to its original position to return the clutch to the engaged condition explained is Section 1. When the left steering clutch is disengaged, the motive force is transmitted only to the right steering clutch, so the machine turns to the left (travels to the left).

F19702026

1 O-48

D275A-2

OPERATION

OF STEERING

BRAKE

1. When steering brake is released When the steering lever and brake pedal are at the neutral position, the steering valve is also at neutral, so the steering clutch is engaged, and oil enters the back pressure port of steering brake piston (6). When the hydraulic pressure rises, it pushes the piston to the left, compresses spring (4), and releases the pressure holding disc (10) and plate (9) together. When this happens, the motive force transthe shaft (15) through mitted from steering steering clutch to housing (27) is transmitted from hub (12) to output shaft (I), and goes to the final drive.

-27

1.5

lb

;1

F19702027

2. When steering brake is applied (steering lever pulled) lever is pulled fully, the When the steering and the steering valve is switched steering At the same time, the oil clutch is disengaged. back pressure to piston (6) is conapplying nected to the drain circuit. the piston is pushed to the In this condition, right by the tension of spring (4), and disc (10) and plates (9) are brought into close contact with stopper (11). The stopper is connected to case (5) by torque pin (7), so it is locked in position. even if the steering clutch is disenTherefore, gaged, the rotation of output shaft (I), that is the rotation of hub (12) caused by inertia, is stopped when the disc and plate are pushed into contact. The hydraulic force applied to spring (4) is controlled by the amount that the steering lever is pulled, so it is possible to adjust the braking speed the turning controlling force, thereby and turning radius.

10

11

li

F1970202%

D275A-2

1o-49

3. When steering brake is applied (brake pedal depressed) When the brake pedal is depressed, the steering valve is switched, and the oil applying back pressure to piston (6) is connected to the drain circuit. The steering clutch remains engaged, and only the brake is actuated to stop the rotation of output shaft (1).

27

15

I#I II I

10

11

12

F19702029

1 O-50

D275A-2

STEERING CONTROL

17MF02038

1. 2. 3. 4. 5. 6.

L.H. steering lever R.H. steering lever Brake lock lever Brake pedal Brake pedal return spring Steering control valve

D275A-2

10-51

STEERING CONTROL VALVE

z
1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11.
CL

197FO2045

Plug Return spring Piston Valve body R.H. steering valve Modulating spring Shaft assy Cover Return spring R.H. brake valve Modulating valve

12. 13. 14. 15. 16. 17. 18. 19. 20. 21.

Shaft assy Guide L.H. brake valve L.H. steering valve Plug Return spring Piston Seat Check valve Spring

To R.H. steering clutch piston port B. To R.H. steering brake piston port C. To steering case D. From power train pump E: To L.H. steering brake piston port F: To L.H. steering clutch piston port CL: Plug for L.H. steering clutch pressure CR: Plug for R.H. steering clutch pressure BL: Plug for L.H. steering brake pressure BR: Plug for R.H. steering brake pressure A.

1 o-52

D275A-2

197FO2046

OUTLINE The steering control valve consists of two steering valves and brake valves, and is in the circuit between the steering clutch and brake pistons and the power train pump passing through the main relief valve. When the steering lever is pulled, the steering clutch is disengaged. If it is pulled further, the brake is engaged and the machine stops. When the lever on one side is pulled, it is possible to adjust the angle of turning to give gradual turns or sharp turns. If the brake pedal is depressed, the brake is engaged and the machine stops.

These operations are made possible by switching the steering control valve which is interconnected with the lever and pedal. The steering control valve sends oil from the power train pump to the steering clutch and brake, and operates the disc clutch of each.

D275A-2

1o-53

VALVE CONTROL

LEVER

D-D

I97FO72

22. 23. 24. 25. 26. 27. 28. 29.

R.H. steering L.H. and R.H. Lever box Roller R.H. steering Brake lever L.H. steering L.H. steering

lever shaft brake lever shaft

lever lever lever shaft

OUTLINE l The steering control valve is operated by lever shafts (22) and (29) and levers (26) and (28) interconnected with the steering lever in the operators compartment, and lever shaft (23) and lever (27) interconnected with the brake pedal. l The steering valve and brake valve inside the steering control valve are interconnected by cam (25) of levers (26) and (28) to enable the steering lever system to be operated.

1o-54

D275A-2

OPERATION 1. When steering lever, brake pedal are at neutral (clutch engaged, brake released)

To toI que converter val ve, To tri lnsmission control valve

flnnnnn

From

F19702030

When the steering lever and brake pedal are at levers (26), (27), and neutral (not operated), (28) are also at neutral, and the oil ports of each valve are opened or closed by the tension of the spring. The oil from the power train pump passes through the main relief valve and enters port A of check valve (20). Some of the oil entering port A enters port B of left and right steering valves (5) and (15), and stops. When this happens, the oil from the back pressure port of the clutch piston returns from port C to drain port H, and the clutch is engaged by the tension of the clutch spring.

The rest of the oil pushes open check valve (20), enters port E of left and right brake valves (10) and (14), and then flows from port F to the back pressure port of the brake piston. When the hyin the circuit rises, the piston draulic pressure the brake spring, moves to the left, compresses and the brake is released.

D275A-2

1o-55

2. When steering lever is pulled (clutch disengaged, brake released)

From power train pump

F19702031

When the left steering lever is pulled, roller (25) of lever (28) pushes shaft (7) to the left and compresses modulating spring (6). The reaction to this moves steering valve (15) to the left. When this happens, the circuit between port C and drain port H is closed, and the circuit between ports B and C is opened. The oil from the power train pump flows from port B and enters port C. Some of the oil flows to the clutch piston port and becomes the back pressure, and the rest of the oil passes through orifice b and enters port D. The oil entering port D pushes piston (3). and the reaction compresses spring (6) and moves valve (15) to the right. This closes the circuit between ports B and C, so the oil cannot flow beyond port C. As a result, the hydraulic pressure does not rise and is maintained at the same level. If the steering lever is pulled further, the above operation is repeated, and when roller (25) of lever (28) reaches the position where it contacts shaft (12) of the brake valve, the hydraulic pressure beyond port C rises to the set pressure of the main relief valve (26 kg/cm*), and the clutch is fully disengaged.

The hydraulic pressure beyond port C is determined by the tension of modulating spring (6), which changes the load in accordance with the amount the steering lever is operated. Therefore, if the steering lever is moved a short distance, the hydraulic pressure beyond port C is set low and the clutch remains partially engaged, and if it is moved a large distance, the hydraulic pressure is set high and the clutch is fully disengaged.

1 O-56

D275A-2

3. When steering lever is pulled (clutch disengaged, brake applied)

18

20

14

11

12

From

pump

F19702032A

When the left steering lever is pulled further from the condition in Item 2, roller (25) of lever (28) pushes shaft (12) to the left and compresses modulating spring (11). The reaction to this moves brake valve (14) to the left. When this happens, the circuit between ports E and F is closed, and the circuit between port F and drain port H is opened. The oil from the power train pump flows from port A, pushes open check valve (20), and enters port E, where is stops. Some of the oil that flows to the brake piston port and becomes the back pressure flows from port F and is drained to port H, and the rest of the oil passes from port F through orifice c and enters port G. However, when the oil beyond port F is drained to port H and the hydraulic pressure drops, the oil enters port G and pushes piston (18). The reaction force pushing valve (14) to the left also becomes smaller, so valve (14) is returned to the right by the tension of return spring (17). This closes the circuit between ports F and H, so the hydraulic pressure beyond port F does not drop, but is maintained at the same level.

If the steering lever is pulled further, the above operation is repeated, and when it reaches the end of its travel, the brake is fully applied. The hydraulic pressure beyond port F is determined by the tension of return spring (17) which changes the load in accordance with the amount the steering lever is operated. Therefore, if the steering lever is moved a short distance, the hydraulic pressure beyond port F is set high and the brake is partially applied, and if it is moved a large amount, the hydraulic pressure is set low and the brake is fully applied. Port J is connected to port F, and this reduces the operating force of lever (28) that pushes out shaft (12) to the left. However, the hydraulic pressure at port J, that is, the booster pressure, follows the hydraulic pressure of port F that changes in accordance with the change in the amount that the steering lever is moved, so the operating force of the steering lever also changes.

D275A-2

1o-57

4. When brake pedal is depressed (clutch engaged, brake applied)

To torque converter To transmission cs

valve,

From power train pump

~--fCG%

F19702033

When the brake pedal is depressed, the two rollers (25) of lever (27) push left and right shafts (12) to the left, and left and right brake valves (IO) and (14) are actuated in the same way as in Item 3. Therefore, the hydraulic pressure is set in accordance with the amount the brake pedal is depressed, and it is possible to adjust the braking effect. The left and right steering levers are not being operated, so the clutch is engaged.

1 O-58

D275A-2

FINAL DRIVE

17MF02039

GENERAL The reduction system consists of one stage using spur gears and another using planetary gears. The lubrication system uses the gears to splash up the oil in the final case to lubricate all the parts. The rotating and sliding parts of the sprocket have floating seals (19) to prevent dirt from getting in from the outside, and to prevent the oil from leaking out.
l

Between inner body (15) and outer body (13) of the sprocket and sprocket boss (12), there are rubber bushings (20) installed equally spaced around the circumference at ten places on each side. These rubber bushings are cylindrical with a two layer construction of rubber and metal. The rubber bushings are deformed when there is external force such as impact force of drawbar pull during operations. This reduces the load on the final drive components. In addition, seal (14) is assembled to separate rubber bushings (20) completely from the outside in order to prevent the entry of dirt or water from outside.

1 O-60

D275A-2

17MF02040

1. 2. 3. 4. 5. 6. 7. 8.

Bearing cage Final drive case No. 1 pinion (20 teeth) No. 1 gear hub No. 1 gear (77 teeth) Cover Ring gear (67 teeth) Planet gear (25 teeth)

9. 10. 11. 12. 13. 14. 15. 16.

Cover Sun gear (17 teeth) Sprocket teeth Sprocket bos Outer body Seal Inner body Cover

17. 18. 19. 20. 21. 22. 23.

Hub Carrier Floating seal Rubber bushing Wear guard Shaft Pivot shaft

D275A-2

lo-61

TRANSMISSION

OF MOTIVE

FORCE

The motive force from the bevel gear shaft and steering clutch is transmitted to No. 1 pinion (3). It is then transmitted through No. 1 gear (5) and No. 1 gear hub (4) to rotate sun gear (10). The rotation of sun gear (10) is transmitted to planet gear (8). However, ring gear (7), which is meshed with the planet gears, is fixed to cover (9). Therefore, planet gear (8) rotates on its own axis and moves along the ring gear in orbit around sun gear (10). The rotation of sun gear (10) is transmitted to carrier (18), and then passes through hub (17) to rotate inner body (15). The inner body rotates in the same direction as sun gear (10). Rubber bushing (20) is installed between inner body (15) and outer body (13) and sprocket boss (12), so the rotation of inner body (15) is transmitted through rubber bushing (20) to outer body (13), sprocket boss (12), and sprocket teeth (11).

17MF02041

1 O-62

D275A-2

MAIN FRAME

A-A

B-B

1. Main frame

D-D
17MF02042

D275A-2

1 O-63

A-A

17MF02043

1. 2. 3. 4. 5. 6.

Idler Idler yoke Carrier roller Track frame Sprocket Track roller (Single flange)

7. 8. 9. 10. 11. 12.

Track roller (Double flange) Track roller guard Cap Bushing Pivot shaft Bushing

1 O-64

D275A-2

RECOIL SPRING

B-B

17MF02044

1. 2. 3. 4. 5. 6. 7. 8. 9. 10.

Idler yoke Front pilot Recoil spring Piston shaft Track frame inner cylinder Track frame outer cylinder Rear pilot Adjustment cylinder Adjustment valve Outer cylinder bushing

OUTLINE
l

Recoil spring (3) is assembled inside track frame inner cvlinder (5). One end is connected to idler yoke (I) through front pilot (2), and the other end is connected to inner cylinder (5) through rear pilot (7). Adjustment cylinder (8) is fixed to track frame outer cylinder (6), and moves inner cylinder (5) backwards or forwards by pumping in or releasing grease from valve (9) to adjust the track tension.

D275A-2

1O-65

SUSPENSION

(l/Z)

Serial No. : 10001 - 10127

----,

../-___.--.--------

__

___.-~

\..

rT-cM_I17MF02045

1. 2. 3. 4. 5. 6. 7. 8.

Pivot shaft assembly Equalizer bar Seal cage Pivot shaft Thrust plate Cover Thrust plate Joint

9. 10. 11. 12. 13. 14. 15.

Side pin Lock plate Bushing Center pin Bolster Small cushion Large cushion

1O-66 @

D275A-2

[Left side of pivot shaft] * For machines with the dual tilt specification, the right side is also the same.

[Right side of pivot shaft]

c
Rear 6

I)

Front

B-B

11

Y 17MF02046

D275A-2

1 O-67

Serial No. : 10128 and up

17MF02045

1. 2. 3. 4. 5. 6. 7. 8.

Pivot shaft assembly Equalizer bar Seal cage Pivot shaft Thrust plate Cover Thrust plate Joint

9. 10. 11. 12. 13. 14. 15.

Side pin Lock plate Bushing Center pin Bolster Small cushion Large cushion

1 O-67- 1 @

Left

side

A-A
of

pivot

shaft

Right

side

of

pivot

shaft

z
z

Ei

c
Rear Front

B-B

SBDOl511

10-67-2 @

SUSPENSION

(2/2)

/ 13 -'-

/ 16

REAR
17

E-E

'16

F-F

D-D

17MF02047

16. 17. 18.

Rod Rod pin Bushing

1 O-68

D275A-2

HYDRAULIC
BLADE

PIPING

17MF02048

1. Blade tilt cylinder 2. Blade lift cylinder 3. Hydraulic pump 4. Blade lift valve 5. Ripper low valve 6. Hydraulic tank 7. Hydraulic filter 8. Ripper high valve

D275A-2

1O-69

VARIABLE

MULTIPLE

SHANK

RIPPER

17MF02049

9. 10.

Ripper tilt cylinder Ripper lift cylinder

1O-70

D275A-2

VARIABLE

GIANT

RIPPER

198FlO89

9. 10. 11. 12.

Ripper tilt cvlinder Ribber lift cilinder Pin puller cylinder Pin puller solenoid valve

10-70-l 0

HYDRAULIC
BLADE CONTROL

CONTROL

/
197FO2069

1. Blade control 2. Lock lever A. RAISE B. LOWER C. FLOAT D. L.H. TILT E. R.H. TILT

lever

D275A-2

1o-71

BLADE

CONTROL

(For dual

tilt

dozer)

17MF02050

1. Blade control lever IA. Dual tilt switch 1 B. Pitch switch 2. Lock lever A. B. C. D. E. RAISE LOWER FLOAT L.H. TILT R.H. TILT

Dual tilt l Dual l Dual l Pitch l Pitch

operation left tilt right tilt back dump

: : : :

Switch Switch Switch Switch

IA IA 1B 1B

+position fposition fposition -l-position

D E D E

1 O-72

D275A-2

RIPPER CONTROL

3. 4.

Ripper control Lock lever

lever

A. RAISE B. LOWER C. TILT ON D. TILT BACK

D275A-2

1o-73

HYDRAULIC
ENGINE RUNNING,

CIRCUIT SYSTEM
HYDRAULIC CONTROL LEVER IN HOLD

I-%

33 /

M I#

17MF02051

1o-74

D275A-2

HYDRAULIC
ENGINE RUNNING,

CIRCUIT DIAGRAM
HYDRAULIC C6NTROL LEVER IN HOLD

Ripper high val\ie

Blade-tilt

ripper

low valve

.-

34

34

35

-_
Pi3Y

I i

2
12

r-----

-------

-1
j

!
I

!
[ Blade

lift valve

1. 2. 3. 4. 5. 6. 7. 8. 9. IO. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24. 25. 26. 27. 28. 29.

2 -I

I
I

----------------_____ &I -t-----l-l

i___________________--______

----------7

.---------$----f--,

1
0 ,I I(

1:II I

D-&__ _-_
!

A -1 B

/ \

Lower

Fr
11
f----)( L ----

e Float 0

100
-1

-II-

r+

,
.

/
\ (Engine at 1915 rpm)

30. 31. 32. 33. 34. 35. 36. 37.

Hydraulic tank Hydraulic pump Main relief valve Check valve Check valve Demand spool Blade lift valve spool Shuttle valve Shuttle valve Blade lift suction valve Quick drop valve Blade lift cylinder Main relief valve Check valve Blade tilt valve spool Check valve Ripper tilt valve spool Check valve Ripper lift valve spool Shuttle valve Blade tilt cylinder Fixed differential pressure valve (for ripper tilt) Shuttle valve Fixed differential pressure valve (for ripper tilt) Shuttle valve Ripper tilt valve spool Fixed differential pressure valve (for ripper lift) Shuttle valve Fixed differential pressure valve (for ripper lift) Shuttle valve Ripper lift valve spool Check valve Ripper lift suction valve Ripper tilt cylinder Ripper lift cylinder Ripper tilt suction valve Hydraulic filter

17MF02052

D275A-2

1o-75

FOR DUAL TILT DOZER ENGINE RUNNING, HYDRAULIC

CONTROL

LEVER IN HOLD 38 A

1 36

Wooer hiah valve

Blade-tilt ripper low valve .-

I
r--

r-l-i-----+

11

Low

1+- +
-

__~&._*

-5-z ---

---3
Tilt bi

I
36

vi

L--J

k#
on _.IA

+{____T=
++-_----____+l,9~

4,
37

0 . I
I 1

Bz , A2 I t

I4 1
-4

i-i

IZ

-_c_--_--

_---_---I

I 11%

*f-R---__----_---__
-7

---__---1 Blade _

____

--1 _

-----_------~-----_----------~~~ -_-_
r--------7
&I

liftvalve

4l
_ _ t

-4 .-1
L

,
P2

f --

f
2 12 --

I---_-__ -t------

______ __ _____ -------~~--------____

-_ ______

_----------1 _ __---__--+---__

-i,

-0

I(

E E

11

g.E+(
I I

I----,,

I
12.

\ I
1
-_

---I!
-+--_
I

1. 2. 3. 4. 5. 6. 7. 8. 9. IQ. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24. 25. 26. 27. 28. 29. 30. 31. 32. 33. 34. 35. 36. 37. 38. 39.

I--,

I
5

L ______ -_ ________----_____

-----___A

\I

.
I

I I

/ Ll

Hydraulic tank Hydraulic pump Main relief valve Check valve Check valve Demand spool Blade lift valve spool Shuttle valve Shuttle valve Blade lift suction valve Quick drop valve Blade lift cylinder Main relief valve Check valve Blade tilt valve spool Check valve Ripper tilt valve spool Check valve Ripper lift valve spool Shuttle valve Dual tilt solenoid valve Blade pitch solenoid valve Blade tilt cylinder Fixed differential pressure valve (for ripper tilt) Shuttle valve Fixed differential pressure valve (for ripper tilt) Shuttle valve Ripper tilt valve spool Fixed differential pressure valve (for ripper lift) Shuttle valve Fixed differential pressure valve (for ripper lift) Shuttle valve Ripper lift valve spool Check valve Ripper lift suction valve Ripper tilt cylinder Ripper lift cylinder Ripper tilt suction valve Hydraulic filter

17MF02053

1O-76

D275A-2

HYDRAULIC

TANK

-I----\

1 i

=:_._.-. LL.il_.,

17MF02054

7. 2. 3. 4. 5. 6. 7. 8.

Oil lever gauge Oil filler Valve Hydraulic oil filter Baffle Tube Blade tilt, ripper low valve Blade lift valve

P : P, : A : B: A, : B, : A,: B, : A,: B, : T:

From small pump From large pump To blade lift cylinder head To blade lift cylinder bottom To blade tilt cylinder bottom To blade tilt cylinder head To ripper tilt cylinder head To ripper tilt cylinder bottom To ripper lift cylinder head To ripper lift cylinder bottom From ripper high valve

D275A-2

1o-77

BLADE LIFT CONTROL VALVE

I97FOSS

OUTLINE l Demand valve (14) is assembled in the blade lift valve, and the oil from the two hydraulic pumps is merged by check valve (4). The demand valve uses the oil from the two hydraulic pumps effectively: the oil from the large pump becomes the pilot pressure; the oil from the ripper circuit and the blade lift circuit through shuttle valve (18B) becomes the pilot pressure.

P, P, A B T

: : : :

: From large pump From small pump To blade lift cylinder head To blade lift cylinder bottom To hydraulic tank

1 O-78

D275A-2

li
A-A

1'1

io

B-B

18 18

E-E

F-F

I97FO99

1. 2. 3. 4. 5. 6. 7.

Valve body Check valve spring Check valve Check valve (for small pump) Check valve spring Blade lift valve spool Shuttle valve seat (plug)

8. 9. 10. 11. 12. 13. 14.

Shuttle valve ball Return spring Detent spring Detent ball Detent shaft Demand valve spring Demand valve spool

15. 16. 17. 18. 18A. 18B.

Suction valve spring Suction valve (for LOWER side) Suction valve (for RAISE side) Main relief and shuttle valve assembly Main relief valve Shuttle valve

D275A-2

1 o-79

MAIN

RELIEF VALVE,

SHUTTLE

VALVE

A-A

197FlOO

1. 2. 3. 4. 5. 6. 7.

Adjustment screw for main relief pressure Sleeve Main relief valve spring Main relief valve poppet Valve seat Plug Valve body

8.

Piston

9. Shuttle valve 10. Shuttle valve spring

PL. From shuttle valve in ripper valve PB. From shuttle valve in blade lift valve
P To demand valve pilot port TY To hydraulic tank

1 O-80

D275A-2

OUTLINE The main relief valve is in the circuit between l the hydraulic tank and the ripper circuit and blade lift circuit (which passes through shuttle valve (9)). The main relief valve sets the hydraulic pressure in the large pump circuit that is, the blade lift cylinder to 210 kg/cm*. The shuttle valve is in the circuit between the l demand valve (which passes through the main relief valve) and the blade lift and ripper circuit. It selects the two circuits to apply pilot pressure to the demand valve. In other words, it selects either the blade lift circuit or the ripper circuit. When the work equipment is not being used (control lever at HOLD), the tension of spring (IO) in the shuttle valve connects the pilot port of the demand valve and the blade lift circuit.

Operation of main relief valve Chamber A forms a pump circuit and chamber l C forms a tank drain circuit. The oil flows into chamber B through the main relief valve orifice to keep the chamber filled. Pilot valve is set in the valve seat.
204FO81

If the pressure in chamber B reaches the pilot valve spring force (set pressure), the pilot valve moves, allowing the oil in chamber B to flow into chamber C through chamber D. In addition, the oil flows from chamber A to B through orifices. If the oil flows through the orifice of valve, a differential pressure occurs between the chambers A and B, moving valve to the right. This allows the oil in chamber A to flow into chamber C.

204FO82

204FO83

D275A-2

lo-81

BLADE TILT CONTROL AND RIPPER LOW VALVE

197FIOI

OUTLINE l The ripper low valve consists of a 3-spool valve. It acts to reduce the hydraulic loss in the independent blade tilt circuit when the blade is being tilted. In the ripper lift and tilt circuits, the pilot pressure switches the demand valve when the control lever is operated. At the same time, the oil which passes through the low valve operates the ripper high valve (fixed differential pressure type valve) at the rear, and improves the response of the ripper.

P : From small pump A, : To blade tilt cylinder bottom B, : To blade tilt cylinder head A, : To ripper tilt cylinder head B, : To ripper tilt cylinder bottom A, : To ripper tilt cylinder head B, : To ripper tilt cylinder bottom C, : To demand valve P,: To shuttle valve in blade lift valve

1 O-82

D275A-2

B-B

D-D
197FlO2

1. 2. 3. 4. 5. 6. 7.

Blade tilt valve spool Ripper tilt valve spool Ripper lift valve spool Valve body Valve joint Return spring Bolt

8. Adjustment screw for main relief pressure 9. Sleeve 10. Main relief valve body 11. Poppet spring 12. Main relief valve poppet 13. Valve seat 14. Main relief valve spring

15. Main relief valve 16. Valve seat 17. Check valve 18. Check valve spring 19. Valve seat 20. Shuttle valve seat (plug) 21. Shuttle valve ball 22. Shuttle valve seat

D275A-2

1 O-83

RIPPER HIGH VALVE

61-l \

BZ-1

AI-2

AZ-2

: PAI : PB, : PA2 : P :

P
197FlO3

A::, B,., A,, B,., A,., B,., A,., B,.,

: : : : : : : :

From large pump From low valve tilt on From low valve tilt back From low valve ripper raise From low valve ripper lower To left tilt cylinder bottom To left tilt cylinder head To right tilt cylinder bottom To right tilt cylinder head To left tilt cylinder bottom To left tilt cylinder head To right tilt cylinder bottom To right tilt cylinder head

1 O-84

D275A-2

10

A-A

,a

B-B

D-D
197FlO4

1. 2. 3. 4. 5. 6. 7. 8. 9. 10.

Valve body Shuttle valve seat Shuttle valve ball Valve body Plug Fixed differential pressure Fixed differential pressure Fixed differential pressure Fixed differential pressure Fixed differential pressure

valve spring valve valve valve valve

11. Plug 12. Check valve spring 13. Check valve 14. Valve return spring 15. Plug 16. Ripper lift valve spool 17. Suction valve spring 18. Suction valve 19. Ripper tilt valve spool

D275A-2

1 O-85

RIPPER TILT SUCTION

VALVE

A-A 17MF02055

1. 2. 3. 4. 5.

Valve body Valve Spring Stopper Plug

A. To hydraulic tank B. From ripper high valve C. To ripper tilt cylinder bottom

1 O-86

D275A-2

OPERATION 1. Blade lever at HOLD, ripper lever at HOLD

I.

II

,.Gz

a
-

t. r.
R.

17MF02056

1O-88

D275A-2

When the blade lever is at the HOLD position, blade lift spool (5) closes the circuit from port B to ports C and D, and opens the circuits of ports H and E and ports J and F. Blade tilt spool (16) closes the circuit from port B, to ports C, and D,. Therefore, the circuits for blade lift cylinder (9) and blade tilt cylinder (17) become closed circuits, and the cylinders are held in the same position. If the ripper lever is placed at the HOLD position, ripper tilt spool (19) closes the circuit from port B, to ports C, and D4, and ripper lift spool (21) closes the circuit from port B, to ports C, and D,. Therefore, the circuits for ripper tilt cylinder (45) and ripper lift cylinder (33) become closed circuits through the two ripper valves, and the cylinders are kept in the same position. If the engine is started in this condition, the oil from the large pump enters port A of the blade lift valve. Some of the oil pushes open check valve (3) and enters port B where it stops. The rest of the oil passes through orifice a of demand valve (I), and enters ports L and M. (The demand valve is pushed to the right by the tension of spring (2).) The oil from the large pump flows to the blade lift valve, but it also enters port A, of the ripper Hi valve, pushes open the two check valves (23) and (35), then enters ports B, and B,, and stops. The oil from the small pump flows from port A, of the ripper Lo valve and blade tilt valve to ports A,, A,, and A,. Some of the oil pushes open check valves (15), (18), and (20), then enters ports B,, B,, and B,, and stops. The rest of the oil flows from port A,, enters port R of the blade lift valve, pushes open check valve (4), and flows to port A, where it merges with the oil from the large pump.

D275A-2

1 O-89

Blade lever at HOLD, ripper lever at HOLD (oil being drained) In the condition in Item 1, if the hydraulic pressure in the circuit rises, the surface pressure (force pushing the demand valve to the left) on port L of demand valve (1) becomes greater than the combined force (force pushing the demand valve to the right) of the surface pressure bearing on port M and tension of spring (2), it moves the demand valve to the left, opens the circuits between ports A and E, and ports R and F. The oil from the large and small pumps is then relieved to ports E and F, and is drained from port G to the hydraulic tank. Therefore, both the large and small pumps are put in an unload condition.

From shuttle
I/ ripper Lo valve 17MF02057

1O-90

D275A-2

3. Blade lever at RAISE (blade operating at high speed) When the blade lever is moved fully to the RAISE position, spool (5) moves to the left, and fully opens the circuits between ports B and C, ports C and H, and ports D and F. When this happens, the oil from the two pumps passes from ports A and B and enters port C. Some of the oil flows to the head end of cylinder (9), and the rest flows from port H, pushes shuttle valve (8) to the right and opens it, flows to port K, and enters ports N, 0, and P of shuttle valve (10). It then enters port Q of demand valve (1) and becomes the pilot pressure. At the same time, the oil from the pump passes through orifice a of demand valve (I), enters ports L and M, and becomes the pilot pressure. The oil at the bottom end of cylinder (9) flows from port D to port F, and returns from port G to the hydraulic tank. When the hydraulic pressure in the circuit rises in this way, spool (5) opens the circuit between ports B and C fully, so the resistance of the oil flowing from port B to port C is small, and there is little pressure difference generated between port B and port C. Therefore, no pressure difference is generated between port L and ports M and Q of the demand valve. The surface pressure acting on the left and right of the demand valve is equal, so the demand valve is moved to the right by the tension of spring (2). When this happens, the circuits between ports A and E, and ports R and F are closed, and all the oil from both the large and small pumps flows to the head end of the cylinder to increase the speed of movement of the cylinder.
-

From shuttle valve inside ripper Lo valve

17MF02058

D275A-2

10-91

4.

Blade lever at RAISE (blade operating at low speed) When the blade lever is moved finely to the RAISE position, spool (5) moves slightly to the opens the circuit between left, and partially ports B and C, ports C and H, and ports D and F. the oil from the two When this happens, pumps passes from ports A and B, is throttled by spool (5), and enters port C. Some of the oil flows to the head end of cylinder (9), and the rest flows from port H, pushes shuttle valve (8) to the right and opens it, flows to port K, and enters ports N, 0, and P of shuttle valve (IO). It then enters port Q of demand valve (1) and becomes the pilot pressure. At the same time, the oil from the pump passes through orifice a of demand valve (I), enters ports L and M, and becomes the pilot pressure. The oil at the bottom end of cylinder (9) flows from port D to port F, and returns from port G tank. When the hydraulic to the hydraulic pressure in the circuit rises in this way the situation is different from in Item 3: spool (5) is throttling the circuit between ports B and C, so the flow of oil from port B to port C is restricted, and a pressure difference is generated port B and port C. The hydraulic between pressure in the circuit up to port B becomes higher. when the surface pressure acting Therefore, on port L of the demand valve (1) becomes greater than the combined force of the surface pressure acting on port M, the surface pressure acting on port Q and the tension of spring (2), the demand valve is moved to the left. When this happens, the circuits between ports A and E and ports R and F are opened, and the oil from both the large and small pumps is retank. This suppresses lieved to the hydraulic pressure at ports A the rise in the hydraulic and B, and the cylinder moves slowly. As explained in Items 3 and 4 above, the speed by of the cylinder is determined of movement the amount of opening of ports B and C correof the lever. If it is sponding to the movement wide open, the flow of oil beyond port C inpressure rises, and the creases, the hydraulic becomes faster. If it is opspeed of movement ened only slightly, the flow of oil beyond port so the oil flow is reduced, the C is throttled, low, and the becomes pressure hydraulic is slow. speed of movement In other words, the hydraulic pressure and oil so this proflow beyond port C is proportional, of the blade that folvides not only operation of the blade lever, lows the fine movements but reduces the pulling force (flow force) acting on spool (5), so the operating force of the spool does not increase.

ripper to Lo valve

10

17MF02059

1 O-92

D275A-2

5. Blade lever at RAISE (cylinder at stroke end) If cylinder (9) moves to the end of its stroke from the condition in Items 3 and 4, the hydraulic pressure in the whole circuit rises. Therefore, the hydraulic pressure beyond port C rises, and the oil entering the main relief valve (45) through shuttle valves (8) and (IO), that is, the oil at port P, pushes open poppet (13) and is relieved to port T. At this point, the circuit from port 0 to port P is throttled by orifice c, so the supply of oil to port P is delayed. As a result, the hydraulic pressure of pilot port Q of demand valve (1) drops, and the demand valve moves to the left. When this happens, the circuit between ports A and E and ports R and F are opened, and the oil from the two pumps is relieved to prevent the hydraulic pressure from rising any further. The hydraulic pressure at this point is 210 kg/ cm2.

4% 1 il.,.,.,.,... _ *

t :...:.:.:.:.:.:.:.:.:.:.:.:.:!/ From small pump through ripper valve From large pump

From shuttle valve inside ripper Lo valve

1'0

i
17MF02060

D275A-2

1o-93

6. Blade lever at LEFT TILT

To ripper

Hi valve IS

17MF02061

When the ripper lever is moved to the LEFT TILT position, spool (16) moves down, opens the circuits of ports B, and C, and ports D, and F,, and closes the circuit of ports A, and A,. When this happens, the oil from the small pump flows from port A,, pushes open check valve (15), flows from port B,, and enters port C,. It flows to the bottom end of cylinder (17), and when the hydraulic pressure in the circuit rises, it extends the cylinder. At this point, the oil at the head end of the cylinder returns from port D, to port F,, and is drained from port E, to the hydraulic tank.

The oil from the large pump enters port A of the blade lift valve, and actuates demand valve (1) in the same way as in Item 2. It is relieved from port A to E, and is drained to the hydraulic tank. When the blade tilt is operated, the circuit between ports A, and A, is closed, so the oil does not enter the ripper circuit, and it is impossible to operate the ripper. In other words, the blade tilt circuit is given priority over the ripper circuit.

1o-94

D275A-2

Blade lever at LEFT TILT (cylinder at stroke end)

To ripper Hi valve

17MF02062

From the condition in Item 6, if cylinder (17) is moved to the end of its stroke, the hydraulic pressure in the whole circuit rises. When this happens, the oil from the small pump flows from port A,, and pushes open main relief valve poppet (14). It is then relieved to port E,, so the hydraulic pressure does not rise any further. The hydraulic pressure at this point is 210 kg/ cm*.

D275A-2

1 o-95

8. Ripper lever at TILT ON (ripper Lo valve, shuttle valve actuated)

/Hs
---22

17MF02063

When the ripper lever is moved to the TILT ON position, spool (19) moves up, opens the circuits between ports B, and D,, ports C, and E,, and ports A, and G,, and closes the circuit between ports A, and A,. When this happens, the oil from the small pump enters port A, and A,. Some of the oil pushes open check valve (18), flows from port B, into port D,, and the flows to port G, of the ripper Hi valve. The rest of the oil passes through the groove in spool (19), enters port G,, pushes shuttle valve (22) down fully, then flows from port H, to port S of shuttle valve (IO).

The oil entering port S passes through orifice b, and pushes piston (11). The reaction moves shuttle valve (IO) to the left, closes the circuit between ports N and 0, and opens the circuit between ports S and 0. The oil entering port 0 from port S then passes through orifice c, and enters ports P and 0. It becomes the pilot pressure of demand valve (I), and moves the demand valve to the right. When this happens, the circuit between ports A and E is closed, so the oil from the large pump is not drained to the hydraulic tank. The whole amount of the oil flows to port A, of the ripper Hi valve.

1 O-96

D275A-2

9. Ripper lever at TILT ON (ripper Hi valve actuated) As explained in Item 8, the oil from the large pump enters A, of the ripper Hi valve, pushes open check valves (23) and (35), flows to ports B, and B,, and stops. The oil from the small pump flows from port D4 of the ripper Lo valve and enters port G,. Some of the oil entering port G, passes through the passage inside valve (39), flows to port L,, and pushes shuttle valve (41) up fully. It then enters port N,, pushes spool (36) to the right, and becomes the pilot pressure. The rest of the oil is throttled by orifice f and enters port C,. Some of the oil entering port C, passes through the passage inside valve (39), flows to port J,, and pushes shuttle valve (44) down fully. It then enters port 0,, pushes spool (36) to the left, and becomes the pilot pressure. The rest of the oil flows from port C, to the bottom end of ripper tilt cylinder (45). When all the above hydraulic circuits are filled with oil, the hydraulic pressure starts to rise.

17MF02064

D275A-2

1o-97

From the condition previously explained, if the hydraulic pressure continues to rise,the oil at port G, is throttled by orifice f and enters port C,. Because of the resistance, the hydraulic pressure at port G, becomes higher than the pressure beyond port C,. Therefore, the hydraulic pressure at pilot port N, of spool (36) becomes higher than the hydraulic pressure at port 0,, so when this pressure difference becomes greater than the tension of spring (38), it pushes spool (36) out to the right. When this happens, the circuits between ports B, and C,, and ports D, and F, open, the oil from the large pump flows from port B, to port C,, enters the bottom end of ripper tilt cylinder (45), and merges with the oil from the small pump to extend the cylinder. Some of the oil at the head end of the cylinder returns from port D, to port F,, and is drained to the hydraulic tank. The rest of the oil flows from port D,, is throttled by orifice g of valve (42), and returns to port H,. It then flows from port C, of the ripper Lo valve, returns to port E,, and is drained to the hydraulic tank.

17MF02065

1 O-98

D275A-2

10. Ripper level at LOWER (ripper Lo valve, shuttle

valve actuated)

To

ripper

Hi valve

(A, port)

A2

A3

A4

17MF02066

When the ripper lever is moved to the LOWER position, spool (21) moves down, opens the circuits of ports B, and C,, ports D, and F,, and ports A, and G, and closes the circuit of ports A, and A,. When this happens, the oil from the small pump enters ports A,, A,, and A4. Some of the oil pushes open check valve (20), flows from port B, into port C,, and then flows to port H, of the ripper Hi valve. The rest of the oil passes through the groove in the spool, enters port G,, pushes shuttle valve (22) up fully, then flows from port H, to port S of shuttle valve (IO).

The oil entering port S passes through orifice b, and pushes piston (11). The reaction moves shuttle valve (IO) to the left, closes the circuit between ports N and 0, and opens the circuit between ports S and 0. The oil entering port 0 from port S then passes through orifice c, and enters ports P and 0. It becomes the pilot pressure of demand valve (I), and moves the demand valve to the right. When this happens, the circuit between ports A and E is closed, so the oil from the large pump is not drained to the hydraulic tank. The whole amount of the oil flows to port A, of the ripper Hi valve.

D275A-2

1o-99

11. Ripper lever at LOWER (ripper Hi valve actuated) As explained in Item 10, the oil from the large pump enters port A, of the ripper Hi valve, pushes open check valves (23) and (35), flows to ports B, and B,, and stops. The oil from the small pump flows from port C, of the ripper Lo valve and enters port H,. Some of the oil entering port H, passes through the passage inside valve (30), flows to port M,, and pushes shuttle valve (32) down fully. It then enters port 0,, pushes spool (24) to the left, and becomes the pilot pressure. The rest of the oil is throttled by orifice e and enters port D,. Some of the oil entering port D, passes through the passage inside valve (30), flows to port K,, and pushes shuttle valve (29) up fully. It then enters port N,, pushes spool (24) to the right, and becomes the pilot pressure. The rest of the oil flows from port D, to the bottom end of ripper lift cylinder (33). When all the above hydraulic circuits are filled with oil, the hydraulic pressure starts to rise.

From CS 17MF02067

10-100

D275A-2

From the condition previously explained, if the hydraulic pressure continues to rise, the oil at port H, is throttled by orifice e and enters port D,. Because of the resistance, the hydraulic pressure at port H, becomes higher than the pressure beyond port D,. Therefore, the hydraulic pressure at pilot port 0, of spool (24) becomes higher than the hydraulic pressure at port N,, so when this pressure difference becomes greater than the tension of spring (25), it pushes spool (24) out to the left. When this happens, the circuits between ports B, and D, and ports C, and E, open, the oil from the large pump flows from port 6, to port D,, enters the bottom end of ripper lift cylinder (33), and merges with the oil from the small pump to extend the cylinder. Some of the oil at the head end of the cylinder returns from port C, to port E,, and is drained to the hydraulic tank. The rest of the oil flows from port C,, is throttled by orifice d of valve (27), and returns to port G,. It then flows from port D, of the ripper Lo valve, returns to port E,, and is drained to the hydraulic tank.

17MF02068

D275A-2

10-101

12. Ripper lever at LOWER (cylinder at stroke end)

-1

I I

I I

17MF02069

D275A-2

From the condition in Items 10 and 11, if cylinder (33) is moved to the end of its stroke, the hydraulic pressure in the whole circuit rises. When this happens, in the same way as in Item 7, the oil from the small pump flows from port A, and pushes open main relief valve poppet (14). It is then relieved to port E,, so the hydraulic pressure does not rise any further. The hydraulic pressure at this point is 210 kg/
2 ;Te

oil passing through shuttle valves (22) and (IO), and flowing from ports S and 0 to port P also pushes open main relief valve poppet (13), and is relieved to port T. The circuit from port 0 to port P is throttled by orifice c, so the supply of oil to port P is delayed. As a result, the hydraulic pressure at pilot port 0 of demand valve (1) also drops, and the demand valve moves to the left. When this happens, the circuit between ports A and E opens, and the oil from the large pump is relieved, so the hydraulic pressure in the circuit of the large pump does not rise any further. The hydraulic pressure at this point is 210 kg/ cm2. When the hydraulic pressure in the whole circuit is set at 210 kg/cm2, the pressure difference on both sides of orifice e of valve (30), that is, the difference in pressure between ports H, and D,, disappears. The pilot pressure at port 0, that is pushing spool (24) to the left becomes the same pressure as the pressure at port N,. When this happens, spool (24) is returned to the right by the tension of spring (25) to a position where it is in balance with the tension of spring (26). At this point, the circuits between ports B, and D, and ports C, and E, are closed. The oil from the large pump goes as far as port B,, and stops. The oil at the head end of cylinder (33) flows from port C,, passes through orifice d of valve (27), and returns only to port G,.

D275A-2

10-103

PISTON VALVE (Blade lift and dual tilt cylinder)

STRUCTURE AND FUNCTION The piston valve is installed on the piston in the blade lift cylinder. When the piston reaches its stroke end, the valve releases the oil from the hydraulic pump to reduce the oil pressure being exerted on the piston. When the blade on a dual tilt dozer is tilted, the blade is subject to a tortional force owing to the uneven position of the pistons in the two cylinders; that is the piston one side is still moving while the piston on the other side has reached its stroke end. The piston valves are installed to prevent the tortional force from occurring. When one of the pistons reaches its stroke end, its piston valve opens to relieve the oil pressure. In addition, the piston valve relieves the shock which occurs when the piston comes into contact with the cylinder head or the bottom and serves to reduce the subsequent surge pressure in the cylinder by letting the oil escape from the cylinder before the piston reaches its stroke end.

1. 2. 3. 4. 5.

Piston rod Cylinder Piston valve seat Piston Piston valve

17MF02070

OPERATION Piston valve CLOSED Pressurized oil from the hydraulic pump acts on piston (4) and piston valve (5). The piston valve is pushed in the direction of the arrow until piston valve seat (3) comes into snug contact with the tapered section, thereby, this causing the pressure in the cvlinder to rise of the and moving piston (4) in the direction arrow.

/i

17MF02071

Piston valve OPEN Just before piston rod (1) reaches its stroke end, the front end of piston valve (5) comes into contact with the cylinder bottom (or the cylinder head) and is prevented from moving any further while piston (4) alone keeps on moving ahead. Then, the oil sealed within the piston valve on the cylinder head side will escape from piston valve seat (3) so that the oil pressure in the cylinder is prevented from rising.
Strike 17MF02072

10-104

D275A-2

QUICK DROP VALVE

STRUCTURE The quick drop valve consists of valve body (I), spring (2), spool (3), check valve (4). The quick drop valve serves to increase the blade lowering speed and to reduce the occurrence of vacuum when the blade is lowering, thereby shortening the time lag before digging is started. The blade lowering speed,- which is generally determined by the pump discharge, can be made faster with the quick drop valve. 1. Valve body 2. Spring 3. Check valve 4. Spool

OPERATION 1. Start of lowering When the blade lever is operated to LOWER, the oil from the control valve enters the cylinder bottom through port A and pushes the piston. In the mean time, the oil in the cylinder head is pushed out into the piston, enters valve port B, and flows into the tank.

17MF02073

2. While lowering Pressurized oil from the cylinder head flows into port C through port B. At this time, the oil flow is restricted by an orifice provided along the way, causing a differential pressure before and after the orifice. When the differential pressure becomes greater than the force of spring (2), it compresses the spring and moves spool (3) and valve (4) to the right. With the spool and the valve have moved, part of the oil flowing from the cylinder head to the tank enters the passage to the cylinder bottom together with the oil from the control valve. Thus, the blade lowering speed increases in accordance with the amount of oil that flows to the bottom of the cylinder and reduces the formation of vacuum at the bottom of the cylin-

I75F209

der.
175F210

D275A-2

10-105

CYLINDER

STAY

17MF02074

1. 2. 3. 4. 5.

Yoke Oil seal Bushing Bushing Air bleeding plug

1 O-l 06

D275A-2

SEMI

U-DOZER

A-A

17MF02075

1. 2. 3. 4. 5.

Cutting edge Arm End bit Straight frame Trunnion

6. Arm 7. Blade 8. Brace 9. Blade tilt cylinder 10. Blade lift cylinder

OUTLINE l The dozing attachment can be broadly divided into the blade and the hydraulic control which operates the blade. the diagram shows the semi U-dozer. The table shows the dimensions and specifications of the semi U-dozer.

lo-108

D275A-2

B-B

D-D

E-E

F-F

G-G

J-J H-H

K-K

L-L

M-M
17MF02076

OPERATION l The blade is moved by hydraulic cylinders. l RAISE: The left and. right lift cylinders retract and raise the frame and blade together. l LOWER: The left and right lift cylinders extend and lower the blade to the ground. . LEFTTILT: The tilt cylinder extends and lowers the left side of the blade to the ground. l RIGHT TILT: The tilt cylinder retracts and lowers the right side of the blade to the ground.

Table of comparisons Unit: mm Semi U-dozer Distance between left and right frame Length of frame Width of blade Height of blade Max. blade raise Max. blade lower Max. blade tilt 3636

I I

3775 4300 1910 1505

I I

660 1025

D275A-2

10-109

VARIABLE

MULTIPLE

SHANK

RIPPER

A-A

C-C

D-D

17MFOi077

10-l 10 0

OUTLINE l The ripping attachment can be broadly divided into the ripper and the hydraulic control which operates the shank. The diagram shows the variable multiple shank ripper. The table shows the dimensions and specifications of the variable multiple shank ripper.

OPERATION l The shank is moved bv hvdraulic cvlinders. The left andright . RAISE: lift cylinders retract and raise the beam and shank together. . LOWER: The left and right lift cylinders extend and lower the beam and shank together to the ground. . TILT ON: The left and right tilt cylinders extend and move the shank forward. . TILT BACK: The left and right tilt cylinders retract and move the shank to the rearward.

Table of comparisons Unit: Multiple Length of beam No. of shanks mm

shank ripper 2495 3 1130 2260

1. 2. 3. 4. 5. 6. 7. 8. 9. 10.

Tilt cylinder Lift cylinder Beam Shank Protector Point Arm Pin Bushing Pin

Shank pitch (with 3 shanks installed) Shank pitch (with 2 shanks installed) Ripping depth

2-stage selection possible

D275A-2

10-l11

8 f 6

-.

_
Section PA-A Section B-B

Section

C-C

9
Section

10
D-D

__.-

Detail

P F197UR034A

10-112 0

OUTLINE l The ripping attachment can be broadly divided into the ripper and the hydraulic control which operates the shank. The diagram shows the variable giant ripper. The table shows the dimensions and specifications of the variable giant ripper.

OPERATION l The shank is moved by hydraulic cylinders. . RAISE: The left and right lift cylinders retract and raise the beam and shank together. The left and right lift cylinders ex. LOWER: tend and lower the beam and shank together to the ground. l TILT ON: The left and right tilt cylinders extend and move the shank forward. . TILT BACK: The left and right tilt cylinders retract and move the shank to the rearward.

Table of comparisons Unit: mm \ Length of beam No. of shanks 1 Giant ripper 1252 1 3-stage selection oossible 1300 870

I
I

1. 2. 3. 4. 5. 6. 7. 8. 9. 10.

Tilt cylinder Lift cylinder Beam Shank Protector Point Arm Pin Bushing Pin

Ripping depth Max. ripping depth Max. raise

I
I

10-112-l 0

123456789

, / /
I

II

J
198F1113

1. 2. 3. 4. 5. 6. 7. 8. 9.

Plug Spring Spring retainer Valve body Spool Spring retainer Spring Push pin Solenoid assembly

OUTLINE
l

A: B: C: D.

To pin-puller cylinder head From power train pump To pin-puller cylinder bottom To steering case

The pin-puller solenoid valve is in the circuit between the pin-puller cylinder and the power train pump passing through the steering control valve. When the pin-puller switch in the operators compartment is operated, it switches the oil from the power train pump and acts on the pin-puller cylinder to operate the shank mounting pin for the ripper shank. Solenoid assembly (9) is deactivated when pushed in and excited when pulled out.

1 o-1 12-2 0

OPERATION 1. Pin-puller switch at PUSH IN position When the pin puller switch is turned to the PUSH IN position, no current flows to solenoid (9) and it is deactivated. When this happens, spool (5) opens ports A and B and ports C and D, and the oil from the power train pump flows from port A to port B and enters the bottom of pin-puller cylinder (IO). The oil entering the bottom end of the cylinder increases the hydraulic pressure in the circuit and extends the cylinder. Shank mounting pin (11) is pushed into shank (13).
From power train pump Switch at PUSH IN position

198FO2028

2. Pin-puller switch at PULL OUT position When the pin-puller switch is turned to the PULL OUT position, current flows to solenoid (9) and it is excited. When this happens, the solenoid pushes out push pin (8), and spool (5) moves to the left in the direction of the arrow. Ports A and B and ports C and D close, and ports A and C and ports B and D open. The oil from the power train pump flows from port A to port C and enters the head of pin-puller cylinder (IO). The oil entering the head end of the cylinder increases the hydraulic pressure in the circuit and retracts the cylinder. Shank mounting pin (I 1) is pulled out of shank (13).

From power train pump

Switch at PULL OUT position

10. 11. 12. 13.

Pin-puller cylinder Shank mounting pin Beam Shank

198FO2029

1 o-1 12-3 0

CAB ELECTRICAL

CIRCUIT DIAGRAM

Serial No. : lOOOl-10127

R.H. door wiper

Front wiper

Rear wiper

Cigarette

lighter

Caution

lamp

Lock-up indication lamp

connection

Front and Rear window washer

oc&o r

Car

stereo

R.H. and L.H. window washer

198FO2034-2

10-118-4 @

Serial No. : 10128 and up

H /xdbor wiper

( ./ !
P. R. H door wiDer

ont

wiper

II

IIll

ear

wiper

r
Alarm L/C L/C indi indi

CN399

I amp
cat cat

( 1 i
i

lamp

rette ter

1
0281330~ 02BOQQ1

(12V for

power radio)

source Car stereo

CNMI

83
M
LY

LR LB LA

Front. wind

rear washe

iI
2 Converter Z

0 0

10-118-5 8

AIR CONDITIONER

ELECTRICAL CIRCUIT DIAGRAM

Serial No. : 10001 - 10127

Control panel

Air-conditioner

switch

Starting switch

Pressure switch

85

CN 108

CN351

CN12 CN381

7L
Floor frame

Air conditioner compressor

Thermostat Blower motor Blower resistor

Air-conditioner

relay

17MF02080

Serial No. : 10128 and up

Control Panel Blower motor switch Air-conditioner switch S tart ina switch Pressure switch

conditioner ComIpressor

OOOQQQO~

Floor

frame

1,IP,P,P,!::

1Ch365

Air

conditioner

unit

8K

Blower

M
motor Blower resistor

L-Y
Thermostat SAD01517

Air

conditioner

relay

10-118-7 @

EVMS

(ELECTRONIC

VEHICLE MONITORING

SYSTEM)

Monitor I

panel

Sensor /

signal

Buzzer signal

Buzzer

Caution Battery

lamp F19702046

OUTLINE The vehicle monitoring system monitors varil ous conditions of the vehicle by means of sensors provided throughout the vehicle. It proand incesses the information immediately, forms the operator of the condition by making a display on the panel. There are two major kinds of panel display. 1. The monitor assembly, which gives a warning when any fault is monitored on the vehicle. 2. The gauge assembly and service meters, which constantly indicate the condition of the vehicle. (Engine water temperature, torque converter oil temperature and fuel level.)

The vehicle monitoring system consists of a monitor panel, sensors, warning lamps, warning buzzers, and the power source. The monitor panel, and sensors are connected by wiring harnesses. The power is supplied from the battery to the monitor panel. As soon as any trouble occurs, the monitor and warning lamps start flashing and the warning buzzer sounds to protect the vehicle.

D275A-2

10-119

67

9
10

F19802003

1. 2. 3. 4. 5. 6. 7.

Engine oil level Radiator water level Fuel level Torque converter oil temperature Engine water temperature Battery charge Engine oil pressure

8. Radiator water level 9. Engine water temperature 10. Torque converter oil temperature 11. Hydraulic oil temperature 12. Preheat 13. Service meter indicator 14. Service meter

OUTLINE l The monitor panel consists of the monitor portion that gives out warning when any abnormality occurs in the machine, and the gauge portion and service meter that always indicate the condition of the machine. The monitor and gauge portions each have microcomputers that process the signals from each sensor and display the results. A liquid crystal display is used. For details of the items displayed on the monitor and gauge portion, see the table on the next page. OPERATION 1. Power switched on (starting switch ON) 1) All items on the gauge and monitor light up for 3 seconds. 2) The warning lamps light up for 2 seconds and the alarm buzzer sounds for 1 second.

2. CHECK items 1) After lighting up as explained in Section 1, if there is any abnormality in any CHECK item, that item flashes. 2) The CHECK items go out when the engine is started. (The rise in the engine oil pressure is used to judge if the engine is running or not, or if the voltage from the alternator is more than 1OV.) CAUTION The caution items are checked from the time the engine is started until the time the engine is stopped. If there is any abnormality, the item flashes, and the warning lamp also flashes. If any items in CAUTION 2 flashes, the alarm buzzer also sounds. The monitor and warning lamps flash in an ON-OFF cycle of approx. 0.8 sec. The flashing cycle of the monitor may change slightly if the ambient temperature is low (approx. -10C or below), but this is not an abnormality.

1 o-1 20

D275A-2

Monitor
Classification 0 displav

panel indications
rmbol Indication items Range of indication Method of indication

Radiator water level 4 P Engine oil level Engine oil pressure

Below LOW level Below LOW level When sensor is abnormal or wiring harness is disconnected

Indicates when the starting switch is turned ON with the engine stopped. If normal, the lamps do not light up. If abnormal, the lamps flash. If normal, the lamps do not light up. If abnormal, the lamps light up. Indicates when the starting switch is turned ON while the engine is running. If normal, the lamp does not light. If abnormal, the lamp flashes and the warning lamp flashes at the same time.

3attet-y charge level

Insufficient charge

Engine oil pressure 3adiator water level

Below 0.5 kg/cm2 Below LOW level When the engine water temperature gauge indicates the red ranqe (108 C or hiaher) When the torque converter oil temperature gauge indicates the red range (over 130C) Over 108C When the preheat switch of seat switch is at ON, the lamp lights .rp (80 sec.) and changes to light going out to indicate that the preheating s completed.

!ngine water temperature

Torque converter

oil temperature

Indicates when the starting switch s turned ON while the engine is running. If normal, the lamp does not light up. If abnormal, the lamp and the warning amp flash and the warning buzzer sounds.

iydraulic

oil temperature

ET

reheating

When preheating

Engine water temperature

102C
Green White 94C 83C 70C

Lights up in the applicable

range

Red Torque converter oil temperature Lights up in the applicable range

Green

Green Fuel level

Red Indicates between 9999 hours.

FULL 617 517 417 3/7 Z/7 EMPTY zero and

All light up below the applicable

level

Service meter

Operates while the alternator charging Clock time: 1 :l

is

Service meter indicator

When the service meter is working

Flashes while the service meter is working

D275A-2

10-121

SUPPLEMENTARY
l

CONTROLLER

Tne supplementary controller acts as a power source box to supply electrical power to the panel assembly, switch panel, lock-up controller, etc. The variations in voltage of the power supply for the machine (battery, alternator) is large, so this supplementary controller transforms the power to a stable voltage before supplying it to the panel. Even if there is over-voltage caused by a failure in the alternator or regulator, it is cut here to protect the monitor panel.

CN 162 (3 pin)

CN464

(4 pin)

197FO2076

SENSOR The signal from the sensor is input directly to the machine monitor panel. One end of contact type sensors is always connected to the chassis ground. When the contacts of all the sensors except the engine oil pressure sensor close, and the signal wire is connected to the chassis ground, the panel judges it to be the normal signal. When the contact of the engine oil pressure sensor is open, and the signal wire is separated from the chassis ground, the panel judges it to be the normal signal.

Type of sensor Engine oil level Radiator Hydraulic water level

Sensor

method

When normal ON ON I ON OFF I

When abnormal OFF OFF OFF ON -

Contact Contact

oil temperature

Contact Contact Resistance Resistance Resistance

Engine oil pressure Engine water Torque temperature oil temperature

converter

Fuel level

10-122

D275A-1

Engine oil level sensor

A
Structure of circuit

197FO2077

1. 2. 3. 4.

Connector Bracket Float Switch

FUNCTION The sensor is installed to the L.H. side face of the oil pan. When the oil goes below the set level, the float goes down and turns the switch OFF. The monitor then flashes to warn of the abnormality.

Radiator

water

level sensor

Structure of circuit

m
I 2

561FO3177

1. Float 2. Sensor 3. Connector

FUNCTION The sensor is installed to the top of the radiator. When the coolant goes below the set level, the float goes down and turns the switch OFF. The monitor then flashes to warn of the abnormality.

D275A-2

lo-123

Hydraulic

oil temperature

sensor

Structure of circuit 198FO2047

1. 2. 3. 4.

Switch Case Wire Connector

FUNCTION The hydraulic oil temperature sensor is installed to the hydraulic pump inlet tube. It detects the temperature at switch (I), and when the temperature goes above the set temperature, the switch is turned OFF. The display appears on the monitor panel, the warning lamp flashes, and the alarm buzzer sounds.

Engine oil pressure sensor

cl 69

@
Structure of circuit

202FO5175

1. 2. 3. 4. 5. 6.

Plug Contact ring Contact Diaphragm Spring Terminal

FUNCTION This sensor is installed to the engine cylinder block. The diaphragm detects the oil pressure, and when it drops below the standard pressure, the switch is turned ON, and the lamp lights up to warn of the abnormality.

1O-l 24

D275A-1

Engine water temperature sensor Torque converter oil temperature sensor

w
Structure of circuit 198FO2046

1. Connector 2. Plug 3. Thermistor

FUNCTION These sensors are installed to the thermostat housing and torque converter outlet port tube. Any change in temperature is taken as a change in resistance of the thermistor. A signal is sent to the monitor panel and the temperature is displayed. When the panel display reaches a set point, the lamp flashes and the buzzer sounds to warn of the abnormality.

D275A-2

10-125

Fuel level sensor

Structure A-A

of circuit

198FO2089

1. 2. 3. 4. 5. 6. 7.

Connector Float Arm Body Spring Contact Spacer

FUNCTION The fuel level sensor is installed to the side face of the fuel tank. The float moves up and down according to the fuel level. This movement of the float is transmitted by the arm and actuates a variable resistance. This sends a signal to the monitor panel to indicate the remaining fuel level. When the display on the monitor panel reaches a certain level, a warning lamp flashes.

1 o-1 26

D275A-2

PANEL SWITCH

OUTLINE
l

The panel switch incorporates soft touch sheet switches for the headlights, rear lamps, working lamps, torque converter lock-up, APS, and the engine starting switch. When a switch is depressed, the red lamp will come on; when depressed once again, the lamp will go off. When the starting switch is turned off while any one of the sheet switches is ON, all the sheet switches will go OFF. They will not come on again when the starting switch is turned on (to prevent the bulbs from breaking).

197F127

RELAY BOX OUTLINE

l

The relay box houses various relays which energize the lamps, torque converter lock-up and APS. The lamp come on or go off through the operation of the corresponding relay when the panel switch is operated. The relay box also houses the APS controller, fuses for protecting various electrical equipment, and the safety relay that protects the panel switch and relays from over-voltage from the power source (battery and alternator).

198FO2055

D275A-2

lo-127

RELAY BOX CIRCUIT

Serial No.: 10001-10127

CN 362

CN361

197FO2085-1

lo-128 @

017M02

0.75 1.25
0. 5 0. 76 0. 6 I. 26

_ _

P 1.

::

I,

e
L

I i
!

0. 75

-++?

1.25

I
2. 0

I-

-0

00

017M02

An over-voltage protection circuit is built into the controller for the monitor power source. The output of this controller turns the safety relay inside the relay box ON, and supplies electrical power to the relay coil and panel switches. In other words, if any over voltage (approx. 34V) should occur in the power source circuit due to an abnormality in the battery or alternator, the output of the controller is cut and the safety relay is turned OFF to protect the relay coil and panel switches. At the same time, power source to the monitor panel is cut. (When this happens, the monitor panel goes out and the panel switches cannot be operated.) When the engine is started, the battery voltage drops, so the circuit does not pass through the controller. A circuit is formed directly from starting switch C to turn the safety relay ON.

Safety function

circuit drawing

Monitor panel power source

r
I I e:lp

Relay box

--

-I-T
tw
+

Relay power source Lock-up

--1 Pane'switch
______ I I

Safety relay

24 output

Supplementary controller (monitor power source)

~
I

I+

;;E&

y&

I
1GND

lA

I
km Alternator

197fO2086

D275A-2

1O-l 29

OPERATION .

OF LAMP SYSTEM

The lamps are lighted up by operating the panel switch. A signal is then sent to the relay box, and the relay inside the relay box is actuated to supply electricity to the lamp.
Panel switch

Example of head lamp system When the head lamp switch on the panel is l pressed, the contacts of the head lamp switch close, and are connected to the ground. Electricity flows from the battery through the safety relay and fuse to the head lamp relay coil to close the head lamp relay contacts. When this happens, the electricity from the battery passes through the fuse, enters the head lamp relay, and flows to the head lamp to light up the head lamp. At the same time, electricity also passes through diode D,, and flows to the monitor night lighting night lighting to light up and air conditioner flows in the these lamps also. The electricity same way when the rear lamp switch and working lamp switch on the panel are pressed. The lamps, then lights up the respective electricity night lighting. monitors, and air conditioner

Monitor panel (night lighting)

\..._,,*

F19702047

Head lamp system circuit diagram

Relay box r---

Safety relay

--1

Panel switch

Head lamp relay (L.H. and R.H.)

Head lamp

I
I I

The power for the monitor night lighting is supplied from R.H. head lamp relay D4 +.am _ -

Monitor illumination (3

Rear lamp -1 Working lamp -1 Diode

ncr
Air conditioner illumination

L
10-130

I __ __I 747
197FO2088

D275A-2

APS CONTROL SYSTEM

Serial No. : 10001 - 10167

Engine From fuel injection pump Air intake manifold Water temperature sensor

Monitor panel

I I I
1 Water manifold

Glow plug

Relay F19702048

APS SYSTEM

DIAGRAM

Fuel motor

1 Glow plug 2

Nozzle CzGT

nl7
J
197FO2090

-__

Alternator

1O-l 32 @

FUNCTION

APS start Flowoftime ---------

APS stop

I
Starting motor running START (hand) ON (hand) Max. 20C OFF Light up ON OFF ON OFF OFF OFF OFF

_____-----------

Glow plug preheating Starting switch Preheat switch (panel switch) APS water temp. sensor Monitor panel display Preheat relay Heater relay Preheat back-up relav Glow plug Nozzle OFF ON (hand)

Engine start Heat up the glow plug ON

OFF (hand)

Min. 20C

OFF OFF

I I

ON
ON

I
ON

OFF OFF OFF 197F134

sj Z Z

The APS functions to heat the air intake by burning the fuel in the intake manifold.

The APS will operate in the following order When the engine cooling water temperature goes below 2oC, the APS water temperature sensor contacts will close, thereby causing the signal line to connect to the machine body and causing the preheating relay to energize. Under the above condition, when the engine heat switch on the panel switch is depressed or when the starting switch is turned to HEAT, the large capacity heater relay to come ON, causing the current to flow to the glow plug to heat up the glow plug. The impressed voltage is lowered by a resistor to 18V to meat the rated voltage of the glow plug. The bimetal timer will operate while the glow plug is heating and the preheat (APS) pilot lamp will also light up. When the glow plug preheating time is up, the bimetal timer will come OFF and the pilot lamp will go OFF. This indicates that the glow plug is heated enough to operate the APS.

After the APS pilot lamp goes off, the APS controller is activated by turning the starting switch to START. The fuel injection nozzle in the intake manifold starts injecting fuel intermittently (IO times/set) through ON operation. After the engine is started, the fuel injection nozzle is operated by the alternator signal (so that the nozzle works only when the engine is running). When the engine water temperature rises above 2oC, the APS water temperature sensor contacts open and the heater relay goes off, causing the glow plug to stop heating and the fuel injection nozzle to stop injection fuel. The preheat backup relay make use of the START signal to short both terminals of the resistor to supplement the voltage drop of the battery when the engine is started.

10-132-l 6%

Serial No. : 10168 and up

Panel

switch

Engine From fuel i,on Pump inject

1 I
Air intake manifold

APS water sensor

temperature

Nozzle

:<*

_-

Water aI / i _____i_______

manifold _j

I I I I I I I

I Glow i______

Plus

1 _____________-_/ ___________---------------_ ~-__________________----____________---______~

I ;

I I I I f I I

; -1

I SAD01521

APS SYSTEM

DIAGRAM

Controller Power Glow Glow Nozzle 1 2

CN142

CN143
GND Water Starting Preheat temp. sensor mater lamp Spare Monitor illmination lamp Preheating lamo

Water

illmination

lam0

SAD01 544

lo- 132-2 @

APS ACTUATION

CHART

APS start Flow of time ___________________ -l-+1Glow plug preheating

Starting motor turns

IEngine starts, intake air heated 1

I

APS stops completely I ________________________________________________

Starting

switch switch OFF Specified

ON

1
I

START

ON ON OFF (manual) Specified water temperature or above I OFF OFF Flashes (2 times/ ON OFF

Preheating

zntLrtemperature Glow plug APS fuel injection nozzle Lamp display When abnormal

water

temperature ON

(20C) or below

I 1
OFF 1 OFF OFF ON (12 set 1

ON OFF

3 set)

OFF

The APS burns fuel inside the intake fold to heat the intake air. order.

mani-

The APS acts in the following

1. When the temperature of the engine cooling water is below the specified water temperature, the contacts of the APS water temperature sensor close and the water temperature sensor ON signal is input to the controller. 2. Under the above conditions, if the preheating switch is turned ON, the controller sends electricity to the glow plug to heat it. When the glow plug is being heated, the preheating pilot lamp lights up. After the preheating time for the glow plug has passed, the lamp goes out to show that the glow plug has been heated sufficiently to actuate the APS. After the preheating lamp goes out, if the starting switch is turned to the START position, the APS fuel injection nozzle inside the intake manifold is switched ON/OFF (IO times/ set) to spray fuel. When the engine cooling water temperature goes above the specified temperature, the APS water temperature sensor contacts open, and the action of the glow plug and APS fuel injection nozzle is stopped. When this happens, the preheating lamp flashes at 1 Hz to show that the preheating has been completed.

6. 7.

The preheating

switch

is turned

OFF.

If the glow plug or APS fuel injection nozzle system are short circuited with the ground, the lamp will light up until the short circuit is canceled. If the lamp does not go out when the preheating is completed (after 12 secor the lamp goes out onds have passed), and then lights up again, stop the engine and check for any short circuit with the ground. If the preheating switch is turned ON when the engine cooling water temperature is above the specified temperature, the lamp lights up for 12 seconds, and then flashes. In this case, the glow plug is not actuated.

3.

8.

4.

5.

lo- 132-3 @

TORQUE

CONVERTER

LOCK-UP CONTROL SYSTEM

Panel switch / / / / A

,c _____

______\

Transmission

Steering clutch

T/C output shaft speed sensor (4 pulses/rev.)

F19702049

TORQUE

CONVERTER

LOCK-UP

CONTROL

CIRCUIT

Panel switch ---__

Lock-up display lamp

.._I_

1
Lock-up controller

L/U valve source L/U valve signal

3 T/C speed (+) 3 T/C speed (-1

,3 T/M
I

oil press.

sen*or

qGiF-&
Battery 24V Battery relay Lock-up solenoid Torque converter speed sensor Transmission oil pressure sensor F19702050

D275A-2

10-133

OUTLINE l The torque converter lock-up control system uses a controller and the signals from two sensors to automatically locks up the torque converter according to the load on the machine. When the torque converter is locked up, the display lamp at the front of the operators compattment lights up. FUNCTION When the lock-up switch on the panel switch is pressed, the switch contact is closed and it is connected to the ground. Electricity from the battery passes through the fuse and flows to the lock-up relay coil in the relay box, and closes the lock-up relay contacts. When this happens, the electricity from the battery passes through the fuse and enters the lock-up relay, flows to the lock-up controller, and becomes the power source. l The lock-up controller receives signals from the transmission oil pressure sensor and torque converter speed sensor. It connects and cuts the lock-up solenoid and display lamp from the ground to switch the lock-up ON/OFF. The lock-up is switched ON-OFF if the signals from the two sensor fulfill the following conditions. t Lock-up ON (solenoid excited) When both of the following two conditions are satisfied (AND circuit) Torque converter output shaft speed: Above 1170 rpm Transmission oil pressure: Above 19.5 kg/cm * Lock-up OFF (solenoid deactivated) When either of the following two conditions are satisfied (OR circuit) Torque converter output shaft speed: Below 11 IO rpm Transmission oil pressure: Below 15 kg/cm2
l

1o-1 34

D275A2

SENSOR
Torque converter speed sensor

@.I^;)
Structure of circuit

\ i
2

561FO3114

1. Connector 2. Flange 3. Sensor

FUNCTION The torque converter speed sensor is installed to the speed sensor gear of the torque converter output shaft. The rotation of the gear teeth generates a pulse voltage and sends a signal to the controller.

Transmission

oil pressure sensor

Structure of circuit

17MF02082

1. 2. 3. 4.

Switch Tube Wire Connector

FUNCTION The transmission oil pressure sensor is installed to the transmission control valve. If the oil pressure is above the set pressure it is ON, and if it is below the set pressure it is OFF, and a signal is sent to the controller.

D275A-2

1o-1 35

20

TESTING

AND

ADJUSTING

Standard value table for engine .......... 20- 2 Standard value table for chassis .......... 20- 3 Standard value table for electrical judgement ......................... ..20- 9 Table of tools for testing, adjusting and troubleshooting ...................... 20-I 1 Testing and adjusting belt tension ........ 20-13 Adjusting valve clearance ............... 20-14 Measuring compression pressure ......... 20-I 5 Measuring blow-by ..................... 20-16 Adjusting fuel injection timing ............ 20-17 Measuring exhaut color ................. 20-I 8 Measuring engine oil pressure ........... 20-I 9 ................ Measuring engine.speed 20-I 9 Measuring boost pressure ............... 20-20 Measuring exhaust temperature .......... 20-21 Adjustment of fuel control linkage ........ 20-22 Adjustment of gear shift lever linkage ..... 20-24 Adjustment of steering clutch linkage ..... 20-28 Adjustment of brake pedal linkage ........ 20-30 Adjustment of work equipment control linkage ............................. 20-32 Adjusting clearance of idler ............. 20-35-I Measuring speed at torque converter stall . 20-36

Measuring speed at torque converter stall + hydraulic pump relief.. . . . . . . . . . . . . . Measuring power train oil pressure . . . . . . . Testing and adjusting work equipment main relief pressure . . . . . . . . . . . . . . . . . . . . . . . Bleeding air from hydraulic cylinder . . . . . . Measuring linkage inside cylinder . . . . . . . . Checking location of cause of hydraulic drift of blade and ripper.. . . . . . . . . . . . . . Procedure for simple test of steering brake performance ........................ Procedure for testing sensors . . . . . . . . . . . . Troubleshooting .......................

20-37 20-38 20-41 20-42 20-43 20-44 20-45 20-46 20-49

The following precautions are necessary when using the STANDARD VALUE TABLE for testing and adjusting, or for troubleshooting. 1. The values in the table are for new machines, and are obtained for reference to values for new machines and the values when shipping from the factory. Therefore, they should be used as target values for judging the progress of wear, or when repairing the machine. 2. The values for judging failures are based on standards when shipping the machine from the factory, and on the results of various tests. These values should be used as reference together with the repair condition and operating record of the machine to make judgements on failures. 3. The values in the table should not be used for judging claims.

A A

When carrying out testing, adjusting or troubleshooting, safety pins and block the tracks.

stop the machine on level ground, install the

When working in groups, use agreed signals and do not allow unauthorized persons near the machine. When checking the water level in the radiator, wait for the water to cool. cap while the water is hot. Boiling water may spurt out. Be careful not to get caught in rotating parts. Do not remove the radiator

A A

20-l 0

STANDARD

VALUE TABLE FOR ENGINE

Machine

model

D275A-2

Serial

numbers

10001 - 10167

Engine

S6D170-1 Standard value 1,960 2 50 600 k 50 1,800 2 50 Permissible value 1,960 + 50 600 2 50 -

Item

Measurement High idling Low idling Rated speed Whole speed range (ambient temperature:

conditions

Unit

Engine

speed

wm
C

Exhaust temperature (turbocharger inlet port temperature) Boost pressure

20C)

Max. 650

Max.

700

At rated output At sudden acceleration At high idling Intake valve Exhaust valve (at cold) Oil temperature: 40 - 60C Engine speed: 210 - 250 rpm (SAEBO oil) At rated output (Water temperature: (SAESO oil) Operating range) range)

kPa {mmHgI Bosch index

Min. 120 {Min. 9001 Max. 6.0 Max. 1.0 0.4 1.0

Min. 108 {Min. 810} Max. Max. 8.6 2.0

Exhaust

gas color

Valve

clearance

mm

Compression

pressure

MPa {kg/cm*1 kPa mmH20)

Min. 2.86 {Min. 29) Max. 2.9 {Max. 3001

Min. {Min.

1.97 20) 8 5 z

Blowby

pressure

Max. 5.9 {Max. 6001

(Water temperature: Operating At high idling (SAESO) At low idling Oil pressure At high idling At low idling (SAEIOW) (SAE 1 OW) (SAE30)

MPa {kg/cm*1

0.3 13.0 Min. {Min. 0.25 12.5 Min. {Min.

0.49 5.0) 0.15 I.51 0.44 4.5) 0.1 1.0)

Min. {Min. Min. {Min. Min. {Min. Min. {Min. Max.

0.25 2.5) 0.7 7.01 0.18 1.8} 0.07 0.7) 120

Oil temperature Fuel injection Alternator timing

Whole B:T.D.C.

speed

ranoe

(inside

oil Dan)

C (de@

80 - 110 38 + 1 15

38 * 1

belt tension compressor

Deflection when pressed with finger force of approx. 58.8 N 16 kg} Deflection when pressed with finger force of approx. 98 N {IO kg}

Air conditioner belt tension

13 -17

mm Fan belt tension (auto tension) Dimension A: 50 f 5

17MF02140

1: For reference

20-2 @

Machine

model

D275A-2

Serial

numbers

10168 and up

Engine

S6D170-2 Standard value 1,960 -c 50 600 2 50 1,800 2 50 Permissible value 1,960 5 50 600 2 50 -

Item

Measurement High idling Low idling Rated speed Whole speed range (ambient temperature:

conditions

Unit

Engine

speed

vm
C
kPa ImmHgI Bosch index

Exhaust temperature (turbocharger inlet port temperature) Boost pressure

20C)

Max.

650

Max. 700

At rated output At sudden acceleration At high idling Intake valve Exhaust valve (at cold) Oil temperature: 40 - 60C Engine speed: 210 - 250 rpm (SAEBO oil) At rated output (Water temperature: (SAE30 oil) Operating range) range)

Min. 120 {Min. 900) Max. Max. 0.4 1.0 6.0 1.0

Min. 108 {Min. 810} Max. 8.0 Max. 2.0

Exhaust

gas color

Valve

clearance

mm

Compression

pressure

MPa {kg/cm21 kPa [mmH201

Min. 2.86 {Min. 29) Max. 2.9 {Max. 3001

Min. 1.97 {Min. 20) Max. 5.9 {Max. 600)

Blowby

pressure

(Water temperature: Operating At high idling (SAESO) At low idling Oil pressure At high idling At low idling (SAEIOW) (SAEIOW) (SAE30)

MPa {kg/cm21

0.3 (3.0 Min. {Min. 0.25 (2.5 Min. {Min.

0.49 5.0) 0.15 1.5) 0.44 4.51 0.1 l.O}

Min. {Min. Min. {Min. Min. {Min. Min. {Min. Max.

0.25 2.5} 0.7 7.0} 0.18 1.8} 0.07 0.71 120

Oil temoerature Fuel injection Alternator timing

Whole B.T.D.C.

speed

range

(inside

oil pan)

C
(de@

80 - 110 22 15

22

belt tension compressor

Deflection when pressed with finger force of approx. 58.8 N (6 kg} Deflection when pressed with finger force of approx. 98 N {IO kg}

Air conditioner belt tension

13 -17

mm Fan belt tension (auto tension)

1: For reference

20-2-l 63

STANDARD VALUE TABLE FOR CHASSIS

Classi ficatio

Check item
l

Conditions Engine oil pressure: within operating range Engine oil temperature: within operating range Power train oil temperature: 70-80C Hydraulic oil temperature: 45-55X No. of speed range : F3 Engine: Center of lever knob low idling - full throttle low idling

Unit

Standard value

Permissible value

Torque converter stall speed

1,580 f 50 rpm 1,375 f 50

Min 1,510

Torque converter stall + hydraulic relief speed

Min 1,240

90 * 20 60 f 20 25 * 5 35 * 5 61 f6 147.5 f 7.5 55 f 5 Play: Max. 5 lOOf

90 z!z20 60*20 25 Z!Y 5 35 * 5 61 f6 147.5 f 7.5 55 + 5 Play: Max. 5 100+5

Fuel control lever

Engine:

- stop
Decelerator pedal
l l

Center of pedal Engine: full throttle Engine stopped Center of lever knob Engine low idling Center of lever knob Engine low idlina Center of pedal Engine low idling Center of lever knob Hydraulic oil temperature: 45 - 55C Engine low idling Center of lever knob Hydraulic oil temperature: 45 - 55C

Low idling

Gear shift lever

l

Between each speed range F-R Full stroke Until clutch is fully disenaaaed Full stroke To point where brake pressure becomes 0 ka/cm* HOLD HOLD RAISE LOWER

Steering lever
l

Brake pedal
l

mm

80 k 5

80 f 5

70 f 7

70 f 7

Blade control lever

HOLD HOLD -

LEFT TILT RIGHT TILT

55 f 6

55+6

Ripper control lever

HOLD HOLD -

RAISE LOWER

55 + 6

55 + 6

I
HOLD HOLD Engine: TILT IN TILT BACK
I

55 dz6

55 z!z6

low idling - full throttle full throttle - low idling low idling - stop full throttle - low idling

12.5 f 2.5

Max. 18 Max. 16 Max. 27

Fuel control lever

Center of lever knob

Engine: Engine:

11+3 17f3

Decelerator

pedal

Engine speed 850 f 50 rpm Center of pedal Engine stopped Center of lever knob

kg
10.5 f 2.5 Max. 17

Engine:

4.8f1.8 3fl

Max. 7

Gear shift lever

l

Max. 5

20-3

Classi, ficatior

Check item
l

Conditions Engine low idling Center of lever knob Until clutch is fully disengaged Until machine turns when brake is aDDlied

I I
Unit

Standard value 3.3 + 0.8 721

Permissible value Max. 7 Max. 10

Steering lever
l

Brake pedal

l l l

Engine: low idling Engine stops or stalls with one brake Center of pedal Engine low idling Center of lever knob Hvdraulic oil temperature: 45 - 55C Engine low idling Center of lever knob Hydraulic oil temperature: 45 - 55C HOLD HOLD I-I HOLD HOLD HOLD HOLD F HOLD HOLD TILT IN TILT BACK RAISE LOWER LEFT TILT RIGHT TILT RAISE LOWER

38 III 4

Max. 45

t I
kq

4.8 f 0.8 3.3 + 0.8

Max. 8

Blade control lever

Max. 8 Max. 6

I
I

3.3 + 0.8

I
3.3f0.8

1
I

Max.6

Ripper control lever

3.13 f 0.8 15+3 6rt3 0.5 91: 0.5 2.0 2.0

Max. 6

Radiator shutter control lever Torque converter relief pressure (inlet) Torque converter outlet pressure

Close -+ Open Open -+ Close Low idling Full throttle Low idling Full throttle Lock-up clutch Low idling ~Full throttle Low idling Full throttle

0.5 91; 0.5 2.0 2.0 (v z z

5.5 2 A:: 0 13 +:, 23 27

5.5 + A:; 0 13 +:, 23 27

Torque converter lock-up pressure Stator clutch Transmission main relief pressure Transmission modulating pressure Transmission ing pressure reducl

27 f 2 27 + 2 27 f 2

27 f 2 Min. 24 Min. 24 21.5f 1.5

Transmission lubrication pressure

Oil temperature in power train: 70 - 80C Engine speed: full throttle Low idling Full throttle Low idling Full throttle Low idling &z-----l kg/cm2

21.5 f 1.5 Min. 0.1 2.0 f 0.5 25 * 2 27 + 2 25 f 2 27 & 2

Min. 0.1 2.0 f 0.5 Min. 22 Min. 24 Min. 22 Min. 24

Steering clutch operating pressure

Brake operating pressure

I
Ripper pin-puller Blade lifting pressure Blade tilting pressure Ripper lifting pressure
l

Hydraulic oil temoerature: 45 i 55C

Low Full throttle

20-4 0

ficatic

Check item

Conditions Posture of work equipment Low idling z z

1 I

Unit

Standard value

Permissible value

8-13

Max. 26

Full throttle

3-5

Max. 6

Blade speed (lift)

197FO1547
l

l l

Hydraulic oil temperature: 45 - 55C Blade: no load From ground to maximum height

z g-J

Low idling

1 .o -

1.5

1.0 -

1.5

Full throttle

1.0 -

1.5

1 .o -

1.5

Posture of work equipment 5 I= t !Y Blade speed (tilt)

197FO1549

Low idling

8-13

Max. 17

Full throttle

3-4

Max. 6

l l

Hydraulic oil temperature: 45 - 55C Blade: no load Left tilt - Right tilt

5 i= z oc

Low idling

6-10

Max. 16

Full throttle

2.5 -

3.5

Max. 5

Posture of work equipment Low 8-12 Max. 15

2.5 qipper speed (lift)

197FO1549 ) Hydraulic oil tempera-

3.5

Max. 5

ture: 45 - 55C 1 Shank set at bottom hole ) From ground to maximum height work equrpmenr

E 19

Low idling

1.5 -

2.5

1.5 -

2.5

Full throttle

1.5 -

2.5

1.5 -

2.5

Low idling

12-

18

Max. 21

Full throttle tipper speed (tilt)

197FO1550 1 Hydraulic oil tempera-

4.5 -

5.5

Max. 6.5

y 2 3 F

ture: 45 - 55C 1Shank set at bottom hole 1 From tilt back tilt in

Low idling

8-12

Max. 15

Full throttle

3-4

Max. 6

20-5

Classificatior

Check item

Conditions Posture of work equipment Pitch dump

Unit

Standard value

Permissible value

2.5 IO.6 degl4.3

Pitch back Pitch speed legree /set

3.0 IO.6 deg/3.5

l l l l

Hydraulic oil temperature: Blade: no load Pitch dump - pitch back Full throttle

45 -

55C

Posture of work equipment Left tilt Dual tilt speed Negree lsec Right tilt 7.1 80.6 degf4.3 s: 7.1 80.6 deg14.3 s

17MF02142

Semi U dozer mm

1,135

Dual tilt

l l l

Hydraulic oil temperature: 45 - 55C Blade: no load Left tilt - Right tilt Full throttle Hydraulic oil temperature: 45 - 55C Lower the blade from the maximum height, and measure the time taken from the point when the blade touches the ground to the point where the idler is raised from the ground

U dozer

1,215

Engine low idling

Max. 6

Max. 12

Time lag (blade)

Engine full throttle

Max. 1.5

Max. 2.0

sec.

Time lag (ripper)

Hydraulic oil temperature: 45 - 55C Lower the ripper from the maximum height, and measure the time taken from the point when the ripper touches the ground to the point where the sprocket is raised from the ground Engine full throttle

Max. 1.0

Max. 1.5

20-6

Classification

Check item Posture

Conditions of work equipment

Unit

Standard value

Permissible value

Hydraulic drift (blade lift)

!EtE&
l l l

197FO1551

Max. 200/l 5

Max. 400/l 5

Hydraulic oil temperature: 45 - 55C Engine stopped Center of blade cutting edge; from height of 800 mm to ground of work equipment

Posture

Hydraulic (machine down)

drift moves

197FO1552
l l l

Max. 3015

Max. 10015

Hydraulic oil temperature: 45 - 55C Engine stopped Blade pushed down, movement at center of idler of wgrk equipment

Posture

LEFT TILT

Max. 3015

Max. 8015

Hydraulic drift (blade tilt)

197FO1553
l

mmlmir

Hydraulic oil temperature: 45 - 55C Tilt blade to raise machine, engine stopped immediately to reach ground Measure retraction of tilt cylinder of work equipment

RIGHT TILT

Max. 3015

Max. 80/5

Posture

Hydraulic drift (ripper lift)

l l l

197FO1554

Max. 80/I 5

Max. 160/l 5

Hydraulic oil temperature: 45 Engine stopped Ripper point: 500 mm above the ground of work equipment

55C

Posture

Hydraulic (machine

drift moves

down)
l l l

197FO1555

Max. 3015

Max. 6015

Hydraulic oil temperature: 45 Engine stopped Ripper pushed down movement at center of sprocket

55C

20-7

Classi ficatioi

Check

item

Conditions F F F R
l l l

1st 2nd 3rd 1st 2nd 3rd 1st 2nd 3rd 1st 2nd 3rd

(3.8 f 0.2) 10.7 * 0.6 (6.7 + 0.3) 6.1 z!z 0.3 (11.8 * 0.6) 14.7 IL 0.8 (4.9 + 0.2) 8.3 + 0.4 (8.7 + 0.4)

(3.8 f 0.2) 10.7 + 0.6 (6.7 f 0.3) 6.1 f 0.3 (11.8 f 0.6) 14.7 + 0.8 (4.9 * 0.2) 8.3 + 0.4 (8.7 f 0.4) 4.8 f 0.3 (14.9 f 0.7) 1.0 18.9f (3.8 f 0.2) 10.4 I!Z 0.6 (6.9 * 0.3) 6.1 f 0.3 (11.7 f 0.6) 14.7 IL 0.7 (4.9 f 0.2) 8.1 f 0.4 (8.9 k 0.4) 4.8 f 0.3 (15.1 + 0.8)

Travel

speed
l

On level surface Engine at full throttle Engine water temperaInside operating ture: range Run up distance: IO-30m distance: Measurement 20 m

R R F F F R R R

sec.
(km/h)

4.8 +I 0.3 (14.9 f 0.7) 1.0 18.9+ (3.8 * 0.2) 10.4 do 0.6 (6.9 f 0.3) 6.1 f 0.3 (11.7 f 0.6) 14.7 * 0.7 (4.9 f 0.2) 8.1 f 0.4 (8.9 f 0.4) 4.8 + 0.3 (15.1 f 0.8)

20-8

STANDARD VALUE TABLE FOR ELECTRICAL JUDGEMENT

SYS
ten

Component

tonnector

No

esting lethod

Judgement

table

Measurement conditions 1) Engine started

1) When using the short connector, the followin results show that the sensor is defective

Coolant

level sensor

CN405 (Male)

1) The following is normal

results show that the sensor

1) Starting switch OFF

I
Coolant temperature sensor (Coolant temperature gauge) CN402 (Male)

Coolant

level normal level abnormal

Max. 1 Q

I 1
1) Starting switch OFF 2) Disconnect CN402 (coolant temperature gauge) 3) Disconnect CN453 (T/C oil temperature gauge) 1) Engine started

I Coolant

1 Min IMP

The following is normal

results show that the sensor

Ambient temoerature 35C

When normal Approx. I Approx. I Approx. 80kS 52kQ 29kQ

Torque converter oil temperature sensor (Torque converter oil temperature gauge)

CN453 (Male)

20C I 10C

1) When CN403 is connected to chassis ground, the following results show that the sensor is defective

Engine oil pressure sensor

CN403 1) The following is normal results show that the sensor 1) Engine started

Engine oil pressure 0.7 ka/cm2

over under

Min. IMQ Max. 1 Q

Engine oil pressure 0.7 ka/cm*

I
is 1) Starting switch OFF 2) Disconnect CN423

The following results show that the sensor normal (Normal temperature 25C)

Fuel level sensor (fuel gauge)

CN423 (Male) Full Empty

CN423 (Male) @ Approx. Approx. 109 or less 859

20-9

systern

Component

Connector

No. ~e~h~~

Judgement

table

I
1) When CN452 (female) is connected to chassis ground, the following results show that the sensor is defective

Measurement conditions 1) Engine started

I I
SF 52 Hydraulic oil temperature sensor CN452 (Male)

1) The following is normal

results show that the sensor

1) Starting switch OFF

8:

1) When CN404 (female) is contacted to chassis ground, the following results show that the

1) Starting switch ON,

Engine oil level sensor

CN404 (Male)

I I
& g 9
0)

1) The following is normal

results show that the sensor

1) Starting switch OFF

.E ; :

Engine oil level normal Engine oil level abnormal

Max. 1 R Min IMR

20-10

TABLE OF TOOLS FOR TESTING, TROUBLESHOOTING

Test measurement
Engine speed item

ADJUSTING

AND

Symbol
A

Part No.
799-203-8001

Part

Name

I
Digital

Remarks
display: L: 60 - 2,OOOrpm H : 60 - 19,999rpm

Multi-tachometer

Water temperature, oil temperature, exhaust temperature

i3

799-101-6000

Digital

temperature

gauge

-50 -

1,200C

799-101-5001 Hydraulic tester Pressure gauge: 2.5, 5.9, 39.2, 58.8 MPa 125, 60, 400, 600 kg/cm2} tester Pressure gauge: 68.6 MPa {700 kg/cm21

Oil pressure

1 790-261-1201 Digital hydraulic gauge gauge gauge

Boost pressure D

2 -

799-401-2320 799-401-2310

Hydraulic Pressure

1.0 MPa {IO kg/cm21 199.9 kPa I1500 mmHg1

1 Compression pressure E 2 Blowby pressure i z z z Exhaust color Valve clearance G F

795-502-1210 795-502-1350

Compression

0 - 6.9 MPa (0 - 70 kg/cm21 Kit Part No.: 795-502-1205

I
Blowby Gauge Feeler gauge
I

1 799-201-1504
2 799-201-1590 Commercially available

cheker

0 - 9.8 kPa (0 - 1000 mmH,OI Intake valve: 0.4 mm; exhaust valve: 1.0 mm j Discoloration: 0 - 70 % (with standard color) (Discoloration x l/IO = Bosch index) -

Operating Stroke, Work

force drift speed

I
H I J K of wiring L of value of voltM P

1 799-201-9000
Commercially available Commercially available Commercially available Commercially available 799-601-7100 799-601-7070 Commercially available 791-627-1130 795-471-1200

Handy

smoke

checker

Smoke

meter

Push-pull

scale

I -

hydraulic equipment

Stopwatch T-adapter Adapter kit

For those owning 799-601-2500 799-601-7000 is possible SWP14

Troubleshooting harness, sensor Troubleshooting aqe, resistance Measuring wear sprocket tooth Fuel injection

Wear Gauge gauge assembly Dial gauge available is commercially

timing

20-11 @

TESTING AND ADJUSTING

Serial No . : 10001 - 10167

BELT TENSION

1. Testing fan belt tension is installed, so check 0 An auto-tensioner that the dimension of the tension spring = 50 k 5 mm when the belt is reb$FdA

4 ?

1. 2. 3. 4. 5. A.

Adjustment nut Washer Tension spring Adjustment bolt Tension pulley Protrusion of adjustment

bolt

6162F291

0
0

Et
2. Testing and adjusting alternator belt tension Testing of the belt when it l Check the deflection is pressed at approx. 58.8N (6 kg) at a midpoint between the alternator and accessory drive pulley. Deflection: 15 mm * Adjusting 1. Loosen alternator assembly mounting bolt (1) and belt tension adjustment bolt (2). 2. Using a pipe, move the alternator to adjust Tighten the adjustment the belt tension. the alternator bolt first, then tighten mounting bolt.
Alternator

belt

569F102

20-l 3 @

Serial

No . : 10168

and

up

1. Testing and adjusting alternator belt tension Testing . Check the deflection of the belt when it is pressed at approx. 58.8 N (approx. 6 kg} at a midpoint between the alternator and accessory drive pulley. * Deflection: 15 mm

Adjusting 1) Loosen alternator assembly mounting bolt (I) and belt tension adjustment locknut (2). 21 Turn adjustment nut (3) to adjust the tension of the belt to the standard value. the belt tension, tighten 3) After adjusting locknut (2), then tighten alternator assembly mounting bolt (1).

20-13-l @

ADJUSTING VALVE CLEARANCE

Adjust the clearance between the rocker lever and crosshead as follows:
Intake valve Cold 0.4 mm Exhaust valve 1.0 mm

1. Remove the cylinder head cover. 2. Rotate the crankshaft in the normal direction to align the 1.6 TOP line on vibration damper (1) with pointer (2) to set the No. 1 cylinder at compression top dead center. When rotating, check the movement of the valves. 3. When No. 1 cylinder is at compression top dead center, adjust the valves marked 0. When No. 6 cylinder is at compression top dead center, adjust the valves marked o.

Valve

arrangement

I
4. To adjust the clearance, insert feeler gauge G between rocker arm (3) and crosshead (4), and adjust with adjustment screw (5) until the clearance is a sliding fit. Then tighten locknut (6) to hole the adjustment screw in position. m
*

TDD00714

Locknut:

58.8 2 9.8 Nm 16 + 1.0 kgm} the locknut, check the

After tightening clearance again.

5. Next, rotate crankshaft one turn in the normal direction and adjust the valve clearance of the remaining valves marked 0. * After adjusting No. 1 cylinder at compression top dead center, it is also possible to turn the crankshaft 120 each time and adjust the clearance of the valves of each cylinder according to the firing order. Firing order: I-5-3-6-2-4

F621201066

6162F658

20-14 8

A
*

Be careful not to touch any hot places when installing or removing the measuring tools. of the cooling water Raise the temperature the operating range before measuring. to

1. Adjust the valve clearance. For details, see ADJUSTING ANCE.

VALVE

CLEAR-

2. Remove the nozzle holder assembly of the cylinder to be measured. j, Be careful not to let dirt or dust get inside. 3. Install tool E2 in the mount of the nozzle holder assembly, then connect tool El to tool E2. Sr Coat the tip of tool E2 with a small amount of oil. 4. Set tool chometer. A to the pick-up port of the ta-

8 Z 6

5. Place the fuel control lever in the NO INJECCrank the engine with the TION position. starting motor and measure the compression pressure.

A
A
* *

If the fuel control lever is not placed at fuel will the NO INJECTION position, spurt out.

compression the measuring When be careful not to touch any pressure, hot parts or rotating parts. pressure at the Measure the compression point where the pressure gauge indicator remains steady. pressthe compression When measuring ure, measure the engine speed to confirm that it is within the specified range. pressthe compression After measuring ure, install the nozzle holder assembly.

20-15

Raise the coolant temperature ting range before measuring.

to the opera-

1. Install tool Fl to the tip of engine hose (I), then connect it to tool F2.

breather

2. Run the engine at rated output, and measure the blow-by pressure.

Adapter

A
*
0 0

When measuring, be careful not to touch anv hot Darts or rotatina Darts. The blow-by should be measured with the engine running at rated output. When measuring in the field, a similar value can be obtained at stall speed. If it is impossible to check at rated output or stall speed, measure at high idling. In this case, the blow-by value will be about 80% of the value at rated output. Blow-by varies greatly according to the condition of the engine. Therefore, if the blow-by value is considered abnormal, check for problems connected with defective blow-by, such as excessive oil consumption, defective exhaust gas color, and prematurely dirty or deteriorated oil.

Nozzle

17MF02143

Fl

17MF02144

20-16

ADJUSTING

FUEL INJECTION TIMING

Serial No . : 10001 - 10167

1. Rotate

the crankshaft in the opposite direction in 40 to 50 from No. 1 cylinder at compression top dead center.

2. Rotate the crankshaft in the normal direction, and align pointer (2) correctly with the 38 I.J line on vibration damper (1). 3. Disconnect fuel injection pipe (3) of No. 1 cylinder. 4. Remove delivery valve holder (4), take out spring (5) and delivery valve (6), then install delivery valve holder (4) again. 5. Place the fuel control lever at the FULL position. * When the coupling is rotated, the injection time is changed as follows. cylinder block to ADTurn TOWARDS VANCE timing. Turn AWAY from cylinder block to RETARD timing. 6. Loosen the bolt in the oblong hole of the laminated coupling and operate the priming pump while moving the coupling. Stop at the point where the fuel stops flowing from the delivery valve holder. 7. Remove delivery valve holder (4), assemble delivery valve (6) and spring (5), then install delivery valve holder (4) again. m Coupling mounting bolt: 88.3 + 4.9 Nm I9.0 d 0.5 kgm} Delivery valve holder: 112.8 + 4.9 ill.5

E: : 6

QGE

f 0.5 kgm}

8. Connect fuel injection pipe (3). m Sleevew nut: 21.6 2 2.0 12.2 f 0.2 kgm1

Oblong hole

6162F663

Serial
1. 2. 3.

No. : 10168 and up

Remove the tube between the air cleaner Komaclone and the muffler. Remove the injection pump coupling cover. Remove the head cover, disconnect spill tube (I) and delivery tube (2) of the No. 1 piston, then remove No. 1 nozzle holder assembly (3). Align No. 1 cylinder with the compression top dead center line (1:6). When doing this, check that the fuel in* jection timing line on the fuel injection pump is near the line on the fuel injection pump body. Set dial gauge Q to the nozzle holder hole where the nozzle holder assembly has been (See the diagram.) removed. Set the scale on dial gauge Q to 0 when the piston is at the top dead center. Rotate the crankshaft in the normal di* rection and in the reverse direction in turn to align the top dead center. Ir Record the value indicated by the short indicator on the dial gauge. Rotate the crankshaft approx. 45 in the reverse direction from the No.1 cylinder TOP position. again slowly in the Rotate the crankshaft normal direction and set to specified dimension c. * Specified dimension c: 6.51 d 0.2 mm * Always rotate the crankshaft in the normal direction to align the position. * Continue to rotate in the normal direction, and when the No.1 cylinder reaches the TOP (top dead center) position (the indicator on the dial gauge starts to rotate in reverse), check that the dial gauge reading is 0 r 0.2 mm. If it is not within 0 f 0.2 mm, carry out from Step 6 again. _..~ Check that fuel injection timing line a on the fuel injection pump is aligned with line

4.

5.

6.

7.

8.

9.

BED00346

b on the coupling.

20-17-l @

10. If the lines are not aligned, loosen bolt (4) in the oblong hole, move the coupling to align the lines, then tighten the bolt.

20-17-2 8

MEASURING

EXHAUST COLOR

0 When measuring in the field where there is no air or electric power supply, use tool Hl; when recording formal data, use tool HZ. * Raise the coolant temperature to the operating range before measuring.

Be careful not to touch any hot parts when removing or installing the measuring tools.

Measuring

with HI.

1) Install filter paper to tool Hl. 2) Insert the exhaust gas suction port into the
exhaust pipe, accelerate the engine suddenly, and operate the handle of tool HI at the same time to collect the exhaust gas on the filter paper. 3) Remove the filter paper and compare it with the scale supplied to judge the condition.

Measuring with H2. 1) Insert probe 0 into the outlet port of the exhaust pipe (I), and tighten the clip to secure it to the exhaust pipe. 2) Connect the air hose and the socket of the probe hose accelerator switch to tool H2. * Keep the pressure of the air supply below 1.47 MPa {I5 kgm2} 3) Connect the power cord to the AC socket. * When connecting the cord, check that the power switch oftool H2 is OFF. 4) Loosen the cap nut of the suction pump, and fit the filter paper. * Fit the filter paper securely so that the exhaust gas cannot leak. 5) Turn the power switch of tool H2 ON. 6) Accelerate the engine suddenly, and depress the accelerator pedal of tool H2 at the same time to collect the exhaust gas color on the filter. 7) Place the filter paper used to catch the exhaust gas color on top of at least IO sheets of unused filter paper inside the filter paper holder, and read the value shown.

17MF02147

Hz

//
17MF027 48

20-18 8

MEASURING

ENGINE OIL PRESSURE

the coolant temperature *Raise ting range before measuring.

to the opera-

1. Remove pressure measurement plug (1) (PT l/8), then install oil pressure gauge C (IO kg/ cm2). 2. Start the engine, and measure the oil pressure at low idling and high idling.

FO2150

MEASURING

ENGINE SPEED

A
*

Be careful not to touch any hot parts when removing or installing the measuring tools. Measure the engine speed under the following conditions: 1) Coolant temperature: Within operating range 70 - 90 C 2) Power train oil temperature: 45 - 55 C 3) Hydraulic temperature:

1. Remove cap (1) from the speed pick-up port, then install the adapter of tachometer A. 2. Connect tachometer A to the adapter with the cable.

When measuring the engine speed, be careful not to touch the rotating parts or hot parts.

3. Start the engine and measure the engine speed at high idling and low idling. Sr When measuring items other than above (torque converter stall, torque converter stall + hydraulic pump relief), see the measurement procedure for each item.

20-19

MEASURING

BOOST PRESSURE

Be careful not to touch any hot parts when removing or installing the measuring

tools.
1. Remove boost pressure measurement plug (1) (PT1/8), then install the coupler inside oil pressure gauge kit C. 2. Connect the oil pressure measurement hose to the coupler and pressure gauge N (14.7 kPa {I,500 mmHg)). When measuring the pressure, be careful not to touch the rotating parts or hot parts. Note: Operate the engine speed at midrange or above, and use the self-seal portion of the gauge to bleed the oil inside the hose. 0 Insert the gauge about half way, repeat the action to open the self-seal portion, and bleed the oil. Sr If there is oil inside the hose, the gauge will no work, so always bleed the oil. 3. Run the engine at the rated speed and read the gauge indicator.

17MF02153

20-20 8

MEASURING

EXHAUST TEMPERATURE

The temperature sensor is installed to the exhaust manifold, so if the machine is being operated, wait for the manifold temperature to drop before installing the sensor. Raise the coolant temperature to the operating range before measuring. Remove the adiabatic plates. (Serial No.:10168 and up) Remove plug (1) from the exhaust manifold, and install temperature sensor (2). l Temperature sensor: 6215-11-8180 (cable length 610 mm) or 6215-11-8170 (cable length 490 mm) gauge B with

: /

17MF02154

Connect to digital temperature the wiring harness.

s: :
6

Measurement procedure 1. When measuring with the torque converter stalled * The conditions are only for torque converter stall, so when measuring the exhaust temperature, the core of the sensor will heat up and the torque converter will overheat before a stable value is obtained. 1) Raise the exhaust temperature by using full stall (torque converter stall + hydraulic pump relief) (standard value: Approx. 650C). 2) In the above conditon, cancel the hydraulic rleief, and carry out only torque ocnverter stall. (If the temperature starts to go down, or goes up without going down, repeat step 1) to raise the set temperature.) when the 3) Note the stable temperature temperature starts to go down. 2. When measuring the maximum value for the exhaust temperature Carry out actual work and measure the maximum value during operation. * Use the peak mode (it can store the maximum value in memory) of the temperature gauge function. Note: The exhaust temperature varies greatly according to the ambient temperature (temperature of the engine intake air), so if any abnormal value is obtained, carry out temperature compensation. * Compensation = Measured value + 2 (converted ambient temperature - ambient temperature) * For the D275A-2, the converted ambient temperature is taken as 20 C.

X-type

connector

(2Pinl Temperature sensor

BLD00675

Temperature

Stable

reading

Exhaust temperature at torque converter stall

When measured only with torque converter

Full + Torque verter

stall constall

Torque converter overheat

-Time

_
BKD00676

20-2 1 @

ADJUSTMENT

OF FUEL CONTROL LINKAGE

1) Make the length between the pins of rod

(1) 637 mm, and interconnect lever (2) and friction clutch (3). 2) Fix fuel control lever (2) at a position where clearance A between friction clutch (3) and idling set spring box (4) is 0 mm. 3) With the friction clutch in the condition in Step I), set lever (5) installed to the engine fuel injection pump to the idling POsition. 4) In this condition, set rods (6), (7), (8) and (9) to the standard length, and interconnect them. * Standard length of rod (6): 887 mm (7): 986 mm (8): 559 mm (9): 845 mm * To adjust for the parts tolerance and assembly tolerance, turn the turnbuckle attached to rod (7), and adjust the length to interconnect rod (7).

F17M02010

E
6

With decelerator pedal linkage rod (IO) not interconnected, pull fuel control lever (2) towards the rear of the machine. Check that lever (5) of the engine fuel injection pump contacts the FULL stopper. 6) Keep the lever in this position, and turn FULL stopper (11) until it contacts the fuel control lever. Then turn the stopper back two turns, and lock it in position. pedal linkage rod (IO) 7) With decelerator not interconnected, push fuel control lever (2) towards the front of the machine. Check that lever (5) of the engine fuel injection pump contacts the STOP stopper. 8) With the lever in this position, turn stop adjustment bolt (12) attached to idling set spring box (4), and adjust clearance B to 0 mm. Then turn the bolt back one turn, and lock it in position. 9) Set fuel control lever (2) at the full throttle position, and set so that clearance C at the decelerator pedal is 0 mm, and clearance D at the end of decelerator pedal linkage rod (10) is also 0 mm. 10) Start the engine, set the throttle lever to 850 _+ 50 rpm, then adjust with the turnbuckle of rod (10) so that clearance C is 0 mm. 11) Run the engine at high idling, and adjust with rod (IO) so that clearance D is 0 mm. Run the engine at high idling, and adjust with adjustment bolt (13) so that clearance E is 0 mm, then lock in position with the nut.
5)

Clearance

E-t_

154F21114

F17M02011

20-23

ADJUSTMENT

OF GEAR SHIFT LEVER LINKAGE

--

3
llMF02184

20-24

Sr Tighten the locknuts of the rods and cables securely, and bend the cotter pins securely. w Locknut (14), (15): 7.25 f1.75 kgm

Speed selector lever (1) and direction selector lever (2) are installed to the transmission control valve. The speed position and direction position of each lever are determined by the detent inside the valve.

1) Set lever (1) in the N position, and connect 2)

gear shift push-pull cable (3) to bracket (4) and lever (1). In this position, adjust the mounting height of the switch so that neutral safety switch (5) is pushed in 1.5 mm. * Movelever(l)@+@+@+@ @ + 0. Check that the push-pull cable moves the correct distance.

3) Set lever (2) in the REVERSE position, and connect direction selector push-pull cable (6) to bracket (4) and lever (2). In this condition, adjust the mounting height of the switch so that backup alarm switch (7) is pushed in 1.5 mm.

17MF02160

1.5 mm

17MF02161

20-25

4) S.et gearshift lever (8) to the N position (N position of change guide (9)), and put safety lock lever (IO) in the LOCK position. * If the LOCK position of the safety lever does not match the position of the change guide, adjust the length of rod (11). * Standard length of rod (11): 115 mm 5) Secure push-pull cables (3) and (6) to bracket (17). 6) Adjust so that the amount of protrusion of push-pull cables (3) and (6) is as follows. * Speed (3): 157 mm Directional (6): 130 mm 7) Turn the turnbuckle and connect push-pull cables (3) and (6) to rods (12) and (13) (with the turnbuckle screwed in approx. 5 mm). j, Position of speed lever (8): FORWARD and 2nd position. * After adjusting all the parts of the linkage, check that gear shift lever (8) moves the correct distance for all eight positions. (FORWARD: @-+@-0-0; REVERSE: @I-@-Q-Q. * Check that when the gear shift lever is put in the N position for FORWARD and REVERSE, it cannot move @ + @ + @ when the safety lock lever is in the lock position.

17MF02162

17MF02163A

20-26 Co

ADJUSTMENT

OF STEERING CLUTCH LINKAGE

45 nlm 147.5+10 mm

1
a

9 1 c! _

197F417

20-28

Tighten the lock nuts of the rods and cables securely, and bend the cotter pins securely.

1. Adjust the length of stopper bumper (2) so that steering lever (1) is 45 mm from the front face of the guide box. 2. Keep the protrusion of push-pull cable (3) above the floor frame at 157 mm, and interconnect rod (4) and cable (3). 3. Push steering levers (5), (6) installed to the steering brake valve towards the rear of the machine at 1 - 2 kg. With the rods in contact with the spool inside the valve, interconnect push-pull cable (3) and rod (7). * Standard length of rod (7): 146 mm 4. After interconnecting all the parts age, if the play of steering lever than 5 mm, screw in yoke (8) at push-pull cable (3) to adjust the remove the play. of the link(1) is more the rear of length and

8 z 6

5. After adjusting all parts of the linkage, pull the steering lever fully and check that it travels 147.5 rtr 7.5 mm. Check also that there is a clearance between the steering lever and the guide box. * The distance the steering lever travels is determined by the contact with the stopper of the spool inside the steering valve. When the steering lever is pulled fully, check that the lever on top of the valve always moves the full stroke (Full stroke = 32 mm).

20-29

ADJUSTMENT

OF BRAKE PEDAL LINKAGE

197F417A

20-30

j,

Tighten the lock nuts of the rods and cables securely, and bend the cotter pins securely.

1. With brake pedal (1) depressed, pull up parking lever (2) and lock the brake pedal. Adjust the length of rod (3) so that the brake pedal moves a distance A = 95 f 5 mm. 2. Push lever (4) towards the rear of the machine at 1 - 2 kg. When it contacts the spool inside the brake valve lightly, interconnect rods (5), (6). * When doing this, adjust the length of rod (6) so that there is no play of the connecting pin at applied side. 3. After adiustino all the parts of the linkage, depress brake pedal (1) fully and check that the distance the brake pedal travels is A = 100 f 5 mm. Check also that brake valve lever (4) travels a distance of 20 - 22 mm. * The distance the brake pedal travels is determined by the contact with the stopper of spring box rod (7) installed to the bottom of the pedal. If the travel of the brake pedal is not adjusted to the specified range, the linkage and brake valve may be acting the stopper. This means that there is excessive load on these parts and the necessary braking force cannot be obtained. This may also cause failures in the brake system. 4. After connecting and adjusting all linkages, depress the brake pedal, pull parking lever (2) up and lock the pedal. In this condition, check that the left and right brake oil pressures are 0. For details of the place and method of measuring the oil pressure, see MEASURING OIL PRESSURE.
I 1

197F419

20-3 1

ADJUSTMENT
1. ADJUSTMENT

OF WORK EQUIPMENT CONTROL LINKAGE

OF BLADE CONTROL LINKAGE

197F420

20-32

1. Set blade control lever (1) at HOLD position, and set blade lock lever (2) at LOCK position to hold blade lever in position. 2. In this position, and (6). jr Standard interconnect rods (3), (4), (5)

length of rod(3): 171 mm (4): 190 mm (5): 485 mm (6): 556 mm To adjust length of each rod, turn the turnbuckle attached to rods (5) and (6). Do not move levers (7), (8) connected to the control valve to interconnect rods (5), (6).

3. After interconnecting all parts of the linkage, move lock lever (2) between the LOCK and FREE positions in turn, and check that rods (5), (6) do not move. * If rods (5), (6) move, this means that the HOLD position of the blade lever does not match the HOLD position of levers (7), (8) on the valve. When the lock lever is at the LOCK position, levers (7), (8) on the valve are always pulled.

f:
5 E;

4. After adjusting all parts of the linkage, move the blade control lever to RAISE, LOWER, FLOAT, LEFT TILT, and RIGHT TILT. Check that the movement of levers (7), (8) on the valve are distances L, to L,. * Travel of lever (L,): 23.4 mm (LJ: 23.4 mm (LJ: 14.6 mm (LJ: 15.6 mm (L,): 15.6 mm

197F421

20-33

2.

ADJUSTMENT

OF RIPPER CONTROL LINKAGE

II
197F422

20-34

1. Set ripper control lever (1) at HOLD position, and set ripper lock lever (2) at LOCK position to hold ripper lever in position. 2. In this position, interconnect rods (3), (4), (5) and (6). * Standard length of rod (3): 200 mm (4): 190 mm (5): 557 mm (6): 538 mm * To adjust length of each rod, turn the turnbuckle attached to rods (5), (6). Do not move levers (7), (8) connected to the control valve to interconnect (5), (6). 3. After interconnecting all parts of the linkage, move lock lever (2) between the LOCK and FREE positions in turn, and check that rods (5), (6) do not move. * If rods (5), (6) move, this means that the HOLD position of the ripper lever does not match the HOLD position of levers (7), (8) on the valve. When the lock lever is at the LOCK position, levers (7), (8) on the valve are always pulled. 4. After adjusting all parts of the linkage, move the ripper control lever to RIPPER RAISE, RIPPER LOWER, RIPPER TILT, and RIPPER TILT BACK. Check that the movement of levers (7), (8) on the valve are distances L, to L4. * Travel of lever (L,): 15.6 mm (LJ: 15.6 mm (LJ: 15.6 mm (LJ: 15.6 mm * For machines with a giant ripper, check that connector CN263 of pin puller switch (9) is connected.

20-35

ADJUSTING

CLEARANCE OF IDLER

If idler side guide (1) and guide plate (2) are worn, and there is play to the side, or the idler is at an angle, adjust as follows.

1. Adjustment in side direction 1) Drive the machine for 1 - 2 m on flat ground, then measure clearance A (left, right, inside, outside: 4 places).

2) If clearance

A is more than 3 mm, remove bolt (3) and (4), then take out shim (5), and adjust as follows. Clearance of one side: Max. 0.5 mm * Type of shim: 0.5 mm, 1.0 mm

17MF02863

20-35-l 0

CONVERTER STALL

Measure the stall speed under the following condition. 0 Coolant temperature : Within operating range 0 Power train oil temperature : 70 - 90C 0 Hydraulic oil temperature : Min. 50C Make sure that there is no one near the machine before starting measurements.

1. Install tachometer A. For details, see MEASURING

ENGINE SPEED.

Red

\I

2. Depress the steering brake firmly and move the gearshift lever to F3. 3. Set the fuel control lever to FULL, run the engine at high idling, and stall the torque converter. 4. When lamp A at the top of the green range of the torque converter oil temperature gauge lights up, return the gearshift lever to neutral, until lamp B and lower the oil temperature lights up. 5. Repeat Steps 2) 6. Repeat Steps 2) verter. 4) three times. 4) to stall the torque con-

Green

1
17MF02164

7. When lamp A at the top of the green range of gauge the torque converter oil temperature IO seconds, then lights up, wait for 5 measure the engine speed. * After completion of the measurement, return the gearshift lever swiftly to neutral, and run the engine at high idling to lower the oil temperature.

A,

Precautions ver-ter

when

relieving the torque

con-

1) Depress the decelerator pedal before pull2)

ing the fuel control lever to the FULL position. Release the decelerator pedal to run the engine at high idling. However, for safety reasons, always keep your right foot on the decelerator pedal until the completion of the measurement operation.

20-36

MEASURING SPEED AT TORQUE CONVERTER STALL + HYDRAULIC PUMP RELIEF (FULL STALL)
Ir Measure the stall speed condition. 0 Coolant temperature under the following

: Within operating

range 0 Power train oil temperature : 70 - 90C l Hydraulic oil temperature : Min. 50C

Make sure that there is no one near the machine before starting measurements.

1. Install tachometer A. For details, see MEASURING 2. Depress the steering brake the gearshift lever to F3. 3. Set the fuel control gine at high idling, verter.

ENGINE SPEED. firmly and move

Red \I

lever to FULL, run the enand stall the torque con-

4. When lamp A at the top of the green range of the torque converter oil temperature gauge lights up, return the gearshift lever to neutral, and lower the oil temperature until lamp B lights up. 8 z 6 5. Repeat Steps 2) 4) three times.

Greez

I
17MF021t

6. Repeat Steps 2) - 4) to stall the torque converter, and at the same time, set the ripper control lever to the RAISE position to relieve the circuit. 7. When lamp A at the top of the green range of the torque converter oil temperature gauge lights up, wait for 5 IO seconds, then measure the engine speed. of the measurement, return * After completion the gearshift lever swiftly to neutral, and run the engine at high idling to lower the oil temperature. Note: If this measurement is carried out immediately after measuring the torque converter stall speed, the measurement can be carried out by performing Steps 1) - 6) once.

Precautions verter

when

relieving

the torque

con-

1) Depress the decelerator pedal before pulling the fuel control lever to the FULL position. 2) Release the decelerator pedal to run the engine at high idling. However, for safety reasons, always keep your right foot on the decelerator pedal until the completion of the measurement operation.

20-37

MEASURING

POWER TRAIN OIL

Stop the machine on level ground, lower the work equipment to the ground and apply the parking brake. When measuring the hydraulic pressure, remove all the sand and dirt from around the nipple and plug. Raise the power train oil temperature to at least 70C before measuring.

Refer to the diagram and table below to install oil pressure gauge C to the nipple for the circuit to be measured.

Table of centralized pressure pick-up port positions and gauges to use when measuring hydraulic pressure
Gauge (kg/cm*) 60 60 60 60 60 60 60 25 10 25 10

Measurement 1. Right brake actuating

location pressure

I 2 Left brake actuating pressure I 3 Rrght clutch actuating pressure I 4 Left clutch actuating pressure I 5 Transmission reducing pressure I 6 Transmission modulating pressure
7. Torque 8. Torque converter converter converter converter stator lock-up outlet clutch pressure pressure pressure

I9 I 10 I 11

Torque Torque

inlet pressure pressure

Transmission

lubricating

11'
17MF02165

20-38

1. Measuring

torque converter

oil pressure

2. Measuring

transmission

oil pressure

Measuring torque converter inlet port and outlet pressure i) Install oil pressure gauge C to torque converter inlet pressure measurement nipple (10) and outlet pressure measurement nipple (9). ii) Set the gearshift lever at neutral, and measure the torque converter inlet port pressure and outlet port pressure with the engine at low idling and high idling. Measuring torque converter lock-up pressure i) Install oil pressure gauge C to torque converter lock-up pressure measurement nipple (8). ii) Set the gearshift lever at neutral, turn the lock-up mode switch ON, and measure the torque converter lock-up pressure with the engine at low idling and high idling. * Start the engine, turn the lock-up mode switch ON, then gradually raise the engine speed. When doing this, check that the lock-up lamp lights up, and at the same time the lock-up oil pressure rises. Reference: Engine speed when lock-up actuation starts (lamp lights up): 1110 - 1170 rpm Measuring torque converter stator clutch pressure i) Install oil pressure gauge C to torque converter stator clutch pressure measurement nipple (7). ii) Set the gearshift lever at neutral, turn the lock-up mode switch OFF, and measure the torque converter stator clutch pressure with the engine at low idling and high idling.

1) Measuring modulating and rotating clutch reducing pressure (clutch circuit pressure) i) Install oil pressure gauge C to modulating pressure measurement nipple (6) and reducing pressure measurement nipple (5). Measure the hydraulic pressure when the clutch is actuated with the engine at low idling and high idling when the gearshift lever is operated to all the positions given below. pressure with ii) Measure the modulating the gearshift lever at neutral. carrying out the following * Before measurements, pull the steering levers (left and right) fully and apply the parking brake securely. iii) Place the gearshift lever at Fl. Measure the modulating pressure and reducing pressure. iv) Place the gearshift lever at F2. Measure the modulating pressure. v) Place the gearshift lever at F3. Measure the modulating pressure. vi) Place the gearshift lever in RI. Measure the modulating pressure. the steering levers, * Before returning place the gearshift lever in neutral, then move the steering levers slowly. Combination of speed range and clutches * No. 5 (1st) is the rotating clutch.

20-39

2) Measuring transmission lubricating oil pressure lubricating oil pressure i) Remove measurement plug (11) (PT1/8), and install oil pressure gauge C. ii) Place the gearshift lever at neutral, and measure the lubricating oil pressure with the engine at low idling and high idling. Note: The oil pressure differs greatly between high temperature and low temperature, so warm up the oil throughly before measuring. For details, see MEASURING ENGINE SPEED AT TORQUE CONVERTER STALL.

3. Measuring

steering

clutch pressure

1) Install oil pressure gauge C to left nipple (4) and right nipple (3) for measuring the steering clutch pressure. 2) Place the gearshift lever at neutral, pull the steering levers fully, and measure the oil pressure with the engine at low idling and high idling.

4. Measuring

steering

brake pressure

1) Install oil pressure gauge C to left nipple (2) and right nipple (1) for measuring the steering brake oil pressure. 2) Place the gearshift lever at neutral, and measure the oil pressure with the engine at low idling and high idling with the steering levers not operated. -j, Check also that the oil pressure is 0 kg/ cm2 with the engine at high idling both when the steering levers are pulled fully and when the brake pedal is locked with the lock lever.

20-40

TESTING AND ADJUSTING WORK EQUIPMENT MAIN RELIEF PRESSURE

A
*

Stop the machine on level ground, lower the work equipment to the ground and apply the parking brake. When remove plug. gauge, the oil pressure installing all the sand and dirt from around the

Small pump relief valve

Measuring

pressure

1) Remove plug (PT1/8) (1) (for large pump) and (2) (for small pump) for measuring main relief pressure, and work equipment install oil pressure gauge C (400 kg/cm*). 2) Measure the relief pressure of the large pump. 0 Operate the ripper to the RAISE position to relieve the circuit, then measure the oil pressure with the engine at low idling and high idling. 3) Measure the relief pressure of the small

pump. to the 0 Operate the blade tilt cylinder end of its stroke to relieve the circuit, then measure the oil pressure with the engine at low idling and high idling.

Large pump
reliel valve

17MF02185

Adjusting

pressure

If the result of measuring the work equipment main relief pressure shows that the value is not within the standard value, adjust as follows.

1) Remove cover (1). 2) Loosen locknut (2), and turn adjustment screw (3) as follows to adjust. Jr TO RAISE pressure, turn CLOCKWISE TO LOWER pressure, turn COUNTERCLOCKWISE screw ad* One turn of the adjustment justs the pressure by approx. 24.8 kg/ cm2.

3
197F430

20-41

BLEEDING AIR FROM HYDRAULIC CYLINDER

j,

for cylinders the hydraulic When operating the first time after replacing or reassembling the cylinders or piping, always bleed the air from the hydraulic cylinders as follows: 1) Start engine and run at low idling for approx. 5 minutes. 2) Run the engine at low idling, and raise and lower the blade or ripper 4 - 5 times. * When operating the hydraulic cylinder, stop the piston rod 100 mm from the end of its stroke. Do not relieve the circuit under any circumstances. 3) Run the engine at high idling and repeat Step 2), then run the engine at low idling and operate the piston rod to the end of its stroke to relieve the circuit.

20-42

If the hydraulic drift exceeds the standard value, check if the cause of the hydraulic drift is in the cylinder or in the control valve. * Oil temperature when measuring: 45 55C

Measurement

posture

1. Blade tilt cylinder, ripper tilt cylinder 0 Fully extend the rod of the cylinder to be measured, and lower the tip of the blade or ripper to the ground. 2. Ripper lift cylinder 0 Remove the shank pin and extend the lift cylinder fully. * The blade lift cylinder has a built-in piston valve, so measurement is impossible.

Measuring

1) Disconnect the head piping, and block the

piping plate. at the chassis end with a blind

Be careful not to disconnect the piping at the bottom end.

Start the engine, run the engine at high idling, and apply the relief pressure to the bottom end of the cylinder. Wait for 30 seconds, then measure the amount of leakage over the next 1 minute.

20-43

CHECKING LOCATION OF CAUSE OF HYDRAULIC DRIFT OF BLADE AND RIPPER

* If hydraulic drift occurs in the blade and ripper (cylinder), check as follows to see if the cause is in the cylinder packing or in the control valve. posture
Blade lift cylinder

1. Inspection

circuit Extend the blade to raise the chassis. 2) Blade tilt cylinder circuit Extend the tilt cylinder rod fully (maximum tilt), then extend the blade to raise the chassis. 3) Ripper lift cylinder Extend the ripper to raise the rear of the chassis from the ground. 4) Ripper tilt cylinder 2. Inspection Set the cylinder of the circuit to be checked in the inspection posture, then stop the engine. * For details of the inspection posture, see Item 1) - 4).

1) Blade lift cylinder

197FOl552

Blade tilt cylinder

Ripper lift cylinder

Operate the control lever in the direction extend the cylinder rod. If the downward movement becomes fast, the packing is defective. If there is no change, the control valve is defective. If the pressure in the accumulator has been removed, run the engine for approx. 10 seconds to charge the accumulator before carrying out the operation. Reference: If the cause of the hydraulic drift is in the packing, the speed of downward movement in the above operation will become faster for the following reasons.

I97FO

I555

Ripper tilt cylinder

1) With the work equipment in the posture given above, (holding pressure applied to the bottom end), the oil will leak from the bottom end to the head end. However, the volume at the head end is smaller than at the bottom end (proportional only to the area of the rod), so if the oil flows in from the bottom end, the internal pressure at the head end will rise. 2) If the internal pressure at the head end rises, a balance will be made in proportion to this at a certain pressure (this differs according to the amount of leakage).

17MF02166

3) When the pressure becomes balanced, the speed of downward movement becomes slower. In this condition, if the lever is operated as shown above, the circuit at the head end is connected to the drain circuit (the bottom end is closed by a check valve), and the oil at the head end flows to the drain circuit to increase the speed of downward movement.

20-44

PROCEDURE FOR SIMPLE TEST OF STEERING BRAKE PERFORMANCE

*
Carry out the measurement under the following conditions. 0 Coolant temperature: Within operating range 0 Power train oil temperature: 70 - 90C

1. Stop the machine on a flat road surface with the blade and ripper in the travel posture. 2. Run the engine at low idling, depress the brake pedal securely, and place the gearshift lever at F2. 3. Depress the decelerator pedal and pull the fuel control lever to the FULL position. 4. Release the decelerator pedal gradually, raise the engine speed to high idling, and check that the machine does not move.

17MF02167

A
Note:

During the measurement, keep your right foot on the decelerator pedal, and if the machine starts to move, quickly depress the decelerator pedal and return the gearshift lever to neutral. If this test is carried out in Fl, an excessive load will be brought to bear on the brake. For this reason, never use Fl; always use F2.

8 z i;

20-45

PROCEDURE FOR TESTING SENSORS

1. Radiator water

level sensor

1) Stop the engine, turn the starting switch

OFF, and remove the sensor from the radiator. 2) Put the test pin of the tester in contact with the sensor connector. 3) Move the sensor float up and down, and measure the resistance between terminals 1 and 2. * Judgement
Condition Float When normal Max. 1 Q Min. 1 M 8

up

Float down

0 The relationship between the sensor and the position of the float is as follows. Float above specified level: CLOSED (ON) OPEN (OFF) Float below specified level:

1. Float 2. Switch 3. Connector

Structure of circuit

56lFO3177

2. Engine oil level sensor 1) Stop the engine, turn the starting switch OFF, and remove the sensor from the engine. 2) Connect a T-adapter to the sensor connector. 3) Move the sensor float up and down, and measure the resistance between terminal 1 and the bracket. j, Judgement
Condition Float When normal

up

I I

Max. 1 R Min. 1 M Q

Float down

The relationship between the sensor and the position of the float is as follows. Float above specified level: CLOSED (ON) OPEN (OFF) Float below specified level:

1. 2. 3. 4.

Connector Bracket Float Switch

f Down

Structure of circuit
I97FO2077

20-46

3. Engine oil pressure sensor and turn the starting switch OFF. 2) with the sensor still installed to the engine, disconnect the wiring harness from the sensor. 3) Measure the resistance between the terminal and the chassis with the engine stopped and with the engine running.

1) Stop the engine

1 \\I///

Judgement
Condition of sensor Engine stopped Engine running When normal

Min. 1 M 8 Max. 1 R

1. Plug
2. 3. 4. 5. 6.

@@ 0
Structure of circuit
I 75 202FO5

The relationship between the sensor and the oil pressure is as follows. Oil pressure above 0.7 kg/cm*: CLOSED (ON) Oil pressure below 0.7 kg/cm2: OPEN (OFF)

Contact ring contact Diaphragm Spring Terminal

4. Engine water temperature, sensor ter oil temperature

torque

conver-

1) Stop the engine, turn the starting switch OFF, and remove the sensor from the engine or torque converter. 2) Measure the resistance between terminals 1 and 2 with the sensor at about the same temperature as the ambient temperature. * Judgement
Ambient temperature 35C When normal Approx. 29 KR

I
20C I 10C

I
Approx. 52 KQ I Approx. 80 KS

1. Connector 2. Plug 3. Thermistor

I96FO2046

Structure of circuit

20-47

5. Hydraulic

oil temperature

sensor

1) Stop the engine, turn the starting switch

OFF.

2) With the sensor still installed to the piping

at the suction side of the hydraulic pump, disconnect the wiring harness from the sensor. 3) Measure the resistance between terminal 1 and the ground. * Judgement
Condition of sensor Between terminal and ground 1 When normal

Max. 1 Q

1. 2. 3. 4.

Switch Case Wire Connector

Structure of circuit

ISSFO2047

6. Fuel level sensor and turn the starting switch OFF. 2) With the sensor still installed to the fuel tank, disconnect the wiring harness from the sensor. 3) Measure the resistance between terminals 1 and 2. * Judgement
Condition of fuel Full

1) Stop the engine

I I

When normal Approx. 10 R

Empty

Approx. 85 R

F91702223

20-48

TROUBLESHOOTING

....... ......... Precautions when carrying out maintenance. ..... Handling connectors. ...................... Checks before troubleshooting. ............... Method of using matrix troubleshooting chart. .... Method of using troubleshooting charts ......... Type of connector and position of installation ..... Connector position drawing. .. _ .............. Connection table for connector ............... Electrical circuit diagrams for each system ....... Troubleshooting of engine. ..................
Point to remember when troubleshooting. Sequence of events in troubleshooting. Troubleshooting Troubleshooting Troubleshooting of hydraulic, mechanical of electrical system systems.

20- 50

........... .....

of machine monitor system.

. . ... ... ... ... ... .. ... .. ... ... ... ... . .. ... ... ... ... ... .. ... ... ... ... . ...

.. ... .. ... .. ... ... .. ... .. ... .. . .. ... .. ... .. ... ... ... ... ... ... .. ..

. . . . . . . . . .

..... .. .. ..... ..... ... ..... ....... ....... .. . ....... ....... ..... ...... .......

. . . . .

. . . . .

. ...... .... ... ........ ... ........ ........ .......

... .... . .... . . .. . . . .... . .... . ... . .... . .... . .... . .... . .... . ....

20- 51 20- 52 20- 59 20- 60 20- 62 20- 66 20- 69 20- 71 20- 72 20- 81 20- 85 20-105 20-123 20-141

20-49

POINTS TO REMEMBER WHEN TROUBLESHOOTING

0 0 0 0 0

Stop the machine in a level place; and check that the safety pin, blocks, and parking brake are securely fitted. 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. Be extremely careful not to touch any hot parts or to get caught in any rotating parts. When disconnecting wiring, always disconnect the negative (-) terminal of the battery first. When removing the plug 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 cases of the failure that would produce the reported symptoms.

1. When carrying out troubleshooting, do not hurry to disassemble the components. If components are disassembled immediately any failure occurs: 0 Parts that have no connection with the failure or other unnecessary parts will be disassembled. 0 It will become impossible to find the cause of the failure. It will also cause a waste of manhours, parts, or oil or grease, and at the same time, will also lose the confidence of the user or operator. For this reason, when carrying out troubleshooting, it is necessary to carry out thorough prior investigation and to carry out troubleshooting in accordance with the fixed procedure. 2. Points to ask user or operator 1) Have any other problems occured apart from the problem that has been reported? 2) Was there anything strange about the machine before the failure occurred? 3) Did the failure occur suddenly, or were there problems with the machine condition before this? 4) Under what conditions did the failure occur? 51 Had any repairs been carried out before the failure? When were these repairs carried out? 61 Has the same kind of failure occurred before? 3. Check before troubleshooting 1) Check for symptoms of any abnormality the machine.

2) Check the CHECKS BEFORE STARTING

items. 3) Other inspection items. 4) Other maintenance items can be checked externally, so check any item that is considered to be necessary. 4. Confirming failure 0 Confirm the extent of the failure yourself, and judge whether to handle it as a real failure or as a problem with the method of operation, etc. * When operating the machine to reenact the troubleshooting symptoms, do not carry out any investigation or measurement that may make the problem worse. 5. Troubleshooting 0 Use the results of the investigation and inspection in Items 2 - 4 to narrow down the causes of failure, then use the troubleshooting tables (matrix) to locate the position of the failure exactly. * The basic procedure for troubleshooting is as follows. 1) Start from the simple points. 2) Start from the most likely points. 3) Investigate other related parts or information. 6. Measures to remove root cause of failure. 0 Even if the failure is repaired, if the cause of the failure is not repaired, same failure will occur again. To prevent this, always investigate the problem occurred. Then, remove root cause.

f: : 6

root the why the

in

20-50

SEQUENCE OF EVENTS IN TROUBLESHOOTING

Office,shop

,= fl

Jobsite

step1
1Examination, 1) When 0 confirmation of symptoms is received, j RIngI Ring1 a request for repairs

first ask the following Name Type, Details of customer serial 0

points: of machine of the

0
2) 0 0 0 0

number

of jobsite,

etc.

Ask questions problem. Condition Work

to gain an outline of failure

being carried

out at the time

of the failure Operating etc. environment details of maintenance, Past history,

Step 2 Determining 1) probable location of cause section of the

Look at the troubleshooting shop manual causes. to find locations

of possible

step

3 Preparation 1) of troubleshooting tools tools

,m
the the

Look at the table of troubleshooting in the shop manual necessary 0 0 tools. pressure gauge parts. T-adapter Hydraulic and prepare

kit, etc.

Pinpoint

locations

of failure

(carry out

2)

Look in the parts book and prepare necessary replacement

I
2)

Before repair 0 0

starting simple

troubleshooting, failures. starting items Section

locate

and

Check before Other

check items of the and select a troubleshooting the symptoms,

See the Troubleshooting shop manual, flowchart that matches

carry out troubleshooting.

I i
I
step 4 1 Go to jobsite

Re-enacting

failure the machine if there to confirm is really a

Drive and operate the condition failure.

and judge

1 Step5 1
of failure

0
0 0

I
anything before strange about occurred? out before the failure occur suddenly? been carried

Was there the machine

Did the failure Had any repairs the failure?

20-5 1

To maintain the performance of the machine over a long period, and to prevent failures or other troubles before they occur, correct operation, maintenance and inspection, troubleshooting, and repairs must be carried out. This section deals particularly with correct repair procedures for 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 hydraulic oil).

1.

PRECAUTION WHEN ELECTRIC EQUIPMENT

HANDLING

1)

Handling wiring harnesses and connectors Wiring harnesses consist of wiring connecting one component to another component, connectors used for connecting and disconnecting one wire from another wire, and protector or tubes used for protecting the wiring. Compared with other electrical components fitted in boxes or cases, wiring harnesses are more likely to be affected by the direct effects of rain, water, heat, or vibration. Furthermore, during inspection and repair operations they are frequently removed and installed again, so they are likely to suffer deformation or damage. For this reason, it is necessary to be extremely careful when handling wiring harnesses.
F20505201

Main failures occurring in wiring harness (1) Defective contact of connectors (defective contact between male and female) Problems with defective contact are likely to occur because the male connector is not properly inserted into the female connector, or because one or both of the connectors is deformed or the position is not correctly aligned, or because there is corrosion or oxidization of the contact surfaces.

Improper

insertion

F20505202

20-52

(2) Defective

compression or soldering of connectors The pins of the male and female connectors are in contact at the compressed terminal or soldered portion, but there is excessive force on the wiring, and the plating peels to cause improper correction or breakage.

Improper

compressio

F56103079

(3) 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 compression of the connector may be lost, or the soldering may be damaged, or the wiring may be broken.

F20505204

(4) High pressure water entering connector The connector is designed to make it difficult for water to enter (drip-proof structure), but if high-pressure water is sprayed directly on the connector, water may enter the connector depending on the direction of the water jet. The connector is designed to prevent water from entering, but at the same time, if the water does enter, it is difficult for it to be drained. Therefore, if water should get into the connector, the pins will be short-circuited by the water, so if any water gets in, immediately dry the connector or take other appropriate action before passing electricity through it. (5) Oil or dirt stuck to connector If oil or grease are stuck to the connector and an oil film is formed on the mating surface between the male and female pins, the oil will not let the electricity pass, so there will be defective contact. If there is oil or grease or dirt stuck to the connector, wipe it off with a dry cloth or blow dry with air, and spray it with a contact restorer. jr When wiping the mating portion of the connector, be careful not to use excessive force or deform the pins.

&
F20505205

F20505206

20-53

If there is water or oil in the air, it will increase the contamination of the points, so clean with air from which all the water and oil has been removed.

2)

Removing, installing, and drying connectors and wiring harnesses. Disconnecting connectors (1)Hold the connectors when disconnecting. When disconnecting the connectors, hold the connectors and not the wires. For connectors held by a screw, loosen the screw fully, then hold the male and female connectors in each hand and pull apart. For connectors which have a lock stopper, press down the stopper with your thumb and pull the connectors apart.
F20505207

(2) Action to take after removing connectors After removing any connector, cover it with a vinyl bag to prevent any dust, dirt, oil, or water from getting in the connector portion.

F20505208

Connecting connectors (1) Check the connector visually. a. Check that there is no oil, dirt, or water stuck to the connector pins (mating portion). b. Check that there is no deformation, defective contact, corrosion, or damage to the connector pins. c. Check that there is no damage or breakage to the outside of the connector. Sr If there is any oil, water, or dirt stuck to the connector, wipe it off with a dry cloth. If any water has got inside the connector, warm the inside of the wiring with a dryer, but be careful not to make it too hot as this will cause short circuits. * If there is any damage or breakage, replace the connector.

20-54

(2) Fix the connector securely. Align the position of the connector correctly, then insert it securely. For connectors with lock stopper Push in the connector until the stopper clicks into position.
Cliks into position

(3) Correct any protrusion of the boot and any misalignment of the wiring harness For connectors fitted with boots, correct any protrusion or the boot. In addition, if the wiring harness is misaligned, or the clamp is out of position, adjust it to its correct position. j, When blowing with dry air, there is danger that the oil in the air may cause improper contact, so clean with air from which all the water and oil has been removed.

F20505209

Drying wiring harness If there is any oil or dirt on the wiring harness, wipe it off with a dry cloth. Avoid washing it in water or using steam. If the connector must be washed in water, do not use high pressure water or steam directly on the wiring harness. If water gets directly on the connector, do as follows. (1) Disconnect the connector and wipe off the water with a dry cloth. * If the connector is blown dry with air, there is the risk that oil in the air may cause defective contact, so avoid blowing with air.

F20505210

F20505211

(4 Dry the inside

of the

connector

witha

dryer. If water gets inside the connector, use a dryer to dry the connector. * Hot air from the dryer can be used, but be careful not to make the connector or related parts too hot, as this will cause deformation or damage to the connector.

F20505212

20-55

(3) Carry out a continuity test on the connector. After drying, leave the wiring harness disconnected and carry out a continuity test to check for any short circuits between pins caused by water. j, After completely drying the connector, blow it with contact restorer and reassemble.

T-adapter

3)

Handling control box (1) The control box contains a micro-computer and electronic control circuits. These control all of the electronic circuits on the machine, so be extremely careful when handling the control box. (2) Do not open the cover unless necessary. (3) Do not place objects box. (4) Cover the control a vinyl bag of the control box

F20505213

on top of the control

connectors

with

tape or

F20505214

(5) During rainy weather, do not leave the control box in a place where it is exposed to rain. (6) Do not place the control box on oil, water, or soil, or in any hot place, even for a short time. (Place it on a suitable dry stand) (7) Precautions when carrying out arc welding When carrying out arc welding on the body, disconnect all wiring harness connectors connected to the controlb box. Fit an arc welding ground close to the welding point.

F20505216

20-56

2.

POINTS TO REMEMBER HANDLING HYDRAULIC

WHEN EQUIPMENT

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

2)

F20505217

3)

Sealing openings After any piping or equipment is removed, the openings should be sealed with caps, tapes, or vinyl bags to prevent any dirt or dust from entering. If the opening is left open or is blocked with a rag, there is danger of dirt entering or of the surrounding area being made dirty by leaking 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.
F20505218

4)

Do not let any dirt or dust get in during refilling operations. Be careful not to let any dirt or dust get in when refilling with hydraulic oil. Always keep the oil filler and the area around it clean, and also use clean pumps and oil containers. If an oil cleaning device is used, it is possible to filter out the dirt that has collected during storage, so this is an even more effective method.

F20505219

20-57

5)

Change hydraulic oil when the temperature is high. When hydraulic oil or other oil is warm, it flows easily. In addition, the sludge can also be drained out easily from the circuit together with the oil, so it is best to change the oil when it is still warm. When changing the oil, as much as possible of the old hydraulic oil must be drained out. (Do not drain the oil from the hydraulic tank; also drain the oil from the filter and from the drain plug in the circuit.) If any old oil is left, the contaminants and sludge in it will mix with the new oil and will shorten the life of the hydraulic oil. Flushing operations After disassembling and assembling the equipment, or changing the oil, use flushing oil to remove the contaminants, sludge, and old oil from the hydraulic circuit. Normally, flushing is carried out twice: primary flushing is carried out with flushing oil, and secondary flushing is carried out with the specified hydraulic oil.

7)

Cleaning operations After repairing the hydraulic equipment (pump, control valve, etc.) or when running the machine, carry out oil cleaning to remove the sludge or contaminants in the hydraulic oil circuit. The oil cleaning equipment is used to remove the ultrafine (about 3 ,~4 particles that the filter built into the hydraulic equipment cannot remove, so it is an extremely effective device.

F20505220

F20505221

20-58

HANDLING CONNECTORS

1. When removing the connectors from the clips, pull the connector in a parallel direction to the clip. * If the connector is twisted to the left and right or up and down, the housing may break.

205FO5609

r
I-

8 6
2. When disconnecting male and female connectors, release the lock and pull in parallel with both hands. * Never try to pull out with one hand.

205FO5610

205FO5611

3. When the wiring harness clamp of the connector has been removed, always return it to its original condition and check that there is no looseness of the clamp.

205FO5612

20-59

CHECKS BEFORE TROUBLESHOOTING

T
1. Check fuel level 2. Check for dirt or water in fuel 3. Check hydraulic oil level 4. Check hydraulic oil strainer

Item

Judgement standard

Remedy Add fuel Clean, drain Add oil Clean, drain Add oil Add oil Add water Clean or replace

5. Check power train oil level 6. Check engine oil level (level of oil in oil pan) 7. Check cooling water level 8. Check condition of dust indicator

9. Check for loose or corroded

battery terminals

or wires or wires or wires

Tighten or replace Tighten or replace Tighten or replace

10. Check for loose or corroded alternator

terminals

11. Check for loose or cooroded starting motor terminals

12. Check for abnormal 13. Check for oil leakage

noise or smell

20 30 v

Repair Repair Bleed air Replace Add or replace Replace Repair Dry area around connector

14. Bleed air from system 15. Check battery voltage (engine stopped) 16. Check level of battery electrolyte 17. Check for discolored, burnt, or bare wiring 18. Check for missing wiring clamps, hanging wires 19. Checks for water leaking onto wiring (check carefully for water leakage at connectors and terminals)

20. Check for broken or corroded fuses !I. Check alternator voltage (engine running at over half throttle)

After running engine for several minutes 27.5 - 29.5 v -

Replace Replace

!2. Noise when battery relay is operated. (Turns starting switch ON - OFF)

Replace

20-60

METHOD OF USING MATRIX TROUBLESHOOTING

CHART

chart is divided into three This troubleshooting questions, check items, and troublesections: shooting. and check items are The questions causes that can used to pinpoint high probability or simple be located from the failure symptoms tools. inspection without using troubleshooting tools or direct inspection Next, troubleshooting causes to are used to check the high probability make final confirmation. [Questions] Sections $9 + @ in the chart on the right corresponds to the items where answers can be obtained from the user. The items in @ are items that can be obtained from the user, depending on the users level. [Check items] carries out simple inspection to The serviceman narrow down the causes. The items under 0 in the chart on the right correspond to this. narrows down the causes from The serviceman from the @ that he has obtained information user and the results of 0 that he has obtained from his own inspection. [Troubleshooting] is carried out in the order of Troubleshooting starting with the causes that have probability, been marked as having the highest probability gained from [Questions] and from information [Check items].

20-62

The basic method of using the troubleshooting chart is as follows. Items listed for [Questions] and [Check items] that have a relationship with the Cause items are marked with 0, and of these, causes that have a high probability are marked with 0 Check each of the [Questions] and [Check items] in turn, and marked the 0 or 0 in the chart for items where the problem appeared. The vertical column (Causes) that has the highest number of points is the most probable cause, so start troubleshooting for that item to make final confirmation of the cause. -*1. For [Confirm recent repair history] in the [Questions] Section, ask the user, and mark the Cause column with A to use as reference for _, locating the cause of the failure. However, do not use this when making calculations to narrow down the causes. *2. Use the A in the Cause column as reference for [Degree of use (Operated for long period)] in the [Questions] section as reference. As a rule, do not use it when calculating the points for locating the cause, but it can be included if necessary to determine the order for troubleshooting.

*1

Confirm Degree

recent of se

repair

history Operated for long period A A A

*2

20-63

Example of troubleshooting when exhaust gas is black Let us assume that [Clogged air cleaner] is taken to be the cause of black exhaust gas. Three symptoms have causal relationship with this problem: [Exhaust gas slowly becomes black], [Power slowly became weaker], and [Dust indicator is red]. If we look from these three symptoms to find the causes, we find that there is a relationship with five causes. Let us explain here the method of using this causal relationship to pinpoint the most probable cause. S-7 Exhaust gas is black (incomplete combustion) General causes
l l l

why exhaust gas is black Insufficient intake of air Improper condition of fuel injection Excessive injection of fuel

20-64

Five causes

Step 1

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 A A A

Steo 2
I-

Add up the total of 0 and 0 marks where the horizontal lines for the three symptoms and the vertical columns for the causes intersect. (1) Clogged air cleaner element: 000 (2) Air leakage between turbocharger and head: 00 0 (3) Clogged, seized injection nozzle: (4) Defective contact of valve, valve seat: g (5) Worn piston ring, cylinder:

Step 3 The calculations in Step 2 show that the closest relationship is with [Clogged air cleaner element]. Follow this column down to the troubleshooting area and carry out the troubleshooting item marked 0. The Remedy is given as [Clean], so carry out cleaning, and the exhaust gas color should return to normal.

20-65

METHOD OF USING TROUBLESHOOTING

1. Category of troubleshooting
code No. Power train, work equipment Electronic system Machine monitor

CHARTS

code number
Component (Hydraulic, mechanical

Troubleshooting

H-00 E-00 M-00

system)

2. Method of using troubleshooting table @ Troubleshooting code number and problem The top left of the troubleshooting chart gives the troubleshooting code number and the problem with the machine. @ Distinguishing condition Even with the same problem, the method of troubleshooting may differ according to the model, component, or problem. In such cases, the troubleshooting chart is further divided into sections marked with small letters (for example, a)), so go to the appropriate section to carry out troubleshooting. If the troubleshooting table is not divided into sections, start troubleshooting from the first check item. @ Method of followinn troubleshooting chart Check or measure the item inside the box, and according to the answer follow either the YES line or the NO line to go to the next box. (Note: The number written at the top right corner of the box is an index number; it does not indicate the order to follow.) Following the YES or NO lines according to the results of the check or measurement will lead finally to the Cause column. Check the cause and take the action given in the Remedy column on the right. Below the box there are the methods for inspection or measurement, and the judgement values. If the judgement values below the box are correct or the answer to the question inside the box is YES, follow the YES line; if the judgement value is not correct, or the answer to the question is NO, follow the NO line. Below the box is given the preparatory work needed for inspection and measurement, and the judgement values. If this preparatory work is neglected, or the method of operation or handling is mistaken, there is danger that it may cause mistaken judgement, or the equipment may be damaged. Therefore, before starting inspection or measurement, always read the instructions carefully, and start the work in order form item 1). @ General precautions When using the troubleshooting chart, precautions that apply to all items are given at the top of the page and marked with *. The precautions marked * are not given in the box, but must always be followed when carrying out the check inside the box. @ Troubleshooting tools When carrying out the troubleshooting, prepare the necessary troubleshooting tools. For details, see TOOLS FOR TESTING, ADJUSTING AND TROUBLESHOOTING. @ Installation position, pin number A diagram or chart is given for the connector type, installation position, and connector pin number connection table, so when carrying out troubleshooting, see this chart for details of the onnector pin number and location for details of the connector pin number and locations for inspection and measurement of wiring connector number 00 appearing in the troubleshooting flow chart.

8 z 6

20-66

Example 1

M-3. When starting

switch is ON (engine stopped),

CHECK items shown abnormality

al Abnormality .

in radiator water

level

Radiator water

level monitor flashes

0
Cause Remedy

YES

Defective radiator water lever sensor.

Replace

1
Does radiator

YES
_ 2 Is resistance between CN-1 (female) (5) and chassis ground less than lQ? . Disconnect CN-1.

3 YES

water level monitor

go off?

Defective monitor module.

Fii?DlPX

e 8 2 b 6

Connect short connector to CN405 (female). Turn starting switch ON.

NO

Is resistance betwee CN405 (female) (2) and chassis ground less than 1 Q?
l

NO

Defective contact, or disconnection in wiring harness between CN405 (female) (1) CN202 (11 - CN201 (1) - CNlOl (2) - CN421 (3) - CN-1 (female) (51. Defective contact or disconnection in wiring harness between CN405 (female1 (21 and chassis ground.

After inspection, repair or replace

Disconnect CN405.

NO

After inspection, repair or replace

* Before carrying out troubleshooting, check that all the related connectors are properly inserted. jr Always connect any disconnected connectors before going on the next step.

20-67

TYPE OF CONNECTOR AND POSITION OF INSTALLATION

$~I~J.~~?RESS column

in this table shows the address

in the connector

position

drawing

(3-dimensional

Connector No. CNI CN2 CN3 CN4 CN5 CNlOl CN102

Connector type AMP040 AMP040 MIC M M SWP X

No. of pins 12 8 5 2 2 14 4

Place of use

ADDRESS B6 B6 84 85 B5 G2 D7

Connector No. CN364 CN371 CN372 CN391 CN399 CN401 CN402 CN403 CN404

Connector type

No. I of pins

Place of use Intermediate connector (without cab) intermediate connector (without cab) Caution lamp, lock-up lamp (without cab) Int;;yaiate connector

ADD.

I RESI
D7 C6 A7 18 G9 G2 E7 G2

Monitor panel Monitor panel Monitor panel Monitor panel Monitor panel Intermediate connector

Caution lamp, lock-up lamp (with cab) Intermediate connector

APS nozzle, glow plug

Engine water temperature sensor Engine oil pressure sensor 1 X ( 1

CN422 CN423

X X

2 2

Intermediate Fuel sensor

connector

I8 H9

CN151 CN153 CN161 CNI 62 CN201 CN202

X SWP SWP X X X

3 6 6 3 4 4

Neutral safety switch Intermediate connector

I8 H3 B8 c7 Dl Dl CN464 CN465 CN466 CN622 X Connector Connector SWP 4 1 1 8 Auxiliary controller Caution buzzer Caution buzzer Lock-up controller C6 D8 D7 I4

Starting switch Auxiliary controller Intermediate Intermediate connector connector

CN653 CNSOl CN224 CN241 CN242 X X M 2 3 1 Pin-puller solenoid Intermediate connector J7 F8 E7 CNSOZ CNS03 CNS04 CNSOS Riooer UP switch Ripper tilt switch

Working lamp (right)

CN361 CN362

SWP SWP

14 8

Intermediate Intermediate

connector connector

J4 J4 CNSIO CNSl2 SWP X 14 2 Intermediate connector H2 Hg

Transmission FORWARD oil pressure switch

20-69

Place of use

ADD-

I RESS I I
~8 F8 G8

Connector No.

Place of use

I I
ADDRESS

1 CNSMI CNSM2 CNSMB I CNSM4 CNSM5 CNSSI CNSS2 1 CNSSB

MIC X X

1 21 1 ELPCvalve
3 2 1 3 2 13 17 4

controller

Feedback potentiometer Solenoid I Throttle potentiometer Engine speed sensor SSC controller SSC controller

X X MIC MIC

~8 E7 D8 D7

1 Acceleration

sensor

F8

20-70

CONNECTOR POSITION DRAWING

CN653 CN452 CN263 /
AA / /

CN423

CNSOS

ZY
CNl

CN399 I

-I

CNS12

CN422 crJ3g1 -_.___

CFj251 \ CN622 N451

CN62 , / Cd404c103
17MF02166

:~!:~:~:i:!:i:i~:i~~.~~~

.................... ~ ............................................................i:i:#:~:i:i:~:i::::::::::::::~~:::~:~::: p:.:.:.:+:.:.:.:.:.:.:.:.:C~-- . ............... ....................................... :y::::::::::::::::::::::::::::::::::::::: :~::~::::i::::::::::::::~,~~:~.:.:.:.: .......................................... D B ..........................................

c ... : : : : ...........................
............................................

~G:~~l ................ ::::::::::::::::::::::::::::::::::::::::::: ....................... ........................ .A.

~.:.:.:.:.:.:.:.:.:.:.:.:.:.:.:.:.:::::::::::jljjii .:.:.:.:.:.:.:.:.:.:.:.:.:.:.:.:.:.: ................................................. ........................................... J :.:.:.:.:.:.:.:.:.:.:.:.:.:.:.:.:.:.:.:.:+:,

20-71

CONNECTION TABLE FOR CONNECTOR

NO. Oi Pins

b
Male connector

X TYPE CONNECTOR Female connector

205FO5309

205FO5310

205FO5311

205FO5312

/
2
205FO5313 205FO5314

4
205FO5315

2
205FO5316

20-72

No. o f Pins

M TYPE CONNECTOR Male connector Female connector

205FO5317

205FO5318

205FO5319

205FO5320

205FO5322

4 El

205FO5323

205FO5324

20-73

No. of Pin

M TYPE CONNECTOR Male connector 1 4 Female connector 4 1

/
3

\
6
205FO5325 205FO5326

20-74

No. c,f
Pins

T
-

AMP040 Male connector

TYPE

CONNECTOR Female connector

8 \

5 1 5
F56103083

1
F56103084

12

12

7
F561 03085

i
F56103086

8 /

16

16

16

\\ 9
205FO5335 205FO5336

20-75

No. c Pins

S TYPE CONNECTOR Male connector Female connector

a
205FO5327 205FO5328

10

205FO5329

205FO5330

12

1
205FO5331

li

s
205FO5332

16

16

1
205FO5333

16

7
205FO5334

20-76

No. c Pins

SWP TYPE CONNECT& Male connector Female connector

H
I I

205FO5339

205FO5340

5 \

1
I

8
205FO5341 205FO5342

14

11

11

14

lb

i4
F56103087 F56103088

20-77

No. of Pins

MIC CONNECTOR Male connector Female connector

142F411

142F410

13

142F413

142F412

17

F7
I

142F415

142F414

11

12
21

21

142F417

142F416

20-78

Total Pins

CONNECTOR Male (mating portion protrudes) Female (mating portion is inset)

195FO5128

195FO5129

20-79

ELECTRICAL CIRCUIT DIAGRAMS

MACHINE MONITOR (except preheating,

FOR EACH SYSTEM

APS system)

Torque converter oil temperature sensor

Hydraulic temneratur esensor

oil Fuel level

Radiator water temperature sens or

Engine Pressure sensor

oil Engine level oil sensor

Starting Radiator water level sensor Alternator

Starting motor

Starting jVb_pnerators cab is installed Central ______ warnina lamp

warnine

lamp

Buzzer

sianal

_ hi---

Monitor

Panel

12\

+l( __

Monitor _____-__-__-__------ module Lighting signal [GND

) _. ._

ill

I I

I I I I I
I I I !/OS\

Power source (+I GND Stating signal Charge amount R Radiator water level Engine oil level Engine oil pressure Hydraulic oil temperature

-I I
Enain water tennerature Torque converter oil temperature Fuel level Preheating selector GND ,., -.-I-__ warnns lamp Buzzer ____________________I En-b a E

CN121

Lock-us

Relay

box

gi

,o 0

3
0

Serviice ___________-__-__-__ meter Lighting signal GND

Battery

relax j -a T;/ 1 cnarae amount x

BR a

0 0 0

40 3 20

I I

04

10

05 I

GND

'""P~S'_arY~_Y!~~____________________;

TDD00706

20-8 1 0

APS SYSTEM
Serial No . : 10001 - 10167

APS controller
r-------7

APS fuse No. 16

53

Monitor module

D9

0.5

:t

I I

I
I

1.25

Panel switch
0.75

IC

pwJerrorce

0.75

I I
Panel switch GND

I I I

Ii

II
0.5 APS relay

II04

I
1Kn l*,I

u
n APS pilot Starting switch R2 OH 013 ,012 01

0.5

II i-l

II 1

I OIC II09

17MF03001

20-82 @

Serial No. : 10168 and up

Start ins motor Safety L switch

Nozze

zzzl
Nl03

N151

?elav box -_-_-__.______________-_-_-______.-.-_-_

-_-_-_-_-------.-_
relay _

APS water sensor

Safety

_-_-__ __ r--- ^^.1 ,^5 i .

Fuse

11

IUH

c
I

CN451

ZUA

j CNl21

I
I

I
I

I
I

I
I

lb8 Ilndl lbiilliiall

II

r r__________.-_-_-_-_-_I

__________________~_onit_arm_odul

1
I

44

I I

LZ
0 -I .-

/
I

Grow

016 017 018 ..I9

1 0151
014 1 1 I I 2u

mo

CN4

CNl

a
I

CN2

J2

I CN361

Panel

switch

Starter

snitch

APS LLl Relay

oilnt

L___-_______.__L__1
APS controller

77

7TDD00709

20-82-l @

PANEL SWITCH SYSTEM

(except APS system)

Right working . -_ z c

lamp CN2.22 >sl

Left working

lamp

Right rear lamp

Right - 7

lamp

Left rear lamp

Left lamp -_ 2

Relay box la Workina

Panel switch To monitor power panel CNl 352 source wq------]

Head

lamp mitcb

:-I

Auxiliary (monitor

controller power source)

ttuo

17MF02173

20-83

RELAY BOX ELECTRICAL CIRCUIT DIAGRAM Serial No.

: 10001 - 10127

CN 362
12345678

CN361

il

II

Ill

CNl21

197FO2085-1

20-84 8

017M02

0. 75 I. 25

IIIIIIIIIIIIIII

Workino

IamP

0.5r-

l._-

I I

III1

1.25 ,_____ __.

25Service

lamPI

12. 0 0. 75 I. 25
I I I

Preheating

1-_--l

I
I
I

I I
I

III

017M02

TROUBLESHOOTING

OF ENGINE

s-

s- 2 s- 3 s- 4 s- 5 S- 6 s- 7 S- 8 s- 9 S-IO S-l 1 S-l 2 s-13 s-14 s-15 S-16

Starting performance is poor. ..................................................... Engine does not start ........................................................... Engine does not pick up smoothly .................................................. Engine stops during operations .................................................... Engine does not rotate smoothly ................................................... Engine lacks output ............................................................ Exhaust smoke is black. ......................................................... Oil consumption is excessive. ..................................................... Oil becomes contaminated quickly. ................................................. Fuel consumption is excessive. .................................................... Oil is in cooling water, or water spurts back, or water level goes down Oil pressure lamp lights up .......................................................

20- 86 20- 87 20- 90 20- 91 20- 92 20- 93 20- 94 20- 95 20- 96 20- 97

........................

20- 98 20- 99 20-100 20-101 20-102 20-l 03

................................................................ Water temperature becomes too high. ............................................... Abnormal noise is made. ........................................................ Vibration is excessive ...........................................................
Oil level rises.

20-85

S-l

Starting performance is poor (Starting always takes time)

General causes why starting performance is poor. 0 Insufficient supply of fuel 0 Insufficient intake of air 0 Improper selection of fuel (particularly in winter) (At ambient temperature of -10 C or below, use ASTEM D975 No. 1) 0 Defective electrical system j, Battery charging rate

7g time

newow3 I 2
Indicator lamp does not light UP

QQ

00 Q

000 Q I I I I I I @

ven when iniection

pump

When compression

pressure is measured,

it is found to be low

I l 1l I
1

When air cleaner element to be clogged

is inspected directly, it is found

When fuel filter, <trainer are inspected directly, there are found to be clogged When feed pump strainer is inspected directly, it is found to be clogged APS combustion portion does not become warm B Yes NO

0 a

.z
8 f $ 2

ml

Voltage is 26 - 30V between alternator terminal and terminal E with engine at low idling Either specific graviol of electrolyte is low

0
0 0

or voltage of battery

Speed of some cvlinders does not chanae when owratina on reduced cylin&rs

When check is made using delivery method, injection timing is found to be incorrect When control rack is pushed. it is found to be heaw or does not return (when blinb plug at rear of pump is remdved, it can be seen that plunaer control sleeve does not move1 When fuel cap is inspected directly, it is found to be clogged Overflow valve is stiff, remains open

I I I I I I I.1

When engine oil is inspected directly, it is found to have high

20-86

S-2 0

Engine does not start.

Engine does not turn

General causes why engine does not turn 0 * Internal parts of engine seized If internal parts of the engine are seized, carry out troubleshooting for Engine stops during operations. Failure in power train Defective electrical system

0 0

When starting switch is turned START, pinion moves out, but

When starting switch is turned to START, pinion does not

Specific gravity of electrolyte,

voltage of battery is low -0 ox ,p 8$ -eZ6W 4 .; g; zt : u-

P G 8 5 4 a c

For the following conditions 1) - 4). turn the starting switch OFF, wnnect the cord, and carry out troubleshooting at ON 1) When the terminal B and terminal C of starting switch are connected, engine starts 2) When terminal B and terminal C of starting motor are connected, engine starts 3) When terminal B and terminal are connected, engine starts C of safety relay

4) When terminal of safety switch and terminal B of starting motor are connected, engine does not start When ring gear is inspected directly, tooth surface is found to be chipped

20-87

Engine turns but no exhaust smoke comes out. (Fuel is not being injected)

General causes why engine turns but no exhaust smoke comes out.
l

0 0

Supply of fuel impossible Supply of fuel is extremely small Improper selection of fuel (particularly in winter)

When fuel filter is drained, fuel does not come out When engine is cranked with starting motor, 1) No fuel comes out even when fuel filter air bleed plug is loosened 2) No fuel spurts out even when injection pipe sleeve nut is loosened

E .E % 2

00

C3

@@,Q hh

Rust and water are found when fuel tank is drained

20-88

Exhaust smoke comes out but engine does not start (Fuel is being injected)

General causes why exhaust smoke comes out but engine does not start 0 0 0 0 Lack of rotating force due to defective electrical system Insufficient supply of fuel Insufficient intake of air Improper selection of fuel (particularly in winter)
1 1 Confirm recent reoair historv Degree of use of machine

Operated

for long period @@ heard from @

e .g : z

Engine oil must be added more frequently

to Operation

Manual

.E
% e 0

When engine is cranked with starting motor, 1) Little fuel comes out even when injection pump sleeve nut is loosened 2) Little fuel comes out even when fuel filter air bleed plug is loosened There is leakage from fuel piping When exhaust manifold is touched immediately engine, temperature of some cvlinders is low after starting

0
@@ @ @ @

When

furl fil+rr is drsinrd

no fwd comes c-m+

I I

I 1

I I

I I

I 1

1-1

Ihl

I
Q

When fuel control lever is moved, injection pump lever does not move

When head cover is removed and inspection is made directly, it is found to be abnormal en control rack is pushed, it is found to be heavy, or does

I I I I I I T-I

xa

YE

When nozzle holder is inspected directly, it is found to be clogged When fuel cap is inspected directly, it is found to be cloaqed Play, stiffness in fuel control linkage When engine oil is inspected directly, it is found to have high

T
20-89

S-3

Engine does not pick up smoothly (Follow-up is poor)

causes why engine does not pick up smoothly

General
l

0 0 0 0

Insufficient intake of air Insufficient supply of fuel Improper condition of fuel injection Improper fuel used Defective injection pump

I.1 I I I I I I I I I

6 <

When compression When turbocharger

pressure is measured,

it is found to be low

is rotated by hand, it is found to be heavy is checked directly, it is found to be outside

When valve clearance standard value

When fuel cap is inspected directly, it is found to be clogged

20-90

S-4

Engine stops during operations

General causes why engine stops during operations 0 0 0 Seized parts inside engine Insufficient supply of fuel Overheating * If there is overheating and insufficient output, carry out troubleshooting for overheating Failure in power train * If the engine stops because of a failure in the power train, carry out troubleshooting for the chassis.

Condition when

Try to turn by hand using barring tool

20-91

S-5

Engine does not rotate smoothly

(hunting)

General causes why engine does not rotate smoothly 0 0 Air in fuel system Defective governor mechanism

Condition of hunting

20-92

S-6

Engine lacks output

(no power)
if the

Measure problem General 0 0 0 0 0 *

the speed of the engine to determine is in the engine or the chassis. causes why engine lacks output

insufficient intake of air Insufficient supply of fuel Improper condition of fuel injection Improper fuel used fuel is used, output drops) (if non-specified Lack of output due to overheating and insufficient output If there is overheating for overheating. carry out troubleshooting

No pulse in injection pipe (all or part) (weak)

strainer is inspected directly, it is found When feed pump to be clogged Speed of some cylinders does not change when operating reduced cylinders on

20-93

S-7

Exhaust smoke is black (incomplete

combustion)

General causes why exhaust smoke is black 0

l l

Insufficient intake of air Improper condition of fuel injection Excessive injection of fuel

of Color exhaust gas

IC3l

harger is rotated by hand, it is found to be heavy

20-94

S-8 j,

Oil consumption

is excessive

(or exhaust

smoke is blue)

To prevent the oil from leaking up or down, do not run the engine at idling for more than 20 minutes continuously. (Both low and high idling) causes why oil consumption is excessive

General . . .

of oil Abnormal combustion External leakage of oil of lubrication system ear W

When intake manifold is removed, dust is found inside When head cover is removed, dirty inside is found to be abnormally

20-95

S-9

Oil becomes contaminated

causes why oil becomes

quickly
quickly

General . . . . . .

contaminated wear

Intake of exhaust gas due to internal passage Clogging of lubrication Improper combustion Improper oil used Operation under excessive load Oil change interval too long

Abnormally

excessive

63

loI

lolol

I >

Oil filter caution lamp stays on even when oil pressure rises When oil filter is inspected, metal particles are found

Engine oil temperature

rises quickly

Oil is above H level on oil level gauge

20-96

S-l 0
General

Fuel consumption

is excessive
is excessive

causes why fuel consumption

.
. 0

Leakage of fuel Improper condition Excessive injection

of fuel injection of fuel

Condition of fuel consumption

20-97

S-l 1 Oil is in cooling water, or water spurts back, or water level goes down
General causes why oil is in cooling leakage leakage water

.
.

Internal Internal

in lubrication system in cooling system

: u

Excessive air bubbles inside radiator, spurts back Power train oil is cloudy white

I@,(@,(
0

Pressure-tightness

test of oil cooler shows there is leakage

I.1

I.1

20-98

S-12
General 0 . .
l

Oil pressure lamp lights up (drop in oil pressure)

causes why oil pressure lamp lights up system

Leakage, clogging, wear of lubricating Defective oil pressure control Deterioration of oil due to overheating Improper oil used (improper viscosity)

Standards

for engine

oil selection

8
H
I-

Condition when oil pressure

When oil filter is inspected directly, it is found to be clogged E? G 8 5 P When oil pan is removed and inspection is made directly, it is found to be abnormal Oil pump rotation is heavy, there is play There is catching of relief valve or regulator valve, spring or valve guide is broken When oil level sensor is replaced, oil pressure sensor lamp goes Ot ) Wlyn oil pressure is measured, it is found to be within standard/

00 0.0 0 08

0 0 .; 8 2 : j

4
e I-

I I I I I I I I I I 1-l;

20-99

S-13
jr

Oil level rises

carry out water.

If there is oil in the cooling water, troubleshooting for Oil is in cooling causes why oil level rises

General
0

. .

Water in oil (cloudy white) Fuel in oil (diluted, and smells of diesel fuel) Entry of oil from other component

Exhaust smoke is white When enaine is first started, draw of water come from muffler

Leave radiator cap open. When engine is run at idling, an abnormal numbe of bubbles arxxar. or water swrts back Water pump breather hole is clogged with mud When water DU~D breather hole is cleaned. water comet out Oil level goes down in damper chamber Enaine oil smells of diesel fuel

1 I
i

20-100

S-l 4 Water temperature

becomes too high (overheating)

becomes too high of

General causes why water temperature

l

0
l

0 *

Lack of cooling air (deformation, damage fan) Drop in heat dissipation efficiency Defective cooling circulation system Rise in oil temperature of power train Carry out troubleshooting for chassis.

Water temperature

gauge

S-l 5 Abnormal
j,

noise is made
noise or an external noise.

Judge if the noise is an internal causes why abnormal

General

noise is made

.
. .

Abnormality due to defective parts Abnormal combustion noise Air sucked in from intake system

Confirm recent repair history

When compression When turbocharger

pressure is measured,

it is found to be low

1s rotated by hand, it is found to be heavy

4 I
0

I
0

I
0

When gear cover is removed and inspected directly, it is found to be abnormal Speed of some cylinders does not change when operating reduced cvlinders on

.& 8

f ;

When control rack is pushed, it is found to be heavy, or does not return Injection pump test shows that injection amount is incorrect

20-l 02

S-l 6 Vibration
*

is excessive
with the for Ab-

If there is abnormal noise together vibration, carry out troubleshooting normal noise is made. causes why vibration parts (abnormal alignment combustion is excessive wear,

General

.
l l

Defective Improper Abnormal

breakage)

Condition of vibration

20-l 03

TROUBLESHOOTING OF HYDRAULIC, MECHANICAL SYSTEM

Table of failure modes and causes. ........................... H- 1 Brakes do not work. ................................. H- 2 Machine does not turn ............................... H- 3 There is travel deviation .............................. H- 4 Machine turns only in one direction ...................... H- 5 Time lag is excessive ................................ H- 6 Machine travels only in one direction ..................... H- 7 Machine does not move .............................. H- 8 Machine does not move in any speed range ................ H- 9 Torque converter oil temperature is high .................. H-l 0 Abnormal noise from around hydraulic pump ............... H-II Blade RAISE speed slow or work equipment lacks power. H-l 2 Ripper lift speed slow, or lacks power. .................... H-13 H-14 H-l 5 H-16 Excessive hydraulic drift of blade. ....................... Excessive hydraulic drift of ripper ....................... Torque converter lock-up does not work. .................. Pin-puller cylinder does not work. .......................

......

........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........

........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........

........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........ ........

20-I 20-l 20-I 20-I 20-I 20-l 20-I 20-I 20-I 20-I 20-I 20-I

06 07 08 09 10 11 11 12 14 16 18 18

20-I 20 20-I 21 20-121 20-I 22 20-I 22

8 E 6

20-l 05

TABLE OF FAILURE MODES AND CAUSES (ELECTRIC, HYDRAULIC, MECHANICAL SYSTEMS)

Torque

converter

Work

equipment

3 4 5 6 7 8 9 IO 1 2 3 4 5 6 7. 8 9 !O !I 12 13

There

is travel

deviation. (lever operated).

00 00

000 0 0

H- 3 H- 4 H- 5 H- 6 H- 7 H- 8 H- 9 H-10 H-l 1 H-l 2 H-13 H-14 H-l 5 H-l 6 -

Machine Time

turns only in one direction

lag is excessive travels only in one direction (forward or in reverse)

00 0

0 0
00000 00000

0 -

Machine Machine Machine Torque

does not move.

(2nd, 3rd. engine range.

running)

00000 00000

does not move in any speed converter oil temperature around

is high. pump.

0000
00 0 000

00000000
0

Abnormal

noise from

hydraulic

Blade RAISE speed Ripper lift speed

slow or lacks power.

0 0000

slow. drift of blade drift of ripper lock-up lock-up lock-up does not work. display is abnormal. 00000 00

0
00

Excessive Excessive Torque Torque Torque

hydraulic hydraulic

0 0 0 0

00 0 0

E-S1 E-S2 E-S3

converter converter converter cylinder

fuse 8 is blown.

0
00 0 0000 0

Pin-puller Preheating Actuation When When

does not work.

E-l E-2 E-3

fuse 11 blows. of APS is defective. are turned are turned ON, lamps do not light up. OFF, lamps do not go out.

0 0 0 0
000

light switches light switches

0 0 0

00 00

E-4 E-5 E-6

Panel switch does not work power source)

(abnormality

in panel switch

20-106

H-l

Brakes do not work.

* Check the power train oil level before starting troubleshoooting.

See Note 1. NO
Is oil pressure in brake, clutch circuit normal? -

Defective seal of clutch piston

ReplaCe

YES
-

3
* See Table 1. When brake linkage is adjusted, does condition become normal?

Does brake valve spool nlOz? smoothly? Defective actuation of spool Repair or replace

NO
-

_ NO

See TESTING AND ADJUSTING.

I NO

Defective adjustment linkage

of

Adjua

z 0

Note 1: Depress the brake pedal fully, place the transmission in IV, and pull the steering lever on one side
fully. When the engine speed is raised gradually from deceleration machine must not move. Table 1
1 Conditions Oil pressure (left and right)

slow (stall) to high idling, the

Engine speed: Brake pedal not depressed

Brake pedal depressed

20-107

H-2

Machine

does not turn. (Machine

can travel only in a straight

line.)

* Check the power train oil level before starting troubleshoooting.

Cause

Remedy

ES

See

H-l

Is clutch disengaged?

YES

Seized clutch disc, plate 4 YES

Replace

*See Notes

1 and 2.

IT

Defective seal of clutch piston

ReplaCe

See Table 1. I NO L *See TESTING AND ADJUSTING. When steering linkage is adjusted, does condition become normal?

Oil pressure (kg/cm*) Brake 273~2 (left and right) 25 k 2 (left and right) Right: 27 + 2 Left: 0 Right: 25 f 2 Left: 0 Right: 0 Left: 27+ Right: 0 Left: 255 2 2 Clutch

Defective actuation of spool

Repair or replace

Defective adjustment of linkage

Adjust

Note 1: Raise the chassis with the blade and ripper, run the engine at low idling, and place the transmission in F3 (R3). When the steering lever on one side is pulled, the track must stop. Note 2: Travel in Fl (RI) with the engine at low idling. When the steering lever on one side is pulled slowly, the machine must stop or must turn slowly. Table 1

8 2 b 6

Conditions

Engine speed: Steering lever not operated

High iding Low idling

0 (left and right) 0 (left and right) Right: 0 Left: 27f Right: 0 Left: 25f2 Right: 27 f 2 Left: 0 Right: 25 k 2 Left: 0 2

Engine speed: Left lever Steering lever operated Right lever

High idling Low idling

Engine speed:

High idling Low idling

20-l

08

H-3

There is travel deviation.

Cause

Remedy

1 YES
See H-l. clutch disengaged?

Is

See Notes 1 and 2.

NO

See H-2.

SI H b 6

Note 1: Raise the chassis with the blade and ripper, run the engine at low idling, and place the transmission in F3 (R3). When the steering lever on one side is pulled, the track must stop. Note 2: Travel in Fl (RI) with the engine at low idling. When the steering lever on one side is pulled slowly, the machine must stop or must turn slowly.

20-109

H-4

Machine

turns only in one direction

(lever operated).

Cause

Remedy

YES 2

Worn brake disc, plate, scuffing

Repair

YES
-

Is clutch, brake
pressure normal? -

3 YES

Defective seal of clutch chamber

Repair or replace

l_ Is adjustment of steering linkage normal? _ Defective actuation of spool Repair or replace . Defective linkage Adjust

* See Table 1. NO

Does valve spool

move smoothly?

NO
* See TESTING AND ADJUSTING.

Table 1:
Oil pressure (kg/cm?) Conditions Clutch Engine speed: Steering lever not operated Brake 27 + 2 (left and right) 25 f 2 (left and right) Right: 27 k 2 Left: 0 Right: 25 f 2 Left: 0 Right: 0 Left: 27+2 Right: 0 Left: 25* 2

High iding Low idling

(left ant right) 0 (left and right) Right: 0 Left: 27+ Right: 0 Left: 25*2 Right: 27 f 2 Left: 0 . Right: 25 ? 2 Left: 0 2

Engine speed: Left lever Steering lever operated Right lever

High idling Low idling

Engine speed:

High idling Low idling

20-110

H-5

Time lag is excessive.

Remedy

YES

Defective transmission valve Defective actuation of spool

Repair or replace

4 YES Is free length of main relief valve spring normal? Does valve spool move smoothly?
. Free length of spring: 120.3 mm

Defective hydraulic pump

Replace

YES
-

IS adjustment of gear shift lever linkage normal? * See TESTING

Engine speed: High idling Oil pressure: 27 !c 2 kg/cm?

NO

NO

Defective spring, clogged with dirt

Replace or clean

Is brake free from dragging?

AND ADJUSTING.

NO

Defective adjustment linkage

of

See Note 1.

NO

See H-l.

Note 1: When the chassis is raised with blade and ripper, the track should move with the engine at low idling and the transmission in F3 (R3).

H-6

Machine

travels only in one direction

(forward or in reverse).

* Conditions: Oil pressure is normal (27 + 2 kg/cm2)

Cause

Remedy

1 YES

Defect inside transmission, or defective valve

Repair or replace

Is adjustment of war shift linkaae

L Defective adjustment linkage of

Adjust

See TESTING AND ADJUSTING.

NO

20-111

H-7

Machine

does not move. (2nd, 3rd engine is running)

* Check the power train oil level before starting troubleshoooting.

YES 5 YES _
4
l

Is modulating
pressure normal?

YES _

Is main relief pressure normal?

Engine speed: High idling Oil pressure: 27 + 2 kg/cm?

NO

IES

Is brake free of dragging when traveling in Fl (Rl)?

. l

Engine speed: High idling Oil pressure: 27 rt 2 kg/cm2

8
El-

YES

N0
Does gear shift lever

YES
-

enter position normally? Is adjustment of linkL

z 6
spring: 120.3 mm

* Free length of

NO

age normal? * See TESTING R

AND ADJUSTING.

Is parking brake released?

Table 1

Engine speed: Steering lever not operated

Engine speed: Left lever Steering lever operated Right lever

High idling Low idling

Right: 0 Left: 27f2 Right: 0 Left: 25+2 Right: 27 5 2 Left: 0 Right: 25 f 2 Left: 0

Right: 27 f 2 Left: 0 Right: 25 + 2 Left: 0 Right: 0 Left: 27f2 Right: 0 Left: 2522

Engine speed:

High idling Low idling

20-112

Cause

Remedy

7 YES
Repair or replace

YES

-(l.....::.rr:HDefective steering clutch (See H-2)

Is oil pressure at
torque converter outlet normal?

* See Table 1.

NO

Engine speed: High idling 011 pressure: 5 - 7 kg/cm2

L
NO

Defect inside torque cOnerter

Repair or replace

Repair or replace

Defective pump

R62pl.Xe

Defective spring, spool scuffing, clogged with dirt

Replace or repair, Clean

Brake dragging

(See H-l)

Defective adjustment linkage

of

4djust

Defective adjustment linkage

of

4djust

20-113

H-8

Machine

does not move in any speed range.

Sr Check the power train oil level before starting troubleshoooting.

YES

YE S
pressure normal?

3
. pressure normal? . Engine speed: High idling Oil pressure: 27 + 2 kg/cm2

Is free length of main relief valve spring normal? Does valve spool move smoothly?
l

Free length of spring: 120.3 mm

NO

Table 1

I
Conditions

Oil pressure (left and right) (kg/cm*) Clutch Brake 27 f 2 25+_2

Engine speed: Brake pedal not depressed

High idling Low idling

0 0

Brake pedal depressed

20-l 14

Cause ES 6

Remedy

Defect inside steering clutch

Replace

YES _ 5

Is steering clutch
pressure normal?

. Replace

* See Table 2.
Is oil pressure at torque converter outlet port normal? [\

Defective steering clutch SeaI

Engine speed: High idling ^.. II pressure: 27 * 2 kg/cm2

See TESTING AND ADJUSTING.

NO

Defective adjustment linkage

of

Adjust

I NO

Defect inside torque converter

Repair or replace

Defective transmission

valve

Repair or replace

Defective pump

Replace

Defective spring, spool scuffing, clogged with dirt

Replace or repair, clean

Defective adjustment linkage

of

Adjust

Defective

brake (See H-l)

Table 2
Oil pressure Conditions Clutch Brake (kg/cm2)

Engine speed: Steering operated lever not

High iding

(left and right)

(left%:

fight)

Steering lever operated Rigt

tnglne

speea:

I-llC

20-115

H-9 *

Torque

converter

oil temperature

is high.

Check the power train oil level before starting troubleshooting.

YES

YES -

IS engine speed at F3 stall normal?

Engine speed: 1580 * 50 rpm

NO

YES 2 YES _ 1 IStOrqe C0WtW

oil temperature SOT normal? sen_

IS main relief
pressure normal? -

8 YES
Is free length of main relief valve spring normal? goes valve spool move smoothly?
l

NO
l

Is brake free from dragging?

Remove oil pressure sensor. Check resistance V&E.

Free length of spring: 120.3 mm

NO

See Note 1.

Note 1: When the chassis is raised with blade and ripper, the track should move with the engine at low idling and the transmission in F3 (R3).

20-l

16

Cause

Remedy

Defective cooling system (see Engine Volume)

7 YES
YES _ 6 Does transmission output shaft stop with operation in Item 4? * Remove the case at the rear of the transfer to check.

Transmission clutch slipping l Increase in engine output

ReplaCe

Adjust

Steering clutch slipping

R&W?

YES 5

IS pressure at torque
converter inlet/outlet port normal?

NO

rl 1 _ -

Does machine stop with operation in Item 4?

=__:__ ____, 1 L,,!j,,lc: >prru. NO High idling Torque converter Inlet port: 7 - 10 kg/cm2 Outlet port: 5 - 7 kg/cm

1 Defect inside torque

COWtW

Repair or replace

NO

- Brake disc slipping

Defective pump l Air leaking in through joint in suction circuit

Repair or replace

R@Xe

Tighten

Defective spring, spool scuffing, clogged with dirt Defective oil temperature sensor

Replace or repair, clean

%DlWX

11

Brake dragging

(See H-l)

20-117

H-10

Abnormal

noise from around hydraulic

pump.

* Check the hydraulic oil level before starting troubleshooting.

YES 2 i Is air being sucked into hydraulic pump suction circuit? YES
-

NO

Is strainer clogged?

4 YES

NO

When hydraulic oil is strained, are metal wear particles found?

NO

H-11

Blade RAISE speed slow or work equipment

lacks power.

A Check the hydraulic oil level before starting troubleshooting. Note: Check for any modification of the blade.
YES I 4 YES
-

Is hydraulic drift normal when lever is at HOLD?

P YES
Is pump discharge pressure normal?

3-p

.
l

Engine stopped Hydraulic drift of hl.adC=. 200mml15 min

NO

_.___.

2
l

6 YES
Engine speed: High idling Oil pressure: 210 To kg/c? NF
L

YES
-

Does cylinder extend and contract smoothly?

When relief valve is adjusted, does pump discharge pressure return to normal? .
l

Is adjustment of blade control linkage

Engine speed: High idling Oil pressure: 210 7, kg/cm2

H
I 1

NO

. = See TESTING AND ADJUSTING.

Pressure adjustment for 1 turn: 24.8 kg/cm2

NO

20-118

Cause
Defecrive seal l Lowe piping clamp . Damaged O-ring

Remedy

Tighten

Clogged strainer

Defective pump

RePlaCe

Operate for a short time and look for any change in the condition Improper oil

Inspect again (according to change in condition)

AL?PlWt?

Cause

Remedy

Defective actuation of valve . Defective actuation of unload valve l Defective actuation of check valve

Replace

parts

5 YES

When cylinder head circuit is blocked, does amont O+ hydraulic drift return to normal?

Excessive leakage inside valve l Leakage inside lift valve

Replace

I
Excessive leakage inside cylinder l Defective piston seal
ReplaCe

NO

Defective

relief valve

Clean or replace

Defective

pump

Replace

Air in circuit

Bleed air

Defective linkage

Adjust

20-l 19

H-12

Ripper lift speed slow, or lacks power.

Sr Check the hydraulic oil level before starting troubleshooting.

-)r If the relief pressure is not normal, go to failure mode H-II
lief pressure.

(blade RAISE speed slow) and adjust the re-

Cause Defective main spool of Hi valve (including shuttle valve)

Remedy

YES 3 YES Is hydraulic drift of ripper lift cylinder normal?

l

?eplace

h
5 YES

4 YES

Defective fixed differential valve of Hi valve

?ep1ace

. YE3 Is ripper tilt speed normal?

Engine stopped Hydraulic drift:

Defective cylinder piston seal NO I

Rt?plXX

1 adjustment of ripper control linkage

Is

Tilt FULL: 4.5 - 5.5 sec. SLOW: 12 - 18 sec. Tilt back FULL: 3 - 4 set SLOW: 8-lzSeCN

Defective shuttle valve 6 YES

R&W2

Is blade lift cylinder speed normal? Is Lo valve pilot pressure normal?

Defective Lo valve pilot circuit

Repair

* See TESTING AND ADJUSTING.

Blade speed RAISE: FULL (3 - 5 set) SLOW (8 - 13 LOWER: FULL (1 - 1.5 set) SLOW (1 - 1.5 set)

Engine speed: High idling Oil pressure: 210 r:, kg/cm2

NO

Carry out troubleshooting of Items 3 and 6 of H-l 1

Defective linkage

4djust

20-120

H-13

Excessive hydraulic drift of blade

Cause

Remedy

1 YES
When hose at cylinder _ end is blocked, does hydraulic drift return to normal?
l l

Excessive leakage inside valve Leakage inside blade lift

VdW

Replace

Engine stopped. Hydraulic drift: Max. 200 mm/15

NO
min

Excessive leakage inside cylinder . Defective piston seal

Replace

H-14

Excessive hydraulic drift of ripper

I
2 YES

Cause

Remedy

I
YES
_

When oil line between npper LO valve and ripper Hi valve is blocked, does hydralit drift return to normal? . Hydraulic drift: Max. 80 mm/15

..I

Defective

ripper Lo valve

Replace

1 Nhen hose at cylinder _ ?nd is blocked, does lydraulic drift return 0 normal?

Defective

ripper Hi valve

Replace

NO
min

1 Engine stopped. ) Hydraulic drift:

Max. 80 mm115 min P.I~
I

Excessive leakage inside cylinder a r,s<ar+i.,~ nic,nn CPQI

Replace

20-121

H-l 5 Torque converter

*

lock-up does not work.

When actuation of lock-up solenoid is normal (if it is abnormal, see E-Sl)

Cause

Remedy

2 YES

Defective lock-up clutch

Replace or repair

drive normal?

I
l

Defect inside torque converter

l

Repair

Is torque converter lock-up pressure normal?

Speed range: F3 Stall speed: 1580 * 50 rpm

4 YES
Defective selector valve

Replace or repair

Engine speed: High idling Oil pressure: 13+1 kg/cm2 _O

YEI

31
R

Is operation of lockUD solenoid SDOOI

QO
u

Scuffing of spool

Replace or repair

Is main relief pressure normal?

5 YES
Defective pump Engine speed: High idling Oil pressure: 27 * 2 kg/cm2

I_
N normal? Does valve spool move smoothly?
l

Free length of spring: 120.3 mm

NO

Defective spring, spool scuffing, clogged with dirt

Replace or repair, Clean

H-l 6

Pin-puller

cylinder does not work.

A When actuation of pin-puller solenoid is normal

(if it is abnormal, see E-l)

Cause

Remedy

YES YE 1

Does pin-puller solenoid valve spool move by hand?

Is transmission relief pressure normal?

main

Disassemble noid valve.

sole-

h
I

Defective pin-puller cylinder

Repair or replace

NO

Defective spool of pin-puller solenoid valve

Replace

Engine speed: High idling Oil pressure: 27 + 2 kg/cm2

Go to H-7

20-l 22

TROUBLESHOOTING SYSTEM
E- 1 E- 2 E- 3 Pin puller cylinder Preheating Defective

OF ELECTRICAL

does not work ........................................................................................... (Serial No. : 10001 - 10167) .............................................

20-124 20-125 .20-126 on 20-126

fuse No.1 1 is blown operation

of APS (Serial

No. : 10001 - 10167). .................................................... @ is pressed, the APS pilot

a)

Even when the monitor

panel preheating

switch

panel does not light up .. . . ..__....................__.................................................. switch m is ON, the APS pilot

b) When panel preheating cl

d) Approx. 80 seconds

on the monitor . . . . . . . . .. 20-128

panel lights up, but it does not go out within after panel preheating performance

the range of 60 - 100 seconds ON, APS pilot

switch is turned

goes out, but starting The engine the engine e) E- 3

is poor (glow

plug works normally)

. . . .._............. 20-130

can be started with the APS, but when the starting

motor stops, 20-I 32

stops also . .. . .. . .. . . .. . . . . . . .. . . . .. . . . . . . . . . . .. . . . . . . .. . . .. . .. . . . . . . . .. . . . . .._....................................

APS does not stop . . .. . . .. . . .. . . . . . . . .. . . . . . . . . . . . .. . . . .. . . . . . . . .. . .. .._.............................................. operation of APS (Serial on monitor

. . . . . . . .. . 20-133

Defective

No. : 10168 and up) . . . . . . . .. . . . . . . . .. . .. . .. . . . . .. .. . . . .. . . .. . . . . . . . .. . . . . . 20-I 34-l panel does not light up when preheating switch 20-134-I

a) APS pilot
@

q q

on panel is pressed on monitor

.. . . . . . .. . . .. . . ..___..................._._._............................................... panel does not go out even when more than

b) APS pilot
12 seconds

has passed after lighting up (glow

up . .._..................................................................... plug system

20-134-4

b-l. APS pilot stays lighted b-2. APS pilot flashes

short circuited) ._._................._...._._ 20-134-4 sensor) . . . . . .. . . . .. . . . . . . 20-134-4 is at START

(disconnection

in APS water temperature starting

c)

APS pilot

on monitor

panel lights up when

switch

(short circuit with ground d)

in nozzle system) . . . . . .. . . . . . . . . .. . . . . . . .. . . . . .. . . . . .. . . . . . . . . . . .. . . . .. .. . . . .. . . .. . 20-I 34-5 in Items a) - c) for Defective 20-I 34-6

APS does not work (When there is no abnormality operation d-l.

of APS) .. . . . . .._...................................._..............................................._................. in C signal input system

Disconnection

. .. . . . . .. . . . . . . . . .. . . . . . . .. .. . . .. .. . . .. . .. . . . . . . .. . . . .. . . . . .. . . . .. . 20-134-6 20-I 34-8 20-134-g

d-2. Disconnection d-3. Disconnection e)

in glow plug system . . .. .. . . .. . .. . . . .. . . .._................................................... in nozzle system . . .. . . . . . . . .._._.....................__.......................................... temperature temperature is above 20C

APS does not stop even when water (short circuit with ground

in APS water

sensor system) . . .. . .. ..__............. 20-134-10 20-135 20-135 20-136 20-I 37 20-138 20-I 38 20-138 20-138 20-139

E- 4

Even when the light switch a) b) c) Head lamp switch m Rear lamp switch Working

is turned

ON, the lamps do not light up ...............................

........................................................................................................

@j ......................................................................................................... ................................................................................................... is turned OFF, the lamps do not go out.. ..............................

lamp switch @

E- 5

Even when the light switch a) b) c)

Head lamp switch ............................................................................................................... Rear lamp switch ................................................................................................................ Working lamp switch .......................................................................................................... in panel switch power source.. ....................

E- 6

Panel switch does not work. - Abnormality

20-123 @

E-l *
*

Pin puller cylinder does not work (For giant ripper)

Before carrying out troubleshooting, check that all the related connectors are properly inserted. After checking, connect the disconnected connectors and relays again immediately unless otherwise specified.

I I
Defective solenoid

Cause
of operation valve (spool)

Remedy

- Disconnect
1 is voltage CN224 between (1) and (2) 20 - 3ov7
* Turn starting ON. switch * Turn pin puller ON. switch -

Defective CN224. j NO

solenoid

Replace

4 Is resistance CN263 between (1) and (2) (male) asshown Table 27 * Disconnect 5 Is voltage CN162 between (2) ;;a~&;:)~and CN263.

YES

YES

bar. in wiring disconnection between short circuit Or (2) - CN122 (female) CN263 (1). (female) (3) - CN224
ness,

3
Is voltage CN263 between (1) and (female) chasis ground 20 - 3ov7 * Turn starting ON. switch * Turn pin puller OFF. switch

1 Defective
NO

pin

puller

switch

Replace

YES

Disconnection ass, or short zx I%%]

harin wiring between circuit 1: j.and

_ NO

_ Defective controller supplementary system. See Troublefor shooting monitor (M-l ).

* Turn starting ON, switch

NO

Table 1
Between (1) CN224
I

Table At

- (2)

40

80&-l

pin puller switch I

I ON
At pin puller switch OFF

1 Cl or below

Between CN224 (2) and chassis (l),

I
I

1 Ml

or above
1

1 s2 or above

E-l

Related electrical

circuit diagram

Supplementary .controller

CN162 -

"H
Pin-puller

\CN263 CN 122 CN224

Pin-puller solenoid

switch

F19702206

20-l

24

E-2

Preheating

fuse No. 11 is blown

Serial No. : 10128 - 10167 * Before carrying out troubleshooting, check that all the related connectors are properly inserted.
* Always connect any disconnected connectors before going on the next step.

1
3
2

C2tJ.W

Remeday

YES

YES

Is resistance betweenCNl21

-{Es

$~~~~and more than t I .l-3QP)

--Tnd more than 1 M Q?

Wiring harness between relay 1161 (4) - R3 - heater relay Ll, and between connector [5] (3) - Rl - heater relay Ll inside r&v box short circuiting with chassis ground, or defective relay

Iepair or replace

ground 1 MQ.

l Turn starting witch

Turn starting switch OFF. l Disconnect CNl21.

0 Turn starting switch OFF. Disconnect CN121.

OFF.

1 NO

Wiring harness between relay 1161 (31 - R4 - connector [41 (11 - connector 151 (2) - R4. R2 CN121 (4). (19)inside relay box short circuiting with chassis ground

epair or replace

NO 8
I
NO

Wiring harness between CNl21 (4). (191 - CNlOl (11, (11) CN102 (1). (4) - glow plug 1. qlow plug 2 short circuiting with chasdis ground Wiring harness between L2 and fuse 11 inside relay box short circuiting with chasks ground

epair or replace

E
6

epair or replace

E-2 Related electric circuit diagram

CNl02
r Timer

Glow 1

II

Glow 2

20-125 8

E-3

Defective

operation

of APS

Serial No . : 10128 - 10167

a) Even when panel preheating does not light up.
Only when water temperature defective. Before carrying out troubleshooting, Always connect any disconnected check that all the related connectors are properly inserted. connectors before going on the next step.
YES

switch

g UF is pressed, 0

the APS pilot

on the monitor

panel

is below 2OC. also does not light up when the preheating switch is pressed, the panel switch is

If the red lamp for the switch

2
YES Is between CN361 (13) and chassis ground 16-ZOV? * Turn starting switch ON. * Turn preheating switch ON.

I
4
3 Is voltage between con;ztc&r, [,I(?& * Turn starting switch ON. * Turn preheating switch ON. YES Is voltage between connectar (51 (1) and chassis ground 16-ZOV? YES

voltage

NF

* Turn starting NO switch ON. * Within 30 set of turning preheating switch ON. NO

YES

6 I
minal L2 inside Is voltage between CN121 (4). (19) and chassis ground IF: -%-Iv, 0 Turn starting switch ON.

* Turn starting switch ON. * Turn preheating switch ON.

YES

* Turn

switch

starting ON. NO

Cause

See M-4

a)

Defective contact or disconnection in wiring harness between connector [5] (1) and CN361 (13).

3efective

timer

Defective contact, or disconnection in wiring harness between connector [5] (2). (31 Rl, R2.

Defective heater relay contact. or disconnection in wiring tiarness between heater relay Ll - Rl, R3.

defective contact, or disconsection in wiring harness >etwee fuse 11 and L2 nside relay box.

Defective preheating [201.

relay

Defective YES nection between [201

contact,

or discon-

in wiring harness preheating relay (4) connector (6) switch.

10
beYES wee co%t,r -;;!, [yle) (1) 9 Is voltage be(3) * Disconnect [6]

socket

Is resistance

[Sl (2). (l)-CN362 CN261 (6) - panel

~
NO

Defective

heater

relay.

rzszt

and chassis ground 20--nOV?

. Turn starting switch ON. 11 Is resistance between APS water temperature sensor _ CN106 and chassis groundless than 1 Q., * Disconnect CN106. NO YES

Defective contact or disconnection in wiring harness between relay [201 socket (3) relay [15] socket (2) - J3. Defective contact or disconnection in wiring harness between J3 - preheating relay [20] socket (2). (1) - CN121 (13) - CNlOl (12) - CN106. Defective APS water temperature sensor, or defective grounding.

20-l

27

b) *
* *
l

OL7-C When panel preheating switch I 0 is ON, the APS pilot it does not go out within the range of 60 - 100 seconds.
Before carrying out troubleshooting, If.the abnormality

%T

on the monitor panel lights up, but

inserted.

check that all the related connectors are properly

Always connect any disconnected connectors before going on the ,next step. is only in the display, go to M-4. goes out in lessthan 60 seconds.

When the APS pilot (preheating monitor)

Cause

Remedy

,YES

1
between chassis CN121

1
2

Defective

timer

Replace

ground
When

switch ON. * Turn preheating switch ON.

NO

of resIstor 1 and rer,sitars 2 Ins,** relay box ar* remove*, I rer,*tence of both reslstor. less than la?

terminals

H
NO NO

YES

Defective contact, or disconnection in wiring harness between Ll - Rl * R3. R2R4 -CN121 (4). (19) inside relay box.

Repair replace

or

Defective resistor (resistor with resistance of more than lsl,.

Replace

When the APS pilot (preheating monitor) does not go out even after 100 seconds.

Defective

timer.

Replace

Defective cOntact nection in wiring * Turn starting switch ON. * Turn preheating switch ON.

or diwonharries* Repair replace or

YES * Turn starting switch ON. . Turn preheating switch ON. 7

Defective contact or disconnection in wiring harness between RZICN121 (4) or R4 -CN121 (19) inside relay box. Defective contact or disconnection in wiring harness between CN121 (4) (19) CNlOl (1). (llkkN102 (1). (p)-glow plug 1, glow Plug 2. Defective glow plug plug with resistance than 3a2). (glow of more

Repair replace

or

Repair
replaCf3

or

Replace

20-128

c) t
t +

Approx. 80 seconds after panel preheating switch is turned ON, APS pilot & El performance is poor (glow plug works normally).
Only when water temperature Before carrying Always connect is below 20C. check that all the related connectors connectors are properly out troubleshooting, any disconnected

goes out, but starting

inserted.

before going on the next step.

YES

ES

- Remove
1
Does head lamp work normally when relay [16] is inserted in socket of relay [14]?
I

CN103 and cm104

Turn starting switch ON. l Turn head lamp switch ON.

NO

20-130

Cause
Defective system APS nozzle fuel

9 YES
Defective APS controller

~~~

Defective contact or disconnection in wiring harness between Connector (41 (5). (6) and CN121 (7). (10). Defective contact or disconnection in wiring harness between CN121 (2) and connector [4] (4).

and CN104. relay 1161. Remove switch starting position. at START

NO

Put

* Turn starting ON. switch * Turn preheating ON. switch

Defective contact nection in wiring tween connector Connector [4] (7)

or disconharness be(41 (1) - R2, - J2.

CN103 * Hemove and CN104. switch * Put starting position, at START NO

NO

or disconcontact Defective harness in wiring nection (2)lCN121 between (1). (~)-cNIo~ c~ioi Disconnection in fuse

11 YES

II

or disconcontact Defective harness in wiring nection (lO)l(7) CN121 between ch1102 (8)_ y2y31)~(7).

Defective esistance 3 - 5s2).

with (nozzle nozzle value not within

Defective contact or disconnection in wiring harness between relay (161 socket (4) R3, (3) - R4. Defective contact or disconnection in wiring harness between relay [16] socket (1) snd relay (201 socket (1). or disconcontact Defective harness in wiring vxtion (3) and CN161 xtween (12). 3N361

defective

starting

switch

Defective preheating relay (161.

backup

20-131

d) The engine can be started with the APS, but when the starting motor stops, the engine stops also. + Before carrying out troubleshooting, check that all the related connectors are properly inserted.
+ t When checking the operation Always connect any disconnected connectors before going on the next step. of the nozzle, the monitor gives a mistaken display (low engine oil pressure warning), but this is not an abnormality.

Cause
Y 40 abnormality in electrical ystem; defective fuel system.

Remedy
After inspection, repair

1
Can operating sound be heard from nozzle when 4 battery relay BR is connected to R? . Connect battery relay BR to R with crocodile clip. . Turn starting witch ON. . Turn preheating switch ON. Y

e
. Connect battery relay BR to R with crocodile clip. * Turn starting switch ON.

Iefectlve

APS controller.

Replace

2
II voltape between CN121 (12) and chsrrll wound 20 -i3ov when b-ttery relay BR Ir connected to R? . Connect battery relay BR to R with crocodile clip. * Turn starting _

kfective contact, or disconwction in wiring harness bewee CN121 (12) and connec :or [41 (3).

NO

YES

jee M-5 a) Abnormality :harge amont.

in

No{xH-

NO

Defective contact, or disconnection in wiring harness between CN121 (12) - CNlOl (9) - CN105.

Repair or replace

E-6 d)

Related

electrical

circuit

diagram

Relay

box

F91702208

20-132

e)
* * 0

APS does not stop

Before carrying out troubleshooting, check that all the related connectors are properly inserted. Always connect any disconnected connectors before going on the next step. Th! * operation of the APS is normal, but the APS does not stop even when the water temperature is above 20C. goes above 20C.

Check when the engine water temperature

Cause 3
YES Defective preheating [201. Contact of + 24V with wiring harness between preheating relay [201 (4) and connector [61 (21. Wiring harness between relay [20] (1) and CN121 (13) short circuiting with chassis ground. Wiring harness between CN121 113) - CNlOl 1121 CN106 ;hdrt circuiting with chassis ground. relay

Remedy

. Disconnect

CN121.

Defective APS ture sesor.

water

tempera.

APS operates even though panel preheating switch is not

pressed.

3
YES 2 c IS resistance between CN362 (male) (6) and chassis ground more than lM11 Is resistance bewee CN261 (male) (6) and chassis ground more than 1 MFi-l? * Oisconneci CN362. Disconnect CN261. _

YES Defective panel switch.

YES -

NO

Wiring harness between CN362 (female) (6) and CN261 (male) (6) short circuiting with chassis ground.

1
Does operation of APS stop when connector [61 is disconnected?

* Disconnect *
connector Disconnect 161. CN362. No

Wirina harness between CN362 (male) (6) and connector 161 (11 short circuitina with ch&& ground. Contact of + 24V harness between 1.2 - CN102 (1) (1) (11) - CN121 resistor R2. R4 with wiring glow plug (4) - CNlOl (4) (19) Rl R3.

YFS

Ll and L2 inside relay box more * Remove relay. heater NO

Defective

heater

relay.

20-133

E-3

Related electrical

circuit diagram

APS SYSTEM

Serial

No. : 10001 - 10167

5 Monitor module

mcltor starting

Panel switch

z
6
Starting switch

@-j-

I-----

Alternator

n 0

Relay bo x
I

17MF02177

20-l

34 @

E-3 Defective Serial

operation No.

of APS

: 10168 and up
on monitor panel does not light up when preheating switch m on panel

a) *

APS pilot is pressed

)1161

When an abnormality occurs and the system returns to normal when the connector has been disconnected and a T-adapter inserted, or when the T-adapter has been disconnected and the connector connected, the system has been reset. Only when the water temperature is below 20C. It is possible to carry out troubleshooting when the cooling water temperature is above 20C by short circuiting the APS water temperature sensor. Check that fuses 9 and 11 inside the fuse box are normal. Always turn the starting switch OFF before disconnecting the connector or connecting the Tadapter (or socket). Before carrying out troubleshooting, check that all the related connectors are properly inserted. Always connect any disconnected connectors before going on the next step.

20-l 34-1 @

,
YES

3 YES Is voltage
between CN2 (5) and chassis ground normal?

ground normal?

NO -12-30V * Turn starting switch ON. * 12 seconds after turning preheating switch ON. 4 YES

-12-30V Is voltage between * Turn starting connector 151(l) switch ON. and (4) inside relay * 12 seconds after N 1 box normal? turning preheating *12-30V switch ON. * Turn starting switch ON. - 12 seconds after turning

NO

8
YEIS
1 Is voltage between CN121 (4). (19) and chassis ground normal? 7 -ll-14v -Turn starting switch ON. -Turn preheating switch ON. voltage between YES relay terminal L2 - (inside relav box) ground ;,r;r;i
Is

1
I-

30 v -20 * Turn starting switch ON. -Turn preheating switch ON.

6 YE between CN261

,20-30V Turn starting switch ON.

NO
- Preheating switch: ON: Max. 1 V OFF:20-30V * Turn starting switch ON. 5 12 YES Is voltage between CN261 (6) and (2) normal? -2O-30V -Turn starting switch ON. -Turn preheating switch OFF. NO

NO

Is voltage between CN362 (6) and (2) normal?

*20-30V * Turn starting switch ON. * Turn preheating switch OFF.

14 YES

-IO-IOOR

NO

connector 161(2) and chassis ground *20-30V -Turn starting switch ON. * Turn preheating switch ON.

* Turn starting switch OFF. - Disconnect connector [61.

I
NO

20- 134-2 @

Cause

Remedy

See M-4 a) Defective contact, or disconnection in wiring harness between CN2 (female) (5) and CN361 (female) (13) Defective contact, or disconnection in wiring harness between connector 151 (female) (4) inside relay box and CN361 (male) (13) Defective APS controller

lepair or eplace

lepair or eplace

leplace

Defective APS controller between connector (inside relay box) NO Defective contact, or disconnection in wiring harness between connector [51 (female) (1) inside relay box and chassis ground 11 YES YE 10 resistance between connector [dlWnale)(l) and (2) NO inside relay box normal?
Is I -IOI 1OOR

leplace

lepair or eplace

connector 151. switch OFF. Is resistance mween relay -terminal Ll and LZ

inside relay box normal? Max. 1 R

I
-

Defective contact, or disconnection in wiring harness between relay terminal Ll and connector 141 (female) (1) inside relay box Defective relay contact

lepair or eplace

Zeplace

NO

- Disconnect terminals Ll and L2. *Turn starting switch ON. *Turn preheating switch ON.

-Turn starting switch OFF. - Disconnect connector 161.

I
NO

Defective relay coil Defective contact, or disconnection in wiring harness between relay terminal L2 and fuse 11 , inside relay box Defective panel switch Defective contact, or disconnection in wiring harness between CN362 (female) (6) - CN261 (6) panel switch Defective contact, or disconnection in wiring -I harness between connector 161 (female) (I) inside relay box and CN362 (male) (6) Defective relay coil

Zeplace

Repair or replace

Replace

Repair or replace

Repair or replace

Replace

Defective contact, or disconnection in wiring harness between connector 161 (female) (21 inside relay box and fuse 9 inside relay box

Repair or replace

20-134-3 8

b) *

on monitor APS pilot passed after lighting up

panel does not go out even when

more than

12 seconds

has

* * t * * * b-l.

When an abnormality occurs and the system returns to normal when the connector has been disconnected and a T-adapter inserted, or when the T-adapter has been disconnected and the connector connected, the system has been reset. Only when the water temperature is below 20C. it is possible to carry out troubleshooting when the cooling water temperature is above 20C by short circuiting the APS water temperature sensor. Check that fuses 9 and 11 inside the fuse box are normal. Always turn the starting switch OFF before disconnecting the connector or connecting the Tadapter (or socket). Before carrying out troubleshooting, check that all the related Remedy connectors are properly inserted. Always connect any disconnected connectors before going on Wiring harness between the next step. APS pilot stays lighted
Y==

up (glow

plug system

short circuited)

CN121 (male) (4),(19) and connector 141 (female) (2),(3) inside relay box chassis ground

?epair or .eplace

between CN121 (female) (4). (19) YES

-0.8-1.3R . Turn starting switch OFF. - Disconnect CN121.

Is resistance between CN 102

Wiring harness between CN121 (female) (4),(19) CNlOl (l),(ll) - CN102 - (female) (l),(4) short circuiting with chassis

3epair or .eplace

Replace -0.8-1.3R . Turn starting switch OFF. - Disconnect CN102.

b-2. APS pilot flashes sensor) Ir

(disconnection

in APS water

temperature Cause is Remedy

It is normal if the lamp flashes when the water temperature above 20C.

Defective APS controller Defective contact, or disconnection in wiring harness between CNl06 CNlOl (12) - CN121 (female) (13) Defective contact, or disconnection in wiring harness between CN121 (male) (13) and connector 151(female) (2) inside relay box Defective APS water temperature sensor

qeplace

3 connector [51(2) relay box normal? * Max. 0.5 V + Turn starting switch ON. Reference: The voltage when the water temperature is above 20C is 7 IOV.

YES

N0

1
I (

Is resistance between CN106 (water temperature end) and chassis around as shown i Table I?

Is resistance tE S between CN121 - (female) (13) and chassis ground as shown in Table I? * Turn starting switch OFF. * Disconnect CN121.

qepair or .eplace

?epair or eplace

NO

* Turn starting switch OFF. * Disconnect CN106.

NO

3eplace

Table

1 temperature Resistance Max. value 1 Q

( Coolant

I
I

Below 20C Above 20C

I I

Min. 1 MR

20-l 34-4 @

APS pilot with ground

on monitor panel lights up when in nozzle system)

starting

switch

is at START

(short circuit

When an abnormality occurs and the system returns to normal when the connector has been disconnected and a T-adapter inserted, or when the T-adapter has been disconnected and the connector connected, the system has been reset. Only when the water temperature is below 20C. It is possible to carry out troubleshooting when the cooling water temperature is above 20C by short circuiting the APS water temperature sensor. Check that fuses 9 and 11 inside the fuse box are normal. Always turn the starting switch OFF before disconnecting the connector or connecting the Tadapter (or socket). Before carrying out troubleshooting, check that all the related connectors are properly inserted. Always connect any disconnected connectors before going on the next step.

Cause

Remedy

Defective APS controller YE Wiring harness between CNl21 (male) (7) and connector [41 (female) (4) inside relay box short circuiting with chassis ground Wiring harness between CN121 (female) (7) CNlOl (7) - CN102 (female) (2) short circuiting with chassis ground Wiring harness between CN102 (male) (2) and nozzle short circuiting with chassis ground

Repair or

z
between CNl21 (female) (7) and .1.5-2.5R . Turn starting switch OFF. . Disconnect CNl21.

1.5-2.5R . Turn starting switch OFF. Disconnect connectors [41 and 151.

ES

Repair or replace

Is resistance between CN102 (male) (2) and (3) I normal? . 1.5 2.5 R * Turn starting switch OFF. - Disconnect CN102. FH_

4 YES

Repair or replace

*3-5R -Turn starting switch OFF. * Remove nozzle.

NO

Defective nozzle

xl- 134-5 @

d) APS does not work (when there is no abnormality

APS)

in Items a) - c) for Defective

operation

of

When an abnormality occurs and the system returns to normal when the connector has been disconnected and a T-adapter inserted, or when the T-adapter has been disconnected and the connector connected, the system has been reset. Only when the water temperature is below 20C. It is possible to carry out troubleshooting when the cooling water temperature is above 20C by short circuiting the APS water temperature sensor. Check that fuses 9 and 11 inside the fuse box are normal. Always turn the starting switch OFF before disconnecting the connector or connecting the Tadapter (or socket). Before carrying out troubleshooting, check that all the related connectors are properly inserted. Always connect any disconnected connectors before going on the next step. d-l. Disconnection
YES

in C signal input system

YES nozzle actuation switch is turned 2 - Disconnect Is voltage between CN103 and connector 151(3) CN104. -Turn preheating NO and (1) inside raiav box normal? switch ON. 4 *Turn starting switch to START. -lo-3ov - Disconnect CN103 and between CN121 switch ON. * Starting switch to START. ground normal? _ *lo-3ov * Disconnect CN103 and . CN104. * Turn preheating switch ON. * Starting switch to START. 3 YES

YES

ground normal? -IO-3ov - Disconnect CN103 and CN104. *Turn preheating switch ON. - Starting switch to START. 7

Is voltage between CN361 NO (3) and chassis ground normal? 4 *IO-3ov - Disconnect CN103 and CN104. . Turn preheating NO switch ON. - Starting switch to START.

NO
YES

Is voltage
between CN161 (4) and chassis ground normal? *lo-3ov . Disconnect CN103 and CN104. *Turn preheating switch ON. - Starting switch to START. NO

20-134-6 @

Cause

Remedy

Defective APS nozzle fuel system

Go to Troubleshooting S-l and S-2 for engine

Go to d-2. Defective contact of glow PLUG system. Defective contact, or disconnection in wiring harness between CN121 (male) (2) and connector [51 (female) (3) inside relay box

Repair or replace

i0

6 Is resistance _ between CN151 _ (male) (1) and (3) normal?

YES

Defective contact, or disconnection in wiring harness between CN121 (female) (2),(3) - CN451 (7),(8) - CN151 (female) (l).(3) Defective safety switch

Repair or replace

Replace

. Gear shift lever NO N: Max. 1 R . Gear shift lever at any position except N: Min. 1 MR * Turn starting switch OFF. * Disconnect CN151.

Defective contact, or disconnection in wiring harness between CN361 (male) (3) and CNl21 (male) (3) Defective contact, or disconnection in wiring harness between CN361 (female) (3) and CN161 (female) (4) Defective starting switch

Repair or replace

Repair or replace

Replace

20-134-7 8

d-2. Disconnection * *

in glow

plug system

in C signal input system first. Before starting, carry out d-l. Disconnection in installation of glow plug. Check if there is abnormality

YES
3 YES 2 Is voltage between CN102 (l).(4) and chassis ground normal? .ll-14v . Turn preheating switch ON. * Turn starting switch ON. 5 Is voltage between connector I41 L (2).(3) inside relay NO box and connector f51 (1) inside relay box normal? .ll-14v -Turn preheating switch ON. * Turn starting switch ON. YES Is resistance between CN102 (malehl),(4) and chassis ground normal? .0.8-1.3R * Turn starting switch OFF. - Disconnect CN102.

Go to d-3. Defective of nozzle -contact system.

Is resistance between each glow plug and chassis ground normal? 4 YES -

Defective contact, or disconnection in wiring harness between CN102 (male) (l),(4) and glow plug Defective glow plug

No

YES 1 Is voltage between CN121 (4Lf19) and chassis ground normal? -ll-14v -Turn preheating switch ON. -Turn starting switch ON.

K -0.8. 1.3R * Turn starting switch OFF. * Disconnect glow plug terminal.

NO

Defective contact, or disconnection in wiring harness between CN102 (female) (l),(4) - CNlOl (l),(ll) - CN121 (female) (4).(19) Defective contact, or disconnection in wiring harness between connector I41 (female) (2),(3) inside relay box and CN121 (male) (4),(19) Defective APS controller

NO

20-134-8 @

d-3. Disconnection *

in nozzle system Disconnection in C signal input system and d-2. Disconnection in

Before starting, carry out d-l. glow plug system first.

Cause

Remedy

Defective contact, or 4YES 3 Is voltage between CN102 (male) (2) and chassis ground normal? 2 Is resistance of nozzle as individual part normal? -3-50 * Turn starting switch OFF. * Disconnect nozzle terminal. NO

YES disconnection in wiring

harness between CN102 (male) (2),(3) and nozzle

Iepair or ,eplace

Defective nozzle

F Ieplace

YI

between CN121 (7) and chassis *0.4-5v * Disconnect CN103 and CN104. * Turn preheating N switch ON. * Starting switch to START.

0.4 - 5 v Disconnect CN103 and CN104. NO . Turn preheating switch ON. . Starting switch to START.

Defective contact, or disconnection in wiring harness between CN102 (female) (2) - CNlOl (7) CN121 (female) (7) Defective contact, or disconnection in wiring harness between CN121 (male) (7) and connector I41 (female) (4) inside relay box Defective APS controller

F tepair or replace

F tepair or r eplace

1 Is resistance between CN102 (female) (3) and chassis ground nnrmal? -Max. 1R * Turn starting switch OFF. * Disconnect CN102.

F Xeplace

IQ * Turn starting switch OFF. . Disconnect CN121.

- Max.

~ 1
Is voltage

. Disconnect CN103 and CN104. . Turn preheating switch ON. . Starting switch to START. Defective contact, or disconnection in wiring harness between CN102 (female) (3) and CN121 (female) (IO)

YES

F Xepair or replace

betweenCN121
(male) (IO) and chassis ground normal? NO

Defective contact, or disconnection in wiring F sepair or harness between CN121 r eplace (female) (IO) - J2 inside relay box - chassis groun d

20-134-9 @

e)

APS does not stop even when water temperature APS water temperature sensor system)

is above 20C (short circuit with

ground

in

When an abnormality occurs and the system returns to normal when the connector has been disconnected and a T-adapter inserted, or when the T-adapter has been disconnected and the connector connected, the system has been reset. Only when the water temperature is below 20C. Check that fuses 9 and 11 inside the fuse box are normal. Always turn the starting switch OFF before disconnecting the connector or connecting the Tadapter (or socket). Before carrying out troubleshooting, check that all the related connectors are properly inserted. Always connect any disconnected connectors before going on the next step.

Cause

Remedy

2 YE 1 between CN 106 ground normal? .7-1ov * Turn starting switch ON. *Turn preheating switch ON.

YES

Is voltage between CN121 (13) and chassis around normal?

.7-1ov

Wiring harness between CN121 (male) (13) and connector [51 (2) inside relay box short circuiting with chassis ground Wiring harness between CN106 - CNlOl (12) CN121 (female) (13) short circuiting with chassis ground Defective APS water temperature sensor

Repair or replace

I
NO

-Turn starting

Repair or replace

switch ON. -Turn preheating switch ON.

Replace

20-134-10 @

E-3 Related

electrical

circuit diagram

NS SYSTEM
Serial No. : 10167 and up
Monitor nodul _ _Q2

Safety

switch

CN151

ADS Pilot
1 ureheatino signal

% 0
L 40 Panel switch

Starting

motor

Starter
4

switch

-FJ-_-_

CNl61
1

CNlO

---------I

APS

controller

GND

Water temperature Starting motor Preheating Iamp

switch C

TDD00710

20-134-11 @

E-4 *
*

Even when the light switch is turned ON, the lamps do not light up
check that all the related connectors are properly inserted.

Before carrying out troubleshooting,

Always connect any disconnected connectors before going on the next step.

a) *

Head lamp switch

(If fuse No.14

g 10 cl
- relay [13] [141 (3) (4) - lamp is in

When fuse No.14 is normal is blown, check if the wiring harness between fuse No.14 contact with the chassis ground.)

Cause

YES

31
Does condition become normal YES relay [131 -when or 1141 is replaced? _ NO

Defective relay on side that does not light up (Defective contact).

4
?ls voltage between CN203 (I) or CN204 (1) and chassis ground 20 - 3OV? . Turn starting switch ON. . Turn head lamp switch ON.

YE _

Defective lamp, or defective contact with ground.

2
Are lamps that on one side

NC

or disconDefective contact nection in wiring harness between lamps and relay on side that does not light up.

..-

Defective contact or disconnection in wiring harness be. tween fuse 14 and relay [13] P41 (31.

Of Panel

switch

* Turn starting switch ON. * Turn head lamp switch ON,

6p
YES Are that not one lamps do light up on side only?

YES

Defective relay on side that does not light up (Disconnection in coil).

5
Do red lamps of other switches

7 YEE Do lamp light UP when CN261 (3) _ is grounded to chassis? NO

Defective

panel switch.

_ NO

* Turn

starting switch ON. * Turn other switches ON.

* Turn starting switch ON. * Turn head lamp switch OFF. * Connect T-adapter to CN261.

-I-

Defective contact or disconnection in wiring harness be[14] (1) tween relay 1131 CN362 (3) - CN261 (male) (3).

Nk

See E-6 (panel switch BOUrce system).

power

20-135

b)

Rear lampswitch
(If fuse No.13

O 00:
0
[171 1181 (3) (a)lamps is in

When fuse No.1 3 is normal is blown, check if the wiring harness between fuse No.13 -relay contact with the chassis ground.)

Cause

Remedy

YES Does condition when relay [171

Defective relay on side that does not light up (Defective contact).

4
Is voltage between CN243 (1) a CN223 (1) and ;hgaywy;und * Turn starting switch ON. * Turn rear lamp switch ON.

YES

Defective lamp, or defective contact with ground.

NO

Defective contact or disconnection in wiring harness between lamps and relay on side that does not light up.

YES

Are that not one

lamps

do light UP on side only?

NO

Defective contact or disconnection in wiring harness between fuse 13 and relay [171 [I81 (3).

starting switch ON. * Turn rear lamp. switch ON.

* Turn

YES

61

1 Are
s

lamps

I ;

Defective relay on side that does not light up (Disconnection in coil).

Defective

panel switch.

1 Turn startina switch ON. . Turn other switches ON.

IL *

startina switch ON. * Turn rear lamp switch OFF. connect T-adapter to CN261.

Turn

NO

Defective contact or disconnection in wiring harness between relay [171 [181 (1) CN362 (4) - CN261 (male) (4).

NO

See E-6 (panel switch power *ource system).

20-136

c) *

Working

lamp switch

Iz AC?
relay [221 (3) (4)-lamps is in contact

When fuse No.12 is normal (If fuse No.12 is blown, check if the wiring harness between fuse No.12with the chassis ground.)

Cause

Remedy

YES

31
YES Is between CN242 (1) or _ CN221 (1) and chassis ground 20 - 3ov7 * Turn starting switch ON. * Turn working lamp switch ON. NO

Defective lamp, or defective contact with ground.

voltage

Defective contact or disconnection in wiring harness CN242 (1) CN221 (1) and CN121 (female) (21).

or

2
Y Are that not one lamps do light up on side only? _ NO

YES

4
Does condition become normal Ihen relay 1221 1s replaced?

Defective relay tive contact).

[22]

(Oefec-

NO Panel switch

Defective contact, or disconnection in wiring harness between fuse 12 - relay [22] (3) (4) - CN121 (male) (21).

. Turn starting switch ON. * Turn working lamp switch ON. YES

YES

6
Does condition become normal _ when relay [221 is replaced?

Defective relay [221 nection in coil).

(Olscon-

5
00 red lamps of other switches light/up? * Turn starting switch ON. other switches ON.

7 \Does UP when CN261 (5) is grounded tochassis?

YE!

Defective

panel switch.

NO

NO

* Turn

* Turn starting switch ON. Turn working switch OFF. Connect T-adapter to CN261.

NC lamp

Defective contact, or disconnection in wiring harness between relay [221 (1) - CN362 (5) - CN261 (male) (5).

I NO

SeelE-6 (panel switch power source system).

20-l

37

E-5
* *

Even when the light switch is turned OFF, the lamps do not go out
check that all the related connectors are properly inserted.

Before carrying out troubleshooting,

Always connect any disconnected connectors before going on the next step.

a)

Head lamp switch

Cause

Remedy

3
YES 2 Do lamps go out when relay is removed on side where lamps do not go out7 -

YES Defective relay

YES -

Are lamps that do not go out on one

* Turn

starting switch ON.

NO

Contact of + 24V with wiring harness between relay [131 [14] (4) and lamps.

1
NO Does red lamp Of Panel switch go out7 * Turn starting -

Wiring harness between relay [131 [141 (1) - CN362 (3) CN.261 (male) (3) short circuiting with chassis ground.

Defective

panel

switch,

* Turn head lamp switch OFF.

b)

Rear lamp switch

g 0:
YES

3
SH-

YES Defective relay.

* Turn starting switch ON.

NO

Contact of + 24V with wiring harness between relay [171 [la] (4) and lamps. Wiring harness between relay [171 [181 (1) - CN362 (41 CN261 (male) (4) short circuiting with chassis ground.

NO Does panel out? red lamp of switch go -

. Turn starting switch ON. * Turn rear lamp switch OFF.

Defective NO

panel

switch.

c)

Working

lamp switch

@
Is resistance between relay [22] (3) and (4) more than 1 Ma? * ri2yjlpve relay

3
yEL

YES

Defective contact, or disconnection in wiring harness between relay [221 (1) - CN362 (5) - CN261 (male) (5).

2
YES 7 Does IamP when relay is removed7 90 Out [22] -

NO

3efective

relay

[22]

1
Does panel out? red lamp of switch go -

* Turn

starting switch ON.

NO

Defective contact or disconnection in wirinq harness between rela;[221 (4) - CN121 (21) - left and right lamps.

. Turn starting switch ON. Turn working switch OFF.

NO lamp

Defective

Panel

switch.

20-138

E-6
*

Panel switch does not work. -Abnormality

(Even when the switch is pressed,

in panel switch power source

does not light up.)

the red lamp for that switch

* .* *

When fuses No.9 and 15 are normal If fuse is blown, check for short circuit with chassis ground in wiring harness between fuse No.9(2) pin of each relay, fuse No.9 - CN362 (1) - CN261 (panel switch), or fuse No.15 - CN162 (1) (supplementary controller) When the battery is normal. Before carrying out troubleshooting, check that all the related connectors are properly Always connect any disconnected connectors before going on the next step. inserted.

Remedy

3
j _ IS Okage between CN261 Ill and (2120 - 3OV? _

YES

Defective

panel

switch.

teplace

Turn starting switch ON.

NO

Defective contact, or disconnection in wiring harness between fuse 9 and (2) of each 1 relay, or between fuse 9 CN362 (1) CN261 (1) (2) CN362 (2) - chassis ground.

Defective * Turn starting switch ON. Does condition

safety

relay

(121

Seplace

- CN361 (7) [121 (1).

(2.

safety relay

YES

5 IS voltage between
CM64 11) and chass,s ground 20 - 3OV? Turn start,&! SWltChON -

Defective contact or disconnection in wiring hare*s between CN464 (1) and CN361 (7).

Repair or
replace

6
NO Is voltage between CNl62 (1) and chassis ground 20 - 3OV? * Turn starting switch ON. _

YES

Defective controller.

supplementary

Replace

NO

Defective contact or disconnection in wiring harness between battery terminal (+) -CN361 (lo)CN162 (1).

Repair replace

or

20-l 39

E-4, E-5, E-6.

Related electrical

circuit diagram

Workhng lamp (R H.) : : CN242 /

Workong lamp 1L.H

Head lamp 03 Hi

Redr lamp 1L.H.)

Head lamp 1R.H I

Relay box

Panel switch

F19702203A

20-l 40

TROUBLESHOOTING MONITOR SYSTEM

OF MACHINE

..... .. ........ Table of failure modes and causes. M- 1 No display appears on the monitor panel when the starting switch is ON. ...................... M- 2 When starting switch is turned ON, monitor panel lamps all stay on and do not go out ............. .................. M- 3 When starting switch is ON (engine stopped), CHECK items show abnormality.
a) Abnormality b) Abnormality M- 4 Abnormality a) in coolant level in engine oil level /BI

...... ..... ...... ....... ..... ....

20-I 43 20-144 20-144 20-145 20-I 45 20-146 20-147 20-147 20-147

.............................................. ............................................

in preheating

....................................................

M- 5

monitor does not light up. ............................................. b) Preheating monitor stays lighted up .............................................. When starting switch is ON and engine is started, CAUTION items flash. Preheating a) b) c) d m & 8 $ 4 $ 0 CAUTION Charge level flashes.

.......................

20-148 20-148 20-148 20-148 20-148 20-149 20-149 20-152 20-I 52 20-l 52 20-I 53 20-I 53 20-153 20-154 20-I 54 20-I 55 20-156 20-157 20-I 58

................................................... ..............................................

Engine oil pressure flashes. Coolant level flashes Coolant temperature Torque converter

...................................................
flashes.

.............................................
flashes. ....................................

8 z 6 M- 6

e) f) a)

oil temperature flashes

Hydraulic oil temperature in buzzer.

..........................................

Abnormality

..........................................................

M- 7

items are flashing, but buzzer does not sound ................................ b) No abnormal display is given on monitor, but buzzer sound. ............................. Abnormality in warning lamp. ..................................................... a) CAUTION items are flashing, but lamps do not flash ................................... b) No abnormal display is given on monitor, but lamp lights up. ............................ Abnormality in gauge

........................................................... a) Abnoramlity in coolant temperature gauge. ......................................... b) Abnormality in torque converter oil temperature gauge. ................................ c) Abnormality in fuel level gauge. ................................................. M- 9 Service meter does not move after engine is started ..................................... Panel lighting for monitor panel does not light up ....................................... M-10
M- 8

20-141

TABLE OF FAILURE MODES MONITOR) (MACHINE

AND

CAUSES

Sensor Parts causing problem

Monitor panel

Troubleshooting table

Failure mode

-z = 0
E .P Lu
is turned ON, monitor panel display panel lamps

For abnormalities in machine monitor system, go to Troubleshooting (YES/NO) Table (M-OX

1 2 3 4 5 6

When starting switch does not appear

M-l

When starting switch is turned ON, monitor all stay lighted up and do not go out

0 0 0 0 0 0 0 0 0 0 0

M-2 M-3 M-4 M-5 M-6 M-7 M-8

When starting switch is turned ON (engine stopped), CHECK items flash Preheating display is abnormal When starting switch is turned CAUTION items are abnormal Buzzer is abnormal Lamp is abnormal ON and engine is started,

I I

Gauge is abnormal After engine is started, service meter does not move panel lighting does not light-up

0 0
0

9
10

I
I

0 0 0

M-9 M-10

Monitor

20-143

M-3

When starting switch is ON (engine stopped), CHECK items show abnormality (Liquid levels is normal for check items before starting)
check that all the related connectors are properly
inserted.

t
t

Before carrying out troubleshooting,

Always

connect any disconnected connectors before going on the next step. in coolant

a)
l

Abnormality

level

8 /_

Coolant level monitor flashes

Cause
YES Defective 1 sensor coolant level

Remedy
After inspedtion sensor. repair or replace according to table of standard 1values

1
Does coolant level monitor go Off? . Connect short connector to CN405 (female). * Turn starting switch ON.

3
yES 2 Is resistance between CN405 (female) Q) and chassis ground than lSZ7 * Disconnect less Is resistance between CNl (female) (5) and chassis ground less than Q-L?

YES

Defective

monitor

module.

Replace

Defective contact nection in wiring NO ~@~e~%$%J$

or disconharness G%J?LF$F-

_ NO

* Disconnect

\CNl

CN405. NO

Defective contact or disconnection in wiring harness between CN405 (female) (2) and chassis ground.

After inspection, repair or replace

E
6

M-3 a) Related electrical

circuit diagram

CN I CN201 CNIOI CN421

Monitor panel

Down

Up

Coolant -

level

sensor

F19702211

561 FO3177A

3.

Connector

20-145

b)
l

Abnormality

in engine

oil level

Engine oil level monitor flashes.

Cause
YES Defective . engine oil level

sensor or defective chassis ground.

1 Doer engine level monitor off? oil go

2
P NO Is resistance between CN 1 (female) (6) and chassis ground than la?

YES Defective Defective contact. or disconnection in wiring harness between CN404 (female) (1) CN401 (4) - CN421 (5) - CNl (female) (6). monitor module.

h
Remedy
After inspection sensor, repair or replace according to table of standard VallleS
REplaCe

* Ground CN404 (female) (1) chassis. * Turn starting switch ON.

to

less

Disconnect

CNl.

NO

After inspection, repair or replace

M-3 b) Related electrical

circuit diagram

CN I
Engine oil level sen*or

CN404 1

CN401

CN421
Monitor panel

197FO1522

Engine

oil

level

sensor

F19702213

20-146

M-4
* * *

Abnormality

in preheating

m
inserted.

Before carrying out troubleshooting, When operation

check that all the related connectors are properly

Always connect any disconnected connectors before going on the next step. of the APS is normal (if it is abnormal, carry out troubleshooting E-6 first.)

a)

Preheating monitor does not light UP

Cause
YES Defective monitor module.

* Turn starting switch ON. * Turn preheating switch ON.

I N

Defective contact, or disconnection in wiring harness between connector [51 (female) (1) - CN361 (female) (13) CN2 (female) (5). or defective bimetal timer.

b)

Preheating monitor stays lighted up

ES Contact of + 24V with wiring harness between connector [51 (female) (1) - CN361 (13) - CN2 (5), or defective bimetal timer.

off when CN2 disconnected?

is

* Disconnect

CN2. NO

Defective

monitor

module.

M-4

Related electrical

circuit diagram

Relay box

CN36l
Check module

I97FO

I523

20-147

M-5

When starting switch is ON and engine is started, CAUTION items flash (When there is no abnormality in the CHECK items or engine)
check that all the related connectors are properly inserted.

*
*

Before carrying out troubleshooting,

Always connect any disconnected connectors before going on the next step.

a) m

Charge level flashes

2
YES _ Is voltage between CNl (4) and chassis ground 20 -3ov7 * Start engine. * Engine at half throttle or more. NO YES Defective monitor module.

1
Is voltage between alternator terminal R and chassis ground 20 -_,3OV? . Start engine. * Engine at half throttle or more.

Defectlve contact or disconnection in wiring harness between alternator tekinal R - CN107 CN105 - CNlOl 19)battery relay tern&l R - CN122 (1) CNl (female (4).

Repair replace

or

Replace NO

b) +&

Engine oil pressure flashes

Remedy
After inspection sensor. repair or replace according to table of standard YalUeS

F
1 Does display go off when CN403 is disconnected? YES I Defective engine sensor system. oil pressure

2
Is resistance between CN 1 (female) (7) and chassis ground morelthan 1 MA-L? * Disconnect CNl. * Turn starting switch OFF. * Disconnect CN403.

YES

Defective

monitor

module.

Replace

* Disconnect CN403. * Start engine.

NJ

ND

Wiring harness between CN403 - CN401 (3) - CN421 (4) 1 CNl (female) (7) short circuiting with chassis ground.

Repair replace

or

c)

0 --

Coolant level flashes

See M-3 a)

Coolant temperature

flashes
2
YES

r
Defective

Cause
temperatur

Remedy
After inspection sensor. repair or replace accord ing to table of standard V&_VZS

YE

I . cOnnectOr

Does display go off when short Is connected tcl CN402 (female)? NO

DefectIvecoolant sesor system.

Connect short connector to CN402 (female). * Start engine.

monitor

module.

Replace

* Engine throttle

*start

engine. at half or more. Defective monitor module. Replace

20-148

Torque converter

oil temperature

flashes

Sfter inspec:ion sensor. epair or

2
YES Does display go off when short connector is connected to CN453 (female)7

YES

Defective torque converter oil temperature sensor system.

.eplace accordng to table ,f standard lalues

Defective

monitor

module.

1
Is torque converter oil temperature gauge within red range? _

-NO . Connect

short connectclr to CN453 (female). . Start engine,

* Start
* Engine throttle

engine. at half or more. jji Defective monitor module.

Hydraulic

oil temperature

flashes Cause
Remedy
After inspection sensor, Defective hydraulic oil temperature sensclr system. repair or replace according to table of standard

YES

1
Does display go off when CN452 is grounded to chassis7 P . Disconnect CN452, and ground (fema,ej (1) * Start

2
_ Is resistance between CNl (female) (8) and chassis ground less than 1 a7 * Disconnect CNl. Ground CN452 to chassis. * Turn starting switch OFF. _ YES

values Defective monitor module.

FlepkX3

NO

to chassis.
engine.

NO

Defective contact, or disconnection in wiring harness between CNl (female) (8) CN421 (12) - CN451 (3) CN452 (female).

20-149

M-5 a) Related electrical

circuit diagram

CN I
Monitor module

Alternator terminal

Service

F19702215

M-5 b) Related electrical

CNI
Monitor module

circuit diagram
CN401 CN403
Engine oil pressure sensor

CN421

F19702216
If the condition is es shown 0.5 in the table below, it is normal No continuity Continuity

Engine

oil pressure oil pressure

kg/cm2 0.5

or above kg/cm

I Engine
M-5 d) Related electrical
CN2
Monitor module

below

circuit diagram
CN42 I CN401 CN 402 Coolant temperature sensor

F19702217 If the condition it is normal

is es

shown in the table

below,

Coolant

temperature

sensor

IILL

F19702218

M-5 e) Related electrical

circuit diagram
CNOFjl

CN453

Torque converter nil +amn0rs+,,m ..,%r.-.v

Monitor module

F19702219 If the condition is as shown in the table below, it is normal.

M-5 f) Related electrical

circuit diagram

CNI

CN421

CN451 ,q

CN452

Hydraulic oil temperature sensor

198FO2242

J&

%I
Structure of circuit 198FO2047

1.

Switch

2. Case 3. Wire
4. Connector

20-151

M-6
* * *

Abnormality

in buzzer
check that all the related connectors are properly inserted. in the charge level.

Before carrying out troubleshooting, Of the CAUTION

Always connect any disconnected connectors before going on the next step. items, the buzzer will not sound if there is an adnormality

a)

CAUTION

items are flashing,

but buzzer does not sound.

1
Does buzzer sound when CN2

YES

Defective

monitor

module.

ReplaCe

NO chassis. * Turn starting switch ON.

Defective contact, or disconnection in wiring harness betree CN454 (male) (1) CN465 - buzzer - CN466 CN2 (female) (EL or defective buzzer.

b)

No abnormal

display is given on monitor,

but buzzer sound.

Cause

Remedy

1 Does buzzer stop when CN2 is removed? - Remove CN2. * Turn starting switch ON.

YES

ON

Wiring harness betwee CN2 (female) (8) and CN466 short circuiting with chassis ground, or defective buzzer.

Repair or replace

M-6

Related

electrical

circuit

diagram

Monitor supplementary cOtrOller

#
I

+24V I

I
CN464 CN465 ( 1 Buzzer CN466

Monitor module

CN2

F91702220

20-152

M-7
t *

Abnormality

in warning

lamp

Before carrying out troubleshooting, check that all the related connectors are properly inserted. Always connect any disconnected connectors before going on the next step.

a) *

CAUTION

items are flashing,

but lamps do not flash.

Check visually to confirm that there is no disconnection in the lamp. (If the lamp bulb is blown, replace the bulb.)

Remedy

1
Does lamp light up when CN2 (female) (7) is connected to chassis ground? Ground CN2 (female) (7) to chassis. * Turn starting switch ON. _

YES

Defective

monitor

module.

NO

Defective contact or disconnection in wiring harness between CN2 (female) (7) - CN364 (2 - CN371 (2) -CN372 (2 1*(l) - CN371 (1) - CN364 (1) - CN464.

5
6

b)

No abnormal

display is given on monitor,

but lamp lights up

Defective Does lamp go out when CN2 is removed? * Remove CN2. Turn starting switch ON. NO

monitor

module. I

Replace

Wiring harness between CN2 (female) (7) - CN364 (2) CN371 (2) - CN372 (2) short circuiting with chassis ground, or defective lamp.

Repair or rePlaCe

M-7

Related

electrical

circuit

diagram
with cab _-___-,

CN372 Caution Lamp 198FO2270

20-153

M-8
* *

Abnormality

in gauge
check that all the related connectors are properly inserted.

Before carrying out troubleshooting,

Always connect any disconnected connectors before going on the next step.

a)
l

Abnormality

in coolant temperature

gauge
low temperature.

Engine coolant temperature

gauge shows abnormally

Cause

Remedy
After inspection sensor,

1
DOBS temperatre

display go off when Short COnnectOr IS connected to CN4027

* Connect

H
NO
is not displayed

YES

Defectwe

coolant sensor system

temperature

repair or replace according to table of standard values

Short

connector to CN402 Ifemalel. * Turn start!ng switch ON.

Defective contact or disconnection in wiring harness between CN402 (female) (1) CN401 (1) CN421 (1) CN2 (female) (11, Or between CN402 (female) (2) - CN401 (21 - CN421 (2) -chassis ground.

Repair replace

or

.~.

Engine coolant temperature

Cause

Remedy
I ifter inspect ion sensor. r epair or

YES

Defective coolant temperature sensor

system.

I eplace

accordng to table

Ic)f standard
\/alues
Repair replace or

* Disconnect connector of CN402 (female). * Turn starting switch ON.

NO

Wiring harness between CN402 (female) (I) CN401 (1) -CN421 (1) CN2 (female) (1) short circuiting with chassis ground.

M-8

a)

Related
CN2

electrical

circuit
CN421

diagram
CN401 CN402 Coolant temperature sensor

If the condition it is normal

is as shown

in the

table

below,

198FO2239

F19702218

20-154

b)
l

Abnormality
low temperature.

in torque converter

oil temperature

gauge

Torque converter oil temperature

gauge shows abnormally

After ~nspection sensor. repair or replace accord,ng to table of standard values

1
Does temperature display go off when short connector is connected to CN4537 * Connect short connector to CN453 (female). * Turn starting switch ON.

YES

Defective torque converter oil temperature sensor wstern. Defective contact nection in wiring between CN453 -CN451 (1) -CN2 (female) between CN453 (2) - CN421 (2) ground. or dixonharness (female) (1) CN421 (8) (2). or (2) - CN451 -chassis

Repair
replaCe

or

NO

Torque converter oil temperature

is not displayed. Cause Remedy

lfter inspec-

1
Does temperature gauge display appear when CN453 is removed? Disconnect connector of CN453 (female). * Turn starting switch ON.

YES

Defective torque converter oil temperature sensor system.

:ion sensor, xpair or replace accordng to table ,f standard ralu?S

NO

Wiring harness between CN453 female) (1) CN451 1) - CN421 (8) CN2 (female) (2) short circuiting with chassis ground.

M-8

b)

Related

electrical

circuit

diagram
Torque converter oil temperature sensor

CN2
Monitor module

CN421

CN451

CN453

F19702221
If the it is condition is es shown in the

normal.

table

below,

Oil temperature 58SOT

F19702218

20-155

c)
l

Abnormality in fuel level gauge

Fuel gauge always displays FULL.

Cause

Remedy

After inspection sensor, repair or YES

1 Does fuel
display gauge go off?

Defective system.

fuel

level

sens0r

replace according to table of standard VIIUBS Repair replace or

2
Does fuel gauge display go off?

YES

. Remove CN423 (fuel level

SWWX).

(3) short circuiting.with chassis ground. Defective monitor module. Replace

_.. .-. ,.,

N<

Turn starting switch ON. * Wait for approx. 1 min.

*

* Remove CN2 *ITurn stamng switch ON. * Waltforapprox.

NO

1ml

Fuel level is not displayed. Cause Remedy

After inspection sensor. repair or replace according to table of standard ValUeS ReplaCe

r
-

ia
Is FULL given7

YES

Defective svstem.

fuel

level

sensor

display 2 Is resistance between CN2 (female) (3) and chassis ground less than 15-Z? YES Defective monitor module.

* Remove CN423 (fuel level SellSOr). . Connect short

I NO

Defective contact or disconnection in wiring harness between CN423 (female) (1) -CN422 (1) - CN421 (7) -CN2 (female) (3). Repair replace or

connector.

Connect short
COnnectOr to CN423 (female) (1) (2).

NO

* Turn starting switch ON.

M-8 c) Related electrical

circuit diagram

CN2
Monitor module

CN421

CN422

CN423
Fuel level sensor

F19702222 Level sensor

F19702223

20-156

M-9
* *

Service meter does not move after engine is started

check that all the related connectors are properly inserted.

Before carrying out troubleshooting,

Always connect any disconnected connectors before going on the next step.

Cause

Remedy

YES 1

See M-5

a)

Does charge abnormality display flash?

2
Is voltage between CN3 (1) and (4) 20-3OV?

YES

Defective

service

meter.

REplfdCe

* Start

engine. NO

Defective contact or dirconnectlon in wiring harness beNyya CN122 (I) and

start

engine.

NO

Repair replace

or

M-S

Related electrical

circuit diagram

CN I
Monitor module T 0 Alternator terminal R

CN3 Battery relay

Service meter

F91702224

20-l 57

M-10 *
*
l l

Panel lighting for monitor panel does not light up (Liquid crystal display is normal)
check that all the related connectors are properly inserted.

Before carrying out troubleshooting,

Always connect any disconnected connectors before going on the next step. Check visually to confirm that there is no disconnection \hE.hen fuses No. 5 is normal (If fuse is blown, check for short circuit between CN361 (female) (8) - CN4 (11, CN5 (1)). in the lamp. (If the lamp bulb is blown,

replace the bulb.)

Cause

Remedy

1
Is voltage between CN361 (8) and chasis ground 20 - 3OV? * Turn starting switch ON. _

YES

Defective contact, or disconnection in wiring harness between CN4 (1) and CN361 (8). or between CN5 (1) and CN361 (6).

NO

1;
jee

E-7,

M-l 0

Related

electrical

circuit

diagram.

Relay

box

CN4

CN361 8

Monitor module

--F
H.H. working

Fuse 6

CN5

F91702225

20-158

30 DISASSEMBLY

AND ASSEMBLY

Method of using manual ............................ .30- 3 Precautions when carrying out operation . . 30- 4 Special tool list ............................................. 30- 6 STARTING MOTOR Removal. ................................................. 30-13 Installation .............................................. 30-13 ALTERNATOR .30-l 4 Removal ................................................. Installation ............................................. .30-l 4 ENGINE OIL COOLER Removal .................................................. 30-15 Installation ............................................. .30-15 TORQUE CONVERTER OIL COOLER Removal ................................................. .30-16 Installation .............................................. 30-16 FUEL INJECTION PUMP Removal ................................................. .30-17 Installation .............................................. 30-17 WATER PUMP Removal .................................................. 30-18 Installation .............................................. 30-18 TURBOCHARGER Removal .................................................. 30-19 .30-19 Installation ............................................. NOZZLE HOLDER Removal ................................................. .30-20 Installation .............................................. 30-20 CYLINDER HEAD Removal ................................................. .30-2 1 Installation .............................................. 30-25 FUEL TANK Removal ................................................. .30-26 Installation .............................................. 30-26 RADIATOR AND FRONT GUARD Turning over.. ........................................ .30-27 .30-27 Installation ............................................. RADIATOR Removal ................................................. .30-28 Installation .............................................. 30-28 RADIATOR GUARD Removal .................................................. 30-29 Installation ............................................. .30-31

ENGINE Removal .................................................. Installation .............................................. DAMPER Removal .................................................. Installation .............................................. Disassembly .......................................... Assembly ................................................ POWER TRAIN UNIT Removal .................................................. Installation .............................................. Disconnection ......................................... Connection ............................................. PTO, TORQUE CONVERTER Disconnection ........................................ Connection ............................................. TORQUE CONVERTER Disassembly ........................................... Assembly ............................................... PTO Disassembly ........................................... Assembly ................................................ TORQFLOW TRANSMISSION Disassembly ........................................... Assembly ................................................ STEERING CASE Disassembly ........................................... Assembly ............................................... STEERING CLUTCH, BRAKE Disassembly ........................................ Assembly ............................................. TRANSFER GEAR HOUSING Disassembly ........................................ Assembly ............................................. TORQUE CONVERTER VALVE Removal ............................................... Installation .......................................... Disassembly ......................................... Assembly ............................................. TRANSMISSION CONTROL VALVE Removal ............................................... Installation .......................................... Disassembly ....................................... Assembly .............................................

30-32 30-34 30-35 30-36 .30-37 30-38 30-40 30-42 30-43 30-45 .30-46 30-47 30-48 .30-53 30-55 30-63 30-68 30-78 30-91 .30-94 .30-100 .30-104 .30-108 .30-l 10 .30-l 12 ..30-112 30-I 14 .30-l 16 .30-l 17 ..30-117 ..30-118 .30-l 19

30-l @

STEERING CONTROL VALVE Removal ................................................ 30-120 Installation ............................................ 30-120 Disassembly ........................................ .30-122 Assembly .............................................. 30-I 22 SCAVENGING PUMP Removal ................................................ 30-124 Installation ............................................ 30-124 POWER TRAIN PUMP Removal ................................................ 30-125 Installation ............................................ 30-125 FINAL DRIVE Removal ................................................ 30-126 Installation ............................................ 30-127 Disassembly ......................................... 30-I 28 Assembly .............................................. 30-136 TRACK FRAME Removal ................................................ 30-148 Installation ............................................ 30-148 IDLER YOKE Reinoval ............................................ .30-148-l Installation ........................................ .30-148-2 RECOIL SPRING Removal.. .............................................. 30-149 Installation ........................................ .30-150-3 Disassembly ...................................... 30-150-4 Assembly ........................................... 30-150-4 IDLER Removal ................................................ 30-152 Installation ............................................ 30-152 Disassembly ........................................ .30-153 Assembly .............................................. 30-154 TRACK ROLLER Removal.. .............................................. 30-156 Installation ............................................ 30-156 Disassembly ......................................... 30-157 Assembly .............................................. 30-158 CARRIER ROLLER Removal ................................................ 30-I 59 Installation ............................................. 30-159 Disassembly ......................................... 30-160 Assembly .............................................. 30-161 TRACK SHOE Removal ................................................ 30-163 Installation ........................................ .30-l 63-2 Overall disassembly ........................... .30-164 Overall assembly ................................ .30-169 Press-fitting jig dimension table for link press .................................. 30-184 Field disassembly of one link ............. 30-185 Field assembly of one link.. ............... .30-187 Disassembly of master link ............... .30-189 Assembly of master link .................... .30-191 PIVOT SHAFT TWISTING SEAL Removal ................................................ 30-194 Installation ............................................ 30-194

PIVOT SHAFT Removal ................................................ 30-195 Installation ............................................ 30-195 EQUALIZER BAR Removal ................................................ 30-196 Installation ............................................ 30-198 EQUALIZER BAR SIDE BUSHING Removal ................................................ 30-199 Installation ............................................ 30-200 SUSPENSION CUSHION Removal ................................................ 30-201 Installation ............................................ 30-20 1 SEGMENT TOOTH Removal ................................................ 30-202 Installation ............................................ 30-202 HYDRAULIC PUMP Removal ................................................ 30-203 Installation ........................................... .30-203 BLADE LIFT VALVE Removal ................................................ 30-204 Installation ............................................ 30-204 Disassembly ......................................... 30-206 Assembly .............................................. 30-208 BLADE TILT, RIPPER LOW VALVE Removal .... _........................................... 30-210 Installation ............................................ 30-2 10 Disassembly ......................................... 30-212 Assembly .............................................. 30-214 RIPPER HIGH VALVE Removal ................................................ 30-216 Installation ............................................ 30-216 Disassembly ......................................... 30-218 Assembly .............................................. 30-220 BLADE LIFT CYLINDER Removal ................................................ 30-222 Installation ............................................ 30-222 BLADE TILT CYLINDER Removal ................................................ 30-223 Installation ............................................ 30-223 RIPPER LIFT CYLINDER Removal ................................................ 30-224 Installation ............................................ 30-224 RIPPER TILT CYLINDER Removal ................................................ 30-225 Installation ............................................ 30-225 HYDRAULIC CYLINDER Disassembly ......................................... 30-226 Assembly .............................................. 30-228 WORK EQUIPMENT Removal ............................................... .30-231 Installation ............................................ 30-232 Disassembly ........................................ .30-233 Assembly .............................................. 30-235 RIPPER Disassembly ......................................... 30-236 Assembly .............................................. 30-237

30-2 0

METHOD OF USING MANUAL

1. When removing (1) (2)

or installing

unit assemblies

When removing or installing a unit assembly, the order of work and techniques used are given for the removal operation; the order of work for the installation operation is not given. Any special techniques applying only to the installation procedure are marked m, and the same mark is olaced after the relevant step in the removal procedure to indicate which step in the installation procedure it applies to. (Example) REMOVAL OF 0 0 0 ASSEMBLY

. . . . . . . . . Title of operation
related to safety when carrying out the

Precautions A .................................. operation 1.

xxxx
*

(1) ........................... ................................ . . . . . .._................

2.

A A A (2):

Step in operation Technique or important point to remember when removing XXXX (1). m Indicates that a technique is listed for use during installation

3. 0 Cl q 0 assembly (3) n : . . . . . . .._...................... OF 0 0 0 ASSEMBLY See Lubricant and Coolant Table

INSTALLATION
l

....

Title of operation

Carry out installation in the reverse order to removal. m.............................. Technique used during installation * . . . . . . . . . . . . . . . . . . . . . . . . . . . . . : Technique or important point to remember

when in-

Adding water, oil . . . . . . . . . . . . . . . . . . * ..............................

Q ..........................

stalling A A A (2). Step in operation Point to remember when adding water or oil
Quantity of filling oil and water

2. General precautions when carrying out installation or removal (disassembly or assembly) of units are given together as PRECAUTION WHEN CARRYING OUT OPERATION, so be sure to follow these precautions when carrying out the operation. 3. Listing of special tools (1) For details of the description, part number, and quantity of any tools (A,, etc.) that appear in the operation procedure, see the SPECIAL TOOLS LIST given in this manual.

30-3 0

PRECAUTIONS

WHEN CARRYING OUT OPERATION

[When carrying out removal or installation (disassembly or assembly) of units, be sure to follow the general precautions given below when carrying out the operation.] 1. Precautions . . . . . . . . .
l

when carrying out removal

work

If the coolant contains antifreeze, dispose of it correctly. After disconnecting hoses or tubes, cover them or fit blind plugs to prevent dirt or dust from entering. When draining oil, prepare a container of adequate size to catch the oil. Confirm the match marks showing the installation position, and make match marks in the necessary places before removal to prevent any mistake when assembling. To prevent any excessive force from being applied to the wiring, always hold the connectors when disconnecting the connectors Fit wires and hoses with tags to show their installation position to prevent any mistake when installing. Check the number and thickness of the shims, and keep in a safe place. When raising components, be sure to use lifting equipment of ample strength. When using forcing screws to remove any components, tighten the forcing screws alternately. Befor removing any unit, clean the surrounding area and fit a cover to prevent any dust or dirt from entering after removal. Precautions when handling piping during disassembling Fit the following blind plugs into the piping after disconnecting 1) Hoses and tubes using sleeve nuts
Nominal number 02 03 04 05 06 10 12 Plug (nut end) 07376-50210 07376-50315 0737650422 Sleeve nut (elbow end) Use the two items below as a set 07221-20210 07221-20315 07221-20422 (Nut), 07222-00210 (Nut), 07222-00312 (Nut), 07222-00414 (Nut), 07222-00515 (Nut), 07222-00616 (Nut), 07222-01018 (Nut), 07222-01219 (Plug) (Plug) (Plug) (Plug) (Plug) (Plug) (Plug)

it during disassembly operations.

] 1

07376-50522 07376-50628

] 07221-20522
/07221-20628 107221-21034 07221-21234

1 07376-51034 07376-51234

2) Split flange type hoses and tubes

Nominal number 04 05 Flange (hose end) 07379-00400 07379-00500 Sleeve head (tube end) 07378-l 0400 07378-l 0500 Split flange 07371-30400 07371-30500

3) If the part is not under hydraulic pressure, the following corks can be used.

A n -a 1 L Taper l/8

i -0 ?a 7

ZOZF2001

2. Precautions

for installation

operations

. . *

Tighten all bolts and nuts (sleeve nuts) to the specified (KES) torque. Install the hoses without twisting or interference. Replace all gaskets, O-rings, cotter pins, and lock plates with new parts. Bend the cotter pin or lock plate securely. When coating with adhesive, clean the part and remove all oil and grease, then coat the threaded portion with 2 - 3 drops of adhesive. When coating with gasket sealant, clean the surface and remove all oil and grease, check that there is no dirt or damage, then coat uniformly with gasket sealant. Clean all parts, and correct any damage, dents, burrs, or rust. Coat rotating parts and sliding parts with engine oil. When press fitting parts, coat the surface with antifriction compound (LM-P). After fitting snap rings, check that the snap ring is fitted securely in the ring groove. When connecting wiring connectors, clean the connector to remove all oil, dirt, or water, then connect securely. When using eyebolts, check that there is no deformation or deterioration, screw them fully, and align the direction of the hook. When tightening split flanges, tighten uniformly in turn to prevent excessive tightening on one side. When operating the hydraulic cylinders for the first time after reassembling cylinders, pumps and other hydraulic equipment removed for repair, always bleed the air as follows: 1. Start the engine and run at low idling. 2. Operate the work equipment control lever to operate the hydraulic cylinder 4 - 5 times, stopping 100 mm from the end of its stroke. 3. Next, operate the hydraulic cylinder 3 - 4 times to the end of its stroke. 4. After doing this, run the engine at normal speed. * When using the machine for the first time after repair or long storage, follow the same procedure.

3. Precautions

when completing

the operations

. . .
.

If the coolant has been drained, tighten the drain valve, and add water to the specified level. Run the engine to circulate the water through the system. Then check the water level again. If the hydraulic equipment has been removed and installed again, add engine oil to the specified level. Run the engine to circulate the oil through the system. Then check the oil level again. If the piping or hydraulic equipment, such as hydraulic cylinders, pumps, or motors, have been removed for repair, always bleed the air from the system after reassembling the parts. * For details, see TESTING AND ADJUSTING, Bleeding air. Add the specified amount of grease (molybdenum disulphide grease) to the work equipment related parts.

30-5 0

SPECIAL TOOL LIST

Nature of work

Symbol

Parts No. 791-654-I 100

Part Name Remover Puller (30 t) Pump Installer assembly Plate Puller (30t) Pump Bracket Repair stand Bracket Repair stand Push tool Ring assembly Ring assembly

Qty 1 1 1 1 1 1 1 1 1 1

Remarks

Removal of radiator guard assembly

790-I 01-2102 790-I 01-l 102 791-600-I 100

Removal of guard pin

Installation of dumper Assy

195-12-11210 B 790-I 01-4200 790-I 01-l 102

I Press-in of , dumper bearing

Disassembly, assembly of torque converter assemblv

790-413-I 010 790-501-5200 790-415-I 011 790-501-5200 791-615-I 130

IFor overseas

IFor overseas
1 1 1 1 IRemoval of No.5

I:lutch piston
Installment of snap I-ing of No. 4 carrier Installment of snap

Disassembly, assembly of TORQFLOW transmission assembly

791-615-I 200 791-615-1101

I.ing of No. 2 and 3 (3peration check of (:lutch piston

f3emoval of cluth

799-301-I 600 Disassembly and assembly of steering case Assy

3il leak tester

791-622-I 1 IO

3racket

k ke Assy xa

790-337-I 032 Removal, installation of final drive assembly 791-627-I 210 F 791-627-I 320

_ifting tool late shackle 3olt 3emover assembly Puller (30 t) Pump Remover assembly Plate Cylinder (30 t) Pump Remover assembly Puller (30 t) ump

1 1 2 2 1 1 1 1 1 1 1 1 1 1 -1 qemoval, press_I iitting of carrier Ilin IRemoval of Irubber bushing fRemovable of final -c drive Assy

0101 O-52090 791-627-I 400 790-I 01-2102 790-I 01-l 102 790-431-1801

-r

Removal of sprocket bearing

Disassembly, assembly of final drive assembly

791-627-I 260 G 2 790-I 05-I 100 790-I 01-l 102 791-627-I 600 3 790-I 01-2102 790-I 01-l 102

30-6 Co

Nature of work

Symbol

Parts No. 791-627-l 200

Part Name Remover assembly

1

W
1 1

Remarks

790-I 01-2102 790-I 01-l 102

791-627-I 250 791-627-I 300

Guide Installer assembly Puller (30 t) Pump Installer assembly Puller (30 t) Pump Installer assembly Puller (30 t) Pump Installer

1 1 1 1 1 1 1 1 1 1

Fitting of pinion and gear

6 Disassembly, assembly of final drive assembly

790-I 01-2102 790-I 01-l 102 791-627-I 700

Press-fittings of center bearing

790-I 01-2102 790-I 01-l 102 791-627-I 500

Press-in of carrier pin

790-I 01-2102 790-I 01-l 102

_ Press-fitting of _ sprocket bearing

791-627-I 280 791-630-I 300

z
2
6

Installation of floating seal

Removal, installation of recoil spring assembly

790-I 01-2102 790-I 01-l 102 791-685-8500 or 790-434-I 700

Disassembly, assembly of recoil spring assembly

791-775-I 110 791-635-3160 790-I 01-l 600 790-I 01-l 102 791-630-I 200 1 790-I 01-2102 790-I 01-l 102

Spacer Extension Cylinder (70 t) Pump

I 1 I I 1 I

I 1 I

Assembly of front idler assembly

J 2

791-630-I 400 790-I 01-2102 790-I 01-l 102 3 791-515-I 520 Installer 1 Installation of floating seal w hiss-i-zf floating

30-7 0

track roller assembl

Assembly of track roller Assy

Disassemby and assembly of track roller Assy

Removal of center bar bushing

g ? z

791-650-I 800 Replacement of equalizer side bushing P 790-I 01-2102 790-I 01-l 102 790-502-I 003 1 790-5&3000 2 790-I 02-3802 790-I 02-3300 Disassembly and assembly of hydraulic cylinder 0 3 790-720-I 000 796-720-I 670 07281-01279 796-720-I 690 4 07281-02169 796-720-I 690 07281-01919

Remover & installer Puller (30 t) Pump

1 1 1 1 Press-in of side

- spherical bushing

Repair stand 1 Multi wrench Wrench Expander Ring Clamp Ring Clamp Ring Clamp 1 1 1 1 1 1 1 1 1 Removal of cylinder head nut Expansion of piston ring Blade lift cylinder Blade tilt and ripper lift cylinder Ripper tilt cylinder _E 5 -z % % ym + z

30-8 a

Nature of work Removal of pin plug of lubricated track link Cleaning of pin of lubricated truck link Installation of pin plug of lubricated track link Installation of seal of lubricated track link Air tightness check of lubricated track link Filling of lubricated track link with oil

Symbol

Parts No. 791-646-7531 I

Part Name Remover

Remarks

I I

I
I

1 1 1 1

I
For washing pin I For lage plug For small plug For F3 type seal

X Y Z KA

791-660-7460 791-646-7900 791-932-I 1 IO 791-632-I 030

Brush Push tool Push tool Push tool

KB

791-601-I 000 791-646-8002

Oil pump Assy Lubricator oil pump assembly

I
I

1 1 1
I

KC 791-601-I 000 790-434-I 1 IO 790-434-l 610 1 195-32-61210 0101 O-51 440 790-101-1102 2 790-I 01-4300 791-685-9510 791-685-9520 791-685-9530 791-685-9550 791-685-9560 Bolt Adapter buide II I

1
2

I
Shoe bolt may be used

I I
I 2 I

1Bolt
I Pump I Cylinder I Frame I Frame

I
I 1

I
1150tons

1 Rod
1Nut 1Bolt

Track link remover

KD

790-434-I I 20 0101 O-51 030 04530-I 2030 790-101-1102 790-I 01-4300 791-685-9540

I Adapter 1Bolt I Eye bolt

I Pump Cylinder Rod Nut Frame Frame

I I I I I I
I

1 1 1 1 4

I I I I I I

I 1 I
I 1 I
1 1 2 1 1

1 I

150 tons

791-685-9550 791-685-9510

5 791-685-9520

30-9 0

Nature of work

Symbol

Parts No.

Part Name

Remarks

Track link remover

KD

Track link Installer

<E

30-10 0

Nature ofwork

Symbol

PartsNo. 791-685-9510 791-685-9520 791-685-9530 791-685-9540 791-685-9550 791-685-9560

Part Name Frame Frame Rod Rod Nut Bolt Adapter Bolt

Q'ty 1 1 1 1 3 4 1 1

Remarks

791-126-0150 01010-51030

791-685-9620 1Extension 791-680-5550 790-434-1140 791-680-9630 790-101-1102 790-101-4300 Track link Installer KE 5 790-434-1160 791-685-9510 791-685-9520 791-685-9530 791-685-9540 791-685-9550 791-685-9560 6 791-126-0150 790-434-1150 790-434-1120 01010-51030 790-434-1160 790-101-1102 790-101-4300 790-101-1102 7 790-101-4200 Rod Nut Bolt Adapter Guide Adapter Bolt Guide Pump Cylinder Pump Puller Frame 1Guide IAdapater

I I

1 1

I I

1 Adapter
~Pump

I I I

1 1 1

I I I

s1 E
0

I I
I

1 I 1 I
1 1 1 30tons 1150tons

30-11 0

Nature of work

Symbol

Parts No. 791-680-9801

Part Name Remover & installer Pump Puller Cylinder

otv 1 1 1 1

Remarks KIT For lubricated type

Track link remover & installer

KF

790-I 01-l 102 790-I 01-4200 790-I 01-4300

30 tons 150 tons

30-12 0

REMOVAL OF STARTING MOTOR ASSEMBLY

Disconnect the cable from the negative terminal of the battery. Disconnect wiring (1) and (2). Disconnect wiring connector (3). Remove starting motor assembly (top) (4). Remove (5). starting motor assembly

(-)

(bottom)

INSTALLATION OF STARTING MOTOR ASSEMBLY . Carry out installation in the reverse order
removal.

to

30-l 3 @

REMOVAL
Serial a-

OF ALTERNATOR

ASSEMBLY

No. : 10001 - 10167

H ter-

Drsconnect the cable from the negative minal of the battery. Disconnect Remove Remove Remove Remove Remove wiring (I 1. bolt (2).

1.
2. 3. 4. 5. 6.

adjustment

fan belt cover (3). mounting belt (5). alternator assembly (6). bolt and nut (4). a

F19703003

INSTALLATION OF ALTERNATOR ASSEMBLY

Serial
l

No. : 10001 - 10167

Carry out installation removal. in the reverse order to

pq * Adjust the alternator belt tension. For details, see TESTING AND ADJUSTING.

30-14 @

REMOVAL

OF ALTERNATOR

ASSEMBLY
I
(-1 ter-

Serial No. : 10168 and up

ADisconnect the cable from the negative minal of the battery.

1. Disconnect wires (I) and (2). 2. Loosen mounting bolts (3) of alternator assembly. 3. Loosen locknut (4), then rotate adjustment nut (5) and remove V-belt (6). 4. Remove bolts (7) and (31, then remove alternator assembly (8) together with belt cover. a

z z

INSTALLATION OF ALTERNATOR ASSEMBLY

Serial No.: 10168 and up
Carry out removal. installation in the reverse order to

Adjusting tension of alternator belt * Adjust the tension of the alternator belt. For details, see TESTING AND ADJUSTING.

30-14-l @

REMOVAL
1. 2. Drain cooling

OF ENGINE OIL COOLER ASSEMBLY

Serial No. : 10168 and UD water.

Remove adiabatic covers (I), (21, and (3). * The adiabatic covers are installed to Serial No. 10168 and up. Remove Remove (2). turbocharger torque outlet tube (I). oil cooler connector

3. 4.

converter

5.

Remove

engine

oil cooler

assembly

(3).

INSTALLATION OF ENGINE OIL COOLER ASSEMBLY

.
Carry out installation removal. in the reverse order to

Refilling with water * Add water to the specified level from filter port, and run the engine to circulate the water through the system. Then check the water level again.

30-l 5 @

REMOVAL
Serial

OF TORQUE CONVERTER

OIL COOLER ASSEMBLY

No . : 10001 - 10167

1. Drain cooling water. 2. Remove cover (1). 3. Disconnect heater hose (2). 4. Remove bly (3). 5. Disconnect torque converter and outlet hoses (4) and (5). 6. Remove tor (6). torque converter oil cooler inlet engine oil cooler drain plug assem-

oil cooler connec-

7. Remove torque converter oil cooler assembly (7). &I kg Torque converter oil cooler assembly: 75 kg

F19703004

INSTALLATION OF TORQUE CONVERTER OIL COOLER ASSEMBLY

Serial
l

No . : 10001 - 10167
in the reverse order to

Carry out installation removal.

Refilling with water * Add water to the specified level from filler port, and run the engine to circulate the water through the system. Then check the water level again.

30-l 6 @

REMOVAL
Serial
1. 2. 3. 4. 5. 6. 7. 8. 9.

OF TORQUE CONVERTER

OIL COOLER ASSEMBLY

No.: 10168 and up

Remove engine underguard. Drain coolant. Open engine right side cover (I) and remove side cover (2). Remove side covers (3), then remove side cover stay. Remove water inlet tube (4). Remove water outlet tube (5). Disconnect oil inlet hose (6). Disconnect oil outlet hose (7). Sling torque converter oil cooler assembly (81, remove mounting bolts, then lower assembly to remove. &I kg Torque converter oil cooler assembly : 75 kg

CED01240

z s

INSTALLATION OF TORQUE CONVERTER OIL COOLER ASSEMBLY

Serial . No . : 10168 and up
installation in the reverse order to

Carry out removal.

Refilling with water Add water to the specified level, and run the engine to circulate the water through the system. Then check the water level again.

30-l 6-1 8

REMOVAL
Serial

OF FUEL INJECTION

PUMP ASSEMBLY

No. : 10001 - 10167

* 1.
2. 3. 4. 5. 6. 7.

Close the fuel supply valve.

Disconnect Disconnect Remove 4 fuel supply hoses (1). fuel control rod (2).

lubrication

tubes (3) and (4). tubes (5). cover (6). m

Disconnect Remove Remove Remove kg L%

6 fuel injection

injection coupling

pump coupling bolts (7).

fuel injection Fuel injection

pump assembly pump assembly:

(8). a 30 kg

z s
INSTALLATION OF FUEL INJECTION PUMP ASSEMBLY
Serial . No . : 10001 - 10167
installation in the reverse order Carry out removal.

to

a w Sleeve nut:

22.1 2 2.5 Nm i2.25 + 0.25 kgm} w

Fuel injection mounting bolt: 53.9 f 19.6 Nm I5.5 = 2.0 kgm} Adjust the fuel injection timing. For details, see TESTING AND ADJUSTING.

30-17 8

REMOVAL
Serial

OF FUEL INJECTION

PUMP ASSEMBLY

No. : 10168 and up

1. Open engine left side cover (I), then remove side covers (2) and (31, and side cover stay. 2. 3. Close fuel supply valve. Remove bracket (4), oil level gauge control rod (6). Disconnect 4 fuel hoses (7).
CED01332

(51, and fuel m

4. 5.

Remove lubrication tubes (8) and (9), and boost compensator tube (IO). Disconnect Remove 6 delivery tubes (II).

6. 7. 8.

coupling

cover (12).

Loosen mounting bolts (13) at drive shaft end and remove 4 pump mounting bolts (14). Remove fuel injection gether with coupling. r+ kg Fuel injection pump assembly (15) tom

9.

pump assembly

: 30 kg

INSTALLATION OF FUEL INJECTION PUMP ASSEMBLY

Serial . No. : 10168 and up
in the reverse order to

Carry out installation removal.

Adjust the fuel control rod. For details, see TESTING AND ADJUSTING, Adjusting fuel control linkage.

* *

Adjust the injection timing. For details, see TESTING AND ADJUSTING, Adjusting fuel injection timing. Bleed the air from the fuel circuit.

30-l 7-l
@

ROMOVAL
Serial

OF WATER PUMP ASSEMBLY

No. : 10001 - 10167

1. Drain cooling water. 2. Remove torque tor (1). converter oil cooler connec-

3. Remove water tube (2). 4. Remove water pump assembly (3).

INSTALLATION OF WATER PUMP ASSEMBLY

Serial . No . : 10001 - 10167
Carry out installation der to removal. in the reverse or-

Refilling with water * Add water to the specified level from

filter port, and run the engine to circulate the water through the system. Then check the water level again.

30-18 @

REMOVAL

OF WATER PUMP ASSEMBLY

Serial No. : 10168 and up 1.

2. Drain coolant. Open engine right side cover (I), then remove side covers (2) and (3), and side cover stay. Remove torque (4) and (5). Remove Remove water water converter oil cooler connectors

3.

4. 5.

tube (6). pump assembly (7).

z
z
0

INSTALLATION OF WATER PUMP ASSEMBLY

Serial No.: 10168 and up . .
Carry out removal. installation in the reverse order to

CED01507

Refilling with water

Add water to the specified level, and run the engine to circulate the water through the system. Then check the water level again.

30-l 8-1 @

REMOVAL
1.

OF TURBOCHARGER

ASSEMBLY
Serial No. : 10168 and up

Remove adiabatic covers (II, (2), and (3). + The adiabatic covers are installed to Serial No. 10168 and up. Remove intake connector turbocharger (1). inlet hose (2). outlet tube (3). assembly assembly: (4). 30 kg

2. 3. 4. 5.

Disconnect Remove Remove kg r&l

turbocharger turbocharger Turbocharger

CEDOl939

INSTALLATION OF TURBOCHARGER ASSEMBLY . Carry out installation in the reverse order

removal.

to

a
* m Fit the gasket with the TOP mark facing up. Mounting bolt: 49.0 = 4.9 Nm I5 + 0.5 kgm}

30-19 @

REMOVAL OF NOZZLE HOLDER ASSEMBLY

1. Remove exhaust pipe. (Only for No. 4 to 6.) & Exhaust pipe: 30 kg

2. Remove radiator top cover and 4 engine side covers at top on left and right. (Only for No. 4 to 6.) * For No. 1 - 3, remove only the top left engine side cover. 3. Lift off hood (3). (Only for No. 4 to 6.) Pl kg Hood: 85 kg

4. Disconnect Komaclone tube. Lift off air cleaner assembly (1). (Only for No. 4 to 6.) & kg Air cleaner assembly: 35 kg

5. Remove cover (2). (Only for No. 1 to 3.) 6. Remove cover (3). (Only for No. 4 to 5.) 7. Remove Komaclone tube (4), then bracket (5). (Only for No. 6.) 8. Remove clamp, then remove fuel pipe (6). (Only for No. 2 to 6.) m * For No. 1, disconnect. 9. Disconnect spill connection (8). 10. hose (7), then remove

injection

remove

Remove cylinder head cover (9).

m m

11. Remove nozzle holder assembly (IO).

INSTALLATION OF NOZZLE HOLDER ASSEMBLY

l

Carry out removal m

installation

in the

reverse

order

to

m Sleeve nut: 22.05 + 2.45 Nm I2.25 +. 0.25 kgm)

m B a m * * Nozzle holder mounting bolt: 26.95 + 2.45 Nm I2.75 2 0.25 kgm} Tighten the nozzle holder mounting bolts uniformly. Set the nozzle holder with the match mark facing the front of the engine, then install. Cylinder head cover mounting bolt: 31.85 + 2.45 Nm i3.25 + 0.25 kgm}

30-20 @

REMOVAL

OF CYLINDER HEAD ASSEMBLY

pipe.

1. Drain coolant. 2. Remove exhaust

Exhaust pipe : 30 kg r&l 3. Rikove radiator top cover, then and right engine side covers. 4. Lift off hood. Hood : 85 kg &I Komaclone 5. DLiconnect cleaner assembly (1). kg r&I Air cleaner

remove

4 left

tube,

and

lift off

air

assembly

: 35 kg

6. 7. 8. 9.

Remove intake connector (2). Remove cover (3). Remove intake connector (4). Disconnect flange (5) of Komaclone

tube.

r: 2 z 10. Remove adiabatic covers (371, (38), and (39). * The adiabatic covers are installed to Serial No. 10168 and up. 4 -

Serial No. : 10168 and UD

11. Disconnect turbocharger inlet hose (6). 12. Remove turbocharger outlet tube (7). 13. Remove muffler drain tube (8).

and exhaust mani14. Sling muffler, turbocharger, fold as an assembly, the lift off muffler, turbocharger, and exhaust manifold assembly (9). a &I kg Muffler, turbocharger, assembly: 160 kg exhaust manifold

15. 16. 17. 18. 19.

Remove Remove Remove Remove Remove

cover (IO). 6 injection pipes (II). Komaclone tube (12). inlet tube (13). turbocharger bracket (I 4).

20. Disconnect wiring connector (15). 2 hoses (16), and move 21. Disconnect (17) down. 22. Remove 2 tubes (18), then remove resistor (19). 23. Remove breather (20).

fuel filter corrosion

tube (40) at in24. Disconnect boost compensation take manifold end. tube is installed to The boost compensation * Serial No. 10168 and up.

Serial No. : 10168 and up

30-22 @

25. Using eyebolt sembly (21).

0,

remove

intake

manifold m

as-

el
kg

Intake manifold

assembly

: 50 kg

26. Remove spill tube (22) and connection (23). In the case of No. 5 and 6, disconnect wiring * connector (24) and ground connection (25), then remove bracket (26).

/hV
27. Using forcing screws 0, remove head cover (27). m

17MFQ2214

/-\

'I

17MF02215_

28. Remove rocker arm assembly (28). loosen the locknut, then loosen + ment screw 2 or 3 turns.

m the adjust-

30-23

29. 30. 31. 32.

Remove Remove Remove Remove

push rod (29). crosshead (30). flange (31). nozzle holder assembly

(32).

m 33. Remove rocker arm housing. 1) Remove pin (33), the use a bar to lever pipe (34) and move it. 2) Remove mounting bolts, then remove rocker arm housing (35).

34. Using eyebolts 0, bly (36). r+ kd Cylinder

remove

cylinder

head assemm

head assembly

: 40 kg

30-24 8

INSTALLATION OF CYLINDER HEAD ASSEMBLY

. @i

1
w . .

Carry out removal.

installation

in the

reverse

order

to

&

Exhaust manifold mounting bolt : 1st step: 0 - @: 49 2 9.8 Nm 6 = 1 kgm1 2nd step: @I,@: 88.2 d 9.8 Nm {9 2 1 kgm} m -@: 110.3 + 12.3 Nm ill.25 c 1.25 kgm} Mounting bolt (2 places marked *) : Anti-friction compound (LM-P) Sleeve nut : 22.1 = 2.5 Nm I2.25 + 0.25 kgm}

17MF02216

w m m
l

Intake manifold mounting bolt : 1st step: 0 - @: 24.5 + 4.9 Nm I2.5 r 0.5 kgm1 2nd step: @I - 8: 63.7 f 9.8 Nm (6.5 + 1.0 kgml Cylinder head cover mounting bolt : 31.9 + 2.5 Nm I3.25 2 0.25 kgm}

a w

I I 17MF02217

m w

Clean the oil holes of the mounting bolts before installing. Check that the ball of the adjustment screw is fitted properly into the socket of the push rod. Adjust the valve clearance. For details, see TESTING AND ADJUSTING, Testing and adjusting valve clearance. Rocker arm assembly mounting bolt : 98 = 4.9 Nm {IO 2 0.5 kgm} Locknut : 67.7 + 9.8 Nm I6.9 r 1 kgm} Adjust the crosshead as follows.

M *

1) Loosen the locknut and turn back the adjustment screw.

2) Press down lightly with a finger on the top

of the crosshead and screw in the adjustment screw. w Locknut: 39.2 c 5.9 Nm (4 f 0.6 kgm} w Flange mounting bolt : 27 z 2.5 Nm I2.75 d 0.25 kgm1 Rocker arm housing mounting bolt : 98.1 +. 4.9 Nm {IO f 0.5 kaml

30-25 @

* * * * *

If any rust of more than 5 mm square is found on the shaft or the thread of the bolt, replace the head bolt with a new bolt. Be careful to check that there is no dirt or mounting surface of the dust on the cylinder head or inside the cylinder. Check that the grommet does not come out when installing the gasket. Tighten the cylinder head mounting bolts 2 hand, then tighten in the - 3 turns by order given in the diagram. After tightening, make one punch mark on the bolt head to indicate the number of times it has been tightened. . If any bolt already has five punch marks, do not reuse it. Replace it with a new bolt. ro1, Mounting bolt : Anti-friction compound (LM-P) QEI Cylinder head mounting bolt :

6162F311

Serial No. : 10001 - 10167 1st step : 77.5 2 14.7 Nm I7.9 = 1.5 kgm} 2nd step : 230.5 + 14.7 Nm (23.5 2 1.5 kgm} 3rd step : 382.5 r 14.7 Nm I39 f 1.5 kgm} Final tightening torque: 495.2 + 14.7 Nm j50.5 + 1.5 kgm}

Serial No. : 10168 and up

1st step : 98.1 2 9.8 Nm {IO + 1 kgm} 2nd step : 186.3 z 4.9 Nm I19 f 0.5 kgm} 3rd step : Make marks with paint on the bolt and head, then tighten bolt a further 60tzZ.

Make

cylinder

marks on head and

bolt

Refilling with water Add water to the specified level, and run the engine to circulate the water through the system. Then check the water level again.

Tighten

bolt

SO;!5 DBD03028

30-25-l @

REMOVAL OF FUEL TANK ASSEMBLY

1. Remove rear cover (1). 2. Close 2 fuel valves (2). 3. Disconnect hose (3). 4. Remove hose mount brackets (4) and (5) with hoses still installed. Disconnect wiring connector (6).

Remove side cover at left side of cab.

17MF02218

Disconnect hose (8). Lift off tank (9). * Be careful that the hose bracket does not get caught when lifting off. & kg Fuel tank assembly: 1,150 kg (When tank is full)

INSTALLATION OF FUEL TANK ASSEMBLY

l

liti
&

I
z

Carry out installation removal.

in the reverse order to

I
30-26 8

198FO2412

TURNING OVER RADIATOR AND FRONT GUARD ASSEMBLY

1. Drain cooling water. 2. Disconnect radiator outlet tube (I), move it to side. 3. Remove radiator top cover. 4. Disconnect ground connector (3). connection (2) and

5. Disconnect aeration hose (4). 6. Disconnect (5). radiator inlet tube of connector

7. Disconnect hose radiator sub-tank.

(6) between

radiator

and

8. Sling radiator and front guard assembly, then disconnect left and right brackets (7) and cap. Lower radiator and front assembly slowly, and secure radiator and front assembly (9) with wire (8).

INSTALLATION OF RADIATOR AND FRONT GUARD ASSEMBLY

l

Carry out installation removal.

in the reverse order to

Refilling with water * Add water to the specified level from filler port, and run the engine to circulate the water through the system. Then check the water level again.

I97FO302

30-27 0

REMOVAL OF RADIATOR ASSEMBLY

1. For details,

see TURNING OVER RADIATOR AND FRONT GUARD ASSEMBLY.

2. Remove left and right bottom mounting brackets. 3. Sling radiator assembly, then remove left and right top caps (2). 4. Raise radiator assembly slowly, then remove radiator assembly (3). * Be careful not to damage the core when removing the assembly. I9 kg Radiator assembly: 350 kg

I97FO3023

INSTALLATION ASSEMBLY
l

OF RADIATOR

Carry out installation removal.

in the reverse order to

30-28 0

REMOVAL OF RADIATOR GUARD ASSEMBLY

Lower the work equipment ground.

completely

to the

1. Sling blade lift cylinder, and remove cap (1) and shim (2) of piston rod. m * Check the number and thickness of the shims, and keep in a safe place. 2. Run engine, and retract piston rod of blade lift cylinder fully. * After disconnecting the blade cylinder, install it to the lock pin on the body to hold it in position.

3. Drain cooling water. 4. Remove radiator outlet hose (3). 5. Remove exhaust pipe. & kg Exhaust pipe: 30 kg top cover and 6 left and

6. Remove radiator right side covers. 7. Lift off hood. g H f15 z & kg Hood:

85 kg

8. Remove cover, and disconnect 2 blade hoses (4). g Operate the control levers several times to release the remaining pressure in the hydraulic piping.

9. Disconnect aeration hose (5) at radiator end. 10. Disconnect end. 11. 12. radiator inlet hose (6) at radiator

Disconnect 2 cooler hoses (7). Disconnect wiring connector (8).

30-29 @

Serial

No. : 10001 - 10167

Serial No. : 10001 - 10167

13. Loosen fan belt tension

nut (9), adjustment then push tension pulley, and remove fan m belt (IO) from pulley. Be careful when pushing the tension pul+ ley, as the pulley will rotate.

'162Fl40

Serial No. : 10168 and UD Serial No. : 10166 and up

13. Loosen tension of tension pulley (91, and a remove fan belt (IO). Ir Using a chain block, pull in the direction shown in the diagram on the right to loosen the tension of the tension pulley belt.

IO
CEDOl944

14. Remove lock bolt (I 1). 15. Sling radiator guard assembly, pull out rear pin (12). Ir Repeat the operation in the same order on the opposite side. If pin (12) is stiff, disconnect the track * and use tool A to remove pin (12).

16. Using tool A, pull out front pin (13). J, Repeat the operation in the same on the opposite side.

order

30-30 @

17. Lift off radiator guard assembly (14) slowly. * Be extremely careful not to damage the core when removing. &I kg Radiator guard assembly

: 2400 kg

INSTALLATION OF RADIATOR GUARD ASSEMBLY . Carry out installation in the

removal.

reverse order to

Adjust so that the play at the spherical portion in the axial direction is within 0.5 mm, and check that it rotates smoothly. Standard shim thickness C : 4 mm

197F381

Bleed the air from the cylinder. For details, see TESTING AND ADJUSTING.

Adjust the fan belt tension. For details, see TESTING AND ADJUSTING.

30-3 1 8

REMOVAL
ADisconnect terminal

OF ENGINE ASSEMBLY
the negative (-1

the cable from of the battery.

1. Drain coolant. 2. Remove exhaust

pipe.

Exhaust pipe : 30 kg &I radiator top cover and left and right 3. Rikove side covers. 4. Lift off hood. Hood : 85 kg &I 2 cab front steps and intake port 5. Rihove cover. 6. Disconnect starting motor wiring (1). 7. Remove cover (2). 8. Remove 2 connectors (3) of torque converter oil cooler. 9. Disconnect radiator outlet hose (4).

Serial

No.

: 10001

- 10167

Serial No . : 10001

- 10167

nut (5) and remove fan IO. Loosen adjustment a belt (6) from pulley. Be careful when pushing the tension pul* ley, as the pulley will rotate.

Serial

No.

: 10168

and

up

Serial No. : 10168 and up

10. Loosen tension pulley (5) and remove fan belt (6). Using a chain block, pull in the direction * on the right to shown in the diagram loosen the tension of the tension pulley belt.

DO1945 CE

30-32 @

11. 12. 13. 14. 15.

Disconnect radiator inlet hose (7). Disconnect aeration hose (8). Remove 2 covers (9). Disconnect 2 air conditioner hoses (IO). Disconnect wiring connector (I I).

16. 17. 18. 19.

Disconnect Disconnect Disconnect Disconnect

fuel control rod (12). 2 fuel hoses (13). ground wire (14). 2 wiring connectors (15).

Disconnect Komaclone cleaner assembly (16).

tube, and lift off air

el
kg

Air cleaner

assembly

: 35 kg

21. Remove 2 battery cables (17). 22. Disconnect fuel control intermediate 23. Disconnect wiring connector (19).

rod (18).

24. Disconnect 25. Disconnect 26. Disconnect

2 air conditioner hoses (20). 2 heater hoses (21). 2 ELPC valve hoses (22).

27. Remove clamp (23) of receiver move receiver tank to left. 28. Lift off bracket (24). kg r&l Bracket : 65 kg

tank,

then

29. Remove damper 30. Lift off universal

level gauge joint (26).

(25). m

17MF02239

17MF02239

m 31. Lift off engine assembly (27). + When removing the engine assembly, check that all wiring and piping has been disconnected, and use a lever block to prevent interference with any parts, and lift off with the front slightly raised. Be particularly careful to make sure that the front mount does not hit the radiator guard mount. &I kg Engine assembly

: 3,000 kg

30-34 (EC

INSTALLATION ASSEMBLY
.
Carry out installation removal.

OF ENGINE
in the reverse order to

Adjust the fan belt tension For details, see TESTING AND ADJUSTING. w Universal joint mounting bolt : 110.3 f 12.3 Nm III.25 f 1.25 kgm) Engine mount cap mounting bolt : 926.7 + 103 Nm I94.5 f 10.5 kgm} Refilling with water Add water to the specified level, and run the engine to circulate the water through the system. Then check the water level again.

a m

30-34-l 8

REMOVAL OF DAMPER ASSEMBLY

1. Using transmission underguard (1). kg L+l Underguard:

jack

0,

remove

rear

360 kg oil from

2. Remove drain plug and drain damper. : Damper: Approx. 2.1 e u

3. Sling universal joint (2), then remove mounting bolts, and remove universal joint. m
I98FO245
I

4. Remove oil level gauge guide (3). 5. Remove mountino bolts and holder (4). then . ,. remove coupling T5). 1#21 6. Remove retainer (6).

3
I

17MF02242

17MF02243

Sling damper cover (7), remove mounting bolts, then screw in 3 forcing screws and m remove.

A
& kg

Set the guide bolt (Q = approx. 200mm) so that the damper cover will not come out suddenly. Damper cover: 60 kg

8. Using eyebolts 0, sling damper assembly (8), then remove mounting bolts and lift off. m

A
PI kg

Set the forcing screws (a = approx. 200mm) so that the damper cover will not come out suddenly. Damper assembly: 75 kg m

17MF02244

11

17MF02245

9. Remove bearing (9) from flywheel.

17MF02246

30-35 0

INSTALLATION

OF DAMPER ASSEMBLY

Carry out installation removal.

in the reverse order to

Universal joint mounting bolts: 11.25 + 1.25 kgm

N~I& m

Holder mounting bolt thread: Thread tightener

(LT-2)

Holder mounting bolt: 28.25 + 3.25 kgm

Install damper cover (7) as follows. 1) Using guide bolt (n = 200mm), set the damper cover in position. 2) Using tool B, press fit bearing.

Use a guide bolt (Q = approx. 200mm) position the damper assembly.

to

r&

Fill 50% of the clearance at the hatched portion in the diagram with grease (G2-U) (approx. 11 g).

17MF02247

Refilling with oil * Add-engine oil to the specified level, and run the engine to circulate the engine oil through the system. Then check the water level again.

30-36 0

DISASSEMBLY

OF DAMPER ASSEMBLY

Disassembly of damper assembly

1. Set damper assembly to block 0.

2. Remove mounting nut (I), then using forcing screws 0, remove flange (2).

17MF02249

17MF02250

6.

Remove shaft (3).

1
0, remove flange (5)

4. Remove rubber (4). 5. Using forcing screws from body (6).

5
17MF02251

6
17MF02252

6. Remove seal (7) from flanges (2) and (5).

Disassembly of damper cover assembly (8) and oil seal (9) from

7. Remove bearing cover (IO).

8. Remove oil seal (11) from retainer (12).

17MF02255

30-37 0

ASSEMBLY OF DAMPER ASSEMBLY

Assembly of damper assembly

Flange

1. Install seal (7) to flanges (2) and (5).

* Install the seal so that the lip is facing the inside as shown in the diagram.

17MF02256

11 1

2. Align bolt holes and install flange (5) to body (6). H-XI& Flange mating surface: Gasket sealant (LG-4)

,I
Seal
I

17MF02257

A Check that there are no dents, rust, oil, grease, or water on the mating surface, then coat both the faces of the flange and body with gasket sealant.

17MF02258

3. Set flange and body assembly then set shaft (3) in position. 4. Assemble rubber (4). a

to block 0,
Shaft

When assembling the rubber, coat the whole surface of the rubber, the outside circumference of the shaft, and the inside circumference of the body with grease (G2-LI). After assembling the rubber, fill the clearance between the shaft and body (16 places) approx. 30% with grease (G2-LI) (approx. 190s).

!ara

Body 17MF02259 17MF02260

5. Install flange (2). & Flange mating surface: Gasket sealant (LG-4)

A Check that there are no dents, rust, oil, grease, or water on the mating surface, then coat both the faces of the flange and body with gasket sealant. 6. Tighten mounting nut (1).

17MF02261

30-38 0

Assembly of damper cover assembly press fit oil seal (11) to

7. Using push tool 0, retainer (12). a *

Oil seal press-fitting surface: Gasket sealant

(LG-1)

Coat the inside surface of the retainer thinly with gasket sealant, and wipe off any sealant that is squeezed out. Lip of oil seal: Grease (G2-LI)

I
8. Using push tool 0, cover (IO). press fit bearing (8) to

17MF02262

I
9. Using push tool 0, cover (10). &I?s * press fit oil seal (9) to Oil seal press-fitting surface: Gasket sealant

17MF02263

(LG-1)

Coat the inside surface of the cover thinly with gasket sealant, andwipe off any sealant that is squeezed out. Lip of oil seal: Grease (G2-LI)

&I?+

17MF02264

30-39 0

1. Draining oil Hydraulic tank: Approx. 95 e Power train unit: Approx. 120 2. Remove fuel tank assembly. For details, see REMOVAL ASSEMBLY.

OF FUEL TANK

3. Remove floor frame assembly. For details, see REMOVAL OF FLOOR FRAME ASSEMBLY. 4. Sling universal joint assembly (2), then remove mounting bolts, and lift off universal joint assembly. m 5. Remove control lever bracket (3) from frame, and move it towards power train unit assembly. 6. Disconnect 2 connectors of wiring (4). 7. Disconnect torque converter cooler hose (5). 8. Disconnect hydraulic oil sensor connector, and remove tube (6). 9 Disconnect 3 hoses (7). wiring
C17MF02266

10. Disconnect 5 ripper circuit hoses (8) at valve end, and move them towards side frame. 11. Disconnect hose (9) between ripper Hi valve at valve end. pump and

12. Disconnect pin puller hoses (IO). 13. Remove fuel hose clamps, (11) to side. and move hoses

14. Remove mount bolt (12) and mount cap (13). m 15. Loosen clamp (14), and move it to outside. m 16. Using forcing screws 0, remove cover (15). 17. Using forcing screws 0, pullout shaft (16). * If the shaft does not come out, use jack 0 to move the sprocket backwards or forwards and adjust to a position where the shaft will come out. 18. Lift off power train unit assembly (17). * Be sure to disconnect all wiring and piping before removing the power train unit assembly. kg C?l Power train unit: 3,600 kg

I98FO2467

I96FO2469

I96FO2470

INSTALLATION

OF POWER TRAIN UNIT ASSEMBLY

Carry out installation removal.

in the reverse order to

Universal joint:

11.25 f

1.25 kgm

m m

Mounting bolts: 94.5 + 10.5 kgm Mount cap: 94.5 f 10.5 kgm

Clamp the peaked portion of the coupling seal securely, and assemble so that the clamp threaded portion is parallel to the seat surface of the cap mount. m Housing clip: 0.675 f 0.175 kgm

Refilling with oil * Add oil to the specified level, and run the engine to circulate the oil through the system. Then check the oil level again.

30-42 0

DISCONNECTION

OF POWER TRAIN UNIT ASSEMBLY

Remove power train unit assembly. For details, see REMOVAL OF POWER TRAIN UNIT ASSEMBLY.

1. Set power train unit assembly (1) on block 0. 2. Remove steering control cables (2) together with bracket. 1111 3. Remove transmission together with bracket. 4. Disconnect (5). control m cables . (3)

3 rods (4), and remove

bracket

5. Remove clamps (6) of central pressure detecting hose at 4 places, disconnect 9 hoses, then remove hose bracket assembly (7). * Before disconnecting the hoses, mark with tags to show their mounting positions. 6. Disconnect wires (8) at connectors, clamps, then remove wiring. 7. Remove pin puller hose (9). remove

17MF02278

8. Sling hydrualic pump (9), remove mounting bolts, then remove pump assembly (9) together with hose. kg C? Hydraulic pump assembly: 35 kg

9. Remove scavenging pump remove oil filler pipe (11).

10. Sling filter assembly

piping (IO), then

(12), remove bolts, then remove filter assembly.

mounting

11. Sling power train pump and strainer assembly (13), disconnect strainer pipe (14) and clamp bracket (15) of pipe, and remove mounting bolts, then remove pump and strainer assembly (13). & kg Pump, strainer assembly: m 55 kg

12. Lift off mount bracket (16). & kg Mount bracket:

150 kg

13. Sling scavenging pump (17), remove mounting bolts, then remove pump assembly. & kg Scavenging clamp, pump assembly: and remove 40 kg tube

14. Disconnect (16).

gauge

15. Disconnect hose (19). 16. Support center of transmission (height: 500mm). with block @

17. Sling oil pan (20), remove 4 mounting bolts at bottom and 15 mounting bolts at top, then remove brackets (21) and (22), and oil pan (20). &I kg Oil pan: 110 kg

18. Sling PTO and torque converter assembly (23), remove mounting bolts, then remove PTO and torque converter assembly (23). lf41 I+ kg PRO, torque converter assembly: 600 kg

Using a lever block, raise the assembly horizontally, and disconnect it from the transmission.

30-44 0

19. Sling transmission assembly (24), remove mounting bolts, then remove transmissin assembly (24) from steering case assembly (25). & kg Sr Use a lever block, and lift off horizontally from the steering case assembly. Transmission assembly: 950 kg

24

17MF02282

CONNECTION OF POWER TRAIN UNIT ASSEMBLY

l

Carry out connection disconnection.

in the reverse order to

m g E 5 )xJ Bend the cotter pin securely. m w Rotating part of PTO boss: Grease (G2-LI) Bend the cotter pin securely.

Using a lever block, raise the PTO and torque converter assembly horizontally, align it with the spline on the shaft at the steering case side, and install.

30-45 0

DISCONNECTION

OF PTO, TORQUE CONVERTER ASSEMBLY

1. Remove coupling assembly (1). 2. using forcing assembly (2). screws 0, m 112) remove retainer

3. Remove shims (3). A Check the number and thickness Sims, and keep in a safe place. 4. Remove (5). m snap ring (4), then remove

of the

spacer

5. Remove mounting bolts, then using eyebolts 0, sling PTO assembly. 6. Using forcing screws 0, bly (6). m & kg PTO assembly: remove PTO assem300 kg

I-

17MF02283

17MF02285

6
30-46 0

17MF02286

CONNECTION OF PTO, TORQUE CONVERTER ASSEMBLY

Carry out connection disconnection.

in the

reverse

order

Retainer

Adjust the clearance between the taper roller bearings as follows. 1) Set retainer assembly to housing, and tighten 6 mounting bolts to 1 kgm in turn. 2) Using thickness gauge, measure clearance a between retainer and housing. * When measuring, measure at 4 places (A.. B. C. D) around the circumference. . and take the average value as clearance a. 3) Selecting shim thickness * Shim thickness = Clearance a (0 to +O.O5mm) * The shims are a divided type, so check the number of shims and make sure that the shim thickness is the same on the left and right. j, Standard shim thickness t = 0.15, 0.20, 0.5 4) Assemble selected shim thickness, then tighten retainer assembly to specified torque. w Mounting bolt: 6.75 f 0.75 kgm

17MF02287

Remova; tap

D \

/A

0 C
/ 0

\ B

:
RerAoval tap
I98FO2487

Assemble the shim as shown in the diagram on the right so that it does not come at the position of the retainer removal tap.

Removal tap A

a &I&

Lip of oil seal: Grease (G2-LI) O-ring: Grease (G2-LI)

Check that the snap ring is fitted securely in the groove.

Rknoval tap
I98FO2488

When assembling the PTO assembly, coat the P portion of the shaft with anti-friction compound (LM-P).

30-47 0

DISASSEMBLY

OF TORQUE CONVERTER ASSEMBLY

1. Torque converter assembly Set the torque converter assembly (1) to tools C. 2. Torque converter valve assembly Remove mounting bolts, then using eyebolts 0, remove valve assembly (2). * Remove the 6 mounting bolts that are marked in black.

17MF02288

3. Draining oil Remove drain plug (3) at 2 places and drain oil from pump case. * After draining the oil, tighten the drain plug. m Plug: 1.15 f 0.15 kgm

17MF02289

17MF02290

f: 5

4. Lockup clutch, drive case assembly 1) Leaving 2 mounting bolts in place, remove mounting bolts (4). Set so that input shaft is at top, then remove remaining mounting bolts. remove off lockup 3) Using eyebolts 0, clutch and drive case assembly (5).

17MF02291

4) Disassemble lockup clutch and drive case assembly as follows. i) Remove mounting bolts, then using forcing screws 0, remove input shaft (6). ii) Remove snap ring (7), then remove plate (8).

17MF02294

30-48 0

iii) Set the clutch housing side facing down, and set block 0 to turbine. iv) Using forcing screws 0, disconnect press-fitting portion of bearing, then remove turbine (9).

v) Remove mounting bolts, then using eyebolts 0, remove housing and piston assembly (10). * When removing, the piston will fall out, so support it by hand. vi) Remove piston (11) from housing (12). vii) Using push tool 0, remove bearing (13) from housing (12).

197F.316

17MF02296

I96FO2496

I96FO2497

197F318

viii) Remove 2 discs (14) and 1 plate (15) from drive case (16) in turn. * Keep the disk and plate in a flat place to prevent distortion.

15

14

16

197F319

5. Stator 1) Remove snap ring (17), then remove stator assembly (18).

li

i8

17MF02297

30-49 0

2) Remove snap ring (19), then remove race

(20) from stator (21). 3) Remoe snap ring (22) from stator (21).

I 98FO2502

11

I99FO2500

6. Pump assembly 1) Remove pump assembly (23).

17MF02298

mounting bolts, then remove retainer (24). 3) Tap with a plastic hammer, and remove bearing and guide assembly (25) from pump. 4) Using push tool 0, from guide (27). remove bearing (26)

2) Remove

2,5

?4

17MF02299

17MF02300 __-I

7. Stator clutch housing Remove mounting bolts, them remove stator clutch housing (28).

17MFfl7?.1ll

30-50 0

8. Spring Remove spring (29). 9. Discs, plate Remove 2 discs (30) and 1 plate (31) in turn. A Keep the disc and plate in a flat place to prevent distortion.

29

do $1
IO. Pin Remove pin (32).

17MF02302

11. Piston Remove piston (33). 12. Gear Remove (35).

snap

ring (34), then

remove

gear

I
13. Stator shaft, shaft assembly 1) Remove mounting bolts (36).

17MF02303

17MF02304

2) Tap stator shaft and shaft assembly (37)

with a plastic hammer to remove from case (38). * When removing the stator shaft assembly, set the case in the condition shown in the diagram. 3) Remove snap ring (39). 4) Remove snap ring (40). 5) Using push tool @, remove shaft assembly (41) from stator shaft assembly (42).

30-51 0

6) Disassemble shaft assembly as follows. i) Remove snap ring (43), then remove inner race (44). ii) Remove collar (45). iii) Remove bushing (46) from shaft (47).

,\
47

\ //////////////y//////////;//

I
17MF02307

7) Disassemble stator shaft assembly as follows. i) Remove snap ring (48). ii) Using push tool @I, remove bearing (49) from stator shaft (50).

14. Case Remove case (38) from tool c.

I98FO25

I5

30-52 0

ASSEMBLY OF TORQUE CONVERTER ASSEMBLY

* *

Clean all parts, and check for dirt or damage. Put a few drops of engine oil on the rotating parts of the fearings, and rotate them several times. Check that the snap ring is fitted securely in the groove. Coat the seal ring thinly with grease (GPLI).

1. Case Set case (38) to tool C.

5 z

i2
2. Stator shaft assemblv 1) Assemble stator shaft assembly as follows. i) Using push tool, press fit bearing (49). and secure with snap ring (48). ii) Install seal ring to stator shaft (50).

\\

I98FOZ5

I5

50

1 4
40 49

17MF02310

2) Install snap ring (39). 3) Tap stator shaft assembly (42) with a plastic hammer, and press fit bearing portion to case.

17MF02311

30-53 0

3. Shaft assembly 1) Assemble shaft assembly as follows. i) Install bushing (46). * Expand fit the bushing. ii) install collar (45). * Install the collar with the chamfered portion of the outside diamediameter facing down. iii) Using push tool, press fit inner race (44), and secure with snap ring (43). iv) Install seal ring to shaft (47).

2) Install shaft assembly (41). jr Using 2 guide bolts (Thread dia. = IOmm, Pitch = 1.25mm, Length = 60mm), align the oil hole and intall the shaft assembly. 3) Tighten mounting bolts temporarily. 4) Install snap ring (40). 5) Tighten mounting bolts (36) fully. a m Mounting bolt: Thread tightener (LT-2) 0.75 kgm
17MF02312

Mounting bolt: 6.75 f

4. Gear Fit gear (35) and secure with snap ring (34). 5. Piston 1) Install seal ring to case. 2) Fit seal ring and install piston (33). * Make sure to assemble the seal ring facing in the correct direction. Assemble with the side taking the pressure facing the case as shown in the diagram.

Side.receiving

pressure

17MF02304

33

32

17MF02313

I?---

6. Pin Remove pin (32).

17MF02303

30-54 0

7. Discs, plate install 2 discs (30) and 1 plate (31) in turn. 8. Spring Install spring (29).

?9

17MF02302

9. Stator clutch housing Align with dowel pin and fit stator clutch housing (28), then tighten with mounting bolts. j, Make sure that the spring is fitted securely in the piston and housing hole. rr\a Mounting bolt: Thread tightener (LT-2) 1.25 kgm

Mounting bolt: 11.25 f

z ;;

10. Pump assembly 1) Using push tool 0, guide (27).

install bearing (26) to

I
2) Set bearing and guide assembly (25) in pump, then using push tool, press fit bearing portion. * When assembling the bearing and guide assembly, align the guide and pump oil holes. 3) Fit retainer (24), and tighten with mounting bolts. * When installing the retainer, align the retainer and pump oil holes. fiw Mounting bolt: Thread tightener (LT-2)

17MF02314

24

17MF02315

17MF02316

Mounting bolt: 6.75 k 0.75 kgm

30-55 0

4) Install pump assembly (23). When installing the pump assembly, * be extremely careful not to damage the seal ring assembled to the shaft.

17MF02298

11. Stator assembly 1) Install snap ring (22) to stator (21). 2) Fit race (20) to stator (21) and secure with snap ring (19).

3) Fit stator assembly snap ring (17).

(18) and secure with

12. Lockup clutch, drive case assembly 1) Assemble lockup clutch and drive assembly as follows. i) Set turbine (9) to block @,.

case

li

is

17MF02297

ii) Using eyebolts 0, to turbine.

set drive case (16)

7MF02317

30-56 0

iii) Install 2 discs (14) and 1 plate (15) in turn.

iv) Install seal ring to housing. v) Fit seal ring to piston (II), and set in housing (12). * When installing, be extremely careful not to damage the seal ring. vi) Using eyebolts 0, fit housing and piston assembly (IO) and tighten with mounting bolts. j, When installing, support the piston by hand to prevent it from falling out, and set it in position in the drive case. Mounting bolt: Thread tightener Mounting bolt: 11.25 f (LT-2)

17MF02318

1.25 kgm

I96FO2497

196FO2496

vii) Using push tool 0, press fit bearing (13). viii) Fit plate (8) and secure with snap ring (7).

8
17MF02319

7
17MF02320

ix) Using eyebolts 0, fit input shaft (6) and tighten with mounting bolts. TV?w Mounting bolt: Thread tightener (LT-2) 6

Mounting bolt: 11.25 k 1.25 kgm

x) Install seal ring to input shaft.

17MF02321

30-57 0

2) Using eyebolts 0, set lockup clutch and drive case assembly (5) to pump. A Install a guide bolt (Thread dia. = 1 Omm, Pitch = 1.5mm, Length = 60mm) to the drive case, align the position of the drain plug, and set to the pump. 3) Tighten mounting bolts (4). N-C& m Mounting bolt: Thread tightener (LT-2)

Mounting bolt: 5.5 + 0.5 kgm

13. Torque converter valve assembly Fit gasket, and using eyebolts 0, install valve assembly (2). * Tighten the mounting bolts uniformly in turn. m Mounting bolt: 5.0 f 0.5 kgm

14. Torque converter assembly Remove torque converter assembly tool c.

(1) from

17MF02288

30-58 a

DISASSEMBLY

OF PTO ASSEMBLY

1. Idler gear assembly 1) Using eyebolts 0, sling PTO assembly. 2) Remove mounting bolts, then remove plate (1).

17MF02322

3) Face torque converter side down, and set PTO assembly on block. 4) Remove lubrication tube. 5) Remove mounting bolts, then using forcing screws 0, remove shaft assembly (2).

6) Remove plug, then using forcing screws 0, remove bearing (3).

7) Remove spacer (4). 8) Remove idler gear assembly (5) and bearing (6) from bottom.of PTO case.

17MF02324

/I

17M:2326

9) Remove outer race (7). IO) Remove snap ring (8).

17MF02326

17MF02327

30-59 0

2. Cover assembly 1) Remove mounting bolts, then using forcing screws 0, remove cover assembly (9).

2) Using

puller

0,

remove

gear

assembly

(IO). 3) Using puller 0, gear (12).

remove bearing (11) from

3. Cover assembly 1) Remove mounting bolts, then using forcing screws 0, remove cover assembly (13).

D--13---

17MF02329

2) Using puller 0, remove bearing (14). 3) Remove mounting bolts, then remove gear (15).

I98FO253

l98FO2532

30-60 a

4) Using push tool 0, remove boss assembly (17) from cage (16). 5) Using forcing screws 0, remove bearing (19) from boss (18).

17MF02330

JI

17MF02331

4. Scavenging pump drive gear 1) Using eyebolts 0, sling PTO assembly. 2) Remove mounting bolts, then remove drive gear (20).

17MF02332

5. Boss 1) Remove snap ring (21) 2) Using push tool, remove boss (22) from bearing pressfitting portion.

17MF02333

3) Remove snap ring (23). 4) Using push tool, remove bearing (24).

30-61 0

6.

Bearing, race assembly 1) Using push tool, remove bearing and race assembly (25).

17MF02336

2) Remove outer race (26).

27 26

7. Sleeve Remove sleeve (27) from PTO case.

17MF02337

30-62 0

ASSEMBLY

OF PTO ASSEMBLY

* *

Clean all parts, and check for dirt or damage. Put a few drops of engine oil on the rotating parts of the bearings, and rotate them several times. j, Check that the snap ring is fitted securely in the groove.

1. Sleeve 1) Face torque conerter side down, and set PTO case on block. 2) Install sleeve (27) to PTO case. * Expand fit the sleeve. 2. Bearing race assembly * Use the bearing and spacer as a set. 1) Using push tool @, press fit outer (26).
17MF02338

race

8 z

2) Set race (28) to press, then using push tool 0, press fit bearing (29). 3) Assemble spacer (30). 4) Usng push tool 0, press fit bearing (31).

Press

-7///////////y///////
5) Assemble bearing and race assembly (25). * Assemble the bearing and race assembly with the lip of the race at the bottom. 6) Assemble spacer (32). 7) Using push tool ($9, press fit outer (33).

17MF02339

race

17MF02340

30-63 0

3. Boss 1) Using eyebolts 0, sling PTO assembly. 2) Using push tool, press fit bearing (24) and secure with snap ring (23). 3) Using a plastic hammer, press fit boss (22) to bearing from inside of case.

17MF02342

-22

17MF02341

4) Secure with snap ring (21).

17MF02333

4. Scavenging pump drive gear Install drive gear (20) and tighten with mounting bolts. AI+m Mounting bolt: Thread tightener Mounting bolt: 6.75 I!I 0.75 kgm (LT-2)

17MF02332

5. Cover assembly 1) Set boss (18) to press, and using push tool @, press fit bearing (19). 2) Using push tool @, press fit boss assembly (17) to cage (16).

30-64 0

3) Install gear (15), and tighten with mounting bolts. 0. m Mounting bolt: Thread tightener (LT-2)

Mounting bolt: 11.25 f 1.25 kgm

4) Set cover assembly to press, then using push tool 0, press fit bearing (14).

5) Face torque converter side down, and set PTO assembly on block. fit O-ring and cover 6) Using eyebolts, assembly (13), then tighten with mounting bolts. * Set the cover assembly to the case, and tap uniformly with a plastic hammer to press fit it. /(i7, O-ring: Grease (G2-LI)

02344

6. Cover assemblv Set gear (12j to press, using push tool 0, press fit bearing (11). Press fit gear assembly (10). * Press fit the gear assembly with the spling portion on the inside of the gear at the top.

17MF02345

17MF02346

Using eyebolts, fit O-ring and cover assembly (9), then tighten with mounting bolts. * Set the cover assembly to the case, and tap uniformly with a plastic hammer to press fit it. AXA-. O-ring: Grease (G2-LI)

30-65 0

7. Idler gear assembly * Match the production number and set number on the inside and outside of the bearing and the spacer to make sets when assembling. 1) Install snap ring (8). 2) Using push tool, press fit outer race (7). 3) Set idler gear (5) to bottom of PTO case.

17MF02327

17MF02326

4) Set shaft to press, and using push tool 0, press fit bearing (3).

I
5) Using bolts 0, fit O-ring and align shaft assembly (2) with idler gear, and assemble temporarily. * Set the shaft assembly to the case, and tap uniformly with a plastic hammer to press fit it. Leave approx. 5 mm space to make it easier to assemble the spacer and bearing. H-X&O-ring: Grease (G2-LI)

1 I98FO2549

6) Using eyebolts, turn over PTO assembly.

7) Assemble spacer (4).

17MF02349

30-66 0

8) Using copper bar, press fit bearing (6).

I
9) Fit plate (1) and tighten with mounting
bolts. &IL Mounting bolt: Thread tightener (LT-2) Mounting bolt: 11.25 f 1.25 kgm m Using eyebolts, sling PTO assembly and tighten shaft assembly fully. Fit gasket and install lubrication tube.

17MF02350

10) 11)

8. Measuring 1) After completing the assembly, check the backlash between the idler gear and the and gear drive pump train power hydraulic pump drive gear. 2) When measuring, put the probe of the dial gauge at right angles against the face of the gear tooth at the tip of the being gear Hold the gear. idler in place and measure the measured readling when the idler gear is moved backwards and forwards. * Standard value for backlash: 0.204 -0.516 mm * Measure at three or more places on diametrically opposite sides.

17MF02351

30-67 0

DISASSEMBLY

OF TORQFLOW TRANSMISSION

ASSEMBLY

Keep the disc and plates in a flat place to prevent distortion.

1. Transmission assembly Set transmission assembly (1) to tool Dl.

I97FO3OU

2. Plate Remove nut, then remove with sleeve (3). 3. Cover Remove (4).

plate (2) together

mounting

bolts, then remove

cover

4. Charging pump assembly Remove mounting bolts charging pump assembly seat.

(5), then remove (6) together with

5. Lubrication valve assembly Remove mounting bolts, then remove lubrication valve assembly (7).

6. Case Remove mounting bolts, then use forcing screws 0 to remove case (18). * When removing the case, use a chain block and lift the case off slowly.

17MF02354

30-68 a

7. Input shaft, No. 1 carrier assembly A Make match marks on each plate and the housing. 1) Remove tie bolt (9). 2) Using forcing screws 0, disconnect inpu shaft and No. 1 carrier assembly (IO), use eyebolts 0 to remove. A Screw in the forcing screws uniformly to disconnect the No. 1 carrier assembly.

3) Disassemble input shaft and No. 1 carrier assembly as follows. . Disassembly of input shaft assembly i) Remove snap ring (11, then remove No. 2 sun gear (12). ii) Remove snap ring (13). iii) Set input shaft and No. 1 carrier assembly to block 0, then tap with copper hammer to remove input shaft assembly (14).

17MF02357

17MF02358

17MF02359

iv) Set input shaft assembly (14) to press, and remove bearing (15).

v) Remove spacer (16). vi) Using push tool, remove No. 1 sun gear (17) and spacer bearing (18).

30-69 0

vii) Set spacer bearing on block 0, use push tool to remove bearing from spacer (20). viii) Set spacer bearing on block 0, use push tool to remove bearing from spacer (20).

then (19) then (21)

17MF02363

11

17MF02364

Disassembly of No. 1 carrier assembly i) Remove inside snap ring (22). ii) Set No. 1 carrier assembly on block, then use push tool @ to remove No. 1 carrier assembly (24) from plate (23).

I97FO3076

I97FO3077

SI 2

iii) Remove spacer (25) from No. 1 carrier assembly (24). 25,

I97FO3076

iv) Remove

snap

ring

(26)

from

plate

(23).
v) Using push tool 0, (27). remove bearing

i3
I97F0307E I 97FO308 Ii

30-70 0

vi) Remove snap ring (28), then remove collar (29). vii) Pull out shaft partially, remove ball (30), then remove shaft (31). j, Be careful not to lose the ball, and keep it in a safe place.

17MF02365

I97FO3083

viii) Remove gear (32) and thrust washer (33) from carrier, then remove bearing (34) from gear.

32

/
17MF0236E

8. Spring Remove spring (35). 9. No. 1 discs, plates, springs Remove springs (36), discs (37), and plates (38) in turn. 10. No. 1 ring gear Remove No. 1 ring gear (39). 11. No. 1 housing assembly Using eyebolts 0, remove No. 1 piston (40) together with No. 1 housing (41).

36 38

35

17MF02367

30-71 0

12. Spring Remove spring (42). 13. No. 2 discs, plates. springs Remove springs (43), discs (44), and plates (45) in turn. 14. Torque pins Remove torque pins (46).

\
15. No. 2, 3 carrier assembly 1) Using eyebolts @, remove No. 2 and 3 carrier assembly (47) together with ring gear. Ir Sling the carrier, then insert a bar in the ring gear holes and lever the carrier to remove it.

17MF02368

17MF02369

2) Disassemble No. 2 and 3 carrier assembly as follows. i) Remove ring (48). ii) Pull out shaft partially, remove ball (49), then remove shaft (50). * Be careful not to lose the ball, and keep it in a safe place.

17MF02370

197FO3085

iii) Remove gear (51) and thrust washer (52) from carrier, then remove bearing (53) from gear. * The ring is held in position by the internal pushing force, so do not disassemble carrier and ring gear (54).

30-72 0

16. No. 2 ring gear Remove No. 2 ring gear (55).

17MF02371

17. No. 2, No. 3 housing assembly Using eyebolts 0, remove No. 2, 3 housing (57) together with No. 2 piston (56).

17MF02372

18. No. 3 piston Remove No. 3 piston (58).

17MF :02373

19. Spring Remove spring (59). 20. Guide pin Remove guide pin (60) 21. No. 3 discs, plates, springs Remove springs (61), discs (62) and plates (63) in turn.

If& EG

$1

17MF02374

30-73 a

22.

Plate Using eyebolts 0, remove plate (64).

MF02375

23.

No. 4 discs, plates, springs Remove springs (65), discs (66), and plates (67) in turn.

24. Torque pins Remove torque pins (68).

I
25. No. 4 housing assembly Using eyebolts 0, remove No. together with No. 4 housing (70).

17MF02376

piston

26. Collar Remove (71).

mounting

bolts, then remove

collar

17MF02377

17MF02378

27.

No. 5 clutch assembly 1) Using eyebolts @I, sling No. 5 clutch assembly (72), then tap bottom of output shaft with a copper hammer to remove.

17MF0237S

30-74 CD

2) Disassemble .

No. 5 clutch assembly as follows. Disassembly of No. 4 carrier assembly i) Remove snap ring (73), then remove No. 3 sun gear (74). ii) Remove bearing and collar (75). iii) Set bearing and collar on block 0, then use push toolto remove bearing (76) from collar (77).

-197F030&3 11 d

17MF02380

78

17MF02381

iv) Using eyebolts @, remove No. 4 carrier assembly (78) together with No. 4 sun gear (79). v) Remove No. 4 sun gear (79). vi) Remove hub (80). A Be careful not to damage the seal ring when removing. vii) Remove snap ring (81), then remove collar (82).
------lI

17MF02382

17MF02383

81

17MF02384

17MF02385

viii) Remove shaft partially, remove ball (83), then remove shaft (84). A Be careful not to lose the ball, and keep it in safe place. ix) Remove gear (85) and thrust washer (86) from carrier, then remove bearing (87) from gear (85).

30-75 a

x) Remove snap ring (88). xi) Using push tool, remove bearing (89). * The ring is held in position by the internal pushing force, so do not disassemble carrier and No. 3 ring gear (90).

89 /

I
l

17MF02388

17MF02389

Disassembly of output shaft, housing assembly i) Remove mounting bolts, use forcing screws @I to disconnect output shaft and housing assembly (91), then use eyebolts @I to remove. A Screw the forcing screws in uniformly to disconnect the output shaft and housing assembly.

91

17MF02390

ii) Remove springs (92), discs (93), and plates (94) from drum (95) in turn.

17MF02391

17MF02392

iii) Set output shaft and housing assembly in press, and using push tool @, remove housing assembly (96) from output shaft assembly (97). * Set block @ in position to prevent the housing assembly from falling out.

I97FO3

IO5

30-76 0

iv) Set housing assembly (96) to press, then use tool D2 to compress spring. * Operate the press slowly and push the spring down uniformly. v) Remove snap ring (98). then remove retainer (99), spring (IOO), and piston (101).

17MF02393

17MF02394

vi) Remove snap ring (102), then using push tool, remove bearing (103).

197F03106

197FO3107

vii) Remove bearing viii) Remove bearing

snap ring (105) from snap ring (107) from

(104), output (106), output

then remove shaft. then remove shaft.

I97FO3

I OE

28. Snap ring Remove snap ring (108). 29. Bearing Using push tool, remove bearing (109).

108

30. Collar Remove (110).

mounting

bolts, then remove

collar

31. Case Remove case (11) from tool Dl.

17MF02395

17MF02396

30-77 0

ASSEMBLY

OF TORQFLOW TRANSMISSION

ASSEMBLY

* *

* *

Clean all parts, and check for dirt or damage. Put a few drops of engine oil on the rotating parts of the bearings, and rotate them several times. Coat the sliding surfaces of all parts with engine oil before installing. Install the piston seal ring with the side receiving the pressure facing the housing, coat it with grease (G2-LI), and install it uniformly so that it does not move to one side. N-^-\~~ Rotation seal ring: Fix in position with grease (G2-LI), and be extremely careful that it does not get caught when assembling.

Side receiving

pressure

I-

l97F337

* *

Check that the snap ring is fitted securely in the groove. Make match marks on each plate and the housing when disassembling.

1. Case Set case (111) to tool Dl. 2. Collar 1) Install seal ring to collar. 2) Fit collar (110) and tighten with mounting bolts. j, Install the seal ring so that the side receiving the pressure faces down. 3. Output shaft assembly Using push tool, press fit bearing (105) and secure with snap ring (104). Set output shaft to press, then using push tool 0, press fit bearing (109). Install seal ring to output shaft. Using eyebolts, set output shaft assembly (97) to case, then using push tool @ press fit bearing portion.
17MF02398

cc2

17MF02397

30-78 0

5) Install snap ring (108). 6) Fit collar (71) an tighten bolts.

/?L

with

mounting

Mounting bolt: Thread tightener

(LT-2)

Mounting bolt: 6.75 f 0.75 kgm

17MF02400

4. No. 5 clutch assembly 1) Assemble No. 5 clutch assembly as follows. Assembly of No. 4 clutch assembly l i) If No. 3 ring gear and No. 4 carrier are supplied as individual parts, use tool D3, and with ring (112) compressed, set No. 3 ring gear (90) on No. 4 carrier, then tap No. 3 ring gear with a plastic hammer to assemble. j, Check that the ring is fitted securely in the groove.
lS;Fd3I 1511

--__

17MF02401

ii) Using push tool, press fit bearing and secure with snap ring (88).

(89)

17MF02402

bearing (87) to gear (85), iii) Assemble then fit thrust washers (86) to both ends and set to carrier. iv) Fit ball (83) and press fit shaft (84). * Check that the gear rotatessmoothly.

b/acg$d
83
17MF0236;

85

17MF02366

30-79 a

v) Install seal rng to collar. vi) Install collar (82) and secure with snap ring (81). * Align the collar with the dowel pin, and tap with a plastic hammer to install. vii) Install seal ring to hub. viii) Install hub (80) to No. 4 carrier assembly (78).

80

17MF02385

17MF02403

Assembly of housing assembly i) Using eyebolts 0, set drum No. 4 carrier assembly.

(95) to

17MF02404

ii) Install discs (93), springs plates (94) in turn. * No. of discs: 5 Sr No. of plates: 4 * No. of springs: 5

(92),

and

17MF02405

17MF02406

iii) Using push tool, press fit bearing (103), and secure with snap ring (102).

197FO31

IO

30-80 0

iv) Install seal ring to piston. v) Set piston (IOI), spring (IOO), and retainer (99) to housing. * Set the 3 springs as shown in the diagram. vi) Set housing assembly (96) in press, then using tool D2, compress spring and secure with snap ring (98). * Operate the press slowly and press the spring down uniformly.

17MF02407

1j

17MF02393]

vii) Using eyebolts @, fit housing assembly (96) and tighten with mounting bolts. ,?_ Mounting bolt: Thread tightener (LT-2)

Mounting bolt: 18 f 2 kgm

viii) Install seal ring to housing.

17MF02408

Using eyebolts @I, set No. 5 clutch assembly (72) to output shaft.

I
Using push portion. tool 0, press fit bearing

17MF02379

17MF02409

30-81 0

5. No. 4 sun gear Install No. 4 sun gear (79). 6. Bearing, collar 1) Set collar (77) on block 0, then using push tool, press fit bearing (76).

cd4

17MF02410

17MF02411

2) Install bearing and collar (75). * Install with the collar lip at the top.

u4
7. No. 3 sun gear Fit No. 3 sun gear (74) and secure with snap ring (73). 8. No. 4 housing assembly 1) Fit seal ring to No. 4 piston, and set in No. 4 housing. 2) Using eyebolts @I, align with dowel pin, and install No. 4 piston (69) together with No. 4 housing (70). * Knock in the area around the dowel pin with a plastic hammer until there is no clearance at the contact surface. 9. Torque pins Install torque pins (68). * Length of torque pin: 162 mm 10. No. 4 discs, plates, springs Install plates (67), discs (66), and springs (65) in turn. * No. of discs: 3 A NO. of plates: 3

17MF02412

17MFr-17377
L

_--.

17MF02376

30-82 0

11. Plate Using eyebolts 0, align with dowel pin and install plate (64). * Knock in the area around the dowel pin with a plastic hammer until there is no clearance at the contact surface.

12. No. 3 discs, plates, springs Install discs (62), springs (61), and plates (63) in turn. h No. of discs: 3 * No. of plates: 2 13. Guide pin Install guide pin (60). 14. Spring Install spring (59). j, Free height of spring: 0 z z 15. No. 2,3 housing assembly 1) Install seal rings to No. 2 piston and No. 3 piston. 2) Set No. 2 piston (56) and No. 3 piston (58) to No. 2 and 3 housing (57). * Tie the No. 3 piston and housing with thin wire. 56 \

60

91 mm
17MF02374

58
3) Using eyebolts 0, align with dowel pin and install No. 2 piston (56), No. 2 and 3 housing (57), and No. 3 piston (58) as one unit. * Knock in the area around the dowel pin with a plastic hammer until there is no clearance at the contact surface.

17MF02413

30-83 0

16. No. 2 ring gear Install No. 2 ring gear (55). * Install with the teeth cut on the inside facing up.

17. Sleeve If sleeve (113) has been removed, install to bolt holes marked % in diagram below with slit at bottom.

17MF02371

Slit

17MF02415

18. No. 2,3 carrier assembly 1) Assemble No. 2 and 3 carrier assembly as follows. i) If ring gear and No. 2, No. 3 carrier are supplied as individual parts, use tool D4, and with ring (114) compressed, set ring gear (54) on No. 2, 3 carrier, then tap ring gear with a plastic hammer to assemble.

ii) Assemble bearing (53) to gear (51), then fit thrust washers (52) to both ends and set to carrier.

50 53 52

30-84 0

__-__
iii) Fit ball (49) and press fit shaft (50). * Check that the gear rotates smoothly. iv) Install ring (48). v) Install seal ring to No. 2 and 3 carrier assembly.

48

i97FO3085

17MF02370

2) Using_ eyebolts @, install No. 2 and 3 carrier assembly (47) together with ring gear.

17MF02417

3) Using portion

push tool @, press fit bearing of No. 2 and 3 carrier assembly.

17MF02418

19. Torque pins install torque pins (46). * Length of torque pin:

199 mm

20. No. 2 discs, plates, springs Install discs (44), springs (43), and plates in turn. * No. of discs: 5 A No. of plates: 4 21. Spring Install spring (42). A Free height of spring:

(45)

70 mm

7MF02368

30-85 0

22. No. 1 housing assembly 1) Fit seal ring to No. 1 piston and set to No. 1 housing. 2) Using eyebolts 0, align with dowel pin and install No. 1 piston (40) together with No. 1 housing (41). * Check that the spring is fitted securely in the piston and the housing hole. * Knock in the area around the dowel pin with a plastic hammer until there is no clearance at the contact surface.
I97FO305 I

23. No. 1 ring gear Install No. 1 ring gear (39). * Install with the inside teeth facing up. 24. No. 1 discs, plates, springs Install plates (38), discs (37), and springs (36) in turn. * No. of discs: 5 * No. of plates: 5 25. Spring Install spring (35). * Free height of spring: 66 mm

17MF02367

26. Input shaft, No. 1 carrier assembly 1) Assemble input shaft and No. 1 carrier assembly as follows. l Assembly of No. 1 carrier assembly i) Assemble bearing (34) to gear (32), then fit thrust washers (33) to both ends and set to carrier.

32

L
ii) Fit ball (30) and press fit shaft (31). * Check that the gear rotates smoothly. iii) Fit collar (29) and secure with snap ring (28).

17MF02366

I97F03083

17MF02365

30-86 0

iv) Using push tool, press fit bearing (27) in plate (23), and secure with snap ring (26). v) install seal ring to plate. vi) Install spacer (25) to No. 1 carrier assembly (24).

i4
17MF02419
I97FO3078

vii) Set plate (23) to No. 1 carrier assembly (24), then using push tool @, press fit bearing portion. viii) Secure with inside snap ring (22).

I
ix) Install No. 1 sun gear (17). x) Using push tool, press fit bearings (21) and (19) to spacer (20).

197FO31

1811

I97F03076

17MF02420

17MF02421

11

1 iMF02422

xi) Using push tool CD, press fit spacer bearing (18). xii) Set spacer (16) in position.

17MF02423

17MF02361

30-87 0

Assembly of input shaft assembly i) Using press, press fit bearing (15) to input shaft. ii) Press fit input shaft assembly (14) to No. 1 carrier assembly, and secure with snap ring (13).

197FO31

IS

17MF02424

iii) Fit No. 2 sun gear (12) and secure with snap ring (11). iv) Install seal ring to No 1 carrier assembly.

17MF02357

2) Using eyebolts 0, align with dowel pin and set input shaft and No. 1 carrier assembly (10) in position. j, Lower slowly and set in position so that the tip of the input shaft does not hit the bearing. * Tap the input shaft with a plastic hammer to press fit the No. 2 carrier and bearing portion.

17MF02425

17MF02426

3) Tighten 4 tie bolts (9) uniformly. 4) Tighten remaining tie bolts (9). w Tie bolt: 26.5 f 1.5 kgm

5) Install seal ring to input shaft.

17MF02427

30-88 0

28. Air check Using tool D5, check stroke of each piston. * Air pressure: 5 - 6 kg/cm*
Unit: mm

Piston

Standard stroke

6.6 3 2
1

I I

4.2 4.7 6.0

17MF02428

29. Case Fit O-ring, then fit case (8) and tighten with mounting bolts. * Lower the case slowly with a chain block.

17MF02429

30. Output shaft bearing 1) Using push tool, press fit bearing (107) to output shaft, then secure with snap ring (106).

17MF02430

31.

Lubrication valve assembly Fit O-ring, then install lubrication valve assembly (7), and tighten with mounting bolts.

32. Control valve assembly Fit O-ring, then install control valve assembly (6) together with seat, and tighten mounting bolts (5). Y-X~ m Mounting bolt: Gasket sealant (LG-1) Mounting bolt: 5 f 0.5 kgm
17MF02353

30-89 a!

33. Cover Fit gasket, then fit cover (4) and tighten with mounting bolts. * Remove plug (115), and align the position of the lever and yoke of the spool. 34. Plate Fit gasket, then fit plate (2) together sleeve (3), and tighten with nut.

with

35. Transmission assembly Remove transmission &sembly Dl.

I
(1) from tool

I97FO3044

30-90 a

DISASSEMBLY

OF STEERING CASE ASSEMBLY

Steering valve assembly Remove mounting bolts, then using shackle 0, remove valve assembly (1).

Clutch, brake assembly Using tool E, sling clutch and brake assembly, remove mounting bolts, then remove clutch and brake assembly (2). * When removing the clutch and brake assembly, be careful not to damage the discs and plates. * Remove the clutch and brake assembly on the opposite side in the same way.

17MF02433

3. Shafts Remove left and right shafts (3). 4. Lubrication tubes Remove lubrication tubes (4) and (5).

I96FO2646

17MF02434

5. Pipes * When removing the pipes, be careful not to damage the O-rings. 1) Remove left and right pipes (6). 2) Remove pipe (7).

17MF02435

17MF02436

6. Seat Remove mounting bolts, then using eyebolts 0, remove seat (8)

17MF02437

7. Input shaft 1) Remove snap ring (9). 2) Remove input shaft (10). 8. Transfer, gear housing assembly 1) Install guide bots 0 to steering case. 2) Using forcing screws 0, pull out housing assembly. 3) Using shackle 0, remove housing assembly (11). 9. Cage 1) Turn over steering case so that R.H. cage is at top. 2) Remove mounting bolts, and using forcing screws, remove bearing cage (12), then remove shim. * Check the number and thickness of the shims, and keep in a safe place. 3) Remove outer race (13) from bearing cage.

17MF02438

17MF02439

17MF02440

17MF02441

13 /

17MF02443

17MF02442

30-92 0

4) Remove mounting bolts, then eyebolts 8, remove cage (14).

using

ed
10. Bevel gear, shaft assembly 1) Using eyebolts, remove shaft assembly (15). bevel gear and

==Q-h=J

17MF02444

2) Assemble bevel as follows. i) Remove nut then remove ii) Using puller and (18) from

gear and shaft assembly and pull out reamer bolt, bevel gear (16). 0, remove bearings (17) shaft (19).

17MF02445

11. Cage 1) Turn over steering case. 2) Remove mounting bolts, and using forcing screws, remove bearing cage (20), then remove shim. * Check the number and thickness of the shims, and keep in a safe place. 3) Remove outer race (21) from bearing cage.
17MF02446

17MF02449

7MF02448

30-93 0

ASSEMBLY OF STEERING CASE ASSEMBLY

*Clean all parts, and check for dirt or damage. Coat the sliding surfaces of all parts with engine oil before installing. 1. Cage Using push tool, press fit outer race (21) in bearing cage.

17MF02449

Assemble shim, then install bearing cage (20), and tighten with mounting bolts. * Standard shim thickness: 2mm m Mounting bolt: 18 f 2 kgm

MF02449

2. Bevel gear, shaft assembly 1) Assemble bevel gear and shaft assembly as follows. i) Set shaft (19) in press, and using push tool @, press fit bearing (18). ii) using push tool @I, press fit bearing (17).

17MF0244

17MF02451

iii) Set bevel gear (16) to shaft, then fit reamer bolt and tighten with nut. QZT Nut: 18 + 2 kgm

17MF02452

30-94 0

2) Turn over so that R.H. cage of steering case is at top. 3) Using eyebolts, install bevel gear and shaft assembly (15).

17MF02445

3. Cage 1) Using eyebolts @, fit cage (14) and tighten with mounting bolts. QF Mounting bolts: 18 f 2 kgm

2) Using push tool, press fit outer race (13) to bearing cage.

17MF02444

17MF02443

3) Assemble shims, then fit bearing cage (12) and tighten with mounting bolts. * Standard shim thickeness: 2mm m Mounting bolt: 18 f 2 kgm
17MF02442

4. Adjusting preload Put push-pull scale @ in contact with tip of bevel gear teeth, and measure rotating torque of bevel gear shaft. * Standard value for rotating torque: 2.2 2.8 kg * Rotate the bevel gear 2 or 3 truns before measuring the rotating torque. * If the value is not within the standard range, adjust as follows. If torque is too HIGH, INCREASE shim thickness If torque is too LOW, DECREASE shim thickness

30-95 0

5. Transfer, gear housing assembly 1) Install guide bolts @ in steering case. 2) Fit O-ring, then using shackle 0, set housing assembly (11) to steering case, and tighten with mounting bolts. w Mounting bolt: 18 + 2 kgm

17MF02454 -_6. Adjusting tooth contact, backlash

1) Adjusting

backlash Put the probe of dial gauge 0 in contact with the tip of the bevel gear teeth at right angles. Hold the bevel pinion in position, and read the measurement when the bevel gear is moved forward and backward. Sr Standard value for backlash: 0.3 - 0.4mm * Measure at least six points diametrically opposite around the gears.
I96FO2664

If the result of the inspection shows that the correct backlash is not being obtained, adjust as follows. If backlash is too small Adjust shim at bevel pinion side to move bevel pinion in direction A; or adjust shim at bearing cage of bevel gear shaft to move bevel gear in direction B.

Backlash small is

I97F342

If backlash is too large Adjust shim at bevel pinion side to move bevel pinion in direction A; or adjust shim at bearing cage of bevel gear shaft to move bevel gear in direction B. * When adjusting the shim at the bearing cage of the bevel gear shaft, do not change the preload of the bearing. Adjust by moving shims from one side to the other. Always keep the same total thickness of shims. * Backlash is
large
l97F343

30-96 0

2) Checking tooth contact Testing i) Coat the tooth face of the bevel pinion (minimum). red lead lightly with Rotate the bevel gear forward and backward and inspect the pattern left on the teeth. ii) Tooth contact should be checked with no load on the bevel pinion. It should be in the center of the tooth height. The tooth contact pattern should be located 20 to 50% from the small end d, and should cover 30 to 75% of the length of the tooth. In addition, there should be no strong a or contact at the addendum dedendum b (tip or root of the gear teeth) or at the big end c and small end d. If the gears are adjusted to this pattern, the tooth contact will be correct when load is applied. a: Addendum b: Dedendum C: Big end d: Small end e: Width contact f: Center of tooth contact
d

I97F344

Adjustment If the result of the inspection shows that the correct tooth contact is not being obtained, adjust again as follows: i) If bevel pinion is too far from center line of bevel gear. Contact is at the small end of the convex tooth face of the bevel gear and at the big end of the concave tooth face. Procedure and adjustment l Adjust the thickness of the shims at the bevel pinion to move the bevel pinion in direction A. Adjust the shim thickness at the bearing cage of the bevel gear shaft to move the bevel gear in direction B. Check the tooth contact pattern and backlash again. ii) If bevel pinion is too close to center line of bevel gear. Contact is at the small end of the concave tooth face of the bevel gear and the big end of the convex tooth face. Procedure for adjustment l Adjust the thickness of the shims at the bevel pinion to move the bevel pinion in direction A. Adjust the shim thickness at the bearing cage of the bevel gear shaft to move the bevel gear in direction B. Check the tooth contact pattern and backlash again. * When adjusting the bevel gear to the right or left, do not change the preload of the bearing. Adjust by moving shims from one side to the other. Always keep the same total thickness of shims.

I97F345

I97F346

BC

fl
A
l97F347

30-97 0

7. Input shaft 1) Assembly input shaft (10) in case. 2) Secure with snap ring (9).

17MF02439

8. Seat
Fit O-ring, then using eyebolts 0, install seat (8), and tighten with mounting bolts.

9. Pipes /-~ O-ring: When installing coat the o-rings grease (G2-LI). the pipes, thinly with

1) Fit O-rings to both ends, and install pipe (7). 2) Fit O-rings to both ends, and intall pipe (6).

17MF02435

10. Lubrication tubes Fit gaskets and install lubrication and (5).

tubes

(4)

17MF02434

30-98 0

11. Clutch, brake assembly Fit O-ring, then using tool E, set clutch and brake assembly (2) in steering case, and tighten with mounting bolts. w Mounting bolt: 18 + 2 kgm installing the lcutch and brake When assembly, be careful not to damage the discs and plates. Install the clutch and brake assembly on the opposite side in the same way.

12. Shafts Install left and right shafts (3). * Procedure for installing shaft 1) Remove plug (22), and screw in bolts (Thread Dia. = 14mm, Pitch = 2.0mm, Length = 90mm) to pull in piston and release brake. 2) Fit right shaft, then rotate bevel gear and install left shaft.

z : 0 13. Steering valve assembly Fit gasket, then using shackle 0, assembly (1). install valve

30-99 0

DISASSEMBLY

OF STEERING CLUTCH, BRAKE ASSEMBLY

Keep the discs and plates in a flat place to prevent distortion.

DISCONNECTION ASSEMBLY

OF CLUTCH BRAKE

1. Plate Remove (1).

mounting

bolts, then remove

plate

2. Collar Remove collar (2). 3. Plate Remove (3).

mounting

bolts, then remove

plate

4.

Sleeve 1) Using forcing (4). 2) Using puller 0, sleeve.

screws

0,

remove bearing

sleeve (5) from

remove

17MF02458

5. Clutch, brake assembly 1) Turn over clutch and brake assembly. 2) Using eyepbolts 0, disconnect clutch assembly (6) and brake assembly (7).

17MF02459

30-100 0

DISASSEMBLY

OF CLUTCH ASSEMBLY

6. Clutch stopper Remove mounting stopper (8).

bolts, then remove clutch /

10 /

7. Discs, springs, plates Remove discs (9), springs (10) and plates (11) in turn. * No. of discs: 8 No. of plates: 8
17MF02460

II

17MF02461

8. Torque pins Remove torque pins (12). 9. Clutch hub Remove mounting bolts, then using eyebolts Q, remove clutch hub (13).

12
17MF02462 17MF02463

Plate 1) Remove mounting bolts, then using forcing screws 0, remove plate (14). 2) Remove outer race (15) from plate.

17MF02464

I98FO2675

11. Bearing cage assembly 1) Remove bearing cage assembly (16). 2) Disassemble bearing cage assembly as follows. i) Remove mounting bolts, then remove plate (17). ii) Remove nut (18). iii) Remove bearing (19), spacer (20), and bearing (21) from cage (22).

17MF02465

17MF02466

30-101 0

12. Spacer Remove spacer (23). 13. Clutch cage 1) Using eyebolts (24). 23 0, remove clutch cage 24

17MF02467

17MF02468

2) Using puller, remove outer race (25).

17MF02469

14. Piston Remove piston (26). 15. Belleville springs Remove Belleville springs (27). A No. of Belleville springs: 2

17MF02470

16. Brake hub 1) Turn over clutch housing 2) Remove mounting bolts, then using eyebolts @I, remove brake hub (28) from clutch housing (29). 3) Remove bearing (30) from brake hub (28).

Ii

2'

17MF02471

/j

17MF02472

30-l

02

DISASSEMBLY

OF BRAKE ASSEMBLY

17. Brake stopper Remove mounting stopper (31).

bolts, then remove

brake

18. Discs, springs, plates Remove discs (32), springs (33), and plates (34) in turn. * No. of discs: 8 No. of plates: 7 A Keep the discs and plates in a flat place to prevent distortion.

17MF02473

17MF02474

19. Torque pins Remove torque pins (35).

20. z z z

Brake cage 1) Remove mounting bolts, then using eyebolts 0, remove brake cage (36). 2) Using puller, remove outer race (37).

17MF02475

38 /

21.

Piston Remove piston (38).

17MF02477

17MF02478

22.

Belleville springs Remove Belleville springs (39). * No. of Belleville springs: 3 Outer race Using push tool 0, remove outer race (40).

23.

17MF02479

30-103 0

ASSEMBLY OF STEERING CLUTCH, BRAKE ASSEMBLY

Clean all parts, and check for dirt or damage. &II& Seal ring: Grease (G2-LI)

Coat the mating surface of the disc and plate with engine oil.

ASSEMBLY 1. Outer race

OF BRAKE ASSEMBLY
I98FO2690

Using push tool @, install outer race (40). 2. Belleville springs Install Belleville springs (39). * Install the Belleville springs as shown the diagram below.

in

17MF02480

17MF02481

1. Piston Fit seal ring and install piston (38).

17MF02478

17MF02482

4. Brake cage 1) Using push tool 0, press fit outer race (37). 2) Using eyebolts, fit seal ring, install brake cage (36) and tighten with mounting bolts. w Mounting bolt: 11.25 + 1.25 kgm

5. Torque pins Install torque pins (35).

17MF024.83

30-104 0

6. Brake hub Using eyebolts 0, set brake hub (28) in brake housing. 7. Discs, springs, plates Install plates (34). springs (33) and discs (32) in turn. * No. of discs: 8 No. of plates: 7

II

17MF02484

II

17MF02474

8. Brake stopper 1) Fit stopper (31), then tighten with mounting bolts. m * Mounting bolt: 18 -I 2 kgm

Check that the springs are fitted securely on the torque pins, then tighten the clutch stopper. 2) After installing brake stopper, use eyebolts 0 to remove brake hub (28).

2 z 0

17MF02485

17MF02486

Assembly

of clutch assembly

9. Brake hub 1) Using push tool @I, press fit bearing (30) to brake hub (28). 2) Using eyebolts, set brake hub (28) to clutch hosing (29), then tighten with mounting bolts. m Mounting bolt: 18 f 2 kgm

10. Belleville springs 1) Turn over clutch housing. 2) Install Belleville springs (27). * Install the Belleville springs as shown in the diagram below.

17MF02487

17MF02488

26

17MF02489

11. Piston Fit seal ring and install piston (26).

I96FO2660

17MF02470

30-105 0

12. Clutch cage 1) Using push tool, press fit outer race (25). 2) Assemble spacer (23). 3) Using eyebolts 0, install clutch cage (24).

-lr

(
3

17MF02490

17MF02468

13. Bearing cage assembly 1) Assemble bearing cage assembly as follows. i) Using push tool, pres fit bearing (21) to cage (22). ii) Install spacer (20). iii) Using push tool, press fit bearing (19). iv) Tighten nut (18). v) Install plate (17), then tighten with mounting bolts. m Mounting bolt: 2.5 + 1 kgm

2) Press fit bearing cage assembly (16). * Tap the cage assembly with a plastic hammer to press fit.

17MF02466

17MF02465

14. Plate 1) Using push tool, press fit outer race (5). 2) Install plate (14), then tighten with mounting bolts. w Mounting bolt: 11.25 f 1.25 kgm
I98FO2675

17MF02491

15. Clutch hub Using eyebolts 0, install clutch hub (13) and tighten with mounting bolts. m Mounting bolt: 5.5 k 2 kgm

16. Torque pins Install torque pins (12).

17MF02463

17MF02462

30-l

06

17. Discs, springs, plates Install plates (II), springs (10) and discs (9) in turn. A No. of discs: 8 No. of plates: 8 18. Clutch stopper Install clutch stopper (8), then tighten with mounting bolts. A Check that the springs are fitted securely on the torque pins, then tighten the clutch stopper. m
l

11
17MF02461 17MF02460

Stopper mounting bolt: 18 f

2 kgm

Connection assembly

of clutch, brake

19. Clutch, brake assembly Using eyebolts 0, set brake assembly position on clutch assembly (6).

(7) in

8 z z 20. Sleeve 1) Using push tool 0, press fit bearing (5) in sleeve. 2) Fit O-ring and seal ring, then set sleeve (4) in clutch and brake assembly.

17MF02492

17MF02494

21.

Plate Install plate (3), then tighten with bolts. m

mounting

Mounting bolt: 6.75 + 0.75 kgm

22. Collar Install collar (2). 23. Plate Install plate (I), then tighten with mounting bolts.
I98F02667

30-107 0

DISASSEMBLY

OF TRANSFER GEAR HOUSING ASSEMBLY

1. Transfer gear housing assembly Set transfer gear housing assembly on block. 2. Lubrication tube Remove lubrication block.

tube

(1) together

with

3. Bearing cage assembly 1) Remove bearing cage assembly (2). 2) Using push tool 0, remove bearing (3).

17MF02495

17MF02496

4. Drive gear 1) Remove drive gear (4). 2) Using puller 0, remove inner races (5) on both sides of drive gear.

17MF02497

;1

17MF02498

5. Lubrication tube 1) Turn over transfer gear housing assembly. 2) Remove lubrication tube (6). 6. Pinion, housing assembly 1) Remove mounting bolts, then using eyebolts 0, remove pinion and housing assembly (7). 2) Remove shim (8). * Check the number and thickness of the shims, and keep in a safe place.
l96FO2698

17MF02499

3) Disassemble pinion and housing assembly as follows. i) Remove mounting bolts, then using forcing screws 0, remove cover (9). ii) Remove holder (10).

17MF02500

17MF02501

30- 108 0

iii) Set pinion gear assembly in press, then using push tool 0, remove pinion gear (11). * When removing the pinion gear, support the bottom of the pinion gear securely with a wooden block. iv) Remove bearing cage assembly (12).

il

17MF02502

4 Using push tool @, remove outer race

(13), bearings (14), and (15), collar (16) and outer race (17). * Keep the bearings and collar as a set. vi) Remove spacer (18) from driven gear (19).

198Fl318

198FO2703 (

vii) Remove holder (20). viii) Using puller 0, pull out inner race (21), From pinion gear.

17MF02503

11

17MF02504

7. Bearings 1) Using push tool @, remove bearing (22). 2) Using puller, remove bearing (23).

30-l 09 0

ASSEMBLY OF TRANSFER GEAR HOUSING ASSEMBLY

+ Clean all parts, and check for dirt or damage.

Coat the sliding surfaces engine oil before installing. of all parts with

1. Bearings 1) Using push tool @I, press fit bearing (23). 2) Turn over case, then using push too, press fit bearing (22).

17MF02506

2. Pinion, housing assembly 1) Assemble pinion and housing assebly as follows. i) Press fit inner race (21) to pinion gear. ii) Install holder (20). @E Mounting bolt: 28.25 + 3.25 kgm

iii) Set driven gear (19) and spacer (18) to pinion gear (11). iv) Using push tool, press fit outer race (17). v) Assemble bearing (15), collar (16), and bearing (14). vi) Using push tool, press fit outer race (13). * Use the bearings and collar as a set.

I SSFO2705

vii) Set bearing cage assembly (12) on pinion gear, then using push tool @, press fit bearing cage assembly.

17MF02508

30-110 0

viii) Install holder (10). w Mounting bolt: 28.25 + 3.25 kgm

10
17MF02501 17MF02509A

ix) Fit O-ring, then install cover (9) as follows. l Tighten cover mounting bolts temporarily in the order shown in diagram on right. (Approx. 5 kgm) l Check clearance A between cover and cage, and check that it is as follows. Clearance A: 0.48 f 0.27 mm * Check that the variation around the whole circumference is less than 0.05 mm. Check also that the bearing is completely press fitted and is not at an angle. l After checking the above, tighten the mounting bolts of cover (9) in the order shown in the diagram on the right. w Mounting bolt: 6.75 + 0.75 kgm

17MF02851

7MF02852

2) Assemble shim (8). * Standard shim thickness: 2mm 3) Fit O-ring, then using eyebolts 0, pinion and housing assembly (7). 3. Lubrication tube Fit gasket and install lubrication tube (6).

install

30-111 0

4. Drive gear 1) Turn over transfer gear assembly. 2) Using push tool 0, press fit inner races (5) to both sides of drive gear. 3) Set drive gear (4) in case.

I98F02707A

17MFO2497

5. Bearing cage assembly 1) Using push tool 0, press fit bearing (3). 2) Install bearing cage assembly (2). 6. Lubrication tube Fit gasket and O-ring, and install lubrication tube (1).

17MF02510

11

17MF02495

30-112 0

REMOVAL OF TORQUE CONVERTER VALVE ASSEMBLY

1. Remove floor plate.

2. Disconnect connector (1). 3. Disconnect 4 pressure detection hoses (2). 4. Remove valve assembly (3). m

I-/

k-F19802211

z
2

INSTALLATION
l

OF TORQUE CONVERTER VALVE ASSEMBLY

in the reverse order to

Carry out installation removal.

Mounting bolt: 5.0 f

0.5 kgm

30-113 0

DISASSEMBLY

OF TORQUE CONVERTER VALVE ASSEMBLY

1. Disassemby

1) 2) 3) 4)

Remove Remove Remove Pull out

of lockup valve solenoid valve assembly (1). cover (2), then remove spring (3). cover (4), then remove piston (5). spool (6).

2. Disassembly of torque converter relief valve 1) Remove cover (7), then remove spring (8). 2) Remove cover (9), then remove valve (IO), spring (II), and valve (12). 3) Pull out spool (13). 3. Disassembly of main relief valve 1) Remove cover (14), then remove shim (15) and spring (16). 2) Remove cover (17), then remove valve (18), spring (19), and valve (20). 3) Pull out spool (21). of stator clutch modulation 4. Disassembly valve 1) Remove cover (22), then remove piston (23), and spring (24). 2) Remove ring (25) from body. 3) Remove cover (26), then remove valve (27), spring (28). and valve (29). 4) Pull out spool (30). 5) Remove shim (31) from spool. of lockup clutch modulation 5. Disassembly valve 1) Remove cover (32), then remove piston (33), and spring (34). 2) Remove ring (35) from body. 3) Remove cover (36), then remove valve (37), spring (38), and valve (39). 4) Pull out spool (40). 5) Remove spool (41) and shim (42) from spool (40).

30-114 0

l!

17MF02511

30-l 15 0

ASSEMBLY OF TORQUE CONVERTER VALVE ASSEMBLY

Clean all parts, and check for dirt or damage. Coat the sliding surfaces of all parts with engine oil before installing. Assemble valves (39) and (37), (29) and (27), (20) and (18), and (12) and (10) in the direction show in the diagram so that the valve with the hole in the center is on the inside of the spool.

5.

Assembly of lockup valve 1) Assemble spool (6). 2) Assemble piston (5) to cover (4), then fit O-ring and insall cover. 3) Assemble spring (3). 4) Fit O-ring and install cover (2). 5) Fit O-ring and install solenoid valve assembly (1).

1. Assemblv of lockuD clutch modulation valve II Set shim (42) on spool (41), then assemble to spool (40). 2) Assemble spool (40). 3) Assemble valve (39), spring (38) and valve (37) to spool, then fit O-ring and install cover (36). 4) Assemble ring (35) to body. 5) Assemble spring (34). 6) Assemble piston (33) to cover (32), then fit O-ring and install cover. 2. Assembly of stator clutch modulation valve 1) Assemble shim (31) to spool (30). 2) Assemble spool (30). 3) Assemble valve (29), spring (28) and valve (27) to spool, then fit O-ring and install cover (26). 4) Assemble ring (25) to body. 5) Assemble spring (24). 6) Assemble piston (23) to cover (22), then fit O-ring and install cover. 3. Assembly of main relief valve 1) Assemble spool (21). 2) Assemble valve (20), spring (19) and valve (18) to spool, then fit O-ring and install cover (17). 3) Assemble spring (16). 4) Assemble shim (15) to cover (14), then fit O-ring and install cover. 4. Assembly of torque converter relief valve Assemble spool (13). Assemble valve (12), spring (11) and valve (10) to spool, then fit O-ring and install cover (9). Assemble spring (8). Fit O-ring and install cover (7).

-o-_u

-0

-/27

30-116 0

REMOVAL OF TRANSMISSION

CONTROL VALVE ASSEMBLY

1. Remove operators seat (1). 2. Remove suspension with turntable. & kg assembly (2) together

Suspension, turntable assembly: 60 kg

3. Remove operators seat bottom cover (3). 4. Disconnect brake rod (4). 1111 * Remove the clamp, then move the steering control cable to the side. 5. Disconnect 4 wiring connectors (5). 6. Disconnect control cables (6). 1111 7. Remove cover (7) together with sleeve. 8. Remove inspection plug (8). 9. Remove tube (9), then using forcing screws, remove control valve cover (10). Iy31 10. Remove 4 bolts (II), assembly (12). m z E
0

17MF02513

Iy21

then

remove

valve
Q

17MF02514

17MF025:j

INSTALLATION OF TRANSMISSION CONTROL VALVE ASSEMBLY

l

Carry out installation removal.

in the reverse order to

Kl Bend the cotter pin securely. El a Sleeve O-ring: Grease (G2-LI)

Check through the plug hole in the cover that the lever and yoke are meshed, then tighten the mounting bolts. When installing the cover, if the dowel pin portion does not go in when it is tapped vvith a plastic hammer, remove the cover, correct the meshing of the lever and yoke, then install again.

Mounting bolt: 5.0 f 0.5 kgm

30-117 0

DISASSEMBLY OF TRANSMISSION 1. Disassembly

CONTROL VALVE ASSEMBLY

of modulating valve, quick return valve, reducing valve 1) Remove snap ring (6), then remove retainer (7), spring (9), shim (8), valves (5), (4), and (2), and spring (3). 2) Remove snap ring (lo), then remove stopper (11) and spool (12). 3) Remove snap ring (13), remove stopper (14), then remove valves (15) and (17), spring (16), spool (18), shims (19) and (20), and springs (21) and (22). 4) Remove cover (1) then remove vlave (23).

2. Disassembly of directional valve 1) Remove spool (24). 2) Remove spool (25).

valve,

speed

17MF02518

30-118 0

ASSEMBLY OF TRANSMISSION

CONTROL VALVE

Clean all parts, and check for dirt or damage. Coat the sliding surfaces of all parts with engine oil before installing.

1. Assembly of modulating valve, quick return valve, reducing valve l)Assemble valve (23), and install cover (1). 2)Fit springs (22) and (21), shims (20) and (19), and spool (18), then fit valve (17), spring (16). and valve (15), and secure with stopper (14) and snap ring (13). * Standard shim thickness: 1 .Omm 3) Fit spool (12). and secure with stopper (11) and snap ring (10). 4) Fit valve (2). spring (3). and valves (4) and (5), then fit spring (9) and shim (8). and secure with stopper (7) and snap ring (6). * Standard shim thickness: 2.5 mm 2. Assembly of directional 1) Install spool (24). 2) Install spool (25). valve, speed valve

30-119 0

REMOVAL OF STEERING CONTROL VALVE ASSEMBLY

1. Remove fuel tank assembly. For details, see REMOVAL ASSEMBLY. 2. Disconnect cable. 2 yokes

OF FUEL TANK

(1) of steering

control

3. Disconnect brake rod (2). m 4. Disconnect 2 pin puller hoses (3). 5. Disconnect 4 pressure detection hoses (4). 6. Remove steering valve assembly (5). m

el
kg

Steering valve assembly:

55 kg

17MF02520

INSTALLATION OF STEERING CONTROL VALVE ASSEMBLY

l

Carry out installation removal. *

in the reverse order to

Bend cotter pin securely. Bend cotter pin securely.

1121 * m w Mounting bolt: 11 + 1.5 kgm

30-l 20 0

DISASSEMBLY OF STEERING CONTROL VALVE ASSEMBLY

1. Disassembly of check valve 1) Remove block (1). then remove spring (2). 2) Remove snap ring (3), then remove seat (4) and check valve (5) from valve body (6). 2. Remove lever case from valve body (6). 3. Remove bolts (8), then remove spring (9) and shim (10). 4. Remove 3 seat mounting remove seat (12). bolts (II), then

ASSEMBLY OF STEERING CONTROL VALVE ASSEMBLY

*
Clean all parts, and check for dirt or damage. Coat the sliding surfaces of all parts with engine oil before installing.

1. Assembly of brake valve Assemble piston (37), valve (36), spring (35) and shim (34) in body (6), then fit O-ring and install plug (33). * Shim thickness: 6 X 0.5 mm 2. Assembly of clutch valve Assemble valve (32), piston (31), spring (30) and shim (29) in body (6), then fit O-ring and install plug (28). * Shim thickness: 2 X 0.5 mm 3. Assembly of brake shaft assembly 1) Set guide (26), spring (25), guide (24) and cylinder (23) in shaft (27), then install nuts (22) and (21). 2) Assemble brake shaft assembly (20) in body (6). 4. Assembly of clutch shaft assembly 1) Set guide (18), spring (17) and guide (16) in shaft (19), then install nuts (15) and (14). 2) Assemble shaft assembly (13) in body (6). 5. Fit O-ring and set seat (12) in postion, then tighten mounting bolts (11). 6. Set shim (IO) and spring (9) in position, then install bolts (8). * Shim thickness: 1 X 1.0 mm 7. Fit gasket and install lever cases (7) to valve body (6). 8. Assembly of check valve 1) Set seat (4) and check valve (5) in body (6), and install snap ring (3). 2) Set spring (2) in body (6), then fit O-ring and install block (1).

5. Disassembly of clutch shaft assembly 1) Remove shaft assembly (13) from body (6). 2) Remove nuts (14) and (15), then remove guide (16), spring (17) and guide (18) from shaft (19). 6. Disassembly of brakes shaft assembly 1) Remove brake shaft assembly (20) from body (6). 2) Remove nuts (21) and (22), then remove cylinder (23), guide (24), spring (25) and guide (26) from shaft (27). 7. Disassembly of clutch valve Remove plug (28), then remove shim (29), spring (30), piston (31) and valve (32) from body (6). 8. Disassembly of brake valve Remove plug (33), then remove shim (34), spring (35), valve (36) and piston (37) from body (6).

z ? z

30-122 a

31 30

32

iSSFl324

30-123 0

SCAVENGING

PUMP ASSEMBLY

1. Drain oil : u Power train oil: Approx. 120

2. Open inspection cover of under cover. * Hold the inspection cover securely, then remove the bolts and open the cover. 3. Remove pump outlet tube (1). 4. Disconnect pump inlet tube (2). 5. Remove 4 pump mounting remove pump assembly (3). & kg Pump assembly: 40 kg bolts, then /

17MF02521

INSTALLATION OF SCAVENGING PUMP ASSEMBLY

l

Carry out installation in the reverse order to removal Refilling with oil Add oil to the specified level, and run the engine to circulate the oil through the system. Then check the oil level again.

30-124 0

REMOVAL OF POWER TRAIN PUMP ASSEMBLY

1. Remove left and right engine side covers, then remove left step cover (1) and cab front cover (2). 2. Disconnect 2 air conditioner hoses (3). 3. Sling torque converter and transmission oil strainer (4), disconnect 4 connecting bolts holding to pump, then remove strainer. 4. Remove 2 pump mounting bolts, install guide bolts 0 (Dia. = 12 mm, pitch = 1.75 mm, length = 200 mm), and sling pump assembly (5). 5. Remove remaining 2 pump mounting bolts, raise pump assembly (5) and pull out to remove. f=GzL Power train pump assembly: 40 kg

8
z!
b

17MF02524

INSTALLATION OF POWER TRAIN PUMP ASSEMBLY

l

Carry out installation in the reverse order to removal. Refilling with oil Add oil to the specified level, and run the engine to circulate the oil through the system. Then check the oil level again.

30-l 25 0

REMOVAL OF FINAL DRIVE ASSEMBLY

1. For detail, see REMOVAL OF TRACK SHOE ASSEMBLY 2. Using jack 0 (50 ton) and ripper, jack up machine and set stand 0 (height: approx. 700 mm) under equalizer bar and rear of chassis.

Set the stand securely in position

3. Drain oil from final drive case. : u Final drive case: Approx. 43 4. Remove covers (I), (2).

(Each side)

5. Remove cover (3). 6. Using bolts 0, pull out shaft (4) until point where spline comes out. * If the shaft will not come out, move the sprocket backwards or forwards, and adjust to a position where the shaft will come out. 7. Leaving 2 or 3 mounting bolts at top from 8 mounting bolts (5) on inside and 17 on outside, remove mounting bolts. 8. Remove 3 mounting bolts of final drive case cover, then set tool F and lever block (l/2 t), and sling final drive assembly (6).

9. Remove remaining mounting bolts, then move to outside and remove from case. * Operate a lever block and twist with a bar to keep the clearance at the mating surface of the case and final drive case assembly uniform when removing. & kg lO.Remove Final drive case assembly: shaft (4). 1950 kg
17MF02530 17MF02531

30-126 0

INSTALLATION

OF FINAL DRIVE ASSEMBLY

Carry out installation removal.

in the reverse order to

Y-ZIL @Z
l

Mounting bolt: Thread tightener Mounting bolt: 135 I!I 15 kgm

(LT-2)

Refilling with oil * Supply engine oil to the specified from filler port.

level

23

Final drive case: Approx. 43 P (Each side)

30-127 0

DISASSEMBLY

OF FINAL DRIVE ASSEMBLY

1. Cover 1) Set final drive assembly on block @ (height: approx. 50 mm). 2) Remove mounting bolts (1) and (2), then using eyebolts 0, remove cover (3).

17MF02532

17MF02533

2. Hub 1) Remove plate (4). 2) Lift off hub (5).

17MF02534

17MF02535

g b _

3. Sprocket, drum assembly 1) Remove mounting bolts (6), then remove holder (7). 2) Using eyebolts 0, sling sprocket and drum assembly (8). 3) Using tool Gl, remove sprocket and drum assembly together with bearing (9).

I97F359

30-128 0

4) Disassemble the sprocket and drum assembly i) Set sprocket and drum assembly on block (height: 100 mm). ii) Remove flooting seal (IO). * Keep the floating seal in a safe place to protect it from damage.

17MF02538

iii) Remove mounting bolts, then remove seal (11). iv) Remove outside drum mounting bolts (12).

17MF02539

17MF02540

v) Remove mounting bolts (13) and (14), then using eyebolts 0, remove cover (15).

17MF02541

17MF02542

vi) Remove mounting bolts, then remove seal (16). vii) Remove inside drum mounting bolts (17).

17MF02543

17MF02544

30-129 0

viii) Lift off inside drum (18).

ix) Using eyebolts 0, remove inner drum assembly (19) from outside drum (20). x) Remove outer race (21). xi) Weld plate of tool G2 around whole circumference of rubber bushing, then set tool G2 as shown in diagram below, and pull out rubber bushing (22).
G2

18

7
I98FO2722

198Fl412

17MF02545

22mm

, ,
17MF02546 Section A-P 17MF02546

4. Wear guard Remove mounting guard (23).

bolts, then remove

wear

17MF02547

30-130 0

5. Cover assembly 1) Remove mounting bolts (24), then using eyebolts @, remove cover assembly (25).

17MF02549

17MF02550

2) Disassemble cover assembly as follows. i) Remove mounting bolts, then remove floating seal cage (26). ii) Remove floating seal (27). A Keep the floating seal in a safe place to protect it from damage.

------In
1
17MF02551 11 17MF02552 _I

iii) Remove spacer (28). iv) Remove bearing (29).

29

20

17MF02553

v) Turn over cover, and remove plate (30). vi) Lift off ring gear (31).

17MF02554

17MF02555

30-l 31 0

6. Carrier assembly 1) Using eyebolts 0, remove carrier assembly (32). 2) Set carrier assembly on block (height: 100 mm), and disassemble as follows. i) Remove spacer (33).

32

I
ii) Using puller 8, remove outer race (34).

17MF02556]1

17MF02557

17MF02558

iii) Remove mounting bolts, then remove holder (35). iv) Using tool G3, remove shaft (36). v) Remove gear (37), bearing (38), and spacer (39). vi) Remove outer race (40) from gear.

40

38
17MF02561 17MF02562

30-132 0

7. Sun gear, shaft assembly 1) Remove sun gear and shaft assembly (41).

17MF02563

2) Disassemble sun gear and shaft assembly as follows. il Remove mounting bolts, then remove plate (42). ii) Using puller 0, remove bearing (43).

-I

17MF02564

17MF02565

iii) Remove mounting bolts, then remove plate (44). iv) Using push tool 09, remove sun gear (45) from shaft (46).

@ /

17MF02566

%02567

8. Hub, shaft assembly 1) Remove 18 mounting bolts (47) of shaft. 2) Remove 2 mounting bolts of gear, then using eyebolts 0, remove hub and shaft assembly (48).

17MF02569

17MF02569

30-133 0

3) Disassemble hub and shaft assembly as follows. i) Remove mounting bolts, then remove holder (49). ii Using tool G4, remove hub assembly (50) and bearing (51) from shaft assembly (52).

G4

17MF02570

iii) Remove spacer (53), then remove bearing (54) from shaft (55). iv) Remove outer race (56) and gear (57) from hub (58).

17MF02572

17MF02573

9. Cage assembly 1) Remove mounting bolts, then using eyebolts 0, remove cage assembly (59). 2) Remove shim (60). * Check the number and thickness of the shims, and keep in a safe place.

17MF02574

17MF02575

3) Disassemble cage assembly as follows. i) Using puller 0, remove outer race (61). ii) Remove oil seals (62) and (63).

I98F02738
L

I97F50

30-134 0

10. Gear assembly 1) Remove gear assembly (64).. 2) Using puller 03, remove beaiing gear (66).

(65) from ..

17MF02576

17MF02i?7

11. Outer race, oil seal 1) Using puller 0, remove outer race (67). 2) Remove oil seals (68) and (69) from case (70).

I97F502

I98FO274

30-l 35 0

ASSEMBLY OF FINAL DRIVE ASSEMBLY

Wash all parts, then dry them, and check for dirt or damage. Coat the sliding surfaces of all parts with engine oil before installing.

1. Oil seal, outer race 1) Using push tool 03, 0, install oil seal (69). (69). A Set the upper oil seal with the pressure side facing up, and the lower oil seal with the pressure side facing down, and install. a a Lip of oil seal: Grease (G2-LI) Press-fitting surface of oil seal: Gasket sealant (LG-5)
17MF02578

A Coat the inside surface of the case thinly with gasket sealant, and wipe off any gasket sealant that is squeezed out. -68

17MF02579

2) Using push tool @, press fit outer (67).

race

17MF02580

2. Gear assembly 1) Using push tool @, press fit bearing (65) to gear (66). 2) Set tool G5 to case, and install gear assembly (64). * Do not remove tool 65 until the cage is installed.

G5

65
17MF02581

I97F405

30-136 a

3. Cage assembly 1) Assemble cage assembly as follows. i) Using push tools @J and 0, install oil seals (63) and (62). * Set the upper oil seal with the pressure side facing up, and the lower oil seal with the pressure side facing down, and install. /F~ mLip of oil seal: Grease (G2-LI) Press-fitting surface of oil seal: Gasket sealant (LG-5)
17MF02582

Coat the inside surface of the case thinly with gasket sealant, and wipe off any gasket sealant that is squeezed out.

62

I
ii) Using push tool @, press fit outer race (61).

17MF02583

17MF02584

2) Using eyebolts 0, set cage (59) to case, then tighten 6 mounting bolts. w * Mounting bolt: 1.5 kgm Rotate the gear and tighten uniformly, then remove tool G5 installed at Step 2-2).

30-l 37 0

gauge 0, as shown in 3) Using thickness diagram, measure clearances 6E and 6F between cage @ and case @ 6 of shim to be inserted 4) Set thickness according to table below.

/I

@M

easurement

Measurement

position

I99FO274511

17MF02ii6

30-138 0

5) Assemble shim (60) set in Item 4), and tighten cage mounting bolts. w Mounting bolt: 11.25 k 1.25 kgm

17MF02587

4. Hub, shaft assembly 1) Assemble hub and shaft assembly as follows. j, The bearing connecting the hub and shaft is a set, so match the match symbols and production numbers on the inner and outer races and inner race spacer when assembling.

of inner race spacer (ex: K-3)

17MF02588

i) Install gear (57) to hub (58). Mounting bolt: 28.25 f 3.25 kgm ii) Using push tool 0, press fit top and bottom outer races (55) to hub (58). QZK

5-S
17MF02589 17MF02590

iii) Using push tool 0, press fit bearing (54) to shaft (55). iv) Assemble spacer (53).

17MF02591

17MF02592

30-139 0

4 Set hub assembly (50) to shaft assembly (52), then using tool G6, press fit bearing (51). * Rotate the hub when press fitting the bearing. r----r

17MF02593

17MF02594

vi) Install holder (49). mw Mounting bolt threaded portion: Thread tightener (LT-2) Mounting bolt: 28.25 + 3.25 kgm

17MF02595

2) Using eyebolts 0, raise hub and shaft assembly (48), then fit O-ring and set to case. 3) Tighten 18 mounting bolts (47) of shaft.

I
5. Sun gear, shaft assembly 1) Assemble sun gear and shaft assembly as follows. i) Press fit shaft (46) to sun gear (45). ii) Install plate (44).

17MF02569

11

17MF02568

17MF02596

17MF02566

30-140 0

iii) Using push tool @, press fit bearing (43). iv) Install plate (42).

17MF02597

17MF02564

2) Set sun gear and shaft assembly hub.

(41) to

6. Carrier assembly 1) Assemble carrier assembly as follows. The planetary gear bearing is a set, so match the match symbols and production numbers on the inner and outer races and inner race spacer when assembling.

I
Match symbol of inner or outer races 1-11 Match symbol of inner or outer races

17MF02598

Install ring and spacer to gear, then using push tool 0, press fit top and bottom outer races (40).

30-141 0

ii) Assemble spacer (39) and bearing (38) to gear (37), and set to carrier. * Set the direction of assembly of the gear as shown in the diagram.

38

17MF02562

17MF02600

iii) Using tool G7, press fit shaft (36). * Align the position of the bearing and spacer holes, and press fit the shaft slowly. iv) Install holder (35). * After tightening the bolts, check that the gear rotates smoothly. w Mounting bolt: 56 f 6 kgm

17MF02560

v) Using push too 8, press fit outer race (34). vi) Assemble spacer (33).

17MF02557

2) Using eyebolts 0, set carrier assembly (32) to shaft assembly. * When installing the carrier assembly, be careful not to damage the bearing.

32

17MF02556

30-142 0

7. Cover assembly 1) Assemble cover assembly as follows. i) Raise ring gear (31), and set to cover. ii) Install plate (30). * install the plate with the chamfered portion on the outside.

II

17MF0255E

17MF02554

iii) Using tool G8, press fit bearing (29). iv) Install spacer (28).

v) Using tool G9, install floating seal (27) to cage. * When installing the floating seal, remove all grease and oil from the O-ring and surface in contact with the O-ring, then dry before installing. * After installing the floating seal, check that the angle of the seal is within 1 mm. vi) Fit O-ring and install floating seal cage (26). * Install cork plugs in the trimming bolt holes. * Install the floating seal cage with the notched portion at the bottom as shown in the diagram.

17MF02602

11

17MF02603

27

Gs
17MF02604

17MF02605

30-143 0

2) Fit O-ring, then using eyebolts

cover assembly (25) to case. 3) Tighten mounting bolts (24). w

8,

set

Mounting bolt: 56 f 6.0 kgm

17MF02550

17MF02549

8. Wear guard Install wear guard (23). m Mounting bolt: 94.5 k 10.5 kgm

17MF02547

9. Sprocket, drum assembly 1) Assemble sprocket and drum assembly as follows. i) Using push tool 0, press fit rubber bushing (22) in inner drum. bushing is stiff and will not go * If them in, press fit with a press. * Press fit the busing until the end face of the inner drum and the end face of the busing are flush as shown in the diagram.
Bushing Inner drum I

17MF02607

17MF02608

Y-XI&

Press fitting portion of bushing: anti-friction compound (LM-P)

ii) Install top and bottom outer races (21). * Expand fit the outer race.

30-144 a

iii) Using eyebolts 0, raise inner assembly (19), then lower slowly and set on outside drum (20).

20

I----17MF02545

iv) Install inside drum (18). * Align the dowel pins of the outside drum and inner drum when installing. xCL Mounting surface: Gasket sealant (LG-6)

I98FO2722

4 Tighten
(17). KCL w

inside

drum

mounting

bolts

Mounting bolt threaded portion: Thread tightener (LT-2) Mounting bolt: 80 f 10 kgm

vi) Install seal (16). /(il\, Seal mounting surface: Gasket sealant (LG-6)

17MF02544

17MF02543

vii) Fit O-ring to inner drum, then using eyebolts 0, set cover (15) in position, and tighten mounting bolts (14) and (13). w Mounting bolt (14): 28.25 f 3.25 kgm Install cork plugs in the trimming bolts holes.

17MF02542

17MF02541

x) Turn over sprocket and drum assembly and set on block, then tighten outside drum mounting bolts (12). a w Mounting bolt threaded portion: Thread tightener (LT-2) Mounting bolt: 80 + 10 kgm

xi) Install seal (7). RQIL Seal mounting surface: Gasket sealant (LG-6)
17MF02540

JL

17MF02539

xii) Using tool G9, install floating seal (10). * Remove all the grease from the O-ring and O-ring contact surface, and dry before installing. * After installing the floating seal, check that slope of the seal is less than 1 mm.

17MF02610

2) Using eyebolts 0, set sprocket and drum assembly (8) to cover. * Check that there is no dirt or dust on the sliding surface of the floating seal, then coat thinly with engine oil. 3) Using tool G8, press fit bearing (9). * When press fitting the bearing, rotate the sprocket and drum assembly.

&G&&g
17MF02611

I97F365

30-146 0

4) Fit holder (7) and tighten (6).

mounting

bolts

Mounting bolt: 28.25 + 3.25 kgm

10. Hub 1) Sling hub (3) and install. 2) Install plate (2). w Mounting bolt: 11.25 I!T1.25 kgm

I
h

8
& 0

I
11. Cover Using eyebolts 0, install cover tighten mounting bolts (2) and (1). AT?-w

17MF02535

17MF02534

(3),

then

Mounting surface: Gasket sealant (LG-5) Mounting bolt: 28.25 + 3.25 kgm

17MF02533

17MF02532

30-147 0

REMOVAL OF TRACK FRAME ASSEMBLY

1. For details,

see REMOVAL

OF TRACK SHOE

ASSEMBLY. 2. Using jack (70 ton), raise the machine and set standard 0 (height: approx. Im) under the equalizer bar case. 3. Remove cover (1). 4. Remove holder (2). 5. Remove pivot shaft mounting bolts (3).
0

198F02753
6. Remove mounting bolts of pivot shaft inside cover (4), and disconnect cover. 7. Remove pin (5). m * Sling the track frame assembly, then remove the lock plate, and knock out the pin. 8. Lift off track frame assembly (6). 1121 * Use a chain block on the inside of the idler yoke and adjust to keep horizontal so that the track frame assembly does not slope to the left. * The oil inside the pivot chamber will leak out, so put a container under it to catch the oil. & kg u Track frame assembly: Pivot chamber: Approx. 4500 kg 12~

I9gF62754

a7

INSTALLATION OF TRACK FRAME ASSEMBLY

l

Carry out installation removal.

in the reverse order to

m !I
0 -

I98FO2757

& m a w
l

Pin: Grease (G2-LI)

Pivot shaft: Anti-friction Plug: 15 f 3 kg

compound

(LM-P)

Refilling with oil * Add engine oil to the pivot case to the specified level. For details, see INSTALLATION OF EQUALIZER BAR ASSEMBLY.

30-148 0

REMOVAL OF IDLER YOKE ASSEMBLY

1. Remove track shoe assembly. For details, see REMOVAL OF TRACK SHOE ASSEMBLY. 2. Remove scrapers (I), (2), (3), and (4) from side face of idler. 3. Remove idler assembly. For details, see REMOVAL OF IDLER ASSEMBLY. 4. Drain oil from spring chamber. + Drain the oil with a pump. 6 5. 6. Spring chamber

: Approx.

75 ~2

CLD01059

Remove idler yoke top cover (5). Disassemble yoke assembly (including idler bogie as follows. I) Loosen idler yoke mounting bolts (6) gradually in turn on diagonally opposite sides. m * Wrap cloth around the chrome plated portion to protect the chrome plated portion from being hit and damaged by the tool. A To prevent danger, never stand in front of the yoke assembly. The recoil spring inside the recoil cyling der is applying a pushing force of 363 kN (37 tons) on the yoke, so be careful not to loosen the mounting bolts suddenly. Loosen the mounting bolts gradually until clearance a between the flange of the recoil cylinder and idler yoke assembly is 8 - 12 mm. 2) When the bolts are loosened, the torque will suddenly drop. Check that the spring is not applying any pushing force on the mounting bolts, then remove all bolts. If the torque increases (the pushing force * of the spring is applied) during the loosening operation, stop the loosening operation and disassemble as follows.

Flange

Plated

bushing

DLD02846

deAhIf the torque does not drop during Step 2)bolts scribed above, and the torque when the are loosened remains large, there is probably damage to recoil spring set bolt (91, or nut (IO) at the tip of the shaft has fallen off, so there is danger that the yoke assembly may fly off to the front. For this reason, disassemble as follows.

CLD01062

30-148-l 0

When disconnecting the yoke assembly and recoil cylinder assembly, do not stand in front of the yoke assembly or behind the recoil cylinder assembly until safety has been confirmed and the recoil spring assembly has been removed. i) Prepare Bolt @ Nut @ Washer the following parts. 791-730-1110 (x6): 01580-12722 (x6): @ (x6): 01643-32780

(use again)
CKD01063

ii)

0, *

Remove 6 nuts@, Check mm. sr Screw bottom

bolts marked %, then install bolts and washers @ listed in Step i). that dimension L is less than 361 in bolts @ until they contact of the yoke thread. 12 bolts (those the
Yoke

remaining iii) Remove marked %_).

not

iv) Hold bolts @ with a wrench to prevent them from turning, then loosen 2 nuts @ simultaneously on opposite sides. * Be careful not to let the load bea,r on only one bolt.

OK002847

v)

When recoil spring is fully extended and torque has completely dropped in loosening direction of nut 0, remove bolt 0. * When clearance b is approx. 165 mm, the spring is fully extended.

CLD01065

7.

Remove

idler yoke (7) from

recoil cylinder

(8). 8

30- 148-2 0

INSTALLATION
.
Carry out removal. installation

OF IDLER YOKE
in the reverse order to

%2

Spring chamber : Approx. 75 4? Ir When using waste oil, use oil that does not include mercury, alkali or any other dangerous substance.

m Sr

Bolt (6): 1324 i. 147 Nm (135 2 15 kgm) If the recoil spring holder nut has come off or fallen out, assemble again. OF RECOIL see ASSEMBLY For details, SPRING ASSEMBLY.

30-148-3 0

REMOVAL OF RECOIL SPRING ASSEMBLY

1. Remove track shoe assembly. For details, see REMOVAL OF TRACK SHOE ASSEMBLY. Drain oil from spring chamber. * Drain the oil with a pump. & 3. 4. Remove Remove & kg 5. Spring chamber idler top cover (1). trunnion Trunnion (2).
17MF02855

2.

: Approx.

75 .t

: 56 kg

Remove outside cover (3) and inside cover (4). * Remove the inside and outside covers.

17MF02618

6.

m Remove pins (5). * Using tool H, remove the inside and outside pins.

17MF02619

i-&

,(-y

17MF02620

7.

Remove idler and recoil spring assembly (6). Ir Using a lever block, keep the assembly horizontal, and be careful not to damage the oil seal at track frame (7) end. & kg Idler, recoil spring assembly

: 1500 kg

8.

Remove recoil cylinder assembly (6). a * Disconnect recoil cylinder assembly from idler yoke assembly (9) as follows. 1) Put idler yoke assembly (9) in contact with ground, then raise recoil cylinder assembly (8). Sr When doing this, check that there is no damage to the weld of recoil spring case + (8). Wrap cloth around the chrome plated portion to protect the chrome plated portion from being hit and damaged by the tool.

CLD01067

2)

3)

Loosen idler yoke mounting bolts (IO) gradually in turn on diagonally opposite sides. ~TO prevent danger, never stand in front of the idler yoke assembly or behind the recoil cylinder assembly. AThe recoil spring inside the recoil spring case is applying a pushing force of 363 kN (37 tons) on the yoke, so be careful not to loosen the mounting bolts suddenly. Loosen the mounting bolts gradually until clearance a between the flange of the recoil cylinder and idler yoke assembly is 8 - 12 mm. When the bolts are loosened, the torque will suddenly drop. Check that the spring is not applying any pushing force on the mounting bolts, then remove all bolts. * If the torque increases (the pushing force of the spring is applied) during the loosening operation, stop the loosening operation and disassemble as follows.

Plated

bushing

DLD02848

CLD01069

glf

the torque does not drop during Steps 2) and 3) described above, and the torque when the bolts are loosened remains large, there is probably damage to recoil spring set bolt (19), or nut (20) at the tip of the shaft has fallen off, so there is danger that the yoke assembly may fly off to the front. For this reason, disassemble as follows.

30-150 0

the yoke assembly and recoil cylinder assembly, do not stand in front of the yoke assembly or behind the recoil cylinder assembly until safety has been confirmed and the recoil spring assembly has been removed.

When disconnecting

i)

Prepare the following parts. Bolt @ (x6): 791-730-I 110 Nut @ (x6): 01580-12722 (use again) Washer @ (x6): 01643-32780
CKD01063

Remove 6 bolts marked %, then install bolts 0, nuts 0, and washers @ listed in Step i). Check that dimension L is less than 361 * mm. Screw in bolts (I) until they contact the * bottom of the yoke thread. not iii) Remove 12 bolts (those remaining marked a). ii) iv) Hold bolts 0 with a wrench to prevent them from turning, then loosen 2 nuts @ simultaneously on opposite sides. Be careful not to let the load bear on * only one bolt.

DKD0.2847
J

v)

and When recoil spring is fully extended torque has completely dropped in loosening direction of nut 0, remove bolt 0. When clearance b is approx. 165 mm, * the spring is fully extended.

CLD01071

9.

Remove

ring (11).

CLD01072

10. Remove adjustment cylinder (12). * Pump in grease from lubricator push out piston assembly (13).

(141, and

CLD01073

CKD01074

Disassembly of piston assembly a i) Remove wear ring (15) from piston assembly, then remove snap ring (16), and remove packing (17).

15

17

16

13

CLD01075

11. Remove &I kg

recoil spring assembly Recoil spring assembly

(18).

: 400 Kg

30-150-2 0

INSTALLATION OF RECOIL SPRING ASSEMBLY

Carry out removal.

installation

in the

reverse

order

to

Spring chamber: Approx. 7% When using waster oil, use oil that does not include mercury, alkali or any other dangerous substance.

When installing the pin, align the center of the idler and recoil spring cylinder with a bar, and install.

& w

bolt (IO): Therad tightener (LT-2) Tightening torqe of bolt (IO): . Top mounting bolt (IO bolts): 1324 +_ 147 Nm (135 +_ 15 kgm) . Bottom mounting bolt with plate (8 bolts) 1564 + 172 Nm (159.5 f 17.5 kgm) If the recoil spring holding nut has fallen off, see ASSEMBLY OF RECOIL SPRING for assembling.

Mounting

Pump in grease as follows to prevent air from collecting inside the cylinder. 1) Fill inside of cylinder with approx. 75cc of grease (each side). 2) Set cylinder drain hole facing up, then loosen lubricator (14). lubricator (14) to specified 3) Tighten torque. m Lubricator: 73.5 f 14.7 Nm (7.5 f 1.5 kgm)

30-150-3 0

DISASSEMBLY OF RECOIL SPRING ASSEMBLY

1. Set recoil spring assembly (I) in tool 0. The spring is under high installed load, a so be careful to set it correctly. * Installed load of spring: 388.3 kN (36.9 tons)

CLD01077

2.

Apply hydraulic pressure spring, then remove lock nut (3). Release tension hydraulic of spring. pressure

slowly to compress plate (2) and remove

0
2 3

3.

gradually

and relieve

4.

Remove rear pilot (8) from

pilot (5), spacer spring (4).

(61, bolt

(7), and

CL001078

ASSEMBLY ASSEMBLY

OF RECOIL SPRING

1. Assemble pilot (8), bolt (7), spacer (61, and rear pilot (5) to spring (4), then set in tool 0. The spring is under high installed load, so be careful to set all parts correctly.

2.

Apply spring,

hydraulic pressure slowly to compress and set so that installed length of spring

~!$$dl~r$~.a

: 1078 mm

CL001079

-1

CKD01080

30-150-4 5

3.

Fit nut (3), then install lock plate (2). Sr When securing the recoil spring mounting nut, make a clearance of 0 - 1.0 mm between lock plate (2) and nut (31, then bring lock plate (2) and bolt (7) into tight contact, and secure in position. * Purpose of making clearance I) If the nut is screwed in a small amount and nut (3) protrudes beyond bolt (71, lock plate (2) may bend and lock bolt (8) may fall off. 2) If the nut is screwed in too far, the load of the spring will always be applied to the set bolt, and the set bolt will break. Gradually release hydraulic pressure to completely relieve tension of spring, then remove recoil spring assembly (1) from tool 0.

TClearance

O-1.

Omm

DKD02849

4.

30-151 0

REMOVAL OF IDLER ASSEMBLY

For details, see REMOVAL OF TRACK SHOE ASSEMBLY. 2. Remove inside and outside covers (I) and (2) (2 each). a ATo prevent danger, never stand in front of the idler yoke assembly. 3. Sling the idler assembly (31, and remove (4), then remove the idler assembly (2). Idler assembly: 350 kg cap 1.

/GJ

17MF02630

INSTALLATION ASSEMBLY
.
Carry out removal. w installation

OF IDLER
02631

in the

reverse

order

to

Mounting

bolt of front cover (I): 549.1 = 58.8 Nm I56 + 6 kgm)

* Ir

Tighten the idler cap mounting bolts in the order @+@I+@ After tightening, check that clearance a at the bottom of the cap is 0 mm. & Cap mounting bolt: Thread tightener (LT-2) Q~EI Cap mounting bolt: 1,324 f 147 Nm (135 t 15 kgm}

30-152 @

DISASSEMBLY

OF IDLER ASSEMBLY

1. Remove plug and drain oil. : u Idler: Approx. 1.5 P 2. Set idler assembly (1) on block 0. 3. Remove mounting screws 0, remove seal guide (2). bolts, then using forcing retainer (3) together with

4. Turn over idler assembly (4), remove mounting bolts, then using eyebolts 0, remove shaft (4) together with retainer. 5. Using puller 0, remove seal guide together with retainer (6) from shaft. (5)

6. Remove seal guides (2) and (5) from retainers (3) and (6).

2-5 \

17MF02635

17MF02636

17MF02639

7. Remove floating seals (7) and (8) from seal guides (2) and (5), and retainers (3) and (6). * Keep the floating seals in a safe place to protect them from damage. 8. Remove bushing (9) from idler (10).

2.5
17MF02637 17MF02638

17MF02640

ASSEMBLY OF IDLER ASSEMBLY

Clean all parts, and check for dirt or damage. Coat the sliding surfaces of all parts with engine oil before installing.

1. Set tool J, to idler (IO), and press fit bushing (3). A When press fitting the bushing, center it with a plastic hammer, then press fit with a puller. * Press fit the bushing so that the distance from the end face of the idler to the top face of the bushng is 15 f Imm.

2. Using tool J,, install floating seal (8) to retainers (3) and (6). 3. Fit O-ring, install retainer with mounting bolts. (3), then tighten

4. Using eyebolts 0, set idler (IO) on shaft (4). j, Set a block (approx. 140mm) under the idler. 5. Turn over idler assembly. j, Tie the shaft with wire to prevent it from falling out. 6. Fit O-ring, install retainer with mounting bolts. (6), then tighten

17MF02644

17MF02&

7. Using tool J,, install floating seal (7) to seal guides (2) and (5). 8. Fit O-ring to seal guide.

J3 17MF02646

30-154 0

9. Set tool J, to idler, and press fit seal guide (2). * Press fit the seal guide so that distance a from the end face of the shaft to the top face of the seal guide is 96 f 0.2mm. j, Turn over the idler assembly, and repeat the same procedure to press fit seal guide (5).

J2 /

10. Add gear oil through oil filler to the specified level. I&
z 5 m

Idler: Approx. Plug: 21 f

1.5

5 kgm

30-155 0

REMOVAL OF TRACK

1. For details, see REMOVAL ASSEMBLY. 2. Remove retainer (1). m

OF TRACT SHOE

3. Remove track roller guard (1).

52
kg

Track roller guard inside: 85 kg 90 kg

kg

Track roller guard outside:

If the mounting bolts cannot be removed, use a power wrench to remove them.

i
4. Start the engine, then operate the blade and ripper levers, and raise the machine.

17MF02649

After raising the machine, set the block on the track shoe, and lock the work equipment layer and brake pedal.

5. Remove track roller assembly (2). 1131 * Set tool K under the track roller assembly, then remove the track roller assembly. I3 kg Track roller assembly: 120 kg

INSTALLATION OF TRACK ROLLER ASSEMBLY

l

Carry out installation removal.

in the reverse order to

& m 1121 * & a N B m * * & N

Retainer mounting bolt: Thread tightener Retainer mounting bolt: 56 f

(LT-2) 6 kgm

Assemble the guard tension bolt with the head on the inside. Guard tension bolt: Thread tightener Guard mounting bolt: Thread tightener Guard tension bolt: 94.5 * Guard mounting bolt: 94.5 f (LT-2) (LT-2)

10.5 kgm 10.5 kgm

Assemble so that the oil plug is on the outside of the machine. Install the dowel pin only on the oil plug side. Roller mounting bolt: Thread tightener (LT-2)

Roller mounting bolt: 94.5 k 10.5 kgm

30-156 n

DISASSEMBLY

OF TRACK ROLLER ASSEMBLY

1. Remove plug, and drain oil. : Track roller assembly: u

Approx.

14 P

2. Set track roller assembly (1) on block 0. 3. Remove mounting bolts, then using forcing screws 0, remove seal guide (2) together with retainer (3) from shaft.

4. Turn over track roller asembly, and remove 0, bolts, then using eyebolts mounting remove shaft (4) together with retainer. 5. Using press, remove seal guide (5) together with retainer (6) from shaft. 6. Remove seal guides (2) and (5) from retainers (3) and (6).

g 3 z 7. Remove floating seals (7) and (8) from seal guides (2) and (5) and retainers (3) and (6). * Be careful not to damage the floating seals, and keep in a safe place.

17MF02654

17MF02639

17MF02656

jj

17MF02657

8. Remove bushing (9) from roller (10).

ASSEMBLY OF TRACK ROLLER ASSEMBLY

Clean all parts, and check for dirt or damage. Coat the sliding surfaces of all parts with engine oil before installing.

1. Set roller (IO) in press, then use tool L, to press fit bushing (9). * When press fitting the bushing, center it with a plastic hammer, then press fit with a press. * Press fit the bushing so that the distance from the end face of the roller to the top face of the bushing is 15 * Imm.
17MF02659 1j 17MF02660

2. Set shaft (4) to roller. 3. Using tool L,, install floating seal (8) to retainers (3) and (6). 4. Fit O-rings, install retainers (3) and (6), then tighten with mounting bolts.

I
5. Using tool L,, install floating seal (7) to seal guides (2) and (5). 6. Fit O-ring to seal guide.

17MF02661

17MF02662

7. Using tool L,, press fit seal guide (2). * Press fit the seal guide so that distance a from the end face of the shaft to the top face of the seal guide is 69 k 0.2mm. * Turn over the track roller assembly, and repeat the same procedure to press fit seal guide (5). 8. Add gear oil through oil filler to the specified level. Q w Track roller: Approx. Plug: 21 f 5 kgm 1.4 P
1 a 17MF02665

30-158 0

REMOVAL OF CARRIER ROLLER ASSEMBLY

1. Track tension Loosen track tension. * For details, see SHOE ASSEMBLY.

REMOVAL

OF

TRACK

2. Carrier roller assembly (1) m A Using a jack, raise the track shoe so that the carrier roller assembly can be removed.

INSTALLATION OF CARRIER ROLLER ASSEMBLY

l

Carry out installation removal.

in the reverse order to

When installing the carrier roller to the support, leave a clearance as shown in the diagram.

&I&

Support mounting bolt: Thread tightener

(LT-2)

30-l 59 0

DISASSEMBLY

OF CARRIER ROLLER ASSEMBLY

1. Remove plug and drain oil. : Carrier roller assembly: Approx. 0 7e u 2. Set carrier roller assembly on block 0. 3. Remove (2). 4. Remove ring (3). mounting bolts, then remove cover

a
17MF02667 17MF02666

5. Using tool M,, remove nut (4). 6. Using puller 0, remove press-fitting portion of seal guide, then use eyebolts to remove bearing (5) together with roller (6).

I
7. Remove outer races (7) from roller. 6. Using puller 0, remove seal guide (8) together with bearing (9) from shaft. 9. Remove floating seal (IO) from seal guide (8).

17MF02669

17MF02670

I-L---J

17MF02671

17MF02672

17MF02675

10. Using push tool 0, remove seal guide (11). 11. Remove (11). floating seal (12) from seal guide

17MF02613

17MFO2614

30-l

60

ASSEMBLY OF CARRIER ROLLER ASSEMBLY

Clean all parts, and check for dirt or damage. Coat the sliding surfaces of all parts with engine oil before installing. press fit bearing (9).

1. Using push tool 0,

2. Using push tool 0, press fit outer race (7).

3. Set roller (6) and bearing (5) on shaft. 4. Using push tool 0, press fit bearing (5) on shaft. * Rotate the roller when press fitting the bearing. Press fit the bearing until the rotation of the bearing becomes slightly heavy.

.
17MF02678 17MF02679

Using tool M,, tighten nut (4) at IO kgm. * After tightening the nut, if the nut hole and the shaft hole are not aligned, align in the direction of loosening the nut. 6. Install ring (3).

17MF02669

i/

17MF02668

7. Fit O-ring, install cover (2), then tighten with mounting bolts.

17MF02680

30-l 61 0

8. Using tool M,, install floating seal (10) to seal guide (8). 9. Fit O-ring, then align with dowel pin and install seal guide (8).

17MF02681

17MF02682

10. Using tool M,, install floating seal (12) to seal guide (11). 11. Using tool M,, press fit seal guide (11). * Press fit the seal guide so that distance a from the end face of the shaft to the top face of the seal guide is 159.75 f 0.2mm.

si$&&
,I

I_

11
17MF02683

17MF02685

12. Add gear oil through oil filler (1) to the specified level. * Rotate the roller when adding the oil. Q m Carrier roller: Approx. Plug: 21 f 5 kgm 0.7 e

30-162 0

CHECKING BEFORE REMOVAL OF TRACK SHOE ASSEMBLY

aln some cases, it may be extremely dangerous to remove the track shoe assembly. To prevent danger, carry out the following checks before removing the track shoe assembly. Checks before starting I) Loosen the lubricator at the adjustment cylinder, release the grease, then move the machine backward and forward a short distance, and check that the track tension is relieved. If the track tension is not relieved and the track shoe assembly remains tense, there may be an abnormality inside the track frame (the recoil spring case is broken, the recoil spring set bolt is broken, or the nut at the end of shaft has fallen off). Never loosen the lubricator more than g one turn.

REMOVAL OF TRACK SHOE ASSEMBLY (NORMAL)

CA ;

If CHECKING BEFORE REMOVAL OF TRACK SHOE ASSEMBLY shows that there is no abnormality, do as follows. 1. Set master link in position. + Set a block (height: approx. 400 mm) so that the master link is approx. 600 mm from the ground at the front. m 2. Relieve track shoe tension. Never loosen lubricator (I) more than one a turn. * If the track is not relieved by loosening the lubricator, move the machine backwards and forwards.
*

3. 4.

Remove mounting bolts of track shoe (2) and a master link (3). Raise tip of master link, move machine towards rear slowly, and lay out track shoe assembly (4).

CLD01083

CLD01084

30-163 z

REMOVAL OF TRACK SHOE ASSEMBLY

(WHEN THERE TRACK FRAME) * IS ABNORMALITY INSIDE

When CHECKING BEFORE REMOVAL OF TRACK SHOE ASSEMBLY shows any abnormality, do as follows. If there is any abnormality inside the track frame, a there is danger that the track shoe assembly may spring back when it is removed or that the idler may spring out when the track shoe assembly is removed. This may lead to serious injury, so remove the track shoe assembly as follows. a If there is any interference or abnormal catching around the idler assembly, examine carefully and remove the problem before starting. 1. Remove work equipment assembly. For details, see REMOVAL OF WORK EQUIPMENT ASSEMBLY. 2. Loosen lubricator (I) of adjustment cylinder, then move machine backwards and forwards to release grease. m Never loosen the lubricator more than one a turn. * Check that all the grease has been removed. 3. Drive slowly forward to put track shoe at idler end in contact with large block @ or a wall (if another large bulldozer of the same capacity as the machine being repaired is available, put in contact with the blade). Stop machine when recoil spring bends and slack is formed in track shoe assembly, then apply brake. When doing this, set so that master link is between idler and front carrier roller. For safety reasons, fit a lever block between carrier roller support and link. Remove shoe (4), then disconnect master link 11 (5). ABe extremely careful to ensure safety when disconnecting the track shoe. Move machine towards rear slowly and lay out track shoe assembly.

4.

CLD01085

5.

30-l 63-1 &

INSTALLATION OF TRACK SHOE ASSEMBLY . Carry out installation in the reverse

removal.

order

to

* m___ t

When adjusting the track shoe tension, dimension a to 25 + 5 mm.

set

Tighten the shoe bolts in the order shown in the diagram. 6 Mounting bolt : Anti-friction compound (LM-P) m Mounting bolt (master bolt) Initial torque : 490.3 + 49.0 Nm (50 ? 5 kgm) Tightening angle : 180 k 10

------GO1048

DKD00282

30-163-2 5,

This section describes only for the lubricated track link. Shoe (master link portion) Set the track assembly on a flat floor with the shoe facing up, then remove the shoe bolt at the master link, and remove the shoe. A Do not use an impact wrench when loosening the master link bolt.

Disassembly into l/4 parts Because of the weight of the track assembly, if the l/2 assembly is too large and there are problems with disassembly and assembly work, divide into l/4 assemblies. Shoe (regular link portion) Raise the track assembly and set it on the floor with the shoe facing up, then use a shoe bolt impact wrench to remove the shoes. * When moving the track assembly, be careful not to damage the master link portion. * If a gas cutter has to be used to remove the shoe nut, to prevent deterioration of the seal due to the heat, keep the temperature of the seal portion below 80C. and take action to prevent welding spatter from entering the gap between the links. Draining oil Before disassembling the link assembly, drain the oil from inside the pin and take precautions so that the link press does not become dirty with oil. * Before disassembling, if it is judged that it is necessary to rebuild the track as a dry type track, the following work need not be carried out. 1) Set the link assembly on a flat floor with the large plug side facing up, then chamfer the burrs on the end face of the pin with a grinder. * If the track is disassembled with burrs still at the end face of the pin, the pin press fitting hole of the link will be scratched, and this will cause leakage from the pin press-fitting portion after rebuilding. 2) Using a drill (elOmm), make a hole in the large plug, then remove the large plug. * If any dirt or deteriorated oil is stuck to the pin hole, drill through with a longer drill to remove it. When doing this, be careful not to damage the oil hole.

F6164026

Burrs

Chamfer

F 19802241

30-164 0

3) After removing the large plug, use a baby grinder (angle of grinder tip: 45 - 607, and chamfer the pin hole so that the plug is not damaged when the plug is knocked in. 4) Turn over the link assembly so that the small plug side is facing up, remove the burrs at the end face of the pin with a grinder, then use tool W to knock the small plug to the inside. j, If the small plug hole is blocked with burrs, grind with a grinder until the hole can be seen completely. 5) Using a drill (olOmm), plug hole. chamfer the small

6) Blow with comressed air to remove the metal particles when draining the oil inside the pin or removing the burrs, then wash the link assembly with high-pressure water or steam.

5. Dissasembly of link 1) Set the link assembly on a link press, then hit with a hammer so that the bushing and jaw are in tioht contact. * If the linktread and outside diameter of the bushing are worn, adjust the height of the shoe or guide plate, and center the disassembly jig with the pin and bushing center to prevent damage to the link hole when disassembling. * If the centering is not carried out the link hole may be properly, damaged, the pin may break, or the bushing may crack during disassembly. 2) Operate the left cylinder and remove the left link and pin and bushing press-fitting portion at the same time. * Check the removal force of the pin and bushing, and use this value as reference to judge if it is possible to obtain the necessary pin and bushing press-fitting force when turning and reassembling. * Do not push the disassembly jig inside more than is necessary as the spacer may break.

F 19802245

Left disassembly

jig

Jaw

Right disassembly jig

9802248

30-165 a

3) Return the left cylinder, then operate the right cylinder and remove the right link and pin and bushing press-fitting portion at the same time. 4) Return the right cylinder, remove the left and right links, pins, bushings, and spacers, then feed the following set for one link assembly into the jaw. To decide if the seal can be used again, carry out inspection when the seal is still installed to the link, so do not remove the seal from the link. If oil is remaining, this can be used as a guide line for reuse of the seal, so mark such links or seals. If the end face of the bushing and seal surface are damaged, it will cause oil leakage, so be extremely careful when handling.

Fl 980224

F19802248

6. Inspection Check the following items to determine if the part can be reused as a lubricated track or as a grease-filled track. Carry out a comprehensive check to determine if the link assembly can be rebuilt as a lubricated track or as a grease-filled track.

When making judgements about reuse of parts, see Shop manual Guidance for Reusable Parts.

Check the pins, bushing, links and spacers visually for damage, and carry out a color check or use a flaw detector to check of being parts that are suspected damaged. Any part that is cracked must not be used again, so scrap it. Check the external appearance of the seal and the end face of the bushing visually to determine if they can be used again. * If only the bushing is replaced with a new part, the worn or damaged part of the seal lip contacts the end face of the bushing directly, so it may not be able to carry out its sealing function. For this always replace the seal reason, together with the bushing, or rebuild as a grease-filled track.

30-166 a

3) Using calipers, measure spacer thickness a and overall length b of the sliding portion of the bushing and spacer. Check if it is possible to obtain the specified seal mounting dimension when reassembling. j, If the amount of wear of the spacer and bushing is greater than the specified amount, the assembly precision of the seal portion cannot be guaranteed, so replace with new parts, or rebuild as a grease-filled track. 4) Using a micrometer, cylinder gauge, and calipers, measure the outside diameter of the pin and the inside diameter of the bushing at the worn portion, and judge if the parts can be used again. j, If the amount of wear is greater than the specified amount, there will be play during travel, and it will also cause the oil to become dirty, so replace with new parts or rebuild as a grease-filled track. * For details of the dimensions when making judgement, see MAINTENANCE STANDARDS. 5) Using a micrometer and cylinder gauge, measure the outside diameter of the pin and bushing press-fitting portion, and the inside diameter of the pin and bushing press-fitting portion of the link to determine if the permitted interference can be obtained. However, when rebuilding as a lubricated track, check the standard interference for the pinand link. * If the permitted interference can not be obtained, replace with new parts or replace with an oversize part. * For details of the dimensions when making judgement, see MAINTENANCE STANDARDS.

0
a

ll

F19802249

Fl9802250

A198022521

30-167 0

I I
A
PRECAUTIONS FOR STORAGE To prevent rust of the counterbore portion of the link, leave the seal installed to the link and be careful not to damage the seal lip during storage. Coat the pin and bushing press-fitting portion, shoe mating surface, and master link mating surface of the link with rust prevention oil to prevent rust. Coat the whole circumference of the pins, bushings, and spacers with rust prevention oil to prevent rust, and be particularly careful not to damage the end face of the bushing during storage.

F 19802253

30-168 0

1. WHEN REBUILDING

AS LUBRICATED

TRACK

1. Preparatory work 1) Washing seal assembly l Machines equipped with F3 type seals Remove the seal assembly from the link, then separate into the seal ring and load ring, and clean the parts. * The seal ring and load ring deteriorate easily when brought into contact with cleaning agent (trichlene, etc.), so wash the parts quickly. After cleaning, wipe the parts with a clean cloth to remove all the cleaning agent.
l

Load ring

Seal ring

Machines eqipped with W7 type seals For seals that are to be reused, leave the seal installed to the link, and do not wash it.

F 19802254

2) When reusing the pin, chamfer the corner of the end face smooth with a grinder. Remove any protruding parts stuck to the press-fitting portion with a grinder. * If the corner of the end face has become sharp due to wear, there will be scuffing when press fitting and this will cause oil leakage.

3) Make a mark on the end face at the small plug end to show the direction of the side hole (hole in the radial direction) in the pin when assembling. * When rebuilding the pin, assemble in the same direction as when the part is new (side hole on the link tread side).

Make a mark to show

30-169 a

4) If the link, pin, bushing, or spacer are dirty, wash them. Remove any protruding parts stuck to the link and bushing with grinder. * These parts easily rust, so wash them immediately before assembly. * Use tool X to wash the pin hole. A Do not polish or carry out any other treatment of the end face of the bushing as this causes the oil leakage. 5) Use tool Y to knock the large plug into the pin. 9 Insert plug into hole in guide through plug insertion window. (Coat the plug with oil.) ii) Push bar by hand and insert the plug as far as it will go. iii) Push plug with bar, and push guide itself against pin. iv) Hit in bar with a hammer. * Dimension a to knock in the plug from end face of pin: 11 k 2 mm

A If there is no more place to chamfer at the pin hole because of wear, use a baby grinder (angle of grinder tip: 45 - 60) to carry out chamfering. * Coat the outside circumference of the plug with G0140B and knock in the smaller diameter part first. 6) Installation of seal assembly l Machines equipped with F3 type seal Clean the link counterbore, then use tool KA to push the seal in fully to the bottom.
Remove all oil and grease fro

17MF02805

Y
Direction to push in

If there is oil stuck to the link counterbore and seal assembly, the seal will rotate and its sealing performance will drop, so do not coat with oil. In addition, be careful not to let oil get into the counterbore portion of the seal when pushing in.

F19802259A

Machines equipped with W7 type seal When reusing the link and replacing the seal with a new part, clean the link counterbore, then push the seal in fully to the bottom.

Remove all oil and grease from shaded area

5% u

If there is oil stuck to the link counterbore and seal assembly, the seal will rotate and its sealing performance will drop, so do not coat with oil. In addition, be careful not to let oil get into the counterbore portion of the seal when pushing in.

F 19802260

30-170 0

7) In order to keep the protrusion of the pin and bushing constant and the installation dimensions of the steel within the specified value during assembly, adjust the press-fitting jig dimensions of the link press For details of the standard dimensions, see PRESS-FITTING JIG DIMENSION TABLE FOR LINK PRESS.

F19802261

To leave a small space for the pin when assembling, ensure that the dimension (dimension a) is greater than dimension a at the pin pushing portion of the left press-fitting jig. When assembling in order @ left link press fitting, @ right link press fitting, provide the extra space.for the pin on the right press-fitting jig.

F 19802262

If the end face of the pin (portion P) or the end face of the link (portion 0, R) are worn, add the amount of wear to the standard dimension when adjusting the dimension of the press-fitting jig so that the amount of protrusion of the left and right pin and bushing is uniform. 8) Adjust the relief pressure of the link press to make sure that the pushing force of the press does not exceed the specified value. * If the pushing force is too strong, excessive force will be brought to bear on the spacer, and it will be pushed against the bushing. This will cause the spacer to break or will cause abnormal wear between the spacer and bushing end face. * If the interference at the press-fitting portion is different from when the part is new, as when reusing a pin or bushing, measure several of the press-fitting portions, and use the value below to determine the set pushing force according to the average interference. * Set pushing force of pin and bushing: 150 ton Set pushing force k 1.8 X average pushing force (Adjust the relief pressure of link press to fix the set pushing force)

I-

F19802263

30-171 0

2. Assembly of link 1) Use a clean brush to coat the area between the pin and bushing with oil (G0140B), set in position, then set in front of the jaw of the link press. * When reusing (turning) the bushing, set the worn surface on the outside circumference of the bushing facing the shoe mounting surface of the link (facing up on the link press).

2) Set the left and right bushing end master link with the shoe mounting surface facing up, then press fit to the bushing. * When doing this, use the pin end master link as a support. * Bushing press fitting force: 10 - 35 ton

3) Using a shoe bolt hole pitch gauge, press fit until the distance between the shoe bolt holes of the left and right link is the specified value. * Use compressed air to remove all metal particles from burrs while press fitting the bushing.

4) Turn over the master link, and check that the left and right master links have been press fitted in parallel.

30-172 0

5) Measure the amount of protrusion of the left and right bushings with a depth gauge. * Adjust the press-fitting jig for the link press so that the protrusion of the left and right bushings is uniform.

6) Feed the master link portion, then set the pin and bushing in position. * When reusing the pin, assemble so that the side hole is on the link tread side in the same way as when the part is new. If the parts are not assembled facing the specified direction, the strength may drop, so mark the direction of the side hole clearly on the end face to prevent any mistake during assembly. * Align the large plugs so that they are on the left side facing the link press when assembling. 7) To prevent oil from leaking out from scuff marks on the pin press-fitting portion, coat the pin press-fitting hole in the link and the outside diameter of the pin press-fitting portion with gasket sealant (198-32-l 9890).

Coat whole circumference

F19802299

8) Set the right link in position and install the spacer to the pin. * Check that there is no dirt or dust stuck to the seal surface and bushing end face, then use a clean cloth or brush to coat with oil (G0140B). j, Wipe the spacer with a clean cloth, then install it.

\\
:

I=19802270

30-173 0

9) Using the right jig as the receiving end

and the left jig as the pushing end, press fit the pin and bushing at the same time. j, When press fitting, the seal may come off the link due to the play, so press fit smoothly. If the seal comes off the link, stop the press-fitting operation and fit the seal correctly on the link, then start the press-fitting operation again. * Pin and bushing press fitting force: 65-105ton

10) Using a fine adjustment

spacer, press fit so that the end face of the pin is in tight contact with the bottom of the receiving jig. * Adjust the depth of lthe hole in the receiving jig so that the protrusion of the left and right pins is uniform.

11) Set the left link in position and install the

spacer to the pin. * Coat with oil in the same way as when installing the right link.

F 19802273

12) Using the left jig as the receiving end and

the right jig as the pushing end, press fit the left link. * When press fitting, be careful that the left and right seal and spacer do not come out of position. j, Provide enough space on the left jig so that the end face of the pin does not contact the bottom of the jig. * Link press fitting force: 65 - 105 ton

30-174 0

13) Press fit the link, spacer, and bushing so that they are each in tight contact. * It is impossible to check from outside if they are in tight contact, so control the hydraulic force of the link press and set the relief pressure to a constant value. Then apply hydraulic force and push in until this pressure is reached. For details of the setting for the relief pressure, see Preparatory work. links rotate * Check that neighboring together.
F19802275

14) After assembling each link, use a dial gauge and pinch bar to measure the end play from the link previously assembled, to check that the link is assembled within the specified value. * If the end play does not come within 0 - 0.13mm even when applying the pushing force until the relief valve is actuated, raise the relief pressure setting gradually to adjust. * Adjust the relief pressure setting carefully and be sure not to raise the pushing force of the link press higher than necessary. Using a shoe bolt hole pitch gauge, check that the distance between the shoe bolt holes is within the standard value. * If the distance between the shoe bolt holes is greater than the specified value, disassemble and check for any abnormality, then press fit again. * If the distance between the shoe bolt holes is smaller than the specified value, and the shoe cannot be installed, the wear of the spacer or bushing end face is probably greater than the repair limit, so disassemble and replace with a new part. * If the end play is too large, the sealing performance will drop, so set the end play to a small value. 16) After assembling each link, use tool KB to remove the air from inside the pin, and check the sealing performance. * Hold the space inside the pin at a vacuum of 650 - 700 mmHg for 5 seconds and check that there is no change in pressure. If the pressure changes, disassemble and check the seal for any abnormality, then assemble again.

30-175 0

17) Assemble the pin end master link as the final link. * Check that the left and right master links are press fitted in parallel.

3. Filling with oil After completion of assembly of the link assembly, fill the pin hole with oil. 1) Using tool KC, remove the air inside the pin from the small plug hole, set to a vacuum of 650 - 700 mmHg, then fill with oil (G0140B) until the pressure is 2 - 3 kg/cm*. * In cold or extremely cold areas, instead of G01408, fill with Komatsu genuine oil (150-09-19270) which has excellent low temperature qualities. j, Be careful not to raise the oil pressure too high as this will have an adverse effect on the seal. * To determine the oil amount, set the small plug end at the top (stand the link assembly on its side), leave for 30 minutes, then charge with oil so that depth L of the space at the pin hole is within the specified value below. Specified value of L: 50 - 80 mm

G0140B

901 FOOl

2) After completion of filling with oil, use tool 2 to knock in the small plug to the specified position. j, Coat the outside circumference of the small plug with G0140B. * Knock in the plug to the depth given below. Depth to drive from end face: 7.5 f 1 mm

30-176 Co

4. Shoe (regular link portion) Set the link assembly on the bed, then use a shoe bolt impact wrench and torque wrench to install the shoe. m Shoe bolt (regular link): Initial tightening torque: 80 + 8 kgm Tightening angle: 120 f 10

5. Connecting to make l/2 assembly Set two completely assembled portions of track on a flat surface in a straight line with the shoes facing up. Pull master link (1) at the pin end to master link (2) at the bushing end, and set at the mating surfaces. Then put shoe (3) on top, ,check that shoe bolt (4) goes in easily by hand, and connect the two parts. &III& m Mounting bolt: Anti-friction compound (LM-P)

Shoe bolt (master link): Initial tightening torque: 50 rir: kgm 5 Tightening angle: 180 + 10 When tightening, tighten in order 0 - 0. Do not use an impact wrench for the master link mounting bolt.

* *

F6164026 F19802282

30-l 77 @

4) Use tools Y and 2 to knock the large and small plug into the pin. i) Insert plug into hole in guide through plug insertion window. (Coat the plug with oil.) ii) Push bar by hand and insert the plug as far as it will go. iii) Push plug with bar, and push guide itself against pin. iv) Hit in bar with a hammer. * Dimension a to knock in the plug from end face of pin: Small plug: 7.5 If: 1 mm Large plug: 11 f 2 mm If the plug is not removed from the pin during disassemlby, it can be used as it is.
Rem from Direction to push in

17MF02805

5) Clean any part where outside diameter of the pin, front face of the spacer, end face or inside diameter of the bushing are dirty. 6) Coat the outside diameter of the pin and the front face of the spacer with grease. 7) Installation of seal assembly Machines equipped with F3 type seal l Clean the link counterbore, then use tool KA to push the seal in fully to the bottom. * If there is grease stuck to the link counterbore and seal assembly, the seal will rotate and its sealing performance will drop, so do not coat with grease.
l

F 19602259A

Machines equipped with W7 type seal When reusing the link and replacing the seal with a new part, clean the link counterbore, then push the seal in fully to the bottom. * If there is grease stuck to the link counterbore and seal assembly, the seal will rotate and its sealing wil drop, so do not performance coat with grease.

Remove all oil and grease from the shaded area

F19602260

8) In order to keep the protrusion of the pin and bushing constant and the installation dimensions of the steel within the specified value during assembly, adjust the of the link press-fitting jig dimensions press. * For details of the standard dimensions, JIG DIMENSION see PRESS-FITTING TABLE FOR LINK PRESS. * If the end face of the pin (portion P) or the end face of the link (portions Q, R) are worn, add the amount of wear to the standard dimension when adjusting the dimension of the press-fitting jig so that the amount of protrusion of the left and right pin and bushing is uniform.

a
b

F19602261

30-l 79 Co

2. Assembly of link 1) Coat the area between the pin and bushing with lithium grease (G2-LI), set in position, then set in front of the jaw of the link press. * When reusing (turning) the bushing, set the worn surface on the outside circumference of the bushing facing the shoe mounting surface of the link (facing up on the link prss).

IF1 9902264

2) Set the left and right bushing end master

link with the shoe mounting surface facing up, then press fit to the bushing. * When doing this, use the pin end master link as a support. * Bushing press fitting force: IO - 35 ton

3) Using a shoe bolt hole pitch gauge, press fit until the distance between the shoe bolt holes of the left and right link is the specified value. * Use compressed air to remove all metal particles from burrs while press fitting the bushing. 4) Turn over the master link, and check that the left and right master links have been press fitted in parallel.

5) Measure the amount of protrusion of the left and right bushings with a depth gauge. jr Adjust the press-fitting jig for the link press so that the protrusion of the left and right bushings is uniform.

30-180 0

6) Feed the master link portion, then set the

pin and bushing in position. * When reusing the pin, assemble so that the side hole is on the link tread side in the same way as when the part is new. If the parts are not assembled facing the specified direction, the strength may drop, so mark the direction of the side hole clearly on the end face to prevent any mistake during assembly. * If the outside diameter of the pin is worn, assemble so that the face that is not worn is on the pulling side. However, in this case, also assemble so that the side hole faces the tread surface of the link. 7) Set the left and right links in position, then operate the left and right pushing jigs to press fit the pin and bushing at the same time. * When press fitting, the seal may come off the link due to the play, so press fit smoothly. If the seal comes off the link, stop the press-fitting operation and fit the seal correctly on the link, then start the press-fitting operation again. * Set pushing force of pin and bushing: 150 ton Set pushing force k 1.8 X average pushing force (Adjust the relief pressure of link press to fix the set pushing force)

F19802284

9802285

8) Using a shoe bolt hole pitch gauge, check

that the distance between the shoe bolt holes is within the standard value.

9) Assemble the pin end master link as the

final link. * Check that the left and right master links are press fitted in parallel.

3. Shoe (regular link portion) Set the link assembly on the bed, then use a shoe bolt impact wrench and torque wrench to install the shoe. QE Shoe bolt (regular link): Initial tightening torque: 80 f 8 kgm Tightening angle: 120 f 10

F 19802240

30-181 0

4. Connecting to make l/2 assembly Set two completely assembled portions of track on a flat surface in a straight line with the shoes facing up. Pull master link (1) at the pin end to master link (2) at the bushing end, and set at the mating surfaces. Then put shoe (3) on top, check that shoe bolt (4) goes in easily by hand, and connect the two parts. NC& m Mounting bolt: Anti-friction compound (LM-P)

Shoe bolt (master link): Initial tightening torque: 50 f 5 kgm Tightening angle: 180 1- 10

j, When tightening, tighten in order 0 - 0. * Do not use an impact wrench for the master link mounting bolt.

~6164026 F19802282

30-182 0

PRESS-FITTING

JIG DIMENSION

TABLE FOR LINK PRESS

a6-b

Unit: mm

Jig dimension b k 2 0.28 2.00 Y!Y

a 4.525

53.6

30-l 84 0

FIELD DISASSEMBLY

OF ONE LINK

This section gives only the procedure for using the tools. For details of the procedure for disassembly or assembly, see OVERALL DISASSEMBLY (or ASSEMBLY) OF TRACK SHOE.

1. Using two bolts (2), install tool KD-1 (adapter, guide, bolt) to link (1). * It is also possible to use two track bolts for bolt (2).

2. Assemble tool KD-2 (pump, cylinder 150t) and toll KD-3 (frame, rod, adapter, bolt X 1, eyebolt), then raise the assembly and set on the track.

KD-2

KDi3

I-

Insert the rod of tool KD-4 from the cylinder end, and install with two nuts.

4. Set tool KD-5 (adapter, guide, pusher) in position, then apply hydraulic pressure and remove pin (3). When the cylinder reaches the end of its stroke, insert extension KD-5 between the adapter and guide, and repeat the operation.

F19802291

_J

30-l 85 0

5. Set tool KD-6 (30t puller) and spacer 0 to the center of the roller tread of the link to be disassembled, then apply hydraulic pressure to the puller, open the link 5 - 6 mm and disconnect the link.

I F19802292A

30-186 0

FIELD ASSEMBLY

OF ONE LINK
Press (or remover)

1. Assemble the link sub-assembly. 1) Set tool KE-1 to the end face of the link, then press fit bushing (1). * Bushing press fitting force: 10 - 35 ton

2) Set tool KE-1 to the end face of the link (pin end), then press fit pin (2). j, Set side hole of pin to the link tread side. * Pin press fitting force: 55 - 70 ton

Press (or remover) Side hole +

side
I I

KE-1

z z
I-

F15421167

FS

2. Set link sub-assembly connected.

(3) on the link to be

F19802294

3. Set link (4) on the opposite side, and support with tool KE-2 (guide).

KE-2

/J

to\

F19802295A

30-187 0

4. Set tools KE-3 and KE-4 in the same way as for the operation to remove the pin, then use tool KE-3 (adapter, extension, guide, adapter, bolt) for press fitting the pin, and tool KE-4 (extension, guide, adapter, bolt) for press fitting the bushing, and press fit in turn. * Pin press fitting force: 55 - 70 ton A Bushing press fitting force: 10 - 35 ton

KE-4

I
5. Use tool KE-7 (30t puller) in the same way as when disassembling, and push open link (5) at the bushing end.

KE13

\A

F19802296A

KE-7

F 19802297A

6. Set link (6) at the pin end to link (5) at the bushing end, connect with tool KE-5 (guide), then remove tool KE-7 (puller).

F19802298A

7. Set tool KE-3 at pin (7) end, then use tool KE-6 (adapter, bolt and guide) to press fit (7). AL, Pin press fitting hole in link: Gasket sealant (198-32-l 9890)
:ylin

A Set side hole of pin to the link tread side. * Pin press fitting force: 110 - 140 ton

F19802299A

30-188 0

DISASSEMBLY

OF MASTER

LINK

1. Removal of track assembly Remove the track assembly from the chassis. 2. Separation of track Disconnect all master into four parts.

portions,

and divide

3. Removal of master link l Master pin type 1) Gas cutting of regular link Gas cut the portion marked WV , and remove @ZB . Special tool to use: Manual gas cutting torches
Bus

32FO21

2) Removal of regular link Press pin (1) in the direction of the arrow with a press, remove from link (2), then remove pin (1) and link (3) at the same time from bushing (4).

32F022A

Master link type 1) Gas cutting, removal of master link at bushing end gas cut the portion EBj, then marked WV , remove move master links (5) and (6) up or down to remove them. Push pins (8) and (9) press fitted to regular link (7) with a press in the direction of the arrows to remove them. Special tool to use: 1. Manual gas cutting torches 2. Tool KF

30-l

89

2) Removal of master link at pin end Gas cut the portion marked WV , remove m , push pin (10) with a press in the direction of the arrow and remove from link (1 then remove pin I), (IO) and link (12) at the same time from bushing (13). Special tool to use: 1. Manual gas cutting torches 2. Tool KF

32F024A

30-190 a

ASSEMBLY

OF MASTER

LINK

1. Assembly of link at bushing end 1) Using a press, press fit master link (1) at the bushing end to bushing (2). A When press fitting the left and right master links, be extremely careful to keep them parallel. * Be careful not to scratch or damage the mating surface of the master link and the end face of the bushing.
Unit: b 184.15 k 0.7 mm

F19802300

D2

2. Assembly of link 1) Push open the with tool KE-7 (Open approx. link.)

at bushing end central part of the link tread as shown in the diagram. 10 mm at the tip of the

mm

-7 mm

17MF02806

2) Set spacer (3) and seal assembly (4) at the counterbore of the link at the connection.

I/

32F014A

30-191 0

3) Align the pin hole and bushing hole, and connect with guide pin 0.

i
4) Remove puller KE-7, press fit pin (5) with tool KF, and install master link (1) at the bushing end. /r;\* Pin press-fitting hole in link: Gasket sealant (198-32-l 9890) Set side hole of pin to the link tread side.

32FO15A

5/
5) Install the shoe to the link at the connection. 6) After knocking in large plug (6) with tool Y, fill with oil using tool KC, then knock in small plug (7) with tool 2. fitting the left and right * When-press master links, be extremely careful to keep the left and right links parallel. (bushing end and pin end) * Be careful not to scratch or damage the mating surface of the master link and the end face of the bushing. * End play at connection (play in thrust direction of links in front of and behind pin): 0 - 0.13 mm * Be extremely careful not to get mud or dust on the tap hole mating face of the master link, bushing end face, spacer, or seal.

Press fit

32F016A

32FO18A

30-192 0

3. Assemblv of link at Din end 1) Set spacer (3) and seal assembly (4) in the counterbore of the master link.

Link

p,f

\.

Bushing

I
32F014A

2) Pass pin (9) through bushing (8), set pin

end master link (10) from the left and right, then press fit with tool KF. 3) After knocking in large plug (11) with tool Y, fill with oil using tool KC, then knock in small plug (12) with tool 2.

9i-1
8 H 12 5; 4) Connecting master link portion Set two completely assembled portions of track on a flat surface in a straight line with the shoe facing up. Pull master link (13) at the pin end to master link (14) at the bushing end, and set at the mating surfaces. Then put the shoe on top, and check that the shoe bolt goes in easily by hand. Mounting bolt: Anti-friction compound (LM-P) U
Fl gBO2301

Shoe bolt (master link): Initial tightening torque: 50 + 5 kgm Tightening angle: 180 + 10

32FOZOA

30-193 0

REMOVAL
1. For details, ASSEMBLY. Remove

OF PIVOT SHAFT TWISTING

see REMOVAL OF TRACK FRAME

SEAL

2.

twisting

seal assembly

(I).

i_Lf

17MF0269C

INSTALLATION OF PIVOT SHAFT TWISTING SEAL

l

Carry out installation removal.

in the

reverse

order

to

* * *

Using tool N, press fit twisting bly (1). Press-fitting

seal assem-

*
&

force: 17.6 - 31.4 kN Il.8 - 3.2 ton1 Set the distance from the end face of the shaft to the end face of the metal fitting on the inside of the seal ring to the dimension below. Dimension a: 493 * 1.0 mm Remove all oil and grease from the oil seal press-fitting surface. .. Press fitting surface Of seat: Gasket sealant (LG-6)

09002981

30- 194 @

1. For details,

see REMOVAL

OF TRACK FRAME

ASSEMBLY. 2. Remove twisting seal assembly. For details, see REMOVAL OF PIVOT SHAFT TWISTING SEAL. 3. Sling pivot shaft assembly (1).

bolts, then using forcing 4. Remove mounting screws 0 and guide bolts 0, pull out pivot shaft assembly. & Pivot shaft assembly: 160 kg

INSTALLATION OF PIVOT SHAFT ASSEMBLY

l

Carry out installation removal.

in the reverse

order

to

j, &,

Set with the match assembling.

marks at the top when

Pivot shaft: Anti-friction Press-fitting force: 0.1 -

compound 2.0 ton

(LM-P)

* mu w

Pivot shaft mounting bolt: Thread tightener Pivot shaft mounting

(LT-2)

bolt: 159.5 k 17.5 kgm

30-l 95 0

REMOVAL OF EQUALIZER BAR ASSEMBLY

1. Using transmission jack, remove underguard (1) under engine and under power train. 2. Disconnect 2). greases hoses (2) (front: 2, rear:

3. Remove stopper plate, and pull out pins (3), then remove rods (4) (front: 1, rear: 1). lfll 4. Remove (5). mounting bolts of left twisting seal

5. Remove mounting (6).

bolts of right twisting seal

17MF02695

6. Remove right side pivot shaft covers (7) and (8). m 7. Remove holder (9), and disconnect hose (IO). blade tilt

8. Remove plates (11) and (12). A The oil inside the pivot chamber will leak out, so put a container under it to catch the oil. : Pivot chamber: 12 e u

30-196 0

9. Remove (14).

left and right pin covers

(13) and

10. Remove lock plate, then remove left and right shafts (15). m 11. Sling equalizer bar assembly and chain block. 12. Support bottom frame draulic jack (30 ton). (16) with crane

of machine

with hy-

13. Remove lock plate, then set tool 0 in position, pull out center shaft (17). m

17MF02701

II

17MF02702

A
PI kg 14.

When operating the hydraulic system, do not operate it in front of or under the puller. Operate it from as far away as possible. Center shaft: 25 kg approx. 200 mm more with

Raise machine hydraulic jack.

15. Operate chain block while operating crane to remove equalizer bar assembly (16). .A\ m equalizer bar assembly: 300 kg

After removing the equalizer bar assembly, do not lower the machine.

Hydraulic jack

17MF02704

Front side

17MF02705

30-l 97 0

INSTALLATION
l

OF EQUALIZER
in the reverse order to

BAR ASSEMLY
Oil quantity of pivot shaft Oil level

Carry out installation removal. & Mounting

bolt: Thread

tightener

(LT-2)

112] w * & a Sr Add oil to replace the oil that leaked out from the pivot shaft chamber. (For the oil level, see the diagram on the right.) Mounting bolt: 277.0 + 31.9 Nm I28.25 d 3.25 kgm) The stopper plate and pin stopper are in tight contact. Cover mounting bolt: Thread tightener (LT-2)

1
T
I

a Serial No. : 10001 - 10127 & Outside surface of pin: Greese (G2-LI) Before installing the side shaft, align the position of flanged bushing (18) and the track frame slit, and drive in so that bushing (18) is in tight contact with faces b and c. Clearance d between the equalizer bar and the track frame is the same (15 5 2 mm) at the front and rear. (When checking this, check that surfaces a, b and c are in tight contact.) k Measure stepped difference A between surface e and surface f with a depth gauge, and adjust with shims so that it is 0.2 - 0.3 mm. Ir When tightening the mounting bolts of the lock plate at the rear of the machine to the specified torque 549.2 + 8.8 Nm (56 f 6 kgm), if the flanged bushing (18) rotates, tighten mounting bolts (19) of cover (14) first to a maximum of 147 Nm (15 kgm1, then tighten the lock plate to the specified torque, and tighten mounting bolt (19) again to the specified torque. QEI Mounting bolt of lock plate at rear of machine: 549.2 z 58.8 Nm {56 2 6 kgm} & Outside surface of center shaft: Grease (G2-LI) t
17MF02708 Slit aiea

Track frame

I
30-198

17MF02710

Serial
&

No.: 10128 and up

of pin : Grease (G2-LI) Before installing the side shaft, align flanged bushing (18) and position of slit in track frame, then drive in bushing (18) until it is in tight contact with surfaces b and c. Clearance d between the equalizer bar and the track frame must be the same (15 2 2 mm) at the front and rear. (When measuring, check that surfaces a, b, and c are in tight contact.) When tightening the lock plate mounting bolts to the specified tightening torque (549.2 r 58.8 Nm {56 f 6 kgm)), if flanged bushing (18) rotates, tighten mounting bolts (19) of cover (14) to a maximum of 147 Nm (15 kgm), then tighten the lock plate mounting bolts, and finally tighten mounting bolts (19) to the specified tightening torque. Lock plate mounting bolt: 549.2 + 58.8 Nm (56 + 6 kgm} Outside surface Center shaft outside surface : Grease (G2-LI)

DBD02982

m m &

30-198-l @

REMOVAL OF EQUALIZER BAR SIDE BUSHING

1. For details, see BAR ASSEMBLY. 2. Remove seal (1). 3. Remove Ring (2).

REMOVAL

OF EQUALIZER

r
17MF02711

4. Using tool P, pull out spherical bushing (3).

i
17MF02712

30- 199 0

INSTALLATION
1. 2.

OF EQUALIZER

BAR SIDE BUSHING

install ring (2) on one side. Using tool P, press fit spherical bushing (3). Direction of assembly for spherical bush* ing I) The split face of the outside ring should be horizontal as shown in the diagram. 2) The grease hole in the outer ring should be at the top and facing the inside as shown in the diagram. & Outside surface of spherical bushing: compound (LM-P) Anti-friction Press-fitting force: 68.6 - 133.4 kN I7 - 13.6 tons}
Grease hole Split face 17MF02713

3.

Install ring on poopsite

side.

Serial No. : 10001 - 10127 4. Using push tool, press fit seals (I) on both side. & Inside, outside circumference of seal: Gasket sealant (LG-6)

Serial 5. Remove equalizer bar assembly. For details, see REMOVAL OF EQUALIZER BAR ASSEMBLY.

No. : 10128 and up

I,

30-200 @

REMOVAL OF SUSPENSION

CUSHION ASSEMBLY

1. Remove equalizer bar assembly. For details, see REMOVAL OF EQUALIZER BAR ASSEMBLY. 2. Set transmission jack under machine, and remove mounting bolts, then remove cap (1) and cushion (2). m

3. Operate transmission jack slowly, and remove bolster assembly (3). 4. Remove cushion (4). m
02716

z z b
TT

INSTALLATION OF SUSPENSION CUSHION ASSEMBLY

l

1jMFO2717

Carry out installation removal.

in the reverse order to

a w m *

Mounting bolt: Thread tightener Mounting belt: 135 + 15 kgm

(LT-2)

The distance between the end face of the circular portion and the machined surface shall be dimension a. The installation dimensions shall be the same on both the left and right sides. a=30flmm

Machined

surface

17MF02719

30-201 0

REMOVAL OF SEGMENT TOOTH

1. Stop machine at position where tooth can be removed (between shoe and track frame). 2. Remove 2 covers (1). 3. Remove (2). m mounting bolts, then remove tooth

IN STALLATION OF SEGMENT TC 1OTH

l

Carry out installation removal.

in the reverse order to

m m Tooth mounting nut: 120 + 10 kgm

30-202 0

REMOVAL OF HYDRAULIC PUMP ASSEMBLY

Lower the work equipment to the ground and stop the engine. Operate the control levers several times to release the remaining pressure in the hydraulic piping. Then loosen the oil filler cap slowly to release the pressure inside the hydraulic tank. 1. Drain oil : u Hydraulic tank oil: Approx 95n 2. Remove floor frame assembly. For details, see REMOVAL OF FLOOR FRAME ASSEMBLY. 3. Disconnect hydraulic connector (1). 4. Disconnect hoses (3). suction oil temperature wiring

tube

(2) and 3 delivery

5. Remove mounting bolts, and lift off hydraulic pump assembly (4). & Hydraulic pump assembly: 35 kg

2 z

INSTALLATION OF HYDRAULIC PUMP ASSEMBLY

l

Carry out installation in the reverse order to removal. Refilling with oil Add engine oil inside the hydraulic tank to the specified level, and run the engine to circulate the oil through the system. Then check the oil level again.

30-203 0

REMOVAL OF BLADE LIFT VALVE ASSEMBLY

Lower the work equipment to the ground and stop the engine. Operate the control levers several times to release the remaining pressure in the hydraulic piping. Then loosen the oil filler cap slowly to release the pressure inside the hydraulic tank.

1. Drain oil. /ci7+ Hydraulic tank: Approx 95 e

2. Remove side cover of hydraulic tank. 3. Remove rod (1). 4. Disconnect pilot hose (2). 5. Disconnect tube (3). 6. Disconnect hose (4). 7. Remove blade lift valve assembly (5). * Sling the lift valve assembly, and remove the mounting bolts. /L m Blade lift valve assembly: 60 kg

INSTALLATION OF BLADE LIFT VALVE ASSEMBLY

. .
Carry out installation in the reverse order to removal. Refilling with oil Add engine oil to the hydraulic tank to the specified level, and run the engine to circulate the oil through the system. Then check the oil level again.

30-204 0

DISASSEMBLY

OF BLADE LIFT VALVE ASSEMBLY

1. Disassembly of main spool assembly Remove lever case assembly (1). Remove case (2). then remove retainer (3), plug (4) and collar (5) from case. Remove plug (6), then remove spring (7), spacer (8) and ball (9). Remove spring (IO), then remove retainer (11) and spool (12). * If there is any abnormality in the spool or body, replace the spool and body as an assembly.

2. Disassembly of demand valve assembly 1) Remove case (13), then remove spring (14). 2) Remove plate (15), then remove spool (16) and seal (17).

3. Disassembly of main relief, shuttle valve assembly 1) Remove main relief valve assembly (18). * If the adjusting screw nut is loosened and the screw turned, the set pressure will change, so do not disassemble. 2) Remove plug (19), then remove piston (20), shuttle valve spool (21) and spring (22). 3) Remove valve body (23).

4. Disassembly of suction valve assembly Remove plug (24), then remove spring (25) and valve (26). 5. Disassembly of check valve assembly Remove plug (27), then remove spring (28) and valve (29). 6. Disassembly of shuttle valve assembly Remove plug (30). then remove ball (31).

30-206 0

30-207 a

ASSEMBLY OF BLADE LIFT VALVE ASSEMBLY

Clean all parts, and check for dirt or damage. Coat the- sliding surfaces of all parts with engine oil before installing. of shuttle valve assembly ball (31), then fit O-ring and install kgm

5. Assembly of demand valve assemblv 1) Assemble seal (17) and spool (16), then fit O-ring and install case (15). w Case mounting bolt: 19 I!I 1 kgm

1. Assembly Assemble plug (30). Q!Z

2) Assemble spring (14) and install (13). m Mounting bolt: 19fl kgm

Plug: 3.5 f0.5

2. Assembly of valve assembly Assemble valve (29), spring and install plug (27). m Plug: 37.5 +2.5 kgm

(28), fit O-ring

6. Assembly of main spool assembly I\ Fit O-ring and install lever case assembly I (1). 2) Set spool (12), retainer (11) and spring (10) in position. 3) Assemble ball (9), spacer (8) and spring (7) in case (2), then fit O-ring and install plug (6). QE Plug: 3.5 f0.5 kgm

3. Assembly of suction valve assembly Assemble valve (26), spring (25), fit O-ring and install plug (24). w Plug: 52.5 +2.5 kgm

4. Assembly of main relief, shuttle valve assembly 1) Fit O-ring and install valve body (23). m Mounting bolt: The first time 3.5 f 0.5 kgm The second time 6.75 f 0.75 kgm

4) Set collar (5), plug (4) and retainer (3) in case (2), then fit O-ring and install case (2).

Tighten the mounting bolts in order shown. 2) Assemble spring (22). shuttle valve spool (21) and piston (20), then fit O-ring and install plug (19). m Plug: 7fl kgm

3) Install main relief valve assembly (18). m Relief valve assembly: 8.5 f 1.5 kgm

It the valve assembly has been disassembled, insall the main control valve aseembly on the machine, then turn the adjustment screw to adjust the set pressure to 210 kg/cm*.

30-208 0

10

1
I

197F371

30-209 a

REMOVAL OF BLADE TILT, RIPPER LOW VALVE ASSEMBLY

Lower the work equipment to the ground and stop the engine. Operate the control levers several times to release the remaining pressure in the hydraulic piping. Then loosen the oil filler cap slowly to release the pressure inside the hydraulic tank. 1. Drain oil. : u Hydraulic tank: Approx 95 II 2. Remove side cover of hydraulic tank. 3. Remove hydraulic tank support bracket (1). 4. Disconnect blade lift control rod (2). 5. Remove control rods (3), (4) and (5) of work equipment. * Before removing the rods, mark the position of installation. 6. Disconnect tube (6) between blade tilt-ripper low valve and blade lift valve at blade lift valve end. 7. Di$;,nrct * hoses (71, (81, (91, (IO), (1 I), (121, 11 Before disconnecting the hoses, mark the position of installation. then remove to \9
17MF02726 1 17MF02724 1) 17MF02725

8. Sling the valve (14) assembly, the mounting bolts. &

Blade tilt, ripper low valve assembly: 54 kg

INSTALLATION OF BLADE TILT, RIPPER LOW VALVE

Carry out installation in the reverse order to removal. Refilling with oil * Add engine oil to the hydraulic tank to the specified level, and run the engine to circulate the oil through the system. Then check the water level again.

30-210 0

DISASSEMBLY

OF BLADE TILT, RIPPER LOW VALVE ASSEMBLY

1. Disassembly of spool assembly 1) Remove case assembly (I), then remove collar (2) from case assembly. 2) Remove joint (3). * Always loosen the joint with the spool assembled in the body. 3) Remove case (4). 4) Remove bolts (5), then remove washer (6), retainer (7), spring (8), collar (9) and retainer (IO). * Always loosen the bolts with the spool assembled in the body. 5) Pull out spool (11) from body (12). * If there is any abnormality in the spool or body, replace the spool and body as an assembly. Main relief valve assembly Remove main relief valve assembly (13). * If the cover is removed and the adjustment screw turned, the set pressure will change, so do not disassemble unless necessary. 3. Disassembly of check valve assembly Remove mounting bolts (14). then remove bar (15), seat (16), spring (17) and valve (18). 4. Disassembly of shuttle valve assembly Remove plug (19), then remove seat (20) and ball (21).

30-212 a

1'4

17MF02728

30-2 13 0

ASSEMBLY OF BLADE TILT, RIPPER LOW VALVE ASSEMBLY

Clean all parts, and check for dirt or damage. Coat the sliding surfaces of all parts with engine oil before installing.

1. Assembly of shuttle valve assembly 1) Assemble ball (21) in plug (19), fit O-ring, then assemble seat (20). 2) Fit O-ring and install plug assembly. m Plug: 3.5+_0.5 kgm

2. Assembly of check valve assembly 1) Assemble valve (18) and spring (17). 2) Fit O-ring and assemble seat (16), then install bar (15) and tighten bolts (14). Main relief valve assembly Fit O-ring and install main relief valve assembly (13). QE Main relief valve assembly: 8.5 f 1.5 kgm If the valve assembly has been disassembled, install the main control valve assembly on the machine, then turn the adjustment screw to adjust the set pressure to 210 kg/cm.

4. Assembly of spool assembly 1) Assemble spool (11) in body (12). 2) Set retainer (IO), collar (9), spring (8). retainer (7) and washer (6) in position, then tighten bolts (5). * Always tighten the bolts with the spool assembled inside the body. m Bolt: 3.5 f 0.5 kgm

3) Fit O-ring and install case (4). 4) Install joint (3). * Always tighten the bolts with the spool assembled inside the body. w Joint: 6.75 f 0.75 kgm

5) Assemble collar (2) in case assembly, then fit O-ring and install case assembly (1). w Mounting bolt: 3.15 f 0.35 kgm

30-214 0

17MF02728

30-215 0

REMOVAL OF RIPPER HIGH VALVE

Lower the work equipment to the ground and stop the engine. Operate the control levers several times to release the remaining pressure in the hydraulic piping. Then loosen the oil filler cap slowly to release the pressure inside the hydraulic tank. 1. Drain oil : u Hydraulic tank: Approx 95 P 2. Disconnect bracket of fuel drain hose (1) from valve. 3. Disconnect 14 pipes (2), (3), and (4). 4. Remove valve assembly (5).

INSTALLATION OF RIPPER HIGH VALVE ASSEMBLY

l

Carry out installation in the reverse order to removal. Refilling with oil * Add engine oil to the hydraulic tank to the specified level, and run the engine to circulate the oil through the system. Then check the water level again. Q Hydraulic tank: Approx 95 P

17MF02730

30-216 a

DISASSEMBLY

OF RIPPER HIGH VALVE ASSEMBLY

1. Disassembly of valve assembly 1) Remove blocks (1) and (2). 2) Remove plug (3), then remove ball (4). 3) Disassembly of fixed differential pressure valve assembly. i) Remove plug (5), then remove retainer (6), spring (7) and retainer (8). ii) Pull out spool (9). * Always loosen the plug with the spool assembled inside the valve. 4) Disassembly of ripper lift high valve assembly. i) Remove plug (IO), then remove spring (11) and retainer (12). ii) Remove plug (13), then remove spring (14) and retainer (15). iii) Pull out spool (16). * Always loosen the plug with the spool assembled inside the valve. 5) Disassembly of ripper tilt high valve assembly. Repeat the procedure for disassembling the ripper lift high valve and disassemble the ripper tilt high valve. 6) Remove plug (17), then remove spring (18) and check valve (19). 7) Remove plug (20), then remove seat (21), spring (22) and valve (23).

30-218 0

i7 3

197F373

30-2 19 0

ASSEMBLY OF RIPPER HIGH VALVE ASSEMBLY

j,

Clean all parts, and check for dirt or damage. Coat the sliding surfaces of all parts with engine oil before installing.

1. Assembly of valve assembly 1) Assemble valve (23), spring (22) and seal (21), then fit O-ring and install plug (20). m Plug: 52.5 + 2.5 kgm

2) Assemble check valve (19) and spring (18),

then fit O-ring and install plug (17). m Plug: 13 f 2 kgm

31 Assembly of ripper lift high valve assembly: i) Assemble spoool (16). ii) Set retainer (15) and spring (14) on spool, then fit PO-ring and install plug (13). m Plug: 6.75 f 0.75 kgm

iii) Set retainer (12) and spring (11) on spool, then fit O-ring and install plug (IO). m * Plug: 6.75 f 0.75 kgm

Always tighten the plug with the spool assembled inside the valve.

4) Assembly of ripper tilt high valve assembly. Repeat the procedure for assembling the ripper lift high valve and assemble the ripper tilt high valve. of fixed differential pressure 5) Assembly valve assembly. i) Assemble spool (9). ii) Set retainer (8), spring (7) and retainer (6) on spool, and install plug (5). * Always tighten the plug with the spool assembled inside the valve. ball 6) Assemble install plug (3). m (4). then fit O-ring and

Plug: 3.5 + 0.5 kgm

7) Fit O-ring and install blocks (2) and (1).

30-220 0

197F373

30-221 0

REMOVAL OF BLADE LIFT CYLINDER ASSEMBLY

Lower the work equipment ground.

completely to the

1. Sling head end of lift cylinder assembly, and remove cap (1). m * Check the number and thickness of the shims, and keep in a safe place.

, Start engine, retract piston rod fully, tie the

rod with wire to prevent it from coming out, then stop engine. * After stopping the engine, operate the control lever several times to release the pressure in the hydraulic remaining piping. Then loosen the oil filler cap slowly to release the pressure inside the hydraulic tank.
F19802231

2. Disconnect hose (2). * Fit a blind plug to prevent dirt or dust from entering the piping. 3. Sling cylinder assembly (3), then remove cap m (4), then remove cylinder assembly. f+l I Blade lift cvlinder assembly: 210 kg

INSTALLATION OF BLADE LIFT CYLINDER ASSEMBLY

l

Carry out installation removal.

in the reverse order to

j,

Standard shim thickness:

4 mm

a
l

Yoke:

Grease (G2-LI)

Bleeding air Bleed the air from cylinder. For details, see TESTING AND ADJUSTING.

30-222 0

REMOVAL OF BLADE TILT CYLINDER ASSEMBLY

A A

Lower the work equipment ground.

completely to the

1. Sling tilt cylinder assembly (I), and remove lock plate, then pull out pin (2). m Start engine, stop engine. + retract piston rod fully, then

After stopping the engine, operate the control lever several times to release the pressure in the hydraulic remaining piping. Then loosen the oil filler cap slowly to release the pressure inside the hydraulic tank.

2. Disconnect 2 hoses (3). * Fit a blind plug to prevent dirt or dust from entering the piping. 3. Remove lock plate, and pull out pin (4), then m remove tilt cylinder assembly. * When slinging, be careful not to damage the hose with the bottom end. & kg Blade tilt cylinder assembly: 225 kg

INSTALLATION OF RIPPER TILT CYLINDER ASSEMBLY

l

Carry out installation removal.

in the reverse order to

Pin: Grease (G2-LI)

a
l

Pin: Grease (G2-LI)

Bleeding air Bleed the air from cylinder. For details, see TESTING AND ADJUSTING.

30-223 0

REMOVAL OF RIPPER LIFT CYLINDER ASSEMBLY

Lower the work equipment ground.

completely to the

1. Sling lift cylinder assembly (I), remove lock plate, then pull out pin (2) at head end. m

Start the engine and retract the piston rod fully. Stop the engine and operate the control lever several times to release the remaining pressure in the hydraulic piping. Then loosen the oil filler cap slowly to release the pressure inside the hydraulic tank.

2. Disconnect 2 hoses (3). * Fit a blind plug to prevent dirt or dust from entering the piping. [121 3. Remove lock plate, then pull out pin (4) at bottom end and lift off cylinder assembly (1).

f=h

Ripper lift cylinder assembly:

205 kg

INSTALLATION OF RIPPER LIFT CYLINDER ASSEMBLY

0 Carry out installation removal. in the reverse order to

Pin: Grease (G2-LI)

&
l

Pin: Grease (G2-LI)

Bleeding air Bleed the air from cylinder. For details, see TESTING AND ADJUSTING.

30-224 0

REMOVAL OF RIPPER TILT CYLINDER ASSEMBLY

A
A

Lower the work equipment ground.

completely to the

1. Sling tilt cylinder assembly (I), remove lock plate, then pull out pin (2) at head end. m Start the engine and retract the piston rod fully. Stop the engine and operate the control lever several times to release the remaining pressure in the hydraulic piping. Then loosen the oil filler cap slowly to release the pressure inside the hydraulic tank. 2. Disconnect 2 hoses (3). * Fit a blind plug to prevent dirt or dust from entering the piping. 3. Remove lock plate, and pull out pin. & kg Ripper tilt cylinder assembly: m 190 kg

I-

8
0

z
INSTALLATION OF RIPPER TILT CYLINDER ASSEMBLY
0 Carry out installation removal. in the reverse order to

&

Pin: Grease (GZ-LI)

RZZ+
l

Pin: Grease (GZ-LI)

Bleeding air Bleed the air from cylinder. For details, see TESTING AND ADJUSTING.

30-225 0

DISASSEMBLY

OF HYDRAULIC CYLINDER ASSEMBLY

(BLADE LIFT, BLADE TILT, RIPPER LIFT, RIPPER TILT CYLINDER) 1. Cylinder tube Remove cylinder tube. 2. Quick drop valve (blade lift cylinder) Remove block (I), then pull out spring (2), spacer (3), valves (4) and (5), and collar (6).

3. Piston rod assembly 0 Blade lift cylinder 1) Set cylinder assembly (7) to tool Q,. 2) Using hydraulic pump or power wrench, disconnect head assembly (8) with tool Q,. 3) Pull out piston rod assembly (9). * Put an oil pan or container under the cylinder to catch the oil.

1 l1h.iF02737
Blade tilt, Ripper lift, Ripper tilt cylinder y, Remove mounting bolts, and disconnect head assembly (10). 2) Pull out piston rod assembly (11). * Put an oil pan or container under the cylinder to catch the oil.

17MF0273P

4. Piston assemblv Blade lift cyli;der bolts, then remove mounting Remove spacer (12), and pull out valve (13). 2) Remove piston assembly (14). 3) Remove backup rings (15), and O-ring (16). 4) Remove retainer (17).

;I

17MF02739

30-226 0

5) Disassemble the piston assembly as follows. i) Remove wear ring (18). ii) Remove piston ring (19). iii) Pull out seat (20), and valve (21).

I
. 1) 2) 3) 4) Blade tilt, ripper lift, ripper tilt cylinder bolts, then remove mounting Remove spacer (22). Pull out piston assembly (23). Remove backup ring (24) and O-ring (25). Disassembly of piston assembly i) Remove wear ring (26). ii) Remove piston ring (27).

I.8

I95FO5365

22

23 24

17MF02740

il

I95FO5364
Blade tilt

5. Head assembly 1) Remove head assembly (8) or (IO). 2) Disassemble the head assembly as follows. i) Remove O-ring (28). (only for blade cylinder) ii) Remove O-ring (29) and backup ring (36). iii) Remove packing (31). iv) Remove snap ring (32), then dust seal (33). v) Remove bushing (34).

17MF02741

Blade lift

remove
Blade tilt Ripper lift Ripper tilt

30-227 0

ASSEMBLY

OF HYDRAULIC CYLINDER ASSEMBLY

(BLADE LIFT, BLADE TILT, RIPPER LIFT, RIPPER TILT CYLINDER) * Clean all parts, and check for dirt or damage. Coat the sliding surfaces of all parts with engine oil before installing. Be careful not to damage the packings, dust seals, and O-rings when assembling.

Blade tilt Ripper lift Ripper tilt

1. Head assembly 1) Assemble head as follows. i) Press fit bushing (34). ii) Assemble dust seal (33), and secure with snap ring (32). iii) Assemble packing (31). iv) Assemble backup ring (30) and O-ring (29). * Do not try to force the backup ring into piston. Warm it in warm water (50 - 60C) before fitting it. v) Assemble O-ring (28). (blade lift cylinder only) 2) Assemble head assembly (8) or (10) to piston rod.

Blade lift

Blade tilt Ripper lift Ripper tilt

17MF02741

2. Piston assembly Blade lift cylinder l 1) Assemble the piston as follows. i) Assemble valve (21) and seat (20). ii) Using tool Q,, expand piston ring (19). j, Set the piston ring on tool Qs and turn the handle 8 - 10 times to expand the ring. iii) Remove piston ring (19) from tool 4, then install it to piston. iv) Using tool Q,, compress piston ring (19). v) Assemble wear ring (18).
17MF02743

J18

17MF02744

2:2FO5487

I 97F3779

30-228 0

2) Install retainer (17). 3) Install O-ring (16) and backup rings (15). * Do not try to force the backup ring into the piston. Warm it in warm water (50 - 60C) before fitting it. * Coat the O-ring and the backup rings with grease, then secure the backup rings so that they do not open. 4) Install piston assembly (14). 5) Assemble valve (13) to spacer (12), then fit spacer and tighten with mounting bolts.
/r\w Mounting bolt: Thread tightener

w
(LT-2)

17MF02739

Mounting bolt: 11.25 Z!I 1.25 kgm

Blade tilt, ripper lift, ripper tilt cylinder 2-l) -ii) - iv), assemble piston ring (27), then assemble wear ring (26).

1) Using tool Q, in the same way as for Step

9
27

@Y
c3
26
I95FO5364

2) In the same way as for Step 2-3) - 4),

assemble O-ring (25), backup ring (24), and piston assembly (23). 3) Fix spacer (22) in position, then tighten with mounting bolts. &, m Mounting bolt: Thread tightener (LT-2)

Mounting bolt: 11.25 k 1.25 kgm

17MF02740

3. Piston rod assembly Blade lift cylinder l 1) Set cylinder (35) in tool 0,. 2) Assemble piston rod assembly (9) to cylinder. Z-EL * Seal portion: Grease (G2-LI)

Push the piston rod in the end of its stroke. 3) Using tool Q,, tighten head assembly (8). w Head assembly: 105 _+ 10.5 kgm
, 1 1 :dFO2737

30-229 0

;, Assemble
H-E>= *

Blade tilt, ripper lift, ripper tilt cylinder piston rod assembly (11) cylinder (36). Seal portion: Grease (G2-LI)

to

2)

Push the piston rod in to the end of its stroke. Tighten head assembly (10) with mounting bolts. m Mounting bolt:
17MF02745

Quick drop valve (blade lift cylinder only) Assemble collar (6), valves (5) and (4), spacer (3), and spring (2), then fit O-ring and install block (1). Tube Fit O-ring and install tube.

l98FO2792

30-230 0

REMOVAL OF WORK EQUIPMENT ASSEMBLY

Stop the machine on a firm, level place, and lower the work equipment to the ground. securely under the Then put blocks 0 straight frame on the left and right. m j, Check the number and thickness shims (2), and keep in a safe place.

1. Remove cap (1).

of the

2. Sling blade lift cylinder (3), start engine and retract piston rod fully, then fit cylinder lock plate to secure to guard. A Tie the rod with wire to prevent it from coming out. * Repeat Steps 1 to 2 to disconnect the cylinder on the other side from the blade. Stop the engine and operate the control lever several times to release the pressure in the hydraulic remaining piping. Then loosen the oil filler cap slowly to release the pressure inside the hydraulic tank.

175FO2577

2
17MF02746 17MF02747

3. Remove right cover (4). 4. Disconnect hose (5). A Make match marks before disconnecting the hose. * Fit a blind plug to prevent dirt or dust from entering the piping. 5. Remove left and right trunnion caps (6).

6. Remove work equipment assembly (7). IfEt21 A Start engine and drive machine slowly in blade assembly reverse to disconnect from trunnion on track frame.

I98FO2808

30-231 0

INSTALLATION

OF WORK EQUIPMENT ASSEMBLY

Carry out installation removal.

in the reverse order to

Adjust so that play C of the spherical portion in the axial direction is within 0.5 mm, but can still rotate smoothly. Standard shim thickness: 4 mm

Adjust with a block @ so that the height and width of the left and right straight frames are dimensions A and B as shown below. Dimensions A: Approx. 2876 mm Dimensions B: Approx. 559 mm

198F1423

30-232 0

DISASSEMBLY

OF WORK EQUIPMENT ASSEMBLY

Insert 5 blocks 0 under the left and right straioht frames, the bottom of the blade, and the left and right arm mounts to set the dozer assembly securely in the position.

1. Sling tilt brace (I), and remove lock plate, then pull out pin (2). * If the pin is stiff, rotate brace (1) with lever (3) to adjust. 2. Remove lock plate, then remove tilt brace (1). & Tilt brace: 150 kg pull out pin (4) and

17MF02749

3. Raise right center brace (5) and left center brace (6), remove pins (7) and (8) and connection with straight frame, then remove. m

A
*

Always prevent

put block @ under arm (9) from falling.

the arm to

There are shims at the spherical connection at the straight frame end, so check the number and thickness of the shims, and keep in a safe place. & Center brace: 130 kg remove 4
17MF02749

8 z lz

4. Sling straight frame (IO), then connecting pin (11) and lift off. & * Straight frame: 900 kg

Check the condition of the block and be careful to prevent the blade from falling over during the operation.

17MF02750

._ 10

\ 11
17MF02751

30-233 0

5. Raise blade (12) and tip blade over. 6. Raise right arm (13), remove connection of blade (12) and left arm (14), then remove. Raise left arm (14). then remove from blade (12). PI kg 6 kg Blade: 3550 kg Arm:

175 kg

A There are shims at both ends and at the

center spherical connection, so check the number and thickness of the shims, and keep in a safe place.

li

17MF02752

17MF02753

8 z z

30-234 0

ASSEMBLY OF WORK EQUIPMENT ASSEMBLY

* There

* .

are shims at all connections, so assemble the same number and thickness of shims as was disassembled, and adjust all dimensions. Coat the connecting pins with grease when installing. Carry out assembly in the reverse order to disassembly.

* * *

Adjust the shim at the spherical joint so that play of the spherical portion in the axial direction is within 1 mm, but can still rotate smoothly. Standard shim thickness: 4 mm If the arm does not match when connecting, shake the straight frame on the left or right to align.

1121 . Adjusting dimension C * Adjust so that the play of the spherical

portion in the axial direction is within 1 mm, but can still rotate smoothly. Standard shim thickness: 4 mm

C
F15A01185

30-235 0

DISASSEMBLY

OF RIPPER ASSEMBLY

1. Set block 0, raise machine, and lower blade assembly to ground.

Lock brake pedal securely.

2. Sling shank (1) temporarily, operate pin-puller cylinder and pull out pin. (For giant ripper) 3. Start engine, raise ripper fully, then shank (1) gradually, and remove. & kg Shank: 350 kg lower

4. Set block 0 under arm and beam to support ripper assembly. 5. Sling lift cylinder assembly (2) temporarily, remove pin (3). * Start engine, retract piston rod fully, and lower to arm. 6. Sling tilt cylinder assembly (4) temporarily, remove pin (3). * Start engine, retract piston rod fully, and lower to arm. * Operate the control levers several times to release the remaining pressure in the hydraulic piping.

2755

7. Sling beam (6), then using forcing screws 0, remove left and right pins (7) and remove beam (6). & Beam: 1750 kg

8. Disconnect hoses (8) and (9). 9. Sling tilt cylinder assembly remove pin (10) and lift off. (4) temporarily, 190 kg (2) temporarily, 205 kg

el
kg

Tilt cylinder assembly:

IO. Sling lift cylinder assembly remove pin (11) and lift off. & kg Lift cylinder assembly:

11. Sling arm, then using forcing screws Q, remove left and right pins (12), and remove arm (13). & kg Arm: 700 kg

30-236 0

ASSEMBLY OF RIPPER ASSEMBLY

_

1. Insert block under the arm, and set arm (13) in mounting position, install left and right pins (12) and lock with lock plate. assembly (2) in mounting 2. Set lift cylinder position, then install pin (11) and lock with lock plate. 3. Set tilt cylinder assembly (4) in mounting position, then install pin (10) and lock with lock plate. 4. Connect hoses (9) and (8).

5. Insert block 0 under the beam, and set beam (6) in mounting position, install left and right pins (7) and lock with lock plate. assembly (4) temporarily, 6. Sling tilt cylinder start engine, extend piston rod and align pin hole, then install pin (5) and lock with lock plate. 7. Sling lift cylinder assembly (2) temporarily, start engine, extend piston rod and align pin hole, then install pin (3) and lock with lock plate. 8. Set block 0, raise machine, assemly to ground. and lower blade

8 Is z

17MF02759

Lock brake pedal securely.

9. Start engine, raise ripper assembly, and insert wire in hole of shank holder hook, then raise shank (1) gradually, align pin hole and install. 10. Raise blade, lower machine from block 0. cylinder.

11. Bleed the air from hydraulic .

Bleeding air Bleed the air from cylinder. For details, see TESTING AND DADJUSTING. * Refill each connect pin with grease.

30-237 0

REMOVAL OF ROPS GUARD

1. Sling ROPS gvard (I), and remove mounting bolts, then remove ROPS guard. )#II & ROPS guard: 550 kg

INSTALLATION GUARD
l

OF ROPS

Carry out installation removal. m

in the reverse order to

762

m Guard mounting bolt: 135 f 15 kgm

30-238 0

REMOVAL OF OPERATORS CAB ASSEMBLY

Disconnect the cable from the negative terminal of the battery.

(-)

1. Remove ROPS guard. For details, see REMOVAL OF ROPS GUARD. 2. Remove left and right covers (I), then remove rubber mat (2). 3. Remove left, right, and rear panel covers (3). 4. Disconnect central wiring connectors (4). * After disconnecting the connectors, fit caps to prevent dirt or dust from getting in. 5. Disconnect panel (6). cable (5), then remove heater

6. Disconnect 4 wiper hoses (vinyl hoses) (7). j, When disconnecting the hoses, mark them with tags to indicate the position where they are connected. m 7. Remove 14 cab mounting bolts, raise slowly, then remove operators cab assembly (8). m

el
kg

Operators cab assembly:

500 kg

17MF02767

30-239 0

Carry out installation removal.

in the reverse order to

They vinyl hoses can be distinguished by their color, so connect the hose with the same color as the joint.

Install the cab assembly as follows. 1) Set mounting dimension a of adjusting joints installed at points A - G in the diagram to 10 - 12 mm. 2) Set cab assembly on floor frame, screw bolts 3 - 4 threads into points A - N in the diagram to check that the bolts can be tightened. 3) Tighten bolts H - N in the diagram. * When tightening the bolts, check that adjusting joints A - G in the diagram are not in contact with the surface of the floor frame. 4) Screw in adjusting joints A - G in the diagram until they contact the surface of the floor frame, then tighten the mounting bolts.

17MFO2769

After installing the ROPS cab, check that the instruments and other equipment work normally.

17MF02770

30-240 0

REMOVAL OF FLOOR FRAME ASSEMBLY

1. Remove operators cab assembly. For details, see REMOVAL OF OPERATORS CAB ASSEMBLY. 2. Remove covers (I), (2), and (3), floor plate (4) and step cover (5).

17MF02

3. Remove wiring clamp, and disconnect wiring connectors (6), (7), (8), (9), (IO), (11) and (12). * After disconnecting the connectors, fit caps to prevent water, dirt or dust from getting in. 4. Disconnect ground connection (13).

17MF02772

E
0
5. Remove cover (14). 6. Loosen top and bottom locknuts, rotate joint, and disconnect 4 transmission and steering control rods (15). 1111 7. Remove 2 mounting cable lock bracket. bolts (16) of control

17MF02774

17MF02775

8. Disconnect heater hoses (17). * After disconnecting the hoses, fit caps to prevent dirt or dust from getting in. 9. Disconnect cooler hose (18). * When disconnecting the hoses, mark them with tags to indicate the position where they are connected. 10. Disconnect fuel control rod (19). m * After disconnecting the rod, tie it with wire to the floor to hold it in position.

30-241 0

11. Disconnect brake rod (20).

12. Disconnect control rod (21) of work equipment. m * After disconnecting the rod, tie it with wire to the floor to hold it in position.

17MF02777

13.

Remove 4 front and rear mounting bolts, then raise floor frame assembly (22) slowly and remove. j, Be careful not to damage the control cables, rods, and wiring when removing the assembly. PI kg Floor frame assembly: 650 kg

17iFOi779

INSTALLATION OF FLOOR FRAME ASSEMBLY

l

Carry out installation removal.

in the reverse order to

After connecting the rod, adjust it correctly. For details, see TESTING AND ADJUSTING, Adjusting brake pedal linkage.

Locknut: 0.8 + 0.2 kgm the cables, adjust them correctly. For details, see TESTING AND ADJUSTING, Adjusting speed lever linkage, and Adjusting steering clutch linkage.

m * Insert the stopper for the yoke connecting pin securely. After connecting the rod, adjust it correctly. For details, see TESTING AND ADJUSTING, Adjusting ripper, blade control linkage.

* After connecting

* *

Insert the stopper for the yoke connecting pin securely. After connecting the rod, adjust it correctly. For details, see TESTING AND ADJUSTING, Adjusting fuel control linkage.

Floor frame mounting bolt: 135 f

15 kgm

m
Bend the cotter securely.

30-242 0

40

MAINTENANCE

STANDARD

Engine mount .......................... Power train mount ...................... Damper and universal joint .............. Torque converter ....................... Torque converter valve .................. Transmission ........................... Transmission control valve ............... Power train and lubricating pump ......... Transfer and bevel pinion ................ Bevel gear shaft, steering clutch and steering brake ..................... Steering control valve ................... Final drive ............................. Main frame ............................ Track frame ............................ Recoil spring ........................... Idler .................................. Track roller ............................ Carrier roller ........................... Track ................................. Suspension ............................ Hydraulic pump ........................ Blade lift control valve ................... ..... l Main relief valve and shuttle valve Blade tilt control and ripper low valve ..... Ripper high valve ....................... Hydraulic cylinder ...................... l Blade lift cylinder .................... l Blade tilt cylinder .................... ................... l Ripper lift cylinder l Ripper tilt cylinder ................... l Dual tilt cylinder ..................... l Pin puller cylinder .................... Quick drop valve ....................... Cylinder stay ........................... Semi U-dozer .......................... l Cutting edge and end bit .............. Ripper ................................. ......... l Variable multiple shank ripper l Variable giant ripper ..................

40- 2 40- 4 40- 6 40- 8 40-I 0 40-I 2 40-14 40-16 40-17 40-18 40-20 40-22 40-24 40-26 40-28 40-30 40-32 40-34 40-36 40-38 40-43 40-44 40-45 40-46 40-47 40-48 40-48 40-48 40-48 40-49 40-50 40-50 40-51 40-52 40-54 40-56 40-58 40-58 40-60

40-l 0

ENGINE MOUNT

94.5 + 10.5 kgm

94.5 f 10.5 kgm

B-B 17MF02101 A-A Unit: mm

No.

Check item

Criteria Tolerance

Remedy

Clearance

between

bracket and cushion

Standard size

Shaft f0.018 -0.012

Hole +0.046 0

Standard clearance -0.018 0.058

Clearance limit

70

0.1

Replace

Standard size 2 Free height of mounting rubber 108

Repair limit 106

40-2

D275A-2

94.5/fl0.5 kgm

94.5f10.5 kgm

j p

2.

,
i!

1
P

A-A
17MF02102

40-4

D275A-2

DAMPER AND UNIVERSAL JOINT

28.5 f 3

km

17MF02103 Unit: mm No. Check item Criteria Tolerance 1 Remedy

Clearance between and cover

flywheel housing

Standard size

Shaft

Hole +0.080 0 f0.110 0

Standard clearance 0.024 0.185 0.022 0.202

Clearance limit

647.7 2 between flywheel and damper 546

-0.024 -0.105 -0.022 -0.092 Standard size

0.2 0.25

Clearance

I
Repair limit 109.9 109.9 47.7 3 Outside diameter of coupling of oil seal contact surface 0 -0.087 of oil seal contact surface 0 l lo-0.035 46 + 0.1

4 5 -

Outside diameter of output shaft Dimension

between

bearing and holder

40-6

11.25fl.25kgm

11.25~1.25kgm

5.5f0.5kgm

6.75 f 0.75 kgm

11.25+

1.25 kgm

11.25+1.25kgm

6.75fl25kgm

1 .I5 f 0.15 kgm

6.75 f 0.75 kgm

-5

17MF02104

40-8

D275A-2

Unit: mm

NO

Check item Standard size

Criteria Tolerance 0 -0.100 +0.040 0 +0.035 0 Repair limit 119.8 170.5 110.5
I

Remedy

Outside diameter of coupling

of oil seal contact surface 120 I I I

I
I I
,

High chrome painting repair or replace

2 3

inside diameter of retainer Inside diameter of sleeve

of seal ring contact surface of seal ring contact surface

170

110
I

Standard clearance 4 Backlash between driven gear PTO drive gear and 0.250 PTO drive gear and 0.204 0.420 0.516

Clearance limit -

5 -

Backlash between driven gear

Standard size 6 Wear of seal ring of stator shaft Width: Height: 5.0 7 Overall thickness Thickness of disc 8 Stator clutch Thickness of plate Overall thickness 5.0 15.0 5.0 5.0 15.0 Standard size 4.45 6.00

Repair limit Width: Height: 4.5 4.00 5.40

I
I I I I I
Installation load 8.7 kg

4.5 13.8 4.5 4.5 13.9 Repair limit Free length 32.8 Installation load 7.4 kg

Replace

Stator clutch spring

Free length 35

Installation length 27

D275A-2

40-9

TORQUE CONVERTER VALVE

6 __-__

17MF02105

40-10

D275A-2

Unit: mm

No.
I

Check item
I 1

Criteria
I

Remedy r Standard clearance

I I

Tolerance
1
I

Clearance between main relief valve and valve body

Standard size
I
I

Shaft
I

Hole

Clearance limit

40 2 3 4 5 Clearance between torque converter relief valve and valve body Clearance between stator clutch modulating valve and valve body Clearance between lock-up clutch modulating valve and valve body Clearance between lock-up selector valve and valve body 40 25 25 40

-0.035 -0.045 -0.035 -0.045 -0.035 -0.045 -0.035 -0.045 -0.035 -0.045 Standard size

f0.016 0 f0.016 0 f0.013 0 f0.013 0 f0.016 0

0.035 0.061 0.035 0.061 0.035 0.058 0.035 0.058 0.035 0.061

0.08 0.08 0.08 0.08 0.08 Replace

Repair limit Installation load 144.57 kg 56.16 kg 20.10 kg 16.18 kg Free length 116.7 I 13.41 100.4 137.16 78.09 106.8 Installation load 137.3 kg 53.35 kg 19.10 kg 15.37 kg 2.85 kg

Main relief valve spring

Free length 120.3 116.92 103.5 141.4 80.5 I 10.07

Installation length 102.0 90.8 92.7 88.7 80.5 100.0

7 8 g

Torque converter relief valve spring Stator clutch modulating valve spring Lock-up clutch modulating valve spring (outer) Lock-up clutch modulating valve spring (inner) Lock-up selector valve spring

I
1o

II

3.0 kg

40-11

TRANSMISSION

17MF02106

40-12

D275A-2

Unit: mm

No.

Check item

Criteria

Remedy

No. I clutch spring

(12 PCS.)

2 3 4

No. 2 clutch spring No. 3 and 4 clutch spring No. 5 clutch spring

(12 PCS.) (I 2 PCS.) 1 91.0 7.75 Standard 1

60.3 71.9 7.40 size 1

22.3 kg 16.6 kg 137.2 kg Tolerance * 0.3 * 0.3 * 0.2 f 0.2 * 0.3 * 0.1 * 0.1 + 0.1

65.8

19.0 kg

85.5 -

14.1 kg 116.6 kg

(5 PCS.)

Repair limit 42.9 38.6 21.4 25.7 38.4 4.3 4.5 3.9 3.6 Width: Thickness: Width: Thickness: Width: Thickness: Clearance limit 2.7 2.9 4.1 5.6 4.5 5.8 Replace

Overall thickness of No. 1 clutch 45.5

6 7 8 9 10 II 12 13

Overall thickness of No. 2 clutch Overall thickness of No. 3 clutch Overall thickness of No. 4 clutch Overall thickness of No. 5 clutch Thickness of discs of No. I 4 clutches

41.2 23 27.3 41 4.8 5.0 4.3 4.0 Width: Thickness: Width: 3.0 3.1 4.5 5.8 5.0 6.0

Thickness of discs of No. 5 clutch Thickness of plates of No. I 4 clutches

Thickness of plates of No. 5 clutch

I
Width:

0.1 -0.01 -0.03 f 0.10 -0.01 -0.03 + 0:15 -0.01 -0.03 * 0.15

14

Wear of seal ring of input shaft

Thickness: Width: Thickness: Width: Thickness:

I5

Wear of seal ring of output shaft Thickness:

16

Wear of seal ring of No. 5 clutch

Width: Thickness:

Standard clearance 17 Backlash between No. I and 2 sun gears and planetary gears 0.13 I

0.40
I

18 19 20

Backlash between and rina aear __

No. 1 planetary

gear

0.13 0.14 -

0.40 0.40

Backlash between No. 2,3 and 4 planetary gears and ring gear Backlash between olanetarv aears No. 3 and 4 sun gears and

0.13 -

0.37

40-13

TRANSMISSION

CONTROL VALVE

17MF02107

D275A-2

Unit: mm

Clearance

between

modulating

valve

10

Reducing valve spring

68.0

55.5

26.7 kg

66.0

25.37 kg

D275A-2

40-15

POWER TRAIN AND LUBRICATING

BAL100+140

PUMP

11.5f

1.0 kgm_

11.5f

1.0 kgm

BALI00

BALI 40
I97F2008

Unit: mm No. Check item Model 1 Side clearance BALl 00 BAL 140 BAL 100 2 Model 3 Pin insertion depth BAL 100 14 BAL 140 4 Rotation torque of spline shaft Revolution @pm) 2200 2200 0.6 kgm Pressure (kg/cm) 30 30 Standard discharge (a/min) 200 280 Repair limit discharge (a/min) 185 258 0 -0.5 Standard size Tolerance Repair limit Clearance between inside diameter of plain bearing and outside diameter of gear shaft BAL 140 0.060 0.145 0.20 Replace Criteria Standard Clearance 0.04 0.07 0.10 0.12 Clearance 0.13 0.15 limit Remedy

Model Discharge Oil: Class-CD SAE 1OW Temperature: 45 50C BAL 140 BAL 100

40-16

D275A-2

TRANSFER AND BEVEL PINION

.25 f 3.25 kgm

f 0.75 kgm

/
m 18+2kgm m

I
18*2kgm

\
m 18f2kgm 17MF02108

Unit: No.

mm

I
Backlash

Check item

I
Standard clearance

Criteria

I
Clearance limit

Remedy

of transfer

gears 0.22 0.61 0.75

Adjustment or replace

Standard 2 Thickness of collar and bearing between transfer gear 15

size

Repair

limit Replace

14.6

Standard

shim thickness

of bearing

cage

2.0

Adjustment

D275A-2

40-17 @

BEVEL GEAR SHAFT, STEERING CLUTCH AND STEERING BRAKE

___-_---------___ ----

j--v /-t
Ir-__ 4d

1;.5+1

kgm

25+15kgm

V 18+2kgm 17MF02109

40-18

D275A-2

Unit: mm No Check item Criteria Standard Thickness of brake and clutch plate 2.9
1

Remedy Repair limit

size

2.6 Repair limit 0.4 Repair limit

Replace

Tolerance Strain of brake and clutch plate within 0.3 Standard Thickness of brake and clutch disc 4.5 2 Tolerance Strain of brake and clutch disc within 0.3 Standard 56.3 4 Overall thickness of clutch plates and discs Backlash between and brake hub Backlash between bevel pinion brake and clutch discs, 59.2 Standard 0.4 6 7 8 bevel gear and 0.3 0.5 clearance 0.7 0.4 0.8 size size

Correct or replace

Replace 4.2 Repair limit 0.4 Repair limit 53.8 57.7 Clearance 1.0 0.75 0.8 0.8 Adjustment or replace limit Replace Correct or replace

3 Overall thickness of brake plates and discs

Clearance between seal ring groove of piston and seal ring Clearance between seal ring groove of cage and seal ring

0.5 -0.8

I
Tolerance Standard size 275 Shaft - 0.110 - 0.191 - 0.100 - 0.172 - 0.100 - 0.172 Standard size Installation load 3.530 kg 3.500 kg Tolerance Hole + 0.081 0 + 0.072 0 + 0.072 0

I
Standard clearance 0.110 0.272 0.100 0.244 0.100 0.244

I
Clearance limit

Inside diameter of seal ring contact surface of cage

10 11

Inside diameter of seal ring contact surface of brake piston Inside diameter of seal ring contact surface of clutch piston

230 220

Replace

Repair limit Free length 15.9 15.9 Installation load 3.550 kg 3.330 kg

12

Brake belleville spring

Free length 16.5

Installation length 10.4 10.6

13 Clutch belleville spring

16.5

14

Interference between reamer bolt

bevel gear and

Standard size 14

Shaft + 0.019 + 0.001

Hole + 0.027 0

Standard interference 0.026 0.019

Interference limit 0.02 ~~~~c&e Adjustment

15 16 17

Face runout of back of bevel gear Preload of tapered roller bearing of lever gear shaft Standard shim thickness of bearing cage

Repair limit: 0.05 (measure

after installing to bevel gear shaft)

Standard rotating torque: 0.4 - 0.5 kgm (2.2 - 2.8 kg at tip of bevel gear teeth with bevel pinion and bevel gear not meshed) 2.0

Adjust shim

D275A-2

40-19

STEERING CONTROL VALVE

197F161

40-20
D275A-2

Unit: mm

No

Check item

Criteria Tolerance

Remedy

Clearance between brake and clutch valves, and valve body

Standard size

_
Shaft -0.020 -0.030 -0.020 -0.030 -0.034 -0.043 -0.034 -0.043 -0.030 -0.040 -0.020 -0.041 Standard size Installation load 14.7 7.3 kg kg Hole +0.013 0 +0.013 0

Standard clearance 0.020 0.043 0.020 0.043 0.034 0.056 0.034 0.056 0.030 0.055 0.020 0.093

Clearance limit

24.0

0.06 0.06 0.08 0.08 0.08 0.11 Replace

2 3 4 5 6 Clearance between valve body Clearance Clearance between between clutch shaft and

I I I
I

24.0 22.0 20.5 9.0 20.0

brake shaft and guide brake shaft and guide brake and clutch valve, check valve and

+0.013 0 f0.013 0 f0.015 0 f0.052 0

Clearance between and piston Clearance between valve body

I
7 Clutch modulating spring Free length 76.0

Repair limit Free length 72.0 40.0 14.0 Installation load 14.0 kg 6.9 kg -

Installation length 49.0 32.0 15.5

8 9 10 11 12

Clutch valve return spring Clutch shaft return spring

41.9 15.5

Brake modulating

spring

50.0 50.2 38.5

42.0 37.0 30.0

6.5 18.0

kg kg

47.5 47.5 34.5

6.2 kg 17.1 kg 0.3 kg

Brake valve return spring Check valve spring

0.34 kg

40-21

N
80flOkgm

w
28.5 f 3 kgm

135?15kgm

8/

,_.l~YmYrjI
bm

cgx53
15.5 * 2.5 kgm

120?10kgm

56+6

kgm

28.5 do3 kgm

17MF02110

40-22

D275A-2

Unit: mm

No

Check item Standard Backlash between No. 1 gear No. 1 pinion and 0.28 Backlash between planetarv aear Backlash between ring gear sun gear and planetary gear and 0.22 0.25 Standard 0.93 0.81 0.90 size clearance

Criteria Clearance 1.5 1.5 1.5 Repair limit limit

Remedy

I I

I I

2 3

Outside diameter of oil seal contact surface of No. 1 pinion 95.0

Replace 94.9 15.0 Tolerance

5 Height of cover and ball 16.5

Clearance carrier

between

pinion shaft and

Standard size

Shaft -0.036 -0.058 0 -

Hole -0.024 -0.059

Standard clearance -0.023 0.034 2)

Clearance limit

85 Clearance in axial direction of No. 1 pinion bearing Press-fitting force of rubber bushing Press-fitting force of sun gear

0.1

0.1 (Standard

shim thickness:

8
9

Max. 13.5 ton Max. 10 ton

Adjustment

40-23

MAIN FRAME

A-A

D-D
17MF02111

40-24

D275A-2

Unit: mm No. Check item Criteria Tolerance Clearance between radiator guard mounting pin and bushing Standard size Shaft Hole Standard clearance 0.410 0.555 0.343 0.405 0.098 0.254 0.1090.260 Clearance limit Remedy

80 Clearance mounting between radiator guard 80 110 90

-0.030 -0.076 -0.030 -0.076 -0.036 -0.090 -0.036 -0.090

f0.479 f0.380 f0.329 f0.313 +0.164 +0.062 +0.170 f0.073 6.2 10.2 7.1 14.1 ton 23.2 ton

1.0 Replace 1.5 1.5 1.5

pin and bushing

Press-fitting force of ripper beam mount bushing Clearance between ripper cylinder mounting pin and bushing Press-fitting force of radiator guard mount bushing Press-fitting force of radiator guard mount bushing Clearance between pin and bushina
I

Adjustment ripper beam mounting

I

14.0 ton 11.7 ton

Press-fitting force of ripper cylinder mount bushina

5.9 -

D275A-2

40-25

TRACK FRAME

_--.-----_--

-%-

15.5 f 2.5 kgm

A-A

i.

-.-.-.--_.e
B-B
17MF02112A

40-26 0

Unit: mm No. Check item Standard 1 Clearance between idler yoke and guide 0 - 0.5 3 size Criteria Repair limit Adjustment Remedy

40-27

56f6kgm

m 25 f 3.25 kgm

135f15kgm

159.5 & 17.5 kgm B-B A-A F17MO2006

40-28

D275A-2

No Check item Criteria

Unit: mm Remedy

Recoil spring

Tolerance Clearance between outside end and inside end of outside cylinder bushing Standard size Shaft -0.055 -0.228 -0.100 -0.350 -0.15 -0.35 Item Bend 5 Deformation of track frame (outside cylinder) Torsion Dents (bent plate) 3 (in length of 300 mm) 10 4.3 4.5 9.8 ton 23.3 ton 4.0 Adjustment Hole f0.317 f0.060 f0.054 0 f0.1 0 Standard clearance 0.115 0.545 0.100 0.404 0.15 0.45 2.0 Clearance limit Replace

340 Clearance bushing between adjustment cylinder and 110

0.8

3 4

Clearance between inside cylinder and adjustment cylinder

50

Repair limit 7 (in length of 3000 mm) Correct or replace

6 7 8 Press-fitting force of outside cylinder bushing Press-fitting force of inside cylinder bushing Dimension between front pilot and nut

40-29

IDLER

1
3 21 zt 5 kgm

L- 40-30

--

___._-I
17MF02114

D275A-2

Unit: mm No. Check item Standard Outside diameter section of idler protrusion 872 size Criteria Repair limit Remedy

2 3 4 5 6

Outside diameter

of idler tread face

830 124 71 266 242

805 107 79.5 Rebuild or replace

Width of idler protrusion section Width of idler tread face Overall width of idler Width of collar of shaft

Clearance

between

shaft and bushing 155 -0.350 -0.413

1

Clearance limit +0.220 -0.120

I

Replace bushing

Standard size 95 -

0.230 0.633

1.5

Tolerance Interference between shaft and seal guard Shaft +0.046 0 clearance 0.83 Hole -0.150 -0.200 I Standard 9 Free play of shaft in the axial direction 0.47 1.5 Clearance limit Standard interference 0.150 0.246 IInterference limit

Replace

D275A-2

40-31

TRACK ROLLER

8,_

,9

,7 /

11 /

12

21 f5

kgm

17MF02115

40-32

D275A-2

Unit: mm

No.

Check item Standard size

Criteria Repair limit -

Remedy

Outside diameter

of flange (outside) 291

2 3

1 Outside
I

diameter

of flange (inside) of track roller

I I

284 255 327 74 74 27.5 27.5 24 276

I
1

219

Outside diameter tread face

4 5 6

1 Overall

width of track roller

83 93 18.5 18.5 14 Rebuild or replace

Width track roller tread face (single flange) Width of track roller tread face (double flange) Width of flange (single flange) Width of flange (double flange outside) Width of flange (double flange inside)

7 8 9

I I I I
Standard size

I I I I

10

Width of collar of shaft

)
11
Clearance 12 Interference seal guard 13

ki

:ta::;;

Cly$ce

between

shaft and bushing 130 -0.350 -0.413 10.260 +0.010 Tolerance shaft and Standard size Shaft Hole Standard interference 0.150 0.246 Clearance 1.5 limit Interference limit 0.360 0.673 1.5

Replace bushing

between

70 Standard 0.49 -

-0.150 -0.200 clearance 0.86

f0.046 0

Replace

Free play of shaft in the axial direction

40-33

CARRIER ROLLER

i-i

-li__li-

3
-

--

-1
I

_-

-21 /

*5kgm

\\

17MF02116

40-34

D275A-2

Unit: mm No Check item Criteria Standard 1 Outside diameter of flange 242 2 3 4 Outside diameter tread face of carrier roller 210 68 23 Tolerance 5 Clearance between shaft and support Standard size Shaft 0 -0.2 Hole f0.350 0 Standard clearance o0.550 Clearance limit Replace bushing size Repair limit Remedy

I I

I I
Rebuild or replace

185 79 12

Width of carrier roller tread face Width of flange

I I

I I

86

I
lnteyferynce

Interference seal guard

between

shaft and

Standard size

~~.::tar:de

90 Standard 7 Free play of roller in the axial direction 0.01 -

+0.245 +0.185 clearance 0.22

f0.035 0

0.150 0.245 Clearance 0.3 limit

Replace

I I

I I

D275A-2

40-35

TRACK (LUBRICATED TRACK LINK)

1st tightening: 80 * 8 kgm 2nd tightening: 120 f IO

1st tightening: 50 5 5 kgm 2nd tightening: 180 f IO

197F169

40-36 0

D275A-2

Unit:
NC

mm

Check item Standard size

Criteria Repair limit

Remedy

1 2

Link pitch 260.6

Turn or replace

Height of grouser

88

30

Lug weld, repair by build-up welding, or replace Repair by build-up welding or replace Turn or replace

3 4 -

Link height

161

143 84 (Normal loading) 86.5 (Hard loading)

Outside diameter

of bushing

92.5

I
5 Interference between link and bushing Standard size

92 6 Interference between link and pin 57 +0.30 +0.20 -0.21 -0.28 0.41 0.58 0.25

Clearance

between

links

ri

Replace

D275A-2

40-37 0

SUSPENSION
Serial No.:

(l/3)

10001 -10127

_..e

___.._----------

,2---\

[Pivot shaft L.H. side]

[Pivot shaft R.H. side]

17MF02117

40-38 @

D275A-2

Rear

Front

C-C

17MF02118

Unit: mm

No.

Check item

Criteria Tolerance

Remedy

Interference and seal

between

thrust washer

Standard size

Shaft f0213 f0.098 +0.140 +0.100 +0.096 +0.050 +0.035 0 f0.250 f0.130 0 -0.018

Hole -0.180 -0.226 -0.061 -0.124 -0.115 -0.187 -0.104 -0.171 0 -0.070 -0.068 -0.098

Standard interference 0.278 0.439 0.161 0.264 0.165 0.283 0.104 0.206 0.130 0.320 0.050 0.098

Interference limit

210 2 Interference and seal Interference and seal Interference and seal Interference Interference between between between between between thrust washer pivot shaft side pin bushing side pin boss side pin boss 140 194 100 180 140

I
3

I
4

,~

Tolerance 7 Clearance between pivot shaft and bushing Standard size Shaft -0.145 -0.208 -0.170 -0.242 -0.036 -0.090 -0.036 -0.090 Hole f0.132 f0.059 f0.144 f0.059 f0.274 f0.180 f0.274 +0.178 3.3 23 ton Standard clearance 0.204 0.340 0.229 0.386 0.216 0.364 0.214 0.364 Clearance limit

155 8 g Clearance between pivot shaft and bushing 190 105 105

1 .o 1 .o 1.o 1.o

I I

Clearance between center shaft and equalizer bar bushing Clearance between center shaft bolster bushing and

1o

11

Press-fitting force of equalizer Press-fitting

bar bushing

12

force of bolster bushing ;I Adjustment

Press-fitting force of side pin bushing

D275A-2

40-39

Serial

No. : 10128 and up

: A-A
[Pivot shaft L.H. side]

7-.-

L.f

[Pivot shaft R.H. side]

17MF02117

40-39-l @

D275A-2

SBDO1524

Unit: mm

No.

Check item

Criteria Tolerance

Remedy

Interference and seal

between

thrust washer

Standard size

Shaft f0.213 f0.098 f0.140 f0.100

Hole -0.180 -0.226 -0.061 -0.124 -0.115 -0.187

Standard interference 0.278 0.439 0.161 0.264

I

Interference limit

210 Interference Interference Interference and seal Interference and seal between between between thrust washer pivot shaft side pin bushing 140

ti
4

194

f0.096
f0.050

0.165 0.283

I
5

between

side pin boss Replace side pin boss

I
6

interference between and bushing

Clearance

between

pivot shaft and bushing

Standard size

/=I Shaft Hole

Standard clearance 0.204 0.340 0229 0.386 0.216 0.364 0.214 0.364

1 Clearance
limit

155 8 g Clearance between pivot shaft and bushing 190

-0.145 -0.208 -0.170 -0.242 -0.036 -0.090 -0.036 -0.090 32.4 - 225.6

f0.132 +0.059 f0.144 +0.059 +0.274 f0.180 f0.274 +0.178

1 .o 1 .o 1 .o 1 .o

Clearance between center shaft and equalizer bar bushing Clearance between center shaft Press-fitting Press-fitting bolster bushing and

105 105

,o

11 12

force of equalizer

bar bushing

kN 13.3 - 23 ton)

force of bolster bushing

19.6 - 127.5 68.6 - 133.4

kN {2 - 13 ton) kN {7 - 13.6 ton)

Adjustment

13

Press-fitting

force of side pin bushing

D275A-2

40-39-2 @

SUSPENSION

(2/3)

F-F

17MF02119

No Tolerance 1 Interference between rod and rod bushing Standard size 90 Check item Criteria

Unit: mm

_
Shaft 0 -0.015 Hole -0.024 -0.059 Tolerance

Standard interference 0.009 0.059

Clearance between rod pin and bolster hole and crossbar hole

I
I

Standard

Standard

Clearance limit

Replace

0.5 3 4 5 Clearance between rod and rod bushing 60 -0.030 -0.060 +0.046 0 0.030 0.106 0.08 0.15 0.7 4.4 ton 0.5 0.5

Clearance

at spherical face of rod pin

I I

80

Press-fitting force of rod bushing

~ D275A-2

40-40

SUSPENSION

(313)

Small cushion Small cushion \ Large cushion / Large cushion \

17MF02120

I
I
Under cover z-z (When chassis is contacting ground) (When chassis is floating)

Z-Z

---_ t3-l
B

z-z

(When chassis is floating) 17MF02121 Unit: mm

No Check item Standard value Total of stepped difference at bottom face of equalizer bar and bottom face of under-bar 2.0 f 2.0 8.0 Criteria Repair limit Replace cushion Remedy

Procedure for measurement Measure the stepped difference at two places (e and f) in front of and behind the center (portion P) of the equalizer bar center pin. When the chassis is floating, operate the blade tilt to make the equalizer bar horizontal. With the chassis in contact with the ground, raise the blade and ripper, and measure stepped difference A at the bottom face of the equalizer bar and the bottom face of the under-bar. (At points e and f) With the chassis floating (the chassis lifted off the ground by using the blade and ripper), measure stepped difference 6 or B at the bottom face of the equalizer bar and the bottom face of the under-bar. (At points e and f) * For machines not equipped with blade and ripper, jack up the chassis at the front and rear. Calculate the movement of the equalizer bar as follows: l With the chassis floating, when the bottom face of the equalizer bar is in the +direction from the bottom face of the under-bar:A -6 l With the chassis floating, when the bottom face of the equalizer bar is in the -direction from the bottom face of the under-bar:A +B * If the movement of the equalizer bar is more than 8.0 mm, check for damage to the cushion (large), (small), and replace the cushion. (The same applies if the value is more than 8.0 mm at either point e or point f.)

D275A-2

40-41

HYDRAULIC PUMP
SAR (3) 100 + SAR (2) 50

/
m 28.5 f 3.5 kgm m 28.5 f 3.5 kgm

.
SAR (3) 100

I=
SAR (2) 50 17MF02122

Unit: mm No Check item Model 1 Side clearance SAR (3) 100 SAR (2) 50 SAR (3) 100 2 Clearance between inside diameter of plain bearing and outside diameter of gear shaft SAR (2) 50 Model 3 Pin insertion depth SAR (3) 100 SAR (2) 50 4 Rotation torque of spline shaft Revolution (rpm) 2500 2500 Standard 14 14 1.4 0.06 size 0.149 Tolerance 0 - 0.5 0 - 0.5 2.4 kgm Standard discharge (n/min) 231 112 Repair limit discharge (n/mm) 214 102 0.20 Repair limit I Criteria Standard 0.13 0.10 0.06 clearance 0.18 0.15 0.149 Clearance 0.22 0.19 0.20 limit

I I
I I

Remedy

I I

Replace

I I I

Model

Pressure (kg/cmz) 210 210

Oil: Class-CD SAE 1OW 45 - 55C Temperature:

SAR (3) 100 SAR (2) 50

I
I

40-43 Q

BLADE LIFT CONTROL VALVE

19fl B-B

kgm

A-A

3.5 _+0.5 kgm

D-D

E-E

F-F

197FO2120

40-44

D275A-2

MAIN

RELIEF VALVE AND SHUTTLE VALVE

k 1 .O kgm

7.0 f

197Fl74

/
m

7.0 f 1 .O kgm
Unit: mm

No

Check item Standard size

Criteria Repair limit Installation load 6.0 3.7 kg kg kg kg Free length 52.1 19.8 69.3 31 .o 69.4 114.7 39.4 38.6 Installation load 4.8 kg

Remedy

Spool return spring

Free size 55.6

Installation length 38.0

2 3 4 5 6

Detent spring

20.5

17.0 43.5
24.5 38.5 99.0 32.6 22.0

2.96 kg

Check valve spring Check valve spring Suction valve spring Demand spool spring Main relief valve spring Shuttle valve spring Height of main relief pressure adjustment screw

75.7
32.7

1.0
4.5

0.8
3.6

kg kg Replace

75.9
121.4 41 .I 42.7

1.16 kg 36.0 26.4 kg kg

0.93 kg 28.8 21.1 kg kg

0.83 kg

0.66 kg

8 (one turn of the screw will charge the pressure by: 24.9 kg/cm)

D275A-2

40-45

BLADE TILT CONTROL AND RIPPER LOW VALVE

3.5 f 0.5 kgm

197F175

0.5 kgm Unit: mm

No.

Check item Standard size

Criteria

Remedy

Spool return spring

40-46

D275A-2

RIPPER HIGH VALVE

135

1 3.5

+ 0.5

52.5 * 2.5

kgm

,3

197FI

76

Unit: : mm

No.

Check item Standard size Spool return spring

Criteria

Remedy

Replace

BLADE LIFT CYLINDER

\
w 11.25+1.25kgm 17MF02123

BLADE TILT CYLINDER

50;5kgm

11.;5f

1.25 kgm 17MF02124

RIPPER LIFT CYLINDER

11.25kl.25 I

kgm

17MF02125

40-48

D275A-2

17MF02126

Unit: mm No Check item Criteria Remedy

Clearance between piston rod and bushing

Blade
tilt

70 90 90 95 70 -0.170 -0.250

f0.200 0 +0.207 +0.120 +0.207 f0.120

1.o 1 .o 1 .o 1 .o

Clearance between piston rod connecting pin and bushing

Ripper lift Ripper tilt

Clearance between trunnion bushing and cylinder stay

Blade lift Blade tilt

+0.174 +0.100 +0.207 f0.120 f0.207 f0.120 4.0

2.0 1 .o 1 .o
I I

Clearance between cylinder bottom connecting pin and bushing

Ripper lift Ripper tilt

90 90
I I

6 Standard shim thickness between too of oiston rod and cao

I I

I
I

Blade lift

Adjustment

DUAL TILT CYLINDER

50+-5kgm

11.25f1.25

kgm

17MF02127

PIN PULLER CYLINDER

45 f 4.5 kgm \

17MF02128

Unit: mm

No.

Check item

Criteria

Clearance between and bushing

piston rod

Dual tilt Pin puller

2 3 4 5 Clearance between piston rod connecting pin and bushing Clearance between pin and spherical face of piston rod Clearance between cylinder bottom connecting pin and bushing Clearance between cylinder bottom support shaft and boss

40-50

D275A-2

QUICK DROP VALVE

17MF02129

Unit: mm

No

Check item

Criteria Tolerance

Remedy

Clearance between valve body

plunger and

Standard size

Shaft -0.011 -0.016 Standard size

Hole +0.010 0

Standard clearance 0.011 0.026

Clearance limit

38.0

Replace Repair limit Installation load 13.9 kg Free length 67.7 Installation load 12.5 kg

Valve spring

Free length 75.2

Installation length 55.9

D275A-2

40-5 1

CYLINDER STAY

17MF02130

Unit: mm No. Check item Criteria Remedy

Tolerance Clearance between and bushing cylinder yoke Standard size Shaft Hole Standard clearance 0.085 0.211 0.072 0.180 0.120 0.242 Clearance limit

140 2 3 Clearance between and bushing Clearance between and bushing cylinder yoke lift cylinder trunnion 105 95

-0.085 -0.148 -0.072 -0.126 -0.120 -0.207

f0.063 0 +0.054 0 +0.035 0

0.5 0.5 0.5

Replace

40-52

D275A-2

SEMI

U-DOZER

li'

B-B

c-c

A-A

14 \

E-E

F-F

G-G

J-J H-H

K-K
17MF02131

40-54

D275A-2

17MF02132

Unit: mm

ce between

joint and bracket

D275A-2

40-55

CUlTING

EDGE AND END BIT

152.5 + 16.5 kgm

152.5 + 16.5 kgm

_-------------------------------

197Fl8l-I

Unit: mm No. Check item Standard 1 Height of end bit outside 415 2 3 4 Width of end bit Height of end bit inside Height of cutting edge 662 330 330 300 Replace 500 260 260 (215 after turned) Replace or turn size Criteria Remedy Repair limit

D275A-2

VARIABLE MULTIPLE SHANK RIPPER

---

A-A

B-B

C-C

D-D

40-58 0

Unit: mm No. Check item Criteria Tolerance Clearance between and bushing bracket and arm pin, Standard size Shaft -0.036 -0.090 -0.036 -0.090 -0.036 -0.090 Hole +0456 f0.369 +0.456 +0.369 f0.207 f0.120 Tolerance * 0.3 size Repair limit Standard clearance 0.405 0.546 0.405 0.546 0.156 0.207 Clearance limit ~c = 1.5 1.5 Replace Standard 4 Dimension of shank mounting pin 80 Standard 5 Wear of point size Repair limit Remedy

..n
1 I

2 3

Clearance between and bushing Clearance between pin and bushing

beam and arm pin, 110 cylinder connecting 90

Wear of protector

131

106

D275A-2

VARIABLE

GIANT RIPPER

-..P-

-.-

A-A

B-B

c-c
-..-

tL_l
D-D

il

Detail P

40-60 0

Unit: mm

No.

Check item

Criteria Tolerance

Remedy

Clearance between and bushing

bracket and arm pin,

Standard size

Shaft 0.036 - 0.090 - 0.036 - 0.090 - 0.036 - 0.090

Hole

Standard clearance 0.405 0.546 0.405 0.546 0.156 0.207

Clearance limit

110 2 3 Clearance between and bushing Clearance between pin and bushing beam and arm pin, 110 90

+ 0456 + 0.369 + 0.456 + 0.369 + 0.207 + 0.120 Tolerance

1.5 1.5 1.5 Reolace

cylinder connecting

I
4

I
Repair limit

I
I

Standard of shank mounting pin 80 I

size

Dimension

I
f 0.3 size

I I I

I
5

I
of point

Standard

Repair limit

1 Wear

Wear of protector

131

106

40-61 0

Komatsu America international Company 440 North Fairwav Drive I Vernon Hills, IL 66061-8112 U.S.A. Attn: Technical Publications Fax No. (847) 970-4186

PROPOSAL

FOR MANUAL

REVlslON

FOR INTERNAL USE ONLY -- No. PMR 2 : : S E R DEPARTMENT: NAME: NAME OF COMPANY: LOCATION: PHONE NO: DATE:

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PROBLEM:

Attach photo or sketch. If more space is needed, use another sheet.

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CORRECTIVE ACTION:

PFMRl 081696