Shop Manual Wa500

CEBM001202
SHOP
MANUAL
WA500-3
WHEEL LOADER
MACHINE MODEL
WA500-3LE
SERIAL NUMBERS
A70001 and up
This material is proprietary to Komatsu America International Company and is not to be reproduced, used, or disclosed
except in accordance with written authorization from Komatsu America International Company.
It is our policy to improve our products whenever it is possible and practical to do so. We reserve the right to make
changes or add improvements at any time without incurring any obligation to install such changes on products sold
previously.
Due to this continuous program of research and development, periodic revisions may be made to this publication. It is
recommended that customers contact their distributor for information on the latest revision.
CONTENTS
01 GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-1
10 STRUCTURE AND FUNCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-1
20 TESTING, ADJUSTING, AND TROUBLESHOOTING . . . . . . . . . . . 20-1
30 DISASSEMBLY AND ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . 30-1
40 MAINTENANCE STANDARD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-1
90 OTHER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-1
00-2
PRODUCT PUBLICATIONS INFORMATION
VARIOUS PRODUCT PARTS & SERVICE PUBLICATIONS ARE AVAILABLE TO ALL KOMATSU CONSTRUCTION
EQUIPMENT OWNERS, INCLUDING OPERATION & MAINTENANCE MANUALS, PARTS BOOKS AND SHOP
MANUALS.
SPECIAL PUBLICATIONS SUCH AS SERVICE TOOL, AIR CONDITIONING, AND TURBOCHARGER SHOP
MANUALS ARE ALSO AVAILABLE AS WELL AS SELECTED OPERATION & MAINTENANCE AND SHOP MANUALS
IN FOREIGN LANGUAGES.
THE PUBLICATIONS LISTED BELOW ARE AVAILABLE FOR THIS PARTICULAR MACHINE(S).
DESCRIPTION
FORM NUMBER
PARTS BOOK - PAPER:

Engine and Chassis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
BEPB002201
PARTS BOOK - MICROFICHE:

Engine and Chassis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
BEPM002201
OPERATION & MAINTENANCE MANUAL:

Chassis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CEAM001400
3666095
SHOP MANUAL:
Chassis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine:
Shop Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Troubleshooting & Repair Manual - Base Engine . . . . . . . . . . . . . . . . . . . . . . .
Specifications Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Standard Repair Times . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Performation Degradation Troubleshooting Procedure . . . . . . . . . . . . . . . . . . .
Outer Base Circle Overhead Set Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Overhead Set Specifications Service Bulletin . . . . . . . . . . . . . . . . . . . . . . . . . . .
CEBM001202
SAFETY MANUAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
WLT70-1
3810487
3666142
3666090
3666031
3666006
3666007
3666089
PARTS AND SERVICE PUBLICATIONS CAN ONLY BE ACQUIRED BY AUTHORIZED KOMATSU DISTRIBUTORS,
USING THE KOMATSU AMERICA INTERNATIONAL COMPANY PARTS INFORMATION PROCESSING SYSTEM
(PIPS).
IF THE PIPS SYSTEM IS NOT AVAILABLE AT THE DISTRIBUTOR LOCATION, THEN THE FOLLOWING
REQUISITION FOR TECHNICAL SERVICE PUBLICATIONS AND SERVICE FORMS CAN BE USED. FORM KDC91D
IS SHOWN ON THE REVERSE SIDE OF THIS PAGE.
REQUISITION FOR TECHNICAL SERVICE PUBLICATIONS AND SERVICE FORMS
COMPLETE FORM
AND RETURN TO
Komatsu America International Company

440 North Fairway Drive
Vernon Hills, IL 60061-8112 U.S.A.
Attn: Technical Publications
Fax No. (847) 970-4186
Tel No. (847) 970-5887
COMPANY NAME
PURCHASE ORDER NO.
SHIP TO
ATTN.
ORDER DATE
STREET ADDRESS
TYPE or PRINT
ONLY
CITY, STATE, ZIP CODE

COUNTRY
PHONE NO.
FAX NO.
SHIPPING METHOD
DISTR/BRANCH CODE
IMPORTANT - TO ASSURE SHIPMENT OF THE CORRECT PUBLICATION(S), THE MODEL NUMBER AND MACHINE
SERIAL NUMBER MUST BE SHOWN.
PARTS BOOK
QTY.
KDC91D 081696
PUBLICATION FORM NO.
P-Paper
M-Microfiche
PUBLICATION
DESCRIPTION
MODEL NUMBER
CURRENT PRICES WILL BE CHARGED
SERIAL NUMBER
The affected pages are indicated with the

following marks. Please update the manual by
deleting, replacing and/or adding pages
according to information in the table below.
Symbol
Indication
Action
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Add
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Replace
( )
Pages to be deleted
Discard
Pages without symbols are not revised at this
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SAFETY
SAFETY NOTICE
SAFETY
SAFETY NOTICE
IMPORTANT SAFETY NOTICE

Proper service and repair is extremely important for the safe operation of your machine. The service and repair techniques
recommended and described in this manual are both effective and safe methods of operation. Some of these operations
require the use of tools specially designed for the purpose.
To prevent injury to workers, the symbols
and
are used to mark safety precautions in this manual. The cautions
accompanying these symbols should always be followed carefully. If any dangerous situation arises or may possibly arise,
first consider safety, and take the necessary actions to deal with the situation.
GENERAL PRECAUTIONS
Mistakes in operation are extremely dangerous. Read the
OPERATION & MAINTENANCE MANUAL carefully BEFORE
operating the machine.
7. Before adding oil or making repairs, park the machine on

hard, level ground, and block the wheels or tracks to
prevent the machine from moving.
1. Before carrying out any greasing or repairs, read all the

precautions given on the decals which are fixed to the
machine.
8. Before starting work, lower blade, ripper, bucket or any

other work equipment to the ground. If this is not
possible, insert the safety pin or use blocks to prevent the
work equipment from falling. In addition, be sure to lock
all the control levers and hang warning signs on them.
2. When carrying out any operation, always wear safety

shoes and helmet. Do not wear loose work clothes, or
clothes with buttons missing.
Always wear safety glasses when hitting parts with a
hammer.
Always wear safety glasses when grinding parts with a
grinder, etc.
3. If welding repairs are needed, always have a trained,
experienced welder carry out the work. When carrying
out welding work, always wear welding gloves, apron,
glasses, cap and other clothes suited for welding work.
4. When carrying out any operation with two or more
workers, always agree on the operating procedure before
starting. Always inform your fellow workers before starting
any step of the operation. Before starting work, hang
UNDER REPAIR signs on the controls in the operator's
compartment.
5. Keep all tools in good condition and learn the correct way
to use them.
9. When disassembling or assembling, support the machine

with blocks, jacks or stands before starting work.
10. Remove all mud and oil from the steps or other places
used to get on and off the machine. Always use the
handrails, ladders or steps when getting on or off the
machine. Never jump on or off the machine. If it is
impossible to use the handrails, ladders or steps, use a
stand to provide safe footing.
PRECAUTIONS DURING WORK
11. When removing the oil filler cap, drain plug or hydraulic
pressure measuring plugs, loosen them slowly to prevent
the oil from spurting out. Before disconnecting or
removing components of the oil, water or air circuits, first
remove the pressure completely from the circuit.
12. The water and oil in the circuits are hot when the engine
is stopped, so be careful not to get burned. Wait for the
oil and water to cool before carrying out any work on the
oil or water circuits.
6. Decide a place in the repair workshop to keep tools and

removed parts. Always keep the tools and parts in their
correct places. Always keep the work area clean and
make sure that there is no dirt or oil on the floor. Smoke
only in the areas provided for smoking. Never smoke
while working.
PREPARATIONS FOR WORK
00-3
SAFETY
13. Before starting work, remove the leads from the battery.
ALWAYS remove the lead from the negative (-) terminal
first.
14. When raising heavy components, use a hoist or crane.
Check that the wire rope, chains and hooks are free from
damage. Always use lifting equipment which has ample
capacity. Install the lifting equipment at the correct places.
Use a hoist or crane and operate slowly to prevent the
component from hitting any other part. Do not work with
any part still raised by the hoist or crane.
15. When removing covers which are under internal pressure
or under pressure from a spring, always leave two bolts
in position on opposite sides. Slowly release the pressure,
then slowly loosen the bolts to remove.
16. When removing components, be careful not to break or
damage the wiring, Damaged wiring may cause electrical
fires.
SAFETY NOTICE
19. Be sure to assemble all parts again in their original places.
Replace any damaged part with new parts.
When installing hoses and wires, be sure that they
will not be damaged by contact with other parts
when the machine is being operated.
20. When installing high pressure hoses, make sure that they
are not twisted. Damaged tubes are dangerous, so be
extremely careful when installing tubes for high pressure
circuits. Also check that connecting parts are correctly
installed.
21. When assembling or installing parts, always use the
specified tightening torques. When installing protective
parts such as guards, or parts which vibrate violently or
rotate at high speed, be particularly careful to check that
they are installed correctly.
22. When aligning two holes, never insert your fingers or
hand. Be careful not to get your fingers caught in a hole.
17. When removing piping, stop the fuel or oil from spilling
out. If any fuel or oil drips on to the floor, wipe it up
immediately. Fuel or oil on the floor can cause you to slip,
or can even start fires.
23. When measuring hydraulic pressure, check that the

measuring tool is correctly assembled before taking any
measurements.
18. As a general rule, do not use gasoline to wash parts. In

particular, use only the minimum of gasoline when
washing electrical parts.
24. Take care when removing or installing the tracks of tracktype machines. When removing the track, the track
separates suddenly, so never let anyone stand at either
end of the track.
00-4
FOREWORD
GENERAL
FOREWORD
GENERAL
This shop manual has been prepared as an aid to improve the quality of repairs by giving the serviceman an accurate understanding
of the product and by showing him the correct way to perform repairs and make judgements. Make sure you understand the contents
of this manual and use it to full effect at every opportunity.
This shop manual mainly contains the necessary technical information for operations performed in a service workshop. For ease of
understanding, the manual is divided into the following sections. These sections are further divided into each main group of components.
GENERAL
This section lists the general machine dimensions, performance specifications, component weights, and fuel, coolant and lubricant
specification charts.
STRUCTURE AND FUNCTION
This section explains the structure and function of each component. It serves not only to give an understanding of the structure,
but also serves as reference material for troubleshooting.
TESTING AND ADJUSTING
This section explains checks to be made before and after performing repairs, as well as adjustments to be made at completion
of the checks and repairs. Troubleshooting charts correlating "Problems" to "Causes" are also included in this section.
DISASSEMBLY AND ASSEMBLY
This section explains the order to be followed when removing, installing, disassembling or assembling each component, as well
as precautions to be taken for these operations.
MAINTENANCE STANDARD
This section gives the judgement standards when inspecting disassembled parts.
NOTICE
The specifications contained in this shop manual are subject to change at any time and without any advance notice. Contact
your distributor for the latest information.
00-5
FOREWORD
HOW TO READ THE SHOP MANUAL
HOW TO READ THE SHOP MANUAL

VOLUMES
REVISED EDITION MARK
Shop manuals are issued as a guide to carrying out repairs.

They are divided as follows:
Chassis volume: Issued for every machine model
Engine volume: Issued for each engine series
Electrical volume: Each issued as one to cover all models
Attachment volume: Each issued as one to cover all models
When a manual is revised, an edition mark (

recorded on the bottom outside corner of the pages.
These various volumes are designed to avoid duplication of

information. Therefore to deal with all repairs for any model, it is
necessary that chassis, engine electrical and attachment be
available.
DISTRIBUTION AND UPDATING
Any additions, amendments or other changes will be sent to your
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):
REVISIONS
Revised pages are shown at the LIST OF REVISED PAGES
between the title page and SAFETY page.
SYMBOLS
So that the shop manual can be of ample practical use,
important places for safety and quality are marked with the
following symbols.
Symbol
Item
Consecutive page number for each

item
Example 2 (Engine volume):
Refer to the pertinent engine manual.
3. Additional pages: Additional pages are indicated by a
hyphen (-) and numbered after the page number. File as in
the example.
Example:
10-4
10-4-1
Added pages
10-4-2
10-5
00-6
Remarks
Safety
Special safety precautions are

necessary when performing the
work.
Caution
Special technical precautions or

other precautions for preserving
standards are necessary when
performing the work.
Weight
Weight of parts or systems.

Caution necessary when selecting
hoisting wire or when working
posture is important, etc.
10 - 3
Item number (10. Structure and Function)
....) is
Tightening torque
Coat
Places that require special

attention for tightening torque
during assembly.
Places to be coated with adhesives
and lubricants etc.
Oil, water
Places where oil, water or fuel

must be added, and the capacity.
Drain
Places where oil or water must be

drained, and quantity to be
drained.
FOREWORD
HOISTING INSTRUCTIONS
HOISTING INSTRUCTIONS
HOISTING
Heavy parts (25 kg or more) must be lifted with a

hoist etc. In the DISASSEMBLY AND ASSEMBLY
section, every part weighing 25 kg or more is indicated
clearly with the symbol
If a part cannot be smoothly removed from the machine by

hoisting, the following checks should be made:
1) Check for removal of all bolts fastening the part to the
relative parts.
2) Check for existence of another part causing interface
with the part to be removed.
WIRE ROPES
1) Use adequate ropes depending on the weight of parts to
be hoisted, referring to the table below:
3)
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)
Wire ropes
(Standard "Z" or "S" twist ropes without galvanizing
Rope diameter (mm)
10.0
11.2
12.5
14.0
16.0
18.0
20.0
22.4
30.0
40.0
50.0
60.0
Allowable 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
Do not sling a heavy load with one rope alone, but sling
with two or more ropes symmetrically wound on to the
load.
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 (kg) when hoisting is made
with two ropes, each of which is allowed to sling up to
1000 kg vertically, at various hanging angles. When two
ropes sling a load vertically, up to 2000 kg of total weight
can be suspended. This weight becomes 1000 kg when
two ropes make a 120
r
hand, two ropes are subject to an excessive force as
large as 4000 kg if they sling a 2000 kg load at a lifting
angle of 150
The allowable load value is estimated to be 1/6 or 1/7 of

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

Slinging near the edge of the hook may cause the rope
to slip off the hook during hoisting, and a serious accident
can result. Hooks have maximum strength at the middle
portion.
00-7
FOREWORD
COATING MATERIALS
COATING MATERIALS
The recommended coating materials prescribed in the shop manuals are listed below.
Category
Code
Part No.
Qty
Container
LT-1A
790-129-9030
150 g
Tube
Used to prevent rubber gaskets, rubber cushions and cork plugs from
coming out
LT-1B
790-129-9050
20 g (x2)
Plastic
container
Used in places requiring an immediately effective, strong adhesive.

Used for plastics (except polyethylene, polypropylene,
tetrafluoroethylene, and vinyl chloride), rubber, metal and non-metal.
LT-2
09940-00030
50 g
Plastic
container
Features: Resistance to heat, chemicals

Used for anti-loosening and sealant purposes for bolts and plugs.
LT-3
790-129-9060
Set of adhesive
and hardening
agent
Adh 1 kg
Hard agt
500 kg
Can
LT-4
790-129-9040
250 g
Plastic
container
Loctite
648-50
79A-129-9110
50 cc
---
LG-1
790-129-9010
200 g
Tube
Used as adhesive or sealant for gaskets and packing of power train

case, etc.
Can
Features: Resistance to heat

Used as sealant for flange surfaces and bolts at high temperature
locations; used to prevent seizure.
Used as sealant for heat resistant gasket for at high temperature
locations such as engine pre-combustion chamber, exhaust pipe.
Features: Resistance to water, oil
Used as sealant for flange surface, thread.
Also possible to use as sealant for flanges with large clearance.
Used as sealant for mating surfaces of final drive case, transmission
case.
Adhesive
LG-3
790-129-9070
1 kg
Main applications, features
Used as adhesive or sealant for metal, glass or plastic.
Used as sealant for machined holes.

Features: Resistance to heat, chemicals
Used at joint portions subject to high temperature.
LG-4
790-129-9020
200 g
Tube
LG-5
790-129-9080
1 kg
Plastic
container
LG-6
09940-00011
250 g
Tube
Features: Silicon based, resistant to heat, cold.

Used as sealant for flange surface, thread.
Used as sealant for oil pan, final drive case, etc.
LG-7
09920-00150
150 g
Tube
Features: Silicon based, quick hardening type.

Used as sealant for flywheel housing, intake manifold, oil pan,
thermostat housing, etc.
Rust prevention
lubricant
---
09940-00051
60 g
Can
Used as lubricant for sliding parts (to prevent squeaking).
Molybdenum
disulfide lubricant
---
09940-00040
200 g
Tube
Used to prevent seizure or scuffing of the thread when press fitting or

shrink fitting.
Used as lubricant for linkage, bearings, etc.
G2-L1
SYG-350Ll
SYG-400Ll
SYG-400Ll-A
SYG-160Ll
SYGA-160CNLl
Various
Various
General purpose type
Calcium grease
G2-CA
SSG2-400CA
SYG2-350CA
SYG2-400CA-A
SYG2-160CA
SYGA-16CNCA
Various
Various
Used for normal temperature, light load bearing at places in contact

with water or steam.
Molybdenum
disulfide grease
---
SYG2-400M
400 g
(10/case)
Bellows type
Gasket sealant
Lithium grease
00-8
Used as sealant for various threads, pipe joints, flanges.

Used as sealant for tapered plugs, elbows, nipples of hydraulic
piping.
Used for places with heavy load.
FOREWORD
STANDARD TORQUE REQUIREMENTS

STANDARD TORQUE REQUIREMENTS OF BOLTS AND NUTS
The following charts give the standard torques values of bolts and nuts. Exceptions are given in sections of
DISASSEMBLY AND ASSEMBLY.
1 kgm = 9.806 Nm
Thread diameter of bolt
Width across flat
mm
mm
kgm
Nm
10
1.35 0.15
13.2 1.4
13
3.20 0.3
31.4 2.9
10
17
6.70 0.7
65.7 6.8
12
19
11.5 1.0
112 9.8
14
22
18 2.0
177 19
16
24
28.5 3
279 29
18
27
39 4
383 39
20
30
56 6
549 58
22
32
76 8
745 78
24
36
94.5 10
927 98
27
41
135 15
1320 140
30
46
175 20
1720 190
33
50
225 25
2210 240
36
55
280 30
2750 290
39
60
335 35
3280 340
This torque table does not apply to the bolts with which nylon packing or other non-ferrous metal washers are to
be used, or which require torquing to otherwise specified values.
00-9
FOREWORD
TORQUE REQUIREMENTS OF SPLIT FLANGE BOLTS

Use these torques values for split flange bolts.
Width across flat
torque requirement values
mm
mm
kgm
Nm
10
14
6.70 0.7
65.7 6.8
12
17
11.5 1.0
112 9.8
16
22
28.5 3
279 29
TORQUE REQUIREMENTS FOR FLARED NUTS

Use these torque values for flared part of nut.
Width across flat
mm
mm
kgm
Nm
14
19
2.5 0.5
24.5 4.9
18
24
5 2
49 19.6
22
27
8 2
78.5 19.6
24
32
14 3
137.3 29.4
30
36
18 3
176.5 29.4
33
41
20 5
196.1 49
36
46
25 5
245.2 49
42
55
30 5
294.2 49
00-10
torque requirement values
FOREWORD
ELECTRIC WIRE CODE
ELECTRIC WIRE CODE

In the wiring diagrams, various colors and symbols are employed to indicate the thickness of wires. This wire code
table will help you understand WIRING DIAGRAMS.
Example: 05WB indicates a cable having a nominal number 05 and white coating with black stripe.
CLASSIFICATION BY THICKNESS
Copper wire
Nominal
number
Cable
O.D. (mm)
Current rating
(A)
0.88
2.4
12
Starting, lighting, signal etc.
0.32
2.09
3.1
20
Lighting, signal etc.
65
0.32
5.23
4.6
37
Charging and signal
15
84
0.45
13.36
7.0
59
Starting (Glow plug)
40
85
0.80
42.73
11.4
135
Starting
60
127
0.80
63.84
13.6
178
Starting
100
217
0.80
109.1
17.6
230
Starting
Number of
strands
Dia. Of strand
(mm)
Cross section (mm)
0.85
11
0.32
26
Applicable circuit
CLASSIFICATION BY COLOR AND CODE

Priority
Classification
Primary
Circuits
Charging
Ground
Starting
Lighting
Instruments
Signal
Other
Code
Color
White
Black
Black
Red
Yellow
Green
Blue
Code
WR
---
BW
RW
YR
GW
LW
Color
White/Red
---
Black/White
Red/White
Yellow/Red
Green/White
Blue/White
Code
WB
---
BY
RB
YB
GR
LR
Color
White/Black
---
Black/Yellow
Red/Black
Yellow/Black
Green/Red
Blue/Red
Code
WL
---
BR
RY
YG
GY
LY
Color
White/Blue
---
Black/Red
Red/Yellow
Yellow/Green
Green/Yellow
Blue/Yellow
Code
WG
---
---
RG
YL
GB
LB
Color
White/Green
---
---
Red/Green
Yellow/Blue
Green/Black
Blue/Black
Code
---
---
---
RL
YW
GL
---
Color
---
---
---
Red/Blue
Yellow/White
Green/Blue
---
Auxiliary
00-11
FOREWORD
CONVERSION TABLES
CONVERSION TABLES
METHOD OF USING THE CONVERSION TABLE
The Conversion Table in this section is provided to enable simple conversion of figures. For details of the method of
using the Conversion Table, see the example given below.
EXAMPLE
Method of using the Conversion Table to convert from millimeters to inches.
1. Convert 55 mm into inches.
(1) Locate the number 50 in the vertical column at the left side, take this as , then draw a horizontal line from
.
(2) Locate the number 5 in the row across the top, take this as , then draw a perpendicular line down from .
(3) Take the point where the two lines cross as . This point gives the value when converting from millimeters
to inches. Therefore, 55 millimeters = 2.165 inches.
2. Convert 550 mm into inches.
(1) The number 550 does not appear in the table, so divide by 10 (move the decimal one place to the left) to
convert it to 55 mm.
(2) Carry out the same procedure as above to convert 55 mm to 2.165 inches.
(3) The original value (550 mm) was divided by 10, so multiply 2.165 inches by 10 (move the decimal one place
to the right) to return to the original value. This gives 550 mm = 21.65 inches.
Millimeters to Inches
1 mm = 0.03937 in
mm
0.039
0.079
0.118
0.157
0.197
0.236
0.276
0.315
0.354
10
0.394
0.433
0.472
0.512
0.551
0.591
0.630
0.669
0.709
0.748
20
0.787
0.827
0.866
0.906
0.945
0.984
1.024
1.063
1.102
1.142
30
1.181
1.220
1.260
1.299
1.339
1.378
1.417
1.457
1.496
1.536
40
1.575
1.614
1.654
1.693
1.732
1.772
1.811
1.850
1.890
1.929
50
1.969
2.008
2.047
2.087
2.126
2.165
2.244
2.283
2.323
60
2.362
2.402
2.441
2.480
2.520
2.559
2.205
2.598
2.638
2.677
2.717
2.953
2.992
3.032
3.071
3.110
3.346
3.386
3.425
3.465
3.504
3.740
3.780
3.819
3.858
3.898
70
80
90
00-12
2.756
3.150
3.543
2.795
3.189
3.583
2.835
3.228
3.622
2.874
3.268
3.661
2.913
3.307
3.701
FOREWORD
CONVERSION TABLES
Millimeters to Inches
1 mm = 0.03937 in
mm
0.039
0.079
0.118
0.157
0.197
0.236
0.276
0.315
0.354
10
0.394
0.433
0.472
0.512
0.551
0.591
0.630
0.669
0.709
0.748
20
0.787
0.827
0.866
0.906
0.945
0.984
1.024
1.063
1.102
1.142
30
1.181
1.220
1.260
1.299
1.339
1.378
1.417
1.457
1.496
1.536
40
1.575
1.614
1.654
1.693
1.732
1.772
1.811
1.850
1.890
1.929
50
1.969
2.008
2.047
2.087
2.126
2.165
2.205
2.244
2.283
2.323
60
2.362
2.402
2.441
2.480
2.520
2.559
2.598
2.638
2.677
2.717
70
2.756
2.795
2.835
2.874
2.913
2.953
2.992
3.032
3.071
3.110
80
3.150
3.189
3.228
3.268
3.307
3.346
3.386
3.425
3.465
3.504
90
3.543
3.583
3.622
3.661
3.701
3.740
3.780
3.819
3.858
3.898
Kilogram to Pound
1 kg = 2.2046 lb
kg
2.20
4.41
6.61
8.82
11.02
13.23
15.43
17.64
19.84
10
22.05
24.25
26.46
28.66
30.86
33.07
35.27
37.48
39.68
41.89
20
44.09
46.30
48.50
50.71
51.91
55.12
57.32
59.53
61.73
63.93
30
66.14
68.34
70.55
72.75
74.96
77.16
79.37
81.57
83.78
85.98
40
88.18
90.39
92.59
94.80
97.00
99.21
101.41
103.62
105.82
108.03
50
110.23
112.44
114.64
116.85
119.05
121.25
123.46
125.66
127.87
130.07
60
132.28
134.48
136.69
138.89
141.10
143.30
145.51
147.71
149.91
152.12
70
154.32
156.53
158.73
160.94
163.14
165.35
167.55
169.76
171.96
174.17
80
176.37
178.57
180.78
182.98
185.19
187.39
189.60
191.80
194.01
196.21
90
198.42
200.62
202.83
205.03
207.24
209.44
211.64
213.85
216.05
218.26
00-13
FOREWORD
CONVERSION TABLES
Liter to U.S. Gallon

1
0
0.264
0.528
0.793
1.057
1.321
1.585
1.849
2.113
2.378
10
2.642
2.906
3.170
3.434
3.698
3.963
4.227
4.491
4.755
5.019
20
5.283
5.548
5.812
6.076
6.340
6.604
6.869
7.133
7.397
7.661
30
7.925
8.189
8.454
8.718
8.982
9.246
9.510
9.774
10.039
10.303
40
10.567
10.831
11.095
11.359
11.624
11.888
12.152
12.416
12.680
12.944
50
13.209
13.473
13.737
14.001
14.265
14.529
14.795
15.058
15.322
15.586
60
15.850
16.115
16.379
16.643
16.907
17.171
17.435
17.700
17.964
18.228
70
18.492
18.756
19.020
19.285
19.549
19.813
20.077
20.341
20.605
20.870
80
21.134
21.398
21.662
21.926
22.190
22.455
22.719
22.983
23.247
23.511
90
23.775
24.040
24.304
24.568
24.832
25.096
25.361
25.625
25.889
26.153
Liter to U.K. Gallon

1
0
0.220
0.440
0.660
0.880
1.100
1.320
1.540
1.760
1.980
10
2.200
2.420
2.640
2.860
3.080
3.300
3.520
3.740
3.950
4.179
20
4.399
4.619
4.839
5.059
5.279
5.499
5.719
5.939
6.159
6.379
30
6.599
6.819
7.039
7.259
7.479
7.699
7.919
8.139
8.359
8.579
40
8.799
9.019
9.239
9.459
9.679
9.899
10.119
10.339
10.559
10.778
50
10.998
11.281
11.438
11.658
11.878
12.098
12.318
12.528
12.758
12.978
60
13.198
13.418
13.638
13.858
14.078
14.298
14.518
14.738
14.958
15.178
70
15.398
15.618
15.838
16.058
16.278
16.498
16.718
16.938
17.158
17.378
80
17.598
17.818
18.037
18.257
18.477
18.697
18.917
19.137
19.357
19.577
90
19.797
20.017
20.237
20.457
20.677
20.897
21.117
21.337
21.557
21.777
00-14
FOREWORD
CONVERSION TABLES
kgm to ft. lb
1 kgm = 7.233 ft. lb
kgm
7.2
14.5
21.7
28.9
36.2
43.4
50.6
57.9
65.1
10
72.3
79.6
86.8
94.0
101.3
108.5
115.7
123.0
130.2
137.4
20
144.7
151.9
159.1
166.4
173.6
180.8
188.1
195.3
202.5
209.8
30
217.0
224.2
231.5
238.7
245.9
253.2
260.4
267.6
274.9
282.1
40
289.3
296.6
303.8
311.0
318.3
325.5
332.7
340.0
347.2
354.4
50
361.7
368.9
376.1
383.4
390.6
397.8
405.1
412.3
419.5
426.8
60
434.0
441.2
448.5
455.7
462.9
470.2
477.4
484.6
491.8
499.1
70
506.3
513.5
520.8
528.0
535.2
542.5
549.7
556.9
564.2
571.4
80
578.6
585.9
593.1
600.3
607.6
614.8
622.0
629.3
636.5
643.7
90
651.0
658.2
665.4
672.7
679.9
687.1
694.4
701.6
708.8
716.1
100
723.3
730.5
737.8
745.0
752.2
759.5
766.7
773.9
781.2
788.4
110
795.6
802.9
810.1
817.3
824.6
831.8
839.0
846.3
853.5
860.7
120
868.0
875.2
882.4
889.7
896.9
904.1
911.4
918.6
925.8
933.1
130
940.3
947.5
954.8
962.0
969.2
976.5
983.7
990.9
998.2
1005.4
140
1012.6
1019.9
1027.1
1034.3
1041.5
1048.8
1056.0
1063.2
1070.5
1077.7
150
1084.9
1092.2
1099.4
1106.6
1113.9
1121.1
1128.3
1135.6
1142.8
1150.0
160
1157.3
1164.5
1171.7
1179.0
1186.2
1193.4
1200.7
1207.9
1215.1
1222.4
170
1129.6
1236.8
1244.1
1251.3
1258.5
1265.8
1273.0
1280.1
1287.5
1294.7
180
1301.9
1309.2
1316.4
1323.6
1330.9
1338.1
1345.3
1352.6
1359.8
1367.0
190
1374.3
1381.5
1388.7
1396.0
1403.2
1410.4
1417.7
1424.9
1432.1
1439.4
00-15
FOREWORD
CONVERSION TABLES
kg/cm to lb/in
1kg/cm = 14.2233 lb/in
kg/cm
14.2
28.4
42.7
56.9
71.1
85.3
99.6
113.8
128.0
10
142.2
156.5
170.7
184.9
199.1
213.4
227.6
241.8
256.0
270.2
20
284.5
298.7
312.9
327.1
341.4
355.6
369.8
384.0
398.3
412.5
30
426.7
440.9
455.1
469.4
483.6
497.8
512.0
526.3
540.5
554.7
40
568.9
583.2
597.4
611.6
625.8
640.1
654.3
668.5
682.7
696.9
50
711.2
725.4
739.6
753.8
768.1
782.3
796.5
810.7
825.0
839.2
60
853.4
867.6
881.8
896.1
910.3
924.5
938.7
953.0
967.2
981.4
70
995.6
1010
1024
1038
1053
1067
1081
1095
1109
1124
80
1138
1152
1166
1181
1195
1209
1223
1237
1252
1266
90
1280
1294
1309
1323
1337
1351
1365
1380
1394
1408
100
1422
1437
1451
1465
1479
1493
1508
1522
1536
1550
110
1565
1579
1593
1607
1621
1636
1650
1664
1678
1693
120
1707
1721
1735
1749
1764
1778
1792
1806
1821
1835
130
1849
1863
1877
1892
1906
1920
1934
1949
1963
1977
140
1991
2005
2020
2034
2048
2062
2077
2091
2105
2119
150
2134
2148
2162
2176
2190
2205
2219
2233
2247
2262
160
2276
2290
2304
2318
2333
2347
2361
2375
2389
2404
170
2418
2432
2446
2460
2475
2489
2503
2518
2532
2546
180
2560
2574
2589
2603
2617
2631
2646
2660
2674
2688
190
2702
2717
2731
2745
2759
2773
2788
2802
2816
2830
200
2845
2859
2873
2887
2901
2916
2930
2944
2958
2973
210
2987
3001
3015
3030
3044
3058
3072
3086
3101
3115
220
3129
3143
3158
3172
3186
3200
3214
3229
3243
3257
230
3271
3286
3300
3314
3328
3343
3357
3371
3385
3399
240
3414
3428
3442
3456
3470
3485
3499
3513
3527
3542
00-16
FOREWORD
CONVERSION TABLES
Temperature
Fahrenheit Centigrade Conversion; a simple way to convert a Fahrenheit temperature reading into a Centigrade temperature reading or vise versa is
to enter the accompanying table in the center or boldface column of figures. These figures refer to the temperature in either Fahrenheit or Centigrade
degrees. If it is desired to convert from Fahrenheit to Centigrade degrees, consider the center column as a table of Fahrenheit temperatures and read
the corresponding Centigrade temperature in the column at the left. If it is desired to convert from Centigrade to Fahrenheit degrees, consider the
center column as a table of Centigrade values, and read the corresponding Fahrenheit temperature on the right.
-40.4
-37.2
-34.4
-31.7
-28.9
-40
-35
-30
-25
-20
-40.0
-31.0
-22.0
-13.0
-4.0
-11.7
-11.1
-10.6
-10.0
-9.4
11
12
13
14
15
51.8
53.6
55.4
57.2
59.0
7.8
8.3
8.9
9.4
10.0
46
47
48
49
50
114.8
116.6
118.4
120.2
122.0
27.2
27.8
28.3
28.9
29.4
81
82
83
84
85
117.8
179.6
181.4
183.2
185.0
-28.3
-27.8
-27.2
-26.7
26.1
-19
-18
-17
-16
-15
-2.2
-0.4
1.4
3.2
5.0
-8.9
-8.3
-7.8
-7.2
-6.7
16
17
18
19
20
60.8
62.6
64.4
66.2
68.0
10.6
11.1
11.7
12.2
12.8
51
52
53
54
55
123.8
125.6
127.4
129.2
131.0
30.0
30.6
31.1
31.7
32.2
86
87
88
89
90
186.8
188.6
190.4
192.2
194.0
-25.6
-25.0
-24.4
-23.9
-23.3
-14
-13
-12
-11
-10
6.8
8.6
10.4
12.2
14.0
-6.1
-5.6
-5.0
-4.4
-3.9
21
22
23
24
25
69.8
71.6
73.4
75.2
77.0
13.3
13.9
14.4
15.0
15.6
56
57
58
59
60
132.8
134.6
136.4
138.2
140.0
32.8
33.3
33.9
34.4
35.0
91
92
93
94
95
195.8
197.6
199.4
201.2
203.0
-22.8
-22.2
-21.7
-21.1
-20.6
-9
-8
-7
-6
-5
15.8
17.6
19.4
21.2
23.0
-3.3
-2.8
-2.2
-1.7
-1.1
26
27
28
29
30
78.8
80.6
82.4
84.2
86.0
16.1
16.7
17.2
17.8
18.3
61
62
63
64
65
141.8
143.6
145.4
147.2
149.0
35.6
36.1
36.7
37.2
37.8
96
97
98
99
100
204.8
206.6
208.4
210.2
212.0
-20.0
-19.4
-18.9
-18.3
-17.8
-4
-3
-2
-1
0
24.8
26.6
28.4
30.2
32.0
-0.6
0
0.6
1.1
1.7
31
32
33
34
35
87.8
89.6
91.4
93.2
95.0
18.9
19.4
20.0
20.6
21.1
66
67
68
69
70
150.8
152.6
154.4
156.2
158.0
40.6
43.3
46.1
48.9
51.7
105
110
115
120
125
221.0
230.0
239.0
248.0
257.0
-17.2
-16.7
-16.1
-15.6
-15.0
1
2
3
4
5
33.8
35.6
37.4
39.2
41.0
2.2
2.8
3.3
3.9
4.4
36
37
38
39
40
96.8
98.6
100.4
102.2
104.0
21.7
22.2
22.8
23.3
23.9
71
72
73
74
75
159.8
161.6
163.4
165.2
167.0
54.4
57.2
60.0
62.7
65.6
130
135
140
145
150
266.0
275.0
284.0
293.0
302.0
-14.4
-13.9
-13.3
-12.8
-12.2
6
7
8
9
10
42.8
44.6
46.4
48.2
50.0
5.0
5.6
6.1
6.7
7.2
41
42
43
44
45
105.8
107.6
109.4
111.2
113.0
24.4
25.0
25.6
26.1
26.7
76
77
78
79
80
168.8
170.6
172.4
174.2
176.0
68.3
71.1
73.9
76.7
79.4
155
160
165
170
175
311.0
320.0
329.0
338.0
347.0
00-17
FOREWORD
00-18
MEMORANDA
01
GENERAL
DIMENSIONS
. . . . . . 01-2
.............................
SPECIFICATIONS
.........................
WEIGHT TABLE ...........................

FUEL, COOLANT
AND LUBRICANTS
..............
ENGINE OIL SPECIFICATIONS

TRANSMISSION,
HYDRAULIC,
.................
DIESEL FUEL SPECIFICATIONS

COOLANT
SPECIFICATIONS
AND BRAKE OIL

................
AXLE OIL SPECIFICATIONS

GREASE SPECIFICATIONS
.........
.............
................
.....
01-4
.....
01-7
.....
01-8
. . . . . . 01-9
. . . . 01-10
. . . . . 01-10
. . . . . 01-10
. . . . 01-10
. . . . . 01-10
01-I
GENERAL
DIMENSIONS
With General Purpose Bucket

4.3 m3 (5.6 yd3)
With Excavating Bucket

4.0 m3 (5.2 yd3)
With Spade Nose Rock

Bucket 4.0 m3 (5.2 yd3)
26.5 x 25 Tires
29.5 x 25 Tires
26.5 x 25 Tires
29.5 x 25 Tires
26.5 x 25 Tires
29.5 x 25
Tread
2.4 m
(7 ft 10 in)
2.4 m
(7 ft 10 in)
2.4 m
(7ft 10 in)
2.4 m
(7 ft 10 in)
2.4 m
(7ft 10 in)
2.4 m
(7 ft IO in)
Width over tires
3.1 m
(10 ft 2 in)
3.2 m
(lOft6in)
3.1 m
(IO ft 2 in)
3.2 m
(lOft6in)
3.1 m
(lOft2in)
3.2 m
(lOft6in)
Wheelbase
3.5 m
(11 ft8 in)
3.5 m
(11 ft 8 in)
3.5 m
(11 ft 8 in)
(113.5
ft 8m in)
iiiixz
Hinge pin height

- maximum
4.3 m
(14 ft 5 in)
4.4 m
(14 ft 7 in)
4.3 m
(14 ft 5 in)
4.4 m
(14 ft 7 in)
4.3 m
(14 ft 5 in)
4.4 m
(14 ft 7 in)
Hinge pin height

- carry position
0.54 m
(1 ft 9 in)
0.59 m
(1 ft 11 in)
0.54 m
(1 ft 9 in)
0.59 m
(1 ft 11 in)
0.54 m
(1 ft 9 in)
0.59 m
(1 ft 11 in)
Ground
clearance
0.44 m
(1 ft 5 in)
0.49 m
(1 ft 7 in)
0.44 m
(1 ft 5 in)
0.49 m
(1 R 7 in)
0.44 m
(1 ft 5 in)
0.49 m
(1 ft 7 in)
Hitch height
1.13 m
(3 ft 9 in)
1.18 m
(3ft 11 in)
1.13m
(3 ft 9 in)
1.18 m
(3 ft 11 in)
1.13 m
(3 ft 9 in)
1.18 m
(3ft 11 in)
01-2
DIMENSIONS
GENERAL
With General Purpose Bucket
4.3 m3 (5.6 yd3)
Overall height to
top of exhaust
With Excavating Bucket

4.0 m3 (5.2 yd3)
With Spade Nose Rock

Bucket 4.0 m3 (5.2 yd3)
26.5 x 25 Tires
29.5 x 25 Tires
26.5 x 25 Tires
29.5 x 25 Tires
26.5 x 25 Tires
29.5 x 25
Tires
3.63 m
(11 ft 11 in)
3.68 m
(12 ft 1 in)
3.63 m
(11 ftll
in)
3.68 m
(12 ft 1 in)
3.63 m
(11 ft 11 in)
3.68 m
(12 ft 1 in)
3.94 m
(12ft 11 in)
3.89 m
(12 ft 9 in)
3.94 m
(12ft 11 in)
3.89 m
(12 ft 9 in)
3.94 m
(12 ft 11 in)
3.27 m
(loftgin)
3.32 m
(lot? 11 in)
3.11 m
(lOft2in)
pipe
G
Overall height to
top of ROPS
canopy
3.89 m
(12 ft 9 in)
Dumping
clearance at
maximum height
& 45 dump
angle
3.21 m
(lOft7in)
3.27 m
(lOftgin)
3.16 m
(10 ft 4 in)
Reach @ 2.13 m
(7 ft) cutting
edge clearance
8 45 dump
angle
2.03 m
(6 ft 8 in)
1.98m
(6 ft 6 in)
1.99 m
(6 ft 7 in)
1.94m
(6 ft 5 in)
2.08 m
(6 ft 10 in)
2.03 m
(6 ft 8 in)
Reach @
maximum height
& 45dump
angle
1.37 m
(4 ft 6 in)
1.32 m
(4 ft 4 in)
1.32 m
(4 ft 4 in)
1.27 m
(4 ft 2 in)
1.46 m
(4 ft 10 in)
1.41 m
(4 ft 8 in)
Reach with lift

arm horizontal &
bucket level
2.81 m
(9 ft 3 in)
2.76 m
(9 ft 1 in)
2.73 m
(8 ft 11 in)
2.68 m
(8 ft 10 in)
2.95 m
(9 ft 8 in)
2.90 m
(9 ft 6 in)
6.07 m
(19ft 11 in)
6.13 m
(20 ft 2 in)
6.18 m
(20 ft 4 in)
6.21 m
(20 ft 5 in)
6.26 m
(20 ft 7 in)
Operating height
- fully raised
6.02 m
(19ft9in)
Overall length
8.97 m
(29 ft 5 in)
8.93 m
(29 ft 4 in)
8.89 m
(29 ft 2 in)
8.85 m
(29 rT 1 in)
9.12 m
(29 ft 11 in)
9.08 m
(29 ft 10 in)
Loader clearance
circle at outside
corner of bucket
& bucket in carry
position
14.39 m
(47 ft 3 in)
14.39 m
(47 ft 3 in)
14.35 m
(47 ft 1 in)
14.35 m
(47 ft 1 in)
14.35 m
(47 ft 1 in)
14.35 m
(47 ft 1 in)
Digging depth at
0
0.175 m
(6.9 in)
0.125 m
(4.9 in)
0.115 m
(4.5 in)
0.065 m
(2.6 in)
0.125 m
(4.9 in)
0.075 m
(3.0 in)
Digging depth at
IO
0.460 m
(1 ft 6 in)
0.410 m
(1 ft 4 in)
0.330 m
(1 ft 1 in)
0.290 m
(11.4 in)
0.385 m
(1 ft 3 in)
0.330 m
(1 ft 1 in)
NOTICE:
All specifications
are subject to change without notice.
01-3
GENERAL
SPECIFICATIONS
SPECIFICATIONS
Machine model
WA500-3L
Serial number
.o,
Operating weight
Distribution (front)
Distribution (rear)
A70001 and up
28,430 kg (63,711 lb)
13,120 kg
15,310 kg
Bucket capacity (piled)

Rated load
4.3 m3 (5.6 yd3)

75.9 kN (7,740 kg)
Travel speed:
FORWARD
FORWARD
FORWARD
FORWARD
REVERSE
REVERSE
REVERSE
REVERSE
1st
2nd
3rd
4th
1st
2nd
3rd
4th
7.1 km/h (4.4 mph)

12.6 km/h (7.8 mph)
21.2 km/h (13.2 mph)
34.8 km/h (21.6 mph)
7.9 km/h (4.9 mph)
14.1 km/h (8.8 mph)
23.5 km/h (14.6 mph)
38.1 km/h (23.7 mph)
Grade-ability
25 deg
Turning radius (bucket at carry - outside corner of

bucket)
7390 mm (24 ft 3 in)
Overall length
9320 mm (30 ft 6 in)
Overall width (Chassis)
3,190mm(10ft5in)
Bucket width (with bolt on cutting edge)
3460 mm (11 ft 4 in)
Overall height (top of cab)
3860 mm (12 ft 7 in)
Overall height (bucket raised)
6115 mm (20 ft 1 in)
Wheelbase
3600mm(11ft10in)
Tread
2400 mm (7 ft 10 in)
Minimum ground clearance
450 mm (1 ft 5 in)
Height of bucket hinge pin
4500 mm (14 ft 8 in)
Dumping clearance
Dumping
reach
(tip of cutting
(tip of cutting
edge)
3335 mm (10 ft 9 in)

1255mm4ftl
Bucket dump angle
45 deg
Bucket tilt angle (SAE carrying position)
48 deg
Digging depth (10 dump angle)
01-4
edge)
in)
425 mm (1.4 in)
GENERAL
SPECIFICATIONS
Machine
model
WA500-3L
Serial number
A70001 and up
Model
Cummins NTA14C diesel engine

4-cycle, water cooled, direct injection, turbocharged
Type
No. of cylinders - bore x stroke
6 - 140 mm (5.5) x 152 mm (5.9)
Piston displacement
14 Q(855 ins) (14,000 cc)
Gross power @ 2100 rpm

Maximum
torque (gross) @ 1500 rpm

High idle
Low idle
Fuel consumption
ratio
Torque converter
908 N*m (670 Ibf ft)
220 g/kW lh (164 g/HP*h)

24V, 25 kW
24V, 70A
12V, 170Ahx2
3-element, single-stage, single-phase
(TCA40-1 C)
Transmission
Planetary gear, constant-mesh multiple-disc,

hydraulic actuated, modulation type
Reduction gear
Spiral bevel gear, splash lubrication
Differential
Straight bevel gear
Final drive
planetary gear, single stage, splash lubrication

Drive type
Front I rear wheel drive
Front axle
Fixed frame full-floating type
Rear axle
Center pin support full-floating type
Tire
(315 HP)
2300 rpm
760 rpm
Starting motor
Alternator
Battery
9E
235kW
29.525-22pr
tubeless (L3)
Wheel rim
25.00 x 25 WTB
Inflation pressure Front tire
4.5 kg/cm2 (64.0 psi) (440 kPa)
Inflation pressure Rear tire
3.5 kg/cm* (49.8 psi) (340 kPa)
Service brakes
Front I rear wheel braking, separate front/rear wheel, wet disc,

hydraulically actuated
Parking brake
Drive shaft, wet type disc brake

Hydraulically released spring type
01-5
GENERAL
SPECIFICATIONS
Machine model
WA500-3L
Serial number
A70001 and
Type
Articulated
Structure
pump
135 P (Gear type: SAR(3) - 63)
Steering pump
172e (Gear type: SAR(3) - 80)
PPC pump
6OP (Gear type: SAR(1)
Set pressure for steering
Boom cylinder
Bucket cylinder
Steering cylinder
stroke
Bucket edge type
01-6
348 P (Gear type: SAR(4) - 160)
Switch pump
Set pressure for work equipment
Linkage type
steering
Fully hydraulic power steering
Work equipment
Hydraulic
Pump
Delivery
UD
qty. - bore x stroke

qty. - bore x stroke
qty. - bore x
Spool type
20.58 Mpa
Orbit-roll valve type
- 28)
(210 kg/cm*)
20.58 Mpa
210 kg/cm2)
Reciprocating
piston 2-200 x 839 (mm)
Reciprocating
piston l-225 x 613 (mm)
Reciprocating
piston 2 - 110 x 486 (mm)
Single link (Z-bar linkage)

Flat edge with bolt on cutting edge
GENERAL
WEIGHT TABLE
WEIGHT TABLE
This weight table is a guide for use when transporting
Machine
model
Serial No.
I
I
Engine
WA500-3LE
723 lb (328 kg)
Transmission
converter
with torque
Machine
A70001 and UQ
3,038 lb (1,378 kg)
Radiator
or handling components.
2,524 lb (1,145 kg)
Upper drive shaft
40 lb (18 kg)
Center drive shaft
73 lb (33 kg)
Front drive shaft
99 lb (45 kg)
Rear drive shaft
86 lb (41 kg)
Center support
93 lb (42 kg)
Front axle assembly
4,277 lb (1,940 kg)
Rear axle assembly
I 4,138 lb (1,877kg)
Axle pivot (Rear axle)
114 lb (251 kg)
Tire and wheel (each)
1,740 lb (789 kg)

591 lb (268 kg)
Tire (each)
1,149 lb (521 kg)
Serial No.
Hydraulic
WA500-3L
A70001 and up
I
1
Hydraulic tank
pump
507 lb (230 kg)

45 lb (20.3 kg)
Switch and PPC pump
42 lb (19 kg)
Steering pump
27 lb (12.2 kg)
PPC valve
8 lb (3.5 kg)
Main control valve
199 lb (90 kg)
Steering cylinder (each)
104 lb (47 kg)
Boom cylinder (each)
600 lb (272 kg)
Rear frame
1 4.817 lb (2,185 kg)
Bucket link
234 lb (106 kg)
Bellcran k
1,151 lb (522 kg)
Boom including
Wheel (each)
model
bushings
4,449 lb (2,018 kg)

I
Bucket with bolt on cutting

edge
Counterweight
1 4,954 lb (2,247 kg)
5,997 lb (2,720 kg)
Front differential
assembly
591 lb (268 kg)
Fuel tank
670 Ib(213 kg)
Rear differential
assembly
612 lb (278 kg)
Battery (each)
117 lb (53 kg)
137 lb (62 kg)
Floor, dash, console
472 lb (214 kg)
227 lb (103 kg)
Cab (ROPS)
661 lb (300 kg)
52 lb (23.5 kg)
Air conditioner
117 lb (53 kg)
Planetary carrier (each)

Planetary
hub (each)
I
Brake valve (Tandem)
I
I
I
Brake valve (Single)
Steering valve
Orbit-roll valve
12 lb (5.3 kg)
Operators seat
unit
88 lb (40 kg)
19 lb (8.5 kg)
12 lb (5.3 kg)
01-7
GENERAL
FUEL, COOLANT AND LUBRICANTS
COOLANT, AND LUBRICANTS

RESERVOIR
FLUID
-22
-30
TYPE
Engine with filter
-4
-20
AMBIENT TEMPERATURE
86
32
50
68
14
30
0
10
20
-10
SAE 15W-40
Engine oil
See
NOTE 1
SAE low-30
Hydraulic system
I
Engine oil
See
NOTE 2
Refill
42 e
11.1 gal
36 P
9.5 gal
70 P
18.5 gal
62 e
16.4 ga
284P
75.0 gal
1751
46.2 ga
78 P
20.6 gal
each
78 e
20.6 ga
each
I
SAE tOW
I
SAE 5W-20
Specified
SAE 30W
SAE 1ow
122F
59C
Synthetic SAE 5W-30
Torque converter, Transmission,

Transfer case
& Oil cooler
CAPACITY
104
40
1
1
Drive axles Front & rear
Axle oil
411lubrication
%tings
Grease
See NOTE 4
Fill as
instructed
--
=uel tank
Diesel fuel
See NOTE 5
465 e
122.8 gal
--
Cooling system
Coolant
See NOTE 6
83~
21.9 gal
--
API:
ASTM:
SAE:
See NOTE 3
American Petroleum Institute

American Society of Testing and Material
Society of Automotive Engineers
Specified capacity: Total amount of oil including oil for components and oil in piping.
Refill capacity: Amount of oil needed to refill system during normal inspection and maintenance.
01-8
GENERAL
NOTES:
1. ENGINE OIL
Normal Operation
Oil performance
recommendations
are as follows:
The use of a high quality engine lubricating oil combined with appropriate oil and filter change intervals are critical
factors in maintaining engine performance and durability.
SAE 15W-40 multi-viscosity heavy duty engine oil meeting the American
classification of CF-4 or CG-4 is recommended.
Petroleum
Institute (API) performance
NOTE: CE oil may be used in areas where CF-4 or CG-4 oil is not yet available.
A sulfated ash content of 1.O mass percent is suggested for optimum valve and piston deposit and oil consumption
control. The sulfated ash must not exceed 1.85 mass percent. The sulfated ash limit of 1.85 mass percent has
been placed on all engine lubricating oils recommended for use in the engine. Higher ash oils can cause valve
and/or piston damage and lead to excessive oil consumption.
The API service symbol displays the following information. The upper half of the symbol displays the appropriate
oil categories; the lower half may contain words to describe oil energy conserving features. The center section
identifies the SAE oil viscosity grade.
Oil viscosity
recommendations
are as follows:
The use of a multi-graded lubricating oil has been found to improve oil consumption control and improve engine
cranking in cold temperatures while maintaining lubrication at high operating temperatures.
While SAE 15W-40 multi-viscosity oil is recommended
oil viscosity recommendations
for extreme climates.
for most operating climates, refer to the previous table for
Limited use of low viscosity oils, such as SAE 1OW-30 may be used for easier starting and providing sufficient oil
flow at ambient temperatures below -5C (+23F). However, continuous use of low viscosity oils can decrease
engine life due to wear.
Special break-in lubricating oils are not recommended
during the break-in as specified for normal operation.
for a new or rebuilt engine. Use the same type of oil
Additional information regarding lubricating oil availability throughout the world is available in the E.M.A.
Lubricating Oils Data Book for Heavy Duty Automotive and Industrial Engines. The data book may be ordered
from the Engine Manufacturers Association, One Illinois Center, 111 East Wacker Drive, Chicago, IL U.S.A.
60601. The telephone number is (312) 644-6610.
Arctic Operation
If an engine is operated in ambient temperatures consistently below -23C (-10F) and there are no provisions to keep
the engine warm when it is not in operation, use a synthetic API performance classification CE/SF engine oil with
adequate low temperature properties such as SAE 5W-20 or 5W-30.
The oil supplier must be responsible
for meeting the performance
service specifications.
IMPORTANT: The use of a synthetic base oil does not justify extended oil change intervals.
intervals can decrease engine life due to factors such as; corrosion, deposits and wear.
Extended
oil change
01-9
GENERAL
2. TRANSMISSION,
HYDRAULIC
Use API performance
classification
SYSTEM AND BRAKE SYSTEM
OIL
CE engine oil.
When using SAE 5W-20 engine oil in the work equipment

the cold season ends.
hydraulic system in cold areas, return to SAE 1OW when
3. AXLE OIL
For axle oil, use only the recommended
SHELL:
CALTEX:
CHEVRON:
TEXACO:
MOBIL:
j,
oil as follows:
DONAX lT or TD
RPM TRACTOR HYDRAULIC FLUID
TRACTOR HYDRAULIC FLUID
TDH OIL
MOBIL AND SUPER UNIVERSAL
It is possible to substitute engine oil SAE 30W API classification

may result, durability should not be affected.
CD for axle oil. Although
increased
brake noise
4. GREASE
The recommended
lubricating grease is No. 2 multi-purpose
lithium grease with 3% molybdenum
disulfide.
5. DIESEL FUEL
WARNING!
Do not mix gasoline or alcohol with diesel fuel. This mixture can cause an explosion.
IMPORTANT: Due to the precise tolerances of diesel injection systems, it is extremely important that the fuel be kept
clean and free of dirt or water. Dirt or water in the system can cause severe damage to both the injection pump and
nozzles.
For normal service above -12C (+lOF), the use of ASTM Grade No. 2-D diesel fuel with a minimum Cetane number
of 40 is recommended. The use of No. 2-D diesel fuel will result in optimum engine performance under most operating
conditions. Fuels with Cetane numbers higher than 40 may be needed in high altitudes or extremely low ambient
temperatures to prevent misfires and excessive smoke.
At operating temperatures
reduce fuel economy.
below -12C (+lOF), use ASTM Grade No. I-D diesel fuel. The use of lighter fuels can
Where a winterized blend of Grade No. 2-D and No. I-D fuels is available, it may be substituted for Grade No. I-D
fuel. However, it is the suppliers responsibility to provide the fuel for the anticipated ambient temperature.
Use a low sulfur content fuel having a cloud point that is at least 10 degrees below the lowest expected
temperature. Cloud point is the temperature at which crystals begin to form in the fuel.
The viscosity
fuel
of the fuel must be kept above 1.3 cSt at 100C (212F) to provide adequate fuel system lubrication.
6. COOLANT
General
Selection and maintenance of the engine coolant is important to long engine life. The following information provides
recommendations
for selecting the engine coolant and maintaining the supplemental coolant additive (SCA).
01-10
GENERAL
Heavy duty diesel engines require a balanced coolant mixture of water, antifreeze, and supplemental coolant additive.
Supplemental coolant additive recommendations are included in the section entitled Supplemental Coolant Additive.
The coolant mixture must be drained and replaced at the specified service interval shown in the SCHEDULED
MAINTENANCE
GUIDE or every two years of operation, whichever comes first.
Water
Use water which has a low mineral content. Water used in conjunction
water must meet the following standards:
with antifreeze,
coolant filters and inhibited
Total Hardness - Not to exceed 170 parts per million (10 grains/gallon maximum) to prevent scale deposits. Water
containing dissolved magnesium and calcium (the usual reason for water hardness) above the specified amount
will cause scale deposits to develop in the engine.
Chlorides
- Not to exceed 40 parts per million (2.5 grains/gallon
Sulfites - Not to exceed 100 parts per million (5.8 grains/gallon
maximum)
maximum)
Dissolved Solids - Not to exceed 340 parts per million (20 grains/gallon
scale deposits, corrosion or a combination of these.
to prevent corrosion.
to prevent corrosion
maximum) to minimize sludge deposits,
If any of the above requirements cannot be met, use distilled, de-ionized, or de-mineralized water. To determine if local
water supplies meet these standards, water samples can be tested by water treatment laboratories. Softened water
that is prepared using common salt (sodium chloride) contains excessive amounts of chlorides and should not be
used.
NOTE: Never use water alone in the cooling system because corrosion
will occur
Antifreeze
In climates where the temperature is above -37C (-34F) use a coolant mixture that contains 50 percent antifreeze.
Antifreeze is essential in any climate. It broadens the operating temperature range by lowering the coolant freezing
point and by raising its boiling point. Do not use more than 50 percent antifreeze in the mixture unless additional freeze
protection is required. Never use more than 68 percent antifreeze under any condition.
An antifreeze concentration greater than 68% will adversely affect freeze protection and heat transfer rates. Antifreeze
concentrations between 68% and 100% actually have a higher freezing point than a 68% antifreeze concentration and
should not be used due to reduced heat transfer rates.
Low silicate ethylene glycol antifreeze is recommended. The antifreeze should contain no more than 0.1% anhydrous
alkali metasilicate. Low silicate antifreeze is recommended to avoid the formation of silica-gel (hydro-gel). This gel
formation can occur when the cooling system contains an over concentration of high silicate antifreeze and/or
supplemental coolant additive. DO NOT use methanol or alcohol as an antifreeze because of its low boiling point.
Antifreeze may retain its freeze protection
maintain corrosion protection.
Antifreeze
formulated
with methoxy
for more than one season
but coolant conditioners
propanol, or propylene glycol, is not recommended
must be added to
for this system.
NOTE: Do not mix types of antifreeze solutions. Mixed solutions make it impossible to determine the protection
against freezing, Antifreeze containing sealer or anti-leak additives should NOT be used in this system. Sealer
or anti-leak additives will cause plugging problems in the cooling system. ,
Check the solution periodically
protection against freezing.
and at normal operating
temperature,
to be sure the cooling system has sufficient
01-I 1
GENERAL
The following table shows the approximate
percentage
solution required for various temperatures.
Percentage of
Antifreeze
Concentration
by Volume
Approximate
Freezing
Point
+32F
+2OF
+lOF
0F
-10F
-20F
-30F
-40F
-50F
-60F
-70F
-80F
-90F
-92F
of antifreeze
1 .ooo
1.025
1.040
1.053
1.062
1.070
1.074
1.080
1.083
1.088
1.092
1.095
1.097
1.098
0
15
25
33
40
45
48
53
56
59
62
65
67
68
(OC)
(-7C)
(-12C)
(-18C)
(-23C)
(-29C)
(-34C)
(-40C)
(-46C)
(-51 C)
(-57C)
(-62C)
(-68C)
(-96C)
In tropical climates where antifreeze availability

cooling system.
Specific
Gravity at
60F (16C)
may be limited, use a corrosion
inhibitor SCA, to protect the engine
Supplemental Coolant Additives

1. All supplemental cooling system additives, including those in antifreeze solutions, become depleted through
normal operation. If the coolant additive in antifreeze are allowed to become depleted, the antifreeze becomes
corrosive and attacks and coats the metallic surfaces of the cooling system which reduces heat transfer. Cooling
system conditioners which contain these additives must be added to maintain corrosion protection.
2. SOLUBLE OIL IS NOT RECOMMENDED
internal engine damage.
for use in this engine as its use will reduce heat transfer and allow
3. There are no miracle additives that will increase heat transfer or prevent overheating.
the best coolant.
4. SCA is recommended
l
to inhibit corrosion
in the cooling system for the following
OF SUPPLEMENTAL
Keeping the engine coolant

corrosion.
properly
COOLANT
inhibited
water is still
reasons:
Improved compatibility with high silicate antifreezes to minimize hydro-gel formation

occurs.
Provides engine protection in the following areas:
- Solder corrosion/bloom
- Copper corrosion/erosion/stress
cracking
- Oil fouling
- Cylinder liner cavitation corrosion
-Aluminum cavitation corrosion
- Seal and gasket degradation
MAINTENANCE
if over concentration
ADDITIVES
will keep the engine and radiator free of rust, scale deposits
New machines are delivered with antifreeze protection. Service at regular scheduled
SCHEDULED MAINTENANCE
GUIDE with a service DCA4 filter.
01-12
Conditioned
interval
specified
and
in the
GENERAL
Each time the coolant is drained and replaced, the coolant must be recharged with SCA. New coolant can be correctly
charged with supplemental coolant additives by using a DCA4 service filter or SCA concentrate listed in the table
entitled. DCA4 Unit Guide.
If coolant is added between drain intervals, additional SCA will be required.
COOLANT
TESTING
FOR CONDITIONER
When the cooling system is maintained

SCA concentration must not fall below
The only accurate method for testing
laboratory analysis. For this reason,
MAINTENANCE
GUIDE.
CONCENTRATION
as recommended, the conditioner concentration should be satisfactory. The

1 .O unit per 3.8 P (1 US gal) or exceed 2 units per 3.8 e (1 US gal) of coolant.
chemical concentrations
in coolant with mixed chemical compounds is a
the coolant inhibitor should be maintained as shown in the SCHEDULED
NOTE: Inadequate concentration of the supplemental coolant additive can result in major corrosive damage to cooling
system components. Over concentration can cause formation of gel that can cause restriction, plugging of
passages and overheating.
REPLENISHING
COOLANT
CONDITIONER
Install a precharge DCA4 filter when the coolant is changed or a significant (more than 50%) coolant loss occurs.
Install a service DCA4 filter as specified in the SCHEDULED MAINTENANCE
GUIDE. When antifreeze is added,
add coolant conditioner equal to 1 .O unit per 3.8 e (1 US gal) of antifreeze.
NOTE: Mixing of DCA4 and other supplemental coolant additives is not recommended because there is currently no
test kit available to measure concentration levels with mixed chemical solutions.
SCA UNIT MAINTENANCE
GUIDE
Use supplemental coolant additives (corrosion inhibitors) to protect the engine cooling system from corrosion.
Antifreeze alone does not provide enough corrosion protection for a heavy duty diesel engine. Supplemental corrosion
protection must be supplied through periodic additions of supplemental coolant additives to the coolant.
To protect against corrosion, a new coolant charge must be brought up to 0.26 SCA unit per liter [one unit per U.S.
gallon] of coolant (initial charge). Maintain the correct SCA concentration by changing the service coolant filter at each
engine oil and filter change interval.
Each time the coolant is drained and replace, the coolant must be recharged with supplemental coolant additives. Use
the appropriate DCA4 spin-on filter listed in following table. The coolant mixture must be drained and replaced as
defined under General.
The amount of replacement inhibitor is determined by the length of the service interval and the cooling system
capacity. Refer to the DCA4 Unit Guide for the selection of the correct filter to replenish the SCA.
If coolant is added between drain intervals, additional SCA will be required. Check the coolant DCA concentration level
anytime make-up coolant is added to the system. The SCA concentration must not fall below 0.13 units per liter or
exceed 0.5 units per liter [0.5 units per U.S. gallon or exceed 2 units per U.S. gallon].
01-13
GENERAL

DCA4 Unit Guide
Fleetguard
Part No.
DCA4
Units
DCA4 Coolant Filter

WF-2070
WF-2071
WF-2072
WF-2073
WF-2074
WF-2075
WF-2076
WF-2077
2
4
6
8
12
15
23
0
DCA4 Liquid
DCAGOL
DCA80L
4 (1 Pint)
1760 (55 US gal)
DCA4 Powder
DCA95
20
DCA4 Precharge
System Capacity
and Service Filters
Precharge Filter
(See NOTE 1)
Service Filter
(See NOTE 3)
WF-2072
WF-2073
WF-2074
WF-2075
WF-2076
(See NOTE 2)
WF-2070
WF-2071
WF-2071
WF-2071
WF-2072
WF-2073
Gallons
5-7
8-l 0
11-15
16-20
21-30
31-50
NOTE l-
After draining and replacing coolant, always precharge the cooling

concentration between 1 .O and 2.0 units per 3.8 P (1 US gal).
NOTE:
NOTE 2 l
NOTE 3 -
01-14
to maintain
the SCA
When performing service which requires draining the cooling system, discard the coolant.
Reusing coolant can introduce contaminates
or over concentrated chemicals, resulting in
premature failure of cooling system components.
To precharge cooling systems larger than 114 r?(30 gal) do the following:
Install appropriate
service filter listed in the above table based on cooling system capacity.
Example:
system
95 gal (360 Q)cooling system capacity

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

SCA Unit Concentration
Number of Solution A Drops to

Cause Color Change
are included with the test kit.
Guide
Coolant Condition
Action Required
0- 10 Drops
Extremely under-concentrated
less than 0.4 SCA units per 3.8 P (1
US gal)
11 - 16 Drops
Marginally under-concentrated
0.45 to 0.8 SCA units per 3.8 e (1
US gal)
17 - 25 Drops
Acceptable - 0.85 to 1.3 SCA units

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

SCA units per 3.8 P (1 US gal)
None.
36 - 55 Drops
Marginally over-concentrated
- 2.1
to 3.3 SCA units per 3.8 P (1 US
Review maintenance
Initially charge the system to a

minimum of 1 .O SCA unit per 3.8 e
(1 US gal).
i Add SCA liquid units to maintain
~ 1.0 SCA unit per 3.8 e (1 US gal)
minimum or change the DCA 4
coolant filter.
practice.
gal)
Over 55 Drops
Extremely
over-concentrated
Drain 50% of the coolant and

replace with water antifreeze
mixture. Retest the system for
correct SCA unit concentration.
01-15
GENERAL
01-16
MEMORANDA
10 STRUCTURE AND FUNCTION

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-2
Radiator and oil cooler . . . . . . . . . . . . . . . . . . . . 10-4
Damper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-5
Torque converter and transmission piping . . . . . 10-7
Hydraulic circuit for power train . . . . . . . . . . . . . . 10-8
Hydraulic circuit diagram for power train . . . . . . 10-9
Torque converter and PTO . . . . . . . . . . . . . . . . 10-10
Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-12
Transmission control valve . . . . . . . . . . . . . . . . 10-22
ECMV (electronic control modulation valve) . . 10-24
Main relief, torque converter relief valve . . . . . . 10-30
Lubricating relief valve . . . . . . . . . . . . . . . . . . . . 10-32
Torque converter oil filter . . . . . . . . . . . . . . . . . 10-33
Pilot filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-34
Transfer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-35
Drive shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-36
Center support . . . . . . . . . . . . . . . . . . . . . . . . . . 10-37
Axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-38
Differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-40
Final drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-44
Axle mount . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-46
Center hinge pin . . . . . . . . . . . . . . . . . . . . . . . . 10-48
Tire and wheel . . . . . . . . . . . . . . . . . . . . . . . . . . 10-49
Steering piping . . . . . . . . . . . . . . . . . . . . . . . . . . 10-50
Steering column . . . . . . . . . . . . . . . . . . . . . . . . 10-51
Steering valve . . . . . . . . . . . . . . . . . . . . . . . . . . 10-52
Orbit-roll valve . . . . . . . . . . . . . . . . . . . . . . . . . . 10-66
Stop valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-70
Diverter valve . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-71
Brake circuit diagram . . . . . . . . . . . . . . . . . . . . 10-75
Brake valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-76
Charge valve . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-82
Accumulator (for brake) . . . . . . . . . . . . . . . . . . 10-86
Slack adjuster . . . . . . . . . . . . . . . . . . . . . . . . . . 10-87
Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-90
Parking brake control . . . . . . . . . . . . . . . . . . . . 10-92
Parking brake . . . . . . . . . . . . . . . . . . . . . . . . . . 10-93
Parking brake solenoid valve . . . . . . . . . . . . . . 10-94
Parking brake emergency
release solenoid valve . . . . . . . . . . . . . . . . 10-95
Hydraulic circuit system . . . . . . . . . . . . . . . . . . 10-102
Work equipment lever linkage . . . . . . . . . . . . 10-104
Hydraulic tank . . . . . . . . . . . . . . . . . . . . . . . . . 10-105
Accumulator (for PPC valve) . . . . . . . . . . . . . 10-108

PPC valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-110
PPC relief valve . . . . . . . . . . . . . . . . . . . . . . . . 10-117
Cut-off valve . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-118
Main control valve . . . . . . . . . . . . . . . . . . . . . . 10-122
Work equipment linkage . . . . . . . . . . . . . . . . . 10-138
Bucket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-140
Bucket positioner and boom kick-out . . . . . . . 10-142
Proximity switch . . . . . . . . . . . . . . . . . . . . . . . . 10-144
Cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-150
ROPS canopy . . . . . . . . . . . . . . . . . . . . . . . . . 10-151
Air conditioner . . . . . . . . . . . . . . . . . . . . . . . . . 10-152
Air conditioner piping . . . . . . . . . . . . . . . . 10-152
Basic information on air conditioners . . . . 10-153
Units related to refrigeration . . . . . . . . . . . 10-153
Principle of cooling . . . . . . . . . . . . . . . . 10-155-2
Refrigerants . . . . . . . . . . . . . . . . . . . . . 10-155-7
Safety precautions . . . . . . . . . . . . . . . . 10-155-7
Refrigerator oil (lube oil) . . . . . . . . . . . . 10-155-8
Air conditioning condenser . . . . . . . . . . . . 10-155-10
Function . . . . . . . . . . . . . . . . . . . . . . . 10-155-10
General description . . . . . . . . . . . . . . 10-155-10
Air conditioner compressor . . . . . . . . . . . . 10-155-13
Receiver with sight glass . . . . . . . . . . . . . . 10-155-14
Air conditioner unit . . . . . . . . . . . . . . . . . . . 10-155-16
Outline . . . . . . . . . . . . . . . . . . . . . . . . . 10-155-16
Electric circuit diagrams . . . . . . . . . . . . . . . . . 10-156
Machine monitor system . . . . . . . . . . . . . . . . . 10-166
Main monitor . . . . . . . . . . . . . . . . . . . . . . . . . . 10-167
Maintenance monitor . . . . . . . . . . . . . . . . . . . . 10-171
All-range electronic control automatic
transmission system . . . . . . . . . . . . . . . . . 10-174
Transmission controller . . . . . . . . . . . . . . . . . . 10-186
Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-188
Engine starting circuit . . . . . . . . . . . . . . . . . . . 10-194
Engine stop circuit . . . . . . . . . . . . . . . . . . . . . . 10-196
Ether start circuit . . . . . . . . . . . . . . . . . . . . . . . 10-197
Electric transmission control . . . . . . . . . . . . . . 10-198
Combination switch . . . . . . . . . . . . . . . . . . . . . 10-199
Kick-down hold switch . . . . . . . . . . . . . . . . . . . 10-201
Kick-down electric circuit . . . . . . . . . . . . . . . . . 10-202
Electric parking brake control . . . . . . . . . . . . . 10-205
10-1
GENERAL
GENERAL
OUTLINE
The power from the engine (1) is transmitted from
the flywheel to damper (2) through the ring gear.
The damper alleviates the torsional vibration
caused by the variation of the engine torque and
transmits the power to torque converter (4) through
drive shaft (3). The torque converter converts the
delivered torque according to the variation in the
load on the oil used as the medium, and transmits
the power to the input shaft of transmission (10).
The engine power then is transmitted to PPC pump
(7), steering pump (9), hydraulic pump (8), switch
pump (6), and torque converter charging pump (5)
through the pump driving gear in torque converter
(4).
In transmission (10), the six hydraulic clutches are
operated by the forward-reverse spool and the
speed change spools in the transmission valves,
which are themselves activated by solenoid valves.
Thus, the desired travel speed can be selected
from among the 4 forward and 4 reverse gear
speeds.
10-2
A multiple disc parking brake is installed to the

output shaft of transmission (10). At the front end,
the power from the output shaft passes through
center drive shaft (12) and front drive shaft (14) and
is transmitted to front differential (15), at the rear
end it is transmitted to rear differential (20) by rear
drive shaft (19).
The power transmitted to front differential (15) and
rear differential (20) is transmitted to the axle
shafts.
The power from the axle shafts has its speed
reduced by final drives (16) and (21), and it is then
transmitted to tires (18) and (23) through the
planetary carrier.
1.
2.
3.
4.
5.
6.
7.
8.
Engine
Damper
Upper drive shaft
Torque converter
Torque converter charging pump
Switch pump
PPC pump
Hydraulic pump
10-3
GENERAL
9.
10.
11.
12.
13.
14.
15.
16.
Steering pump
Transmission
Parking brake
Center drive shaft
Center support
Front drive shaft
Front differential
Front final drive
17.
18.
19.
20.
21.
22.
23.
Front brake
Front tire
Rear drive shaft
Rear differential
Rear final drive
Rear brake
Rear tire
RADIATOR AND OIL COOLER
RADIATOR AND OIL COOLER
1.
2.
3.
4.
5.
Radiator
Coolant level sensor
Fan guard
Torque converter oil cooler
Hydraulic oil cooler
A.
B.
C.
D.
E.
F.
Coolant inlet port

Coolant outlet port
Hydraulic oil outlet port
Hydraulic oil inlet port
Torque converter oil outlet port
Torque converter oil inlet port
10-4
Specifications:
Radiator
Radiator core type: G7 type
Total heat dissipation area: 98.44 m2
Cross-sectional area of water flow: 193.8 cm2
Torque converter oil cooler
Type: PTO-OL (multiple disc type)
Heat dissipation area: 1, 829 m2
Type: SF-2 (Air to Air)
Heat dissipation area: 14.04 m2
Hydraulic oil cooler
Type: PTO-LS (multiple disc type)
Heat dissipation area: 1.147 m2
DAMPER
DAMPER
FUNCTION
1.
2.
3.
4.
5.
6.
7.
8.
Coupling
Output shaft
Cover
Bearing
Bearing
Outer body
Rubber cushion
Inner body
10-5
The damper reduces the twisting and vibration

caused by the variations in the engine torque, and
acts to protect the engine and other parts from
such twisting and vibration.
OPERATION
The engine power is transmitted to the flywheel and

outer body (6) and rubber cushion (7) absorbs the
twist and vibration of the engine. The engine power
is then transmitted through the inner body (8) to
output shaft (2). From here, the engine power is
transmitted through the coupling to the torque
converter and drive shaft.
10-6
DAMPER
TORQUE CONVERTER AND TRANSMISSION PIPING
TORQUE CONVERTER AND TRANSMISSION PIPING
1.
2.
3.
4.
5.
6.
7a.
Transmission
Transmission valve
Torque converter
Accumulator
Parking brake emergency release valve
Radiator
Oil cooler (water-cooled type)
7b.
8.
9.
10.
11.
12.
Oil cooler (air-cooled type)

Parking brake solenoid valve
Oil filter
Parking brake
Torque converter oil cooler (air to air)
10-7
HYDRAULIC CIRCUIT FOR POWER TRAIN
HYDRAULIC CIRCUIT FOR POWER TRAIN
10-8
HYDRAULIC CIRCUIT DIAGRAM FOR POWER TRAIN
HYDRAULIC CIRCUIT DIAGRAM FOR POWER TRAIN
1. Transmission case
2. Strainer
12.
3. Torque converter charging pump
4. Torque converter oil filter
5. Main relief valve
14.
6. Torque converter relief valve
15.
7. Torque converter
8a. Oil cooler (water-cooled type)
8b. Oil cooler (air-cooled type)
9. Transmission lubrication
19.
10. Lubrication relief valve
11. Pilot oil filter

13. Parking brake emergency
release valve
Accumulator
Parking brake
16. FORWARD ECMV
17. REVERSE ECMV
18. 3rd ECMV
4th ECMV
20. 2nd ECMV
21. 1st ECMV

22. Flow detector valve
23. Pressure control valve
24. FORWARD clutch
25. REVERSE clutch
26. 3rd clutch
27. 4th clutch
28. 2nd clutch
29. 1st clutch
10-9
TORQUE CONVERTER AND PTO
10-10
Flow of motive force

The torque converter is installed between the damper and
transmission. The motive force from the damper passes
through the drive shaft and enters drive case (7). Drive case
(7), pump (10) and PTO gear (drive) (13) are fixed with bolts.
They are rotated directly by the rotation of the engine.
The motive force of pump (10) uses oil to rotate turbine
(8). This transmits motive force to transmission input
shaft (12).
The motive force of drive case (7) passes through PTO gear
(drive) (13) and is also used as the motive force to drive the
gear pump.
Flow of oil
The oil pressure is adjusted by the torque converter relief
valve and then enters inlet port A, passes through the oil
passage in housing (9) and flows to pump (10). In pump (10)
centrifugal force is applied. The oil enters turbine (8) and the
energy of the oil is transmitted to the turbine.
Turbine (8) is fixed to transmission input shaft (12), so the
motive force is transmitted to the transmission input shaft
(12).
The oil from turbine (8) is sent to stator (11) and again
enters the pump. However, part of the oil passes from the
stator through outlet port B and is sent to the cooler.
10-11
TRANSMISSION
TRANSMISSION
1.
2.
3.
4.
5.
Main relief, torque converter relief valve

Transmission valve
Transmission input shaft
Transmission
Transfer
10-12
6.
7.
8.
9.
10.
Parking brake
Output coupling (front)
Output coupling (rear)
Oil filler port
Strainer
A.
B.
C.
D.
E.
F.
G.
H.
To torque converter
From torque converter case
Breather mount port
From oil filter
Transmission main oil pressure port
To parking brake emergency release valve
Lubricating oil pressure port
From oil cooler
TRANSMISSION
I. Mounting port for parking brake actuation pilot lamp

J. To torque converter charging pump
K. To REVERSE clutch
L. To 3rd clutch
M. To 1st clutch
N. To 2nd clutch
O. To 4th clutch
P. To FORWARD clutch
10-13
TRANSMISSION
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.
10-14
Input shaft
No. 1 sun gear (22 teeth)
No. 1 planet gear (24 teeth)
No. 1 ring gear (90 teeth)
No. 1 clutch
No. 1 idler gear (70 teeth)
Lubrication relief valve
No. 2 clutch
(Output shaft)
No. 3 clutch
No. 4 clutch
No. 5 clutch
No. 6 gear (90 teeth)
No. 6 clutch
Output shaft
No. 5 carrier
No. 3, 4 carrier
No. 2 carrier
No. 1 carrier

OUTLINE
The transmission consists of a 4-FORWARD, 4REVERSE speed planetary gear transmission,
transfer, and transmission control valve.
In the transmission, the motive force of the input
shaft is changed by the combination of No.1 or
No.2 clutch with No.3,4,5, or 6 clutch to give
FORWARD 1 - 4 or REVERSE 1 - 4 speed, and is
transmitted to the output shaft
TRANSMISSION
Speed range
Clutch combination
F1
No.2, No.6
F2
No.2, No.5
F3
No.2, No.4
F4
No.2, No.3
R1
No.1, No.6
R2
No.1, No.5
R3
No.1, No.4
R4
No.1, No.3
OPERATION OF CLUTCH
Engaged
The oil sent from the transmission control valve
passes through the oil passage inside the
transmission. When it reaches the rear piston (1),
it moves the piston (1).
When the piston (1) moves, disc (2) and plate (3)
are pressed together. Ring gear (4) is meshed with
disc (2), so the rotation is stopped.
Disengaged
When the supply of oil from the transmission
control valve is shut off, the pressure of the oil is
acting on the rear of piston (1) is reduced. The
piston is then pushed back to the right by return
spring (5), and disc (2) and plate (3) are separated.
Ring gear (4) then rotates freely, and no motive
force is transmitted.
10-15
TRANSMISSION
FORWARD 1st
In 1st FORWARD, No. 2 clutch and No. 6 clutch are

engaged. The motive force transmitted from the
torque converter by input shaft (2) is transmitted to
output shaft (31).
No. 2 clutch is actuated by the hydraulic pressure
applied to the clutch piston, and it locks ring gear (15)
in position. No. 6 clutch is actuated by the hydraulic
oil pressure applied to the clutch piston and holds
gear (29) to carrier (32).
10-16
The motive force from the torque converter is

transmitted to the input shaft (2). The rotation of the
input shaft (2) is transmitted to planetary gear (14)
through sun gear (13).
Ring gear (15) is held in position by No. 2 clutch so
the rotation of planetary gear (14) rotates carriers
(33) and (34), which is on the inside ring gear (15).
This carrier is connected to No. 5 carrier (32)
through No. 4 ring gear (23, so when No. 6 clutch
is actuated, the rotation of carrier (32) is transmitted
to gear (29) and rotate output shaft (31).
TRANSMISSION
FORWARD 2nd
In 2nd FORWARD, No. 2 clutch and No. 5 clutch are

output shaft (31).
applied to the clutch piston, and it locks ring gears
(15) and (27) in position.
input shaft (2) is transmitted to planetary gear (14)

The rotation of carrier (33) is transmitted through
ring gear (23) to carrier (32).
Ring gear (27) is held in position by No. 5 clutch, so
the rotation of carrier (32) rotates planetary gear
(26). The planetary gear rotates on the inside of
ring gear (27), and rotates sun gear (25). The sun
gear rotates output shaft (31).
10-17
TRANSMISSION
FORWARD 3rd
In 3rd FORWARD, No. 2 clutch and No. 4 clutch are

output shaft (31).
No. 2 clutch and No. 4 clutch are actuated by the
hydraulic pressure applied to the clutch piston, and it
locks ring gears (15) and (23) in position.
input shaft is transmitted to planetary gear (14)
10-18

the rotation of carrier (33) is transmitted to
planetary gear (22) rotates on the inside of ring
gear (23), and rotates sun gear (21). The sun gear
rotates output shaft (31).
TRANSMISSION
FORWARD 4th
In 4th FORWARD, No. 2 clutch and No. 3 clutch are

output shaft (31).
No. 2 clutch and No. 3 clutch are actuated by the
hydraulic pressure applied to the clutch piston, and it
locks ring gears (15) and (19) in position.

the rotation of carrier (33) is transmitted to
planetary gear (18). The planetary (18) rotates on
the inside of ring gear (19), and rotates sun gear
(17), which forms one unit with output shaft (31).
10-19
TRANSMISSION
REVERSE 1st
In 1st REVERSE, No. 1 clutch and No. 6 clutch are

output shaft (31).
applied to the clutch piston, and it locks carrier (35) in
position. No. 6 clutch is actuated by the hydraulic
pressure applied to the clutch piston and hold ring
gear (29) in position.
10-20
Carrier (35) is held in position by No. 1 clutch, so

the rotation of planetary gear rotates the ring gear.
Ring gear (15) rotates in the opposite direction from
the input shaft. Ring gear (15) rotates carrier (34),
and the rotation of carrier (34) rotates ring gear
(23), which then rotates carrier (32). Carrier (32)
rotates No. 6 clutch (30). When No. 6 clutch is
actuated, the rotation of carrier (32) is transmitted
to gear (29) and rotates output shaft (31).
TRANSMISSION
- MEMORANDA -
10-21
TRANSMISSION CONTROL VALVE
10-22

1.
2.
3.
4.
5.
6.
7.
8.
ECMV (for FORWARD clutch)

ECMV (for REVERSE clutch)
ECMV (for 3rd clutch)
ECMV (for 4th clutch)
ECMV (for 2nd clutch)
ECMV (for 1st clutch)
Pilot filter
A, A:
B, B:
C, C:
D, D:
E, E:
F, F:
G:
H:
FORWARD clutch oil pressure measurement port.

REVERSE clutch oil pressure measurement port.
3rd clutch oil pressure measurement port.
4th clutch oil pressure measurement port.
2nd clutch oil pressure measurement port.
1st clutch oil pressure measurement port.
To parking brake emergency release valve.
To parking brake emergency release valve (Pilot pressure).
ECMV actuation table

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

gear shift lever is placed, is ON.
10-23
ECMV (ELECTRONIC CONTROL MODULATION VALVE)
A.
D.
P.
T.
To clutch
Drain port
From pump
Clutch drain port
10-24
ECMV
1.
2.
3.
4.
5.
6.
7.
8.
9.
ECMV
Connector
Connector
Spring
Pressure control valve spool
Proportional solenoid
Fill switch
Pin
Spring
Flow detector valve spool
10-25

OUTLINE OF ECMV
The ECMV (Electronic Control Modulation Valve) consist of
two valves: The pressure control valve and the flow detection
valve.
Pressure control valve
The proportional solenoid receives the flow of electricity sent
from the transmission controller, and the pressure control
valve converts this into hydraulic pressure.
Flow detection valve
This valve is actuated by a trigger from the pressure control
valve and has the following functions:
1) When the clutch is filled with oil, it sends a signal (fill
signal) to the controller to inform the controller that the
filling is completed.
2) While oil pressure is applied to the clutch, it outputs a
signal (fill signal) to the controller to inform the controller
of the existence of the oil pressure.
ECMV AND PROPORTIONAL SOLENOID

There is one proportional solenoid installed to each ECMV.
It generates propulsion as shown in the diagram on the right
according to the command current from the transmission
controller.
The propulsion generated by the proportional solenoid acts
on the pressure control valve spool and generates oil
pressure as shown in the diagram on the right. In this way,
the command current is controlled and the propulsion force
varies to actuate the pressure control valve and control the oil
flow and oil pressure.
ECMV AND FILL SWITCH
There is one fill switch installed to each ECMV.
When the filling of the clutch is completed, the fill switch is
turned on by the action of the flow detection valve. With this
signal, the oil pressure starts the build-up.
10-26
ECMV
ECMV
ACTUATION OF ECMV
The ECMV is controlled by the command current from the
transmission controller to the proportional solenoid and the
fill switch output signal. The relationship between ECMV
proportional solenoid command current and the clutch input
pressure and fill switch output signal is as shown in the
diagram on the right.
Range A:
Range B:
Range C:
Range D:
Range E:
Before shifting gear (when draining)

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

graph.
When no current is flowing to proportional solenoid (5),
proportional solenoid (5) is pushed back by the reaction of
pressure control valve spring (3) through pressure control
valve spool (4), so pressure control valve (4) drains the oil
at clutch port A through drain port T.
When this happens, there is no hydraulic force acting on
flow detection valve spool (9), so flow detection valve spool
(9) is separated from fill switch (6) by the reaction force of
fill switch spring (8).
10-27

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

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

When electric current flows to proportional solenoid (5), the
solenoid generates a force proportional to the current. The
total of this propulsion force of the solenoid and the propulsion
force of the oil pressure at the clutch port and the reaction
force of pressure control valve spring (3) is balanced. Flow
detection valve spool (9) is pushed to the right by the
difference in the force of the oil pressure applied to both sides
of orifice a, and it continues to send the fill signal to the shift
controller.
10-29
MAIN RELIEF, T.C. RELIEF VALVE
MAIN RELIEF, TORQUE CONVERTER RELIEF VALVE
1.
2.
3.
4.
5.
6.
7.
8.
9.
Body
Torque converter relief valve
Valve spring
Piston
Piston spring
Main relief valve
Valve spring
Piston spring
Piston
A.
B.
C.
D.
E.
P1
Drain port (torque converter relief)

Drain port
From pump
Drain port
To torque converter
Main relief oil pressure detection port
10-30
OUTLINE
1. Main relief valve.
Main relief valve (6) sets the pressure of the
transmission oil.
2. Torque converter relief valve.
Torque converter relief valve (2) acts to protect the
torque converter from abnormally high pressure. It
relieves the pressure when the pressure at the inlet
port of the torque converter goes above the
specified pressure.
Specified pressure
Main relief pressure
3.52 MPa (35.9 kg/cm2)

(engine at rated speed
Torque converter inlet

port pressure
0.84 MPa (8.5 kg/cm2)

(cracking pressure)
MAIN RELIEF, T.C. RELIEF VALVE
OPERATION OF MAIN RELIEF VALVE

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

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

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

B. Drain
C. Drain
OUTLINE
The lubricating relief valve is assembled to the left
face of the REVERSE clutch housing, and protects
the lubricating circuit and oil cooler
Unit: MPa (kg/cm2)

Specified value
Pressure when normal
Cracking pressure
10-32
0.15 - 0.23 (1.5 - 2.3)

0.3 (3.0)
TORQUE CONVERTER OIL FILTER
TORQUE CONVERTER OIL FILTER
OPERATION
The oil from the torque converter charging pump enters the
filter inlet port A and passes from the outside of element (2)
to the inside. It then flows to the outlet port B.
If the element (2) is clogged with dirt, or the oil temperature

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

Transfer input gear (teeth 48)
Transfer idler gear (teeth 45)
Output gear (teeth 43)
Output shaft
Front coupling
Rear coupling
Parking brake
Part of the power transmitted to the output shaft is

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

2. Center support
3. Center drive shaft
Outline
The motive force from the engine passes through
the damper, upper drive shaft (5), torque converter,
transmission and transfer. Part of this motive force
passes through rear drive shaft (4) and goes to the
rear axle: the rest of the motive force passes
through center drive shaft (3), center support (2)
and front drive shaft (1) and is sent to the front axle.
In addition to transmitting the motive force, the drive
shafts have the following purposes.
10-36
4. Rear drive shaft

5. Upper drive shaft
When the body is articulated, or when there is

shock from the road surface during traveling, or
when there is shock during operations, the axle in
front and behind the engine and transmission
change position.
To allow the motive force to be transmitted without
damage to parts of the machine when there is
shock or when the components move position, the
drive shafts have a universal joint and a sliding
joint. This allows them to handle changes in angle
and length.
CENTER SUPPORT
CENTER SUPPORT
Function
1.
2.
3.
4.
Front coupling
Case
Grease fitting
Rear coupling
The center support is installed to the front frame

between the center drive shaft and the front drive
shaft.
With the articulating frame, this part is constantly
twisting from side to side, so there is liable to be a
large amount of stress on the drive shafts. Therefore, the center support is used to transmit the
power smoothly, to reduce the stress on the drive
shafts, and improve the durability of the drive
shafts.
10-37
AXLE
FRONT
10-38
AXLE
AXLE
Rear
10-39
DIFFERENTIAL
Front
1.
2.
3.
4.
5.
Slide gear (18 teeth)

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

Shaft
Slide gear (18 teeth)
Pinion (10 teeth)
Bevel pinion (9 teeth)
10-41

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

speed of the left and right wheels is the same, so the pinion
gear (4) inside the differential assembly (6) is sent through
the pinion gear (4) and the side gear (3) and is transmitted
equally to the left and right sun gear shafts (2).
When turning
When turning, the rotating speed of the left and right wheels
is different, so the pinion gear (4) and side gear (3) inside the
differential assembly rotate in accordance with difference
between the rotating speed of the left and right wheels. The
motive force of the carrier (6) is then transmitted to the sun
gear shafts (2).
10-42
DIFFERENTIAL

TORQUE PROPORTIONING DIFFERENTIAL
FUNCTION
Because of the nature of their work, 4-wheel-drive
loaders have to work in places where the road
surface is bad. In such places, if the tires slip, the
ability to work as a loader is reduced, and also the
life of the tire is reduced. The torque proportioning
differential is installed to overcome this problem.
DIFFERENTIAL
"b" is less than 1 : 1.38 (that is, the difference
between the resistance from the road surface to
the left and right tires is less than 38%), the pinion
gear will not rotate freely, so drive force will be
given to both side gears, and the tires will not slip.
Because of this effect, the tire life can be increased
by 20 - 30%, and at the same time the operating
efficiency is also increased.
In structure it resembles the differential of an automobile, but the differential pinion gear (4) has an
odd number of teeth. Because of the difference in
the resistance from the road surface, the position of
meshing of the pinion gear (4) and side gear (3A),
(3B) changes, and this changes the traction of the
left and right tires.
OPERATION
When traveling straight (equal resistance from road
surface to left and right tires)
If the resistance from the road surfaces to the left
and right wheels is the same, the distance between
the pinion gear and the meshing point "a" of the left
side gear is the same as the distance between the
pinion gear and meshing point "b" of right side gear
(3B).
Therefore the left side traction TL and the right side
traction TR are balanced.
When traveling on soft ground (resistance from
road surface to left and right tires is different)
On soft ground, if the tire on one side slips, the side
gear of the tire on the side which has least resistance from the road surface tires to rotate forward.
Because of this rotation, the meshing of the pinion
gear and side gear changes.
If left side gear (A) rotates slightly forward, the
distance between the pinion gear and the meshing
point "a" of the left side gear becomes longer than
the distance between the pinion gear and the
meshing port "b" of the right side gear. The position
is balanced as follows:
a x TL = b x TR
The ratio between the distances to "a" and "b" can
change to 1 : 1.38.
Therefore when the ratio of the distances to "a" and
10-43
FINAL DRIVE
FINAL DRIVE
1.
2.
3.
4.
5.
6.
Axle shaft
Planetary gear (29 Teeth)
Ring gear (78 Teeth)
Planetary carrier
Sun Gear (18 Teeth)
Wheel
10-44
Outline
To gain a large drive force, the final drive uses a
planetary gear system to reduce speed and send
drive force to the tires.
FINAL DRIVE
Operation
The motive force transmitted from the differential through
axle shaft (1) to sun gear (5) is transmitted to planetary gear
(2). The planetary gear rotates around the inside of a fixed
ring gear (3) and in this way transmits rotation at a reduced
speed to the planetary carrier (4). This motive force is then
sent to the wheels (6) which are installed to the planetary
carriers (4).
10-45
AXLE MOUNT
10-46
AXLE MOUNT
1.
2.
3.
4.
5.
Front axle
Rear axle
Front frame
Rear frame
Axle mounting bolts
AXLE MOUNT
Front axle
The front axle (1) receives the force directly during
operations, so it is fixed directly to the front frame
(3) by axle mounting bolts (5).
Rear axle
The rear axle (2) has a structure which allows the
center of the rear axle to float, so that all tires can
be in contact with the ground when traveling over
soft ground.
10-47
CENTER HINGE PIN
CENTER HINGE PIN
1.
2.
3.
4.
5.
6.
Front axle
Rear axle
Front frame
Rear frame
Upper hinge pin
Lower hinge pin
10-48
OUTLINE
The front frame (3) and rear frame (4) are connected through a bearing by the center hinge pin (5)
and (6). The steering cylinders are connected to
the left and right front and rear frames, so when the
cylinders are operated, the frame bends at the
middle to give the desired angle, that is the desired
turning radius.
TIRE AND WHEEL
TIRE AND WHEEL

The tire acts to absorb the shock from the ground
surface to the machine, and at the same time they
must rotate in contact with the ground to gain the
power which drives the machine
Various types of tires are available to suit the
purpose. Therefore it is very important to select the
correct tires for the type of work and bucket capacity.
1.
2.
3.
4.
5.
Specifications
Tire type: 26.5 x 25, 20PR
TRA code: L3
Nominal size of wheel: 22.00 x 25WTB
Nominal inflation pressure:
FRONT tire:
441.3 kPa (4.5 kg/cm, 63.9
psi)
REAR tire:
343.2 kPa (3.5 kg/cm, 49.7
psi)
Tire
Rim
Air valve
Lock ring
Side ring
10-49
STEERING PIPING
STEERING PIPING
1.
2.
3.
4.
5.
6.
Steering cylinder (R.H.)

Orbit-roll valve
Stop valve (R.H.)
Hydraulic tank
Hydraulic pump
Oil cooler
10-50
7. Switch pump and PPC pump

8. Steering pump
9. Stop valve (L.H.)
10. Steering valve
11. Steering cylinder (L.H.)
STEERING COLUMN
STEERING COLUMN
1.
2.
3.
4.
Steering wheel
Steering column
Joint
Orbit-roll valve
10-51
STEERING VALVE
STEERING VALVE
1.
2.
3.
4.
5.
Safety valve (with suction)

Check valve
Steering spool
Relief valve
Demand spool
10-52
A:
B:
Pa:
Pb:
P1:
P2:
PB:
T:
To steering cylinder
To steering cylinder
From orbit-roll valve
From orbit-roll valve
From steering pump
From steering pump
To main control valve
Drain (to oil cooler)
STEERING VALVE
OPERATION OF DEMAND VALVE

Steering spool at neutral
The oil from the steering pump enters port A, and

the oil from the switch pump enters port B.
When steering spool (2) is at neutral, pressurereceiving chamber (II) is connected to the drain
circuit through orifice (b), and notch (c) is closed.
Notch (c) is closed, so the pressure of the oil at port
A and port B rises. This pressure passes through
orifice (a), goes to pressure-receiving chamber (I),
and moves demand spool (1) to the left in the
direction of the arrow.
When the pressure at pressure-receiving camber

(I) reaches a certain value (set by spring {5}), notch
(f) opens, and the oil from the steering pump flows
to the drain circuit. At the same time, notch (g)
closes, and the oil from the switch pump all flows
to the main control valve.
10-53
STEERING VALVE
Steering spool operated

Engine at low speed
When steering spool (2) is pressed (operated),

pressure-receiving chamber (III) and the drain
circuit are shut off, ans at the same time notch (c)
opens.
When this happens, the pressure in pressurereceiving chamber (III) rises, and demand spool (1)
moves to the right in the direction of the arrow until
notch (h) closes.
The passage from port B to the main control valve
is shut off, so the oil from switch pump pushes up
merge check valve (3), and merges with the oil at
port A from the steering pump.
10-54
The merged oil passes through notch (c) and notch

(d), pushes up load check valve (4), and flows to
the cylinder. The oil returning from the cylinder
passes through notch (e) and enters the drain
circuit.
In this condition, the pressure before passing
through notch (c) goes to pressure-receiving
chamber (I), and the pressure after passing notch
(c) goes to pressure-receiving chamber (II).
Demand spool (1) moves to maintain the pressure
difference on the two sides of notch (c) at a
constant value. Therefore, a flow corresponding to
the amount of opening notch (c) is discharged from
the cylinder port. These pressure differences
(control pressure are set by spring (5).
STEERING VALVE
Engine at high speed
The extra oil from the switch pump is not needed,

so the steering pump pressure rises until notch (g)
closes, and shuts off the merge passage at port B.
The pressure difference on the two sides of notch
(c) is controlled only by notch (f), so the excess oil
from the steering pump is drained from notch (f) to
drain the circuit (when this happens, notch (g) is
completely closes.
The oil from steering passes through notch (c) and

notch (d), pushes up load check valve (4), and
flows to the cylinder. The oil returning from the
cylinder passes through notch (e) and flows to the
drain circuit.
Notch (g) is closed, so the oil from the switch pump
is sent from port B to the main control valve.
10-55
STEERING VALVE
FLOW AMP
1.
2.
3.
4.
Steering spool
Valve housing (body)
Spring seat
Return spring
5. Cap
6. Capscrew
7. Orifice
A: From orbit-roll valve

B: From orbit-roll valve
C: Passage (inside housing)
Operation of flow amp

1. Spool at neutral (Orbit-roll valve not actuated)
When the Orbit-roll valve is not actuated, both pilot

port PiA and pilot port PiB are connected through
the Orbit-roll to the drain (return) circuit, so steering
10-56
spool (1) is kept at neutral by return spring (4).
STEERING VALVE
2. Spool actuated (oil flows to port PiA)
When oil flows to port PiA, the pressure inside the

cap end A rises and moves steering spool (1) in the
direction of the arrow.
The oil entering from port PiA passes through the
hole in spring seat (3), through orifice (7) in steering
spool (1), and then flows to the opposite end (B
end).
Port PiB is connected to the drain circuit through

the Orbit-roll valve, so the oil flowing to end B is
drained.
The pressure generated at port PiA is proportional
to the amount of oil flowing in, so steering spool (1)
moves to a position where the opening of the flow
amp notch balances the pressure generated with
the force of return spring (4).
10-57

3. Spool returning (steering wheel stopped, flow of oil to port PiA cut)
When steering wheel (Orbit-roll valve) is stopped,

ports PiA and PiB are both connected to the drain
circuit through the Orbit-roll valve. For this reason,
steering spool (1) is returned to neutral position by
return spring (4).
10-58
STEERING VALVE
STEERING VALVE
OPERATION OF STEERING VALVE

Neutral
The steering wheel is not being operated, so

steering spool (1) does not move.
The oil from the steering pump enters port A, the
oil from the switch pump enters port B.
When the pressure at ports A and B rises, demand

spool (4) moves to the left in the direction of the
arrow. The oil from the steering pump passes
through port C of the spool and is drained. The oil
from the switch pump passes through port D and
flows to the main control valve.
10-59
STEERING VALVE
Turning right
When the steering wheel is turned to the right, the

pressure oil from the Orbit-roll valve acts on
steering spool (1), and steering spool (1) moves to
the left in the direction of the arrow.
The oil from the steering pump enters port A,
passes through demand spool (2), and flows to
steering spool (1). It pushes open load check valve
(4) of the spool, and the oil flows to the bottom end
of the left cylinder and the rod end of the right
cylinder to turn the machine to the right.
10-60
The oil from the left and right cylinders passes

through load check valve (3) of the steering spool,
and is drained.
The oil from the switch pump enters port B, flows
through demand spool (2), pushes open check
valve (5), and merges with the oil from the steering
pump.
STEERING VALVE
Turning left
When the steering wheel is turned to the left, the

pressure oil from the Orbit-roll valve acts on
steering spool (1), and steering spool (1) moves to
the right in the direction of the arrow.
The oil from the steering pump enters port A,
passes through demand spool (2), and flows to
steering spool (1). It pushes open load check valve
(3) of the spool, and the oil flows to the bottom end
of the right cylinder and the rod end of the left
cylinder to turn the machine to the left.
The oil from the left and right cylinders passes

through load check valve (4) of the steering spool,
and is drained.
The oil from the switch pump enters port B, flows
through demand spool (2), pushes open check
valve (5), and merges with the oil from the steering
pump.
10-61
STEERING VALVE
STEERING RELIEF VALVE

1.
2.
3.
4.
5.
Function
The steering relief valve is inside the steering valve,
and sets the maximum circuit pressure of the
steering circuit when the steering valve is actuated.
When the steering valve is being actuated, if the
steering circuit goes above the set pressure of this
valve, oil is relieved from this valve. When the oil is
relieved, the flow control spool of the demand valve
is actuated, and the oil is drained to the steering
circuit.
10-62
Adjustment screw
Spring
Plug
Pilot popper
Valve seat
STEERING VALVE
Operation of relief valve
When the pressure in the circuit rises, and it

reaches the pressure set by adjustment screw (1)
and spring (2), pilot poppet (4) opens, and the oil is
drained.
When this happens, the balance in pressure
between pressure-receiving chamber (I) and
pressure-receiving chamber (II) is lost, so demand
spool (6) moves to the left in the direction of the
arrow.
When demand spool (6) moves, the oil from the

steering pump is drained, and the oil from the
switch pump is released to the main control valve.
This prevents the pressure in the steering circuit
from going above the set value.
10-63
STEERING VALVE
SAFETY VALVE (WITH SUCTION)

1.
2.
3.
4.
5.
Function
The safety valve is installed to the steering valve. It has the
following two functions:
1) When the steering valve is at neutral, if any shock is
applied to the cylinder, and an abnormal pressure is
generated, the oil is relieved from the valve. In this way,
it functions as a safety valve to prevent damage to the
cylinder or hydraulic piping.
2) If negative pressure is generated at cylinder end, it
functions as a suction valve to prevent a vacuum from
forming.
Operation
Acting as relief valve
Port A is connected to the cylinder circuit and port B is
connected to the drain circuit. Oil passes through the hole in
poppet (1) and acts on the different areas of diameters d1
and d2, so check valve poppet (3) and relief valve poppet (2)
are firmly seated in position.
When the pressure at port A reaches the set pressure of the
relief valve, pilot poppet (4) opens. The oil flows around pilot
poppet (4), passes through the drill hole, and flows to port B.
10-64
Poppet
Relief valve poppet
Check valve poppet
Pilot poppet
Spring
STEERING VALVE
When pilot poppet (4) opens, the pressure at the back of

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

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

When negative pressure is formed at port A, the difference in
area of diameters d3 and d4 causes check valve poppet (3) to
open. When this happens, the oil from port B flows to port A,
and prevents any vacuum from forming.
10-65
ORBIT-ROLL VALVE
ORBIT-ROLL VALVE
1.
2.
3.
4.
Needle bearing
Center spring
Drive shaft
Valve body
10-66
5.
6.
7.
8.
Rotor
Cover
Center pin
Sleeve
9. Spool
10. Stator
11. Lower cover
12. Check valve
ORBIT-ROLL VALVE
Outline
The steering valve is connected directly to the shaft of the
steering wheel. It switches the flow of oil from the steering
pump to the left and right steering cylinders to determine the
direction of travel of the machine.
The orbit-roll valve, broadly speaking, consists of the
following components: Rotary type spool (9) and sleeve (8),
which have the function of selecting the direction, and the
Girotor set (a combination of rotor (5) and stator (10)), which
acts as a hydraulic motor during normal steering operations,
and as a hand pump (in fact, the operating force of the
steering wheel is too high, so it cannot be operated) when the
steering pump or engine have failed and the supply of oil has
stopped.
Structure
Spool (9) is directly connected to the drive shaft of the
steering wheel, and is connected to sleeve (8) by center pin
(7) (it does not contact the spool when steering wheel is at
neutral) and centering spring (2).
The top of drive shaft (3) is meshed with center pin (7), and
forms one unit with sleeve (8), while the bottom of the drive
shaft is meshed with the spline of rotor (5) of the Girotor.
There are four ports in valve body (4), and they are connected
to the pump circuit, tank circuit, and the circuits at
the head end and bottom end of the steering cylinders. The
pump port and tank port are connected by the check valve
inside the body. If the pump or engine fail, the oil can be
sucked in directly from the tank by the check valve.
10-67

CONNECTION BETWEEN HAND PUMP AND SLEEVE
The diagrams above show the connections with the

sleeve ports used to connect the suction and
discharge ports of the Girotor.
If the steering wheel has been turned to the right,
ports a, c, e, g, I, and k are connected by the
vertical grooves in the spool to the pump side. At
the same time, ports b, d, f, h, j, and l are
connected to the head end of the left steering
cylinder in the same way.
In the condition in Fig. 1, ports 1, 2, and 3 are the
discharge ports of the Girotor set. They are
connected to ports l, b, and d, so oil is sent to the
cylinder. Ports 5, 6, and 7 are connected and the oil
flows in from the pump.
If the steering wheel is turned 90
n
changes to the condition shown in Fig. 2. In this
case ports 1, 2, and 3 are the suction ports, and
are connected to ports I, k, and c. Ports 5, 6, and 7
are the discharge ports, and are connected to ports
d, f, and h.
10-68
ORBIT-ROLL VALVE
ORBIT-ROLL VALVE
In this way the ports of the Girotor acting as delivery ports are
connected to ports which are connected to the end of the
steering valve spool. The ports acting as suction ports are
connected to the pump circuit
Adjusting delivery in accordance with angle of the steering
wheel:
For every 1/7 turn of the steering wheel, the inner teeth
of the Girotor gear advances one position so the oil flow
from the pump is adjusted by this movement. In this way,
the oil delivered from the pump is directly proportional to
the amount the steering wheel is turned.
FUNCTION OF CENTER SPRING
Centering spring (2) consists of four layers of leaf springs
crossed to form an X shape. The springs are assembled in
spool (9) and sleeve (8) as shown in the diagram on the right.
When the steering wheel is turned, the spring is compressed
and a difference in rotation (angle variation) arises between
the spool and the sleeve. Because of this, the ports in the
spool and sleeve are connected and oil is sent to the cylinder.
When the turning of the steering wheel is stopped, the Girotor
also stops turning, so no more oil is sent to the cylinder and
the oil pressure rises.
To prevent this, when the turning of the steering wheel is
stopped, the action of the centering spring only allows it to
turn by an amount equal to the difference in angle of rotation
(angle variation) of the sleeve and spool, so the steering
wheel returns to the NEUTRAL position.
10-69
STOP VALVE
STOP VALVE
1.
2.
3.
4.
5.
6.
7.
Boot
Wiper
Seal
Poppet
Spring
Spool
Spring
10-70
A:
B:
DR:
From orbit-roll
To steering valve
To drain
DIVERTER VALVE
DIVERTER VALVE
1.
2.
3.
4.
Spool
Valve body
Check valve
Check valve
A.
B.
C.
D.
E.
F.
G.
From steering pump

To steering valve
To hydraulic tank
Sensor mounting port
Ground driven steering pump port
Ground driven steering pump port
From hydraulic tank
FUNCTION
If the engine stops or the pump seizes while the
machine is traveling, it becomes impossible to
steer, the rotation of the transmission is used to
turn the ground driven steering pump to make
steering possible
10-71

OPERATION
Pump and engine are working normally.
When the steering pump and engine are working normally,

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

machine is traveling, the rotation of the wheels is transmitted through the transfer to rotate the ground driven
steering pump. The steering pump is not rotating, so no
oil pressure is formed at port D. As a result, spool (3) is
pushed in the direction of the arrow by spring (4).
The oil from the ground driven steering pump passes
from port A through port B and flows to the steering valve
to make steering possible.
The ground driven steering pump is designed so that
it can rotate both directions.
10-73
BRAKE PIPING
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
10-74
Brake valve (right)

Hydraulic tank
Parking brake switch
Emergency release parking
brake switch
Rear brake (right)
Charge valve
Filter
Accumulator
Parking brake valve
Slack adjuster (rear)
Rear brake (left)
PPC pump (also for brake)
Transmission control valve
Parking brake (built into
transmission)
Brake valve (left)
Front brake (left)
Slack adjuster (front)
Front brake (right)
BRAKE CIRCUIT DIAGRAM
BRAKE CIRCUIT DIAGRAM
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
Hydraulic tank
Brake, PPC pump
Charge valve
Check valve
Accumulator (rear brake)
Brake valve (right)
Rear slack adjuster
Rear brake cylinder
Front slack adjuster
Front brake cylinder
11. Check valve

12. Accumulator
(Front brake, emergency parking brake)
13. Brake valve (left)
14. Transmission (case)
15. Torque converter charging pump
16. Transmission control valve
(Parking brake valve)
17. Emergency parking brake
18. Parking brake
10-75
BRAKE VALVE
BRAKE VALVE
BRAKE VALVE (RIGHT)
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
Brake pedal (left, right brake)

Rod (right brake)
Pilot piston (right brake)
Spool (right brake)
Upper cylinder (right brake)
Spool (right brake)
Lower cylinder (right brake)
Rod (left brake)
Spool (left brake)
Cylinder (left brake)
10-76
A.
B.
C.
D.
E.
Pilot port (right brake)

To rear brake (right brake)
To front brake (right brake)
Drain (left, right brake)
To pilot port (left brake)
BRAKE VALVE
BRAKE VALVE (LEFT)
Outline
There are two brake valves installed in parallel
under the front of the operators cab, and these are
actuated by depressing the pedal.
When the right pedal is depressed, oil is sent to the
brake cylinders to apply the brakes.
When the left pedal is depressed, oil is sent to the
right pedal to apply the brakes in the same way as
when the right pedal is depressed.
In addition, the left brake pedal operates the

transmission cut-off switch to actuate the
transmission solenoid valve electrically and set the
transmission to neutral.
10-77

Operation
Brake applied (right brake valve)
Upper portion
When brake pedal (1) is depressed, the operating force is
transmitted to spool (3) through rod (2) and spring (4). When
spool (3) goes down, drain port a is closed, and the oil from
the pump and accumulator flows from port A to port C and
actuates the rear brake cylinder.
Lower portion
When brake pedal (1) is depressed, the operating force is
transmitted to spool (3) through rod (2) and spring (4). When
spool (3) goes down, spool (5) is also pushed by plunger (6).
When this happens, drain port b is closed, and the oil from
the pump and accumulator flows from port B to port B and
actuates the rear brake cylinder.
Brake applied (left brake pedal)

When pedal (7) is depressed, spool (10) is pushed up by rod
(8) and spring (9), and drain port c is closed. The oil
from the pump and the accumulator flows from port E to port
F.
Port F of the left brake valve and port Pp of the right brake
valve are connected by a hose, so the oil flowing to port F
flows to pilot port Pp of the right brake valve.
The oil entering pilot Pp enters port G from orifice d, and
pushes pilot piston (11). The spring pushes spool (3) down,
so the operation is the same as when the right brake valve is
depressed.
10-78
BRAKE VALVE
BRAKE VALVE
Applying brake when upper valve fails (right brake valve)

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

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

Brake released (right brake valve)
Upper portion
When brake pedal (1) is released and the operating force is
removed from the top of the spool, the back pressure from
the brake cylinder and the force of the spool return spring
move spool (3) up. Drain port a is opened and the oil from
the brake cylinder flows to the hydraulic tank return circuit to
release the rear brake.
Lower portion
When the pedal is released, spool (3) in the upper portion
moves up. At the same time, the back pressure from the
brake cylinder and the force of the spool return spring move
spool (5) up. Drain port b is opened and the oil from the
brake cylinder flows to the hydraulic tank return circuit to
release the front brake.
10-80
BRAKE VALVE
MEMORANDA
10-81
CHARGE VALVE
CHARGE VALVE
A.
ACC.
PP.
P.
T.
10-82
To PPC valve
To brake valve
To brake valve
From pump
Drain
Function
The charge valve is actuated to maintain the oil
pressure from the pump at the specified pressure
and store it in the accumulator.
When the oil pressure reaches the specified
pressure, the oil from the pump is connected to the
drain circuit to reduce the load on the pump.
1.
2.
3.
4.
5.
CHARGE VALVE
Valve body
Main relief valve (R3)
Relief valve (R1)
PPC relief valve (R2)
Relief valve (H1)
10-83

Operation
1. When no oil is being supplied to accumulator (cut-out
condition)
The pressure at port B is higher than the set pressure of
the relief valve (R1), so piston (8) is forcibly pushed up by
the oil pressure at port B. Poppet (6) is opened, so port
C and port T are short circuited.
The spring chamber at the right end of spool (15) is
connected to port C of the relief valve (R1), so the
pressure becomes the tank pressure. The oil from the
pump enters port P, pushes spool (15) to the right at a
low pressure equivalent to the load on spring (14), and
flows from port A to the PPC valve. At the same time, it
also passes through orifices (17), (18), and (16), and
flows to the tank.
2. When oil is supplied to accumulator

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

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

Operation
1. When brake pedal is depressed
Before the brake is depressed, piston (4) is returned by the
distance of stroke S (full stroke). When the brake pedal is
depressed, the oil discharged from the brake valve flows
from port P of the slack adjuster and is divided to the left and
right cylinders (2), where it moves piston (4) by stroke S to
the left and right.
When this is done, brake piston (7) moves by a distance of

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

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

When the brake is released, piston (4) is returned by brake
return spring (8) by an amount equivalent to the oil for stroke
S, and the brake is released. In other words, return stroke T
of brake piston (7) is determined by the amount of oil for
stroke S of the slack adjuster. The time lag of the brake is
always kept constant regardless of the wear of the brake
disc.
10-89
BRAKE
BRAKE
1.
2.
3.
4.
5.
6.
7.
8.
10-90
Guide pin
Return spring
Cylinder
Brake piston
Outer gear (138 Teeth)
Inner gear (105 Teeth)
Plate
Disc
Function
The brakes are wet-type multiple disc brakes, and
are fitted to all four wheels.
BRAKE
Operation
When the brake pedal is depressed, the pressure oil from the
brake valve moves brake piston (4) to the right in the direction
of the arrow. This brings disc (8) and plate (7) into contact,
and friction is generated between the disc and plate. The
wheel is rotating together with the disc, so the machine speed
is reduced, and the machine is stopped by this friction.
When the brake pedal is released, the pressure at the back

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

2. Parking brake emergency release switch
Outline
The parking brake is a wet-type multiple-disc brake
built into the transmission. It is installed to the
output shaft bearing, and uses the pushing force of
a spring to apply the brake mechanically and
hydraulic power to release the brake.
When parking brake switch (1) installed in the
operators compartment is switched ON, parking
brake solenoid valve (4) installed to the
transmission control valve (3) shuts off the oil
pressure and applies the parking brake. When the
parking brake switch is turned OFF, the oil pressure
in the cylinder releases the parking brake.
When the parking brake is applied, the neutralizer
10-92
4. Parking brake solenoid valve

5. Transmission (built-in parking brake)
relay shuts off the electric current to the

transmission solenoid valve and keeps the
transmission at neutral.
Emergency release switch (2) for the parking brake
is installed for use when moving the machine, if the
machine has stopped (the parking brake is
automatically applied) because of trouble in the
engine or drive system.
PARKING BRAKE
PARKING BRAKE
Outline
The parking brake is a wet-type multiple-disc brake.
It is actuated mechanically by a spring and applies
the braking force to output shaft (1) of the
transmission.
The pushing force of spring (5) pushes piston (2),
Plate (4), and disc (3) into contact and applies the
braking force to stop output shaft (1).
1.
2.
3.
4.
5.
Output shaft
Piston
Disc
Plate
Spring
10-93
PARKING BRAKE SOLENOID VALVE
Operation
Parking brake applied (solenoid deactivated)
When the parking brake switch in the operators
compartment is turned ON, the solenoid is turned OFF and
spool (6) is pushed to the left by spring (5). When this
happens, the passage between pump port P and parking
brake port A is closed, and the pressure oil from the pump
does not flow to the parking brake.
At the same time, the pressure oil from the parking brake
flows from port A to port T and is drained. As a result, the
disc inside the parking brake is pushed by the spring and the
parking brake is applied.
When the parking brake switch is turned OFF, the solenoid is

turned ON and spool (6) is moved to the right. As a result, the
pressure oil from the pump passes from port P through the
inside of spool (6), flows to port A and then flows to the
parking brake. At the same time, port To is closed, so the oil
is not drained. As a result, the spring inside the parking brake
is pushed back by the oil pressure and the parking brake is
released.
10-94
PARKING BRAKE EMERGENCY RELEASE SOLENOID VALVE
1. Valve assembly
2. Solenoid valve
A:
B:
C:
T:
P:
To parking brake
From parking brake valve
From pilot circuit
Drain
From brake (accumulator circuit)
Function
The emergency release solenoid valve is installed
between the transmission and the transmission
control valve. If the engine breaks down and no oil
pressure is supplied from the transmission pump,
it is possible to actuate the solenoid for the parking
brake release switch in the operators
compartment. This allows the accumulator charge
pressure in the brake circuit to flow to the parking
brake cylinder.
Operation
When the parking brake is emergency release
turned ON, solenoid valve
e
pressure stored in the accumulator
port P. The circuit is switched by pilot pressure, so
the oil flows from port A to the parking brake, to
release the parking brake.
10-95
10-96
MEMORANDA
HYDRAULIC PIPING
HYDRAULIC PIPING
OUTLINE
The hydraulic system consists of the work
equipment circuit and the steering circuit. The
work equipment circuit controls the movement of
the bucket and attachment.
The oil in hydraulic tank (5) is sent to the main
control valve (1) by hydraulic pump (13). When
the bucket and boom spools of the main control
valve are at HOLD, the oil passes through the
drain circuit of the main control valve, is filtered
by the filter inside the hydraulic tank, and then
returns to the tank.
When the work equipment control levers are
operated, the bucket or boom spool of the PPC
valve (6) moves, and the spools of the main
control valve are actuated by hydraulic pressure,
so oil flows from the main control valve to boom
cylinder (17) or bucket cylinder (2) to move the
boom or bucket.
Control of the maximum pressure in the hydraulic
circuit is carried out by the relief valve inside the
main control valve. A safety-suction valve si
installed to the bucket cylinder circuit to protect
the circuit.
Accumulator (10) is installed in the PPC pilot
circuit, so this makes it possible to lower the
boom to the ground even when the engine si
stopped.
Hydraulic tank (5) is a pressurized sealed type
and is equipped with a breather with relief valve.
This compresses the inside of the tank and also
prevents negative pressure, so this prevents
cavitation of the pump.
1.
2.
3.
4.
5.
6.
7.
8.
9.
Main control valve

Bucket cylinder
Steering valve
Orbit-Roll
Hydraulic tank
PPC valve
Solenoid valve
Switch, PPC pump
Check
10.
11.
12.
13.
14.
15.
16.
17.
Accumulator
Radiator
Oil cooler
Hydraulic pump
Steering pump
Cut-off valve
Steering cylinder
Boom cylinder
10-97
WORK EQUIPMENT HYDRAULIC CIRCUIT DIAGRAM
WORK EQUIPMENT HYDRAULIC

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

FOLDOUT 10-99
WORK EQUIPMENT HYDRAULIC CIRCUIT DIAGRAM
(MACHINE WITH OPTIONAL SPECIFICATIONS)
10-99
10-100
MEMORANDA
MEMORANDA
10-101
HYDRAULIC CIRCUIT SYSTEM
10-102

1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
Hydraulic tank
Oil filter
Breather
Switch, PPC (brake) pump
Hydraulic pump
Steering pump
Filter
Accumulator charge valve
Check valve
Accumulator
PPC valve
Main control valve
13A.
Main relief valve
13B.
Bucket spool
13C.
Safety valve with suction
13D.
Unloader valve
13E.
Float selector valve
13F.
Boom spool
13G. Suction valve
13H.
Slow return valve
Boom cylinder
Bucket cylinder
Orbit-roll valve
Stop valve
Steering valve
18A.
Demand spool
18B.
Steering spool
18C.
Steering relief valve
18D.
Safety valve with suction
Steering cylinder
Cut-off valve
Oil cooler
10-103
WORK EQUIPMENT LEVER LINKAGE
1.
2.
3.
4.
5.
Boom lever
Kick-down switch
Hold switch
Bucket lever
Attachment lever
10-104
6.
7.
8.
9.
Solenoid valve for bucket lever

Solenoid valve for boom lever
Safety lever lock
PPC valve
HYDRAULIC TANK
HYDRAULIC TANK
10-105

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

Valve (2) moves up and acts as a check valve.
By-pass valve set pressure: 25.5 kPa (0.26 kg/cm2)
10-106
HYDRAULIC TANK
HYDRAULIC TANK
BREATHER
1.
2.
3.
4.
Body
Filter element
Poppet
Sleeve
Function
Preventing negative pressure inside the tank
The tank is a pressurized, sealed type, so negative
pressure is formed inside the hydraulic tank when
the oil level drops during operations. When this
happens, the difference in pressure between the
tank and the outside atmospheric pressure opens
the poppet (3), and air from the outside is let into
the tank to prevent negative pressure.
Preventing rise in pressure inside the tank

When the hydraulic cylinders are being used, the
oil level in the hydraulic circuit changes and the
temperature rises. If the hydraulic pressure rises
above set pressure, sleeve (4) is actuated to
release the hydraulic pressure inside the tank.
10-107
ACCUMULATOR (FOR PPC VALVE)
ACCUMULATOR (FOR PPC VALVE)

1.
2.
3.
4.
5.
6.
Gas plug
Shell
Poppet
Holder
Bladder
Oil port
Specifications:
Type of gas:
Nitrogen gas
Gas amount:
500 cc
Actuation Pressure:
Maximum: 3.4 MPa (35 kg/cm2)
Minimum: 1.2 MPa (12 kg/cm2)
Function
The accumulator is installed between the
accumulator charge valve and the PPC valve. Even
if the engine stops when the boom is raised, it is
possible to lower the boom and bucket under their
own weight by using the pressure of the nitrogen
gas compressed inside the accumulator to send
the pilot oil pressure to the main control valve to
actuate it.
Operation
After the engine stops, if the PPC valve is at hold,
chamber A inside the bladder is compressed by the
oil pressure in chamber B.
When the PPC valve is operated, the oil pressure
in chamber B goes below 2.9 MPa (30 kg/cm2).
When this happens, the bladder is expanded by the
pressure of the nitrogen gas in chamber A, and the
oil inside chamber B is used as the pilot pressure
to actuate the main control valve.
10-108
MEMORANDA
10-109
PPC VALVE
PPC VALVE
FOR BUCKET / BOOM
P. From PPC pump.

P1. To TILT end of main control valve bucket spool.
P2. To LOWER end of main control valve boom spool.
10-110
P3. To RAISE end of main control valve boom spool.

P4. To DUMP end of main control valve bucket.
T. Drain.
1.
2.
3.
4.
5.
Bolt
Piston
Plate
Collar
Retainer
PPC VALVE
6.
7.
8.
9.
Centering spring
Metering spring
Valve
Body
10-111

FOR OPTION
P.
P2.
P3.
T.
From PPC pump.

To main control valve attachment spool.
To main control valve attachment spool.
Drain.
10-112
PPC VALVE
1.
2.
3.
4.
5.
Bolt
Piston
Plate
Collar
Retainer
PPC VALVE
6.
7.
8.
9.
Centering spring
Metering spring
Valve
Body
10-113

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

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

The ppc valve supplies pressure oil from the charging
pump to the side face of the spool of each control valve
according to the amount of travel of the control lever.
This pressure oil actuates the spool.
Operation
1. Control lever at "hold". (Fig. 1)
Ports PA1, PA4, PB1, and P1 are connected to drain
chamber D through fine control hole (f) in valve (8).
2. Control lever operated slightly (fine control)

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

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

Plate (10) pushes piston (2) down, and piston (2)
forcibly pushes in valve (8). Fine control hole (f) is
shut off from drain chamber D, and is connected to
pump pressure chamber PP. Therefore, pressure
oil from the charging pump passes through fine
control hole (f), and flows from port P4 to chamber
PA1 to push the spool of the control valve. The oil
returning from chamber PB1 flows from port 1P
through fine hole (f1) to drain chamber D.
10-116
PPC VALVE
PPC RELIEF VALVE
PPC RELIEF VALVE
1.
2.
3.
4.
5.
6.
Main valve
Spring
Valve seat
Pilot poppet
Spring
Screw
Function
The PPC relief valve is between the PPC brake
pump and the PPC valve. When the PPC pump is
not being actuated, or when abnormal pressure is
generated, the oil sent from the pump is relieved
through this valve to protect the pump and circuit
from damage.
Operation
The relief valve is installed to the charge valve. Port
A is connected to the pump circuit, and port C is
connected to the drain circuit.
The oil passes through the orifice of main valve (1)
and fills port B. In addition, pilot poppet (4) is
seated in valve seat (3).
When the pressure at port A and B reaches the set
pressure, pilot poppet (4) opens and the oil
pressure at port B escapes from port D to port C to
lower the pressure at port B.
When the pressure at port B goes down, a
difference in pressure is generated at ports A and
B by the orifice in main valve (1). Main valve (1) is
opened by the pressure at port A, and the oil at
port A is drained to port C to relieve the circuit.
10-117
CUT-OFF VALVE
CUT-OFF VALVE
1.
2.
3.
4.
Unload valve
Check valve
Cut-off valve
Screen
C.
P.
T1.
T2.
Port C (from hydraulic pump)

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

Cut-off operation conditions
O: Cut-off (drain)
X: Not actuated (to main control valve)
More than
17.2 MPa
(175 kg/cm2)
Less than
17.2 MPa
(175 kg/cm2)
Kick-down
switch
ON
OPERATION
1. When the work equipment valve is held.
The oil at the switch pump (the oil from the steering
valve) presses up check valve (1), merges with the
oil from the work equipment pump and flows to the
work equipment valve.
2. When the work equipment valve is activated.

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

1) When the work equipment pump pressure
is higher than the cut-off pressure.
When the cut-off pressure is reached, the
pressure of the oil in chamber a opens cut-off
valve (2), and the oil in unload valve (3)
chamber b passes through cut-off valve (2)
chamber c and is drained. The oil in unload
valve (3) chamber d passes through orifices e
and f, and into chamber b causing the oil
pressure in chamber d decrease, and unload
valve (3) to open. Thus, the oil from the switch
pump is drained.
10-120
CUT-OFF VALVE
MEMORANDA
10-121
MAIN CONTROL VALVE
MAIN CONTROL VALVE
PA1.
PA2.
PB1.
PB2.
P.
P1.
P2.
From PPC valve P4

From PPC valve P2
From PPC valve P1
From PPC valve P3
From pump
From PPC valve P2
From PPC valve P3
A1. To bucket cylinder bottom end
10-122
A2. To boom cylinder bottom end

B1. To bucket cylinder head end
B2. To boom cylinder head end
D1. Drain port
D2. Drain port
T.
Drain port
1.
2.
3.
4.
5.
Main relief valve

Bucket spool return spring
Boom spool return spring
Boom spool
Bucket spool
MAIN CONTROL VALVE
6.
7.
8.
9.
10.
Body
Suction valve
Unloader valve
10-123
A1.
A2.
A3.
B1.
A2.
A3.
To attachment cylinder
To bucket cylinder bottom
To boom cylinder bottom
To attachment cylinder
To bucket cylinder head
To boom cylinder head
10-124
MAIN CONTROL VALVE
D1. Drain port

D2. Drain port
P.
From pump
P1.
From PPC valve P2
P2.
From PPC valve P3
PA1.
From option PPC valve
PA2.
PA3.
PB1.
PB2.
PB3.
T.
From PPC valve P4

From PPC valve P2
From option PPC valve
From PPC valve P1
From PPC valve P3
Drain port
1.
2.
3.
4.
5.
6.
Main relief valve

Attachment spool return spring
Bucket spool return spring
Boom spool
Bucket spool
MAIN CONTROL VALVE
7.
8.
9.
10.
11.
12.
Attachment spool
Body
Unloader valve
Suction valve
10-125
MAIN CONTROL VALVE
Outline
The main control valve controls the actuation of the
attachments and the bucket in the hydraulic system. It has a tandem circuit which gives priority to
the bucket circuit.
The oil from the pump enters port P. The maximum
pressure is set by the main relief valve. The oil
passes through the by-pass circuit of dump spool
(5) and lift spool (4). It then flows from port T to the
drain circuit, passes through the filter and returns to
the tank. If the dump and lift spools are actuated,
the oil flows to the dump and lift cylinders.
10-126
However, the circuit gives priority to the bucket, so

when the dump spool is being operated, even if the
lift spool is operated, the lift arm will not move.
There are two safety valves (with suction valves)
(10) to protect the circuit if abnormal pressure is
generated in the bucket circuit. If one of the two
safety valves is acting as a relief valve, the other
valve acts as a suction valve to make up for any
lack of oil.
MEMORANDA
10-127
MAIN CONTROL VALVE
RELIEF VALVE
1.
2.
3.
4.
5.
6.
Main valve
Valve seat
Pilot poppet
Pilot poppet spring
Adjustment screw
Lock nut
Set pressure:
Function
The relief valve is installed to the inlet portion of the
main control valve. If the oil goes above the set
pressure, the relief valve drains the oil to the tank to set
the maximum pressure for the work equipment circuit,
and to protect the circuit.
Operation
Port A is connected to the pump circuit and port B
is connected to the drain circuit. The oil passes
through the orifice of the main valve (1) and fills
port B. Pilot poppet (3) is seated in valve seat (2).
If the pressure port A and port B reaches the set
pressure of pilot poppet spring (4), pilot poppet (3)
opens, and the oil pressure at port B escapes from
port D to port C, so the pressure at port B drops.
When the pressure at port B drops, a difference in
pressure between port A and port B is created by
the orifice of main valve (1). The main valve is
pushed open and the oil at port A passes through
port C, and flows to the drain circuit to release the
abnormal pressure.
The set pressure can be varied by changing the
tension of pilot poppet spring (4). To change the set
pressure, remove cap nut, loosen lock nut (6) and
turn adjustment screw (5), to adjust the set
pressure as follows:
Tighten to increase pressure
Loosen to decrease pressure
10-128
20.6 MPa (210 kg/cm2)
MAIN CONTROL VALVE
SAFETY VALVE (WITH SUCTION)
1.
2.
3.
4.
5.
6.
Suction valve
Main valve
Main valve spring
Pilot piston
Suction valve spring
Valve body
Set pressure:
22.6 MPa (230 kg/cm2)
Function
The safety valve is in the bucket cylinder circuit
inside the main control valve. If any abnormal
pressure is generated by any shock to the cylinder
when the main control valve is at the neutral
position, this valve relieves the abnormal pressure
to prevent damage to the cylinder.
Operation
1. Operation as safety valve.
Port A is connected to the cylinder circuit and
port B is connected to the drain circuit. The oil
pressure at port A is sent to port D from the
hole in pilot piston (4). It is also sent to port C
by the orifice formed from main valve (2) and
pilot piston (4). Pilot piston (4) is secured to the
safety valve, and the size of the cross-sectional
surface (cross-sectional area) has the
following relationship: d2 > d1 > d3 > d4.
If abnormal pressure is created at port A,
suction valve (1) is not actuated because of
relationship d2 > d1 >, but relationship between
port A and port C is d3 > d4 , so main valve (2)
receives oil pressure equivalent to the
difference between the areas of d3 and d4 . If
the oil pressure reaches the force (set
pressure) of main valve spring (3), main valve
(2) is actuated, and the oil from port A flows to
port B.
10-129
MAIN CONTROL VALVE
2. Operation as suction valve

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

FLOAT
SELECTOR
UNLOADER VALVE
VALVE
MAIN CONTROL VALVE

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

port B becomes greater than the specified
pressure, float selector valve (2) is moved to the
right, and port C and port D open.
When port C opened, the oil pressure in chamber
E drops, unload valve (4) is moved up in the
direction of the arrow, and the oil from the pump
flows to the drain circuit, and also flows to the rod
end of the boom cylinders.
The oil at the bottom end of the boom cylinders is
connected to the drain circuit and forms the FLOAT
position.
10-131
MAIN CONTROL VALVE
BOOM SPOOL AT RAISE POSITION
Operation
The oil from the pump enters port A and the maximum pressure is set by the relief valve (11).
Bucket spool (1) is at HOLD, so the by-pass circuit is
open. The oil at port A passes around the spool and
flows to port B. Boom spool (2) is also at HOLD, so
the by-pass circuit is open. The oil at port B passes
around the spool and flows to port C in the drain
circuit. From here it passes through the filter and
returns to the tank.
10-132
The oil from the PPC pump passes through check

valve (13) and enters port L of the PPC valve.
However, the boom and bucket levers are at the
HOLD position, so the oil returns from PPC relief
valve (12) to the hydraulic tank.
MAIN CONTROL VALVE
BOOM SPOOL AT RAISE POSITION
Operation
When boom lever (3) is pulled, pressure oil from
port L of the PPC valve flows to port N and port S.
The oil in port T passes through port M and flows to
the drain circuit. The pressure oil in port S pushes
the push piston against the force of the spring and
moves boom spool (2) to the RAISE position.
open check valve (10). The oil then flows from port
H to port I, and goes to the bottom end of the
cylinder.
At the same time, the oil at the rod end of the
cylinder flows from port K to drain port C, and
returns to the tank. Therefore, the boom rises.
The oil flows from the pump through the by-pass

circuit of the bucket spool, and then flows to the bypass circuit of boom spool (2). The by-pass circuit
is closed by the spool, so the oil pushes
10-133
MAIN CONTROL VALVE
BOOM SPOOL AT LOWER POSITION
Operation
When boom lever (3) is pushed, pressure oil from
port L of the PPC valve flows to port M and port T. In
addition the oil at port S is connected to the drain
circuit. The pressure oil at port T pushes the push
piston against the force of the spring and moves
boom spool (2) to the LOWER position
The oil from the pump passes through the by-pass
circuit of the bucket spool and flows to the by-pass
circuit of boom spool (2). The by-pass circuit is
closed by the spool, so the oil pushes open check
10-134
valve (10). The oil then flows from port J to port K,

and goes to the rod end of the cylinder.
At the same time, the oil at the bottom end of the
cylinder flows from port I to drain port C, and
returns to the tank. Therefore, the boom goes
down.
MAIN CONTROL VALVE
BOOM SPOOL AT FLOAT POSITION
Operation
When boom lever (3) is pushed to the FLOAT
position, the spool of the PPC valve moves further
from the LOWER position to the FLOAT position.
Pressure oil at port L flows to port M, and at the same
time, it also flows to port T and port W. In addition,
the pressurized oil at port S flows to port N.
The pressure oil at port T pushes the push piston
against the force of the spring and moves boom
spool (2) to the LOWER position.
If the pressure difference between port W and port X
goes above the specified level, valve (7) moves to the
right and opens ports C1 and C to connect them
to the drain circuit. When port C1 1 is connected to

the drain circuit, unload valve (8) moves up, and
the oil from the pump flows to the drain circuit.
Therefore, the oil at the rod end of the cylinder
flows from port K, and then flows from unload
valves (8) to the drain circuit. At the same time, the
oil at the bottom end of the cylinder flows from port
I to port C, and then flows to the drain circuit.
Therefore, the boom is set to the FLOAT condition.
10-135
MAIN CONTROL VALVE
BUCKET SPOOL AT DUMP POSITION
Operation
When bucket lever (4) is pushed, pressure oil from
port L of the PPC valve flows to port V via port Q. In
addition, the oil at port R is connected to the drain
circuit. The pressure oil at port V pushes the push
piston against the force of the spring and moves
bucket spool (1) to the DUMP position.
The by-pass circuit is closed by bucket spool (1), so
the oil from port A pushes open check valve (9).
The oil from check valve (9) then flows from port F
and enters port G, and goes to the rod end of the
cylinder.
10-136
At the same time, the oil at the bottom end of the

cylinder flows from port D to drain port C, and
returns to the tank. Therefore, the bucket is
dumped.
MAIN CONTROL VALVE
BUCKET SPOOL AT TILT POSITION
Operation
When bucket lever (4) is pulled, the pressure oil at
port L of the PPC valve flows to port R via port P. The
oil in port V is connected to the drain circuit. The
pressure oil at port R pushes the push piston against
the force of the spring and moves bucket spool (1) to
the TILT position.
The by-pass circuit is closed by bucket spool (1), so
the oil from port A pushes open check valve (9). The
oil from check valve (9) flows from port D to port E,

and goes to the bottom end of the cylinder.
At the same time, the oil at the rod end of the
cylinder flows from port G to drain port C, and
returns to the tank. Therefore, the bucket is tilted.
10-137
WORK EQUIPMENT LINKAGE
1.
2.
3.
4.
5.
Bucket
Bellcrank
Bucket cylinder
Boom cylinder
Boom
10-138
6.
7.
8.
9.
Bucket link
Bucket hinge pin
Cord ring
Cord ring
10-139
BUCKET
1. Bucket
2. Tooth
3. Corner tooth
10-140
BUCKET
MEMORANDA
10-141
BUCKET POSITIONER / BOOM KICK-OUT
BUCKET POSITIONER AND BOOM KICK-OUT
10-142
BUCKET POSITIONER / BOOM KICK-OUT
Bucket positioner
The bucket positioner is electrically actuated and is
used to automatically obtain the optimum digging
angle for the bucket.
When the bucket is moved from the DUMP position
to the TILT position, and it reaches the desired
angle, the dump lever is automatically moved from
the TILT position to the neutral.
Lever (4) is secured by bolts to dump cylinder rod
(3). A proximity switch (1) is fixed by bolts to the
cylinder.
When the bucket is moved from the DUMP position
to the TILT position, the dump cylinder rod moves
to the left. At the same time, lever (4) also moves
to the left. When it reaches the desired position,
lever (4) separates from proximity switch, and the
bucket lever returns to neutral.
Boom kick-out
The boom kick-out is electrically operated and acts
to stop the lift arm. When the lift arm reaches the
desired position before the maximum height, the lift
arm lever is returned to neutral.
Plate (5) is secured to the lift arm. A proximity
switch (2) is fixed to the frame. When the lift arm is
moved from the LOWER position to the RAISE
position, the lift arm rises. When it reaches the
desired position, the proximity switch and plate
come into contact and the lift arm lever is returned
to neutral.
10-143
PROXIMITY SWITCH
PROXIMITY SWITCH
Function
Proximity switches are installed by a support to the
boom and bucket cylinders. The lift arm RAISE
position and the TILT BACK position can be
selected to match the operating conditions. When
these positions are reached, a pulse is generated
from the
Operation of Proximity Switch

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

or dump lever is returned to the hold position. When
this happens, the main control valve is also returned to
hold and the movement of the lift arm or bucket stops.
PROXIMITY SWITCH
When the boom lever is moved to the RAISE

position, the lever cam and the cam follower keep
the lift spool in the RAISE position, so the boom
arm goes up.
10-145
PROXIMITY SWITCH
Kick-out
When the boom goes up and reaches the set
position for the kick-out (that is, the detection unit
(steel plate) is separated from the sensing surface
of the proximity switch), the proximity switch and
relay circuit act to send electric current to the magnet

coil. This actuates the magnet, the cam is pulled out of
the cam detent, and the lift spool is returned to the
neutral position by the return spring.
Action of proximity switch

Position
Proximity switch actuation

display
When detector is in position at

detection surface of proximity switch
When detector is separated from

detection surface of proximity
switch
Lights up
Goes out
Proximity switch load circuit

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

(Solenoid circuit)
Current flows
Current shut off
10-146
PROXIMITY SWITCH
BUCKET "TILT"
Hold
When the bucket is dumped beyond the set
position for the bucket leveler, the sensor (steel
plate) is above the detection surface of the bucket
proximity switch, so electric current flows in the
proximity switch load circuit. The positioner relay is
turned ON and the current for the solenoid is shut
off.
10-147

Tilt
When the bucket lever is moved to the TILT
position, the bucket spool is held at the TILT
position by the cam follower and cam on the lever,
and the bucket tilts.
10-148
PROXIMITY SWITCH
PROXIMITY SWITCH
Positioned
When the bucket tilts and reaches the set position
for the bucket leveler (that is, the detection unit
(steel plate) is separated from the sensing surface
of the proximity switch), the proximity switch and
relay circuit act to send electric current to the
magnet coil. This actuates the magnet, the cam is
pulled out of the cam detent, and the dump spool
is returned to the neutral position by the return
spring.
Action of proximity switch

Position
Proximity switch actuation

display
Positioner relay
Solenoid (for bucket)
When sensor is in position at

detection surface of proximity switch
When sensor is separated from

detection surface of proximity
switch
Lights up
Goes out
Current flows
Current shut off
Current shut off
Current flows
10-149
CAB
1.
2.
3.
4.
Front glass
Front wiper
Rear wiper
Door
10-150
CAB
ROPS CANOPY
ROPS CANOPY
1. ROPS guard
2. Cab
10-151
AIR CONDITIONER
AIR CONDITIONER
AIR CONDITIONER PIPING
1.
2.
3.
4.
5.
Vent
Window defroster
Vent
Dry receiver
Air conditioner condenser
10-152
6.
7.
8.
9.
Compressor
Hot water inlet port
Hot water outlet port
Air conditioner unit
AIR CONDITIONER
AIR CONDITIONING (GENERAL)

BASIC INFORMATION ON AIR CONDITIONERS
UNITS RELATED TO REFRIGERATION
Heat
The kinetic energy of the molecular activity of a
substance takes the form of heat. If a substance is
given heat by any other substance, its temperature
will rise. If heat is taken away by another body, the
temperature will decrease.
1. Quantity of heat.
If the heat is transferred from one substance to
another, the temperatures of both substances will
change. The amount of change in temperature will
depend on the quantity of heat transferred. The
quantity of heat is indicated in units of calories (cal)
or kilocalories (Kcal). One cal denotes the quantity
of heat required to raise the temperature of 1g of
water by 1 degree. One Kcal denotes the quantity
of heat required to raise the temperature of 1 kg of
water by 1 degree.
2. Specific heat.
The quantity of heat required to raise or lower the
temperature of substance varies depending on the
type, weight, and amount of change in temperature
of the substance. The quantity of heat required to
raise the temperature of one unit weight of a
substance by 1 degree is called the "specific heat"
of the substance. The unit of the specific heat is
"kcal/kg C. The specific heat is often indicated with
a numerical value without the unit.
The larger the specific heat of a substance, the
more difficult it is for the substance to warm up and
cool down. The specific heat of water is 1, the
largest value of any solid or liquid.
Substance
Specific heat (Kcal/kg
Water
1.0
Alcohol
0.57
Ice
0.49
Iron
0.11
Copper
0.09
Aluminum
0.21
10-153

Temperature
When cooling or warming a substance, the units of
warmth or coolness measurement are expressed as
degrees C (Centigrade) or F (Fahrenheit).
1. Scales of temperature.
The temperature at which water freezes at the
standard barometric pressure (1 barometric
pressure) (the "freezing point"):
Centigrade . . . . . . . . . . . . . . . . 0 degree ( C)
Fahrenheit . . . . . . . . . . . . . . . 32 degrees ( F)
Temperature at which water boils at the standard
barometric pressure (the "boiling point"):
Centigrade . . . . . . . . . . . . . . . 100 degrees ( C)
Fahrenheit . . . . . . . . . . . . . . . 212 degrees ( F)
On the Centigrade scale, the scale is equally
divided into 100 graduations ranging from 0 to 100
degrees. One graduation is 1
e
below the freezing point (a sub-zero temperature)
is indicated by a negative number, such as -a
On the Fahrenheit scale, the scale is divided into
180 graduations ranging from 32 to 212 degrees.
One graduation is 1
F is called sub-zero temperature and indicated by
a negative number, such as -B F.
Relationship between the Centigrade and the
Fahrenheit scales:
Centigrade and Fahrenheit temperatures can be
converted according to the following formulas:
Centigrade temperature (
Fahrenheit temperature (
10-154
AIR CONDITIONER
AIR CONDITIONER
2. Absolute temperature (Kelvin scale)

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

4. Vacuum and the degree of the vacuum.
Normally, a pressure gauge has a red zone on its
scale to indicate the pressure below 0 kg/cm. Any
gas pressure indicated in the red zone is below the
atmospheric pressure.
The term "vacuum" refers to a given space filled
with gas at a pressure below the atmospheric
pressure. A perfect vacuum refers to a space
completely empty of gas pressure (an absolute
pressure of 0 kg/cm abs).
The degree of vacuum applies to the static
pressure below the atmospheric pressure and is
indicated in terms of absolute pressure in units of
cm Hg. On the gauge scale, the atmospheric
pressure is set at zero and the perfect vacuum is
set at 76 cm Hg. To convert the reading, h cm Hg,
of the vacuum gauge into the absolute pressure P
kg/cm abs., the following formula is used:
P = 1.03 x (1 - h/76)
In this case, the degree of vacuum is (76-h) cm Hg.
Humidity
The amount of water contained in the air is called
the humidity. Humidity is generally classified into
absolute humidity and relative humidity.
1. Absolute humidity.
The absolute humidity is the weight of moisture per
kg of dry air contained in the wet air, expressed in
units of x kg/kg. Practically, an air diagram is used
to indicate the weight of moisture contained in 1 kg
of wet air. For example, if 30 g of moisture is
contained in 1 kg of wet air, the absolute humidity
on the air diagram is indicated as follows:
Absolute humidity = 0.03 (kg)/1 (kg) = 0.03 kg/kg.
2. Relative humidity.
The ratio between the water partial pressure P
(kg/cm) of the wet air and the max. partial
pressure Ps contained in the water at that humidity
(the water partial pressure of the saturated air) is
called the "relative humidity".
That is, Relative humidity = P/Ps x 100 (%).
Generally, when we speak of humidity, we mean
relative humidity. This is the humidity obtained from
a home hygrometer or a weather forecast.
10-155-1
AIR CONDITIONER
AIR CONDITIONER
PRINCIPLE OF COOLING
1. Why do coolers cool?
We have all experienced the cold feeling when we
are sweating and the wind blows, or when we put a
liquid like alcohol on our skin. This feeling occurs
because water and alcohol draw heat from the
surrounding area when evaporating and turning
into gas. If we express this another way, if we apply
heat to a liquid it turns into gas. This is called
evaporation latent heat.
In a cooler, freon (R134a) is used instead of
alcohol. When the liquid freon (R134a) turns into
gas, it takes latent heat from its surroundings.
However, if it is allowed to disperse as a gas, this is
uneconomical. We need a device which can collect
this gas and turn it back into liquid before
evaporating it again, and then repeat this cycle
continuously. A cooler is such a device. The fluid
which turns into a liquid and then becomes a gas to
cool the surroundings is called the refrigerant.
2. Refrigerator using evaporation latent heat
The liquid refrigerant freon (R134a) is sent under
high pressure through a valve where it is allowed to
expand and is sent to the heat exchanger. The
refrigerant takes heat from the air in the room (or
cab) sucked in by low pressure vapor (moist
vapor), turns into gas (super heated vapor) and is
discharged. The air which has lost its heat is blown
into the cooled room. This is the basic principle of
the cooler, but using only this device to cool is
uneconomical and not very practical.
3. Refrigeration method (Vapor compression)
The refrigerant gas is compressed by a
compressor (adiabatic compression) and changes
to high temperature and high compression. It is
then sent to the condenser and undergoes forced
cooling in the condenser to be turned to liquid. If
this liquefied refrigerant is expanded suddenly at
the expansion valve, it changes into a low
temperature and low pressure mist and flows inside
the evaporator.
The refrigerant, which enters the evaporator as a
mist, passes through the fins of the evaporator and
takes latent evaporation heat from the surrounding
air. This causes it to evaporate and turn to its
original gaseous condition. In this way it acts to cool
the surrounding air.
10-155-2

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

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

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

pressurized. However, if it is cooled at the same time as
being pressurized, it can be liquefied easily.
For this reason, compressors and condensers are
needed in the present refrigerating systems.
B) Properties of R-134a
Using R-134a as an example, let us explain
how the refrigerant can be liquefied.
High temperature (70
5
kg/cm) gaseous refrigerant is compressed in
the compressor. It then enters the condenser
where it is cooled and liquefied.
R-134a starts to liquefy at about 62
5
kg/cm, so the temperature of the refrigerant
need only be brought below 62
10-155-4
AIR CONDITIONER
C) Temperature and pressure in the refrigeration cycle
1. Receiver
2. Evaporator
3. Condenser
In the refrigeration cycle, the refrigerant transforms

from a liquid to a gas (evaporation) and from a gas to
a liquid (condensation). Both the temperature and
pressure of the refrigerant vary throughout the
refrigeration cycle.
The figure above indicates variations of the temperature
and pressure in the refrigeration cycle. (The numbers
in the diagram are taken from the design values of a
standard air conditioner, and are given only for
reference. These values vary depending on the
conditions for the actual cycle).
10-155-5
4. Compressor
5. Blower
6. Expansion valve
AIR CONDITIONER
5. Heating cycle
The heating cycle uses cooling water taken from
the engine cooling system.
A) The cooling water absorbs the heat from the
engine, and its flow is controlled by the water
valve to enter the heater core.
B) In the heater core, the heat of the cooling
water is transferred to the air at the surface of
the core.
C) The heat is sent by the blower to the operator's
compartment.
D) The cooling water which has given up its heat
in the heater core returns to the engine.
By repeating the above steps (A) to (B), the inside
of the operator's compartment is heated.
10-155-6

REFRIGERANTS
The refrigerant plays the most important role in the
refrigeration cycle. Various kinds of refrigerants are
available for various types of applications. The most
critical characteristic of a refrigerant is the ease with it
liquefies and vaporizes at normal or low temperatures.
However, only a few kinds of refrigerants are used in air
conditioners, depending on various conditions, such as
the type of compressor, evaporation temperature
(pressure), and condensation temperature (pressure).
Ammonia and freon type gases, which satisfy the
requirements, are widely used. Air conditioners usually
use "freon type" gases because of their safety and the
small size required for a refrigeration system.
Freon-type gases
Components in this system are compatible with
Refrigerant
134a
(CCL2F2
Dichlorodifluoromethane). Use of other refrigerants
would not achieve performance characteristics,
and more importantly, would, in most cases,
chemically deteriorate components.
SAFETY PRECAUTIONS
WARNING! The refrigerant R-134a can be a
fire and health hazard if handled incorrectly.
Avoid contact with the substance and never
expose it to extreme heat, sparks or open
flame.
The substance used in the air conditioning system,
called R-134a is basically a safe, non-toxic refrigerant.
However, when it is exposed to an open flame, it
changes to a very highly poisonous and deadly
phosgene gas. This phosgene gas will tarnish bright
metal surfaces.
The liquid refrigerant will boil (or vaporize at -29.8
(-21.7 F) at atmospheric pressure (or when it is
exposed to the air). It also evaporates so rapidly that the
gas may displace the oxygen in the area, if it happens
to be a small enclosed area. Therefore, whenever the
system is worked on, a safe practice would be to work
on it in a well ventilated area.
The refrigerant, when exposed to the air, is
approximately -29 C (-21 F). Upon contact with the skin,
the effect is just like frostbite. Treat the same as you
would for frostbite.
If the refrigerant contacts the eyes, immediately flush
the eyes with water and continue to do so until the
temperature is above the freezing point. Consult an eye
specialist immediately. Blindness could result from an
injury of this sort and it is highly recommended that
safety goggles be worn whenever servicing the system
10-155-7
AIR CONDITIONER
AIR CONDITIONER
If the air conditioning system must be discharged, do it

out of doors or in a well ventilated area where no
extreme heat or open flame is present. Release the
refrigerant slowly as it will suck the oil from the
compressor if the system is opened too fast.
Always use the correct type of hoses for the air
conditioning system. Do not use any hose which is not
specified for refrigeration use. Never apply heat of any
sort on any of the air conditioning hoses or components
of the system while it is charged. The extra heat could
cause the pressure of the refrigerant in the system to
become excessive and cause a dangerous rupture.
Be sure the pressurized refrigerant containers are
never exposed to or stored in an area where the
temperature could exceed 52
Do not discard empty refrigerant containers where they
might be subjected to a temperature of 52
or higher.
Do not add alcohol or other liquid driers to the system
to prevent freeze-up. The desiccant in the dryer prefers
alcohol to water and will discharge moisture to absorb
alcohol.
Refrigerant oil is the exception to the rule that water and
oil do not mix. If left in an open container it will absorb
moisture and may cause freeze-ups at the expansion
valve or sludge build up.
Use only refrigerant oil in the compressor.
Remember:
1. Wear safety goggles.
2. Keep refrigerant away from heat, flame or sparks.
3. Do not smoke or have an open flame near when
discharging refrigerant.
4. Work in a well ventilated area.
5. Avoid physical contact with refrigerant.
REFRIGERATOR OIL (LUBE OIL)
The lubricant used in air conditioners is generally called
refrigerator oil. Its purpose in the compressor is to
minimize wear of the piston, cylinder walls, and other
frictional parts like bearings, and to prevent them from
seizing by removing the heat created by friction. In
addition, the substance helps prevent leakage of
refrigerant by maintaining a uniform thin oil film on the
contact surface of parts.
10-155-8

Freon type refrigerant dissolves in oil better than
ammonia does. When the freon is dissolved in oil, the
freezing point of the oil goes down, which causes no
hindrance to the use of the oil at low temperatures. The
flash point and the ignition point of the refrigerant oil are
ordinarily 160
,
respectively.
The lube oil for air conditioners will contact refrigerant.
Thus, the viscosity of the oil when mixed with refrigerant
is an important factor in the selection of the refrigerant
oil. The lube oil used in air conditioners is a mineral oil
refined from petroleum, and various types are
available. The refrigerant has a large effect on the
durability of the compressor and therefore, the oil must
conform to that specified for each compressor.
Characteristics of SUNISO (SUNISO is a U.S.
specification) refrigerator oil:.
1. Chemical stability
The oil is resistant to chemical reactions with the
refrigerant or any other substance in the system.
2. Thermal stability
No carbon deposits are formed at high
temperatures in the valve and delivery (discharge)
portion of the compressor.
3. Low wax content
The flocculent material does not separate from the
oil-refrigerant mixture in the low-temperature
portion of the refrigeration system.
4. Low pour point
The oil in the refrigeration system does not freeze
because the pour point is lower than the lowest
temperature in the system.
5. High insulation resistance
6. Proper viscosity
Excessive wear of the compressor is prevented
because the proper viscosity is maintained even at
high temperatures. Sufficient fluidity of the oil is
maintained at low temperatures and a satisfactory
oil film is formed at all times.
7. Cleanliness of oil
No dust, or foreign matter that accelerate the
deterioration of oil are mixed in the oil. Thus, the
cylinder liners and bearings will not get flawed and
oil grooves will not get clogged.
10-155-9
AIR CONDITIONER
AIR CONDITIONING CONDENSER

FUNCTION
In a refrigeration system, the job of the condenser is to
convert the heated, high pressure gaseous refrigerant
compressed in the compressor back into a liquid
refrigerant. Heat at the same time dissipates into the
atmosphere. An auxiliary fan helps force the heat
exchange.
GENERAL DESCRIPTION
In the condenser, the quantity of heat to be emitted
from the gaseous refrigerant depends on the quantity of
heat absorbed from the room air in the evaporator and
the work to be done to compress the gas in the
compressor. Accordingly, the effect of the heat
radiation on the cooling effect is so large that the forced
cooling is performed by two special cooling fans, in
addition to the cooling fan for the engine radiator. This
independent condenser helps prevent overheating of
the engine and does not effect engine performance.
1. 2-Stage control of condenser fan motor

The electric fan of the condenser is controlled to
two speeds by the pressure of the refrigerant on
the pressure side.
If the pressure of the refrigerant on the high
pressure side rises above 18 kg/cm, the pressure
switch is turned ON and the fan motor runs at high
speed.
When the pressure of the refrigerant on the high
pressure side drops below 14 kg/cm, the pressure
switch is turned OFF and a resistor reduces the
voltage to make the fan motor run at low speed.
This extends the life of the fan motor, and also
avoids the unnecessary use of electricity.
10-155-10

2. Pressure switch
This switches ON and OFF according to the
pressure of the refrigerant.
ON:
14 kg/cm (199 psi)
OFF: 18 kg/cm (266 psi)
1) Pressure switch
3. Defrosting device
Frost can build up on the evaporator fins if their
temperature drops below freezing. Efficiency will
suffer, so a thermistor has been provided, attached
to the evaporator fins, to signal when the fins are
too cold. If so, the controller will turn off the
magnetic clutch, stopping the compressor.
10-155-11
4. Magnetic clutch
The compressor pulley incorporates a magnetic
clutch to connect and disconnect from the engine.
The clutch engages whenever current is supplied
to its magnet stator coil (air conditioning is switched
on). The drive belt then can power the compressor.
5. Electric fan motor

This turns the electric fan and carries out the forced
cooling of the condenser.
1) Fan
2) Fan motor
10-155-12
AIR CONDITIONER
COMPRESSOR
The compressor is a pump to raise the pressure of the
refrigerant. As the refrigerant pressure increases, so
does its temperature, and the high temperature
refrigerant gas then will condense rapidly in the
condenser by releasing heat to the surroundings.
The compressor illustrated here, a swash plate type,
operates paired pistons on the swash plate. Rotation of
the shaft and attached swash plate operates the pistons
in their bores. The swash plate and shoes convert
rotary motion of the shaft to reciprocating motion of the
pistons.
Intake stroke: When the piston moves to the left, the

right side of the piston draws the refrigerant through the
suction valve while the discharge valve is held closed
against the valve plate.
Discharge stroke: When the piston moves to the left,
the left side of the piston forces out the refrigerant
through the discharge valve while the suction valve is
held closed against the valve plate.
A shaft seal and seal plate seal the compressor shaft.

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

The refrigerant liquified in the condenser is temporarily stored in this tank so that the refrigerant can be supplied to the
evaporator according to the cooling load.
A strainer is provided in the tank and the silica-gel is sealed on the external surface of the strainer. A sight glass and
a fusible plug are provided in the top. The purpose of the strainer and silica-gel is to remove dust and water content from
inside the refrigeration cycle.
If water gets into the refrigeration cycle, functional parts will corrode and/or water can freeze in the small port of the
expansion valve, and obstruct refrigerant flow.
1.
2.
3.
4.
Body
Sight glass
Drier
Drier
10-155-14

1. Fusible plug
A fusible plug, also called a melt bolt, has a hole
through its center which is filled with special solder
that melts at 103
r
cannot ventilate properly, and thoroughly dissipate
the heat, the special solder in the fusible plug will
melt. The refrigerant escapes to the open air
before the pressure in the condenser and receiver
can increase enough to damage them.
When the special solder melts at 103
the pressure of the refrigerant is approx. 30 kg/cm.
2. Sight glass
This small window allows observation of the
refrigerant flowing through the refrigeration cycle.
Generally, if air bubbles appear, the refrigeration
system is lacking refrigerant. When no air bubbles
are observed, the proper quantity of refrigerant is in
the system.
When there is no refrigerant in the system, no
air bubbles will be seen.
10-155-15
RECEIVER
AIR CONDITIONER UNIT

OUTLINE
In this all-season-type air conditioner unit, the air is
cooled and dehumidified through the evaporator and
reheated to the proper temperature through the heater
for a comfortable cab atmosphere. In hot weather, only
the evaporator operates and in cold weather, mainly the
heater operates. In other seasons, particularly rainy
and humid weather, the heater and evaporator operate
to dehumidify and heat the air.
1. BLOWER SWITCH
Acts as the main switch and is used for controlling
the air flow when cooling or heating.
This switch controls the air flow to three levels:
Low Medium High
If the knob is turned to the OFF position, the air
conditioner will stop.
2. AIR CONDITIONER SWITCH
Switching when cooling (power for compressor)
When the button is pressed, the switch is
turned on and the pilot lamp lights up.
When the button is pressed again, the switch is
turned off and the pilot lamp goes out.
If the air conditioner switch is turned on but the
blower switch is still off, the air conditioner will
not work (the pilot lamp does not light up).
Turn the air conditioner switch on after turning
the blower switch on.
3. TEMPERATURE CONTROL
This lever controls the temperature during cooling
or heating.
Move the lever towards (left) the Cool position
to lower the temperature; move the lever
towards (right) the WARM position to raise the
temperature.
If the air conditioner switch and blower switch
are turned on, and the lever is moved to the
WARM position, the air conditioner will give
dehumidifying and heating.
4. AIR SOURCE SELECTOR
This lever switches the source of air during cooling
or heating.
FRESH (right - outside air is brought in) This is
used for normal cooling and heating. Fresh air
from the outside is used in addition to the air
inside the operator's compartment.
RECIRC (left - inside air is recirculated) This is
used for quick cooling and heating.
In this position, only the air inside the operator's
compartment is used.
10-155-16
ELECTRIC CIRCUIT DIAGRAM
AUTO-GREASING
10-161
ELECTRONIC CONTROLLED SUSPENSION SYSTEM (E.C.S.S.)
10-162
10-163

JOYSTICK STEERING REMOTE POSITIONER
10-164
10-165
MACHINE MONITOR SYSTEM
MACHINE MONITOR SYSTEM
1.
2.
3.
4.
Fuel level
Engine water temperature
Torque converter oil temperature
Engine water temperature
OUTLINE
The machine monitor system uses the sensors and
other devices installed to various parts of the
machine to observe the condition of the machine.
It processes this information swiftly and displays it
on the monitor panel to inform the operator of the
condition of the machine.
The machine monitor system consists of the main
monitor, maintenance monitor, sensors, switches,
relays, alarm buzzer, and power source.
The displays can be broadly divided into the
following: Cautions displayed on the monitors
(abnormalities in the machine where an alarm is
given), and normal conditions which are always
displayed on the instrument panel (pilot lamps,
readings for the gauges, speedometer, and service
meter).
10-166
5.
6.
7.
8.
Engine oil level

Brake oil pressure
Engine oil pressure
Air cleaner clogging
There are also various switches built into the

monitor panel which function to operate the
machine.
The main monitor uses the network wiring to send
signals to the controller, and functions to display
the following information:
Shift indicator: 1st - 4th, N, F, R (F and R are
optional).
HOLD
Failure action code, failure code, time elapsed
since failure (failure data display mode).
MAIN MONITOR
MAIN MONITOR
1. Check lamp
2. Caution lamp
3. Caution items
3A. Ground driven steering
actuated (option)
4. Pilot items
4A. Turn signal (left)
4B. Turn signal (right)
4C. High beam
4D. Shift indicator
4E. Speedometer
4F. Shift hold

4G. Parking brake
4H. Ground driven steering
normal (option)
4I. Not used
4J. Failure action code
5. Switches
5A. Auto grease switch
(option)
5B. Travel damper switch
(option)
OUTLINE
The main monitor has a display function for the
speedometer and other gauges, and a switching
function to control the electric components and
controllers.
There is one CPU (Central Processing Unit)
installed internally, and this processes the signals
from the sensors and outputs the display.
5C. Working lamp (front) switch

5D. Working lamp (rear) switch
5E. Transmission cut-off switch
5F. Auto shift, manual selector
switch
A liquid crystal display and LEDs are used for the

display. The switches are embossed sheet
switches.
10-167

MAIN MONITOR DISPLAY FUNCTION
10-168
MAIN MONITOR
MAIN MONITOR
MAIN MONITOR SWITCH FUNCTION

Item
Function
Display
Actuation
Auto-greasing
Forced greasing is carried

out while switch is being
pressed when display is
lighted up.
Lights up (goes out momentarily

when switch is turned ON)
Auto-greasing control
actuated (automatic greasing
carried out at fixed interval)
Flashes (slowly)
Grease empty
Flashes (rapidly)
Abnormality in auto-greasing
controller system
Goes out
Auto-greasing controller not

installed
E.C.S.S. function is
actuated or stopped each
time switch is pressed
Lights up
E.C.S.S. function actuated
Goes out
E.C.S.S. function stopped
Front working lamp lights

up or goes out each time
switch is pressed when
side lamps are lighted up
Lights up
Front working lamp lights up
Goes out
Front working lamp goes out
Rear working lamp lights

up or goes out each time
switch is pressed when
side lamps are lighted up.
Lights up
Rear working lamp lights up
Goes out
Rear working lamp goes out
Transmission cut-off
function is actuated or
stopped each time switch
is pressed
Lights up
Cut-off function actuated
Goes out
Cut-off function stopped
Auto shift mode switches

to manual mode when
switch is pressed
Lights up
Manual mode
Goes out
Auto shift mode
E.C.S.S.
Working lamp
(front)
Working lamp
(rear)
Transmission
cut-off
Manual
10-169
MAIN MONITOR
TROUBLE DATA DISPLAY MODE (When optional controller is installed)

Item
Switch operation
Actuation
Method of switching to
trouble data display
mode
With engine stopped and starting switch turned

ON, press 2nd switch from top on left side of
main monitor (switch below ground driven
steering display) and work lamp (front switch
simultaneously for at least 5 seconds
All switch displays (LEDs) go out, and

failure code is displayed on speedometer
display and time elapsed since failure is
displayed on failure action code display.
1)
Failure code is two-digit display
given in numbers or letters. The
display for the failure now occurring
flashes and the display for past
failures lights up.
2)
The time elapsed since failure is
displayed as a three-digit number to
show how long ago the failure
occurred (the oldest failure time is
displayed. Any time greater than
999H is displayed as 999H).
3)
A maximum of 9 times are stored in
memory for the failure codes.
Method of sending
failure code
Press working lamp (front) switch
Failure code and time elapsed since

failure change to next item
Clearing failure code
Press working lamp (rear) switch

for at least 2 seconds
Failure code and time lapsed since

failure being displayed are cleared.
Failure code for problem now occurring
(flashing display cannot be cleared.
Resetting from travel

data display mode
Press 2nd switch from top on left side of main

monitor (switch below ground driven steering
display) and front working lamp switch
simultaneously for at least 5 seconds, or start
the engine.
Changes to normal display
10-170
MAINTENANCE MONITOR
MAINTENANCE MONITOR
Outline
The maintenance monitor has a display function for
the caution items and gauges, and switch functions
to control the work equipment controller.
The m aintenance monitor consists of the monitor
module, switch module, service meter, case, and
other mechanisms.
The monitor module has a built-in CPU (Central

Processing Unit). It processes the signal from the
sensors, and carries out the display and output.
A liquid crystal display and LEDs are used for the
display portions. The switches are embossed sheet
switches.
10-171

MAINTENANCE MONITOR DISPLAY FUNCTION
10-172
MAINTENANCE MONITOR
MAINTENANCE MONITOR
MAINTENANCE MONITOR SWITCH FUNCTION

Item
Function
Display
Remote boom
positioner LOWER
position setting
Sets stopping position in LOWER

direction for remote boom
positioner (boom position when
switch is pressed is recorded)
Flashes (2.5 sec)
Remote boom
positioner RAISE
position setting
Sets stopping position in RAISE

direction for remote boom
positioner (boom position when
switch is pressed is recorded)
Flashes (2.5 sec)
Selection of remote
boom positioner
RAISE/LOWER
Sets remote boom positioner in

stopping direction (Switches
function each time switch is
pressed)
Goes out
Remote boom positioner

function Off
RAISE lights up

RAISE stop function ON
LOWER lights up

LOWER stop function ON
RAISE, LOWER light

up

RAISE/LOWER stop
function ON
Goes out
Goes out
Actuation
Sets stopping position
Sets stopping position
-
10-173
AUTOMATIC TRANSMISSION SYSTEM
ALL-RANGE ELECTRONIC CONTROL AUTOMATIC

TRANSMISSION SYSTEM
OUTLINE OF SYSTEM
the all-range electronic control automatic

transmission system consist of the transmission
controller, directional and speed levers, engine
speed sensor, speed sensor, and all-speed-range
ECMV (transmission clutch modulation valve).
The transmission controller controls the shifting to
the appropriate speed range according to the lever
position and travel speed signal.
To reduce shock when shifting gear (engaging the
clutch), all-speed-range ECMV carries out
modulation control.
A travel damper function and joystick steering
control function are available as options, and these
controls are possible if the function is installed to
the machine.
To improve durability, there is a safety function
which prevents the machine from moving suddenly
when the engine is started, and a transmission
protection function which protects the clutch when
the direction of travel is changed.
10-174
The self-diagnostic function always observes the

input and output condition, and displays the output
condition on the two 7-segment LED displays on
the transmission controller. There is also a failure
detection function, and if any abnormality occurs, it
displays a failure code. Depending on the
condition, it also displays a failure action code on
the main monitor and flashes the caution lamp to
improve safety.
The transmission controller has a communications
function, and it sends the speed range (N, 1st-4th)
data to the main monitor, which displays the speed
range. (If the joystick mode is used, it also displays
F and R.)
SYSTEM STRUCTURE DIAGRAM
10-175

FUNCTION
1. Auto-shift function.
Shifting the transmission up or down is carried out
when the engine speed is above 1450 rpm. Shifting
is decided by signals from the directional lever,
speed lever, and travel speed sensor according to
(Table 1 Automatic gear shift change point table)
recorded in the memory of the transmission
controller.
1) Speed lever (1st - 4th).
This controls the maximum speed range
(available speed range) for automatic gear
shifting.
Example: Speed lever at 4th: 2nd - 4th
Speed lever at 2nd: 2nd only
2) Directional lever N position.
To prevent the vehicle from moving
accidentally, when the lever is at neutral
position, only the 2nd clutch is engaged.
3) Directional lever F position.
When the directional lever is operated from N
to F, the transmission turns ON the F and 2nd
ECMVs (F2). (Automatic start in 2nd)
a) Shift up (when speed lever is at 4th) When
the accelerator pedal is depressed to
increase the engine speed and the travel
speed rises, when the travel speed
reaches approx. 9.3 km/h, the ECMV 3rd
is turned ON, and at the same time, 2nd is
turned OFF. (Shifting to F3)
When the travel speed rises further to
approx. 17.6 km/h, the ECMV 4th is turned
ON, and at the same time, 3rd is turned
OFF. (Shift to F4)
b) Shift down (speed lever at 4th).
When traveling in 4th, if the accelerator
pedal is let back, and the travel speed
comes down to approx. 15.6 km/h, the
ECMV 3rd is turned ON, and 4th is turned
OFF. (Shift to F3)
When the travel speed goes down to
approx. 9.8 km/h, the ECMV 2nd is turned
ON, and 3rd is turned OFF. (Switches to
F2)
4) Directional lever R position.
Automatic gear shifting is carried out according
to the travel speed between 2nd and 4th
speeds (when the speed lever is at 4th) in the
same way as when the speed lever is at the F
position.
5) Skip shift.
When coasting (in engine speed OFF mode) in
3rd or 4th speed with the accelerator pedal
depressed, if the travel speed is less than 8
km/h, the gear shifts down to 2nd to make it
easier to accelerate. If the travel speed is more
than 8 km/h, the speed range is maintained,
and when the engine speed goes above 1450
10-176

rpm, the gear is shifted to a range that
matches the travel speed.
6) Gear shift prevention interval.
To prevent shift hunting after shifting gear, a
time interval is set to maintain the speed range.
The gear shift prevention interval differs
according to the shift pattern. For details, see
[Table 1 Automatic gear shift change point
table].
2. Modulation control.
The modulation control acts to reduce the shock
when shifting gear (when engaging the clutch). It
uses the data for the engine speed, transmission oil
temperature, and gear shift pattern to control the
clutch oil pressure (including the characteristics
when starting) to match the condition of the
hydraulic circuit to control all speed ranges to the
optimum according to the data in the transmission
modulation table stored in the transmission
controller memory. In addition, to reduce the torque
cut, it carries out modulation control of the ECMV
at the side which switches OFF also.
The transmission modulation data table is set for
each transmission oil temperature. In addition, it
has a learning function (transmission clutch piston
data) to prevent any abnormal time lag when
shifting gear.
3. HOLD function.
When the HOLD switch is pressed, the speed
range is held at the optimum speed range, and
even if the travel speed goes down, the
transmission does not shift down. However, when
switching between forward and reverse, the
transmission normally shifts down to 2nd according
to the travel speed, and then shifts up to the HOLD
shift range according to the travel speed and gear
shifting conditions. (This prevents any unnecessary
shift down when leveling ground, or when traveling
downhill.)
4. Kickdown function.
When operator turns the kickdown switch ON, it
overrides the auto shift and switches down forcibly
to 1st if the conditions (speed range, travel speed)
in [Table 1 Automatic gear shift change point table,
5. Kickdown] are fulfilled.
transmission shifts down to 2nd according

to the deceleration.
(For details, see Fig. 1 F-R selection gear
shift pattern, table 1 Automatic gear shift
change point table, 7. F-R selection.)
b). Alarm buzzer.
When the speed range control and travel
fulfill the conditions for range III, the alarm
buzzer sounds to warn the operator. (If the
engine speed is above 1700 rpm and the
travel speed is above 13 km/h, or the
travel speed is above 14 km/h).
(See Fig. 2 F-R selection alarm buzzer
range.)
4). Manual shift.
If the travel speed sensor is abnormal and it is
impossible to detect the travel speed data, the
transmission is set to manual (shift) mode.
5. Travel mode.
1). Manual mode (option).
It is possible to switch between auto and
manual shift. When using the manual mode,
the gear is shifted according to the operation of
the speed lever. When traveling in F2, it is also
possible to use the kickdown function.
2). Joystick steering control function (option).
a). If the machine is equipped with the joystick
steering function, the operator can switch
between steering wheel and joystick
steering mode as desired.
b). The transmission controller controls the
signals from the travel system. (The
steering system is controlled by the work
equipment controller.)
c). When switching the steering between
steering wheel and joystick steering,
always stop the machine first, return the
speed lever to the N position, then switch
the steering. When this is done, the
transmission controller is set to the neutral
safety condition to prevent the machine
from suddenly moving.
6. Safety function.
1). Neutral safety.
When the engine is started, if the directional
lever is at any position other than N, the
transmission controller keeps the transmission
in neutral and prevents the machine from
moving. If the N signal is input after the engine
is started, the neutral safety is canceled.
2). Speed lever priority.
It is possible to shift down immediately by
operating the speed lever, so the engine can
be used as a brake when traveling downhill.
3). Transmission protection.
When traveling in 3rd or 4th speed, the travel
speed is controlled and a warning buzzer
sounds to protect the transmission when
shifting between forward and reverse.
a). Speed range control.
speed fulfill the conditions for range I, the
transmission shifts down to 2nd.
speed fulfill the conditions for range II, the
speed range is maintained and the
10-177

Table 1:
Automatic gear shift change point table.

Item
1. Basic shift change.
Speed
range
Travel speed
(Km/h)
Gear shift
prevention interval
5.1 (5.3) or above
8.7 (9.2) or above
16.5 or above
Less than 14.5
Less than 9.2 (8.7)
2. Engine speed.
(less than 1450
rpm)
Less than 1.0
Less than 1.0
3. Engine speed.
(less than 1450
rpm
1450 rpm)
Less than 8.0
Less than 8.0
4. Shift when HOLD is

ON.
5.1
8.7
16.5
Whole range
Less than 12.0
Less than 12.0
4
3
1
(Note 1)
5. Shift down when

kickdown is ON.
6. FR selection (range I)
(F
(R
7. FR selection (range II)

(F
(R
(Note 2)
16.5 or above
Less than 14.5 - 16.5
86.
16.5 or above
Less than 8.7 - 16.5
Less than 8.7
FR selection
(F
(R
Note 1:
When the engine speed is less than 1900 rpm and the travel speed is less than 16 km/h, or the travel
speed is less than 13 km/h.
Note 2:
When the travel speed is 1900 rpm or above and the travel speed is 13 km/h or above, or the travel speed
is 16 km/h or above, the speed range maintained and the transmission shifts down to 2nd according to
deceleration.
10-178
10-179

7. Self-diagnostic function
The transmission controller always observes the
input and output signals of the automatic gear
shifting system. It carries out self diagnosis and
displays the results on the LEDs of the
transmission controller. In addition, it sends the
following data to the main monitor.
Table 2:

1) Normal display:
Transmission controller LEDs display output range.
2) Failure code display:
If an abnormality is detected, the nature of the
failure is displayed as a code. For details of failure
code, see Table 2 Failure code table.
Failure code table.
Code
Item
System
Main Monitor
Short Circuit
Disconnection
Action Code
10
Back-up alarm relay
None
11
None
12
F ECMV solenoid
Call
13
R ECMV solenoid
Call
14
1st ECMV solenoid
Call
15
2nd ECMV solenoid
Call
16
3rd ECMV solenoid
Call
17
4th ECMV solenoid
Call
18
None
19
Joystick direction switch
E00
20
Directional switch signal
Call
21
Range switch signal
None
22
Travel speed sensor
E00
23
Engine speed sensor
E00
24
Abnormality in memory (EEPROM)
None
25
Transmission oil temperature sensor
E01
26
F ECMV fill switch
Call
27
R ECMV fill switch
Call
28
1st ECMV fill switch
Call
29
2nd ECMV fill switch
Call
30
3rd ECMV fill switch
Call
31
4th ECMV fill switch
Call
32
F or R ECMV fill switch
E00
33
1st, 2nd, 3rd, or 4th ECMV fill switch
E00
10-180

8. Communications function
The transmission controller is equipped with a
communications function using S-NET. It always
maintains communications with the main monitor,
and when the engine is started, it receives model,
travel damper availability, and tire compensation
data.
When any abnormality occurs, it displays an action
code on the main monitor according to the
condition of the problem to warn the operator in
order to increase safety.
The failure code can recognize the codes recorded
in the main monitor memory using the main
monitor problem history mode. For details of
operating the main monitor, see the section on the
main monitor.
9. Travel damper (option)
If the machine is equipped with a travel damper
function, the operator can use this function by
operating a switch.
When the engine is started, the availability of the
travel damper function is transmitted from the main
monitor, and the troubleshooting function can also
be actuated for the travel damper system.
TRANSMISSION CONTROLLER POWER

SOURCE
When the starting switch is turned ON and the
supply voltage is more than 2OV, and +20V or
more is supplied to the transmission controller
solenoid power source input, it is possible to drive
each solenoid valve.
If the supply voltage is less than 19V, all outputs
are turned OFF and the solenoids cannot carry out
control (travel is impossible).
INPUT SIGNALS
1. Directional lever (F,N,R) signal
This signal is a +24V/OPEN digital signal, and
when it is normal, one of F, N, or R signals (+24V)
is input.
2. Speed lever (lst - 4th) signal
This signal is a +24V/OPEN digital signal and +24V
is input for the signal for the lever position.
3. Kickdown switch
is input when the kickdown switch on the work
equipment control lever is pressed. The switch
operation is judged from the +24V starting signal
from the OPEN condition at that point.

4. FORWARD switch
is input when the HOLD switch on the work
equipment control lever is pressed. The switch
operation is judged from the +24V starting signal
from the OPEN condition at that point.
5. Neutralizer relay signal
is input when the parking brake switch is pressed.
When signal is OPEN, the transmission controller
maintains the neutral condition.
6. Transmission cut-off signal
This signal is a GND/OPEN digital signal, and when
the transmission cut-off switch is operated (using
the left brake), it changes to GND. When it is
actuated, the transmission controller changes to
the neutral output condition, and when it is
restored, it sets to a suitable speed range for the
travel speed at that point.
7. Manual mode signal
the manual mode switch is ON, GND is input.
8. Fill switch (F, R, 1st - 4th signals)
This signal is a GND/OPEN digital signal, and is
installed to each ECMV. The switch is operated by
oil pressure.
When the ECMV is on, GND is input.
9. Engine selection signal
the engine is started, the type of engine mounted is
judged from this signal. (The speed conversion
data is different.)
Table 3 Engine selection signal table
Input signal
Engine
Speed conversion
data
GND
Cummins
118
10. Memory clear signal

This signal is a GND/OPEN digital signal. It is
normally OPEN. When clearing the memory, start
the engine, then input OPEN
N
signals.
10-181

11. Engine speed sensor signal
This signal is a pulse signal, and it converts the
pulses from the electromagnetic pickup sensor to
rotation speed for control. When the engine speed
is 1450 rpm or above, it is called the engine speed
ON mode, and when the speed is less than 1450
rpm, it is called the engine speed OFF mode.
Komatsu engine: Speed P (rpm)
= Input frequency (Hz) x 60/6
Cummins engine: Speed P (rpm)
= Input frequency (Hz) x 60/118
12. Travel speed sensor signal
This signal is a pulse signal, and it converts the
pulses from the electromagnetic pickup sensor to
rotation speed for control.
To convert to the travel speed, the tire
compensation data (communications data from the
main monitor) are added.
In addition, the
acceleration is also calculated to judge the travel
speed for gear shifting.
Speed P (rpm) = Input frequency (Hz) x 60/ 59
Travel speed V (km/h) = Speed P (rpm)/
(101.6 x tire compensation value k) or Travel
speed V (km/h) = Input frequency (Hz)/(99.9 x
tire compensation value k)
13. Transmission oil temperature sensor signal
This signal is an analog signal and converts 0 - 5 V
inside the controller to temperature. This is used
for selecting the modulation table when shifting
gear.
14. Communications signal (S-NET)
This receives the following data set in the main
monitor and is used for control.
1) Model selection
It selects the automatic gear shift change point
data table for each model to use for shifting
gear.
2) Tire compensation data
This adds the compensation value (covering a
range from 0.86 to 1.14) to the speed data
from the travel speed sensor to obtain an
accurate travel speed.
3) Travel damper function selection This is a
function selection signal and judges if the
travel damper function exists. lt controls the
travel
damper
system,
including
troubleshooting.
10-182

OUTPUT SIGNALS
1. Transmission modulation valve (ECMV
command current)
This signal is an electrical output (O - 1A). There
are six types of ECMV: R and F for direction, and
lst, 2nd, 3rd, and 4th for each speed range. This
valve is a pressure control valve and converts to a
pressure matching the value of the current flowing
to the solenoid. Therefore, it controls the oil
pressure for the clutch selected for each speed
range and controls the engagement of each
independent clutch. In addition, only the 2nd clutch
is actuated when the transmission is at neutral.
Table 4:
Combination of speed ranges and ECMV
ECMV/
Speed range
F1
F2
F3
1st
2nd
3rd
4th
O
O
O
F4
N
R1
R2
R3
R4
O
O
O
O
O = ON
2. Backup lamp relay signal

This signal is a +24V digital (ON/OFF) output. It is
actuated when the directional lever is placed at R
and lights up the backup lamp and caution lamp.
3. F1 (cut-off) signal
This signal is a +24V digital (ON/OFF) output. This
signal is output when the kickdown is operated and
sets the machine to Fl.
4. Engine speed signal
This outputs a signal at the same cycle as the
engine speed sensor signal input to the
transmission controller.
5. Communications signal (main monitor display

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

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

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

(+24v)
Engine speed
Power supply (+24V)
NC
potentio power supply

4
NC
NC
5
NC
NC
6
NC
10
ENC select
7
NC
11
T/M oil temp. Sensor

8
NC
12
NC
9
GND (for rotate sensor)
13
NC
10
NC
14
NC
11
Network (-)
15
NC
12
Network (-)
16
GND (for pressure sensor)
17
GND (for potentio)
18
NC
19
Jotstick ON/OFF SW
20
Pressure SW
8
9
10
11
12
13
F1 output
Damper solenoid 5
High pressure solenoid
Back lamp relay
GND
Power supply (+24V)
CNC2
1
2
3
4
5
6
7
Sol. power supply (+24V)

ECMV 3 (+)
NC
CNC5
ECMV 4 (+)
NC
NC
ECMV F (+)
GND (for plus)
Speed
GND
GND
Kick down SW
T/M cut-off SW
Joystick N (NC)
Joystick F (NC)
Joystick R (NC)
10
GND (for plus)
11
Fill SW 3
12
Fill SW 4
13
Hold SW
14
Manual SW
15
Joystick N (NO)
16
Joystick F (NO)
17
Joystick R (NO)
CNC3B
8
9
10
11
12
13
14
15
16
17
18
19
ECMV R (+)
1
Pressure SW B
Fill SW F
Fill SW 1
NC
Direction F
Direction R
Range SW 1
Range SW 3
Damper SW
10
Fill SW R
11
Fill SW 2
12
NC
ECMV 1 (+)
ECMV 2 (+)
P GND
Sol. power supply (+24V)
ECMV 3 (-)
NC
ECMV 4 (-)
NC
ECMV F (-)
ECMV R (-)
ECMV 1 (-)
20
ECMV 2 (-)
21
P GND
10-187
SENSORS
SENSORS
FUNCTION
The sensors are a contact type sensor with one
end grounded to the chassis. The signal from the
sensor is input directly to the monitor panel, and
when the contacts are closed, the panel judges the
signal to be normal. However, the engine oil
pressure uses a relay to reverse the sensor signal.
Sensor detection
item
Sensor
method
When
normal
When
abnormal
Speedometer
sensor
Electromagnetic
Engine oil level
Contact
ON
OFF
Radiator water
level
Contact
ON
OFF
Engine oil
pressure
Contact
OFF
ON
Engine water
temperature
Resistance
Torque converter
oil temperature
Resistance
Engine speed
sensor
Electromagnetic
Fuel level sensor
Resistance
SPEEDOMETER SENSOR
FUNCTION
The speedometer sensor is installed to the
transmission output gear. A pulse voltage is
generated by the rotation of the gear teeth, and
signal is sent to the machine monitor to display the
travel speed.
1. Connector
2. Magnet
3. Case
10-188
SENSORS
ENGINE SPEED SENSOR
1.
2.
3.
4.
5.
Magnet
Terminal
Case
Boot
Connector
FUNCTION
The engine speed sensor is installed to the ring gear
portion of the flywheel housing. A pulse voltage is
generated by the rotation of the gear teeth, and a signal
is sent to the controller and monitor panel.
ENGINE OIL PRESSURE SENSOR
1.
2.
3.
4.
5.
6.
Plug
Contact ring
Contact
Diaphragm
Spring
Terminal
FUNCTION
This sensor is installed to the engine block and the
diaphragm detects the oil pressure. If the pressure
goes below the specified pressure, the switch is
turned ON, and a relay is actuated to turn the
output OFF. This makes the maintenance monitor
flash to warn of the abnormality. The caution lamp
and alarm buzzer are also actuated at the same
time to warn of the abnormality.
10-189
SENSORS
RADIATOR WATER LEVEL SENSOR
1. Float
2. Sensor
3. Connector
FUNCTION
The sensor is installed to the top of the radiator. If
the coolant goes below the specified level, the float
goes down and the switch is turned OFF. The
caution lamp and alarm buzzer are also actuated
at the same time to warn of the abnormality.
ENGINE OIL LEVEL SENSOR
1.
2.
3.
4.
Connector
Bracket
Float
Switch
10-190
FUNCTION
This sensor is installed to the side face of the oil
pan. When the oil goes below the specified level,
the float goes down ant the switch is turned OFF.
This makes the maintenance monitor flash, and the
check lamp to also light up at the same time to
warn of the abnormality.
SENSORS
FUEL LEVEL SENSOR
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 as the
level of the fuel changes. As the float moves up
and down, the arm actuates a variable resistance,
and this sends a signal to the maintenance monitor
to display the fuel level. When the display the
maintenance monitor reaches the specified level,
the warning lamp flashes.
10-191
SENSORS
ENGINE WATER TEMPERATURE SENSOR

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

terminal BR
o
the battery relay switch is closed. This forms
the following circuit.
[2] Battery (+)
terminal B
relay terminal C
and the engine starts.
y
,
If the directional lever is at any position other

than N (Neutral), circuit [1] is not formed, and
the engine does not start.
a) Safety relay.
10-195
ENGINE STOP CIRCUIT
ENGINE STOP CIRCUIT

Operation
When the starting is turned ON, electric current
flows in the following circuit.
[1] Battery (+)
ing switch terminal BR
ground connection.
When electric current flows to the fuel cut solenoid,
the fuel governor is put in the FREE position by the
fuel control linkage.
Fuel flows to the fuel injection pump and the
engine starts.
10-196
When the starting switch is turned OFF, circuit [1] is

shut off, but the engine is rotating, so there is still
voltage at terminal R of the alternator. For this
reason, the following circuit is formed.
[2] Alternator terminal R
BR
The battery relay is maintained, but because of the

diode inserted into the circuit, no electric current
flows to the fuel cut solenoid, so the engine stops.
ETHER START CIRCUIT
ETHER START CIRCUIT
Function
The ether injection system delivers a 3cc shot of
ether to the engine to aid in cold weather starting.
Operation
With the lever in N (neutral) turn key to start position.
This completes cranking circuit as described in
engine starting section, and engine begins cranking.
This also completes circuit from start switch B to
start switch R2" applying power to ether start switch.
Move ether start switch to ON position then release
immediately (Do not hold it at ON position for more
than 5 seconds. This will cause failure of ether start
solenoid) This allows current to flow in the following
circuit. Start switch terminal R2" to ether start switch
terminal 1" to ether start switch terminal 2" to ether
solenoid 1" to ground. This actuates ether start
solenoid, injecting ether.
10-197
ELECTRIC TRANSMISSION CONTROL
1. Transmission cut-off selector switch

3. Directional lever
4. Speed lever
5. Kick-down switch
6. Maintenance Monitor
7. Relays
8. Fuse boxes
9. Transmission controller
11. Speed sensor

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

desired position, the switch, which is interconnected
by a shaft, acts to allow electric current to flow to
that circuit only.
General locations, function

1
Directional lever switch
Switches between F, R, and N
Speed lever switch
Selects speed range
Speed lever stopper
Stopper used to prevent speed lever from entering 3rd or 4th during
operations
Turn signal indicators
Direction indicator lamps used when turning left or right
Self cancel
Turn signal indicator lever automatically returns to central position after

machines turns left or right
Lamp switch
Switches on clearance lamp, head lamp, parking lamp, etc.
Dimmer switch
Selects high beam for travel and low beam for passing
Hazard switch
Makes both left and right turn signal indicator lamps flash at the same
time
Emergency flashing pilot lamp
Flashes at the same time as the emergency flashing lamp flashes
10
Applies or releases parking brake
10-199

Operation
Directional lever (1) and shaft (2) of the speed lever
of the combination switch form one unit with
magnet (3), and magnet (3) also moves together
with lever (1).
Control switch (5) with built-in hole IC (4) is
installed at the bottom of magnet (3), and hole IC
(4) is positioned on the board to match each
position.
When directional lever (1) is operated to the F
position, magnet (3) is immediately above hole IC
(4) for the F position of the control switch. The
magnetism from magnet (3) passes through the
gap and case (6), and magnetism is applied to hole
IC (4).
When this happens, hole IC (4) is inside a
magnetism detection circuit, so it detects the
magnetism of magnet (3) and sends the F position
signal to the electric current amplification circuit. In
the electric current amplification circuit, a signal is
output to actuate the transmission.
10-200
KICK-DOWN / HOLD SWITCH
KICK-DOWN / HOLD SWITCH
1.
2.
3.
4.
5.
KICK-DOWN SWITCH
OPERATION
The kick-down (shifting down from 2nd
s
actuated only when traveling in F2.
When traveling in F2, if it is desired to shift down to
1st without operating the speed lever, operate the
kick-down switch on the boom lever to ON to shift
down to F1.
After this, even if the kick-down switch is pressed,
the transmission is kept at F1.
Kick-down switch
Spring
Spring
Hold switch
Wiring harness
HOLD SWITCH
The hold switch is installed to the boom lever, and
when the hold switch is pressed, the speed range
displayed on the main monitor transmission
indicator is held.
Press the hold switch again to cancel.
Cancellation (or not actuated)

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

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

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

When the speed lever is at the 2nd
position,thesignal is inputtotransmission controller
2nd CNC3B terminal 15, and electricity flows as the
2nd signal from CNC2 terminal 10
CNC2 terminal 20, and the 2nd solenoid is
actuated.
WHEN KICK-DOWN SWITCH IS OPERATED

(Operation with speed lever at F2 position)
(When kickdown switch is pressed ON)
When the kick-down switch is pressed, the main

monitor network signal (-) enters from CNLO8
terminal 2 to controller CNC5 terminal 5. The kickdown circuit is formed inside the controller and the
solenoid output signal flows from CNC2 terminal 7
and terminal 9 to the F solenoid and 1st solenoid,
the solenoid valves are actuated, and the speed
range is set to F1.
In this way, if the kick-down switch is pressed when

the speed lever is at F2, the transmission is
automatically shifted to F1. At the same time, the
self-hold function of the kick-down circuit keeps the
condition at F1 even if the switch is released or is
pressed several times.
This kick-down circuit continues to be actuated

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

(When directional lever is set to N or R)
If the directional lever is operated to the R position,

the contact of terminal F of the lever is turned off,
so the electricity stops flowing from battery (+)
speed lever switch terminals 1 - 2
n
controller.
The FORWARD circuit inside the transmission
controller is opened, so electricity stops flowing to
the kick-down circuit. As a result, the kick-down
self-hold circuit is canceled and the 1 st solenoid
stops actuating. (Even if the directional lever is set
to the N position, the same operation as above is
carried out and the kick-down circuit is canceled.)
The FORWARD circuit is also opened, so the F
solenoid also stops actuating.
10-204
When the directional lever is set to the R position,

current flows from battery speed lever terminals 1 4
ransmission controller CNC3B terminal 6
CNC 2-8 terminal (Reverse circuit formations R (+)
signal inside controller)
r
(-) CNC2 terminal 18, and the REVERSE solenoid
valve is actuated.
At the same time, electricity flows from
transmission controller 2nd signal (+) CNC2
terminal 10
,
and the 2nd solenoid valve is actuated to set to R2.
ELECTRIC PARKING BRAKE CONTROL
ELECTRIC
CONTROL
PARKING
BRAKE
1. Parking brake emergency release switch

2. Neutralizer relay
3. Parking brake safety relay (parking brake
emerge release relay)
6. Parking brake solenoid valve
7. Parking brake (built into transmission)
8. Parking brake emergency release valve
9. Charge valve
10. Accumulator
OUTLINE
l
The parking brake is a wet type multiple disc
brake built into the transmission.
When
electricity flows to the parking brake solenoid
valve, the oil pressure from the transmission
pump is applied to the parking brake cylinder
and releases the parking brake.
l
When the flow of electricity is stopped, the
hydraulic pressure from the transmission pump
is shut off. The hydraulic pressure inside the
parking brake cylinder passes through the
parking brake solenoid valve and is drained. The
force of the brake spring then applies the
parking brake.
s0w02111
1O-205
STRUCTURE
AND FUNCTION
Function
1. Applying and releasing parking brake
The parking brake is applied or released by using
the parking brake switch (combination switch).
2.
Automatic parking brake

When the engine stops (when the starting switch
is OFF), the parking brake is automatically applied
to prevent the machine from running away when
the operator is away from his seat.
3.
Emergency brake
If the pressure in the oil pump should drop
because of damage to the hydraulic circuit and the
braking force can not be ensured, the parking
brake is applied automatically
to act as an
emergency brake.
4.
Parking brake safety

It is dangerous if the parking brake can be
released simply by turning the starting switch ON
after the automatic parking brake has been
applied. Therefore, to ensure safety, the system
is designed so the brake cannot be released
unless the starting switch is turned ON and then
the parking brake switch is also turned ON.
5.
Neutralizer
The parking brake may seize if the machine is
driven with the parking brake still applied. To
prevent this problem, the caution lamp lights up
and the alarm buzzer sounds to warn the operator
of the mistaken operation. In addition to this, when
the parking brake is applied, the transmission is
forcibly shifted to neutral to make it impossible to
drive the machine. However, the braking distance
will become longer if the transmission is shifted to
neutral when the emergency brake is applied. It
may also be necessary to move the machine if it
stops in places where it is prohibited to stop (such
as on railway crossings). To overcome this, the
circuit is designed so that the transmission is not
shifted to neutral when the emergency brake is
applied.
IO-206
ELECTRIC
6.
PARKING
BRAKE
CONTROL
Parking brake emergency release solenoid

valve
If the supply of pressure oil from the transmission
pump should stop because of some failure, it is
possible to actuate the emergency relief solenoid
valve with the parking brake emergency release
switch in the operators compartment. This sends
the accumulator charge pressure in the brake
piping to the parking brake cylinder to release the
parking brake.
PARKING BRAKE EMERGENCY RELEASE SWITCH
EMERGENCY BRAKE SWITCH
10-207

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

relay is opened, so electricity does not flow to the
parking brake circuit. For this reason, if the starting
switch is at the OFF position, no electric current
flows to the parking brake solenoid valve,
regardless of whether the parking brake switch is
ON (applied) or OFF (released), so the parking
brake is actuated. (Automatic parking brake)
10-209
2. Starting switch ON
2-1 When parking brake switch is ON (actuated) before starting switch is turned ON.
The electric current flows in circuit

e
battery +
ground, so the battery relay is closed. When this
happens, electric current flows in circuit
battery +
h
terminal 1 - 3
ng brake safety relay terminal
1-2
the parking safety relay
is actuated and safety relay terminals 3 - 5 are
closed.
When this happens, circuit
e
battery +
y
terminal 5 - 3
d. From this point, the parking safety relay
is in the condition of circuit
g
switch is turned OFF.
10-210
In this condition, electric current does not flow to

the parking brake solenoid valve, so the parking
brake is actuated.
In addition, in this condition, neutralizer relay
terminals 3 and 5 are open, so electric current
does not flow to the transmission directional circuit,
and the transmission is shifted to neutral.
2-2 When parking brake switch is OFF (actuated) before starting switch is turned ON
Electric current flows in circuit

starting switch
relay coil
the battery relay is closed. However, in this case,
the parking brake switch is OFF (released), so the
parking safety relay is not actuated. For this
reason, the electric current does not flow to the
parking brake solenoid valve, so after the
automatic parking brake is applied, the parking
brake is not released automatically even when the
starting switch is turned ON.
In addition, the electric current does not flow to the

transmission directional circuit, so the machine
does not move.
10-211
3. Parking brake switch OFF (released)

When the parking brake switch is turned from ON to OFF after the starting switch is turned ON
If the parking brake switch is turned from ON

(actuated) to OFF (released), the circuit for
terminals 2 and 3 of the parking brake switch is
connected, and the parking brake safety relay is
also actuated. For this reason, electric current
flows in circuit
parking brake safety relay
e
switch, and then flows to circuits
n
below.
10-212
This circuit is formed from the emergency

brake switch
arking brake solenoid valve
ground, and the parking brake is released.
This circuit is formed from the battery +
battery relay neutralizer relay terminal 3 - 5
transmission directional circuit, so when the
directional lever is operated, the machine will
move.
4. Parking brake switch ON (actuated)
If the parking brake switch is turned ON (applied)

after carrying out operations with the parking brake
switch OFF (released), the circuit in the diagram
above is formed.
Electric current does not flow to the parking brake
solenoid valve, so the oil pressure from the
transmission pump to the parking brake cylinder is
shut off. At the same time, the oil pressure inside
the parking brake cylinder passes through the
parking brake valve and is drained, so the parking
brake is applied by the force of the spring.
In addition, at the same time, the neutralizer relay

is reset, so the circuit between terminals 3 and 5 is
opened, and no electricity flows to the transmission
directional circuit, so the transmission is shifted to
neutral. This kind of neutralizer relay shuts off the
electric current going to the transmission solenoid
valve when the parking brake is applied and shifts
the transmission to neutral to prevent seizure of the
parking brake if the operator should drive the
machine with the parking brake still applied.
10-213
5. When main brake oil pressure drops (emergency brake actuated)
Operation
If the oil pressure in the main brake line drops, the
emergency brake switch installed to the
accumulator is opened.
For this reason, the electric current stops flowing to
the parking brake solenoid valve, so the oil
pressure inside the parking brake cylinder is
drained and the parking brake is applied.
However, in this case, the condition is different from
the case where the parking brake switch is ON
(applied), because there is electric current flowing
to the neutralizer relay coil.
10-214
For this reason, electric current flows to the

transmission directional circuit, and it is possible to
engage the transmission clutch. In this way, it is
possible to use the engine brake when the emergency
brake is applied, so the braking distance becomes
shorter. At the same time, if the emergency brake has
been applied and it is necessary to move the machine
(for example, if the emergency brake is applied when
the machine is on a railway crossing), it is possible to
move the machine by operating the transmission lever.
6. Parking brake emergency release
Operation
If the machine should stop because of engine
trouble, the oil pressure from the transmission
pump to the parking brake cylinder is shut off and
the parking brake is applied. When this happens,
the oil pressure in the main brake line is stored in
the accumulator. When the emergency release
switch is turned on (released), the buzzer sounds,
and at the same time, electric current flows to the
emergency parking brake release solenoid valve.
The oil pressure stored in the accumulator in the

main brake line then flows to the parking brake
cylinder to release the parking brake.
The emergency release switch should normally be
kept at the OFF position and should be returned to
the OFF position after the emergency release.
10-215
7. Function of parking brake neutralizer relay
OUTLINE
When the parking brake is being actuated, the
transmission is held at neutral to prevent the
parking brakes from dragging if the machine is
operated by mistake.
OPERATION
1. When the parking brake is actuated (ON),
electricity flows from the battery relay
g
brake switch terminals 1 - 3
relay terminal 1
y
relay coil is actuated, and safety relay terminals 3
and 5 are connected to form the circuit.
10-216
2. When the parking brake switch is OFF (released)

and the engine is started, the circuit in Item 1 is not
formed, so the parking brake switch must be turned
ON.
3. When the parking brake is being actuated,
electricity does not flow to the neutralizer relay coil,
so neutralizer relay terminal 3 and terminal 5 are
separated and no electricity flows to the
transmission directional circuit. In this way, when
the parking brake is applied, the transmission is
held at neutral.
20 TESTING, ADJUSTING AND

TROUBLESHOOTING
Standard value table for engine - in chassis . . . 20-3
Standard value table for chassis . . . . . . . . . . . . . 20-4
Standard value table for electrical system . . . . . 20-9
Service tools for testing, adjusting &
troubleshooting . . . . . . . . . . . . . . . . . . . . . . 20-22
Sketches of special tools . . . . . . . . . . . . . . . . . 20-23
Measuring engine speed . . . . . . . . . . . . . . . . . . 20-24
Measuring intake manifold pressure . . . . 20-25
Measuring intake air restriction . . . . . . . . . 20-26
Measuring engine lubricating oil pressure . 20-27
Measuring fuel filter inlet restriction . . . . . . 20-28
Measuring blow-by pressure . . . . . . . . . . . 20-29
Measuring exhaust back pressure . . . . . . . 20-30
Measuring coolant temperature . . . . . . . . . 20-31
Measuring and adjusting valve clearance 20-32
Alternator drive belt . . . . . . . . . . . . . . . . . . . . . . 20-33
Air conditioner belt . . . . . . . . . . . . . . . . . . . . . . . 20-34
Measuring exhaust temperature . . . . . . . . . . . . 20-35
Exhaust gas color . . . . . . . . . . . . . . . . . . . . . . . 20-36
Measuring engine stall speeds . . . . . . . . . . . . . 20-38
Measuring torque converter stall . . . . . . . . . . . 20-38
Measuring hydraulic stall . . . . . . . . . . . . . . . . . . 20-39
Measuring full stall . . . . . . . . . . . . . . . . . . . . . . . 20-39
Adjusting engine speed sensor . . . . . . . . . . . . . 20-40
Measuring shift levers . . . . . . . . . . . . . . . . . . . . 20-41
Measuring accelerator pedal . . . . . . . . . . . . . . 20-42
Measuring torque converter and
transmission oil pressure . . . . . . . . . . . . . . 20-44
Flushing torque converter and
transmission hydraulic circuit . . . . . . . . . . . 20-47
Moving machine when transmission
valve fails . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-48
Testing and adjusting steering wheel . . . . . . . . 20-50
Steering oil pressure . . . . . . . . . . . . . . . . . . . . . 20-52
Steering stop valve . . . . . . . . . . . . . . . . . . . . . . 20-54
Measuring brake pedal . . . . . . . . . . . . . . . . . . . 20-55
Measuring brake performance . . . . . . . . . . . . . 20-56
Testing brake oil pressure . . . . . . . . . . . . . . . . . 20-57

Measuring brake disc wear . . . . . . . . . . . . . . . . 20-58
Parking brake performance . . . . . . . . . . . . . . . 20-59
Parking brake oil pressure . . . . . . . . . . . . . . . . 20-60
Parking brake disc wear . . . . . . . . . . . . . . . . . . 20-62
Manual release method for parking brake . . . . 20-63
PPC oil pressure . . . . . . . . . . . . . . . . . . . . . . . . 20-64
Adjusting PPC valve linkage . . . . . . . . . . . . . . . 20-66
Accumulator charge pressure . . . . . . . . . . . . . 20-67
Work equipment hydraulic pressure . . . . . . . . . 20-68
Releasing remaining pressure in
hydraulic circuit . . . . . . . . . . . . . . . . . . . . . . 20-70
Adjusting work equipment lever linkage . . . . . . 20-71
Bleeding air . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-72
Bucket positioner . . . . . . . . . . . . . . . . . . . . . . . . 20-73
Boom positioner . . . . . . . . . . . . . . . . . . . . . . . . . 20-74
Transmission controller . . . . . . . . . . . . . . . . . . . 20-76
Adjusting main monitor
(speed module) . . . . . . . . . . . . . . . . . . . . . 20-78
Points to remember when troubleshooting . . 20-202
Sequence of events in troubleshooting . . . . . 20-203
Points to remember when carrying
out maintenance . . . . . . . . . . . . . . . . . . . . 20-204
Checks before troubleshooting . . . . . . . . . . . . 20-212
Handling connectors . . . . . . . . . . . . . . . . . . . . 20-213
Precautions when troubleshooting . . . . . . 20-214
Method of reading troubleshooting
tables . . . . . . . . . . . . . . . . . . . . . . . . . 20-216
Air conditioner / heater (Denso) . . . . . . . . . . . 20-902
Visual and audible inspection . . . . . . . . . . 20-902
Troubleshooting with manifold gauge . . . 20-903
Troubleshooting the electrical circuit . . . . 20-907
Cooler circuit troubleshooting . . . . . . . . . 20-911
20-1
WARNING! When carrying out testing, adjusting, or troubleshooting, park the machine on level
ground, insert the safety pins, and use blocks to prevent the machine from moving.
WARNING! When carrying out work together with other workers, always use signals and do not
let unauthorized people near the machine.
WARNING! When checking the coolant level, always wait for the coolant to cool down. If the
radiator cap is removed while the coolant is still hot, the coolant will spurt out and cause burns.
WARNING! Be careful not to get caught in the fan, fan belt or other rotating parts.
20-2
STANDARD VALUE TABLE FOR ENGINE
STANDARD VALUE TABLE FOR ENGINE - In Chassis
Item
Machine model
WA500-3L
Engine model
Cummins N14
Measure condition
Unit
High idle
Engine speeds
Low idle
kW / rpm
Rated speed
Standard value for

new machine
Service limit value
2300 50
2300 100
760 50
760 75
250 / 2100
250 / 2100
Intake manifold
pressure
At T.C. stall and W.O.T

(Wide Open Throttle)
mm Hg
1170 - 1500
1170 - 1500
Intake air restriction
At T.C. stall and W.O.T. at

restriction indicator port
mm H 2O
New element: 380

Used Element: 635
635 max.
Lubricating oil
pressure with SAE
15W-40 oil &
coolant temperature
in operating range
Minimum at low idle
kPa
(kg/cm)
70
(0.70)
70
(0.70)
Minimum at high idle
kPa
(kg/cm)
175
(1.75)
175
(1.75)
Fuel filter inlet

restriction
Maximum restriction at high

idle
mm Hg
New filter: 102

Used filter: 203
New filter: 102

Used filter: 203
Blow-by pressure
Coolant temperature in
operating range:
Service Tool orifice size:
7.67 mm
At T.C. stall and W.O.T.
mm H 2O
305
460
Exhaust back
pressure
Maximum at T.C. stall and

W.O.T.
mm Hg
76
76
Coolant
temperature
Maximum operating
temperature at engine outlet
80 - 90
100 max.
Valve clearance
Engine cold:
Intake valves
Exhaust valves
mm
0.35
0.69
0.35
0.69
N
(lbf)
620
(140)
270 - 490
(60 - 110)
mm
10 - 15
10 - 15
Alternator belt
Deflection when pressed

with finger force of approx.
98 N (10 kg)
Air conditioner
compressor belt
tension
Deflection when pressed

with finger force of approx.
98 N (10 kg)
For further detailed information, refer to Engine Shop Manual.
20-3
STANDARD VALUE TABLE FOR CHASSIS

Machine model
WA500-3L
Engine model
Cummins N14
Standard value for
new machine
Service limit
value
2140 100
2140 100
2180 100
2180 150
1820 100
1820 200
N (kg)
71.05 2.45
(7.25 0.25)
Max. 97 (10)
Operating angle:
x1
x2
degree
degree
48
34 - 35
Stopper height (L)
mm
60
Item
Engine stall speeds:
Torque converter
Hydraulic
Full
Measurement condition
Coolant temperature in
operating range
Torque converter oil
temperature in operating
range
Hydraulic oil at normal
operating temperature
Accelerator pedal:
Operating force
Item
Shift lever operating force and

stroke
Measure at center of
lever knob
Directional lever operating

force
N-F
N-R
Speed lever operating
force
1st - 2nd
2nd - 3rd
3rd - 4th
Directional lever travel
N-F
N-R
Speed lever travel
1st - 2nd -3rd -4th
20-4
Unit
rpm
---
Standard value
for new machine
Service limit
value
N (kg)
5.88 +4.9 / -2.94

(0.6 +0.5 / -0.3)
Max. 16.66
(1.7)
N (kg)
5.88 +4.9 / -2.94

(0.6 +0.5 / -0.3)
Max. 16.66
(1.7)
mm
35 10
35 20
mm
35 10
35 20
Unit
Engine stopped
Item

Standard value
for new machine
Service limit
value
0.39 0.1
(4 1)
0.39 0.1
(4 1)
0.83 0.1
(8.5 1)
0.83 0.1
(8.5 1)
3.28 0.2
(33.5 2)
3.48 0.15
(35.5 1.5)
3.28 0.2
(33.5 2)
3.48 0.15
(35.5 1.5)
3.23 0.15
(33 1.5)
3.53 0.15
(36 1.5)
3.23 0.15
(33 1.5)
3.53 0.15
(36 1.5)
0.21 0.08
(2.15 0.85)
0.21 0.08
(2.15 0.85)
Max. 2.5
Max. 4.0
mm
2 - 10
mm
N (kg)
Max. 50
12.25 2.45
(1.25 0.25)
50-100
Max.19.6 (2.0)
Sec.
Sec.
Max. 5.5
Max. 3.1
Max. 6.5
Max. 4.5
Engine speed: High

idling
Turns
3.6 0.4
Max. 4.5
Engine speed: 1200 rpm
mm
25 2
Unit
Oil pressure of torque converter and transmission.

Torque converter outlet
port oil pressure
Torque converter inlet port
oil pressure
ECMV output (clutch) oil
pressure
1st
2nd, 3rd, 4th, F-R
Main relief valve
Low idling
Torque converter oil

temperature: 60-80
Engine speed: High
idling
MPa
kg/cm
Manual switch ON
High idling
Lubrication pressure (oil

cooler outlet port)
Tire and wheel
Fitting of wheel lock ring
(A)
(B)
Clearance of wheel lock
ring
(C)
Steering wheel
Steering wheel play
Steering wheel operating
force
Operating time of
steering wheel
Low idle
High idle
Turning speed
Clearance between front and
rear frame
Tire inflation pressure

Specified pressure
Road surface: Flat,

horizontal, dry, paved
surface:
Hydraulic temp.:
45 55
Machine posture:
Facing straight
20-5
Testing and measuring item

Steering oil pressure
Main relief oil pressure
Hydraulic temperature: 45
- 55
Engine speed: High idle
Orbit-roll output pressure
Brake pedal
Operating force
Engine speed: Low idle

Hydraulic temperature:
45-55
Operating angle
Play
Accumulator
Charge cut-in pressure
Point where brake oil
pressure warning lamp
goes out
Brake performance
Drop in brake oil pressure
Wear of brake disc
20-6
Road surface: Flat,

horizontal, dry, paved
surface
Speed when applying
brakes: 20 km/h
Time lag when pressing
the pedal:
0.1 sec.
Brake pedal operating
force: 294 29.4 N (30
3 kg)
Tire inflation pressure:
Specified pressure
Coolant temperature:
Inside operating range
Test pressure:
53 kg/cm/5 min.
Piston stroke
Service limit
value
20.58 +0.98 /
-0.29
(210 +10 / -3)
3.72 +0.39 /
-0.19
(38 +4 / -2)
3.72 +0.39 /
-0.19
(38 +4 / -2)
N (kg)
294 29.4
(30 3)
Max. 421.4
(43)
degree
45
mm
15 +1 / -0
5.88 +0.49 / -0
(60 +5 / -0)
5.88 +0.49 / -0
(60 +5 / -0)
9.8 +0.98 / -0
(100 +10 / -0)
9.8 +0.98 / -0
(100 +10 / -0)
kg/cm
6.0 0.1
6.0 +0.4
6.0 0.1
6.0 +0.4
Max. 5
Max. 5
kg/cm
Max. 5
Max. 5
mm
2.2-5.5
Max. 8.0
MPa
kg/cm2
MPa
kg/cm
Inside operating range
Standard value
for new machine
20.58 +0.98 /
-0.29
(210 +10 / -3)

45-55
Charge cut-out pressure

Point where oil
pressure is going up
and then starts to go
down
Warning buzzer pressure
Actuating starting
Actuating stopping
Unit
Parking brake performance
Thickness of pad
Clearance between
disc and pad
Dump and lift control levers
Lift arm control lever
operating force
Hold
Raise
Hold
Lower
Lower
Float
Dump control lever
operating force
Hold
Hold
Tilt
Unit
Tire inflation pressure:

Specified pressure
Road surface:
Flat, dry, paved
surface with 1/5
(11
Machine:
In operating
condition
No
machine
movement
With back plate

Total of both side
mm
kg
45 - 55
Inside operating
range
Lift arm control lever travel

Hold
Hold
Hold
Service limit
value
No
machine
movement
31.7
12.7
1.06 0.18
Max. 2.3
Max. 2.5
2-4
Max. 2.5
2-4
2-4
Max. 3.5
Max. 6
Max. 3.5
Max. 6
Max. 6
Max. 2.5
Max. 2.5
2-4
Max. 3.5
Max. 3.5
Max. 6
52 - 82
34 - 64
52 - 82
37 - 97
19 - 79
37 - 97
45 - 75
45 - 75
30 - 90
30 - 90
38 - 40
210 5
36 - 42
210 10
mm
Dump control lever travel

Hold
Hold
Relief oil pressure

PPC valve
Main control valve
Standard value
for new machine
Inside operating
range
45 - 55
Engine speed:
High idle
kg/cm
20-7
Operating speeds
Lift arm lifting time
Lift arm lowering time
Bucket dumping time
Bucket tilt back time
(Full stroke)
Bucket tilt back time
(Horizontal position of
bucket)
Inside operating
range
45 - 55
Steering position:
Neutral
Bucket: empty
Hydraulic drift of lift arm and

bucket
Retraction of lift cylinder
rod
Inside operating
range
45 - 55
Stop engine, leave for 5
minutes, then measure
for next 15 minutes.
Lift arm horizontal
Bucket horizontal
Bucket: empty
Retraction of dump
cylinder rod
Unit
sec.
mm
Bucket positioner
Clearance of switch
Standard value
for new machine
Service limit
value
6.8 - 7.4
3.0 - 4.0
1.4 - 2.0
Max. 8.9
Max. 4.8
Max. 2.4
1.9 - 2.5
Max. 3.0
1.3 - 1.9
Max. 2.3
Max. 40
Max. 40
Max. 20
Max. 20
3-5
3-5
mm
Boom kick-out
Clearance of switch
20-8
STANDARD VALUE TABLE FOR ELECTRICAL SYSTEM

Name of component
Connector
number
Inspection
method
Measurement
conditions
Judgement table
If the condition is as shown in the table below, it is
normal
Between C1 (7), (13) - chassis
Power source
C1
Measure voltage
Between C2 (1), (12) - chassis

20 - 30 V
Between C1 (7), (13) - (6), (12)
1. Turn starting
switch OFF
2. Insert T-adapter
3. Turn starting
switch ON
Transmission & Travel Damper Controller
Between C2 (1), (12) - (11), (21)

normal
Power source (signal)
C3A
Measure voltage
Between (6) - (17)

20 - 30 V
Between (6) - chassis
If the condition is as shown in table below, the
sensor is normal
CN
L01
Measure voltage
Parking brake ON, Between (1) - (3),
20 - 30V
Parking brake OFF, Between (1) - (3),
Max. 1V
If condition is as shown in the table below, the

sensor is normal
ECMV solenoid (1st)
CN4
(male)
Measure
resistance
Between (1) - (2)
5 - 15
Between (1), (2) - chassis
Min. 1 M
If the condition is as shown in the table below, the

sensor is normal
ECMV solenoid (2nd)
CN6
(male)
Measure
resistance
Between (1) - (2)
5 - 15
Min. 1 M

sensor is normal
ECMV solenoid (3rd)
CN12
(male)
Measure
resistance
Between (1) - (2)
5 - 15
Min. 1 M
1. Turn starting
switch OFF
2. Insert T-adapter
3. Turn starting
switch ON
4. Apply parking
brake
1. Turn starting
switch OFF
2. Insert T-adapter
3. Turn starting
switch ON
1. Turn starting
switch OFF
2. Disconnect
connector
3. Connect Tadapter
1. Turn starting
switch OFF
2. Disconnect
connector
3. Connect Tadapter
1. Turn starting
switch OFF
2. Disconnect
connector
3. Connect Tadapter
20-9
Name of component
ECMV solenoid
(4th)
ECMV solenoid (F)
ECMV solenoid (R)
Connector
number
CN8
(male)
CN16
(male)
CN14
(male)
1st - CN5
(male)
Inspection
method
Measure
resistance
Measure
resistance
Measure
resistance
Measure
resistance
2nd - CN7
(male)

normal
Between (1) - (2)
5 - 15
Min. 1 M
If the condition is as shown in the table below, the sensor is normal

Between (1) - (2)
5 - 15
Min. 1 M

normal
Between (1) - (2)
5 - 15
Min. 1 M

normal
Speed lever at measurement

position:
3rd - CN13
(male)
4th - CN9
(male)
Max. 1
Speed lever not at measurement

position:
ECMV fill switch

F - CN17
(male)
Measurement
conditions
Judgement table
Measure
resistance
R - CN15
(male)
Directional lever at measurement
position:
Max. 1
Directional lever not at measurement

position:
20-10
1. Turn starting
switch OFF
2. Disconnect
connector
3. Connect Tadapter
1. Turn starting
switch OFF
2. Disconnect
connector
3. Connect Tadapter
1. Turn starting
switch OFF.
2. Disconnect
connector.
3. Connect Tadapter.
4. Start engine.
5. Place directional
lever at N.
6. Turn manual
switch ON.
Min. 1

normal
1. Turn starting
switch OFF
2. Disconnect
connector
3. Connect Tadapter
Min. 1
1. Turn starting
switch OFF.
2. Disconnect
connector.
3. Connect Tadapter.
4. Start engine.
5. Turn
transmission
cut-off (lamp
OFF)
6. Turn parking
brake switch
OFF.
7. Depress brake.
Name of component
Transmission oil
temperature
sensor
Transmission oil
temperature
(controller)
Engine speed
sensor
Engine speed
(controller)
Connector
number
CN11
(male)
C2
E04
(male)
C4
Inspection
method
Measure
resistance
Measure
resistance
Measure
resistance
Measure
voltage

Normal temperature (25
3.8 - 4.8
100
3.6 - 3.9

normal
Between (11) - (17)
4.4 - 4.6
100
Between (11) - (17)
2.1 - 2.3

sensor is normal
Between (1) - (2)
500 - 1000
Between (1) - (2) - chassis
Min. 1 M

normal
Measure with AC range
Between (2) - (9)
Engine speed
___
CN3
(male)
Adjust
Measure
resistance
Speed
Adjust
___
Measurement
conditions
Judgement table
Max. 0.5 V

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

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

above.

normal
Between (1) - (2)
500 - 1000
Min. 1 M

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

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

above.
1. Turn starting
switch OFF
2. Disconnect
connector
3. Connect Tadapter
1. Turn starting
switch OFF
2. Disconnect
connector
3. Connect Tadapter
1. Turn starting
switch OFF
2. Disconnect
connector
3. Connect Tadapter
1. Turn starting
switch OFF
2. Disconnect
connector
3. Start engine.
___
1. Turn starting
switch OFF
2. Disconnect
connector
3. Connect Tadapter
___
20-11
Name of component
Connector
number
Inspection
method
Speed lever
(1st)
Directional
lever (R)
Directional
lever (N)
20-12
20 - 30 V
Speed lever not at 1st.

Max. 1 V
Speed lever at 2nd.

20 - 30 V
Speed lever not at 2nd.

Max. 1 V

sensor is normal
C3B
Directional
lever (F)
Speed lever at 1st.


normal
Speed lever
(3rd)
Controller
Speed lever
(2nd)
Speed lever
(4th)
Measurement
conditions
Judgement table
Measure
voltage
Speed lever at 3rd.

20 - 30 V
Speed lever not at 3rd.

Max. 1 V

normal
Speed lever at 4th.
20 - 30 V
Speed lever not at 4th.

Max. 1 V

sensor is normal
Directional lever at F.
20 - 30 V
Directional lever at F.
Max. 1 V

normal
Directional lever at R.
20 - 30 V
Directional lever not at R.

Max. 1 V

sensor is normal
Directional lever at N.
20 - 30 V
Directional lever not at N.

Max. 1 V
1. Turn starting
switch OFF
2. Disconnect
connector
3. Turn starting
switch ON
Controller
Name of component
S-NET
(between
transmission
and main
controller
Connector
number
C3B
Inspection
method
Measure
voltage
If the condition is as shown in the table below, the sensor

is normal
Kick-down Switch
Hold Switch
Transmission cut-off
switch
Power source
4-8V
If the condition is as shown in the table below, it is normal
L15
(male)
L12
(male)
C5
Measure
resistance
Measure
resistance
Measure
voltage
Controller
Manual Switch
Measurement
conditions
Judgement table
CN3
(male)
Measure
voltage
Kick-down switch ON
Between (1) - (2)
Max. 1
Kick-down switch OFF

Between (1) - (2)
Min. 1 M

is normal
Hold switch ON
Between (3) - (4)
Max. 1
Hold switch OFF

Between (3) - (4)
Min. 1 M

When operated normally
Between (1) - (2)
Max. 1
When left brake is depressed

Between (1) - (2)
Min. 1 M

is normal
Manual switch ON
Between (14) -chassis
20 - 30 V
Manual switch OFF

Between (14) -chassis
Max. 1 V

Main Monitor
20 - 30 V
Between (1) - (2) - (3)
Charge (alternator)
L05
Measure
voltage

is normal
Engine running (at above throttle.
Between (5) - (3)
28 2 V
Starting switch ON
Between (5) - (3)
Max. 1 V
1. Turn starting
switch OFF
2. Insert Tadapter
3. Turn starting
switch ON
1. Turn starting
switch OFF
2. Disconnect
connector
3. Connect Tadapter
1. Turn starting
switch OFF
2. Disconnect
connector
3. Connect Tadapter
1. Turn starting
switch OFF
2. Disconnect
connector
3. Connect Tadapter
1. Turn starting
switch OFF
2. Insert Tadapter
3. Turn starting
switch ON
1. Turn starting
switch OFF
2. Insert Tadapter
3. Turn starting
switch ON
1. Turn starting
switch OFF
2. Insert Tadapter
* If the battery is old, or after starting in cold areas, the voltage may not rise for some time.
20-13
Name of component
Directional switch
(N)
Starting switch
terminal C
Maintenance Monitor Related
Starting switch
terminal C
Starting switch
terminal BR
Connector
number
L05
L09
(male)
L04
L09
(male)
Inspection
method
Measure
voltage
Measure
voltage
Measure
voltage
Measure
voltage

Directional lever at N
Between (8) - (3)
20 - 30 V
Directional lever not at N

Between (8) - (3)
Max. 1 V

normal
Starting switch at start
20 - 30 V
Starting switch at OFF or ON

Max. 1 V

sensor is normal
Engine started
Between (4) - (3)
20 - 30 V
Starting switch OFF or ON

Between (4) - (3)
Max. 1 V

normal
Starting switch ON
Starting switch OFF
Starting switch
terminal BR
Parking brake
indicator switch
Directional switch
(F)
L07
CN19
(male)
L08
Measure
voltage
Measure
resistance
Measure
voltage
20 - 30 V
Starting switch ON
20 - 30 V
Starting switch OFF

Max. 1 V

normal
Parking brake ON
Between (1) - (2)
Max 1
Parking brake OFF

Min. 1 M

sensor is normal
Directional lever not at F

1. Turn starting
switch OFF
2. Insert Tadapter
3. Turn starting
switch ON
1. Turn starting
switch OFF
2. Insert Tadapter
1. Turn starting
switch OFF
2. Insert Tadapter
1. Turn starting
switch OFF
2. Disconnect
connector
3. Connect Tadapter
Max. 1 V

sensor is normal
Directional lever at F
20-14
Measurement
conditions
Judgement table
20 - 30 V
Max. 1 V
1. Turn starting
switch OFF
2. Insert Tadapter
1. Turn starting
switch OFF
2. Disconnect
connector
3. Connect Tadapter
1. Turn starting
switch OFF
2. Insert Tadapter
3. Turn starting
switch ON
Name of component
Directional lever
(R)
Power source
Connector
number
L08
L18
Inspection
method
Measure
voltage
Measure
voltage
Measurement
conditions
Judgement table
Directional lever at R
20 - 30 V
Directional lever not at R

Max. 1 V

normal
20 - 30 V
Between (1), (2) - (3)
Engine water
temperature
sensor
Torque converter
oil temperature
sensor
E06
(male)
CN18
(male)
Measure
resistance
Measure
resistance

sensor is normal
50
Between (A) - (B)
Approx. 19
100
Between (A) - (B)
Approx. 3.6

normal
Between (1) - (2)
130
Between (1) - (2)
Fuel level sensor
Radiator water
level sensor
Engine oil
pressure sensor
R07
(male)
G01
(male)
E11
Measure
resistance
Measure
resistance
Measure
resistance
Approx. 40
1. Turn starting
switch OFF
2. Insert Tadapter
3. Turn starting
switch ON
1. Turn starting
switch OFF
2. Insert Tadapter
3. Turn starting
switch ON
1. Turn starting
switch OFF
2. Disconnect
connector
3. Connect Tadapter
1. Turn starting
switch OFF
2. Disconnect
connector
3. Connect Tadapter
Approx. 1.7

sensor is normal
Float raised to stopper
Approx. 4
Float lowered to stopper
Approx. 85

normal
Water level normal
Between (1) - (2)
Max 1
Water level low

Between (1) - (2)
Min. 1 M

sensor is normal
Engine oil pressure: Min. 0.13 MPa
(1.3 kg/cm2(Start engine) Between
(A) - (C)
Min. 1 M
Engine oil pressure: Max. 0.07 MPa

(0.7 kg/cm2(Starting switch ON)
Between (A) - (C)
Max. 1
1. Turn starting
switch OFF
2. Disconnect
connector
3. Drain fuel
4. Remove fuel
level sensor
5. Connect Tadapter
1. Turn starting
switch OFF
2. Disconnect
connector
3. Connect Tadapter
1. Turn starting
switch OFF
2. Disconnect
connector
3. Connect Tadapter
4. Start engine
20-15
Name of component
Brake
accumulator low
pressure switch
Connector
number
B08
(male)
B13
(male)
Inspection
method
Measure
resistance

Accumulator pressure: Min. 5.39
0.49 MPa (55 5 kg/cm2) Between
(1) - (2)
Depress brake and lower
accumulator pressure to below
4.41 0.49 MPa (45 5 kg/cm2)
Between (1) - (2)
Charge
(alternator)
L18
Measure
voltage
Measurement
conditions
Judgement table
Max. 1
Min. 1 M

normal
Engine running (at above 1/2
throttle)
Between (12) -(3), (14)
Starting switch ON
Between (12) -(3), (14)
1. Turn starting
switch OFF
2. Disconnect
connector
3. Connect Tadapter
28 2 V
1. Turn starting
switch OFF
2. Insert Tadapter
3. Start engine
Max. 1 V
*If the battery is old, or after starting in cold areas, the

voltage may not rise for some time.
Engine oil level
sensor
Dust indicator
E10
(male)
E19
(male)
E20
(female)
Measure
resistance
Measure
continuity

sensor is normal
Oil level normal
Between (1) - (2)
Max. 1
Oil level abnormal

Between (1) - (2)
Min. 1 M

normal
Air cleaner normal
Between E19 (1) - E20 (1)
Air cleaner clogged or engine
stopped - No continuity
Between E19 (1) - E20 (1)
20-16
Continuity
No continuity
1. Turn starting
switch OFF
2. Disconnect
connector
3. Connect Tadapter
Measurement
conditions
Check carefully that there is no one in the surrounding area before starting inspection.
When carrying out operations during inspection, raise the work equipment control lever stand for
operations, and lower it when traveling.
Turn the starting switch OFF before inserting the T-adapter, or making any connections.
Name of component
Measurement
conditions
Judgement table
If the condition is as shown in Table 1, the monitor panel is normal
Table 1 (CHECK, CAUTION portion)

Connector
No.
CHECK,
CAUTION
portion
L18
(male)
Monitor item
(input connector)
Measurement
conditions
Display
Sensor
signal input
Engine water level

(8) - (3), (14)
Engine stopped,
Starting switch ON
Flashing
15 - 20 V
OFF
Max. 1 V
Flashing
15 - 20 V
OFF
Max. 1 V
Flashing
15 - 20 V
OFF
Max. 1 V
Flashing
15 - 20 V
OFF
Max. 1 V
Flashing
Max. 10 V
OFF
Min. 12 V
Flashing
15 - 20 V
OFF
Max. 1 V
Engine oil level

(13) - (3), (14)
Engine oil pressure
(10) - (3), (14)
Brake oil pressure
(11) - (3), (14)
Battery charge
(12) - (3), (14)
Air cleaner
(15) - (3), (14)
Engine stopped,
Starting switch ON
Start engine
Start engine
Start engine
Start engine
1. Connect Tadapter
20-17
Name of component
Judgement table
Measurement
conditions
Table 2 (Gauge portion)
Gauge portion
20-18
1. Turn starting
switch OFF,
then insert
dummy
resistance or
measure
resistance of
sensor.
2. Turn starting
switch ON
and check
display
Name of component
Parking brake
emergency cancel
switch
Parking brake
emergency cancel
solenoid
L90
B14
B09, B10
(male)
Inspection
method
Measure
voltage
Measure
voltage
Measure
resistance
Others
Emergency brake
switch
Connector
number

Parking brake emergency cancel
switch ON
Between (1) -(2) and (3) - (4)
20 - 30 V

switch OFF
Between (1) -(2) and (3) - (4)
Max. 1 V

normal
switch ON
Between (1) -(2)
20 - 30 V

switch ON
Between (1) -(2)
Max. 1 V

sensor is normal
B09 (1) - B10 (2)
3.63 0.49 MPa (37 5 kg/cm2)
Between B09 (1) - B10 (2)
Emergency brake
switch
BR1
Measure
voltage

3.63 0.49 MPa (37 5 kg/cm2)
Between B09 (1) - B10 (2)
F05
Measure
voltage
Max. 1
1. Turn starting
switch OFF
2. Insert Tadapter
3. Turn starting
switch ON
1. Turn starting
switch OFF
2. Insert Tadapter
3. Turn starting
switch ON
1. Turn starting
switch OFF
2. Disconnect
connector
3. Connect Tadapter
Min. 1 M

normal
(7) - (8)
Bucket positioner
proximity switch
Measurement
conditions
Judgement table
20 - 30 V
1. Turn starting
switch OFF
2. Insert Tadapter
3. Turn starting
switch ON
Max. 1 V

sensor is normal
Between
When
screwdriver is
brought close
When
screwdriver is
not brought
close
(1) - (2)
20 - 30 V
Max. 3 V
(1) - (3)
20 - 30 V
20 - 30 V
(2) - (3)
Max. 3 V
20 - 30 V
1. Turn starting
switch OFF
2. Insert Tadapter
3. Turn starting
switch ON
20-19
Name of component
F06
Inspection
method
Measure
voltage
Others
Boom kick-out
proximity
switch
Connector
number
Boom kick-out
solenoid
Bucket
positioner
solenoid
20-20
L16
L17
Measure
resistance
Measure
resistance
Measurement
conditions
Judgement table
Between
When
screwdriver is
brought close
When
screwdriver is
not brought
close
(1) - (2)
20 - 30 V
Max. 3 V
(1) - (3)
20 - 30 V
20 - 30 V
(2) - (3)
Max. 3 V
20 - 30 V

normal
Between (1), (2)
19 - 23
Min. 1 M

sensor is normal
Between (1), (2)
19 - 23
Min. 1 M
1. Turn starting
switch OFF
2. Insert Tadapter
3. Turn starting
switch ON
1. Turn starting
switch OFF
2. Disconnect
connector
3. Connect Tadapter
1. Turn starting
switch OFF
2. Disconnect
connector
3. Connect Tadapter
Name of component
Power source
voltage
Connector
number
L28
Inspection
method
Measure
voltage
Measurement
conditions
Judgement table
sensor is normal.
Between (8), (17), (18) - (9), (18)
Joystick R
(right)solenoid
Joystick Controller
Joystick L (left)
solenoid
Joystick neutral
switch
CNR
(male)
CNL
(male)
NEUTRAL
Measure
resistance
Measure
resistance
Measure
resistance
When actuated
20 - 30 V
When not actuated
Max. 1 V

normal
Between (1) - (2)
10 - 20
Min. 1 M

sensor is normal
Between (1) - (2)
10 - 20
Min. 1 M

normal
Joystick neutral switch between (1) - (3)
Not at N
Max. 1
1. Turn starting
switch OFF
2. Insert Tadapter
3. Turn starting
switch ON
1. Turn starting
switch OFF
2. Disconnect
connector
3. Connect Tadapter
1. Turn starting
switch OFF
2. Disconnect
connector
3. Connect Tadapter
1. Turn starting
switch OFF
2. Disconnect
connector
3. Connect Tadapter
At N
Min. 1 M
Joystick
potentiometer
L27
Measure
voltage

normal
Between (20) - (9)
When actuated
Joystick
potentiometer
JS7
(male)
Measure
resistance
0.5 - 4.5 V

sensor is normal
Between (1) - (2)
0-5
Between (2) - (3)
4-5
Between (3) - (1)
0-5
1. Turn starting
switch OFF
2. Insert Tadapter
3. Turn starting
switch ON
1. Turn starting
switch OFF
2. Disconnect
connector
3. Connect Tadapter
20-21
SERVICE TOOLS AND TROUBLESHOOTING
SERVICE TOOLS FOR TESTING, ADJUSTING & TROUBLESHOOTING

No.
Check or Measurement
Item
Tool Description
Tool Number
Remarks
799-203-8001
799-203-9000
(Kit)
Digital display
L: 60 - 20,000 rpm
H: 60 - 19,999 rpm
Engine speeds
Digital Optical
Tachometer
Intake manifold pressure
Pressure gauge
See Engine Shop Manual
Intake air restriction
Water manometer
Lubricating oil pressure
Pressure gauge
Fuel filter inlet restriction
Vacuum gauge
Blow-by pressure
Tool, adapter &

manometer
Exhaust back pressure
Mercury
manometer
Coolant temperature
Digital
temperature
gauge
Valve clearance
Feeler gauge
10
Alternator, fan & water

pump drive belts
Tension gauge
ST-1138
Smoke detector
799-201-9000
11
Exhaust gas color

Smoke meter
Commercially
available
Brake test kit
793-520-1805
Nipple
793-520-1851
Push-pull scale
79A-264-0020
0 - 294.2 N (0 - 30 kg)
79A-264-0090
0 - 490.3 N (0 - 50 kg)
12
13
Brake oil pressure
Operating effort
Commercially
available
14
Stroke, hydraulic drift
Scale
Commercially
available
15
Work equipment speed
Stop watch
Commercially
available
16
Measuring brake disc

wear
Calipers
Commercially
available
20-22
Discoloration
0-70% with standard color
% x 1/10
Check or Measurement
Item
No
SERVICE TOOLS AND TROUBLESHOOTING
Tool Description
Tool Number
Remarks
17
Moving machine when

there is failure in
transmission valve
Plate
793T-6851110
18
Measuring voltage,
resistance value
Tester
79A-264-0210
T-adapter
assembly
799-601-7400
799-601-7310
SWP12P
799-601-7320
SWP16P
799-601-7340
M8P
799-601-7380
JFC2P
19
Troubleshooting of wiring,
harness, sensors
Adapter
SKETCHES OF SPECIAL TOOLS

TOOL N
Note:
Komatsu cannot accept any responsibility for special

tools manufactured according to these sketches.
20-23
MEASURING ENGINE SPEEDS
MEASURING ENGINE SPEEDS

When measuring engine speeds, one worker should
measure the engine speed while the other sits in the
operator's seat to operate the controls. Always check that
the operation is safe, and use agreed upon signals.
When removing or installing the measuring equipment, be
careful not to touch any high temperature parts.
Measure the engine speed under the following conditions.
Coolant temperature: Within operating range
Torque converter oil temperature: 70 to 90
Hydraulic oil temperature: 45 to 55
1.
Install the digital optical tachometer using the instructions

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

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

procedure.
20-26
MEASURING ENGINE LUBRICATING OIL PRESSURE
MEASURING ENGINE LUBRICATING OIL PRESSURE

procedure.
20-27
MEASURING FUEL FILTER INLET RESTRICTION
MEASURING FUEL FILTER INLET RESTRICTION

procedure.
20-28
MEASURING BLOW-BY PRESSURE
MEASURING BLOW-BY PRESSURE

procedure.
20-29
MEASURING ENGINE BACK PRESSURE
MEASURING EXHAUST BACK PRESSURE

procedure.
20-30
MEASURING COOLANT TEMPERATURE
MEASURING COOLANT TEMPERATURE

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

procedure.
20-32
ALTERNATOR DRIVE BELT
ALTERNATOR DRIVE BELT

BELT TENSION CHART
Unit: N(lbf)
Belt tension
New tension
Used tension
620 (140)
270 - 490
(60 - 110)
Testing alternator belt tension.

Belts will loosen during use. They must be adjusted to the
values listed in the Belt Tension Chart.
A belt is considered used if it has been in operation for 10
minutes or longer.
Use the belt tension gauge, Part No. ST-1138. Check the belt
tension.
To adjust the alternator belt tension, see the "Engine
Operation and Maintenance Manual"
20-33
AIR CONDITIONER BELT

1. Testing
Measure deflection cof the belt when it is pushed with
force of approximately 98 N (10 kg) at a point midway
between the fan pulley and the air conditioner
compressor pulley.
Deflection cof belt (standard value): 10 - 15 mm
2. Adjusting
1) Loosen mount bolt and nut, and the adjustment plate bolt
and nut.
2) Move the position of the air conditioner compressor to adjust
the tension of the belt.
3) When the position of the air conditioner compressor is
correct, tighten adjustment plate bolt and nut, and the
mounting bolt and nut to secure it in position.
4) After adjusting the belt tension, repeat the testing procedure
above to check that the tension is adjusted within the
standard value.
20-34
AIR CONDITIONER BELT
MEASURING EXHAUST TEMPERATURE
MEASURING EXHAUST TEMPERATURE

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

ambient temperature - actual ambient temperature).
The converted ambient temperature is taken as 20
2. When measuring periodically (during preventive maintenance,
etc.)
1) Raise the exhaust temperature by using full stall (torque
converter stall + hydraulic pump relief).
Standard value:
Approximately 700
2) In the above condition, cancel the hydraulic relief, and

carry out only torque converter stall. (The temperature
will start to go down. If it goes up without going down,
raise the set temperature shown in (1) of the right
figure).
3) Note the stable temperature when the temperature
starts to go down.
If only torque converter stall is used when
measuring the exhaust temperature, torque
converter will overheat before a stable value is
obtained.
20-35
EXHAUST GAS COLOR
EXHAUST GAS COLOR

Coolant temperature: Inside operating range
Valve clearance: Standard value
Special tools:
No.
Part Number
Part Name
Qty.
A-1
799-201-9000
Handy smoke
checker
A-2
Commercially
available
Smoke checker
For tests in the field where there is no air or electricity available, use A-1; for tests in a repair shop,
use A-2.
Measuring with A-1
WARNING! When measuring the exhaust
color, be careful not to touch the exhaust pipe.
When measuring the exhaust color, warm the
engine up thoroughly (oil temperature 60
1. Fit the filter paper in tool A-1.
2. Insert the exhaust gas suction port into the exhaust
pipe, accelerate the engine suddenly, and operate
the handle to catch the exhaust gas on the filter
paper.
3. Remove the filter paper and compare it with the
scale provided to judge the condition.
20-36
EXHAUST GAS COLOR
Measuring with A-2

WARNING! When measuring the exhaust
color, be careful not to touch the exhaust pipe.
When measuring the exhaust color, warm the
engine up thoroughly (oil temperature 60
1. Insert probe (A) in outlet of exhaust pipe (1) and
secure to exhaust pipe with clip.
2. Connect probe hose, connector hose of
accelerator switch plug and air hose to tool A-2.
The pressure of the air supply should be under
15 kg/cm.
3. Connect power cord to AC 100 V socket.
Check that the power switch is OFF before
connecting the cord.
20-37
MEASURING ENGINE STALL SPEEDS

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

1). Start the engine and run at low idle.
2). Put the directional lever in FORWARD or REVERSE,
and speed control lever in the highest speed range.
3) Using the brake, stop the machine and measure the
engine speed when the engine when the accelerator
pedal is fully depressed.
Turn the transmission cut-off selector switch (1)
to the OFF position, and use the left brake.
(Check that the pilot lamp is OFF).
Do not run at stall speed for more than 20
seconds, and do not let the torque converter oil
temperature raise above 120
Turn the parking brake switch OFF (release).
20-38
2. Measuring hydraulic stall

1) Start engine and run at high idle.
2) Operate the dump or lift control lever to move
the cylinder to the end of its stroke and actuate
the relief valve of the main control valve.
3) Measure the engine at this point.
Do not run the engine at stall speed for more
than 20 seconds, and operate the control lever
quickly.
3. Measuring full stall

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

1. Engine speed sensor
1) Screw in until the tip of the sensor (1) contacts gear (2).
2) When sensor (1) contacts gear (2), turn back 1 turn.
3) Tighten locknut (3).
Locknut:
49 4.9 Nm (5.0 0.5 kgm)
Be particularly careful when handling the sensor
wiring to ensure that no excessive force is brought to
bear in the wiring.
Be careful not to let the tip of the sensor be
scratched, or let any foreign particles stick to it.
2. Transmission output shaft speed sensor

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

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

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

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

OPERATING FORCE
1. Measuring procedure
1) Put push-pull scale "A" in contact with the accelerator
pedal at point 150 mm from pedal fulcrum "a".
The center of push-pull scale
n
contact with a point 150 mm from the pedal
fulcrum.
2) Start the engine, push the pedal in the direction of
operation and measure the maximum value when
pushing from low idle to the end of the pedal travel
(high idling).
2. Testing and adjusting

1) Stop the engine.
2) Disconnect cable (1) at the bottom of the accelerator
pedal, and check that plate (2) at the bottom of the
pedal moves smoothly.
3) Connect the cable at the bottom of the pedal, then
disconnect at the connection for the injection pump,
and check that cable (3) moves smoothly.
When performing this inspection, adjust or
replace parts as necessary. Measure the
operating force again and check that all
measurements are within the standard values.
20-42
OPERATING ANGLE
1. Measuring procedure
1. Stop the engine.
2. Put angle gauge "A" in contact with the accelerator
pedal, then measure the operating angle from low
idle to high idle, and calculate operating angle a = a1 a2.
2. Adjusting procedure
1. Remove the cover under the cab, and open the
inspection cover on the right side of the engine.
2. Loosen nut (1) and adjust bolt (2) so that mounting
height "L" of the accelerator pedal stopper is within a
range of 45 5 mm.
3. Loosen locknut (4) and adjust length of cable (3) so
that the fuel pump lever contacts the high idle stopper
when the accelerator pedal is fully depressed (high
idle).
Check that the P.T. pump governor lever is in
contact with the low idle stopper when the
accelerator pedal is released (low idle).
Adjust the travel of the governor lever with joint of
cable (3).
After completing the above adjustments,
measure each part again to check that it is within
the standard values.
20-43
TORQUE CONVERTER AND TRANSMISSION
MEASURING TORQUE CONVERTER

AND TRANSMISSION OIL PRESSURE
Coolant temperature: Inside operating range.
Manual switch ON
WARNING! Apply the parking brake and block the
tires.
1. Measuring main relief pressure
1) Remove the cover at the front of the engine and the
cover at the rear of the operators compartment.
2) Remove oil pressure measurement plug (PT1/8) (1),
then install oil pressure gauge C1 (5.9 MPa {60
kg/cm2}).
3) Start the engine and measure the oil pressure with
the engine at low idling and high idling.
2. Adjusting main relief valve

CAUTION: Adjust the main relief valve with the engine
stopped.
If the main relief pressure is not within the standard value,
adjust as follows:
1) Remove plug (1) and washer (2).
2) Remove inner spring (3) and outer spring (4).
3) Adjust by changing the thickness of shim (5).
Standard shim thickness: 3.0 mm (0.5 x 6)
Amount of adjustment for one shim: 0.04MPa
(0.4 kg/cm2)
20-44
3. Measuring torque converter relief (inlet port) pressure

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

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

2) Remove the oil pressure measurement plug for the
clutch to be measured.
Plug for measuring 1st clutch pressure: (1)
Plug for measuring 2nd clutch pressure: (2)
Plug for measuring 4th clutch pressure: (3)
Plug for measuring 3rd clutch pressure: (4)
Plug for measuring reverse clutch pressure: (5)
Plug for measuring forward clutch pressure: (6)
: Gasket sealant (LG-5)
3) Install oil pressure gauge C1 (5.9 MPa {60 kg/cm2}).
4) Start engine and measure the 1st, 2nd, 3rd, and 4th
clutch pressures under the following conditions at high
idling.
a) Leave the directional lever at neutral.
b) Turn the main monitor manual switch ON.
c) Place the gear shift lever at the speed range to be
measured.
5) Start the engine and measure the forward and reverse
clutch pressures under the following conditions at high
idling.
WARNING! Put blocks under the tires and depress the
brake securely.
a) Turn the transmission cut-off selector switch OFF
(lamp off).
b) Turn the parking brake switch OFF.
c) Depress the brake.
d) Turn the main monitor manual switch ON and place
the gearshift lever in 4th.
e) Keep the brake depressed and place the directional
lever at F or R.
6. Measuring lubricating oil pressure (oil cooler outlet port)

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

CIRCUIT
Metal particles and other dirt in the torque
converter and transmission hydraulic circuit will
reduce the life of the torque converter and
transmission, and will cause internal damage. To
prevent this, flush the system to remove the dirt or
metal particles in the hydraulic circuit.
1. Flush the circuit if the following conditions
apply.
1) If there has been any breakage of the torque
converter,
transmission,
or
hydraulic
equipment, and metal particles are circulating
in the hydraulic circuit.
2) When the torque converter and transmission
have been overhauled or repaired.
3) Repeat the procedure in 4-1, and run the

engine at low idling for approximately 20
minutes.
5. Replace the flushing element.

1) Using the procedure in step 2-1, replace the
flushing element with the standard element
(424-16-11140).
CAUTION! If the flushing element is used for
a long time, there will be premature clogging,
so always replace the flushing element with the
standard element.
2) Add oil and check the level again.
2. Install the flushing element.

1) Drain the oil from the filter case.
2) Remove the two transmission oil filters, then
install two flushing elements (561-15-55670).
After flushing the system, assemble the
parts that were removed, and the parts
inside the case.
3. Fill the transmission case with oil.
Add fresh oil through the oil filler port to the
specified level, and run the engine to circulate
the oil through the system. Then check the
level again.
Transmission case: 62
6. Replace the transmission fail safe filter.

1) Use a wrench to turn portion A of fail safe filter
case (1) to remove it.
If there is any dirt inside the filter case,
wash the case.
2) Remove element (2) and replace with a new
element.
3) Install new O-ring (3) to the outside
circumference of the case.
Coat the outside circumference of the Oring with a small amount of grease.
4) Install the case.
Case: 39.2 Nm (4 kgm)
4. Carry out flushing as follows.

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

If the machine cannot be moved because of a
failure in any part of the transmission valve system
(electrical system, solenoid valves, spools, etc.), it
is possible to move the machine by installing plate
N.
WARNING! Plate N is only for emergency use
when the machine cannot be moved by any
other means because of a failure in the
transmission control valve system. DO NOT
install plate N to the ECMV except when there
has been a failure and it is necessary to move
the machine from a dangerous working area to
a safe place for repairs.
WARNING! When carrying out this operation
keep strictly to the procedure and pay careful
attention to safety when moving the machine.
WARNING! To prevent the machine from
moving, lower the work equipment completely
to the ground, apply the parking brake, and put
blocks under the tires.
WARNING! Carry out the operation with the
engine stopped.
WARNING! Be careful not to burn yourself if
the oil is hot.
1. Remove the cover at the bottom of the operators

cab, and the cab at the bottom of the step on the
left side.
2. Remove valve cover (1).
Wash the area around the ECMV, clean and
remove all dirt and mud.
3. Disconnect wiring connectors (2) through (13).
For details of precautions when removing the
wiring connectors, see DISASSEMBLY AND
ASSEMBLY, REMOVAL OF TRANSMISSION
CONTROL VALVE ASSEMBLY.
20-48
4. Depending on the direction for moving the machine (forward

or reverse), remove the following 2 ECMV solenoids (14) and
install plate N.
FORWARD: F solenoid and 2nd solenoid
REVERSE: R solenoid and 2nd solenoid
If there is any mistake in the selection of the solenoid
to remove, there is danger that the transmission may
be damaged.
Install plate N with the protruding surface facing the
ECMV. Check also that there is an O-ring installed to
the mating surface.
Be careful not to let any dirt or mud get inside the
removed solenoid or valve
5. Depress the left brake pedal securely.

6. Start the engine, release the parking brake, then release the
brake pedal gradually to allow the machine to start, then
move the machine.
WARNING! Remove the blocks from under the tires.
WARNING! When the engine is started, the transmission

is also engaged to start the machine. To ensure safety
when starting the engine, check carefully that the
direction of travel and area around the machine are safe,
and always keep the brake pedal depressed when
starting.
WARNING! After moving the machine, stop the
engine, apply the parking brake, put blocks under the
tires.
20-49
TESTING
AND
STEERING WHEEL
ADJUSTING
MEASURING PLAY OF STEERING WHEEL

Engine speed: Stopped
Machine posture: Facing straight forward
Method of measurement
1. Move the steering wheel 2 or 3 times lightly to the
left and right, check that the steering mechanism is
at the neutral position, then make a mark on the
outside frame of the machine monitor.
2. Turn the steering wheel to the right, and make a
mark at the position where the operating force
starts to become heavy (when the steering valve
lever starts to move).
3. Turn the steering wheel to the left in the opposite
direction from Step 2, and make a mark at the point
where the operating force becomes heavy (when
the steering valve lever starts to move). Then
measure the distance in a straight line between the
marks made in Step 2 and Step 3.
MEASURING OPERATING FORCE OF STEERING

WHEEL
Road surface: Flat, horizontal, dry paved
surface
Engine water temperature: Within green range
on engine water temperature gauge
Tire inflation pressure: Specified pressure
Engine speed: Low idling (bucket empty)
Measurement method
1. Install push-pull scale l2 to the steering wheel knob.
2. Start the engine.
After starting the engine, raise the bucket
approx. 400 mm and remove the safety bar.
3. Pull push-pull scale l2 in the tangential direction
and measure the value when the steering wheel
moves smoothly.
Avoid measuring when the steering wheel
starts to move.
20-50
STEERING WHEEL
STEERING WHEEL
MEASURING OPERATING TIME FOR STEERING WHEEL

Road surface: Flat, horizontal, dry paved surface
Engine water temperature: Within green range on
engine water temperature gauge
Engine speed: Low and high idling
Measurement method
After starting the engine, raise the bucket
approx. 400 mm and remove the safety bar.
2. Operate the steering wheel to the end of its stroke
to turn the machine to the left or right.
3. Measure the time taken to operate the steering
wheel to the end of the stroke to the right (left).
Operate the steering wheel as quickly as
possible without using force.
Carry out the measurements both at low idling
and high idling, and to both the left and right.
20-51
STEERING OIL PRESSURE

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

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

1) Disconnect pilot hose (2) or (3) from steering valve
(1).
2) Install the adapter and oil pressure gauge (5.9 MPa
{60 kg/cm2}) inside tool Cl.
3) Start the engine and measure the oil pressure when
the steering wheel is turned with the engine running
at high idling.
Hose (2): Turn steering to right
Hose (3): Turn steering to left
20-52

3.
Measuring Orbit-roll output pressure

1) Disconnect Orbit-roll output hose (1) or (2).
2) Install the adapter and oil pressure gauge (5-9 MPa {60
kg/cm2}) inside tool Cl.
3) Start the engine and measure the oil pressure when the
steering wheel is turned with the engine running at high
idling.
Hose (1): Turn steering to right
Hose (2): Turn steering to left
Adjusting
WARNING! Always stop the engine before adjusting the
pressure
1. Adjusting steering relief valve
Loosen locknut (2) of steering relief valve (1), then turn
adjustment nut (3) to adjust.
Turn the adjustment screw to adjust the set pressure as
follows.
To INCREASE pressure, turn CLOCKWISE
To DECREASE pressure, turn COUNTERCLOCKWISE
Pressure adjustment for one turn of adjustment screw:
Approx. 14.8 MPa (151 kg/cm2)
20-53
STEERING STOP VALVE

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

rear frame when steering stop valve contact surface (3)
and stopper bolt (1) coming into contact and the turning
stops. - Standard clearance a: 405 mm
Adjusting
If the clearance between the front frame and rear frame is not within
the standard value, adjust as follows.
1. Loosen locknut (2), tighten stopper bolt (1), and make sure
that there is no contact with the steering stop valve.
2. Start the engine, run at low idling, then turn the steering
wheel slowly to bring the front and rear frames into contact.
When turning, be extremely careful not to get your arm or
any other part of your body caught between the front and
rear frames.
3. Stop the engine, then loosen the stopper bolt until it
contacts the steering stop valve contact surface.
4. Set the front and rear frames facing straight.
5. Loosen stopper bolt (1) 8.5 turns, then tighten locknut (2).
Carry out the procedure in Steps 1 - 5 to adjust both the
left and right sides.
6. Start the engine, turn the machine, and check that
clearance a between the front and rear frames is within the
standard value for both the left and right and that the
steering stopper valve and stopper bolt come into contact
and the steering is stopped.
20-54
STEERING STOP VALVE
MEASURING BRAKE PEDAL
MEASURING BRAKE PEDAL

Engine water temperature: Within green range on engine
water temperature gauge
Engine speed: Low idling
Operating force of pedal

1. Install push gauge (1) to the operator's foot.
Align the center of the push gauge with the center of the
pedal.
2. Start the engine, run at low idling, and measure the operating
force when the pedal is depressed.
Travel of pedal
1. Install push gauge (1) to the operator's foot.
Align the center of the push gauge with the center of the
pedal.
2. Start the engine, and measure pedal angle a1 when running
at low idling, and pedal angel a2 when the pedal is depressed
with a force of 30 kg.
Install angle gauge (2) to the brake pedal when
measuring.
Pedal play
2. Push the brake pedal lightly by hand, and measure pedal
angle a3 when the pedal starts to become heavy.
20-55
MEASURING BRAKE
PERFORMANCE
Road surface: Flat, horizontal, dry paved
surface
Travel speed: 20 km/h when brakes are
applied
Delay in applying brakes: 0.1 sec.
Measurement method
1. Start the engine and move the machine.
2. Set the speed lever to the highest speed position
and drive the machine.
3. When the travel speed reaches 20 km/h, depress
the left brake pedal with the specified operating
force.
Before carrying out this operation, determine
the run-up path and the point for applying the
brakes, then apply the brakes when the
machine reaches that point.
Switch the transmission cut-off switch ON
when carrying out this operation.
4. Measure the distance from the point where the
brakes were applied to the point where the machine stopped.
Repeat this measurement three times and take
the average.
20-56
MEASURING BRAKE PERFORMANCE
TESTING BRAKE OIL PRESSURE
TESTING BRAKE OIL PRESSURE

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

1) Remove bleeder screw (1), then install oil
pressure gauge tool l (39 MPa {400 kg/cm2}),
the joint, bleeder screw, and nipple.
2) Connect hose (2) to the bleeder screw and
bleed the air from the brake circuit. For details,
see BLEEDING AIR.
3) Depress the left brake and measure the brake
oil pressure.
2. Measuring drop in brake piston pressure

1) Remove bleeder screw (1), then install oil pressure
gauge tool l (39 MPa {400 kg/cm2}), the joint,
bleeder screw, and nipple.
2) Connect hose (2) to the bleeder screw and bleed
the air from the brake circuit. For details, see
BLEEDING AIR.
3) Stop the engine, depress the left brake pedal,
leave for 5 min. with the oil pressure at 4.9 MPa (50
kg/c M2 }, and measure the drop in pressure.
Be careful not to move the brake pedal for 5
minutes.
After completing the operation, bleed the air
from the brake circuit again.
20-57
MEASURING BRAKE DISC WEAR

Brake oil pressure: 4.9 0.49 MPa (50 5 kg/cm2)
CAUTION! Park the machine on horizontal ground and
put blocks securely under the tires.
Measurement method
1. Remove plug (1).
2. Depress the brake pedal fully.
3. Use calipers M to measure depth a from the end face of the
housing to the spring guide.
When measuring, keep the brake pedal depressed.
4. Install a vinyl hose (3) to bleeder (2), then loosen the bleeder
and drain the brake oil.
After draining the brake oil, check that the brake piston
has returned to the end of its stroke.
5. Measure depth b from the end face of the housing to the
spring guide pin.
Calculating piston stroke

S=a-b S=Max.3.9mm
20-58
MEASURING BRAKE DISC WEAR
PARKING BRAKE PERFORMANCE
PARKING BRAKE PERFORMANCE

Road surface: Flat, dry, paved surface with 1/5 (11
gradient.
Machine: In operation condition
Measuring procedure
1. Start the engine, ser the machine facing in a straight
line, then drive the machine up a 1/5 grade slope with the
bucket empty.
2. Depress the brake, stop the machine, set the directional
lever to the neutral position, then stop the engine.
3. Turn the parking brake switch ON, then slowly release
the brake pedal, and the machine must not move at all.
Carry out the measurement in two ways. Once with
the machine facing uphill, and once more with the
machine facing downhill.
20-59
PARKING BRAKE OIL PRESSURE

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

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

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

If the parking brake effect becomes weak, measure the wear
of the parking brake disc as follows.
CAUTION! To prevent the machine from moving, lower
the work equipment completely to the ground and put
CAUTION! Always stop the engine before carrying out
this procedure.
1. Drain oil from the transmission case.

Transmission case: 62
2. Remove one of two plugs (1) on each side.

3. Using calipers M, measure depth a from the end face of cage
(2) to piston (3).
Standard depth a: Max. 40.3 mm
4. If depth a is greater than the specified value, remove parking

brake disc (4), and check thickness W of the disc. For details,
see DISASSEMBLY AND ASSEMBLY, REMOVAL OF
PARKING BRAKE DISC.
Dimension W: Min. 3.2 0.1 mm
If the thickness of the parking brake disc is below the
standard value, replace it.
20-62
PARKING BRAKE DISC WEAR
MANUAL RELEASE
PARKING BRAKE
MANUAL RELEASE METHOD FOR PARKING BRAKE
METHOD
FOR
The parking brake is controlled by hydraulic pressure, so if

there should be any failure in the transmission and it
becomes impossible to release the parking brake, it is
possible to release it manually to move the machine.
CAUTION! The manual release of the parking brake is
designed only to move the machine from a dangerous
working area to a safe place where repairs can be
carried out. This method must not be used except when
there has been a failure
CAUTION! To prevent the machine from moving, lower
the work equipment completely to the ground and put
CAUTION! Always stop the engine before carrying out
this procedure.
1. Remove two plugs (1).
After releasing the parking brake, coat the plugs with
gasket sealant (LG-5), then tighten the plugs.
2. Remove two cage mounting bolts (2), then screw them into
the plug mount gradually in turn.
When bolts (2) are screwed in, piston (3) is pulled and
the parking brake is released.
20-63
PPC OIL PRESSURE

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

pressure)
1) Disconnect hose (1), then install the adapter and oil
pressure gauge (5.9 MPa {60 kg/cm2}) in tool C1.
operate the work equipment control lever and measure
the oil pressure.
20-64
PPC OIL PRESSURE
PPC OIL PRESSURE
3. Measuring PPC valve output pressure

CAUTION! Loosen the oil filler cap slowly to release the
pressure inside the hydraulic tank.
CAUTION! Operate the control levers several times to
release the pressure in the PPC accumulator circuit.
1) Remove the main control valve cover.

2) Remove oil pressure detection plug (PT1/8) (1) of the
circuit to be measured, then install oil pressure gauge C1
(5.9 MPa {60 kg/cm2}).
Plug A: Boom LOWER, boom FLOAT
Plug B: Boom RAISE
Plug C: Boom DUMP
Plug D: Boom TILT
operate the work equipment control lever and measure
the oil pressure.
Adjusting
1. Adjusting PPC relief valve
Loosen locknut (2) of PPC relief valve (1), then turn
adjustment screw (3) to adjust.
Turn the adjustment screw to adjust as follows:
To INCREASE the pressure, turn clockwise.
To DECREASE the pressure, turn counter
clockwise.
Amount of adjustment - for one turn of adjustment screw:
1.8 MPa (18.3 kg/cm2)
Locknut: 83.4 4.9 Nm (18.3 0.5 kgm)
After completion of the adjustment, re-check the

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

1. Remove cover (1) at the bottom of the work equipment
control lever.
2. Adjust dimension a from nut (1) of the PPC valve linkage to
the top surface of the floor.
Dimension a (target value): 54 mm
3. Loosen nuts (2) and (3), then adjust the installed height of
trunnion (5) so that there is no play in lever (4).
4. After adjusting, tighten nuts (2) and (3).
20-66
ADJUSTING PPC VALVE LINKAGE
ACCUMULATOR CHARGE PRESSURE
ACCUMULATOR CHARGE PRESSURE

Measuring
CAUTION! Stop the engine, then depress the brake
pedal at least 100 times to release the pressure inside
the accumulator circuit.
1. Disconnect accumulator inlet port hose (1), then install the
adapter and oil pressure gauge (30 MPa {400 kg/cm2}) in tool
C1.
2. Measure the accumulator charge cut-in pressure. Start the
engine, run at low idling, and measure the oil pressure when
the brake oil pressure warning pilot lamp on the
maintenance monitor goes out.
3. Measure the accumulator charge cut-out pressure. After the
accumulator charge cut-in, the pressure rises. Measure the
oil pressure at the point where the oil pressure gauge
indicator suddenly drops after rising.
Adjusting
When the accumulator charge cut-out pressure is
adjusted, the cut-in pressure also changes because of
the valve area ratio. For this reason, there is no cut-in
pressure adjustment nut.
1. Loosen locknut (2) of the accumulator charge cut-out valve
(1), then turn adjustment screw (3) to adjust.
Turn the adjustment screw to adjust as follows:
To DECREASE the pressure, turn counter
clockwise.
Amount of adjustment - for one turn of adjustment

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

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

CAUTION! Loosen the oil filler cap slowly to release the
pressure inside the hydraulic tank.
1. Measuring work equipment relief pressure

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

then install oil pressure gauge C1 (39 MPa {400
kg/cm2}).
20-68
WORK EQUIPMENT HYDRAULIC PRESSURE
5) Start the engine, raise the lift arm approx. 400 mm, run
the engine at high idling, tilt the bucket back, then
measure the oil pressure when the relief valve is
actuated.
CAUTION! After measuring, repeat the procedure used
when installing the oil pressure gauge to release the
pressure inside the circuit, then remove the oil pressure
gauge.
Adjusting
1. Adjusting work equipment relief valve.
Loosen locknut (2) of work equipment relief valve (1), then
turn adjustment screw (3) to adjust.
Turn the adjustment screw to adjust as follows.
To DECREASE the pressure, turn counter clockwise.
Amount of adjustment for one turn of adjustment screw:
5.18 MPa {52.9 kg/cm2)
Locknut: 39.2 9.8 Nm (4 1 kgm)
After completion of the adjustment, repeat the above

procedure to measure the work equipment relief
pressure again.
20-69
RELEASING
REMAININ G
PRESSURE
IN
HYDRAULIC
CIRCUIT
1. Releasing remaining pressure between each
hydraulic cylinder and control valve.
If the piping between the hydraulic cylinder and
the control valve is to be disconnected, release
the remaining pressure from the circuit as
follows:
1) Stop the engine.
2) Release the oil filler cap slowly to release the
pressure inside the tank.
3) Operate the control levers.
When the levers are operated 2 - 3 times,
the pressure stored in the PPC
accumulator is removed. Start the engine,
run at low idling for approximately 5
minutes, then stop the engine and operate
the control levers.
Repeat the above operation 2 - 3 times to
release all the remaining pressure.
2. Releasing remaining pressure in brake
accumulator circuit.
If the piping between the brake accumulator
and emergency parking brake valve, between
the accumulator and check valve, and
between the accumulator and brake valve is to
be disconnected, release the remaining
pressure from the circuit as follows.
1) Stop the engine.
2) Depress the brake pedal at least 100 times to
release the pressure inside the brake
accumulator circuit.
3. Releasing remaining pressure PPC accumulator
circuit.
If the piping between the PPC accumulator and
PPC valve is to be disconnected, release the
remaining pressure from the circuit as follows:
Repeat the above operation 2 - 3 times to
release all the remaining pressure.
20-70
PRESSURE IN HYDRAULIC CIRCUIT
ADJUSTING WORK EQUIPMENT LEVER

LINKAGE
Always stop the engine before adjusting the work equipment
lever linkage.
Check that the operating effort of the work equipment control
lever is within the standard value.
1. Do as follows to set solenoid (1) in a pulled condition.
1) Disconnect wiring connectors (F05) (2) and (F06) (3).
F05:
Proximity switch for bucket positioner
F06:
Proximity switch for boom kick-out
2) Connect a T-adapter, then connect the terminals
between (1) and (2).
Check that the solenoid is pulled l2 mm.
2. With the solenoid pulled, move solenoid (1) so that clearances
a between boom lever cam (4) and boom lever cam follower
(5) and between bucket lever cam (6) and bucket lever cam
follower (7) are each 0 - 0.5 mm.
Carry out the adjustment with the boom and bucket levers
at the HOLD position.
3. Operate the boom lever and adjust distance c between the
pins of rod (8) so that clearance b between the notches at both
ends of boom lever cam (4) and boom lever cam follower (5)
is 0 - 1 mm.
Distance c between pins of rod (8): 337 mm
4. Operate the bucket lever and adjust distance c between the
pins of rod (8) so that clearance d between the notches (1
place) bucket lever cam (6) and bucket lever cam follower (7)
is 0 - 1 mm.
Distance c between pins of rod (8): 337 mm
20-71
BLEEDING AIR
CAUTION! Put blocks securely under the tires
1. Bleeding air from brake system

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

1) Start the engine and run at idling for
approximately 5 minutes.
2) Run the engine at low idling, the raise and
lower the boom 4 - 5 times in succession.
Operate the piston rod to a point
approximately 100 mm before the end of
its stroke. Do not relieve the circuit under
any circumstances.
3) Run the engine at full throttle and repeat step
2). After that, run the engine at low idling, and
operate the piston rod to the end of its stroke to
relieve the circuit.
4) Repeat steps 2) and 3) to bleed the air from
the bucket cylinder.
When the cylinder has been replaced,
bleed the air before connecting the piston
rod.
20-72
BLEEDING AIR
BUCKET POSITIONER
BUCKET POSITIONER
Testing
1. Start the engine, operate the bucket and actuate
proximity switch (1), then stop the engine and
measure clearance a between the proximity switch
and angle (2).
Standard clearance a: 3 - 5 mm
2. Run the engine at mid-range speed (1500 rpm),
actuate the proximity switch, and check that the
bucket angle is 0 - 1
e
bucket is lowered to the ground. Measure
dimension b between the center of the proximity
switch to the tip of the angle.
Measure three times and take the average.
Standard dimension b: 15 mm
Adjusting
1. If dimension a is not within the standard value,
adjust as follows:
1) Adjust mounting nut (4) so that clearance c
between the tip of the switch protector (3) and
the sensing surface of proximity switch (1) is
the standard value.
standard clearance c: 0.5 - 1.0 mm
Mounting nut: 17.15 2.45 Nm (1.75 0.25
kgm)
2) Adjust with washer (5) and shim (6) so that

clearance a between the sensing surface of
proximity switch (1) and angle (2) is the
standard value.
Adjust with shim (6) so that clearance a is
within the standard value for the whole
stroke of the angle.
Secure in position, making sure that the
center of proximity switch sensing surface
and the angle do not move away from the
center.
After adjusting, operate the bucket lever
and check that the proximity switch is
actuated normally.
2. If the bucket angle and dimension b are not within
the standard value, move the switch protector (3) to
adjust.
20-73
BOOM POSITIONER
CAUTION! Always be sure to apply the safety
lock to work equipment control lever.
Testing
1. Start the engine, operate the boom lever to actuate
proximity switch (1), then stop the engine and
measure dimension a between the center of
proximity switch (1) and the top of plate (2).
Standard clearance a: 0 - 5 mm
2. Measure dimension b between the proximity switch
sensing surface and the plate.
Standard dimension b: 3 - 5 mm
Adjusting
1. If the dimension a is not within the standard value,
move the plate to adjust.
2. If dimension b is not within the standard value,
adjust proximity switch mounting nut (3).
Mounting nut: 17.15 2.45 Nm (1.75
0.25 kgm)
After adjusting, operate the boom lever and

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

The proximity switch is equipped with a pilot lamp which shows
when it is being actuated, so use this when adjusting.
Proximity switch
actuation
pilot lamp
Lights up
Detector position
When detector is positioned at detection

surface of proximity switch
Goes out
When detector has moved away from detection

surface of proximity switch
Bucket
positioner
Boom kick-out
20-75
The transmission controller is equipped with a
learning function to self compensate so that it
provides a constant gear shifting feeling to match
the changes in the transmission clutches occurring
with the wear.
If the transmission is overhauled or replaced, the
transmission controller keeps the control command
values learned to match the previous transmission.
For this reason, transmission shock or abnormal
noise may occur. After operating the machine for a
short time, the controller will learn to match the
condition of the new transmission and will
gradually return to the normal condition, but if it is
desired to reset the condition quickly and to carry
out learning again, it is possible to reset the
learning data and to carry out initial learning as
follows.
1. Method for resetting learning control data
Do as follows to return all the previously
learned control data in the controller to the
default values.
1) Check that the starting switch is at the OFF
position.
2) Remove the cover at the right side of the work
equipment control box.
3) Disconnect wiring connector (C3B) (1) and
connect T-adapter P to the controller only
(leave the harness hanging).
4) Turn the starting switch ON.
Do not start the engine.
5) Short circuit between terminals No. (1) to (16)
for at least one second, then return them to
free condition.
2. Initial learning method

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

the left brake pedal depressed fully, so
there is no need to travel.
3) When the torque converter oil temperature
gauge rises to the 2nd level on the
maintenance monitor, return the engine to low
idling.
Target value for torque converter oil
temperature: 40 - 50
There is no problem If the oil temperature
gauge goes down to the 1st level.
4) Operate the speed lever and directional lever
twice in succession as follows:
N
Operate the levers with the engine running
at low idling, the transmission cutoff
selector switch at OFF, and the manual
switch at ON.
Hold for the following periods of time for
each speed range.
Speed range 4 only: 3 seconds
Other speed ranges: 2 seconds
After carrying out the gear shifting
operation in Step 2), if the engine is
stopped before carrying out the gear
shifting operation in Step 4), repeat Step 2)
again.
It is possible to carry out this operation with
the left brake pedal depressed fully, so
there is no need to travel.
CAUTION! Check that the area around the

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

(SPEED MODULE)
The speedometer on the main monitor is a common part for
all machines, and the input signal for the travel speed differs
according to the machine, so it is necessary to adjust the
monitor for use with the particular model.
In addition, the tire diameter also differs according to the type
of tire fitted, so it is necessary to adjust to give the correct
travel speed.
It is also necessary to change the switches if the optional
E.C.S.S. (Electronically Controlled Suspension System) is
installed.
Adjustment procedure
Turn off the power, then remove the machine monitor and
adjust the switches at the back of the speedometer.
1. Setting machine model
1) Remove the rubber caps from dip switches (1), (2) and
(3) at the back of the speedometer.
2) When the rubber cap is removed, a rotary switch can be
seen inside. Using a flat-headed screwdriver, turn this
switch to adjust it to the settings in the table below.
Tire size
Switch 1
Model
selection
Switch 2
Speedometer
correction
Switch 3
Tachometer
input
selection
km
per
hour
mile
per
hour
26.5-25
29.5-25
20-78
3) When the cap is removed from dip switch (4) at

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

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

Switch position
Amount of correction
(%)
+14
+12
+10
+8
+6
+4
+2
Switch position
Amount of correction
(%)
-2
-4
-6
-8
-10
-12
-14
20-79
20-80
MEMORANDA
TABLE OF CONTENTS
TROUBLESHOOTING
TROUBLESHOOTING
Points to remember when troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Sequence of events in troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Points to remember when carrying out maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Checks before troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Handling connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Precautions when troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Method of reading troubleshooting tables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Preventing recurrence of trouble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Connector types and mounting locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Connection table for connector pin numbers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Explanation of functions of electric control mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Transmission control system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Main monitor system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Maintenance monitor system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ECSS (Electronically Controlled Suspension System) control system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Joystick steering control system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Method of displaying action and failure code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Chart of action codes and failure codes, and re-enaction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Transmission controller LED display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Method of using judgement table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Method of using judgement charts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Method of using matrix troubleshooting tables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
20-202
20-203
20-204
20-212
20-213
20-214
20-216
20-218
20-220
20-229
20-240
20-240
20-244
20-248
20-252
20-256
20-258
20-260
20-263
20-264
20-266
20-268
20-201
TROUBLESHOOTING
POINTS TO REMEMBER WHEN TROUBLESHOOTING

WARNING!
Stop the machine in a level place, and check that the safety pin, blocks, and parking brake
are securely fitted.
WARNING!
When carrying out the operation with two or more workers, keep strictly to the agreed
signals, and do not allow any unauthorized person to come near.
WARNING!
If the radiator cap is removed when the engine is hot, hot coolant may spurt out and cause
burns, so wait for the engine to cool down before starting troubleshooting.
WARNING!
Be extremely careful not to touch any hot parts or to get caught in any rotating parts.
WARNING!
When disconnecting wiring, always disconnect the negative (-) terminal of the battery first.
WARNING!
When removing the plug or cap from a location which is under pressure from oil, water or air,
always release the internal pressure first. When installing measuring equipment, be sure to connect it
properly.
The aim of troubleshooting is to pinpoint the basic cause of the failure, to carry out repairs swiftly, and to prevent reoccurrence of the
failure.
When carrying out troubleshooting, an important point is to understand the structure and function of the machine. However, a short
cut to effective troubleshooting is to ask the operator various questions to form some idea of possible causes of the failure that would
produce the reported symptoms.
1.
2.
3.
When carrying out troubleshooting, do not hurry to

disassemble the components.
If components are
disassembled immediately after a failure occurs:
Parts that have no connection with the failure or other
unnecessary parts will be disassembled.
It will become impossible to find the cause of the failure.
It will also cause a waste of man hours, parts, or oil and
grease. At the same time, it 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.
Points to ask the user or operator.
1. Have any other problems occurred 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?
5. Had any repairs been carried out before the failure?
When were these repairs carried out?
6. Has the same kind of failure occurred before?
Check before troubleshooting.
1. Check the oil level.
2. Check for any external leakage of oil from the piping or
hydraulic equipment.
3. Check the travel of the control levers.
4. Check the stroke of the control valve spool.
20-202
5.
Other maintenance items can be checked externally, so

check any item that is considered to be necessary.
4. Confirming the failure.
1. 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
1. Use the results of the investigation and inspection in
Steps 2 - 4 to narrow down the causes of the failure, then
use the troubleshooting flowchart to locate the position of
the failure exactly.
2. 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.
1. Even if the failure is repaired, if the root cause of the
failure is not repaired, the same failure will occur again.
2. To prevent this, always investigate why the problem
occurred. Then, remove the root cause.
TROUBLESHOOTING
SEQUENCE OF EVENTS IN TROUBLESHOOTING
20-203
TROUBLESHOOTING
POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE

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

1.
Handling wiring harnesses and connectors.

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

i.
Defective contact of connectors (defective contact
between male and female). Problems with
defective contact are likely to occur because the
male connector is not properly inserted into the
female connector, or because one or both of the
connectors is deformed or the position is not
correctly aligned, or because there is corrosion or
oxidization of the contact surfaces.
20-204

ii.
Defective crimping or soldering of connectors. The

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

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

The
connector is designed to make it difficult for water to
enter (drip-proof structure), but if high pressure water is
sprayed directly on the connector, water may enter the
connector, depending on the direction of the water jet.
Since the connector is designed to prevent water from
entering, but at the same time, if water does enter, it is
difficult for it to be drained. Therefore, it water should
get into the connector, the pins will be short-circuited by
the water, so if any water gets in, immediately dry the
connector or take other appropriate action before
passing electricity through it.
TROUBLESHOOTING
20-205
TROUBLESHOOTING
v.
2.
Oil or dirt stuck to connector. If oil or grease is stuck to

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

c.
d.
TROUBLESHOOTING
Action to take after removing connectors

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

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

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

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

3.
TROUBLESHOOTING
Handling control box

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

Cover the control connectors with tape or a vinyl bag.
Never touch the connector contacts with your hand.
During rainy weather, do not leave the control box in a
place where it is exposed to rain.
i.
ii.
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).
Precautions when carrying out arc welding .
When carrying out arc welding on the body,
disconnect all wiring harness connectors
connected to the control box. Fit an arc welding
ground close to the welding point.
Points to remember when troubleshooting electric circuits

1.
2.
3.
4.
Always turn the power OFF before disconnecting or connecting connectors.

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

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

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

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

5.
Change hydraulic oil when the temperature is high. When

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

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

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

xxxxxxxx
xxxxxxxxx
Checks
before
starting
Lubricating
oil, cooling
water
Item
1.
2.
3.
4.
5.
6.
7.
8.
Item
Electrical
Equipment
9.
10.
11.
12.
Other
check items
Add fuel
Clean, drain
Add oil
Clean, drain
-----
Add oil
Add oil
Add water
Clean or replace
Check for loose or corroded battery

terminals
Check for loose or corroded alternator
terminals
Check for loose or corroded stating
motor terminals
Check operation of instruments
--
Tighten or replace
--
Tighten or replace
--
Tighten or replace
--
Repair or replace
-----
Repair
Repair
Bleed air
Repair or replace
Check for abnormal noise or smell

Check for oil leakage
Bleed air from system
Check parking brake and wheel
brakes
Electrical
components
17.
Check battery voltage (engine

stopped)
Check level of battery electrolyte
Check for discolored, burnt, or bare
wires
Check for missing wiring clamps,
hanging wires
Checks for water leaking onto wiring
(checks carefully water leakage at
connectors and terminals)
Check for broken or corroded fuses
Check alternator voltage (engine
running at over throttle)
(If the battery charge is low, the
voltage may be approximate, 25V
immediately after starting.)
Sound of actuation of battery relay
(when switch starting is turned ON,
OFF)
21.
22.
23.
24.
20-212
-----
13.
14.
15.
16.
20.
Remedy
Check fuel level

Check for dirt or water in fuel
Check hydraulic oil level
Check hydraulic oil filter (Torque
converter, transmission oil)
Check brake oil level
Check engine oil level
Check cooling water level
Check condition of dust indicator
Hydraulic
mechanical
components
18.
19.
Standard
value
24 - 26 V
Replace
---
Add or replace
Replace
--
Repair
--
Disconnect connector
and dry connection
-28.5 - 29.5 V
Replace
Replace
Replace
--
HANDLING CONNECTORS
TROUBLESHOOTING
HANDLING CONNECTORS
1.
When removing connectors from clips, pull the connector

in a parallel direction to the clip.
If the connector is twisted to the left and right or up
and down, the housing may break.
2.
When disconnecting male and female connectors,

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

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

b.
1. SAFETY
Stop the machine on level ground, and check that the
safety pins and parking brake are correctly applied,
and that the tires are blocked.
c.
d.
When working in groups, use agreed upon signals and

do not allow unauthorized persons near machine.
e.
f.
Be careful not to get burned by hot parts or get caught

in rotating parts.
2)
Always disconnect the cable from the negative (-)
terminals of the battery before disconnecting any
wiring.
Always release the pressure before removing the
plugs or caps of any place under hydraulic or air
pressure, and connect all measuring tools
correctly.
a.
b.
c.
d.
3)
2.
METHODS FOR TROUBLESHOOTING

Just because a failure occurs, do not immediately start
to disassemble the machine.
a.
The machine may be disassembled in such a way that

the problem cannot be located, so the cause of the
problem will be unknown.
b.
Was there anything unusual before the machine broke

down?
Did the breakdown occur suddenly, or had there been
signs of trouble before?
What was the machine doing when break down
occurred?
Had the machine been repaired before the breakdown?
If so, who carried out the repair, and when?
Had the same kind of failure occurred before?
Check the following items which can be checked
simply by visual checks etc.
Check oil level.
Check for leakage of oil from piping or hydraulic
equipment.
Check travel of control levers.
Check stroke of spool in control valves.
Reenact the failure and check the condition of the
machine (particular conditions at the time of failure).
Ask the user or operator if the decision about the failure
was made based on measured values, or by comparison,
or by feeling.
Compare extent of failure with standard values.
Check safety before carrying out any check.
Did not make any check or measurement that will
make the condition worse.
As a result,
4)
The customer and operator will lose confidence in you.
Time will be wasted, and unnecessary costs will be
incurred for excess parts and greasing.
To avoid these problems, use the following procedure when
troubleshooting.
1)
Ask the customer and operator the following

questions about the breakdown.
a. Have there been any other problems apart from the
one reported?
20-214
Try to locate the possible causes for the failure.

The transmission system consists of the transmission
itself, the transmission control valve, and the transmission
electrical control.
In particular, when trouble occurs in the transmission
system, the probable location of the failure can be divided
as follows;
Transmission itself, or transmission control valve.
Transmission electric control.
HANDLING CONNECTORS
To decide which of the two is the location of the failure,
refer to JUDGMENT ON POWER TRAIN.
5)
Carry out troubleshooting using the troubleshooting

charts.
There are the following two types of troubleshooting
charts.
1.
TROUBLESHOOTING TABLE
POWER TRAIN
STEERING SYSTEM
BRAKE AND AIR SYSTEM
WORK EQUIPMENT SYSTEM
2.
TROUBLESHOOTING FLOW CHART

ELECTRICAL SYSTEM
TROUBLESHOOTING
When removing parts, check their condition of
mounting, and distinguish between front and rear,
left and right, and top and bottom.
Check the match marks, or make match marks to
prevent mistakes when installing.
If part cannot be removed even when the nuts and
bolts have been removed, do not use excessive
force to remove it. Check the part to see if there is
any problem with it and remove the problem before
trying to disassemble the part.
When installing or assembling, clean off all dust and
dirt and repair any scratches or dents. Remove all
grease or oil before coating with gasket sealant.
The troubleshooting charts consist of:

1) Items which can be checked easily.
2) Items which are likely to be the cause of such
failures.
Follow theses charts to carry out troubleshooting. At
the same time, do not forget the following points.
Check related items.
Check that there are no other failures or
breakdowns.
6)
Investigate causes of breakdown

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

DISASSEMBLING OR ASSEMBLING PARTS DURING
TROUBLESHOOTING
Carry out the various testing and adjusting while
observing the items on quality control given in
"Testing and Adjusting".
20-215
TROUBLESHOOTING
METHOD OF READING TROUBLESHOOTING
TABLES
DESCRIPTION
OF
SYMBOLS
USED
IN
TROUBLESHOOTING TABLES
The following symbols are used in the "Remedy" column to
indicate the method of eliminating the cause of a fault.
X: Replace
A: Adjusting
C: Clean
METHOD OF READING TROUBLESHOOTING TABLE
The symbol o in the table is inserted only for causes
which can be diagnosed. If a cause cannot be
diagnosed, the corresponding box is left blank.
If the result of problem 1 using the troubleshooting table
shown at right is abnormal, the cause of the trouble can
be assumed to lie between "a" and "d". Because it is not
passible to make a problem regarding "e", it is necessary
to perform the next problem (owing to the possibility of a
multiple fault).
If the result of problem 1 is normal, the cause of the fault
does not lie between "a" and "d". In such a case, before
diagnosing the causes as "e", however, carry out a check
by means of problem 2 or 5.
If now the result of problem 1 is abnormal and the result
of problem 2 normal, the cause is one of "a", "b" or "d". In
addition, if the result of problem 3 is abnormal, the cause
will be narrowed down to one of "b" or "d". To determine
which of "b" or "d" is the actual cause, perform problem
4.
If the result of problem is abnormal, blacken out the
corresponding o in the table and then perform the next
problem on these causes in order to narrow the likely
causes.
Example 1:
Problem 1
Problem 2
Problem 3
Problem 4
20-216
METHOD OF READING TABLES

Example 2:
Problem 1
Problem 2
the cause of the
fault is "b".
In example 2, it is evident that the cause is "e"
without carrying out problem 2, however problem 2
is performed by way of an additional check.
METHOD OF READING TABLES
TROUBLESHOOTING
Example 3:
Problem 1
Abnormal
Problem 2
Abnormal
Problem 3
Normal
From the table of example 3, the cause

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

one of "a", "b", or "d".
Continue problems
Problem 3
Abnormal
Problem 4
Abnormal
Problem 5
Normal
From table of example 4-1, the cause is

"a" or "d".
As can be seen from the above examples, it is not necessary

to perform all the problems.
Also, looking at a particular cause, no matter how many
marks there are in the column corresponding to that cause, it
will cause to be an actual cause if there is even one o mark in
the same column.
20-217
TROUBLESHOOTING
PREVENTING RECURRENCE OF TROUBLE
PREVENTING RECURRENCE OF TROUBLE

The troubleshooting table is used to establish the direct cause of damage or breakdown of a part or piece of equipment. It is not
able to establish the root cause of the damage or failure, however.
Also, this table only describes the action to be taken with the particular part or piece of equipment. It does not mention what action
should be taken to prevent a recurrence of the root cause.
In order to remove the root cause of a fault so as to prevent a recurrence, carefully investigate the real cause while referring to
the following items.
Regarding the method of checking and adjusting each part or piece of equipment, refer to "Testing and Adjusting" in the Shop
Manual.
HYDRAULIC EQUIPMENT
1. Oil checks
The fundamental cause of almost all faults occurring
in hydraulic equipment is the inclusion of water, air or
other foreign matter in the oil. Accordingly, it is
necessary to check the oil to see whether or not it
contains any of the above substances, and then take
appropriate action.
1)
2)
20-218
Oil checks
Check for water contamination.
Check the oil for possible water contamination by
means of a diesel engine oil checker or a hot
plate.
Check for contamination of other foreign matter.
Remove the drain plug and filter, then check the
bottom of the tank and also the filter to see if any
foreign matter has collected there. Check the
degree of contamination by means of a
contamination checker.
Viscosity check
Check the viscosity of the oil using a viscometer
in order to confirm whether or not the oil is
satisfactory.
Check of contamination point
If, as a result of the above checks, it is discovered that the oil is contaminated by water or
other foreign matter, it is necessary to find out
where the contamination is occurring and also to
take steps to prevent it.
Water:
Sand:
Oil storage tank, breather, etc.

Oil replenishing or replacing method,
etc.
Rubber: Cylinder packing, etc.
Metal: Wear or damage to hydraulic
equipment such as pump and motor,
as well as transmission and torque
converter, etc.
3)
2.
Oil cleaning and replacement

If a large amount of metal particles or other
foreign matter is discovered in the oil, either
wash the oil using an oil refresher or
replace it.
If the oil is contaminated by water, it is not
possible to remove the water by means of
an oil refresher.
When washing the oil, also wash or
replace the strainer and replace the filter.
Cleaning fragments of damaged parts

If a part becomes damaged, fragments may pass
into the oil line. It is thus necessary to wash the oil.
In addition, disassemble and wash such parts as
valves and cylinders which are liable to collect metal
fragments and other foreign matter, thus helping to
prevent a recurrence of faults due to such fragments
becoming lodged in various parts of the engine or
hydraulic equipment.
TROUBLESHOOTING
CONNECTOR ARRANGEMENT DIAGRAM
20-219
CONNECTOR ARRANGEMENT DIAGRAM
20-219-1
TROUBLESHOOTING
TROUBLESHOOTING
CONNECTOR TYPES AND MOUNTING LOCATION
CONNECTOR TYPES AND MOUNTING LOCATIONS

The address column in the table below shows the address in the connector arrangement diagram.
Connector
Number
Type
No. of
pins
A4
Air servo motor
W5
A5
Thermistor
U1
A6
SWP
Air mix servo motor
V2
A7
Blower motor and resistor
V2
A8A
10
Intermediate connector (air conditioner relay)
V2
A8B
Intermediate connector (air conditioner relay)
V2
A9
KES 0
Blower relay (Main)
W3
A10
KES 0
Blower relay (Hi)
W3
A11
KES 0
Blower relay (M2)
W3
A12
KES 0
Condenser relay
W3
A13
KES 0
Blower relay (M1)
W2
A14
M6 switch
W4
A14
KES 0
Condenser relay (Hi)
W4
Hi / Lo switch
W5
A15
Place of use
Address
A15
KES 0
Magnet clutch relay
W2
A16
SWP
12
Air conditioner controller
R1
A17
SWP
16
Air conditioner controller
R1
A18
SWP
L.H. detection servo motor
A19
SWP
R.H. detection servo motor
AF1
Solenoid 1 (relief)
E1
AF2
Solenoid 2 (Hi)
F1
AF3
Solenoid 3 (Lo)
F1
AF4
Solenoid 4 (selector)
E1
AF5
Solenoid 5 (charge)
B3
AF6
Boom bottom pressure switch
B3
AF7
Charge pressure switch
B2
B01
Condenser (upper)
F9
B03
KES 1
Window washer
M5
B04
KES 1
Window washer
K4
20-220
TROUBLESHOOTING
Connector
Number
Type
No. of
pins
B05
KES 1
Diode
B06
KES 1
Diode
B07
Condenser (lower)
F8
B08
Brake accumulator low pressure switch
I2
B09
Emergency brake switch
F7
B10
Emergency brake switch
F7
B11
Condenser (upper)
F9
B12
Condenser (lower)
F9
B13
Brake accumulator low pressure switch
I2
B14
Parking brake emergency release solenoid
F8
BOOM
Boom proximity switch
BR1
SWP
14
Intermediate connector (washer, condenser)
J3
C01
Front wiper motor
Q1
Radio
Q3
C02
Place of use
Address
C03
Front working lamp
R8
C04
Front working lamp
T9
Warning lamp switch
R9
C05
C06
KES 1
Room lamp
T9
C07
Rear wiper motor
W8
C1
MIC
13
Transmission and ECSS controller
a5
C2
MIC
21
a3
C3A
AMP040
20
Y4
C3B
AMP040
16
Y4
C4
AMP040
12
Y4
C5
MIC
17
Y3
CH1
AMP
13
For T-adapter connection
CH2
AMP
21
For T-adapter connection
CL1
12
Intermediate connector (working lamp, radio)
Q2
CL2
10
Intermediate connector (air conditioner)
Q2
CL3
Intermediate connector (air conditioner)
Q1
CN3
Speed sensor
H1
CN4
JFC
1st solenoid
D7
20-221
TROUBLESHOOTING
Connector
Number
Type
No. of
pins
CN5
1st fill switch
C8
CN6
JFC
2nd solenoid
D7
CN7
2nd fill switch
C9
CN8
JFC
4th solenoid
D7
CN9
4th fill switch
D9
CN10
Parking brake solenoid
E7
CN11
I2
CN12
JFC
3rd solenoid
E7
CN13
3rd fill switch
D9
CN14
JFC
R solenoid
E8
CN15
R fill switch
D9
CN16
JFC
F solenoid
E8
CN17
F fill switch
E9
CN18
Torque converter oil temperature sensor
I2
CN19
Parking brake indicator switch
I2
CNL
Joystick solenoid (L)
S1
CNR
Joystick solenoid (R)
T1
D01
KES 1
Diode
D02
KES 1
Diode
D1
KES 1
Diode
D2
KES 1
Diode
E01
Slow blow fuse
M3
E02
Slow blow fuse
M2
E04
Engine speed sensor
K3
Engine water temperature sensor (Standard specification)
L8
L4
E05
Place of use
Address
E06
Engine water temperature sensor (Standard specification)
E07
Heater relay
E08
Heater relay
I9
E09
Heater relay
H9
E10
Engine oil level sensor
L4
E11
Engine oil pressure sensor
G9
20-222
TROUBLESHOOTING
Connector
Number
Type
No. of
pins
Place of use
Address
E12
Air conditioner compressor
J9
E13
Starting motor
L4
E15
Alternator terminal B
M7
E16
Alternator terminal R
M6
E17
Alternator terminal E
M6
E19
1-pin
connector
Dust indicator
H9
E20
1-pin
connector
Dust indicator
H9
E23
KES 1
Diode
ECSS
SWP
Intermediate connector
E7
ER1
SWP
14
Intermediate connector (air conditioner, engine water

temperature sensor)
J3
EST
Remove when installing emergency steering
F01
Head lamp (RH)
D6
F02
Front combination lamp (RH)
D6
F03
Front combination lamp (LH)
B1
F04
Head lamp (LH)
B1
F05
Proximity switch for bucket
B4
F06
Proximity switch for boom kick-out
E6
F07
Horn
D6
F08
Horn
G1
F09
Horn
G1
F10
Horn
C6
F11
Switch pump cut-off solenoid
G1
F12
KES 1
Diode
F21
Boom RAISE switch
B4
F22
Boom LOWER switch
B5
F23
Boom lever detent switch
B4
F26
Damping solenoid
B5
F30
Boom cylinder oil pressure sensor
FR1
10
Intermediate connector (head lamp)
H1
20-223
TROUBLESHOOTING
Connector
Number
Type
No. of
pins
FR2
Intermediate connector (boom, bucket SIG)
FR5
SWP
FS1
Power source
W6
FS2
12
Fuse
W6
FS3
Fuse
W7
FS4
Power source
W7
FS5
Fuse
W7
FS6
Fuse
W7
G01
Coolant level
K9
G02
Working lamp (RH)
K9
G03
Working lamp (LH)
K9
GE01
SWP
Rack sensor
GER1
SWP
GER2
SWP
GLR1
SWP
GLR2
SWP
GR1
Intermediate connector (working lamp)
GRE
SWP
Grease
GVN
Model selection connector
HEAT
JS1
Buzzer
W5
JS3
1-pin
connector
Cut-off switch power source
W5
JS4
1-pin
connector
Cut-off switch GND
W5
JS5
KES 1
Joystick ON-OFF switch
Q8
JS6
Neutral switch
W4
JS8
KES 0
Caution relay
a7
JS9
KES 0
Solenoid cut relay
a8
JS10
KES 0
Selector switch
a8
JS11
KES 0
Steering neutral interlock relay
Z9
JS12
Intermediate connector (joystick switch)
U1
20-224
Place of use
Address
H1
L8
TROUBLESHOOTING
Connector
Number
Type
No. of
pins
Place of use
Address
JS14
Intermediate connector (joystick lever switch)
U1
JSA
(male)
1-pin
connector
Intermediate connector (neutral)
W3
JSB
(male)
1-pin
connector
Intermediate connector (neutral)
W4
JSC
1-pin
connector
Neutral
S1
JSD
1-pin
connector
Neutral
S1
L01
SWP
Q5
L02
SWP
Light and dimmer switch
Q5
L03
SWP
Turn signal and hazard switch
Q4
L04
SWP
14
F/R and speed switch
Q3
L05
AMP040
20
Main monitor
Q4
L06
AMP040
16
Main monitor
Q4
L07
AMP040
12
Main monitor
Q4
L08
AMP040
Main monitor
Q4
L09
Starting switch
Q3
L10
10
Wiper switch
Q3
L12
Transmission cut-off switch
U1
L13
Accelerator potentiometer
R1
L14
Accelerator limit switch
R1
L15
Kick-down and hold switch
Q7
L16
KES 1
Boom kick-out solenoid
Q7
L17
KES 1
Bucket positioner solenoid
Q6
L18
AMP040
16
Maintenance monitor
Q6
L19
AMP040
Maintenance monitor
Q6
L20
AMP040
16
Maintenance monitor
Q8
L21
KES 1
Maintenance monitor
Q7
L22
KES 1
22
Maintenance monitor
Q7
L23
10
Engine throttle controller
L24
18
L25
24
20-225
TROUBLESHOOTING
Connector
Number
Type
No. of
pins
L26
MIC
21
Work equipment and joystick controller
T1
L27
MIC
20
T1
L28
MIC
16
U1
L32
Intermediate connector (power source, GND)
Q5
L33
Intermediate connector (boom kick-out output)
Q6
L34
Intermediate connector (network, buzzer output)
S1
L42
1-pin
connector
Caution buzzer
T9
L43
1-pin
connector
Caution buzzer
U9
L44
KES 0
Wiper relay
V8
L46
KES 1
Flasher unit
V9
L48
KES 0
Bucket relay
Z6
L49
KES 0
Boom relay
a7
L52
KES 0
Hazard relay
Y6
L53
KES 0
Stop lamp relay
Y6
L54
KES 0
Back-up lamp relay
a7
L55
KES 0
Horn relay
a8
L56
KES 0
Spare relay
a9
L57
KES 0
Neutral relay
X6
L58
KES 0
Neutralizer relay
X8
L59
KES 0
Parking brake safety relay
Z9
L60
KES 0
Front working lamp relay
a9
L61
KES 0
Rear working lamp relay
a9
L62
KES 0
Engine stop relay
Y9
L63
1-pin
connector
Horn switch
Q5
L64
KES 0
Engine oil pressure relay
X9
L75
KES 1
Pressure release switch
V8
L80
KES 0
Dust indicator relay
Y9
L81
Stop lamp switch
T1
L82
KES 0
Switch pump cut-off relay
L90
KES 1
Parking brake emergency release switch
20-226
Place of use
Address
W6
TROUBLESHOOTING
Connector
Number
Type
No. of
pins
L91
KES 0
ECSS relay
LGL
16
LGL2
LM1
10
MDC monitor panel
LR1
12
Intermediate connector (lamp)
B7
LR2
SWP
14
Intermediate connector(air conditioner, washer)
A7
LR4
SWP
14
Intermediate connector (monitor related)
A7
LR5
Intermediate connector (power source, GND)
B6
LR6
Intermediate connector (power source)
A6
LR11
SWP
14
Intermediate connector (boom switch)
E7
M01
MIC
20
MDC monitor panel (not used)
M02
MIC
M03
MIC
20
M04
MDC monitor controller (not used)
M05
M07
Cancel, sub total switch
M08
1-pin
connector
Printer power source
M09
1-pin
connector
Printer GND
M13
M15
1-pin
connector
M16
MIC
16
MDC monitor controller
M17
MIC
MDC monitor controller
M20
KES 1
Resistor
M21
KES 1
Resistor
MR1
SWP
OP1
1-pin
connector
Fuse outlet
OP2
1-pin
connector
Fuse outlet (power source)
R01
KES 1
Diode
R02
KES 1
Diode
20-227
Place of use
Address
Y9
W6
20-227
TROUBLESHOOTING
Connector
Number
Type
No. of
pins
R03
KES 1
Diode
R04
KES 1
Diode
R07
Fuel level sensor
K4
R08
Rear combination lamp (LH)
M6
R09
Rear combination lamp (RH)
J9
R11
Terminal
Battery
L8
R12
Terminal
Battery relay
K1
R13
Terminal
Battery relay
L1
R15
Terminal
Slow blow fuse
M4
R17
Terminal
Slow blow fuse
M1
R18
1-pin
connector
License lamp
M7
R19
1-pin
connector
License lamp (GND)
M8
R20
Battery electrolyte level sensor
RES
KES 1
Resistance
SEL1
Engine select
Q3
SEL2
Joystick function selection
Q2
TM1
SWP
14
Intermediate connector (transmission)
B6
TM2
SWP
16
Intermediate connector (transmission)
A6
20-228
Place of use
Address
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
TROUBLESHOOTING

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

TRANSMISSION CONTROL SYSTEM
20-240

1. Function of equipment at input end.
(1) F/R switch.
This detects the condition of operation of
directional lever and inputs it to the controller
as a digital (ON-OFF) signal. (On machines
equipped with joystick, the signal from the
joystick switch is also input.)
(2) Speed range switch.
speed lever and inputs it to the controller as a
digital (ON-OFF) signal.
(3) Manual selector switch.
This detects the condition of operation of the
manual selector switch and inputs it to the
controller as a digital (ON-OFF) signal.
(4) Transmission cut-off selector switch.
transmission cut-off switch, and controls the
signal of the ON-OFF signal from CUT-OFF
oil pressure switch to the controller signal.
(5) Hold switch.
hold switch or shift up switch (when using the
joystick) and inputs it to the controller as a
(6) Kick-down switch.
kick-down switch or shift-down switch (when
using the joystick) and inputs it to the
(7) Engine speed sensor.
This detects the speed of the engine flywheel
as the engine speed and inputs it to the
controller as a pulse (rotation) signal.
(8) Cut-off oil pressure switch.
left brake pedal from the brake circuit oil
pressure, and inputs it to the controller as a
digital (ON-OFF) signal. (When the main
monitor cut-off switch is ON.)
(9) Speed sensor.
This detects the speed of the transmission
output shaft as the travel speed and inputs it
to the controller as a pulse (rotation) signal.
(The speed sensor is also used with the main
monitor system.)
20-241
(10)
TROUBLESHOOTING
Transmission oil temperature sensor.

This detects the temperature of the
transmission oil and inputs it to the controller
as a analog (resistance) signal.
(11)
Speed range switch.

(F, R, 1st, 2nd, 3rd, 4th)
This detects the condition of actuation of the
ECMV flow detection valve and inputs it to the
(12)
Neutralizer relay.
parking brake and inputs it to the controller as a
2. Limit function of controller (outlet port).

Auto-shift function:
This calculates the optimum speed range
from the signals from the switches and
sensors, and outputs it to the ECMV as an
analog (current) signal in order to shift up or
down.
Modulation control function:
This calculates the optimum modulation
pattern from the signals from the switches
and sensors in order to reduce the shock
when shifting up or down, and outputs it to
the ECMV of both the clutch to be engaged
and the clutch to be disengaged as an
analog (current) signal.
Hold function:
When the hold switch is turned ON, it outputs
a signal to the ECMV to stop the auto-shift
and hold it at the same speed range.
Kick-down function:
When the kick-down switch is turned ON, if it
matches the control conditions, the signal is
output to the ECMV to shift down to 1st.
TROUBLESHOOTING
Manual shift function:

When the manual shift is turned ON, the
signal is output to the ECMV to shift the
speed to the selected speed range with the
shift lever.
For machines with joysticks, when operating
in the manual mode, the hold switch
becomes the shift-up switch and the kickdown switch becomes the shift-down switch,
so the transmission is shifted up or down
within the range of the speeds selected by
the speed range switch (the range of speeds
between 1st and the selected speed range).
Parking brake neutralizer function:
To prevent seizure of the parking brake, the
signal from the neutralizer relay stops the
out-put of the directional signal to the ECMV
and holds the transmission at neutral even if
the directional lever is operated to F or R.
Back-up lamp drive function:
The signal from the directional switch is sent
to the back-up lamp relay as a digital (ONOFF) signal.
Buzzer function:
The signal is sent through the main monitor
to the alarm buzzer as a digital (ON-OFF)
signal according to the condition of the input
signal.
Self-diagnostic function:
The controller always observes the
directional switch, speed range switch, speed
sensor, engine speed sensor, transmission
oil temperature sensor, the 6 ECMV fill
switches at the input side, and the 8 ECMV
solenoids at the output side to check that no
abnormality occurs in the back-up lamp relay
systems.
20-242
Network communication with main monitor:

1) The controller communicates the
actuated speed range through the
network.
2) The controller communicates the
actuated F/R position through the
network. (Machines with joystick.)
3) It communicates the condition of
actuation of the hold mode through the
network.
4) If any abnormality is detected by the selfdiagnostic function, it communicates the
details of the abnormality through the
network.
3. Functions of output equipment.
1) ECMV solenoid valve.
(F, R, 1st, 2nd, 3rd, 4th)
The solenoid receives the signal from the
controller, is driven, and controls the
transmission clutch oil pressure.
2) Back-up lamp relay.
The relay receives the signal from the
controller, is driven, and turns the power for
the back-up lamp relay ON-OFF.
4. Main monitor display.
For details, see MAIN MONITOR.

-MEMORANDA-
20-243
TROUBLESHOOTING
TROUBLESHOOTING
MAIN MONITOR SYSTEM
20-244

1. Functions of equipment at input end
1) Parking brake oil pressure switch This
detects the condition of actuation of the
parking brake and inputs it to the main
monitor as a digital (ON-OFF) signal.
2) Engine speed sensor.
This detects the speed of the engine flywheel
as the engine speed and inputs it to the main
monitor as a pulse (rotation) signal.
3) Speed sensor.
output shaft as the travel speed and inputs it
to the main monitor as a pulse (rotation)
signal. (The speed sensor is also used with
the transmission control system.)
4) Engine water temperature sensor.
This detects the temperature of the engine
cooling water and inputs it to the main
monitor as an analog (resistance) signal.
5) Transmission directional switch.
directional lever to the Nposition and inputs
it to the main monitor as a digital (ON-OFF)
signal. (The transmission directional switch is
also used for the transmission control
system.)
6) Emergency steering detection switch.
emergency steering hydraulic circuit and
inputs into the main monitor as a digital (ONOFF) signal.
7) Turn signal, hazard switch.
turn signal and hazard switch, and inputs it to
the main monitor as a digital (ON-OFF)
signal.
8)
Dimmer switch.
dimmer switch and inputs it to the main
TROUBLESHOOTING
10) Preheating relay.

Optional equipment, detects actuation of the
relay from the secondary outlet voltage of the
preheating relay, and inputs it to the main
11) Maintenance monitor.
CHECK lamp signal.
This inputs the CHECK lamp drive signal
(the output signal from the maintenance
monitor) to the main monitor as a digital
(ON-OFF) signal.
CAUTION lamp signal.
This inputs the CAUTION lamp drive
signal (the output signal from the
maintenance monitor) to the main
Lamp synchronous signal.
This inputs the lamp synchronous signal
(the output signal from the maintenance
monitor) to the main monitor as a digital
(ON-OFF) signal.
12) Starting switch.
Terminal BR.
the starting switch to the ON position and
inputs it to the main monitor as a digital
(ON-OFF) signal.
Terminal C.
the starting switch to the START position
and inputs it to the main monitor through
the neutral relay as a digital (ON-OFF)
signal.
13) Alternator (terminal R).
This detects the condition of electricity
generated by the alternator and inputs it to
the main monitor as an analog (voltage)
signal.
2. Network communication with controllers.
With transmission, ECSS controller.
1) The speed range (1 - 4) now being used
is communicated.
9) Head lamp relay/rear lamp relay.

relay from the secondary outlet voltage of the
head lamp relay and rear lamp relay, and
inputs it to the main monitor as a digital (ONOFF) signal.
20-245
20-245
TROUBLESHOOTING
3.
2) The directional position (F, N, R) now

being selected is communicated
(machines with joystick).
3) When the hold function is actuated, the
actuation signal is communicated.
4) If any abnormality occurs in the
transmission control system or ECSS
control system, the details of the
abnormality are communicated.
Turn signal pilot lamp function:

The left or right turn signal pilot lamps are
made to flash (in the case of hazard the
lamps on both sides flash) by the signal from
the turn signal and hazard switch.
Hi beam pilot lamp function:
When the Hi beam is used, the Hi beam pilot
lamp is lighted up by the signal from the
dimmer switch.
With work equipment, joystick controller:

If any abnormality occurs in the transmission
control system or joystick control system, the
details of the abnormality are communicated.
CHECK lamp function:

The CHECK lamp is made to flash by the
CHECK lamp signal from the maintenance
monitor. When this happens, the flashing of
the lamp on the maintenance monitor and
the flashing of the CHECK lamp are
synchronized by the flash synchronous signal
from the maintenance monitor.
CAUTION lamp function:
The CAUTION lamp is made to flash by the
CAUTION lamp signal from the maintenance
monitor. When this happens, the flashing of
the lamp on the maintenance monitor and
the flashing of the CAUTION lamp are
synchronized by the flash synchronous signal
from the maintenance monitor.
Emergency steering indicator function:
The emergency steering pilot lamp is made
to flash by the signal from the emergency
steering detection switch.
ECSS switch function (machines equipped
with ECSS):
For details, see ECSS CONTROL
SYSTEM.
Working lamp switch function (front, rear):
The condition of operation of the working
lamp switch is output to the working lamp
relay as a digital (ON-OFF) signal. At the
same time, the indicator is lighted up by the
signal from the working lamp relay.
Functions of main monitor

Self-check function:
When the starting switch is turned ON, all
lamps and meters light up for 3 seconds and
the alarm buzzer sounds for 1 second to
carry out a self check. (If the starting switch is
turned to the START position during the 3
seconds of the self check, the self check
stops.)
Speedometer function:
The speedometer is displayed on the meter
portion by the signal from the speed sensor.
(When the system is set to the tachometer
display specification, the tachometer is
displayed on the meter portion by the signal
from the engine speed sensor.)
Transmission shift indicator function:
The speed range or directional N is displayed
on the shift indicator portion by the network
communication from the transmission and
ECSS controller.
Transmission directional indicator function:
(Machines with joystick)
The directional F or R is displayed at the
bottom of the speedometer portion by the
network communication from the
transmission and ECSS controller. (Even on
machines with joystick, the directional N is
displayed on the shift indicator portion.)
Hold indicator function
When the hold mode is actuated, the hold
indicator is lighted up by the network
communication from the transmission and
ECSS controller.
2-246
TROUBLESHOOTING
Parking brake dragging warning function:

If the directional lever (switch) is set to the F
or R position when the parking brake is still
applied (ON), the CAUTION lamp flashes
and the alarm buzzer sounds intermittently.
Action code and failure code display function:
If an abnormality signal is received by
network communication from the controllers,
the action code (normally displayed) or
failure code (when failure code is displayed)
are displayed on the speedometer portion. At
the same time, when the abnormality code is
received, the total hours of operation of the
machine is calculated by the signal from the
alternator terminal R, and this is displayed as
the elapsed time since failure on the failure
mode display.
4. Functions of equipment at output end.
1) Alarm buzzer:
This receives the signal from the main
monitor and generates the alarm sound.
(The alarm buzzer is also used for the
maintenance monitor system.)
2) Front, rear working lamp relay:
This receives the signal from the controller
and switches the power for the front or rear
working lamp relay ON-OFF according to the
switching of the relay.
20-247
TROUBLESHOOTING
MAINTENANCE MONITOR SYSTEM
2-248

1. Functions of equipment at input end.
1) Fuel level sensor:
This detects the fuel level in the fuel tank and
inputs it to the maintenance monitor as an
analog (resistance) signal.
2) Engine water temperature sensor:
This detects the temperature of the engine
cooling water and inputs it to the
maintenance monitor as an analog
(resistance) signal.
3) Torque converter oil temperature sensor:
This detects the temperature of the torque
converter oil and inputs it to the maintenance
monitor as an analog (resistance) signal.
4) Engine water level switch:
This detects the level of the engine cooling
water in the radiator reservoir tank and inputs
it to the maintenance monitor as a digital
(ON-OFF) signal.
TROUBLESHOOTING
9) Alternator (terminal R):

This detects the condition of generation of
electricity by the alternator and inputs it to the
maintenance monitor as an analog
(electricity generation) signal.
10) Starting switch (terminal C):
starting switch to the START position and
inputs it through the neutral relay to the
maintenance monitor as a digital (ON-OFF)
signal.
2. Control functions of maintenance monitor.
Self-check function:
When the starting switch is turned ON, all
lamps and meters light up for 3 seconds and
the alarm buzzer sounds for 1 second to
carry out a self check. (If the starting switch is
turned to the START position during the 3
seconds of the self check, the self check
stops.)
5) Engine oil level switch:

This detects the level of the oil in the engine
oil pan and inputs it to the maintenance
Fuel gauge:
The fuel gauge is displayed and the pilot
lamp flashes or goes out according to the
signal from the fuel level sensor.
6) Brake accumulator low-pressure switch:

This detects the oil pressure in the wheel
brake accumulator circuit and inputs it to the
maintenance monitor as a digital (ON-OFF)
signal.
Engine water temperature gauge:

The engine water temperature gauge is
displayed and the pilot lamp flashes or goes
out according to the signal from the engine
water temperature sensor.
7) Engine oil pressure switch:

This detects the engine oil pressure inputs it
to the maintenance monitor as a digital (ONOFF) signal.
Torque converter oil temperature gauge:

The torque converter oil temperature gauge
is displayed and the pilot lamp flashes or
goes out according to the signal from the
torque converter oil temperature sensor.
8) Air cleaner clogging switch:

This detects the clogging condition of the air
cleaner and inputs it to the maintenance
Engine water level pilot lamp:

The pilot lamp flashes or goes out according
to the signal from the engine water level
sensor.
20-249
TROUBLESHOOTING
Engine oil level pilot lamp:

The pilot lamp flashes or goes out according
to the signal from the engine oil level sensor.
Brake oil pressure caution lamp:
The caution lamp flashes or goes out
according to the signal from the brake
accumulator low-pressure switch.
Engine oil pressure caution lamp:
The caution lamp lights up, flashes, or goes
out according to the signal from the engine
oil pressure switch.
Battery charge caution lamp:
The caution lamp lights up, flashes, or goes
out according to the signal from alternator
terminal R.
Air cleaner clogging caution lamp:
The caution lamp flashes or goes out
according to the signal from the air cleaner
clogging sensor.
Service meter:
The service meter is driven by the signal from
the engine oil pressure switch.
Output to main monitor:
The CHECK lamp signal, CAUTION lamp
signal, and flash synchronous signal are
output to the main monitor as a digital (ONOFF) signal according to the condition of the
input signal.
Alarm buzzer function:
The digital (ON-OFF) signal is output to the
alarm buzzer according to the condition of
the input signal.
2-250
3.
Functions of equipment at output end.

1) Main monitor:
This receives the signal from the
maintenance monitor and makes the CHECK
lamps or CAUTION lamps flash.
2) Alarm buzzer:
This receives the signal from the
maintenance monitor and makes the alarm
buzzer sound. (The alarm buzzer is also
used for the main monitor system.)
TROUBLESHOOTING
-MEMORANDA-
20-251
TROUBLESHOOTING
ECSS (Electronically Controlled Suspension System) CONTROL SYSTEM

This system has functions in the transmission controller, and judges the function by the select signal from the
main monitor when the engine is started.
2-252

1. Functions of equipment at input end
1) ECSS actuation switch:
ECSS switch and inputs it to the controller as
a digital (ON-OFF) signal.
2) Output speed range signal:
This detects the condition of the output speed
range. (The ECSS system carries out control
with the same controller as the transmission
control system, so the speed range switch
signal is also used inside the controller.)
3) Speed sensor:
output shaft as the travel speed (speed) and
inputs it to the controller as a pulse (rotation)
signal. (The ECSS system carries out control
with the same controller as the transmission
control system, so the speed sensor signal is
also used inside the controller.)
4) Charge oil pressure switch:
This detects the basic oil pressure of the
damper circuit and inputs it to the controller
as a digital (ON-OFF) signal.
5) Boom bottom oil pressure switch:
This detects the oil pressure of the boom
cylinder bottom circuit and inputs it to the
6) Pressure release switch:
This switch is the drive power to the selector
solenoid (SOL4) by the operation of the
pressure release switch. (The signal from the
pressure release switch does not pass
through the controller, and is output directly
to the selector solenoid (SOL4). It is actuated
at the same time has the normal return
solenoid valve (SOL1).)
2.
Control function of controller

Damper function:
To prevent pitching and bouncing of the
bucket, the input signals from the switches
and sensors are output as a digital (ON-OFF)
TROUBLESHOOTING
signal to the relief solenoid (SOL1), Highpressure solenoid (SOL2), Low-pressure
solenoid (SOL3), and pressure release
solenoid (SOL4).
Accumulator charge function:

To prevent the oil pressure in the
accumulator circuit from dropping and the
boom from going down when the damper
function is actuated, the signal from the
charge oil pressure sensor is output to the
charge solenoid (SOL5) as a digital (ONOFF) signal.
Pressure release function:
The pressure release switch signal drives the
pressure release solenoid (SOL4) to release
the remaining pressure in the boom cylinder
circuit during the disassembly and assembly
operation. (The pressure release switch
signal does not pass through the controller; it
can be input directly to the pressure release
solenoid (SOL4).)
The controller always observes the system to
check that no abnormality has occurred in
the systems for the four solenoids at the
output end.
If the self-diagnostic function detects any
abnormality, it communicates the details of
the abnormality through the network. (The
ECSS system carries out control with the
same controller as the transmission control
system, so the network communication circuit
is used in both systems.)
3. Functions of equipment at output end.
1) Return solenoid valve (SOL1):
and the solenoid is driven to open or close
the circuit between the boom cylinder head
circuit and the hydraulic tank.
20-253
TROUBLESHOOTING
2) High-pressure solenoid valve (SOL2):

the circuit between the boom cylinder bottom
circuit and the high-pressure accumulator.
3) High-pressure solenoid valve (SOL3):
the circuit between the boom cylinder bottom
circuit and the low-pressure accumulator.
4) Pressure release check solenoid valve
(SOL4):
The return solenoid valve (SOL1) and the
pressure release check solenoid valve
(SOL4) are turned ON-OFF through the
relay. The valve receives the signal from the
controller or the pressure release switch, and
the solenoid is driven to open or close the
circuit between the boom cylinder bottom
circuit and the damper (high-pressure, lowpressure accumulator) circuit.
5) Accumulator pressure solenoid valve
(SOL5):
This receives the signal from the controller,
the circuit between the hydraulic pump circuit
and the damper (high-pressure, low-pressure
accumulator) circuit.
4.
Main monitor display

For details, see MAIN MONITOR
SYSTEM.
2-254
TROUBLESHOOTING
-MEMORANDA-
20-255
TROUBLESHOOTING
JOYSTICK STEERING CONTROL SYSTEM
2-256

This section describes only the items related to
steering in the joystick steering control system.
For details of the transmission, see
TRANSMISSION CONTROL SYSTEM.
Buzzer drive function:

If any abnormality occurs in the system, this
turns the digital (ON-OFF) signal to the
caution relay OFF and actuates the buzzer.
The controller always observes the condition
to check that there is no abnormality in the
joystick potentiometer and joystick neutral
switch systems at the input end and the left
and right steering solenoids, solenoid cut
relay, and caution relay systems at the output
end.
If the self-diagnostic function detects any
abnormality, it communicates the details of
the abnormality to the main monitor through
the network. (The joystick control system
carries out control with the same controller
as the work equipment control system, so the
network communication circuit is used in both
systems.)
1. Functions of equipment at input end.

1) Joystick ON-OFF switch:
joystick ON-OFF switch and inputs it to the
2) System cut-off switch:
This detects the slide position of the joystick
lever stand and inputs it to the controller as a
3) Joystick neutral switch:
This detects the neutral position of the
steering lever and inputs it to the controller as
a digital (ON-OFF) signal.
4) Joystick potentiometer:
This detects the angle of operation of the
steering lever and inputs it to the controller as
an analog (current) signal.
2.
TROUBLESHOOTING
3.
Control functions of controller.

System cut-off function:
This actuates or stops the system according
to the signals from the system cutoff switch
and joystick ON-OFF switch. Joystick neutral
interlock function When starting the engine, if
the joystick is not at the neutral position, the
engine cannot be started.
Steering function:
This calculates the signal from the steering
potentiometer and outputs an analog
(current) signal corresponding to this to the
left and right steering solenoids.
Solenoid stop function:
If any abnormality occurs in the system, this
outputs a signal to the solenoid cut relay as a
Functions of equipment at output end

1) Left, right steering solenoid valve This
receives the signal from the controller and
drives the solenoid to control the solenoid
valve output pressure effortlessly.
2) Steering neutral interlock relay:
and drives the solenoid to drive the neutral
safety relay when the engine is started.
3) Solenoid cut relay:
and drives the solenoid to switch the circuit at
the return side of the steering solenoid ONOFF.
4) Caution relay:
and drives the relay to switch the alarm
buzzer circuit ON-OFF.
4.
Main monitor display

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

AND FAILURE CODE
1. Outline
The speedometer display on the main monitor is
used to display the troubleshooting for each
control system. The nature of the
troubleshooting is displayed as the failure action
code, failure code, and the time elapsed since
failure. The signals between the main monitor
and each controller are transmitted in serial
through the network circuit. (Only the engine
controller uses a special parallel signal.)
2. Display of failure action code
This code informs the operator directly of the
abnormality, and takes action, such as stopping
the machine immediately. There are three types
of action code: EOO, EON + CALL (EON and
CALL are displayed alternately), and CALL. If a
failure occurs suddenly, one of these codes is
shown on the speedometer display.
3. Failure code and time elapsed since failure
The failures detected by each controller are
changed to a code and displayed. It is possible to
tell from this code which system in which
controller has failed, so carry out troubleshooting
for the applicable controller.
4. Saving failure code
The transmission controller writes the failure
codes to memory.
1) A total of 9 failure codes can be saved in
memory.
2) The data that is saved to memory is as follows:
A) Failure code
B) Time elapsed since failure (up to 1000
hours)
3) The failures are saved in the order that they
occur. If a failure code already exists in the
memory, the repeat failure code is not saved.
2-258
4) If there are already 9 items in memory, and a

10th failure occurs, the oldest item is deleted
and the new item is saved. It is possible to
display the failure code and time elapsed
since failure for items saved in memory by
operating the main monitor set switch.
TROUBLESHOOTING
5. Switch operation procedure actuation

Switch operation
Trouble data memory
mode display
1)
Stop engine
2)
Turn starting switch
ON
3)
Push operation
mode switch (1)
and head lamp
switch (2)
simultaneously and
keep pressed for at
least 5 seconds.
Going to next failure

code
4)
Press head lamp
switch (2).
Clearing failure code

5)
Keep rear lamp
switch (3) pressed
for at least 2
seconds.
Quitting trouble data

memory display mode
6)
Push operation
mode switch (1)
and head lamp
switch (2)
simultaneously and
keep pressed for at
least 5 seconds. Or
start the engine.
Actuation
The failure code is

displayed on the
speedometer display
and the time elapsed
since failure is
displayed on the action
code display.
If there is no failure,
the speedometer
display shows [CC] and
the action code display
shows [0000].
The failure code and

time elapsed since
failure are displayed in
turn (when this is done,
the failure code for the
latest failure is
displayed first).
If the failure still exists,
the display flashes; if
the failure has been
restored, the display
lights up.
The failure and
elapsed time on the
display are cleared.
If the failure still exists,
the failure code is not
cleared.
The display returns to

the normal display.
20-259
TROUBLESHOOTING
CHART OF ACTION CODES, FAILURE CODES, AND RE-ENACTION

After an error occurs, turn the starting switch OFF, and if the display goes out, it is possible to re-enact the
problem as follows.
For details of the method of displaying the action codes and failure codes, see METHOD OF DISPLAYING
SELF DIAGNOSIS (ERROR CODE) AND SAVING TO MEMORY.
Re-enaction marks
Turn starting switch ON (with engine stopped)
Start engine
Carry out operation to actuate actuator.
1. Transmission controller
1) Transmission control system.
Main monitor
action code
None
Failure
code
Item
Failed system
Short
circuit
Disconnection
Re-enaction
Short
circuit
Memory
Alarm
buzzer
Disconnection
10
Back-up lamp relay
12
F ECMV solenoid
13
R ECMV solenoid
14
1st ECMV solenoid
15
2nd ECMV solenoid
16
3rd ECMV solenoid
17
4th ECMV solenoid
E00
19
Joystick directional switch
CALL
20
Directional switch signal
None
21
Range switch signal
22
Travel speed sensor
23
Engine speed sensor
None
24
EEP ROM abnormality
E01+CALL
25
CALL
E00
2-260

Main monitor
action code
Failure
code
Item
Failed system
Short
circuit
Disconnection
TROUBLESHOOTING
Re-enaction
Short
circuit
Memory
Alarm
buzzer
Disconnection
26
F ECMV fill switch
27
R ECMV fill switch
28
1st ECMV fill switch
29
2nd ECMV fill switch
30
3rd ECMV fill switch
31
4th ECMV fill switch
32
F, R ECMV fill switch
33
1st, 2nd, 3rd, 4th ECMV fill switch
CALL
E00
E23 (short circuit engine speed sensor) can only be detected if the machine is traveling at 4 km/h (3 mp/h) or more.
20-261
TROUBLESHOOTING
2) ECSS control system

Main
monitor
action code
None
Failure
code
Item
Failed system
Short
circuit
Disconnection
Re-enaction
Short
circuit
Memory
Alarm
buzzer
Disconnection
d0
Solenoid 1 (relief)
d1
Solenoid 2 (high pressure)
d2
d3
2. Joystick controller
Main
monitor
action code
None
CALL
E00
Failure
code
Item
Failed system
Short
circuit
Disconnection
Re-enaction
Short
circuit
Memory
Alarm
buzzer
Disconnection
56
Back-up lamp relay
57
F ECMV solenoid
58
R ECMV solenoid
59
1st ECMV solenoid
60
2nd ECMV solenoid
61
3rd ECMV solenoid
62
4th ECMV solenoid
63
Joystick directional switch
E59 and E60 cannot be distinguished, so they are issued at the same time.
Disconnection cannot be detected for E56. It is always ON and is called up when there is a failure warning.
2-262
TROUBLESHOOTING
3. Action code table.

Action
code
Transmission control system

Problem system
E00
E01 +
CALL
CALL
Action of machine
Disconnection in
travel speed sensor
system
Automatic gear
shifting not carried
out (changes to
manual gear
shifting)
Disconnection, short
circuit, or
abnormality in
engine speed sensor
system
Engine speed taken

as 2100 rpm (there
is shock when
shifting gear)
Disconnection in fill
switch
Clutch engaged
with out fill signal
(there is shock
when shifting gear)
Short circuit in
transmission oil
temperature sensor
Joystick control system

Problem system
Disconnection,
short circuit with
ground, or short
circuit in joystick
FNR signal system
__
__
Action of machine
Action
buzzer
Shifts to neutral
(possible to switch
to manual)
__
Normal manual
gear shifting
possible
No
__
__
Short with ground in

fill switch
Shifts to neutral,
travel impossible
(modulation output
OFF)
__
__
circuit with ground,
or short circuit in
shift lever system
Shifts to neutral,
travel impossible
(controller input
judged as N)
__
__
or short circuit in F,R
ECMV solenoid
system
Shifts to neutral,
travel impossible
(ECMV output
OFF)
or short circuit in
speed range ECMV
solenoid system
Shifts to neutral,
travel impossible
(ECMV output
OFF)
Normal
operation
possible but
there is shock
when shifting
gear
Normal
operation
possible but
there is shock
when shifting
gear
__
Suitable gear
shifting data for
transmission oil
temperature cannot
be selected (there
is shock when
shifting gear)
Action by
operator
Yes
Travel under
own power
possible, move
to safe place
then call for
service
Stop machine
immediately,
turn starting
switch OFF,
then call for
service
Yes
__
__
__
__
20-263
TROUBLESHOOTING
TRANSMISSION CONTROLLER LED DISPLAY

The transmission controller uses two 7-segment LEDs to display the internal condition of the controller and
input/output errors. The display shows two characters at the same time, and changes these in turn to give the
display.
When the engine is started, Program part No. display mode" appears, followed by "Output speed range
display mode". If there is any abnormality in the controller, it changes to "Troubleshooting mode".
The failure mode is saved to memory by the main monitor.
Method of displaying failure codes for transmission controller
Table 1 (Output speed range display mode)
2-264
Display
Content
Display
Content
0. 1.
NEUTRAL, 1st
F. 4.
FORWARD, 4th
0. 2.
NEUTRAL, 2nd
A. 1.
REVERSE, 1st
0. 3.
NEUTRAL, 3rd
A. 2.
REVERSE, 2nd
0. 4.
NEUTRAL, 4th
A. 3.
REVERSE, 3rd
F. 1.
FORWARD, 1st
A. 4.
REVERSE, 4th
F. 2.
FORWARD, 2nd
F. F.
Neutral safety condition
F. 3.
FORWARD, 3rd
TROUBLESHOOTING
MEMORANDA
-MEMORANDA-
20-265
TROUBLESHOOTING
MEMORANDA
METHOD OF USING JUDGEMENT TABLE

This judgement table is a tool to determine if the problem with the machine is caused by an abnormality in the
electrical system or by an abnormality in the hydraulic or mechanical system. The symptoms are then used to
decide which troubleshooting table (E-00, H-00, etc.) matches the symptoms.
The judgement table is designed so that it is easy to determine from the self-diagnostic display which
troubleshooting table to go to.
The abnormality display given by the monitor panel leads directly to troubleshooting of the monitor system (M00, K-00, C-00).
(See troubleshooting of the machine monitor system)
[Method of using judgement table]
A 0 mark is put at the places where the failure mode and self-diagnostic display match, so check if an error
code is displayed on the graphic display portion of the monitor panel.
If an error code is displayed:
Go to the troubleshooting code at the bottom of the judgement table (E-00, etc.).
If there is a problem but no error code is displayed:
Go to the troubleshooting code on the right of the judgement table (H-00).
For failure modes where no 0 mark is given, go directly to the troubleshooting code on the right of the
judgement table.
2-266
TROUBLESHOOTING
MEMORANDA
-MEMORANDA-
20-267
TROUBLESHOOTING
METHOD OF USING TROUBLESHOOTING CHARTS
METHOD OF USING JUDGEMENT CHARTS

1.
Category of troubleshooting code number

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

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

4) Main flow.
a) CHECK lamp.
b) CAUTION lamp.
C-11
Related electrical circuit diagram.
20-269
TROUBLESHOOTING
METHOD OF USING MATRIX TROUBLESHOOTING TABLES

The troubleshooting tables use the same method as for other troubleshooting table (YES/NO type) to locate the causes of failures
in the machine. The troubleshooting tables are divided broadly into categories for the main components, such as the steering
system and work equipment hydraulic system. Follow the procedure given below and carry out troubleshooting to locate the
problems accurately and swiftly.
Step 1. Questioning the operator
The questions to ask the operator are given below the
failure symptom. If the answers to the questions match
the information given, follow the arrow to reach the
probable cause of the failure.
Consider the contents of the questions and consult the
table while proceeding to Steps 2 and 3 to grasp the
true cause.
1.
STEERING does not work symptom [Example]
Ask the operator about the following points.

Did the steering suddenly stop working?
Breakage in steering equipment
Had the steering gradually been becoming heavy?
Internal wear of steering equipment, defective seal
Checks before starting [Example]
Step 2. Checks before troubleshooting

Before starting the main troubleshooting and
measuring the hydraulic pressure, first check the
Checks before Starting items, and check for oil leakage
and loose bolts. These checks may avoid time wasted
on unnecessary troubleshooting.
The items given under Checks before Starting are
items which must be considered particularly for that
symptom before starting troubleshooting.
Step 3. Using cross-reference table
1) Operate the machine to carry out the checks in
the troubleshooting item column. Mark the items
where the results match the symptom.
It is not necessary to follow the
troubleshooting checks in order; follow an
order which is easiest to carry out
troubleshooting.
2)
Find the appropriate cause from the cause

column. If the symptom appears, the
that line indicate the possible causes. (For item No.
2 in the table on the right, the possible causes are
c or e.) If there is only one :
Carry out the other troubleshooting items (where
the same cause is marked with ), check if the
symptom appears, then repair.
If there are two :
Go on to Step 3) to narrow down the possible
causes.
20-270
Is the oil level in the hydraulic tank correct?

Is the type of oil correct?
Is there any leakage of oil from the steering valve or
Orbit-roll?
Has the safety bar been removed from the frame?

3)
Operate the machine and check the

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

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

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

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

Action taken by controller when abnormality occurs and problems on machine . . . . . . . . . . . . . . . . . . . . . . . .
Electrical circuit diagram for transmission controller system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
T- 1
Failure code [10] (Short circuit, disconnection, short circuit with power source in back-up
lamp relay) is displayed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
T- 2
Failure code [12] (Short circuit, disconnection, short circuit with power source in F solenoid)
is displayed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
T- 3
Failure code [13] (Short circuit, disconnection, short circuit with power source in R solenoid)
is displayed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
T- 4
Failure code [14] (Short circuit, disconnection, short circuit with power source in 1st solenoid)
is displayed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
T- 5
Failure code [15] (Short circuit, disconnection, short circuit with power source in 2nd solenoid)
is displayed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
T- 6
Failure code [16] (Short circuit, disconnection, short circuit with power source in 3rd solenoid)
is displayed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
T- 7
Failure code [17] (Short circuit, disconnection, short circuit with power source in 4th solenoid)
is displayed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
T- 8
Failure code [19] (Short circuit, disconnection in joystick directional switch system) is displayed . . . .
T- 9
Failure code [201 (Short circuit, disconnection in directional switch system) is displayed . . . . . . . . . .
T-10
Failure code [211 (Short circuit, disconnection in range switch system) is displayed . . . . . . . . . . . . . .
T-11
Failure code [221 (Disconnection in travel speed sensor system) is displayed . . . . . . . . . . . . . . . . . .
T-12
Failure code [231 (Short circuit, disconnection in engine speed sensor system) is displayed . . . . . . .
T-13
Failure code [241 (Short circuit, disconnection in EEP ROM) is displayed . . . . . . . . . . . . . . . . . . . . . .
T-14
Failure code [251 (Short circuit in transmission oil temperature system) is displayed . . . . . . . . . . . . .
T-15
Failure code [26] (Short circuit in F ECMV fill switch system) is displayed . . . . . . . . . . . . . . . . . . . . . .
T-16
Failure code [27] (Short circuit in R ECMV fill switch system) is displayed . . . . . . . . . . . . . . . . . . . . . .
T-17
Failure code [281 (Short circuit in 1st ECMV fill switch system) is displayed . . . . . . . . . . . . . . . . . . . .
T-18
Failure code [291 (Short circuit in 2nd ECMV fill switch system) is displayed . . . . . . . . . . . . . . . . . . .
T-19
Failure code [301 (Short circuit in 3rd ECMV fill switch system) is displayed . . . . . . . . . . . . . . . . . . . .
20-354
20-356
20-364
20-366
20-367
20-368
20-369
20-370
20-371
20-372
20-373
20-374
20-378
20-381
20-382
20-383
20-384
20-385
20-385
20-386
20-386
20-387
20-351
TROUBLESHOOTING
T-20
T-21
T-22
T-23
T-24
T-25
T-26
T-27
T-28
T-29
T-30
T-31
T-32
T-33
T-34
T-35
T-36
T-37
TABLE OF CONTENTS
Failure code [311 (Short circuit in 4th ECMV fill switch system) is displayed . . . . . . . . . . . . . . . . . . . .
Failure code [32] (Short circuit in F or R ECMV fill switch system) is displayed . . . . . . . . . . . . . . . . . .
Failure code [33] (Short circuit in 1st, 2nd, 3rd, or 4th ECMV fill switch system) is displayed . . . . . . .
Hold switch system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Kick-down switch system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Transmission cut-off signal system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Neutralizer relay signal system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Buzzer signal system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Network system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Transmission controller power source system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Short circuit in travel speed sensor system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Disconnection in transmission oil temperature sensor system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Disconnection in F ECMV fill switch system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Disconnection in R ECMV fill switch system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Disconnection in 1st ECMV fill switch system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Disconnection in 2nd ECMV fill switch system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Disconnection in 3rd ECMV fill switch system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Disconnection in 4th ECMV fill switch system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
20-352
20-387
20-388
20-390
20-392
20-392
20-393
20-394
20-395
20-396
20-397
20-398
20-399
20-400
20-400
20-401
20-401
20-402
20-402
MEMORANDA
TROUBLESHOOTING
20-353
TROUBLESHOOTING JUDGEMENT TABLE FOR TRANSMISSION CONTROLLER SYSTEM
JUDGEMENT TABLE FOR TRANSMISSION CONTROLLER

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

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

CONTROLLER SYSTEM
20-364
ELECTRICAL CIRCUIT DIAGRAM FOR TRANSMISSION CONTROLLER
TROUBLESHOOTING
20-365
TROUBLESHOOTING
T-1
Failure code [10] (Short circuit, disconnection, short circuit with

power source in back-up lamp relay) is displayed
This troubleshooting is carried out when there is still an abnormality, so when disconnecting the connector
and inserting the T-adapter, or when removing the T-adapter and returning the connector to its original
position, if the error code is no longer displayed on the monitor display, the problem has been removed.
T-1 Related electrical circuit diagram
20-366
T-1
T-2
TROUBLESHOOTING
T-2

power source in F solenoid) is displayed
This troubleshooting is carried out when there is still an abnormality, so when disconnecting the connector and inserting
the T-adapter, or when removing the T-adapter and returning the connector to its original position, if the error code is no
longer displayed on the monitor display, the problem has been removed.
T-2 Related electrical circuit diagram
20-367
TROUBLESHOOTING
T-3

power source in R solenoid) is displayed
20-368
T-3
T-4
TROUBLESHOOTING
T-4

power source in 1st solenoid) is displayed
20-369
TROUBLESHOOTING
T-5

power source in 2nd solenoid) is displayed
20-370
T-5
T-6
TROUBLESHOOTING
T-6

power source in 3rd solenoid) is displayed
20-371
TROUBLESHOOTING
T-7

power source in 4th solenoid) is displayed
20-372
T-7
T-8
TROUBLESHOOTING
T-8
Failure code [19] (Short circuit, disconnection in joystick

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

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

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

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

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

20-384
T-15, T-16
T-15
TROUBLESHOOTING
Failure code [26] (Short circuit in F ECMV fill switch system) is

displayed
T-16
Failure code [27] (Short circuit in R ECMV fill switch system) is

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

is displayed
20-388
MEMORANDA
TROUBLESHOOTING
MEMORANDA
20-389
TROUBLESHOOTING
T-22
T-22
Failure code [33] (Short circuit in 1st, 2nd, 3rd, or 4th ECMV fill
switch system) is displayed
20-390
T-22
TROUBLESHOOTING
20-391
TROUBLESHOOTING
T-23
T-23, T-24
Hold switch system
Always turn the starting switch OFF before disconnecting the connector or connecting the T-adapter (or socket).
T-24
20-392
Kick-down switch system
TROUBLESHOOTING
T-23, T-24
20-393
TROUBLESHOOTING
T-25
Transmission cut-off signal system
20-394
T-25
TROUBLESHOOTING
T-26
T-26
Neutralizer relay signal system
Check that the parking brake works normally.

Always turn the starting switch OFF before disconnecting the connector or connecting the T-adapter.
20-395
TROUBLESHOOTING
T-27
Buzzer signal system
Check that the main monitor and alarm buzzer work normally.
20-396
T-27
TROUBLESHOOTING
T-28
T-28
Network system
20-397
TROUBLESHOOTING
T-29
Transmission controller power source system
Check that fuse 11 @ is normal.

20-398
T-29
TROUBLESHOOTING
T-30
T-30
Short circuit in travel speed sensor system
20-399
TROUBLESHOOTING
T-31
Disconnection in transmission oil temperature sensor system
20-400
T-31
TROUBLESHOOTING
T-32
T-32, T-33
Disconnection in F ECMV fill switch system
T-33 Disconnection in R ECMV fill switch system

20-401
TROUBLESHOOTING
T-34
Disconnection in 1st ECMV fill switch system
T-35
Disconnection in 2nd ECMV fill switch system
20-402
T-34, T-35
TROUBLESHOOTING
T-36
T-36, T-37
Disconnection in 3rd ECMV fill switch system
T-37
Disconnection in 4th ECMV fill switch system
20-403
TROUBLESHOOTING
20-404
T-36, T-37
TABLE OF CONTENTS
TROUBLESHOOTING
TROUBLESHOOTING OF MAIN MONITOR

SYSTEM
(M MODE)
Trouble data display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Electrical circuit diagram for machine monitor system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Electrical circuit diagram for lamp and horn system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Electrical circuit diagram for turn signal and hazard system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
M- 1
Main monitor does not work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
M- 2
When starting switch is turned ON and engine is started immediately, all lamps stay
lighted up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
M- 3
Speedometer display does not work properly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
M- 4
Abnormality in shift indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
a)
Displays N even when directional lever is at F . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
b)
Displays N even when directional lever is at R . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
c)
Does not display N even when directional lever is at N, and displays R when
directional lever is at F . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
d)
Does not display N even when directional lever is at N, and displays R
when directional lever is at F . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
e)
Does not display 1st - 4th . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
M- 5
High beam does not light up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
M- 6
Turn signal display does not light up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
a)
L.H. turn signal display does not light up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
b)
R.H. turn signal display does not light up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
M- 7
Abnormality in parking display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
a)
Parking lamp display does not light up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
b)
Parking lamp display stays lighted up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
M- 9
Night lighting does not light up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
M-10
Abnormality in front working lamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
a)
Neither monitor display nor front working lamp light up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
b)
Working lamp lights up but monitor display does not light up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
c)
Monitor display lights up but working lamp does not light up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
M-11
Abnormality in rear working lamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
a)
Neither monitor display nor rear working lamp light up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
b)
Working lamp lights up but monitor display does not light up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
c)
Monitor display lights up but working lamp does not light up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
20-453
20-456
20-458
20-459
20-460
M-12
20-474
Abnormality in transmission cut-off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

a)
When monitor switch (transmission cut-off switch) is pressed, cut-off function is
not switched and display does not change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
b)
When monitor switch (transmission cut-off switch) is OFF, monitor display goes
out but cut-off function is actuated when pedal is depressed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
c)
When monitor display is turned off (transmission cut-off switch turned OFF),
cut-off function is always actuated . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
d)
Cut-off function is always actuated regardless of monitor display
(transmission cut-off switch ON or OFF) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
e)
Monitor display lights up (transmission cut-off switch turned ON), but
20-461
20-462
20-463
20-463
20-463
20-463
20-464
20-464
20-465
20-466
20-466
20-466
20-467
20-467
20-467
20-469
20-470
20-470
20-470
20-470
20-472
20-472
20-472
20-472
20-474
20-474
20-474
20-474
20-451
TROUBLESHOOTING
M-13
M-14
M-15
M-16
M-17
M-18
M-19
M-20
M-21
M-22
M-23
20-452
TABLE OF CONTENTS
cut off function is not actuated . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Abnormality in parking brake dragging warning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
a)
When parking brake is applied, buzzer sounds (intermittently) and caution lamp
flashes even when directional lever is at N . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
b)
When parking brake is applied, buzzer does not sound and caution lamp
does not light up even when directional lever is at position other than N . . . . . . . . . . . . . . . . . . . . . .
When parking brake dragging warning is given, buzzer and caution lamp are actuated
continuously, or they are not actuated . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
a)
Actuated continuously . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
b)
Not actuated . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Abnormality in buzzer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
a)
Buzzer does not sound when starting switch is at ON (for 3 seconds)
(during self-check) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
b)
Buzzer always sounds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Condition of monitor switches is not stored in memory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Abnormality in failure display mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
a)
Does not enter failure display mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
b)
Count for time elapsed since failure in failure display mode does not advance . . . . . . . . . . . . . . . . .
Buzzer is not made to sound by transmission controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Abnormality in emergency steering normal display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
a)
Emergency steering normal display does not light up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
b)
Emergency steering normal display stays lighted up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Abnormality in emergency steering actuation display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
a)
Emergency steering actuation display does not light up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
b)
Emergency steering actuation display stays lighted up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Abnormality in auto-greasing system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
a)
Forced greasing cannot be carried out . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
b)
Monitor display flashes rapidly (2 times/sec) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
c)
When no more grease remains, monitor display flashes rapidly (2 times/sec) . . . . . . . . . . . . . . . . . .
d)
Monitor display flashes slowly (1time/sec), confirm that grease is not empty . . . . . . . . . . . . . . . . . . .
e)
Monitor display goes out . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Abnormality in ECSS system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
a)
Display does not change when switch is pressed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
b)
Monitor display lights up but ECSS function does not work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Failure code is not sent to main monitor (abnormality in network) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
20-475
20-476
20-476
20-476
20-478
20-478
20-478
20-479
20-479
20-479
20-480
20-481
20-481
20-481
20-482
20-483
20-483
20-483
20-484
20-484
20-484
20-486
20-486
20-486
20-486
20-487
20-487
20-488
20-488
20-488
20-489
TROUBLE DATA DISPLAY
TROUBLESHOOTING

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

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

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

not carried out (changes
to manual gearshifting)
__
__
Normal manual
gear shifting
possible
circuit, or abnormality
in engine speed sensor
system
Engine speed taken as

2100 rpm (there is
shock when shifting
gear)
__
Normal
operation
possible but
there is shock
when shifting
gear
__
No
Disconnection in fill
switch
CALL
20-454
Action by
operator
Problem system
E00
E01
+
CALL
Action
Buzzer
Clutch engaged with out

fill signal (there is shock
when shifting gear)
Short circuit in
transmission oil
temperature sensor
Suitable gearshifting
data for transmission oil
temperature can not be
selected (there is shock
when shifting gear)
Short circuit with

ground in fill switch
Shifts to neutral, travel

impossible (modulation
output OFF)
circuit with ground, or
short circuit in shift
lever system

impossible (controller
input judged as N)
short circuit in F, R
ECMV solenoid system

impossible (ECMV
output OFF)
short circuit in speed
range solenoid system

impossible (ECMV
output OFF)
__
Normal
operation
possible but
there is shock
when shifting
gear
__
__
Yes
Travel under
own power if
possible, move
to safe place
then call for
service
__
__
__
__
Yes
Stop machine
immediately,
turn starting
switch OFF,
then call for
service
__
__
__
__
__

Action
code
Joystick control system

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

HAZARD SYSTEM
20-459
TROUBLESHOOTING
M-1
Main monitor does not work
20-460
M-1
M-2
M-2
TROUBLESHOOTING
When starting switch is turned ON and engine is started

immediately, all lamps stay lighted up
20-461
TROUBLESHOOTING
M-3
Speedometer display does not work properly
Check that the gap between the speed sensor and gear is normal.
20-462
M-3
M-4
M-4
TROUBLESHOOTING
Abnormality in shift indicator
Check that the transmission shifts.
20-463
TROUBLESHOOTING
20-464
M-4
M-5
M-5
TROUBLESHOOTING
High beam does not light up
Before starting troubleshooting, check that the lamp bulb is not blown.
20-465
TROUBLESHOOTING
M-6
Turn signal display does not light up
Before starting troubleshooting, check that the lamp bulb of the turn signal indicator on the monitor is not blown.
20-466
M-6
M-7
M-7
TROUBLESHOOTING
Abnormality in parking display
20-467
TROUBLESHOOTING
M-8
-MEMORANDA-
20-468
M-9
M-9
TROUBLESHOOTING
Night lighting does not light up
Before starting troubleshooting, check that the lamp bulbs are not blown.
Check that fuse 1-6 is normal. If it is blown, check for a short circuit with the chassis ground in the wiring harness between
FS2 (female) (5) and L05 (female) (16).
20-469
TROUBLESHOOTING
M-10
Abnormality in front working lamp
Before starting troubleshooting, check that the monitor lighting is lighted up.
20-470
M-10
M-10
M-10
TROUBLESHOOTING
20-471
TROUBLESHOOTING
M-11
Abnormality in rear working lamp
Before starting troubleshooting, check that the monitor lighting is lighted up.
20-472
M-11
M-11
M-11
TROUBLESHOOTING
20-473
TROUBLESHOOTING
M-12
Abnormality in transmission cut-off
20-474
M-12
M-12
TROUBLESHOOTING
20-475
TROUBLESHOOTING
M-13
Abnormality in parking brake dragging warning
20-476
M-13
M-13
M-13
TROUBLESHOOTING
20-477
TROUBLESHOOTING
M-14
When parking brake dragging warning is given, buzzer and

caution lamp are actuated continuously, or they are not actuated
20-478
M-14
M-15
M-15
TROUBLESHOOTING
Abnormality in buzzer
20-479
TROUBLESHOOTING
M-16
Condition of monitor switches is not stored in memory
20-480
M-16
M-17
M-17
TROUBLESHOOTING
Abnormality in failure display mode
20-481
TROUBLESHOOTING
M-18
Buzzer is not made to sound by transmission controller
20-482
M-18
M-19
M-19
TROUBLESHOOTING
Abnormality in emergency steering normal display
20-483
TROUBLESHOOTING
M-20
Abnormality in emergency steering actuation display
20-484
M-20
M-20
TROUBLESHOOTING
-MEMORANDA-
20-485
TROUBLESHOOTING
M-21
Abnormality in auto-greasing system
20-486
M-21
M-21
TROUBLESHOOTING
20-487
TROUBLESHOOTING
M-22
Abnormality in ECSS system
ECSS : Electronic Controlled Suspension System.
20-488
M-22
M-23
M-23
TROUBLESHOOTING
Failure code is not sent to main monitor (abnormality in network)
Set dipswitch 3 at the rear of the main monitor to 'F".
MDC: Multiple Display and Condition.
20-489
TROUBLESHOOTING
M-23
-MEMORANDA -
20-490
TABLE OF CONTENTS
TROUBLESHOOTING
TROUBLESHOOTING OF MAINTENANCE
MONITOR SYSTEM
(K MODE)

K- 1
When starting switch is turned ON, all lamps on maintenance monitor do not light up
for 3 seconds, maintenance monitor does not work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
a)
No lamps on maintenance monitor light up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
b)
Some lamps do not light up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
K-2 When starting switch is turned ON, all lamps on maintenance monitor light up but
do not go out (even after 3 seconds) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
K- 3
When engine is started immediately after starting switch is turned ON
(within 3 seconds), no lamps on maintenance monitor go out . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
K- 4
When starting switch is turned ON (engine stopped), CHECK items flash . . . . . . . . . . . . . . . . . . . . . . . . . . . .
a)
Engine oil level display flashes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
b)
Engine water level display flashes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
K- 5
When starting switch is turned ON (engine started), CAUTION items flash . . . . . . . . . . . . . . . . . . . . . . . . . . .
a)
Engine oil pressure display flashes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
b)
Battery charge level display flashes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
c)
Brake oil pressure display flashes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
d)
Air cleaner display flashes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
K- 6
CAUTION items are flashing but caution buzzer does not sound . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
K-7 There is no abnormality in monitor display but caution buzzer sounds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
K-8 CAUTION items are flashing but warning lamp (CHECK lamp, CAUTION lamp) does
not flash . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
a)
CHECK lamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
b)
CAUTION lamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
K- 9
There is no abnormality in maintenance monitor display but warning lamp
(CHECK lamp, CAUTION lamp) lights up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
a)
CHECK lamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
b)
CAUTION lamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
K-10
Night lighting does not light up when lamp switch is turned ON (only lighting of maintenance
monitor does not light up) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
K-11
Night lighting lights up even when lamp switch is OFF, night lighting stays lighted up . . . . . . . . . . . . . . . . . . .
K-12
Service meter does not work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
20-504
20-506
20-506
20-506
20-507
20-508
20-509
20-509
20-510
20-511
20-511
20-512
20-513
20-514
20-515
20-516
20-517
20-517
20-517
20-518
20-518
20-518
20-519
20-520
20-521
20-501
TROUBLESHOOTING
K-13
K-14
20-502
TABLE OF CONTENTS
Service meter is running even when engine is stopped . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Abnormality in gauge items . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
a)
Abnormality in fuel gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
b)
Abnormality in engine water temperature gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
c)
Abnormality in torque converter oil temperature gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
20-521
20-522
20-522
20-523
20-524
MEMORANDA
TROUBLESHOOTING
20-503
TROUBLESHOOTING
20-504
TROUBLESHOOTING
20-505
TROUBLESHOOTING
K-1
When starting switch is turned ON, all lamps on maintenance

monitor do not light up for 3 seconds, maintenance monitor does
not work
before carrying out troubleshooting, check that all the related connectors are properly inserted.
20-506
K-1
K-2
K-2
TROUBLESHOOTING
When starting switch is turned ON, all lamps on maintenance

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

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

flash
a)
Engine oil level display flashes

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

Before starting troubleshooting, check the engine water level again. (Check that the water level is correct).
20-511
TROUBLESHOOTING
K-5
When starting switch is turned ON (engine started), CAUTION items

flash
20-512
K-5
K-5
20-513
TROUBLESHOOTING
TROUBLESHOOTING
20-514
K-5
K-5
20-515
TROUBLESHOOTING
TROUBLESHOOTING
K-6
K-6
CAUTION items are flashing but caution buzzer does not sound
The buzzer does not sound for CHARGE or ENGINE OIL LEVEL
check that fuse 1-10 is normal. If it is blown, check for a short circuit with the chassis ground in the wiring harness between
fuse 1-10 - FS2 (9) - L42.
20-516
TROUBLESHOOTING
K-7
There is no abnormality in monitor display but caution buzzer

sounds
20-517
K-7
TROUBLESHOOTING
K-8
CAUTION items are flashing but warning lamp (CHECK lamp,

CAUTION lamp) does not flash
Before carrying out troubleshooting, check that there are no blown lamp bulbs.
20-518
K-8
TROUBLESHOOTING
K-9
There is no abnormality in maintenance monitor display but warning

lamp (CHECK lamp, CAUTION lamp) lights up
Always connect any disconnected connectors before going on to the next step
20-519
K-9
TROUBLESHOOTING
K-10
Night lighting does not light up when lamp switch is turned ON (only
lighting of maintenance monitor does not light up)
20-520
K-10
TROUBLESHOOTING
K-11
Night lighting lights up even when lamp switch is OFF night lighting
stays lighted up
20-521
K-11
TROUBLESHOOTING
K-12
Service meter does not work
K-13
Service meter is running even when engine is stopped
20-522
K-12, K-13
K-14
K-14
TROUBLESHOOTING
Abnormality in gauge items
a)
20-523
Abnormality in fuel gauge

Before carrying out troubleshooting, check the fuel level and make sure the level is correct.
TROUBLESHOOTING
b)
Abnormality in engine water temperature gauge
20-524
K-14
K-14
c)
Abnormality in torque converter oil temperature gauge
20-525
TROUBLESHOOTING
TABLE OF CONTENTS
TROUBLESHOOTING
TROUBLESHOOTING OF ELECTRICAL SYSTEM

(E MODE)
Electrical circuit diagram for power supply, engine starting / stop system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Electrical circuit diagram for parking brake system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Electrical circuit diagram for lamp and horn system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Electrical circuit diagram for boom kick-out and bucket positioner system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Electrical circuit diagram for transmission controller system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
E- 1
Engine does not start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
a)
Starting motor does not turn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
b)
Starting motor turns . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
E- 2
Engine does not stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
E- 3
Engine stops when machine is traveling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
E- 4
Not used
E- 5
Parking brake does not have effect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
a)
Parking brake has no effect when parking brake switch is turned ON (actuated) . . . . . . . . . . . . . . .
b)
Parking brake has no effect when brake pressure drops
(Does not work as emergency brake) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
E- 6
Parking brake is applied when machine is traveling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
E- 7
Parking brake is released when starting switch is turned ON . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
E- 8
Transmission does not change to neutral when parking brake is applied
(But parking brake works normally) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
E- 9
Kick-down switch does not work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
a)
Kick-down switch does not work (shift works correctly during normal gear
shift operations) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
b)
Kick-down is not canceled . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
E-10
Boom kick-out cannot be used . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
E-11
Abnormality in bucket positioner function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
E-12
Abnormality in lighting up of front working lamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
E-13
Abnormality in lighting up of rear working lamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
E-14
Abnormality in transmission cut-off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
E-15
Abnormality in parking brake dragging warning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
E-16
Abnormality in buzzer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
20-551
20-552
20-553
20-554
20-555
20-556
20-558
20-558
20-562
20-564
20-564
20-567
20-567
20-567
20-568
20-570
20-570
20-572
20-572
20-573
20-574
20-578
20-581
20-581
20-581
20-581
20-581
TROUBLESHOOTING
ELECTRICAL CIRCUIT DIAGRAMS
ELECTRICAL CIRCUIT DIAGRAM FOR POWER SUPPLY,

ENGINE STARTING / STOP SYSTEM
20-552
20-553
TROUBLESHOOTING
TROUBLESHOOTING
ELECTRICAL CIRCUIT DIAGRAM FOR PARKING BRAKE SYSTEM
20-554
TROUBLESHOOTING
20-555
TROUBLESHOOTING
ELECTRICAL CIRCUIT DIAGRAM FOR BOOM KICK-OUT AND

BUCKET POSITIONER SYSTEM
20-556
TROUBLESHOOTING
ELECTRICAL CIRCUIT DIAGRAM FOR TRANSMISSION

CONTROLLER SYSTEM
20-557
TROUBLESHOOTING
20-558
E-1
E-1
TROUBLESHOOTING
Engine does not start
When connecting or disconnecting the T-adapter (or socket adapter) or short connector to carry out checks, always turn the
starting switch OFF before starting.
When connecting the T-adapter (or socket adapter), connect to the connector specified as CNOA( ).
After checking, connect the disconnected connectors and disconnect the T-adapter immediately to return to the original
condition before going on to the next check.
a)
Starting motor does not turn
20-559
TROUBLESHOOTING
20-560
E-1
E-1
TROUBLESHOOTING
20-561
TROUBLESHOOTING
20-562
E-1
E-1
b)
TROUBLESHOOTING
Starting motor turns
20-563
TROUBLESHOOTING
20-564
E-1
E-1
E-2
TROUBLESHOOTING
Engine does not stop
E-3
Engine stops when machine is traveling
Check if the starting motor turns. If it does not turn, check E-1, a) Starting motor does not turn.
20-565
TROUBLESHOOTING
E-1, E-2, E-3
20-566
E-2, E-3
E-1, E-2, E-3
TROUBLESHOOTING
-MEMORANDA-
20-567
TROUBLESHOOTING
E-5
E-4
Parking brake does not have effect
When carrying out troubleshooting of the brake system, stop the machine on flat ground.
When connecting the T-adapter (or socket adapter), connect to the connector specified as CNOA().
20-568
E-6
E-6
TROUBLESHOOTING
Parking brake is applied when machine is traveling
When carrying out troubleshooting of the brake system, stop the machine on flat ground.
20-569
TROUBLESHOOTING
20-570
E-6
E-6
E-7
TROUBLESHOOTING
Parking brake is released when starting switch is turned ON
When connecting the T-adapter (or socket adapter), connect to the connector specified as CNOL( ).
E-8
Transmission does not change to neutral when parking brake is

applied (but parking brake works normally)
20-571
TROUBLESHOOTING
E-6, E-7, E-8
20-572
Related electrical diagram
E-7, E-8
E-9
TROUBLESHOOTING
E-9 Kick-down switch does not work

a)
Kick-down switch does not work (shift works correctly during normal gear shift operations)
20-573
TROUBLESHOOTING
b)
Kick-down is not canceled
20-574
E-9
E-10
E-10
TROUBLESHOOTING
Boom kick-out cannot be used
Check that fuse I (10) is normal. If it is blown, check for a short circuit with the ground in the wiring harness between fuse I
(10) - FS2 (10) - L49 (3) - LR2 (1) - FR2 (1) - F06 (female) (1), or FS2 (10) - L32 (1) - L33 (1) - L40 (female) (1)
20-575
TROUBLESHOOTING
20-576
E-10
E-10
E-10
TROUBLESHOOTING
20-577
TROUBLESHOOTING
E-10
-MEMORANDA -
20-578
E-11
E-11
TROUBLESHOOTING
Abnormality in bucket positioner function
Check that fuse I (10) is normal. If it is blown, check for a short circuit with the ground in the wiring harness between fuse I
(10) - FS2 (10) - L48 (1), (3), or FS2 (10) - LR2 (1) - FR2 (1) - F05 (female) (1)
Figure 284
20-579
TROUBLESHOOTING
20-580
E-11
E-11
E-11
TROUBLESHOOTING
20-581
TROUBLESHOOTING
E-12
Abnormality in lighting up of front working lamp

Go to Troubleshooting M-10.
E-13
Abnormality in lighting up of rear working lamp

Go to Troubleshooting M-11
E-14
Abnormality in transmission cut-off

Go to Troubleshooting M-12.
E-15
Abnormality in parking brake dragging warning

Go to Troubleshooting M-13, M-14.
E-16
Abnormality in buzzer
Go to Troubleshooting M-15, M-18.
20-582
E-11
E-12, E-13, E-14, E-15, E-16
TROUBLESHOOTING
-MEMORANDA -
20-583
TABLE OF CONTENTS
TROUBLESHOOTING
TROUBLESHOOTING OF HYDRAULIC AND

MECHANICAL SYSTEM
(H MODE)
Power train
H- 1
H- 2
Machine does not start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Travel speed is slow, thrusting power is weak, lacks power on slopes,
Does not shift gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
H- 3
Excessive shock when starting machine of shifting gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
H- 4
Excessive time lag when starting machine of shifting gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
H- 5
Torque converter oil temperature is high . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Steering system
H- 6
Steering does not turn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
H- 7
Steering does not turn (machine with joystick) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
H- 8
Turning, response of steering is poor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
H- 9
Turning, response of steering is poor (machine with joystick) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
H-10
Steering is heavy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
H-11
Joystick is heavy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
H-12
Steering wheel shakes or jerks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
H-13
Steering shakes or there is excessive shock (machine with joystick) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
H-14
Turning radius is different between left and right at maximum steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Brake system
H-15
Wheel brakes do not work or braking effect is poor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
H-16
Wheel brakes are not released or brakes drag . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
H-17
Parking brake does not work or braking effect is poor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
H-18
Parking brake is not released or brake drags (including emergency release system) . . . . . . . . . . . . . . . . . . . .
Work equipment
H-19
Neither boom nor bucket move . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
H-20
Both boom and bucket are slow or lack power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
H-21
Boom does not move . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
H-22
Not used
H-23
Boom is slow or boom lacks power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
H-24
Not used
H-25
Boom cannot be set to FLOAT or cannot be released from FLOAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
H-26
Boom drops momentarily when control lever is operated from HOLD to RAISE . . . . . . . . . . . . . . . . . . . . . . . .
H-27
Not used
H-28
Excesseve hydraulic drift of boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
H-29
Bucket does not move . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
H-30
Bucket is slow or lacks power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
H-31
Excesseve hydraulic drift of bucket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
H-32
ECSS does not work, and there is pitching and bouncing (machines with ECSS) . . . . . . . . . . . . . . . . . . . . . .
20-602
20-605
20-609
20-611
20-613
20-614
20-615
20-616
20-618
20-620
20-620
20-621
20-622
20-623
20-624
20-626
20-627
20-628
20-629
20-630
20-631
20-633
20-635
20-635
20-637
20-638
20-639
20-640
20-641
20-601
TROUBLESHOOTING
H-1
H- 1 Machine does not start

Ask the operator the following questions.
Did the problem suddenly start?
Yes = Clutch seized, part broken
Was there any abnormal noise when this happened?
Where did the noise come from?
Checks before troubleshooting
Does the main monitor function properly?
Is any failure code for the electrical system displayed on
the main monitor?
20-602
Is the transmission oil level correct? Is the type of

oil correct?
Is the transmission oil deteriorated? Does the oil
smell of burning?
Is the transmission filter or strainer clogged? Is
there any damage or leakage of oil that can be
seen externally?
Is the drive shaft broken?
Is the wheel brake or parking brake locked?
H-1
TROUBLESHOOTING
20-603
TROUBLESHOOTING
H-1
Method of determining defective clutch and ECMV (check using failure code)
For details of the method for checking the failure code display, see 'Method of displaying action code and failure code' and
'Action code and failure code table and re-enaction"
When replacing the ECMV and carrying out troubleshooting, remove all mud and dirt from around the ECMV, then wash it
and tighten the mounting bolts to the specified tightening torque.
Carry out the following troubleshooting with the manual mode for starting the engine.
20-604
H-2
H-2
TROUBLESHOOTING
Travel speed is slow, thrusting power is weak, lacks power on

slopes, does not shift gear

Yes = Related equipment broken
Did the problem gradually appear?
Yes = Wear of related parts, defective seal
Checking for abnormalities
Measure digging operations and speed when traveling
on level ground and on slopes, and check if there is
actually an abnormality or whether it is just the feeling
of the operator.
Is the failure code for the electrical system displayed on
the monitor?
Is the transmission oil level correct? Is the type of oil
correct?
Is the transmission filter or strainer clogged?
Is there any oil leaking from the joints of the piping or
valves around the torque converter or transmission?
Is there any dragging of the wheel brake or parking
brake?
Is the tire inflation pressure and tread pattern correct?
Is the method of operation correct?
Note:
If it is judged that there is a drop in the engine
performance, go to troubleshooting of the
engine system (S mode).
20-605
TROUBLESHOOTING
20-606
H-2
H-2
TROUBLESHOOTING
20-607
TROUBLESHOOTING
H-2
For details of the method for checking the failure code display, see 'Method of displaying action code and failure code" and
20-608
H-3
H-3
TROUBLESHOOTING
Excessive shock when starting machine or shifting gear

Where did the noise come from? Did the problem
gradually appear?
Is the travel speed slow, is the thrusting force weak,
does the machine lack power when traveling uphill, is it
impossible to shift gear, or are there any other
abnormalities occurring at the same time?
Yes = Carry out Troubleshooting H-2

Is the failure code for the electrical system
displayed on the monitor?
oil correct?
Is there any oil leaking from the joints of the piping
or valves around the torque converter or
transmission?
Defective operation of solenoid or defective operation of pressure control valve spool and flow detector valve spool caused by
dirt.
Go to Method of determining defective clutch and ECMV (check using failure code).
20-609
TROUBLESHOOTING
H-3
For details of the method for checking the failure code display, see 'Method of displaying action code and failure code" and
"Action code and failure code table and re-enaction"
20-610
H-4
H-4
TROUBLESHOOTING
Excessive time lag when starting machine or shifting gear

Is the travel speed slow, is the thrusting force weak,
does the machine lack power when traveling uphill, is it
impossible to shift gear, or are there any other
abnormalities occurring at the same time?
Yes = Carry out Troubleshooting H-2

Is the failure code for the electrical system
displayed on the monitor?
oil correct?
Is there any oil leaking from the joints of the piping
or valves around the torque converter or
transmission?
Defective operation of solenoid or defective operation of pressure control valve spool and flow detector valve spool caused by
dirt in the spool.
Go to Method of determining defective clutch and ECMV (check using failure code).
20-611
TROUBLESHOOTING
H-4
For details of the method for checking the failure code display, see "Method of displaying action code and failure code" and
20-612
H-5
H-5
TROUBLESHOOTING
Torque converter oil temperature is high

Does oil temperature rise during torque converter stall
and go down when there is no load?
Yes = Improper selection of transmission range
Does oil temperature rise only when carrying out
scooping work?
Yes = Improve method of operation

Are the radiator water level and fan belt tension
correct?
oil correct?
Note:

Measure the torque converter oil temperature. Is it
actually high?
No = Defective oil transmission gauge
If it is judged that there is a drop in the engine

performance, go to troubleshooting of the engine
system (S mode).
20-613
TROUBLESHOOTING
H-6
H-6
Steering wheel does not turn


Is the oil level in the hydraulic tank correct? Is the
type of oil correct?
Is the steering shaft broken?
Is the stop valve stopper properly adjusted?
There is a close connection between the steering circuit and the work equipment circuit, so if any abnormality is felt in the
steering, check the operation of the work equipment also.
20-614
H-7
H-7
TROUBLESHOOTING
Steering does not turn [machine with joystick]


Is the steering shaft broken?
Is the stop valve stopper properly adjusted?
Is the operation of the steering and the steering
mode switch correct?
20-615
TROUBLESHOOTING
H-8
- MEMORANDA -
20-616
H-8
H-8
TROUBLESHOOTING
Turning, response of steering is poor


20-617
TROUBLESHOOTING
H-8
-MEMORANDA -
20-618
H-9
H-9
TROUBLESHOOTING
Turning, response of steering is poor [machine with joystick]

Was there previously any symptom, such as difficulty in
steering?
Yes = Wear of related equipment, defective seal

20-619
TROUBLESHOOTING
H-9
- MEMORANDA -
20-620
H-9
TROUBLESHOOTING
20-621
TROUBLESHOOTING
H-10
H-10, H-11
Steering is heavy

Is the steering difficult to turn?
Yes = Go to H-8 or H-9
Measure the operating effort and turning speed, and
check the STANDARD VALUE TABLE to see if they
are abnormal.

Is the tire inflation pressure correct?

Was there previously any symptom, such as heavy
steering?
Yes = Wear of related equipment, defective seal
H-11
Joystick steering is heavy (machines equipped with joystick)
Causes and remedy

Abnormality of joystick (X)
(The joystick is an electrically operated lever, so if the operating effort is large, the abnormality is in the joystick).
20-622
H-12
H-12
TROUBLESHOOTING
Steering wheel shakes or jerks

Yes = Go to H-8
Is there any abnormal noise from around the steering
equipment?

Is the steering wheel play correct?
Is there any abnormality in the connection between
the steering shaft and the Orbit-roll?
20-623
TROUBLESHOOTING
H-13
Steering shakes or there is excessive shock [machine with joystick]

Yes = Go to H-9
Is there any abnormal noise from around the steering
equipment?
20-624
H-13

Is any failure code for the electrical system
displayed on the main monitor?
Is the steering wheel play correct?
Is there any abnormality in the connection between
the steering shaft and the Orbit-roll?
H-14
H-14
TROUBLESHOOTING
Turning radius is different between left and right at maximum

steering
Causes and Remedy

Defective adjustment of stop valve (
20-625
TROUBLESHOOTING
H-15
H-15
Wheel brakes do not work or braking effect is poor

Measure the actual brake performance, and check if
there is actually an abnormality or whether it is just the
feeling of the operator. For details, see TESTING AND
ADJUSTING, Measuring brake performance.

Is the brake pedal play correct?
Is there any leakage of oil from the brake tube? Is
there any deformation of the tube?
Is the tire inflation pressure and tread pattern
correct?
The PPC pump is used for the wheel brake actuation pressure in the same way as for the work equipment circuit and
steering circuit, so if any abnormality is felt in the wheel brake, check the condition of actuation of the work equipment and
steering also. (The circuit set pressure is different).
20-626
H-15
TROUBLESHOOTING
20-627
TROUBLESHOOTING
H-16
Wheel brakes are not released or brakes drag

20-628
H-16

Does the brake pedal come back fully?
Is the parking brake still applied?
H-17
H-17
TROUBLESHOOTING
Parking brake does not work or braking effect is poor


Is parking brake emergency release switch open?
(Normally it is open)
Is parking brake mechanical release operation
being carried out?
20-629
TROUBLESHOOTING
H-18
H-18
Parking brake is not released or brake drags (including emergency

release system)

is there any abnormality in the power train system?
Yes = Carry out Troubleshooting H-1 - H-4
(Power train hydraulic system)
The power train main relief pressure is used for the parking brake release pressure, so if any abnormality is felt in the parking
brake release system, check the condition of actuation of the power train (the emergency release circuit uses the wheel brake
circuit presure).
20-630
H-19
H-19
TROUBLESHOOTING
Neither boom nor bucket move


20-631
TROUBLESHOOTING
H-20
H-20
Both boom and bucket are slow or lack power

20-632
H-21
H-21
TROUBLESHOOTING
Boom does not move

20-633
TROUBLESHOOTING
H-22
-MEMORANDA -
20-634
H-23
H-23
TROUBLESHOOTING
Boom is slow or boom lacks power

20-635
TROUBLESHOOTING
H-24
-MEMORANDA -
20-636
H-25, H-26
H-25
Boom cannot be set to FLOAT or cannot be released from FLOAT

H-26
TROUBLESHOOTING

Can other operations of boom (RAISE, HOLD,
LOWER) be carried out normally?
Boom drops momentarily when control lever is operated from HOLD

to RAISE

With the engine running at low idling, if the boom control lever is gradually moved from HOLD to RAISE, the boom moves
down momentarily under its own weight.
If the control lever is operated fully to the RAISE position, the condition becomes normal.
Causes and Remedy
Defective slow return check valve for control valve boom spool (X) or (
20-637
TROUBLESHOOTING
H-27
-MEMORANDA -
20-638
H-28
H-28
TROUBLESHOOTING
Excessive hydraulic drift of boom

Note:
Before starting troubleshooting, the PPC accumulator must be charged, so run the engine at low idling for 5 - 10
seconds, then stop the engine.
20-639
TROUBLESHOOTING
H-29
Bucket does not move

20-640
H-29
H-30
H-30
TROUBLESHOOTING
Bucket is slow or lacks power

20-641
TROUBLESHOOTING
H-31
H-31
Excessive hydraulic drift of bucket

Note:
20-642
Before starting troubleshooting, the PPC accumulator must be charged, so run the engine at low idling for 5 - 10
seconds, then stop the engine.
H-32
H-32
TROUBLESHOOTING
ECSS does not work, and there is pitching and bouncing [machines
with ECSS]
Ask the operator the following questions


Is operation of ECSS switch correct?
20-643
TROUBLESHOOTING
H-32
-MEMORANDA -
20-644
TABLE OF CONTENTS
TROUBLESHOOTING
TROUBLESHOOTING OF ECSS
(ELECTRONICALLY CONTROLLED
SUSPENSION SYSTEM)
(D MODE)
Judgement table for controller electrical system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Electrical circuit diagram for ECSS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
D-1 ECSS does not work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
a)
Error code [d0] is displayed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
b)
c)
d)
e)
No abnormality display is given . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
D-2 ECSS cannot be canceled . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
20-652
20-654
20-655
20-656
20-656
20-657
20-657
20-659
20-662
20-651
TROUBLESHOOTING
JUDGEMENT TABLE FOR CONTROLLER ELECTRICAL SYSTEM

ECSS CONTROL SYSTEM
Failure code
Abnormal system
Nature of abnormality
1)
2)
d0
sol 1 (relief) and sol 14 relay
3)
4)
1)
2)
d1
sol 2 (high pressure)
3)
4)
1)
2)
d2
sol 3 (low pressure)
3)
4)
1)
2)
d3
sol 5
3)
4)
20-652
Defective sol 1 and sol 14 relays.

Short circuit with power source, short circuit with ground, defective
contact, or disconnection in wiring harness between transmission
controller C1 (female) (3) and ECSS relay L90 (1).
Defective contact or disconnection in wiring harness between sol 1
and sol 14 relay L90 (female) (2) and chassis ground.
Defective transmission controller.
Defective sol 2.
controller C1 (female) (10) - ECSS (2) - AF2 (1).
connector AF2 (female) (2) and chassis ground.
Defective sol 3.
connector AF3(female) (2) and chassis ground.
Defective sol 5.
connector AF5 (female) (2) and chassis ground.

Condition when normal (Voltage, current, resistance)
Action by controller
when abnormality is
detected
TROUBLESHOOTING
Problem that appears

on machine when there
is abnormality
1) Resistance of relay coil: 200 - 400

2) Resistance of wiring harness between transmission
controller C1 (female) (3) and ECSS relay L90 (female)
(1): Max. 1
3) Voltage between transmission controller C1 (3) and
chassis ground: Less than 1 V (Command OFF); 20 V or
above (Command ON).
4) Resistance of wiring harness between ECSS relay L90
(female) (2) and chassis ground: Max. 1
1) Resistance of solenoid: 30 - 80
chassis ground at neutral: Less than 1 V.
3) Resistance between transmission controller C1 (female)
(10) and chassis ground: Min. 1 M
controller C1 (female) (10) - ECSS (2) - AF2 (1): Less
than 1
5) Resistance between sol 2 connector AF2 (2) - chassis
ground: Less than 1
controller C1 (female) (5) - ECSS (3) - AF3 (1): Less than
1
ground: Less than 1
controller C1 (female) (9) - ECSS (7) - AF5 (1): Less than
1
ground: Less than 1
Troubleshooting
code
D-1
a)
D-1
b)
ECSS function: OFF
Swaying (pitching,
bouncing) of machine
when traveling at high
speed (2nd - 4th)
D-1
c)
D-1
d)
20-653
TROUBLESHOOTING
ELECTRICAL CIRCUIT DIAGRAM FOR ECSS
ELECTRICAL CIRCUIT DIAGRAM FOR ECSS
20-654
D-1
D-1
TROUBLESHOOTING
ECSS does not work
Carry out troubleshooting with the starting switch ON.
Check that the ECSS switch on the main monitor is ON.
20-655
TROUBLESHOOTING
20-656
D-1
D-1
TROUBLESHOOTING
20-657
TROUBLESHOOTING
D-1 a), b), c), d) Related electrical circuit diagram
20-658
D-1
D-1
e)
TROUBLESHOOTING
No abnormality display is given

(1)
Does not work at all
Before starting troubleshooting, check that the main monitor dipswitch is set to ON for ECSS function.
20-659
TROUBLESHOOTING
20-660
D-1
D-1
TROUBLESHOOTING
20-661
TROUBLESHOOTING
D-2
ECSS cannot be canceled
20-662
D-2
TABLE OF CONTENTS
TROUBLESHOOTING
TROUBLESHOOTING OF JOYSTICK STEERING

CONTROLLER SYSTEM
(J MODE)
Judgement table for joystick controller system related parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Action taken by controller when abnormality occur . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Electrical circuit diagram for joystick system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
J- 1 Failure code [56] (short circuit, disconnection in caution relay output) is displayed . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
J- 2 Failure code [57] (short circuit in steering right solenoid (detected when output)
is displayed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
J- 3 Failure code [58] (short circuit in steering left solenoid (detected when output)
is displayed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
J- 4 Failure code [59] (short circuit in steering right solenoid (HOT end) is displayed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
J- 5 Failure code [60] (short circuit in steering left solenoid (HOT end) is displayed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
J- 6 Failure code [61] (short circuit, disconnection in steering solenoid cut relay output)
is displayed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
J- 7 Failure code [62] (short circuit, disconnection in joystick steering neutral signal)
is displayed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
J- 8 Failure code [63] (short circuit, disconnection in joystick steering lever potentiometer
system) is displayed (Not used) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
J- 9 Abnormality in power source, voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
J-10
Abnormality in joystick steering ON-OFF signal system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
J-11
Disconnection in steering right solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
J-12
Disconnection in steering left solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
20-702
20-704
20-708
20-709
20-710
20-711
20-712
20-713
20-714
20-715
20-716
20-717
20-718
20-719
20-720
20-701
TROUBLESHOOTING
JUDGEMENT TABLE FOR JOYSTICK CONTROLLER SYSTEM

RELATED PARTS
20-702
TROUBLESHOOTING
-MEMORANDA-
20-703
TROUBLESHOOTING
ACTION TAKEN BY CONTROLLER WHEN ABNORMALITY OCCUR

JOYSTICK CONTROLLER SYSTEM
Failure code
Abnormal system
1)
2)
56
Joystick caution relay system

3)
4)
57
Steering (R) (right) sol. System
Defective caution relay

Short circuit with ground, defective contact, or disconnection in
wiring harness between work equipment controller L28 (female)
(13) and JS8 (1)
Defective contact or disconnection in wiring harness between
caution relay J8 (female) (2) and chassis ground
Defective work equipment controller
1)
2)
3)
Defective R sol
Defective steering solenoid cut relay
Short circuit in wiring harness between work equipment controller
L26 (female) (6) and (16)
Short circuit with ground, defective contact, or disconnection in the
following wiring harness:
4) Wiring harness between work equipment controller L26 (female)
(6) and R (2)
(16) and JS9 (3)
6) Wiring harness between steering solenoid cut relay JS9 (5) and
R (1)
7) Defective work equipment controller
1)
2)
3)
58
Steering (L) (left) sol. System
59
Short circuit with power source

in wiring harness between
steering (R) (right) sol. System
Defective L sol
Defective steering solenoid cut relay
Short circuit in wiring harness between work equipment controller
L26 (female) (7) and (16)
Short circuit with ground, defective contact, or disconnection in the
following wiring harness:
(7) and L (2)
(16) and JS9 (3)
6) Wiring harness between steering solenoid cut relay JS9 (5) and L
(1)
1)
2)
3)
60
Short circuit with power source

in wiring harness between
steering (L) (left) sol. System
1)
2)
3)
20-704
Defective R sol
Short circuit with power source in wiring harness between work
equipment controller L26 (female) (6) and R (2)
Defective L sol
Short circuit with power source in wiring harness between work
equipment controller L26 (female) (7) and L (2)

Condition when normal (voltage, current, resistance)
TROUBLESHOOTING
when abnormality is
detected

on machine when
there is abnormality
1) Joystick caution relay: ON (voltage between L28 (15) and

chassis ground: 20 - 30 V)
2) Resistance of relay coil between work equipment controller
L28 (female) (13) and J chassis ground: 200 - 400
3) Resistance of wiring harness between work equipment
controller L28 (female) (13) and caution relay JS8 (female)
(1): Less than 1
4) Resistance of wiring harness between caution relay JS8
(female) (2) and chassis ground: Less than 1
Caution output: OFF
Joystick caution
actuated
1) Steering solenoid cut relay: ON (voltage between L26 (8)

and chassis groung: 20 - 30 V)
2) Resistance of steering R solenoid: 10 - 20
3) Resistance between work equipment controller L26 (female)
(6), (16) and chassis ground: Min. 1M
Resistance of the following wiring harness: Less than 1
4) Wiring harness between work equipment controller L26
(female) (6) - R (female) (2)
(female) (16) - JS9 (female) (3)
6) Wiring harness between steering solenoid cut relat JS9
(female) (5) and L (female (1)
Steering R, L solenoid
output: OFF
and steering solenoid
cut relay output: OFF
and caution relay: OFF

and chassis groung: 20 - 30 V)
2) Resistance of steering L solenoid: 10 - 20
3) Resistance between work equipment controller L26 (female)
(7), (16) and chassis ground: Min. 1M
Resistance of the following wiring harness: Less than 1
(female) (7) - L (female) (2)
(female) (16) - JS9 (female) (3)
6) Wiring harness between steering solenoid cut relat JS9
(female) (5) and L (female (1)
output: OFF
Joystick lever at neutral

Voltage between work equipment controller L26 (female) (6)
and chassis ground: Less than 1 V
output: OFF
Impossible to use
joystick
and joystick caution
actuated
Joystick lever at neutral

and chassis ground: Less than 1 V
output: OFF
Impossible to use
joystick
actuated
Troubleshooting
code
J-1
Impossible to use
joystick
actuated
J-2
Impossible to use
joystick
actuated
J-3
J-4
J-5
20-705
TROUBLESHOOTING
Failure code
Abnormal system
Steering sol. cut relay system
1) Defective steering sol relay

2) Short circuit with ground, defective contact, or disconnection in
wiring harness between work equipment controller L26 (female) (8)
and JS9 (1)
3) Defective contact or disconnection in wiring harness between
NEUTRAL SW (1) and chassis ground
62
Joystick neutral SW system
1) Defective joystick neutral SW

2) Short circuit with ground, defective contact, or disconnection in
wiring harness between work equipment controller L27 (female)
(17) - D01 (2), (1) - NEUTRAL SW (3)
3) Defective contact or disconnection in wiring harness between
NEUTRAL SW (1) and chassis ground
63
Joystick potentiometer system
61
20-706
1) Defective boom angle potentiometer

2) Short circuit with power source, short circuit with ground, defective
contact, or disconnection in wiring harness between work
equipment controller L27 (female) (20) and JS7 (1)

Condition when normal (voltage, current, resistance)
TROUBLESHOOTING
when abnormality is
detected

on machine when
there is abnormality
Resistance between work equipment controller L27 (female)

Less than 1
output: OFF
Impossible to use
joystick
actuated

and L27 (9): 0.5 - 4.5 V
(voltage when joystick is at neutral: Approx. 2.5 V)
output: OFF
Impossible to use
joystick
actuated

and chassis ground: 20 - 30 V)
2) Resistance of relay coil between work equipment controller
L28 (female) (8) and chassis ground: 200 - 400
3) Resistance of wiring harness between work equipment
controller L28 (female (8) and JS9 (female) (1)
4) Resistance of wiring harness between steering solenoid cut
relay JS9 (female) (2) and chassis ground: Less than
1
output: OFF
Impossible to use
joystick
actuated
Troubleshooting
code
J-6
J-7
J-8
20-707
TROUBLESHOOTING
ELECTRICAL CIRCUIT DIAGRAM FOR JOYSTICK SYSTEM
ELECTRICAL CIRCUIT DIAGRAM FOR JOYSTICK SYSTEM
20-708
J-1
TROUBLESHOOTING
J-1
Failure code [56] (Short circuit, disconnection in caution relay

output) is displayed
When the joystick steering lever is not being used, leave it at the neutral position and turn the joystick steering selector switch
ON.
Always turn the starting switch OFF before disconnecting any connector
20-709
TROUBLESHOOTING
J-2
J-2
Failure code [57] (Short circuit in steering right solenoid (detected

when output)) is displayed
This troubleshooting is carried out when there is still an abnormality, so when disconnecting the connector and inserting the
T-adapter, or when removing the T-adapter and returning the connector to its original position, if the failure code is no longer
displayed on the monitor display, the problem has been removed.
ON.
20-710
J-3
TROUBLESHOOTING
J-3
Failure code [58] (Short circuit in steering left solenoid (detected

when output)) is displayed
ON.
20-711
TROUBLESHOOTING
J-4
J-4
Failure code [59] (Short circuit in steering right solenoid (HOT end)
is displayed
ON.
20-712
J-5
TROUBLESHOOTING
J-5
Failure code [60] (Short circuit in steering left solenoid (HOT end) is
displayed
ON.
Always turn the starting switch OFF before disconnecting any connector to connect the T-adapter (or socket adapter).
20-713
TROUBLESHOOTING
J-6
J-6
Failure code [61] (Short circuit, disconnection in steering solenoid

cut relay output) is displayed
ON.
20-714
J-7
TROUBLESHOOTING
J-7
Failure code [62] (Short circuit, disconnection in joystick steering

neutral signal) is displayed
ON.
20-715
TROUBLESHOOTING
MEMORANDA
-MEMORANDA-
20-716
J-9
TROUBLESHOOTING
J-9
Abnormality in power source, voltage
Check that fuse I (11) is normal.
ON.
20-717
TROUBLESHOOTING
J-10
J-10
Abnormality in joystick steering ON-OFF signal system
Check that fuse I (11) is normal.
ON.
20-718
J-11
J-11
TROUBLESHOOTING
Disconnection in steering right solenoid
ON.
20-719
TROUBLESHOOTING
J-12
J-12
Disconnection in steering left solenoid
ON.
20-720
TABLE OF CONTENTS
TROUBLESHOOTING
TROUBLESHOOTING OF MDC (MULTIPLE DISPLAY

AND CONDITION) MONITOR SYSTEM
(C MODE)
Electrical circuit diagram for MDC (Multiple Display and Condition) monitor system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
C- 1
When engine is running, engine oil level display shows Abnormal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
C- 2
When engine is running, battery electrolyte level display shows Abnormal . . . . . . . . . . . . . . . . . . . . . . . . . . .
C- 3
Abnormality in engine coolant level display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
a)
Display shows Abnormal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
b)
Display shows Disconnection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
c)
Display shows Short circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
C- 4
Abnormality in brake oil pressure display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
a)
When engine is running, display shows Abnormal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
b)
Display shows Disconnection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
c)
C- 5
Abnormality in engine oil pressure display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
a)
When engine is running, display shows Abnormal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
b)
When engine is stopped or running, display shows Disconnection . . . . . . . . . . . . . . . . . . . . . . . . .
c)
Only when engine is stopped, display shows Disconnection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
d)
C- 6
When starting switch is at ON(engine started), battery charge display shows Abnormal . . . . . . . . . . . . . .
C- 7
When starting switch is at ON(engine started), air cleaner display shows Abnormal . . . . . . . . . . . . . . . . .
C- 8
CAUTION item display shows Abnormal, but alarm buzzer does not sound . . . . . . . . . . . . . . . . . . . . . . . . .
C- 9
Monitor display does not show Abnormality, but alarm buzzer sounds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
C-10
CAUTION item display shows Abnormal, but warning lamp (CHECK lamp,
CAUTION lamp) does not flash . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
a)
CHECK lamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
b)
CAUTION lamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
C-11
Monitor display does not show any abnormality, but warning lamp (CHECK lamp,
CAUTION lamp) lights up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
a)
CHECK lamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
b)
CAUTION lamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
C-12
Service meter does not work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
C-13
Service meter is running when engine is stopped . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
C-14
Abnormality in fuel gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
a)
Display shows Disconnectionor low fuel level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
b)
Display always shows FULL and does not go down . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
C-15
Abnormality in engine coolant temperature gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
a)
b)
Display always shows lowest level and does not go up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
20-804
20-806
20-808
20-809
20-810
20-810
20-810
20-810
20-812
20-812
20-813
20-813
20-814
20-814
20-814
20-814
20-815
20-816
20-817
20-818
20-819
20-820
20-820
20-820
20-821
20-821
20-821
20-822
20-822
20-823
20-823
20-823
20-824
20-824
20-824
20-801
TROUBLESHOOTING
C-16
C-17
C-18
C-19
C-20
C-21
C-22
C-23
C-24
C-25
C-26
C-27
C-28
C-29
20-802
TABLE OF CONTENTS
Abnormality in torque converter oil temperature gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

a)
b)
Display always shows lowest level and does not go up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
When starting switch is turned ON, monitor is not actuated (KOMATSU is not displayed . . . . . . . . . . . . . . . .
a)
Main monitor CHECK lamps do not light up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
b)
Main monitor CHECK lamps light up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Does not switch to working memory (engine running) mode, or switches to check
before starting mode when engine is running . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Abnormality in MDC monitor display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
a)
Display color is abnormal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
b)
Display flickers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Even when switch is operated, nothing functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Does not switch to TV/video mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
a)
Stays at PARKING BRAKE APPLIED display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
b)
Display does not light up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Abnormality in memory data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
a)
Load meter data is not saved to memory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
b)
Maintenance time is not saved to memory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine speed stays at 0 rpm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pressure sensor display shows Disconnection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
a)
Sensor power source display also shows Abnormal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
b)
Only pressure sensor display shows Disconnection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Load meter cannot weigh load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
a)
Cannot carry out calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
b)
Can carry out calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Abnormality in lever switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
a)
Sub-total switch does not work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
b)
Cancel switch does not work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Printer does not print out . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Abnormality in antenna system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Abnormality in speaker system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
a)
Abnormality in right speaker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
b)
Abnormality in left speaker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
20-825
20-825
20-825
20-826
20-826
20-827
20-828
20-829
20-829
20-829
20-830
20-832
20-832
20-834
20-836
20-836
20-836
20-837
20-838
20-838
20-838
20-839
20-839
20-840
20-841
20-841
20-841
20-842
20-843
20-844
20-844
20-844
MEMORANDA
TROUBLESHOOTING
20-803
TROUBLESHOOTING
ELECTRICAL CIRCUIT DIAGRAM FOR MDC MONITOR SYSTEM
ELECTRICAL CIRCUIT DIAGRAM FOR MDC (MULTIPLE DISPLAY AND

CONDITION) MONITOR SYSTEM
20-804
ELECTRICAL CIRCUIT DIAGRAM FOR MDC MONITOR SYSTEM
TROUBLESHOOTING
20-805
TROUBLESHOOTING ELECTRICAL CIRCUIT DIAGRAM FOR MACHINE MONITOR SYSTEM
20-806
ELECTRICAL CIRCUIT DIAGRAM FOR MACHINE MONITOR SYSTEM TROUBLESHOOTING
20-807
TROUBLESHOOTING
C-1
When engine is running, engine oil level display shows "Abnormal'
Before starting troubleshooting, check the engine oil level again. (The engine oil level must be correct.)
20-808
C-1
C-2
C-2
TROUBLESHOOTING
When engine is running, battery electrolyte level display shows

"Abnormal"
Check that the cell where the battery electrolyte level sensor is installed is normal.
20-809
TROUBLESHOOTING
C-3
Abnormality in engine coolant level display
Before starting troubleshooting, check the engine coolant level again. (The engine coolant level must be correct.)
20-810
C-3
C-3
TROUBLESHOOTING
20-811
TROUBLESHOOTING
C-4
Abnormality in brake oil pressure display
20-812
C-4
C-4
TROUBLESHOOTING
20-813
TROUBLESHOOTING
C-5
Abnormality in engine oil pressure display
20-814
C-5
C-5
TROUBLESHOOTING
20-815
TROUBLESHOOTING
C-6
When starting switch is at ON (engine started), battery charge

display shows "Abnormal"
20-816
C-6
C-7
TROUBLESHOOTING
C-7 When starting switch is at ON (engine started), air cleaner display shows
"Abnormal"
Check that the air cleaner is not clogged.
20-817
TROUBLESHOOTING
C-8
C-8
CAUTION item display shows Abnormal, but alarm buzzer does

not sound
The buzzer does not sound for CHARGE or AIR CLEANER.

Check that fuse 1-10 is normal. If it is blown, check for a short circuit with the chassis ground in the wiring harness between
fuse 1-10 - FS2 (9) - L42 (1).
20-818
C-9
C-9
TROUBLESHOOTING
Monitor display does not show Abnormal, but alarm buzzer

sounds
20-819
TROUBLESHOOTING
C-10
CAUTION item display shows Abnormal, but warning lamp

(CHECK lamp, CAUTION lamp) does not flash
20-820
C-10
C-11
C-11
TROUBLESHOOTING
Monitor display does not show any abnormality, but warning lamp
(CHECK lamp, CAUTION lamp) lights up
20-821
TROUBLESHOOTING
C-12
Service meter does not work
C-13
Service meter is running when engine is stopped
20-822
C-12, C-13
C-14
C-14
TROUBLESHOOTING
Abnormality in fuel gauge
Before starting troubleshooting, check the fuel level again.

20-823
TROUBLESHOOTING
C-15
Abnormality in engine water temperature gauge
20-824
C-15
C-16
C-16
TROUBLESHOOTING
Abnormality in torque converter oil temperature gauge
20-825
TROUBLESHOOTING
C-17
When starting switch is turned to ON, monitor is not actuated

(KOMATSU is not displayed)
20-826
C-17
C-17
b)
TROUBLESHOOTING
Main monitor CHECK lamps light up

Check that the WAITING display on the remote control receiver portion of the monitor is flashing.
It will flash if the chamber temperature is high, so in this case, lower the chamber temperature.
20-827
TROUBLESHOOTING
C-18
20-828
Does not switch to working memory (engine running) mode, or

switches to check before starting mode when engine is running
C-18
C-19
C-19
TROUBLESHOOTING
Abnormality in MDC monitor display
20-829
TROUBLESHOOTING
C-20
Even when switch is operated, nothing functions
Before starting troubleshooting, check that there is no mistake in the operation of the switch.
20-830
C-20
C-20
TROUBLESHOOTING
- MEMORANDA -
20-831
TROUBLESHOOTING
C-21
Does not switch to TV/video mode
After turning the starting switch ON, keep the TV/video mode switch pressed for at least 2 seconds.
If the parking brake switch (indicator switch) is not ON, the system does not switch to this mode.
20-832
C-21
C-21
TROUBLESHOOTING
20-833
TROUBLESHOOTING
20-834
C-21
C-21
TROUBLESHOOTING
20-835
TROUBLESHOOTING
C-22
Abnormality in memory data
20-836
C-22
C-23
C-23
TROUBLESHOOTING
Engine speed stays at 0 rpm
20-837
TROUBLESHOOTING
C-24
Pressure sensor display shows "Disconnection"
20-838
C-24
C-25
C-25
TROUBLESHOOTING
Load meter cannot weigh load
20-839
TROUBLESHOOTING
20-840
C-25
C-26
C-26
TROUBLESHOOTING
Abnormality in lever switch
20-841
TROUBLESHOOTING
C-27
Printer does not print out
Check that the printer power is switched on.

Check that the paper is set properly and that the platen lever is lowered.
20-842
C-27
TROUBLESHOOTING AIR CONDITIONING
C-28
TROUBLESHOOTING
Abnormality in antenna system
20-843
TROUBLESHOOTING
C-29
Abnormality in speaker system
20-844
C-29
TROUBLESHOOTING

Air conditioner / heater (Denso) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Visual and audible inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Troubleshooting with manifold gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Troubleshooting the electrical circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cooler circuit troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Wiring diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
20-902
20-902
20-903
20-907
20-911
20-919
20-901
TROUBLESHOOTING
AIR CONDITIONER / HEATER

(DENSO)
TROUBLESHOOTING
Visual and Audible Inspection
Is the drive belt loose?
Are condenser fins blocked or clogged -- covered with
dirt or dust (condenser and air conditioner efficiency
both will suffer)?
Is the air filter clogged (clogged air filter will reduce air
flow and lower the cooling capacity)?
Are oil stains present in the refrigeration cycle
connections and joints (stains are evidence of
compressor oil, usually accompanied by refrigerant)?
Does the system contain the correct refrigerant quantity
as seen in the sight glass (only a small quantity of
bubbles appear)?
Is the system louder than usual (abnormal noise)?
Component
Check these items
Compressor
Shaft, cylinder head
Magnetic clutch
Worn or damaged bearing

Contact between stator and rotor
Loose mounting screw on stator
Blower motor
Upside down blower motor

Loose blower mounting
V-belt
Improper tension
Idle pulley
Worn mounting
Worn or damaged bearing
Piping parts
Improper fastening or mounting of

bracket or clamp
Incorrect clearance.
20-902
TROUBLESHOOTING
Troubleshooting with manifold gauge (refrigeration

cycle)
Trouble often can be detected and diagnosed for repair with
the help of a manifold gauge. The manifold gauge unit
indicates the refrigeration system pressure on both sides
(high and low pressure sides) simultaneously on the two
dials.
NOTE:
Be sure air has been purged from the

charging hoses of the manifold gauge by
using the refrigerant pressure in the system.
Normal Conditions
After engine warm-up, check the following conditions:
Engine speed
1500 rpm
A/C inlet temperature
30-35
Blower speed
HI
Temperature control
Maximum cooling
NOTE:
Gauge indications before A/C operation, both

high and low pressure sides: 5-8 kg/cm (0.5 0.8 Mpa).
(B) Insufficient refrigerant

Problem
Cause
Check and
remedy
Pressure low on
both low
pressure side
and the high
pressure side
Quantity of
refrigerant is too
small.
-Check for gas

leak and repair.
Bubbles visible in
sight glass
Air output is not
cool
Replenish
refrigerant.
Gas leakage
If pressure near
0, evacuate air
after repairing
leak.
20-903
TROUBLESHOOTING
(C ) Refrigerant fails to circulate (system clogged)

Problem
Cause
Check and
remedy
Vacuum is
immediately
indicated on low
pressure side
(completely
clogged).
Clogging of
A/C system.
-Check condition
of receiver,
expansion valves,
etc.
-A temperature
difference occurs
between IN and
OUT of the
defective parts.
-Evacuate air after
repair.
Vacuum
gradually
indicated on low
pressure side
(partially
clogged).
(D) Moisture in system
Problem
Cause
Check and
remedy
Normal
operation at first;
vacuum on low
pressure side is
indicated after
time.
Moisture in
expansion valve
freezes.
-Check condition
of expansion
valve, etc.
-Replace receiver
(or dryer)
-Evacuate air
after repair.
20-904
TROUBLESHOOTING
(E) Compressor failure

Problem
Cause
Check and
remedy
Pressure on low
pressure side is
high; pressure
on high pressure
side is low.
Compressor
defect.
-Check
compressor
condition.
-Compressor unit
is cool to the
touch if there is a
compression
malfunction.
When the A/C is

turned off, the
low and high
pressure sides
quickly equalize.
(F) Excessive refrigerant or insufficient condenser cooling

Problem
Cause
Check and
remedy
Pressure high
on both sides.
Bubbles not
visible in the
sight glass.
Poor cooling
performance.
Excessive
refrigerant.
-Check refrigerant
quantity and slowly
vent excess if
overcharged.
-Check and repair
condenser fan.
-Check engine
cooling system
Poor
condenser
cooling.
20-905
TROUBLESHOOTING
(G) Air in the system

Problem
Cause
Check and
remedy
Pressure high
on both sides.
Low pressure is
hot to the touch.
Bubbles are
visible in the
sight glass.
Air has entered

the system.
-Replace the
refrigerant.
-Evacuate the air
after the repair.
(H) Expansion valve opens too far

Problem
Cause
Check and
remedy
Pressure is high
on both sides.
Frost
(condensation)
appears on low
pressure side
piping.
Expansion valve
fault (problem
frequently
occurs after
replacing
expansion
valves).
-Check
condition of
expansion
valves.
-Check the
temperature
sensing bulb
condition and
installation.
20-906
TROUBLESHOOTING
Troubleshooting the electrical circuit

The flow charts on the following pages break down air conditioning problems into two categories: blower-related problems and
cooling equipment related problems. Check for blower troubles first, including such items as gauge fuse, circuit breaker, heater
relay, blower motor, blower resistor, and blower switch. Then check other air conditioning electrical components like air
conditioner fuse and switch, magnetic clutch and relay, sensors and wiring (input to amplifier) and amplifier. Cooler circuit
troubleshooting steps are shown on the next flow chart.
Blower troubleshooting
Start the engine and allow it to run at idle speed with the vehicle stationary. Follow the steps as shown in the chart. Descriptions
of the inspection metthods can be found on the pages that follow the flow chart.
20-907
TROUBLESHOOTING
20-908
TROUBLESHOOTING
Electrical circuit checks

Heater relay (steps 4 and 5)
Turn on the ignition switch and check input voltage at
terminal 5 and 3. If no voltage (0V), there should be open
circuit between heater relay and gauge fuse, or between
heater relay and the battery. Inspect the continuity with a
circuit tester or ohmmeter. Repair or replace as necessary.
Standard:
terminal No. 1-3

terminal No. 2-4
terminal No. 4-5
continuity
continuity
no continuity
Applying the battery voltage between terminal Nos. 1 and 3,

check continuity between terminal 4 and 5 (point is closed).
Blower switch (step 6)
If the blower doesnt operate correctly, remove the blower
switch connector and check the continuity between the
terminals with each switch position. If all conditions are good
reconnect the blower switch.
Check continuity between the heater relay terminals and the
blower switch terminals as follows.
(a) Check continuity between the heater relay terminal 1
and blower switch terminal 12, and between blower
switch terminal 9 and vehicle ground.
(b) Check the resistance betwen the heater relay terminal 4
and blower switch terminal 9 with each blower switch
position.
When changing blower switch position from OFF to HI, the
resistance value should change from a high value to a low
value.
20-909
TROUBLESHOOTING
Consult this troubleshooting flow chart for procedures to check the cooler equipment after problems with the blower circuit have
been ruled out. Details about the procedures appear on the pages that follow.
20-910
TROUBLESHOOTING
Cooler circuit troubleshooting

Air Conditioner switch
Step 1-2
Turn on the blower switch and air conditioner switch, check
the voltage of the amplifier at terminal 10.
If 12 volts is not present (battery voltage), the wiring
between the air conditioner fuse and the amplifier input
terminals is faulty (open circuit) or the A/C swtich is
defective.
Magnetic clutch relay

Step 4 and 4-1
Check that continuity exists between terminal no. 1 and 3
but not between terminals 2 and 4.
Apply the battery voltage between terminal 1 and 3, check
the continuity between terminals 2 and 4 (the point is
closed).
20-911
TROUBLESHOOTING
Condenser fan operation circuit

Step 2-2
Turn on the blower switch and A/C switch. Then inspect
the condenser fan operation .
Conditions
A/C
switch
Mag.
clutch
ON or
OFF
OFF
Coolant
temp.
(
below 83
above 90
ON
ON
ON
ON
Refrigerant
pressure
(kg/cm)
Fan
speed
Stop
below 12.5
below 83
HI
LO
below 83
above 15.5
above 90
below 12.5
HI
above 15.5
Under the low coolant temperature and low thermal load
(low room and ambient temperature) conditions, the fan
rotates at low speed with the magnetic clutch on, while as
the coolant temperature increases, the fan starts high speed
rotation.
In the case of high thermal load, the fan rotates at high
speed also.
Check four relays used in the condenser fan operation.
(a) Engine main relay (identical to the heater relay)
(b) Condenser fan relay (3), identical to magnetic clutch
relay.
(c) Condenser fan relay (2) differs slightly from the heater
relay in the terminal layout. Check continuity as follows:
continuity between terminals 5 and 2, 1 and 3. No continuity
between terminals 1 and 4.
Applying the battery voltage between terminals 5 and 2,
check the continuity between terminals 1 and 4 (point is
closed). Note that the diode permits current flow between
terminal 5 and terminal 2 in only one direction.
20-912
TROUBLESHOOTING
If the thermistor signal is wrong, check the resistance of the

termistor. Its resistance characteristics are shown in the
illustration.
Idle speed check

When the air conditioner switch is turned ON, the idle
speed should increase. Make sure the speed change
20-913
TROUBLESHOOTING
20-914
TROUBLESHOOTING
Troubleshooting
Setup:
Abbreviations:
Controller on Temp. 60
Defrost off, Fan on high
(A) Problem - EO error message display on the controller:
Possible Cause
Inspection
Remedy
1. Open EC power circuit
Check the EC circuit breaker for power,

voltage, and continuity
a) Repair the wiring

b) Replace open circuit breaker
2. Defective EC relay (circuit)
Check for output voltage on the yellow

wire, at the relay coil. Check the voltage
and continuity across the relay contacts.
a) Repair the connections / wiring

b) Replace the defective relay
3. Open EC voltage detection circuit
Check for input voltage on the brown

wire, at the controller.
a) Repair the wiring or connector
4. Improper wiring installation
Applicable to systems without an EC
a) See note #3
5. Defective controller
Check for output voltage on the yellow

a) Replace the controller
(B) Problem - E1 error message display on the controller:

Possible Cause
Inspection
Remedy
1. Abnormal A/C refrigerant

pressure(s).
* Cool weather operation may cause
low pressure short cycling
Check the refrigerant pressures with

gauges.
2. Opened compressor clutch circuit
Check for output voltage on the green

wire at the compressor. Check the wire
connections. Check for continuity across
the pressure switch(es) and thermostat.
Check the continuity of the clutch
solenoid to ground.
a) Repair the connections/wiring

b) Replace the defective switch(es)
or the thermostat
c) Replace the defective compressor
clutch
3. Opened pressure switch detection

circuit
Check for an input voltage on the tan

a) Repair the connections/ wiring
Check for output voltage on the green

High side greater than:

320 psig (R12), or 350 psig (R134a).
Low side less than:
3 - 6 psig.*
a) Check the condenser operation

for air and refrigerant blockage
b) Leak check system, repair the
leaks and recharge the system
c) Relocate the low pressure switch
to the evaporator outlet
20-915
TROUBLESHOOTING
(B) Problem continued

False E1 error message / cold weather charging problems:
(Occurs particularly when vapor charging in cold weather)
1.
E1 error message may occur during charging when the low pressure switch (LPS) opens at 3 psig. The suction
side pressure must rise above 45 psig to reset the E1 error message.
2.
When the system is fully charged, the E1 error message should not appear under normal operating conditions.
3.
In order to continue charging, by-pass the LPS, turn the controller offthen on, and set the controller to 60
This will reset the controller and force into the air conditioning mode.
4.
If the LPS cant be easily reached, disconnect the clutch wire at the compressor, and run a hot wire directly to the
compressor clutch solenoid. Take care not to short out the controller clutch circuit.
5.
E1 error message may occur while charging, when the compressor is wired hot.
(C) Problem - No Heat

Possible Cause
Inspection
Remedy
1. Opened heat solenoid circuit.

Poor connection, loss of voltage.
Check for an output voltage on the white

wire, at the heat solenoid valve. Check
the solenoid continuity to ground.
a) Repair connections/wiring
2. Defective heat solenoid or improper

installation.
Check for coolant blockages in the heat

solenoid valve and hoses.
Check the direction of coolant flow (feel
the hoses).
a) Repair or replace the valve.

b) Reverse the coolant hoses to the
valve.
Check for output voltage on the white

20-916
TROUBLESHOOTING
(D) Problem - No display, the blower fan will not turn off, when the power is turned on.
Possible Cause
1. Fan wires shorted to ground or
vehicle chassis
Inspection
Disconnect the controller from the
external harness, Individually check the
continuity of the orange and black fan
wires to ground, in the external harness.
Remedy
a) Unground and repair the shorted
wiring.
(E) Problem - Compressor clutch will not engage, unless defrost button is pushed.
Possible Cause
Inspection
Remedy
1. Defective preset thermostat inside

evaporator. Opened preset thermostat
circuit. Broken thermostat wiring.
Evaporator coil temperature too cold for
a/c operation.
Push, hold defrost / temperature

decrease buttons simultaneously. Check
display for OPor CLreadout.
Disconnect red leads, and check for
continuity across thermostat terminals.
a) If CL, go to step 2.
b) If OP, repair connections or
wiring to preset thermostat.
c) Replace preset thermostat.
2. Ambient cab temperature too cool

(below 60
Set controller at 68-70

Warm-up ambient temperature probe
with fingers or heat gun.
a) Verify if compressor clutch will pull

in or not.
b) If not go to step 3.
3. Opened ambient cab temperature

probe (thermistor)
Push, hold temp. Decrease/increase

buttons simultaneously. Display will read
40F if probe is defective. Disconnect the
controller, check for continuity across
black probe leads. Check resistance of
thermistor.
a) If display reads 49F, at room

temperature, replace thermistor.
b) Repair connections/wiring.
c) If 10K ohms +/- 20%, thermistor is
good. If 100K-1M ohms, replace
thermistor.
Notes:
1.
Wire colors may vary with installation. Refer to the wiring schematic.
2.
For 24V controllers, resistor (R17) must be clipped and removed from the circuit board. (Refer to figure below) If the resistor
is not clipped on the 24V system, the controller display will light up, but the blower fan will not turn on.
20-917
TROUBLESHOOTING
3.
For air conditioning systems that do not use an electric condenser, the blue and brown wires must be connected together, on
the external harness. The brown wire must be connected to the battery voltage, or the EO error message will result.
4.
Care must be taken during installation, not to pinch or cut wiring from the controller. Shorted wiring may result in damage to
the controller.
5.
Improper probe location of the evaporator coil thermostat sensor, or ambient cab temperature sensor, may cause short
cycling of the compressor.
6.
Eagle climate controllers are designed to use normally closed heat solenoid valves.
7.
Disconnect the vehicle battery leads, if a machine is to be inactive, or put into storage, for a period of a week or more. The
current drain from the controllers memory may result in a dead vehicle battery. An optional ignition relay may be installed to
disable the controllers memory function, when the key switch is turned off.
20-918
TROUBLESHOOTING
WIRING DIAGRAM
NOTES:
1.
2.
Wire Chart
Socket
Position the ambient temperature probe near waist high level, out of air flow and sun load.
Insert the sensing tube from present thermostat down into the evaporator coil, parallel to the coil face, between the
1st and 2nd rows, to a depth of the coil height minus 1 inch.
CONNECTOR DETAIL
Size
Color
Wire function
10GA
Red
Battery positive in
18GA
Red
evap coil thermostat in
18GA
Black
ambient thermistor in
18GA
Red
evap coil thermostat in
N/A
N/A
Not used
18GA
Black
ambient thermistor in
14GA
Orange
Fan positive out
16GA
Dk. Green
Clutch out
18GA
Dk. Blue
Ignition switch in
10
14GA
Black
Fan negative out
11
18Ga
Brown
Condenser blown fuse in
12
16GA
White
Heat solenoid out
13
18GA
Tan
Pressure switch detect in
14
16GA
Yellow
Condenser fan relay out
15
12GA
Black
Battery negative in
16
N/A
N/A
Not used
20-919
TROUBLESHOOTING
Sensor circuit
Servomotors
Body ground
Wire harness
Problem
Fuses
No.
Connectors
Main inspection areas
Others inspection items
Fuse blows easily
No blower operation
Heater relay, blower motor, blower

resistor, blower switch
Blower speed does not change
Blower resistor, blower switch
No compressor operation
Magnetic clutch and relay,

compressor, heater relay, A/C switch,
A/C amplifier
A/C lamp doesnt light
Engine speed signal lines, A/C

amplifier, A/C switch
A/C lamp flashes (only for compressor with

lock sensor)
Compressor, drive belt, A/C amplifier,

magnetic clutch
No A/C operation (cooled air does not come

out)
Cab temperature does not decrease

(insufficient cooling).
Water temperature switch (for variable

compressor type) A/C amplifier
Warm air doesnt come out.
Engine coolant volume, A/C

temperature control , heater radiator
10
No condenser fan operation.
Relays (for condenser fan, radiator

fan), condenser fan motor, condenser
fuse
11
No engine idle speed increase when A/C

switch is turned on.
Idle-up actuator, vacuum hose line, air

conditioner amplifier
20-920
30 DISASSEMBLY AND ASSEMBLY

Precautions when carrying out operation . . . . . . . . . . . 30-3
Special tool list . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-6
Sketches of special tools . . . . . . . . . . . . . . . . . . . . . . 30-11
Starting motor assembly . . . . . . . . . . . . . . . . . . . . . . 30-14
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-14
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-14
Alternator assembly . . . . . . . . . . . . . . . . . . . . . . . . . . 30-15
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-15
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-15
Engine oil cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-16
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-16
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-16
Fuel injection pump assembly . . . . . . . . . . . . . . . . . . 30-17
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-17
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-17
Water pump assembly . . . . . . . . . . . . . . . . . . . . . . . . 30-18
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-18
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-18
Injector assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-19
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-19
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-19
Turbocharger assembly . . . . . . . . . . . . . . . . . . . . . . . 30-20
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-20
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-20
After cooler assembly . . . . . . . . . . . . . . . . . . . . . . . . . 30-22
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-22
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-23
Cylinder head assembly . . . . . . . . . . . . . . . . . . . . . . . 30-24
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-24
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-26
Radiator assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-29
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-30
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-31
Damper assembly
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-32
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-32
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-33
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-36
Torque converter and transmission
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-41
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-44
Disconnection . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-45
Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-45
Torque converter
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-46
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-50
Transmission
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-58
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-75
Transfer assembly
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-92
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-96
Parking brake assembly
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-92
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-104
Transmission control valve (ECMV assembly)
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-108
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-108
Disassembly of center
support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-110
Assembly of center support . . . . . . . . . . . . . . . . . . . 30-112
Disassembly of drive shaft. . . . . . . . . . . . . . . . . . . . . 30-115
Assembly of drive shaft . . . . . . . . . . . . . . . . . . . . . . 30-118
Removal of front axle assembly . . . . . . . . . . . . . . . . 30-121
Installation of front axle assembly . . . . . . . . . . . . . . 30-122
Removal of front differential assembly . . . . . . . . . . . 30-123
Installation of front differential assembly . . . . . . . . . 30-125
Removal of rear axle assembly . . . . . . . . . . . . . . . . 30-126
Installation of rear axle assembly . . . . . . . . . . . . . . . 30-131
Removal of rear differential assembly . . . . . . . . . . . 30-132
Installation of rear differential assembly . . . . . . . . . . 30-133
Disassembly of differential gear assembly . . . . . . . . 30-134
Fine disassembly of pinion assembly . . . . . . . . . . . . 30-136
Fine disassembly of differential gear
case assembly . . . . . . . . . . . . . . . . . . . . . . . . . 30-137
Fine assembly of differential gear
case assembly . . . . . . . . . . . . . . . . . . . . . . . . . 30-138
Disassembly of final drive assembly . . . . . . . . . . . . . 30-146
Assembly of final drive assembly . . . . . . . . . . . . . . 30-149
Removal of orbit-roll assembly . . . . . . . . . . . . . . . . . 30-153
Installation of orbit-roll assembly . . . . . . . . . . . . . . . 30-153
Disassembly of orbit-roll assembly . . . . . . . . . . . . . . 30-154
Assembly of orbit-roll assembly . . . . . . . . . . . . . . . . 30-159
Removal of steering cylinder assembly . . . . . . . . . . 30-166
Installation of steering cylinder assembly . . . . . . . . . 30-167
Disassembly of steering cylinder assembly . . . . . . . 30-168
Assembly of steering cylinder assembly . . . . . . . . . 30-170
Removal of steering valve assembly . . . . . . . . . . . . 30-172
Installation of steering valve assembly . . . . . . . . . . . 30-174
Removal of brake valve assembly . . . . . . . . . . . . . . 30-175
Installation of brake valve assembly . . . . . . . . . . . . . 30-176
Removal of slack adjuster assembly . . . . . . . . . . . . 30-177
Installation of slack adjuster assembly . . . . . . . . . . . 30-177
Disassembly of slack adjuster . . . . . . . . . . . . . . . . . 30-178
Assembly of slack adjuster . . . . . . . . . . . . . . . . . . . 30-179
Removal of brake assembly (front, rear) . . . . . . . . . 30-180
Installation of brake assembly (front, rear) . . . . . . . . 30-180
Disassembly of brake assembly (front, rear) . . . . . . 30-181
Assembly of brake assembly (front, rear) . . . . . . . . 30-184
Removal of hydraulic pump (switch &
PPC, loader, torque converter-transmission, steering)
assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-188
Installation of hydraulic pump (switch &
PPC, loader, torque . . . . . . . . . . . . . . . . . . . . . 30-189
Removal of hydraulic tank assembly . . . . . . . . . . . . 30-190
Installation of hydraulic tank assembly . . . . . . . . . . . 30-191
Removal of hydraulic filter assembly . . . . . . . . . . . . 30-192
Installation of hydraulic filter assembly . . . . . . . . . . . 30-192
30-1

Removal of PPC valve assembly . . . . . . . . . . . . . . .
Installation of PPC valve assembly . . . . . . . . . . . . .
Disassembly of PPC valve assembly . . . . . . . . . . . .
Assembly of PPC valve assembly . . . . . . . . . . . . . .
Removal of main control valve assembly . . . . . . . . .
Installation of main control valve assembly . . . . . . .
Assembly of main control valve . . . . . . . . . . . . . . . .
Removal of bucket cylinder assembly . . . . . . . . . . .
Installation of bucket cylinder assembly . . . . . . . . . .
Removal of boom cylinder assembly . . . . . . . . . . . .
Installation of boom cylinder assembly . . . . . . . . . .
Disassembly of boom and bucket
cylinders assembly . . . . . . . . . . . . . . . . . . . . . .
Assembly of boom and bucket cylinders
assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal of center hinge pin . . . . . . . . . . . . . . . . . .
Installation of center hinge pin . . . . . . . . . . . . . . . . .
Removal of work equipment . . . . . . . . . . . . . . . . . .
Installation of work equipment assembly . . . . . . . . .
Removal of bulkhead assembly . . . . . . . . . . . . . . . .
Installation of bulkhead assembly . . . . . . . . . . . . . .
Installation of engine hood assembly . . . . . . . . . . . .
Removal of floor frame assembly . . . . . . . . . . . . . . .
Installation of floor frame assembly . . . . . . . . . . . . .
Removal of counterweight . . . . . . . . . . . . . . . . . . .
Installation of counterweight . . . . . . . . . . . . . . . . . .
Removal of fuel tank assembly . . . . . . . . . . . . . . . .
Installation of fuel tank assembly . . . . . . . . . . . . . . .
Removal of cab assembly . . . . . . . . . . . . . . . . . . . .
Installation of cab assembly . . . . . . . . . . . . . . . . . . .
Removal of air conditioner
unit assembly . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation of air conditioner unit
assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
condenser assembly . . . . . . . . . . . . . . . . . . . . .
Installation of air conditioner
condenser assembly . . . . . . . . . . . . . . . . . . . . .
Removal of receiver tank . . . . . . . . . . . . . . . . . . . . .
Installation of receiver tank . . . . . . . . . . . . . . . . . . . .
compressor assembly . . . . . . . . . . . . . . . . . . . .
Installation of air conditioner compressor
assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
30-2
TABLE OF CONTENTS
30-193
30-193
30-194
30-194
30-195
30-197
30-202
30-206
30-207
30-208
30-209
30-210
30-212
30-215
30-221
30-225
30-229
30-230
30-231
30-232
30-233
30-235
30-236
30-236
30-237
30-238
30-239
30-241
30-242
30-243
30-244
30-244
30-245
30-245
30-246
30-246
PRECAUTIONS WHEN CARRYING OUT OPERATION

When carrying out removal or installation (disassembly or assembly) of units, be sure to following general
precautions.
1. Precautions when carrying out removal work.
If the coolant contains anti-freeze, dispose of it
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 th e
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 connectors
when disconnecting. Do not pull the wires.
Fit wires and hoses with tags to show thei r

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 with ample strength.
When using forcing screws to remove any
components, tighten the forcing screws
uniformly in turn.
Before removing any unit, clean the
surrounding area. Fit a cover to prevent any
dust or dirt from entering after removal.
Precautions when handling piping during disassembly.

Fit the following blind plugs into the piping after disconnecting it during disassembly operations.
1) Hoses and tubes using sleeve nuts.
Nominal
number
Plug (nut end)
Sleeve nut (elbow end)
Use the two items below as a set
02
07376-50210
07221-20210 (Nut), 07222-00210 (Plug)
03
07376-50315
07221-20315 (Nut), 07222-00312 (Plug)
04
07376-50422
07221-20422 (Nut), 07222-00414 (Plug)
05
07376-50522
07221-20522 (Nut), 07222-00515 (Plug)
06
07376-50628
07221-20628 (Nut), 07222-00616 (Plug)
10
07376-51034
07221-21034 (Nut), 07222-01018 (Plug)
12
07376-51234
07221-21234 (Nut), 07222-01219 (Plug)
2) Split flange type hoses and tubes.

Nominal
number
Flange (hose end)
Sleeve head (tube end)
Split flange
04
07379-00400
07378-10400
07371-40400
05
07379-00400
07378-10500
07371-30500
30-3
3) If the part is not under hydraulic pressure, the following corks can be used
Nominal
number
Part Number
06
Dimensions
D
07049-00608
08
07049-00811
6.5
11
10
07049-01012
10
8.5
12
12
07049-01215
12
10
15
14
07049-01418
14
11.5
18
16
07049-01620
16
13.5
20
18
07049-01822
18
15
22
20
07049-02025
20
17
25
22
07049-02228
22
18.5
28
24
07049-02430
24
20
30
27
07049-02734
27
22.5
34
2. Precautions when carrying out installation work.

Tighten all bolts and nuts (sleeve nuts) to the
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 pins and lock plates securely.
When coating with adhesive, clean the part
and remove all oil and grease, then coat the
threaded portion with two - three 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
anti-friction 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 eye bolts, check that there is no
deformation or deterioration, screw them in
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 four - five times, stopping the
cylinder 100 mm from the end of its stroke.
30-4
3. Next, operate the steering, bucket, and boom cylinders to the end of their
stroke three - four times, stop the engine, loosen air bleed plug (1), bleed
the air from the hydraulic tank, then tighten plug (1) again.
4. Raise the engine speed, repeat Step 3 to bleed the air, and repeat this
operation until no more air comes out from the plug.
5. After doing this, run the engine at normal speed.
When using the machine for the first time after repair or long storage,
follow the same procedure.
3. Precautions when completing the operation.

If the coolant has been drained, tighten the drain valve, and add water to the specified level. Run the engine
to circulate the water through the system. Then check the water level again.
If the hydraulic equipment has been removed and installed again, add engine oil to the specified level. Run the
engine to circulate the oil through the system. Then check the oil level again.
If the piping or hydraulic equipment have been removed, always bleed the air from the system after
reassembling the parts.
For details, see TESTING AND ADJUSTING, Bleeding air.
Add the specified amount of grease (molybdenum disulfide grease) to the work equipment parts.
30-5
SPECIAL TOOL LIST
SPECIAL TOOL LIST

Tools with part number 790T-000-0000 cannot be supplied (they are items to be locally manufactured).
Necessity:
Cannot be substituted, should always be used.
Extremely useful if available, can be substituted with commercially available part.
New/remodel: N: Tools with new part numbers, newly developed for this model.
R: Tools with upgraded part numbers, remodeled from items already available for other models.
Blank: Tools already available for other models, used without any modification.
Tools marked O in the sketch column are tools introduced in special sketches (See SKETCHES OF SPECIAL
TOOLS).
Component
Symbol
Installation of engine
cylinder head
Installation of engine
front seal, rear seal
Part Name
Nece Qty New/

Sketch Nature of work, remarks
ssity
remodel
790-331-1110
Wrench
795-521-1110
Push tool
2 2
790-101-5221
Grip
01010-51225
Bolt
01050-31640
Bolt
795-931-1210
Sleeve jig
3 2
795-931-1220
Sleeve jig
01050-31625
Bolt
01050-31645
Bolt
793T-615-1230
Push tool
1 2
793T-615-1240
Spacer
790-101-5421
Grip
01010-51240
Bolt
790-102-1871
Wrench
790-201-2730
Spacer
791-520-4140
Screw
3 3
02215-11622
Nut
01643-32780
Washer
790-101-2102
Puller (294.2
kN {30 ton})
79-101-1102
Pump
Assembly of damper
Part No.
2
B
Disassembly, assembly
of PTO
30-6
Tightening of head
assembly
Press fitting of front seal
Press fitting of rear seal
Press fitting of oil seal and

dust seal
Removal, installation of
round nut
Press fitting of PTO gear

bearing inner race

Component
Disassembly,
assembly of torque
converter assembly
Symbol
Part No.
SPECIAL TOOL LIST

Part Name
Repair stand
Necessity
Qty
New/
remodel
Sketch
790-501-5200
790-901-2110 Bracket
790-310-2160 Plate
799-301-1500 Oil leak

tester
Checking
actuation of
clutch piston
1 796-514-2000 Remover
2 796-515-2140 Adapter
Removal of
No.3 planet
gear shaft
2
Disassembly,
assembly of
transmission
assembly
Nature of work,
remarks
790-201-1702 Push tool kit

D
1
1
Press fitting of
No.3, No.4
carrier bushing
1741
4
1
5021
1
Disassembly,
assembly of
Orbit-roll
assembly
790-452-1200 Pilot ring tool
Centering of
body and upper
cover
790-452-1100 Installer set
Press fitting of
spacer
1 790-520-2510 Bracket
2 790-520-2610 Plate
Removal,
installation of
differential
assembly
1
F
2
Removal,
installation of
differential
assembly
790-501-5000 Repair stand
100V
790-501-5200 Repair stand
220V, 240V
1
2
H
Disassembly,
assembly of
differential
assembly
2 790-901-2110 Bracket
3 793-310-2160 Plate
1 793T-622-1120 Push tool
2 793T-622-1130 Spacer
3 790-101-5421 Grip
4 01010-51240
3
Bolt
1 792-525-1000 Micrometer
2 792-525-1230 Adapter
Press fitting of
dust seal and
oil seal of
coupling cage
Adjusting
preload of
bearing
30-7

Component
Symbol
Part No.
SPECIAL TOOL LIST

Part name
Necessity
Qty
New/
remodel
Sketch
1 793T-622-1110
Plate
2 790-101-5421
Grip
3 01010-51240
Bolt
Fixture
1 793-520-1805
Brake tester
2 793-520-1851
Nipple
1 793-520-2680
Installer
2 791-580-1600
Push tool
793T-622-1150
Press fitting of oil seal of

outer drum
of final drive assembly
of brake assembly
30-8
wheel hub
Checking leakage of brake
oil
Installation of floating seal

(gear end)
8
H
Nature of work, remarks
10 792-530-1630
Stud
1 793-520-2680
Installer
2 793-622-1200
Push tool
Installation of floating seal

(hub end)

Component
Symbol
Part No.
SPECIAL TOOL LIST

Part name
793-520-2630
Bar
793-520-2640
Push tool
793-520-2530
Guide
790-101-2300
Push puller
Press fitting of bearing of

top center hinge portion
2
790-101-2102
790-101-1102
Pump
793-520-2550
Guide
01010-31480
Bolt
01643-31445
Washer
793-520-2640
Push tool
790-101-2102
Puller (294.2
kN {30 ton})
790-101-1102
Pump
Repair stand
790-502-1003
or
790-502-2000
790-101-1102
Pump
790-330-1100
Wrench
assembly
cylinder head
790-302-1290
Socket (width
across flats
60 mm)
nut
790-201-1500
Push tool
Sketch
New/
remodel
Puller (294.2
kN {30 ton})
of hydraulic cylinder
assembly
Qty
6
center hinge
Necessity
Press fitting of bearing of

bottom center hinge
portion
Press fitting of dust seal
Steering cylinder
Boom cylinder
Bucket cylinder
All cylinders
30-9

Component
Symbol
1
SPECIAL TOOL LIST
Part No.
Part name
790-201-1702
Push tool kit
Necessity Qty
New/
remodel
Sketch
Press fitting of roll bushing
Steering cylinder
Boom cylinder
Bucket cylinder
All cylinders
Disassembly, assembly of
hydraulic cylinder
U
assembly
790-720-1000
Expander
796-720-1660
Ring
07281-01159
Clamp
796-720-1690
Ring
07281-02169
Clamp
796-720-1720
Ring
07281-02429
Clamp
790-102-2303
Wrench
assembly
790-102-4300
Wrench
assembly
790-102-4310
Pin
790-720-1000
Expander
796-720-1660
Ring
07281-01159
Clamp
792-610-1700
Charging tool
assembly
799-703-1200
Service tool
kit
799-703-1100
799-703-1110
799-703-1120
799-703-1400
Expansion of piston ring
Steering cylinder
Boom cylinder
Bucket cylinder
Disassembly, assembly of
accumulator assembly
2
X
3
Charging air conditioner

with gas
30-10
Vacuum
pump
Gas leak
tester
Removal, installation of round

head
Expansion of piston ring
Charging with N2 gas
110V
220V
240V

Note:
H3-2
Komatsu cannot accept any responsibility for special tools manufactured according to these sketches.
H6
30-11

H5-1
H3-1
30-12
B1-2
B1-1
30-13
STARTING MOTOR ASSEMBLY

REMOVAL OF
WARNING! Stop the machine on level
ground and install the safety bar on the
frame. Lower the bucket to the ground and
stop the engine. Then apply the parking
brake and put blocks under the wheels to
WARNING! Disconnect the cable from the
negative (-) terminal of the battery.
1. Remove catch, open side cover, then remove two

side covers.
2. Disconnect connector (1) and wire (2).
3. Remove ground connection (3), then remove
starting motor assembly (4).
4. For details, see Cummins Engine "Troubleshooting
and repair manual.
INSTALLATION OF
1. Fit gasket and install starting motor assembly (4),
then tighten together with ground connection (3).
2. Connect wire (2) and connector (1).
3. Install cover, close two side covers, then lock with
catch.
4. Connect cable to negative (-) terminal of battery.
and repair manual.
30-14
STARTING MOTOR ASSEMBLY
ALTERNATOR ASSEMBLY
ALTERNATOR ASSEMBLY
REMOVAL OF
WARNING! Disconnect the cable from the
1. Remove catch, then open side cover.
2. Disconnect wires (1, 2 and 3).
3. Remove bolt (4) of adjustment plate, then loosen
mounting bolt and nut (5).
4. Remove adjustment plate (6).
5. Move alternator assembly towards lower position to
loosen belt tension, then remove belt (7).
6. Remove mounting bolt and nut, then remove
alternator assembly.
and repair manual.
INSTALLATION OF
1. Install alternator assembly (8), then partially tighten
mounting bolt and nut (5).
2. Fit belt (7) in pulley groove and install.
3. Install adjustment plate (6), and partially tighten
bolt (4) of adjustment plate.
4. Insert a bar between the alternator assembly and
cylinder block, raise the alternator and adjust the
belt tension.
The belt should deflect about 15mm when
pushed with a finger pressure of 6kg at a point
midway between the alternator and the fan
pulley.
5. Tighten the adjustment plate bolt, and the
alternator assembly bolt and nut.
6. Connect wires (3, 2 and 1).
7. Close cover, then lock with catch.
8. Connect cable to negative (-) terminal of battery.
and repair manual.
30-15
ENGINE OIL COOLER

REMOVAL OF
1. Remove catch, then open left engine side cover.
2. Loosen drain valve (1), and drain the cooling water.
If the coolant contains antifreeze, dispose of it
correctly.
3. Remove the turbocharger oil supply tube (3) and
the by-pass filter return tube (4).
4. Remove the cover and the water transfer tube (2).
5. Remove the full flow and by-pass filters (5).
6. Remove the oil cooler assembly, then remove the
remaining bolts from the support.
and repair manual.
INSTALLATION OF
1.
2.
3.
4.
Install the oil cooler support.

Install the oil cooler assembly (6).
Install the cover and the water transfer tube (2).
Install the turbocharger oil supply tube (3), and the
by-pass filter return tube (4).
5. Install the full flow and by-pass filters (5).
and repair manual.
30-16
ENGINE OIL COOLER
FUEL
INJECTION
ASSEMBLY
FUEL INJECTION PUMP ASSEMBLY
PUM P
REMOVAL
1. Remove the three engine side covers on the left
side.
2. Disconnect wire (1) to the fuel shut-off valve.
3. Remove control rod (2).
4. Disconnect the fuel inlet hose (3) and the air supply
hose (4).
5. Remove fuel tubing (5, 6, and 7).
6. Remove fuel pump (8).
and repair manual.
INSTALLATION OF
1. Install fuel pump (8), then install the drive spider
coupling.
2. Install fuel tubing (5, 6, and 7).
3. Connect the fuel inlet hose (3) and air supply hose
(4).
4. Connect fuel shut-off valve wire (1).
5. Install control rod (2).
6. Install the three engine side covers, then lock with
catch.
and repair manual.
30-17
WATER PUMP ASSEMBLY

REMOVAL OF
1. Remove radiator assembly (see removal of
radiator)
2. Remove water pump belt (1).
3. Remove fan hub (2), and the water pump idler
pulley assembly (3).
4. Remove fan hub support bracket (4).
5. Remove air compressor coolant outlet tube (5).
6. Remove thermostat by-pass tube (6).
7. Remove coolant inlet transfer connection (7) from
the water pump.
8. Remove water pump assembly (8).
and repair manual.
INSTALLATION OF
1. Install water pump assembly (8) with a new gasket.
2. Install coolant inlet transfer connection (7) with a
new gasket.
3 Install coolant outlet tube (5), and the thermostat
by-pass tube (6).
4. Install fan hub support bracket (4).
5. Install fan hub (2), and the water pump idler pulley
(3).
6. Install water pump belt (1).
and repair manual.
30-18
WATER PUMP ASSEMBLY
INJECTOR ASSEMBLY
INJECTOR ASSEMBLY
REMOVAL
Preparatory work
Remove engine side covers, hood, and exhaust
pipe.
Remove cylinder head assembly, injector assembly, muffler, intake connector, and air
cleaner assembly, then disconnect all
injectors.
1. Remove mounting bolt (1) of the head cover, then
remove head cover (2).
2. Loosen adjusting screw locknut (3) and move the
injector push rod to the side.
3. Remove the injector link.
4. Remove injector hold down clamp (4).
5. Using injector puller (Cummins part #3376497),
remove injectors (5).
and repair manual.
INSTALLATION OF
Replace the three o-rings on each injector.
1. Install injectors (5) in the cylinder head injector
bore.
2. Install injector hold down clamp (4).
3. Install the injector link in each injector.
4. Align the push rod with the injector rocker lever,
turn the adjusting screw, and tighten locknut (3).
5. Install rocker lever head cover (2), and mounting
bolts (1).
and repair manual.
30-19
TURBOCHARGER ASSEMBLY
REMOVAL OF
Preparatory work
Remove hood, engine side covers, and exhaust
muffler.
To remove exhaust muffler and air cleaner
assembly
1. Disconnect inlet connector (1).
2. Disconnect oil supply tube (2), and drain tube (3).
3. Remove mount bolts (4), and remove turbocharger
assembly (5).
INSTALLATION OF
Replace gaskets and o-rings with new.
1. Fit new gasket and install turbocharger assembly
(5), then tighten turbocharger mounting bolts (4).
2. Fit new gasket, connect drain tube (2), and supply
tube (3).
3. Fit new o-ring and gasket, install inlet connector
(1).
4. Install exhaust muffler, hood, and side covers.
30-20
TURBOCHARGER ASSEMBLY
MEMORANDA
- MEMORANDA -
30-21
AFTER COOLER ASSEMBLY

REMOVAL OF
1. Engine hood and radiator grille.
a) Remove exhaust pipe (1), remove radiator
grille (2).
b) Refer to REMOVAL OF ENGINE HOOD
ASSEMBLY.
2. Ether injector.
a) Remove ether injector (3), and bracket (4).
3. Draining water.
a) Open radiator drain valve (5), and drain
coolant.
b) Open after cooler drain valve (6), and drain
coolant.
If the coolant contains antifreeze, dispose
of it properly.
4. Crossover connection.
b) Remove air crossover connection (7).
5. Hoses and hose clamps.
a) Loosen hose clamps (8).
b) Remove after cooler inlet hose (9), and outlet
hose (10).
c) Remove air compressor air inlet tube (11), and
after cooler signal tube (12).
d) Remove any other hoses which are attached to
the after cooler assembly.
6. After cooler assembly.
a) Remove after cooler assembly (13), and
mounting bolts.
and repair manual.
30-22
INSTALLATION OF
1. After cooler assembly.
a) Install the guide studs (14) in the cylinder head,
then install the after cooler assembly (13).
2. Hoses and clamps.
a) Install after cooler inlet hose (9), and outlet
hose (10), and tighten the hose clamps (8).
b) Install air compressor air inlet tube (11), and
after cooler signal tube (12).
c) Remove any other hoses which are attached to
the after cooler assembly.
3. Crossover connection.
a) Install air crossover connection (7).
4. Ether injector.
a) Install ether injector (3), and bracket (4).
5. Refilling coolant.
a) Close radiator drain valve (5), and after cooler
drain valve (6)
b) Add coolant through the radiator filler neck to
the specified level.
Run the engine to circulate the coolant through
the system.
Then check the coolant level again.
Coolant:
81
21.4 gal.
6. Hood and engine side covers.

a) Install left and right hand engine side covers.
b) Install hood (2), and exhaust pipe (1).
and repair manual.
30-23
CYLINDER HEAD ASSEMBLY

REMOVAL OF
a) Remove exhaust pipe (1), remove
grille (2).
b) Refer to REMOVAL OF ENGINE
ASSEMBLY.
a) Remove exhaust pipe (1), remove
grille (2).
b) Refer to REMOVAL OF ENGINE
ASSEMBLY.
radiator
HOOD
radiator
HOOD
2. Draining coolant.
1) Open radiator drain valve (3), and drain
coolant.
If the coolant contains antifreeze,
dispose of it properly.
3. Bracket.
1) Disconnect fuel control cable bracket (4).
4. Drain tube.
1) Remove muffler drain tube (5).
5. Muffler.
1) Remove exhaust pipe (6), then loosen the
pipe clamps.
2) Disconnect aspirator pipe (7), then remove
clamp (8).
3) Sling muffler (9), then lift off.
30-24
6. Intake connector assembly

1) Disconnect aspirator intermediate hose (10).
2) Remove mounting bolts (11), loosen connector
clamp (13), then remove intake connector
(12).
7. Air cleaner assembly.

1) Remove air cleaner mounting band.
2) Remove intake connector bracket mounting
bolts (14).
3) Sling air cleaner assembly (15), then remove
air cleaner and intake connector as one unit.
Air cleaner assembly:
35 kg
(77 lb)
8. Cylinder heads.
1) Remove after cooler assembly (16).
2) Remove turbocharger assembly (17).
3) Remove exhaust manifold (18).

4) Remove water manifold (19).
5) For
details,
see
Cummins
Engine
"Troubleshooting and repair manual.
30-25

INSTALLATION OF
1. Cylinder head assembly.
1) Install new head gaskets on the dowel pins in
the cylinder block.
Make sure the side of the gasket marked
"TOP" is facing up.
2) For
details,
see
Cummins
Engine
"Troubleshooting and repair manual.
3)
4)
5)
6)
30-26
Install water manifold (19).

Install exhaust manifold (18).
Install turbocharger assembly (17).
Install after cooler assembly (16).
2. Air cleaner assembly.

1) Sling air cleaner assembly and intake
connector as one unit, then install the air
cleaner assembly (15).
2) Tighten the intake connector bracket mounting
bolts (14).
3) Secure the air cleaner mounting band.
3. Intake connector assembly.

1) Install a new gasket, then install the air intake
connector (12), tighten mounting bolts (11),
and install connector clamp (13).
2) Connect aspirator intermediate hose (10).
4. Muffler.
1) Sling the muffler assembly (9), then install.
2) Connect aspirator pipe (7), then install
clamp (8).
3) Install exhaust pipe (6), then tighten the pipe
clamps.
30-27

5. Drain tube.
1) Connect the muffler drain tube (5).
6. Bracket.
1) Connect fuel control cable bracket (4).
7. Refilling coolant.
1) Close radiator drain valve (5), and after
cooler drain valve (6)
2) Add coolant through the radiator filler neck
to the specified level.
Run the engine to circulate the coolant
through the system.
Then check the coolant level again.
Coolant:
81
21.4 gal.

1) Install hood, refer to INSTALLATION OF
ENGINE HOOD ASSEMBLY.
2) Install radiator grille (2), and exhaust pipe (1).
30-28
MEMORANDA
MEMORANDA
30-29
RADIATOR ASSEMBLY
REMOVAL OF
Loosen the oil cap slowly to release the
pressure inside the hydraulic tank. Then
operate the control levers several times
to release the remaining pressure in the
hydraulic piping.
1. Remove engine hood assembly, see REMOVAL
OF ENGINE HOOD ASSEMBLY.
2. Open radiator drain valve (1), and drain coolant.
If the coolant contains antifreeze, dispose of it
properly.
Coolant:
88
23.23 gal.
3. Disconnect aeration hose (2) and return hose (3).

4. Disconnect make-up line (4).
5. Remove fan guard (5).
6. Disconnect radiator outlet hose (6).
7. Disconnect torque converter cooler outlet and inlet
hoses (7).
8. Disconnect hydraulic cooler outlet and inlet hoses
(8).
9. Remove cover (9) at front bottom of radiator.

10. Loosen radiator mounting bolts (10).
30-30
RADIATOR ASSEMBLY
RADIATOR ASSEMBLY
11. Sling radiator assembly (11) and remove mounting

bolt (10).
Disconnect supports from radiator, loosen
supports at frame, and rotate out of way.
12. Lift off radiator assembly.

Sling the radiator assembly, and lift off while
moving radiator to the rear.
Be careful, and make sure the cooling fan
does not interfere with the radiator core.
Radiator assembly: 330 kg
(728 lb.)
INSTALLATION OF
Carry out installation in the reverse order to
removal.
Install so that the clearances between the fan and
fan guard at the left and right, and the top and
bottom are the same.
Add coolant through the radiator filler neck to the
specified level.
Coolant:
88
23.23 gal.
Add transmission oil through the oil filler to the

specified level.
Run the engine to circulate the oil and coolant
through the system.
Recheck oil and coolant levels again.
30-31
DAMPER ASSEMBLY
DAMPER ASSEMBLY
REMOVAL OF
WARNING! Stop the machine on level ground
and install the safety bar on the frame. Lower the
bucket to the ground and stop the engine. Then
apply the parking brake and put blocks under the
wheels to prevent the machine from moving.
1. Remove engine hood assembly. For details, see
REMOVAL OF ENGINE HOOD.
2. Remove bulkhead assembly. For details, see REMOVAL
OF BULKHEAD.
3. Disconnect switch pump suction tube (1) and outlet hose
(2), then remove switch pump + PPC pump (3).
4. Disconnect hydraulic pump suction tube (4) and outlet
tube (5), then remove hydraulic pump (6).
5. Disconnect steering pump outlet hose (7), remove tube
(8) at pump end.
6. Disconnect damper lubrication tubes (9) and (10).
7. Disconnect drive shaft (11). (Refer to note A).
8. Pull out flange (12).
9. Remove mounting bolt (13).
Remove the mounting bolt, insert a guide bolt, then
sling the cover and push the cover out with forcing
screws.
10. Lift off cover assembly (14).
Cover:
32 kg
(71 lb)
11. Sling damper assembly (15), then remove mounting bolt

(16) and insert guide bolt.
Pull out the damper assembly using forcing screws.
Damper assembly:
60 kg
(132 lb)
INSTALLATION OF
Carry out installation in the reverse order to removal.
Note A:
Mounting bolts:
DISASSEMBLY OF
1. Cover assembly.
30-32
110.7 12.7 Nm
(11.3 1.3 kgm)
(81.5 9 lbf.ft)
1) Remove elbows (1) and (2).
DAMPER ASSEMBLY
2) Remove mounting bolts, then using forcing

screws, remove cover (3).
Tighten the two forcing screws uniformly.
3) Remove oil seal (4) and o-ring (5) from cover

(3).
4) Turn over cover (6), then pull out shaft (7).

Cover: 29 kg
(64 lb)
30-33

5) Remove snap rings (8) and bearing (9) from
shaft (7).
6) Remove snap rings (10). (11), and oil seal (12)

from cover (6).
2. Damper.
1) Remove spacer (14).
2) Using forcing screws, remove flange (13).

Tighten the two forcing screws evenly.
30-34
DAMPER ASSEMBLY
DAMPER ASSEMBLY
3) Remove inner body (15) and rubber (16).
4) Remove snap ring (17) and oil seal (18) from

the inner body.
5) Remove flange (20) from outer body (19).

Screw in the mounting bolts, then tap with
a hammer to remove.
30-35

ASSEMBLY OF
1. Damper assembly.
1) Install flange (20) at bottom of outer body (19).
Contact surface of flange and outer body: Gasket
sealant (LG-4).
2) Press fit oil seal (18) in the inner body (15), then
assemble snap ring (17).
Fit the snap ring securely in the groove.
Set the oil seal with the sleeve on the snap ring
side, and fit it close in contact with the snap
ring.
Inside surface portion (hatched portion) of inner
body (15): Lithium base molybdenum disulphide
extreme pressure grease.
Fill the circumference uniformly with grease.
Lip of oil seal: Lithium base molybdenum

disulphide extreme pressure grease.
Brand of Lithium base molybdenum disulphide
Kyoto Oil Malleolus No.2 or equivalent.
Show Shell Sunlight TB-2 or equivalent.
Nippon Sekiyu Molytex No.2 or equivalent.
3) Assemble inner body (15) in outer body (19), then

assemble rubber (16).
Whole surface of rubber: Grease (G2-LI)
Outer surface of inner body: Grease (G2-LI)

Inner surface of outer body: Grease (G2-LI)
Between inner body and rubber: Grease (G2-LI)
30-36
DAMPER ASSEMBLY
DAMPER ASSEMBLY
Fill clearance "b" at four places evenly with

270g of grease.
4) Install flange (13), and tighten mounting bolts.

Contact surface of flange and outer body:
Gasket sealant (LG-4).
Mounting bolts: 66.6 6.9 Nm
(6.8 0.7 kgm)
(49 5 lbf.ft.)
2. Cover assembly.
1) Fit snap ring (11), then fit snap ring (10) after
press fitting the oil seal (12) in cover (6).
Press fit the oil seal with the lip face on the
bearing side.
2) Assem ble snap rings (8) and bearing (9) to
shaft (7).
Bearing portion "C" (hatched portion):
Lithium base molybdenum disulphide
Do not leave any space when filling with

grease.
Brand of Lithium base molybdenum
Kyoto Oil Malleolus No.2 or
equivalent.
Show Shell Sunlight TB-2 or
equivalent.
Nippon Sekiyu Molytex No.2 or
equivalent.
30-37

3) Press fit shaft (7) into cover (6).
4) Press fit oil seal (4) into cover (3), and install oring (5).
Oil seal portion "d" (hatched portion):
Brand of Lithium base molybdenum disulphide
Kyoto Oil Malleolus No.2 or equivalent.
Show Shell Sunlight TB-2 or equivalent.
Nippon Sekiyu Molytex No.2 or equivalent.
30-38
DAMPER ASSEMBLY
DAMPER ASSEMBLY
5) Set cover (3) on mounting position, and tighten

the mounting bolts.
6) Install elbows (1) and (2).

Elbow (1) and (2): Thread tightener (LT-2).
Elbow (1): 3.9 1.0 Nm
(0.4 0.1 kgm)
(3.0 0.7 lbf.ft)
Be careful of the direction of elbow (2).
30-39

3. Greasing.
1) Assemble damper to the engine, and connect
the grease hose, then fill the inside of the
damper with grease (310g) from portion "e".
Damper portion "e" (hatched portion):
Brand of Lithium base molybdenum

Kyodo Oil Molylex No.2 or equivalent.
Showa Shell Sunlight TB-2 or equivalent.
Nippon Sekiyu Molytex No.2 or
equivalent.
30-40
DAMPER ASSEMBLY
TORQUE
CONVERTER
TRANSMISSION
TORQUE CONVERTER, TRANSMISSION
AND
REMOVAL OF
Loosen the oil cap slowly to release the
pressure inside the hydraulic tank. Then
operate the control levers several times
to release the remaining pressure in the
hydraulic piping.
1. Drain oil.
Hydraulic oil:
120
31.7 gal.
Transmission:
62
16.4 gal.
2. Remove bulkhead assembly. For details, see

REMOVAL OF BULKHEAD ASSEMBLY.
3. Remove floor frame assembly. For details, see
REMOVAL OF FLOOR FRAME ASSEMBLY.
4. Remove drive shaft between switch + PPC pump,
loader pump, and engine - torque converter. For
details, see REMOVAL OF HYDRAULIC PUMP
ASSEMBLY
5. Disconnect drive shaft (1) between transmission
and rear differential at the transmission end. (Refer
to note A).
6. Disconnect drive shaft (2) between transmission
and center support at the differential end. (Refer to
note A).
30-41

7. Disconnect hose (3) from oil cooler on left side of
transmission and hose (4) leading to transmission
valve.
8. Disconnect transmission oil outlet tube (5)
9. Disconnect hoses (6) and (7) leading to steering

valve at right side of transmission.
10. Disconnect hose (8) to loader control valve.
11. Disconnect hydraulic tank outlet hose (9).

12. Remove clamps (10) and (11), then remove tube
(12).
13. Disconnect hoses (13) and (14) leading to

emergency brake valve from transmission control
valve.
14. Disconnect grease supply hose (15) at bottom of
transmission support.
30-42
15. Disconnect connectors (16), (17), and (18) at

bottom left of floor frame. (LR1 - 6 and TM1, 2).
16. Disconnect (19) at left side of center of machine.
(FR1, 2).
17. Remove filler tube (20).
18. Remove two mount bolts (21) at torque converter

end. (Refer to note B).
19. Disconnect parking brake hose (22) at bottom left
of transfer.
20. Remove four mount bolts (23) at transfer end.
(Refer to note B).
21. Raise transmission assembly (24) and remove
cushion.
22. Remove mounting bolts (26), then remove bracket

(27). (Refer to note C).
Remove the bracket and move the
transmission assembly to the left while slowly
raising the assembly.
30-43

INSTALLATION OF
removal.
Adjust the mount at the transfer end as shown i n
the diagram to the right.
Note A:
Drive shaft: 110.7 12.7 Nm
(11.3 1.3 kgm)
(81.0 9.0 lbf.ft)
Note B:
Mount bolt: 744.8 83.3 Nm
(76.0 8.5 kgm)
(549.0 61.0 lbf.ft)
Note A:
Bracket mounting bolts:
274.4 29.4 Nm
(28.0 3.0 kgm)
(202.0 22.0 lbf.ft)
Refilling hydraulic tank and transmission case
with oil.
Add oil through oil filler to the specified level. Run
the engine to circulate the oil through the system.
Then check the oil level again.
30-44
DISCONNECTION OF
1. Remove torque converter and transmission
assembly. For details, see REMOVAL OF
TORQUE
CONVERTER,
TRANSMISSION
ASSEMBLY.
2. Disconnect suction tube (1).
3. Remove flange (2).
4. Remove tube (3) between torque converter and
transfer.
5. Remove support (4).

6. Disconnect connector (5).
7. Remove mounting bolts (6), then lift off torque
converter assembly (7).
Using a lever block set, set with the torque
converter end at the top.
After setting the assembly in position, check
that it is stable, before removal of the lifting
tool.
CONNECTION OF
Carry out connection in the reverse order to
disconnection.
Note A:
Input shaft seal ring:
G2-LI
Make the protrusion from the shaft equal.

Be careful when pushing in. If the assembly is
pushed in by force, the seal ring (8) may be
damaged.
Torque converter mounting bolts:
110.7 12.7 Nm
(11.3 1.3 kgm)
(81.0 9.0 lbf.ft)
30-45
TORQUE CONVERTER ASSEMBLY

DISASSEMBLY OF
1. Disconnect torque converter and PTO
assembly from transmission assembly.
For details, see DISCONNECTION OF TORQUE
CONVERTER, TRANSMISSION ASSEMBLY.
2. PTO assembly
1) Set tool C to torque converter and PTO
assembly (1).
2) Remove holder (2) and coupling (3).
3) Using eye bolts a, sling PTO assembly.

4) Using forcing screw b, lift off PTO assembly
(4).
5) Disassemble PTO assembly as follows.

I) Remove retainer (5).
ii) Remove oil seal (6) from retainer (5).
iii) Remove bearing (7).
30-46
iv) Using tool B2, remove nut (8).

v) Using puller d, push out gear (9).
At this point, put in contact with the
bearing outer race and push the gear
out. Do not remove the gear.
vi) Remove bearing (10a).

vii) Using snap ring pliers, remove snap ring
(11)
viii) Remove spacer (12).
ix) Using gear puller e, pull out outer races

(13a) and (13b) approx. 10 mm.
x) Remove gear (9), then remove outer races
(13a) and (13b) and spacer (14).
xi) Remove spacer (40) and bearing (10b)
from gear (9).
3. Turbine case assembly

1) Leave two pump mounting bolts (15) on
diagonally opposite sides and remove other
mounting bolts.
2) Set with case at top and remove remaining two
mounting bolts.
3) Using eye bolt c , remove turbine and case
assembly (16).
30-47

4) Disassemble turbine and case assembly as
follows.
I) Remove shaft (17) and gear (18).
ii) Using snap ring pliers, remove snap ring
(19).
iii) Remove spacer (20).
iv) lnsert two round bars f from

l
hole and remove turbine assembly (21).
Push the inner race of the bearing with
a forcing screw.
v)
Using snap ring pliers, remove snap ring

(23) from case (22).
vi) Using push tool g, remove bearing (24).
4. Stator
1) Remove snap ring (25).
2) Remove stator (26).
30-48
5. Stator shaft, pump assembly.

1) Remove 10 mounting bolts (27).
2) Remove stator shaft and pump assembly (28)
from housing (29).
3) Disassemble stator shaft and pump assembly

as follows.
I) Remove two plugs (31) of stator shaft (30).
ii)
Using round bar (h), knock out bearing

inner race from hole where plug has been
removed, then remove pump assembl y
(32).
iii) Remove bolts, then remove retainer (33),

pump (34), and guide (35).
iv) Remove bearing (36) from guide (35).
30-49

ASSEMBLY OF
1. Stator shaft, pump assembly.
1) Assemble stator shaft and pump assembly as
follows:
I) Using push tool (j), press fit bearing (36)
(outside diameter: 120 mm) to guide (35).
After press fitting the bearing, apply
drops (6 cc) of engine oil (EO10-CD
or EO30-CD) and rotate 10 times.
ii)
Align with oil groove and install guide (35)

and retainer (33) to pump (34).
Mounting bolt:
Thread tightener (LT-2)
Mounting bolt:
59 - 74 Nm
(6 - 7.5 kgm)
(43.5 - 54.6 lbf.ft)
iii) Install seal ring (39) to stator shaft (30).

Apply grease to the seal ring and
make the protrusion from the shaft
uniform.
iv) Using push tool (k), press fit pump

assembly (32) to stator shaft (30).
30-50

v)
Install two plugs (31) to stator shaft (30).

Do not coat the plugs with adhesive.
Plug:
3 - 6 Nm
(0.3 - 0.6 kgm)
(2.2 - 4.4 lbf.ft)
2) Set housing (29) to tool C.

3) Install stator shaft and pump assembly (28).
Mounting bolt:
Mounting bolt:
59 - 74 Nm
(6 - 7.5 kgm)
(43.5 - 54.6 lbf.ft)
2. Stator.
1) Install stator (26).
2) Using snap ring pliers, install snap ring (25).
3. Turbine case assembly.

1) Assemble turbine case assembly as follows:
i) Using push tool (g), press fit bearing (24)
to case (22).
ii) Using snap ring pliers, install snap ring
(23).
30-51

iii) Using push tool (1), press fit turbine
assembly (21) to case (22).
Support the inner race of the case
bearing and press fit the turbine
assembly.
After press fitting, apply drops (6 cc) of
engine oil (EO10-CD or EO30-CD)
and rotate 10 times.
iv) Install spacer (20).

v) Using snap ring pliers, install snap ring
(19).
vi) Using push tool (m), press fit inner race
(37) to shaft (17).
vii) Install gear (18) and shaft (17) to case

(22).
30-52
Mounting bolt:
Mounting bolt:
59 - 74 Nm
(6 - 7.5 kgm)
(43.5 - 54.6 lbf.ft)
2) Using eyebolt (c), install turbine and case

assembly (16), then tighten 24 mounting bolts
(15).
Mounting bolt:
Mounting bolt:
49 - 59 Nm
(5 - 6 kgm)
(36 - 43.5 lbf.ft)
4. PTO assembly.
1) Assemble PTO assembly as follows:
i) Using push tool (n), press fit bearing (10b)
(inside diameter: 50 mm) to gear (9).
ii)
Set gear (9) to each pump mount portion

of housing (38).
Gear (spline portion): Grease (G2-LI)
iii) Using push tool (p), press fit outer race

(13b) (outside diameter: 90 mm).
Be careful of the mounting direction.
30-53

iv) Install spacer (14).
v)
Using push tool (p), press fit outer race

(13a) (outside diameter: 90 mm).
Be careful of mounting direction.
vi) Fit spacer (40), the using puller (q), press

fit bearing (10a) (inside diameter: 50 mm).
vii) Install spacer (12).

viii) Using snap ring pliers, install snap ring
(11).
30-54
ix) Using tool B2, tighten mounting nut (8).

Mounting nut:
Mounting nut:
392 - 441 Nm
(40 - 45 kgm)
(289 - 325 lbf.ft)
After tightening the mounting nut,

apply drops (6 cc) of engine oil
(EO10-CD or EO30-CD) to bearings
(10a) and (10b) and rotate 10 times.
Then check the tightening torque of
the mounting nut again.
x)
Using push tool (r), press fit bearing (7)

(outside diameter: 130 mm) to coupling
mount portion of housing (38).
After tightening the mounting nut,
apply drops (6 cc) of engine oil
(EO10-CD or EO30-CD) to bearings
(7) and rotate 10 times.
xi) Using push tool, press fit oil seal (6) to

retainer (5).
Lip of oil seal:
Grease (G2-LI)
Coat the oil seal press-fitting surface

of the retainer with gasket sealant
(LG-5).
When coating with gasket sealant,
coat the hole in the housing thinly, and
wipe off all gasket sealant that is
squeezed out.
xii) Fit O-ring and install retainer (5).

O-ring: Grease (G2-LI)
2) Fit O-ring, then using eyebolts (a), install PTO
assembly (4).
30-55

3) Fit O-ring and install coupling (3) and holder
(2).
30-56
Mounting bolt:
Mounting bolt:
157 - 196 Nm
(16 - 20 kgm)
(116 - 145 lbf.ft)

- MEMORANDA -
30-57
TRANSMISSION ASSEMBLY
DISASSEMBLY OF
1. Torque converter and PTO assembly.
Disconnect torque converter and PTO assembly.
For details, see DISCONNECTION OF TORQUE
CONVERTER, TRANSMISSION ASSEMBLY.
2. Cover.
Remove cover (1) from top of transmission control
valve.
Remove main relief valve (3).
4. Transmission control valve.

1) Remove wiring harness (4).
Disconnect the ECMV solenoid connector.
For details, see REMOVAL OF
ASSEMBLY (ECMV ASSEMBLY).
2) Remove parking brake hose (5).
3) Lift off transmission control valve assembly (6).
Remove the bolts at the positions marked
by arrows in the diagram on the right.
5. Lubrication tube.
Remove lubrication tube (7) from front of transfer.
6. Sleeves.
Using eyebolt a, remove four sleeves (8) (length:
74mm) and 1 sleeve (9) (length: 79mm).
30-58
7. Transmission, transfer assembly.

1) Using eyebolts b and chain block, raise
transmission and transfer assembly (10), then
set on block c with transfer assembly at
bottom.
2) Using eyebolts d, sling transmission

assembly (11), then using forcing screw e,
disconnect from transfer assembly.
8. Transmission assembly.
1) Remove 6 mounting bolts (12) from output
shaft end of transmission case assembly (11).
2) Set transmission case assembly (11) on block

c.
3) Remove 15 mounting bolts (13) from input
shaft of transmission case assembly (11).
30-59

4) Remove two tie bolts (14) shown in diagram on
the right, and install eyebolts f.
5) Lift off transmission assembly (16) from
transmission case (15), and set to g.
9. Checking actuation of clutch piston.

1) Install four sleeves (8) and 1 sleeve (9) to
transmission assembly (16).
2) Using tool D1, check actuation of piston before
disassembling.
3) After checking actuation of piston, remove four
sleeves (8) and 1 sleeve (9).
10. Input shaft, No. 1 carrier, housing assembly.

1) Remove remaining 10 tie bolts (14).
2) Using eyebolts h, remove input shaft and No.
1 carrier and housing assembly (17), and put
on block c.
3) Disassemble input shaft, No. 1 carrier and

housing assembly (17) as follows:
i) Using snap ring pliers, remove snap ring
(19).
ii) Remove No. 2 sun gear (20).
30-60
iii) Support housing (21), then using push tool

i, push input shaft (22) with press and
remove.
iv) Using snap ring pliers, remove snap ring
(166) from input shaft (22).
v) Remove seal ring (167).
vi) Using snap ring pliers, remove snap ring

(25).
Remove from the bearing inner race
end.
vii) Support housing (21), then using push tool

j, push No. 1 carrier assembly (26) with
press and remove.
viii) Remove spacer (27).
ix) Using snap ring pliers, remove snap ring

(169).
x) Remove bearing (170).
xi) Remove seal ring (171).
30-61

4) Disassemble No. 1 carrier assembly as
follows:
i) Remove snap ring (23).
ii) Remove No. 1 ring gear (24).
iii) Remove shaft (29) and ball (173) from No.
1 carrier.
Be careful not to lose ball (173).
iv) Remove two thrust washers (174), needle
bearing (175), and planetary gear (176).
v)
Remove sun gear (30) and spacer (31).
vi) Using push tool k, remove spacer and

bearing assembly (32).
vii) Using snap ring pliers, remove snap ring
(33) from spacer and bearing assembly
(32).
viii) Using push tool l, remove bearing (34).
ix) Using snap ring pliers, remove snap ring

(36) from No. 1 carrier.
x) Using push tool m, remove bearing (37).
30-62
11. No 1 spring.
Remove No. 1 spring (38).
12. No 1 plates, springs, No 1 discs.

Remove four No. 1 plates (39), 20 springs (41),
and four No. 1 discs (40).
13. Guide pins, plate.

Remove five guide pins (42) and plate (43).
14. Valve, spring.

Remove valve (44) and spring (45).
30-63

15. No 1, No 2 piston, housing assembly.
1) Using eyebolts n, lift off No. 1 and No. 2
piston and housing assembly (46).
Tap with a copper hammer to pull out the
dowel pin, then remove.
When raising the housing assembly, be
careful not to drop the No. 2 piston.
2) Using eyebolt o, remove No. 1 piston (48)
from No. 1 housing (47).
3) Turn over No. 1 housing, then remove No. 2
piston (52).
4) Remove seal ring (49) from No. 1 piston (48).

6) Remove seal rings (50) and (51) from No. 1

housing (47).
16. Plate.
Remove plate (54).
17. No. 2 springs.
Remove 10 No. 2 springs (164).
30-64
18. No. 2 discs, springs, No. 2 plates.

Remove four No. 2 discs (55), 20 springs (56), and
four No. 2 plates (57).
19. Spacer.
1) Using snap ring pliers, remove snap ring (58).
2) Remove spacer (59).
20. No. 2 carrier, housing assembly.

1) Using eyebolts p, lift off No. 2 carrier and
housing assembly (60).
2) Using snap ring pliers, remove snap ring (61)
from bearing inner end.
3) Support No. 2 housing assembly (62), then

using push tool q, push No. 2 carrier assembly (63) with press and remove.
Push the No. 2 carrier.
30-65

4) Disassemble No. 2 housing assembly (62) as
follows:
(64).
ii) Support No. 2 housing (65), then using
push tool r, push bearing (66) with press
and remove.
iii) Remove seal ring (67) from No. 2 housing

(65).
5) Disassemble No. 2 carrier assembly (63) as

follows:
i) Remove spacer (68).
ii) Remove ring gear (69).
iii) Insert thin rods into four holes (70) for

removing snap ring, then push snap ring
(71), and remove No. 2 carrier assembly
(163) from ring gear (72).
30-66
iv) Remove shaft (73) and ball (74) from No.

2 carrier (163).
v) Remove two thrust washers (75), needle
21. No. 3 springs.

Remove three No. 3 discs (79), 20 springs (80),
and two No. 3 plates (81).
23. No 3 piston.
1) Remove No. 3 piston (82).
2) Remove seal ring (158).
24. Guide pins.
Remove five guide pins (162).
25. No. 3 ring gear.
Remove No. 3 ring gear (83).
26. No. 3, No. 4 housing, No. 4 piston assembly.

1) Using eyebolts s, liftoff No. 3 and No. 4
housing and piston assembly (159).
2) Turn over No. 3 and No. 4 housing (84), and
remove No. 4 piston (86).
30-67

4) Remove two seal rings (85) from No. 3 and
No. 4 housing (84).
27. No. 4 springs.

29. No. 3, No. 4 carrier assembly.

1) Using bar t, push up No. 3 and No. 4 carrier
assembly (92) and remove.
2) Disassemble No. 3 and No. 4 carrier assembly

as follows:
i) Using tool D2, pull out No. 3 shaft (93) and
remove.
ii) Remove two thrust washers (95), needle
bearing (96), and No. 3 planetary gear
(97).
30-68
iii) Using round bar, knock pin (98) into No. 4

shaft (99).
iv) Using round bar u, knock out No. 4 shaft
(99) from No. 3 carrier end and remove.
v)
Remove two thrust washers (100), needle

bearing (101), and No. 4 planetary gear
(102).
vi) Using push tool v, push bearing (103)

with press and remove.
vii) Remove bushing (161).

viii) Remove No. 3 and No. 4 seal ring (104).
30-69

30. No. 4 sun gear.
2) Remove spacer (106) and No. 4 sun gear
(107).

1) Remove snap ring (108).
2) Remove No. 4 ring gear (109).
32. No. 5 housing, No. 5 piston assembly.

1) Using eyebolts w, lift off No. 5 housing and
No. 5 piston assembly (110).
When raising the housing, be careful not to
drop the No. 5 piston.
2) Using eyebolt o, remove No. 5 piston (112)
from No. 5 housing (181).
3) Remove seal ring (113) from No. 5 piston

(112).
4) Remove seal ring (111) from No. 5 housing
(110).
30-70
33. No. 5 plate.

Remove No. 5 plate (114).
34. No. 5 springs.
35. No. 5 discs, springs, No. 5 plate.
Remove two No. 5 discs (116), 10 springs (117),
and No. 5 plate (118).
36. Guide pins.

Remove 5 guide pins (119).
Remove No. 5 ring gear (120).
38. No. 5 plate.
Remove No. 5 plate (121).
39. No. 5 carrier assembly.

1) Remove nine mounting bolts (122).
2) Remove No. 5 carrier assembly (123).
3) Remove spacer (124) from No. 5 carrier
assembly (123).
4) Disassemble No. 5 carrier assembly (123) as

follows.
(182).
30-71

ii)
Remove shaft (125) and ball (126).

Be careful not to Iose baII (126).
iii) Remove two thrust washers (127), needle
40. No. 5 sun gear.
Remove No. 5 sun gear (130).
41. Spring, pin.

Remove spring (131) and pin (132).
43. No. 6 piston.

1) Remove No. 6 piston (136).
2) Remove seal ring (156).
44. Guide pins.

Remove five guide pins (153).
45. Seal ring.
Remove seal ring (154) from housing (149).
30-72
46. No 6 hub.
Remove No. 6 hub (137).
47. Output shaft.

1) Support cage, then push output shaft (139)
2) Remove two seal rings (140) from output shaft
(139).
48. Cage assembly.

2) Support No. 6 housing assembly (143), then
using push tool x, push cage assembly (144)
3) Using push tool nn, push bearing (145) with

press and remove from cage (146).
4) Remove two seal rings (147).
30-73

49. No. 6 housing assembly.
2) Using push tool y, remove bearing (150),

bushing (151), and ball (152) from housing
(149).
30-74
ASSEMBLY OF
1) Using push tool z, press fit bearing (150) to
No. 6 housing (149).
2) Using push tool aa, press fit bushing (151)
and ball (152) to No. 6 housing (149).

2. Cage assembly.
1) Install two seal rings (147) to cage (146).
Seal ring:
Grease (G2-LI)
2) Using push tool bb, No. 6 housing assembly

(143) to cage assembly (144) with press.
Push the inner race of bearing (150).

3. Output shaft.
1) Install two seal rings (140) to output shaft
(139).
Seal ring:
Grease (G2-LI)
30-75

2) Using push tool cc, press fit bearing (145) to
output shaft (139) with press.
3) Set No. 6 housing assembly (143) to g.
4) Using push tool dd, press fit output shaft and
Push bearing (145) of the output shaft.
4. Seal ring.
Install seal ring (154) to No. 6 housing (149).
Set the groove of the seal ring facing the
direction receiving the pressure.
Seal ring:
Grease (G2-LI)
5. Guide pin.
Install guide pin (153).
6. No. 6 piston.
1) Install seal ring (156) to No. 6 piston (136).
Seal ring:
Grease (G2-LI)
7. No. 6 gear.
1) Install No. 6 gear (137).
30-76
2) Install No. 6 piston (136).
8. No. 6 plates, springs, No. 6 discs.

Install two No. 6 plates (135), 15 springs (134), and
three No. 6 discs (133).
9. Pin, spring.
Install pin (132) and spring (131).
10. No. 5 sun gear.

Install No. 5 sun gear (130).
1) Assemble No. 5 carrier assembly as follows:
i) Assemble needle bearing (128) to
planetary gear (129), put washers (127) to
both ends, then set to No. 5 carrier.
Align the center of each part with the
shaft hole.
ii) Install shaft (125) and ball (126).
Check that the gear rotates smoothly.
30-77

3) Align position of dowel pin and install No. 5
carrier assembly (123).
Tap with a copper hammer to knock in the
dowel pin.
4) Install 9 mounting bolts (122).
Mounting bolt:
Mounting bolt:
157 - 177 Nm
(16 - 18 kgm)
(116 - 131 lbf)
5) Assemble spacer (124).

1) Assemble No. 5 housing assembly as follows:
i) Install No. 5 ring gear (120) to No. 5 plate
(121).
ii) lnstall guide pins (119).
iii) Install two No. 5 discs (116), 10 springs
(117), and No. 5 plate (118).
iv) Install 10 No. 5 springs (115).
v) Install No. 5 plate (114).
vi) Install seal ring (113) to No. 5 piston (112).
Set the groove of the seal ring facing
the direction receiving the pressure.
Seal ring:
Grease (G2-LI)
vii) Install seal ring (111) to No. 5 housing

(181).
Set the groove of the seal ring facing
the direction receiving the pressure.
Seal ring:
Grease (G2-LI)
viii) Install No. 5 piston (112) to No. 5 housing.
30-78
ix) Align position of dowel pin and install No.

5 housing and No. 5 piston assembly
(110).
Be careful not to drop the No. 5 piston.
Tap with a copper hammer to knock in
the dowel pin.
2) Fit clamps ee to No. 5 housing assembly

(157) to hold in position.
3) Using eyebolts w, install No. 5 housing
assembly (157).

1) Install No. 4 ring gear (109).
2) Install snap ring (108).

Install three No. 4 discs (89), 15 springs (90), and
two No. 4 plates (91).
15. Springs.
Install 10 springs (88).
30-79

16. No. 4 piston.
Install seal ring (87) to No. 4 piston (86).
Seal ring:
Grease (G2-LI)
17. No. 3 piston.

Install seal ring (158) to No. 3 piston (82).
Seal ring:
Grease (G2-LI)
18. No. 3, No. 4 housing.

1) Install two seal rings (85) to No. 3 and No. 4
housing (84).
Seal ring:
Grease (G2-LI)
2) Install No. 3 piston (82) and No. 4 piston (86)

to No. 3 and No. 4 housing (84).
3) Using eyebolts s, lift off No. 3 and No. 4
When raising the housing, be careful not to
drop the No. 4 piston.
dowel pin.
19. No. 4 sun gear, spacer.
1) Install No. 4 sun gear (107) and spacer (106).
20. No. 3, No. 4 carrier assembly.

1) Assemble No. 3 and No. 4 carrier assembly as
follows:
i) Install seal ring (104) to No. 3 and No. 4
carrier (160).
Seal ring:
30-80
Grease (G2-LI)

ii)
Using tool D3, press fit bushing (161) to

No. 3 and No. 4 carrier (160).
iii) Using push tool ee, press fit bearing

(103) to No. 3 and No. 4 carrier (160).
iv) Assemble needle bearing (101) to No. 4

planetary gear (102), put thrust washers
(100) to both ends, then set to No. 4
carrier.
shaft hole.
v) Align roll pin hole and install No. 4 shaft
(99).
The deviation between the position of
the No. 4 shaft and carrier roll pin hole
must be less than 0.2 mm.
vi) Install roll pin (98).
Install so that the side of the roll pin
with the slit is facing the planetary
gear.
vii) Assemble needle bearing (96) to No. 3
planetary gear (97), and put thrust
washers (95) to both ends, then set to No.
4 carrier.
viii) Install No. 3 shaft (93) and ball (94).
30-81

2) Install No. 3 and No. 4 carrier assembly (92).
Put plate ff to No. 3 and No. 4 carrier
assembly (92), then press fit the bearing
inner race portion to the output shaft.

Install No. 3 ring gear (83).
22. Guide pins.
Install guide pins (162).

Install three No. 3 discs (79), 20 springs (80), and
two No. 3 plates (81).
24. No. 3 springs.
Install 10 No. 3 springs (78).
25. No. 2 carrier, housing assembly.

1) Assemble No. 2 carrier assembly as follows:
i) Set snap ring to No. 2 carrier (163) and
install ring gear (72).
ii) Set snap ring (71) in groove of ring gear
(72).
30-82
iii) Assemble needle bearing (76) to planetary

gear (77), put thrust washers (75) to both
ends, then set to No. 2 carrier.
shaft hole.
iv) Install shaft (73) and ball (74).
v)
Install spacer (68) and ring gear (69) to

No. 2 carrier assembly.
2) Assemble No. 2 housing assembly as follows:

i) Install seal ring (67) to No. 2 housing (65).
Seal ring:
Grease (G2-LI)
ii)
Support No. 2 housing (65), then using

push tool gg, press fit bearing (66) with
press.
iii) Using snap ring pliers, install snap ring
(64).
30-83

3) Support No. 2 carrier assembly (63), then
using push tool hh, press fit No. 2 housing
assembly (62) with press.
Press fit the bearing inner race.

5) Using eyebolts p, lift off No. 2 carrier and
26. Spacer.
1) Install spacer (59).

Install four No. 2 plates (57), 20 springs (56), and
four No. 2 discs (55).
30-84
Assemble discs (55), springs (56), and plates

(57) in the order shown in the diagram.
28. No. 2 springs.

29. Plate.
Install plate (54).
30. No. 1 piston, housing assembly.

Seal ring:
Grease (G2-LI)

Seal ring:
Grease (G2-LI)
3) Install seal rings (50) and (51) to No. 1 housing

(47).
Seal ring:
Grease (G2-LI)
4) Install No. 1 piston (48) and No. 2 piston (52)

to No. 1 housing (47).
30-85

5) Using eyebolts n, lift off No. 1 piston and
When raising the housing assembly, be
careful not to drop the No. 2 piston.
dowel pin.
31. Spring, valve.

Install spring (45) and valve (44).

1) Using push tool ii, press fit bearing (37) to No.
1 carrier (165).
3) Assemble needle bearing (175) to planetary

gear (176), put thrust washers (174) to both
ends, then set to No. 1 carrier.
Align the center of each part with the shaft
hole.
4) Install shaft (29) and ball (173).
5) Set No. 1 ring gear (24) to No. 1 carrier
assembly.
30-86
33. Input shaft.

1) Install seal ring (167) to input shaft (22).
Seal ring:
Grease (G2-LI)

3) Support No. 1 carrier assembly (26), then
using push tool i, press fit input shaft (22) with
press.
Press fit until snap ring (166) of the input
shaft contacts the bearing.
34. Spacer, sun gear.

Install spacer (31) and sun gear (30).
35. Bearing, spacer.
1) Using push tool jj, press fit bearing (34) to
spacer (136).
2) Using push tool kk, press fit spacer and

After assembling, check that the bearing
rotates easily.
36. No. 2 sun gear.

1) Install No. 2 sun gear (20).
37. Input shaft, No. 1 carrier assembly.
Raise input shaft and No. 1 carrier assembly (1 68)
and install.
30-87

38. Guide pins.
Install five guide pins (42).
39. Plate.
Install plate (43).

Install four No. 1 plates (39), 20 springs (41), and
four No. 1 discs (40).
Assemble in the order shown in the diagram.
41. No. 1 springs.

30-88
42. Housing.
1) Install seal ring (171) to housing (21).
Seal ring:
Grease (G2-LI)
2)
3)
4)
5)
Using push tool al, press fit bearing (170).

Using snap ring pliers, install snap ring (169).
Install spacer (27) to No. 1 carrier assembly.
Install housing (21).
Fit eyebolt an to the input shaft, then fit
the wire, apply slight tension to the wire,
and press fit the housing.
7) Install 10 tie bolts (14).
Tie bolt:
157 - 177 Nm
(16 - 18 kgm)
(116 - 131 lbf)
Do not install the two tie bolts at the

position where the eyebolts are installed.
43. Checking actuating condition and travel of piston.
1) Install four sleeves (8) and 1 sleeve (9) to
2) Using tool D1, check actuating condition and
travel of piston.
Air pressure:
0.29 - 0.49 MPa
(3 - 5 kg/cm)
(42 - 71 psi)
(mm)
Piston
Travel
No. 1
No. 2
5.5
No. 3
3.5
No. 4
4.5
No. 5
No. 6
4.2
3) Remove four sleeves (8) and 1 sleeve (9) from

30-89

44. Transmission assembly.
1) Install dowel pin (171) from output shaft end.
2) Install eyebolts fat positions shown by arrows
in diagram on right.
3) Put transmission case (15) on block c.
4) Raise transmission assembly (16) and install to
transmission case (15).
Align the position of the mounting bolt hole
on the top of the transmission.
Check that dowel pin (171) has entered
the transmission case.
5) Remove eyebolts f, and install remaining two
tie bolts (14).
Tie bolt:
157 - 177 Nm
(16 - 18 kgm)
(116 - 131 lbf)
6) Install six mounting bolts (12) to output shaft

end.
7) Install 15 mounting bolts (13) to input shaft
end.
Mounting bolt:
Mounting bolt:
98 - 123 Nm
(10 - 12.5 kgm)
(72 - 91 lbf)
45. Transmission case assembly.

1) Set transfer assembly (172) to block c.
2) Fit O-ring, then using eyebolts d, raise
transmission case (11) and install.
Mounting bolt:
30-90
98 - 123 Nm
(10 - 12.5 kgm)
(72 - 91 lbf)
46. Sleeves.
Fit O-ring and install four sleeves (8) (length:
74mm) and 1 sleeve (9) (length: 79mm).
47. Lubrication tube.
Install lubrication tube (7) to transfer.
48. Transmission control valve.

1) Fit O-ring to transmission case and valve seat,
then raise transmission control valve assembly
(6) and install.
Tighten the mounting bolts in the positions
shown in the diagram on the right.
Check that there is an O-ring fitted to the
rear of the transmission case.
2) Install parking brake hose (5).
3) Install wiring harness (4).
Install the ECMV solenoid connector. For
details,
see
INSTALLATION
OF
(ECMV ASSEMBLY).
Fit O-ring and install main relief valve (3).
Mounting bolt:
44 - 54 Nm
(4.5 - 5.5 kgm)
(33 - 40 lbf)
50. Cover.
Install cover (1) to top of transmission control valve.
51. Torque converter, PTO assembly.
Connect torque converter and PTO assembly to
transmission assembly. For details, see
CONNECTION OF TORQUE CONVERTER AND
TRANSMISSION ASSEMBLY.
30-91
TRANSFER ASSEMBLY
DISASSEMBLY OF
1. Transmission.
Remove transmission assembly from transfer. For
details, see DISASSEMBLY OF TRANSMISSION
ASSEMBLY.
2. Parking brake assembly.
Remove parking brake assembly. For details, see
DISASSEMBLY OF PARKING BRAKE ASSEMBLY.
3. Input shaft cage assembly.
1) Using forcing screws a, remove input shaft
cage assembly (1).
2) Remove shims (2).
Check the number and thickness of the
shims at each mounting position, and keep
in a safe place.
4. Input shaft gear assembly.

1) Remove input shaft gear assembly (3).
2) Remove bearings (4) and (5) from input shaft
gear assembly (6).
5. Outer race.
1) Using push tool b, remove outer race (7)
from input shaft cage (34).
2) Remove outer race (35).
30-92
TRANSFER ASSEMBLY
TRANSFER ASSEMBLY
6. Strainer.
1) Remove cover (8).
2) Remove spring (9).

3) Remove strainer (10).
7. Intermediate shaft cage assembly.

1) Turn over transfer.
2) Using forcing screws c, remove intermediate
cage assembly (11) and shims (12).
shims at each mounting position, and keep
in a safe place.
8. Intermediate shaft gear assembly.

1) Remove intermediate shaft gear assembly
(14).
2) Remove two bearings (16) from intermediate
shaft gear (15).
30-93

9. Outer race.
1) Remove outer race (13) from intermediate
cage (32).
2) Remove outer race (17) from transfer case.
10. Coupling.
Remove holder (18) and coupling (19).
11. Cover.
1) Using forcing screws c, remove cove r
assembly (22) and shims (23).
2) Remove dust seal (25) and oil seal (26) from
cover(35).
30-94
TRANSFER ASSEMBLY
TRANSFER ASSEMBLY
12. Output shaft.

Using tool D4, remove output shaft (20) and spacer
(21).
13. Cage.
1) Using forcing screws d, remove cage and
2) Using push tool e, remove outer races (28a)
and (28b), collar (28c), and bearings (28d) and
(28e) from cage (29).
The
two
bearings
are
not
interchangeable, so keep them as
separate sets.
14. Spacer.
Remove spacer (30).
15. Output shaft gear.
Remove output shaft gear (31).
30-95
TRANSFER ASSEMBLY
ASSEMBLY OF
1. Outer race.
Using push tool f, press fit outer race (17) to
transfer case.

1) Using push tool g, press fit two bearings (16)
to intermediate shaft gear.
2) Install intermediate gear assembly (14).
3. Intermediate shaft cage assembly.

1) Using push tool h, press fit outer race (13) to
intermediate shaft cage (32).
2) Fit O-ring and install shims (12) and

intermediate shaft cage assembly (11).
Standard shim thickness: 2 mm
4. Adjusting preload of intermediate shaft bearing.

1) Remove cover (33).
30-96
TRANSFER ASSEMBLY
TRANSFER ASSEMBLY
2) Using tool D6 and torque wrench, measure

preload of intermediate shaft.
3) Adjust shims as follows:
i) Adjust with shims (12) so that preload is
0.29 - 0.54 Nm (0.03 - 0.055 kgm).
ii) After adjusting, add a further 0.1 mm o f
shim.
There are four types of shim
thickness: t=0.15, t=0.2, t=0.3, and
t=1.0
Check that there is no play in the gear.
If there is any play, adjust the shims
again.
4) After adjusting preload, remove intermediate
shaft cage assembly (11), shims (12), and
intermediate shaft gear assembly (14).
5. Outer race.
1) Using push tool i, press fit outer race (35) to
transfer case.
2) Using push tool i, press fit outer race (7) to
input shaft cage (34).
6. Input shaft gear assembly.
1) Using push tool j, install bearings (4) and (5)
to input shaft gear (6).
2) Install input shaft gear assembly (3).
7. Input shaft cage assembly.

Install shims (2) and input shaft cage assembly (1).
Standard shim thickness: 2 mm
30-97

8. Adjusting preload of input shaft bearing.
Using tool D7 and torque wrench, measure preload
of input shaft. If measurement is not within
standard, adjust with shim (2).
Preload standard value: 0.1 - 0.98 Nm (0.01 0.1 kgm)
There are four types of shim thickness: t=0.15,
t=0.2, t=0.3, and t=1.0
Check that there is no play in the gear. If there
is any play, adjust the shims again.
Reference: Standard value for preload when
assembling input shaft and intermediate shaft
(measure at input shaft end): 0.2 - 1.27 Nm
(0.02 - 0.13 kgm)
9. Output shaft gear.
Assemble output shaft gear (31) to transfer case.
10. Spacer.
Install spacer (30).
11. Outer race.

Using push tool k, press fit outer race (28a) to
cage (29).
12. Output shaft.
Assemble output shaft (20) and spacer (21), and
support with block l.
13. Cage assembly.

Fit O-ring and install cage assembly (36).
30-98
TRANSFER ASSEMBLY
TRANSFER ASSEMBLY
14. Bearing.
1) Using tool D5, press fit bearing (28d).
2) Press fit bearing (28e) in same way.
15. Outer race.

1) Install collar (28c).
2) Using push tool l, press fit outer race (28b).
16. Cover.
1) Using push tool, press fit oil seal (26) and dust
seal (27) to cover (37).
Oil seal:
Grease (G2-LI)
Oil seal press-fitting surface:

Gasket sealant (Three Bond 1110B)
When coating with gasket sealant, coat the
inside surface of the hole in the housing
thinly, and wipe off all the gasket sealant
that is squeezed out.
Dust seal:
Grease (G2-LI)
2) Adjust shims as follows:

i) Fit O-ring and install shims (23) and cover
assembly (22).
Do not tighten the mounting bolts.
ii)
Put feeler gauge between shims (23) and

cover assembly (22) and measure
clearance, adjust number of shims so that
clearance is 0.05 - 0.10 mm, then tighten
mounting bolts.
Standard shim thickness: 0.25 mm
30-99

17. Coupling.
1) Install coupling (19).
2) Fit O-ring and install holder (18).
Mounting bolt:
Mounting bolt: 662 - 829 Nm

(67.5 - 84.5 kgm)
(488 - 611 lbf)

Install intermediate shaft gear assembly again. For
details, see steps 2, 3, and 4.
Assemble the shims adjusted in step 4.
30-100
TRANSFER ASSEMBLY
PARKING BRAKE
PARKING BRAKE ASSEMBLY

DISASSEMBLY OF
1. Transmission.
Disconnect transmission assembly from transfer.
For
details,
see
DISASSEMBLY
OF
TRANSMISSION ASSEMBLY.
2. Coupling.
Remove holder (1) and coupling (2).
3. Sleeve.
1) Remove flange (3).
2) Using eyebolt I, remove sleeve (4).

1) Remove 12 mounting bolts (5).
Do not remove four mounting bolts (6).
2) Using forcing screws a, disconnect parking
brake assembly (7).
3) After removing forcing screws afrom parking

brake assembly (7), fit eyebolts band lift off.
30-101

5. Cover assembly.
1) Remove cover assembly (8).
2) Disassemble cover assembly as follows
i) Remove dust seal (9) and oil seal (10).
ii) Remove bearing (11).
iii) Remove dowel pin (29).
6. Springs.
Remove 18 outer springs (12) and 18 inner springs
(13).
7. Spacer assembly.
1) Remove spacer assembly (14).
2) Using push tool c, remove inner race (15)
from spacer (16).
8. Piston.
1) Using eyebolts d, lift off piston (17).
2) Remove seal rings (18) and (19).
30-102
PARKING BRAKE
PARKING BRAKE
9. Snap ring.
10. Plates, springs, discs.
Remove 9 plates (21), 8 springs (22), and 8 discs
(23).
11. Gear.
Remove gear (24).
12. End plate.
Remove end plate (25).
13. Housing.
Using snap ring pliers, install snap ring (26) from
housing (27).
30-103
PARKING BRAKE ASSEMBLY

ASSEMBLY OF
1.
Cover.
1) Assemble cover assembly as follows:
i) Using push tool f, press fit bearing (11).
ii) Install two dowel pins (29).
iii) Using push tool, press fit oil seal (10) and dust
seal (9).
Oil seal: Grease (G2-LI)
Oil seal press-fitting surface:
Gasket sealant (Three Bond 1110B)
Dust seal:
Grease (G2-LI)
When coating with gasket sealant, coat the

inside surface of the mount thinly, and wipe off
all the gasket sealant that is squeezed out.
2.
Spacer assembly.
1) Using push tool e, press fit inner race (15) to
spacer (16).
2) Install spacer assembly (14) to cover assembly (8).
3.
Springs.
Install 18 outer springs (12) and 18 inner springs (13) to
cover assembly (8).
4.
Piston.
1) Install seal rings (18) and (19) to piston (17).
direction shown in the diagram on the right.
Seal ring:
2)
Grease (G2-LI)
Set piston (17) on outer spring (12) and inner spring

(13).
Align the position of the hole in piston (17) and
dowel pin (27) of the cover assembly.
30-104
PARKING BRAKE
PARKING BRAKE
5. Housing.
1) Using snap ring pliers, install snap ring (20) to
housing (27).
2) Fit O-ring and install housing (27) to cover
assembly (8), then tighten four mounting bolts
(6).
Be careful not to twist the piston against
housing (27), and tighten the bolts
uniformly a little at a time.
6. Plugs.
1) Remove two plugs (28).
2) Tighten two mounting bolts of parking brake
assembly together with washers to mounting
portion of plug (28).
Tighten the bolts a little at a time in turn.
The piston is pulled when the bolts are
tightened.
7. Gear.
Install gear (24).
Be careful of the direction of mounting.
8. Plates, springs, discs.

Install 9 plates (21), 8 springs (22), and 8 discs
(23).
30-105

9. End plate.
Install end plate (25).
10. Snap ring.
11. Mounting bolts.
Remove two mounting bolts installed in Step 6 - 2),
then install two plugs (28).
Loosen the two mounting bolts a little at a time
in turn.
Plug:
Gasket sealant (LG-5)

Using eyebolts b, fit O-ring, raise parking brake
assembly (7) and install.
When installing, gradually mesh the spline on
the inside of spacer assembly (14) and gear
(24) with the spline of the output shaft, and
install.
Mounting bolt:

(10 - 12.5 kgm)
(72 - 91 lbf)
13. Sleeve.
1) Fit O-ring and install sleeve (4).
2) Fit O-ring and install flange (3).
30-106
PARKING BRAKE
PARKING BRAKE
14. Coupling.
1) Install coupling (2).
2) Fit O-ring and install holder (1).
Mounting bolt:

(67.5 - 84.5 kgm)
(488 - 661 lbf)
15. Transmission.
Connect transmission assembly and transfer. For
details, see ASSEMBLY OF TRANSMISSION
ASSEMBLY.
30-107
TRANSMISSION CONTROL
VALVE ASSEMBLY (ECMV
ASSEMBLY)
REMOVAL
1. Remove cover (1) between bulkhead and cab.
2. Remove transmission top cover (2).
3. Disconnect solenoid connector (3) and fill
connector (4).
When disconnecting the solenoid connector, hold
the ECMV body lightly with one hand, and hold the
connector housing with the other hand as shown in
the diagram on the right. Then lift up the connector
housing lightly in direction A and in this condition,
pull it in direction B to disconnect.
4. Remove four mounting bolts (5), then remove

ECMV assembly (6).
INSTALLATION
Clean around the valve before installing the ECMV
assembly.
When fitting the solenoid connector, align the lock
and guide as shown in the diagram on the right,
and push in.
Do not twist when inserting.
ECMV assembly mounting bolt:
31.4 3.9 Nm
(3.2 0.4 kgm)
(23 3 lbf)
30-108
TRANSMISSION CONTROL VALVE ASSEMBLY
CENTER SUPPORT ASSEMBLY

REMOVAL
Disconnect center drive shaft (1) from center
support.
Set a block under the drive shaft when removing.
Center drive shaft: 36.4 kg (80.1 lb)
2. Sling front drive shaft (2) and disconnect from
center support.
Front drive shaft: 44 kg (97 lb)
3. Disconnect grease tube.
4. Sling center support (4), remove mounting bolts,

then remove.
If there are shims between the center support and
frame, check the number and thickness of the
shims and use as a guide when assembling.
Center support: 43 kg (94.8 lb)
30-109

removal.
Center drive shaft mounting bolt:

110.7 12.7 Nm)(800.7 91 lbf ft)
Front drive shaft mounting bolt :

110.7 12.7 Nm)(800.7 91 lbf ft)
Center support mounting bolt

548.8 58.8 Nm)(405.1 43.4 lbf ft)
30-110
DISASSEMBLY OF CENTER
SUPPORT
1. Coupling
Remove center bolt (1), then remove retainer (2),
O-ring (3), and coupling (4).
2. Retainer
Remove mounting bolts (5) or retainer.
Remove all mounting bolts while rotating
coupling.
3. Shaft
1) Set shaft case assembly (6) on press stand.
2) Push out shaft (7) with press.
Be careful because the shaft will fall out
suddenly.
3) Remove spacer (8), bearing cone (9) and retainer

(5) from shaft.
30-111

4. Oil seal
1) Remove oil seal (10 )and O-ring (11) from
retainer.
2) Remove oil seal (12) from case.

5. Case
Remove bearing cone (13) and bearing outer race
(14) and (15).
30-112
ASSEMBLY
SUPPORT
OF
CENTER
1. Bearing outer race

Assemble bearing outer race (14) and (15), in case
(16).
2. Oil seal
Assemble oil seal (10) in retainer (5).
Outer circumference of oil seal
Grease (G2-LI)
3. Bearing cone
Assemble retainer (5) shaft and press fit bearing
cone (9).
After assembling bearing, check that there is
no clearance at tip of shaft.
Assemble spacers.
Lip of seal : Grease (G2-LI)
Inner circumference of bearing
Grease (G2-LI)
4. Case
1) Assemble O-ring (11) in retainer.
Insert O-ring completely in groove.
30-113

2) Stand shaft and insert case (16).
Fill a" and "b" of case and inner
circumference of oil seal completely with
grease.
5. Retainer
Secure retainer (5) in case.
Be careful that O-ring does not get caught or
damaged when installing.
Mounting bolt:
65.7 6.9 Nm)(48.5 5.1 lbf ft)
6. Bearing seal
1) Press fit bearing (13) to shaft.
2) Assemble oil seal (12) in case.
Dimension of seal press fit and outer edge
of case: 0.5 mm
Seal: Grease (G2-LI)
7. Coupling
Assemble coupling (4), install O-ring (3) and
retainer (2), and secure center bolt (1).
Center bolt: 931 98 Nm (687.1 7.2
lbf ft)
30-114
8. Inspection of end play

Check that end play is within specified range.
End play: Less than 0.22 mm
If end play is 0", with the seal and bearing
coated with grease check that the free rotating
torque is less than 3.9 Nm (0.4 kgm).
30-115
DISASSEMBLY OF DRIVE SHAFT

1. Shaft
1) Remove shaft (2)
Make match marks a before removing to
ensure that the direction of the spider
assembly does not change.
Cover (1) and (1A) is caulked with a punch

at four places, so it must not be remove d
unless necessary.
When removing cover (1) and (1A) be
extremely careful not to damage cover (1),
(1A) and yoke (3).
When removing the caulking, raise the
caulking with a screwdriver.
2) Remove mounting bolts (4), then remove

spider assembly (5).
Make match marks on yoke and spider.
30-116
DRIVE SHAFT
DRIVE SHAFT
3) Remove bearing caps (6) from spider

assembly.
Remove strap (7) of cap.
4) When replacing bearing (8), seal (9), and

derling washer (10) from bearing cap (6),
replace whole cap assembly.
2. Yoke
1) Remove mounting bolts (11) from yoke (3),
then remove spider assembly (12).
Stamp match marks on the yoke and
spider.
2) Remove bearing caps (13) from spider

assembly.
30-117

3) When replacing bearing (14), seal (15), and
derling washer (16) from bearing cap (13)
replace whole cap assembly.
30-118
DRIVE SHAFT
DRIVE SHAFT
ASSEMBLY OF DRIVE SHAFT

1. Yoke
1) Install bearing (14), and seal (15) to bearing
cap (13).
Bearing, seal : Grease (G2-LI)
2) Assemble derling washer (16), and bearing

cap (13) to spider assembly (12)
Be careful not to damage bearing with
heat when welding strap.
Bearing cap: Grease (G2-LI)
3) Assemble spider assembly (12) to yoke (3).

Carefully align match marks.
Clean the mounting face of the bearing
cap by wiping with a clean cloth.
Mounting bolts :
142.2 9.8 Nm (104.9 7.2 lbf ft)
2. Shaft
1) Assemble bearing (8) and seal (9) in bearing
cap (6).
Bearing seal : Grease (G2-LI)
30-119

2) Assemble derling washer (10 )and bearing cap
(6) to spider assembly (5).
Be careful not to damage bearing with
heat when welding strap.
Bearing cap: Grease (G2-LI)
3) Assemble spider assembly (5) to shaft (2).

Carefully align match marks.
Clean the mounting face of the bearing
cap by wiping with a clean cloth.
Mounting bolt:
142.2 9.8 Nm (104.9 70.8 lbf ft)
4) Align match marks a, then install shaft (2) to

yoke (3).
Check that the direction of the spider
assembly is the same.
If the spline is worn, replace the whole
drive shaft assembly.
Spline: Grease (G2-LI)
30-120
DRIVE SHAFT
DRIVE SHAFT
5) lf cover (1) and (1A) has been removed, do as

follows.
Front and rear drive shaft.
Insert seal and retainer to cover (1) and
shaft (2), assemble cover (1), then caulk
with a punch on diagonally opposite sides.
Center drive shaft.
Insert shaft (2) to cover (1A), assemble
cover (1A), then caulk with a punch on
diagonally opposite sides.
30-121
REMOVAL OF
ASSEMBLY
FRONT
FRONT AXLE ASSEMBLY
AXLE

ground, install the safety bar on the frame,
and put blocks under the wheels to prevent
the machine from moving.
1. Insert block
n top face (1) of left and right
rear axle housings and frame (2).
2. Start engine, operate work equipment to raise front
axle, then set block
er front frame on left and
right sides and operate work equipment to lower
frame.
Check that the front wheels can be removed,
then lower the work equipment to the ground.
3. Sling left and right wheels (3), remove hub nuts,
then lift off.
Tire, wheel: 660 kg (1452 lb)
4. Disconnect front drive shaft (4) at differential end.
Make counter marks to act as a guide when

assembling.
5. Disconnect brake tube (5) from slack adjuster.

6. Remove brake tubes (6) and (7).
Seal the brake system with blind plugs after
disconnecting the piping.
30-122
FRONT AXLE ASSEMBLY
7. Sling one side of front axle assembly (8) and

set garage jack to other side.
8. Remove mounting bolts (9).
9. Operate crane and garage jack to lower the
axle assembly.
Be careful not to let the slack adjuster on
top of the axle housing hit the frame.
Front axle assembly: 1,850 kg (4070
lb)
10. Pull out front axle assembly from chassis.
INSTALLATION OF FRONT AXLE

ASSEMBLY
Carry out installation procedure in reverse order to
remove.
Hub nut: 470.4 49.0 Nm (347.2 36.2

lbf ft)
Drive shaft mounting bolt:

110.7 12.7 Nm (81.7 9.4 lbf ft)
Axle mounting bolt:

2744.0 294.0 Nm (2025 217 lbf ft)
30-123
FORWARD
FRONT DIFFERENTIAL ASSEMBLY
REMOVAL
OF
F R O NT
DIFFERENTIAL ASSEMBLY
ground, install the safety bar on, the frame,
1. Remove drain plugs (1) and (2), and drain oil.
Axle oil : 78
2. Operate work equipment to raise front axle, then
set stand under left side of axle.
3. Sling left wheel (3), then remove hub nut and lift
off.
4. Remove left and right final drive covers (4).
5. Using forcing screws

approx. 200 mm together with sun gear (6).
30-124
FORWARD
6. Remove front drive shaft (7).

Sling the drive shaft and lower it
slowly.
7. Remove two mounting bolts of differential

(8), and install guide bolt
Screw in the guide bolt fully and check that all
the threads have entered the hole.
First, screw in the guide bolt, then remove the
remaining mounting bolts.
8. Set lever block
ntial case (9), and set so
that differential assembly does not fall over.
Fit both ends of a lever block to the front frame
inspection window.
9. Pull out differential (8) approx. 20 mm from axle
housing (10) along guide bolts.
Be careful not to damage the O-ring.
10. Install tools H1-1 and H1-2 to garage jack, and
insert between differential and axle housing, then
install differential to tool H1-1.
11. Adjust lever block and height of jack, and remove
differential assembly slowly.
Differential assembly: 282 kg (620.4 lb)
12. Operate jack and pull out differential assembly (8)
to outside of chassis.
13. Remove O-ring (11).
30-125
FORWARD
INSTALLATION
OF
FRONT
remove.
Drain valve
151.9 24.5 Nm (112.1 18.1 lbf ft)
Hub nut: 470.4 49.0 Nm (347.2 36.2 lbf ft)

110.7 12.7 Nm (74.5 9.4 lbf ft)
Differential mounting bolt:

548.8 58.8 Nm (405.1 43.5 lbf ft)
Refilling with oil (axle)
Add oil through the oil filler to the specified level.
30-126
REMOVAL OF
ASSEMBLY
REAR
REAR AXLE ASSEMBLY
AXLE

1. Jack up chassis, set block under rear frame, and
support bottom of counterweight with stand
2. Sling left and right wheels (1), then remove hub nut
and lift off.
3. Disconnect rear drive shaft (2) from rear

axle.
Rear drive shaft: 37 kg (81.4 lb)
4. Disconnect hose (3) between brake pedal and

slack adjuster at slack adjuster end.
5. Disconnect tubes (4) and (5) between slack
adjuster and left and right wheel brakes.
Be sure to remove the brake tube before
removing the axle. There is danger that it may
be crushed.
30-127

6. Disconnect grease tubes (6) and (7) from axle
support at rear end.
7. Disconnect grease tube (8) from axle support at

front end.
Remove the clamps of the brake hose from
the support.
8. Secure axle support and rear axle with chain.
9. Remove mounting bolts, then using garage jack to

maintain balance, lower axle assembly.
Rear axle assembly: 1,710 kg (3762 lb)
10. Pull out rear axle assembly (9) from chassis.
Support both ends of the axle with jacks.
30-128
REAR AXLE ASSEMBLY
REAR AXLE ASSEMBLY
11. Remove front support (10) from rear axle.

Be careful not to damage the packing.
Front support: 95 kg (209 lb)
12. Remove packings (11) and (12) from front support.
13. Remove bushing (13) from front support.

Remove all dirt and oil from the bushing
mounting surface inside the front support.
14. Sling rear support, and remove thrust cap (14).
30-129

15. Remove thrust washer (15), thrust plate (16), and
thrust washer (17) from rear axle.
16. Lift off rear support (18).

Rear support: 115 kg (253 lb)
17. Remove packing (19) from rear support.
30-130
REAR AXLE ASSEMBLY
REAR AXLE ASSEMBLY
18. Remove bushing (20) from rear support.

Remove all dirt and oil from the bushing
mounting surface inside the rear support.
30-131
REAR AXLE ASSEMBLY
INSTALLATION OF REAR AXLE

ASSEMBLY
Installation is the reverse of removal procedure.
Hub nut: 471 49 Nm (347.2 36 lbf

ft)
110.7 12.7 Nm (745 7.9 lbf ft)
Rear support mounting bolt:
1,568 196 Nm (1157.3 144.7 lbf ft)
Soak a cloth with primer for Loctite Prism
adhesive, then wipe the adhesion surface at
the bushing end.
Adhesion surface at rear support end:
Instant adhesive Loctite Prism 411
(approx. 3g)
Install the bushing within five minutes of
coating it with primer.
Do not mix the primer with adhesive whe n
using it.
Be careful to install the packing with the lip
facing in the correct direction.
Lip of packing: Grease (G2-LI)
Rear axle mount portion: Grease (G2-LI)
Front support mounting bolt:

1,568 196 Nm (1157.3 144.7 lbf ft)
Coat the bushing the same as the rear axle.
Lip of packing: Grease (G2-LI)
Front axle mount portion: Grease
LI)
(G2-
Thrust cap mounting bolt:

279.3 29.4 Nm (206.14 21.7 lbf ft)
Thrust plate mounting bolt:

279.3 29.4 Nm (206.14 21.7 lbf ft)
30-132
REMOVAL OF REAR DIFFERENTIAL

ASSEMBLY
WARNING! Stop the machine on level ground, install
the safety bar on the frame, and put blocks under the
1. Remove rear axle assembly from chassis. For details, see
REMOVAL OF REAR AXLE ASSEMBLY.
Do not remove the rear support from the rear axle.
2. Remove plug (1) and drain axle oil.
Set so that the drain plug is at the bottom.
Axle oil: 78
3. Remove cover (2).
4. Using forcing screws, pull out drive shaft (3).

Pull the drive shaft out approx. 200 mm (7.8 in).
5. Using eyebolts, lift off rear differential assembly (4).
Rear differential assembly: 282 kg (620.4 lb)

Remove the O-ring from the housing mating surface.
30-133
INSTALLATION
OF
REAR
remove.

548.8 58.8 Nm (405.1 43.4 lbf ft)
Adjusting shims on shaft
Adjust the shims on the shaft if the differential
assembly or axle housing have been replaced.
1) Tighten mounting bolts of shaft (5) uniformly,
then measure clearance a between axle
housing and shaft.
(Do not assemble the shims. Tighten th e
mounting bolts to 3.9 0.1 Nm (2.89 lbf ft).)
2) Add 0.1 0.05 mm to the measurement fo r
clearance a, then select a shim within that
range and assemble it.
Shim thickness:
Clearance a + (0.1 0.05 mm)
Mounting bolt:
112.7 9.8 Nm (83.18 7.2 lbf ft)
30-134
DISASSEMBLY OF DIFFERENTIAL
GEAR ASSEMBLY
1. Set differential assembly (1) on special tools H2-1,
H2-2, and H-3.
Differential assembly: 230kg (506 lb)
2. Pinion assembly
1) Remove case (2).
2) Remove oil seal (3) and dust seal (3A) from

case.
3) Screw in jack screw (D (Thread dia. = 18 mm,

Pitch = 1.75 mm), and lift out pinion assembly
(4).
Check number of shims (5).
30-135

3. Differential gear case assembly
1) Remove left and right locks (6), and with a bar,
turn nut (7) until it become loose.
2) Remove mounting bolts (9) of cap (8).
3) Remove nut and lift out differential gear case

assembly (10).
30-136
FINE DISASSEMBLY OF PINION

ASSEMBLY
4. Bearing, collar, cage
1) Support cage (11), push shaft with press and
tack out pinion.
2) Remove bearing (12) and collar from cage.
3) Remove outer races (13) and (14) from cage

(11).
5. Pinion, bearing
1) Remove snap ring (15), then remove bearing
(16).
2) Remove bearing (17).
30-137
FINE DISASSEMBLY OF
DIFFERENTIAL GEAR CASE
ASSEMBLY
6. Bevel gear (large)
Remove mounting bolts, using eye-bolts (2)
(Thread dia. = 16 mm, Pitch = 2.0 mm), lift of f
bevel gear (18).
7. Bevel gear (small)

Remove thrust plate (19) and bevel gear (20).
8. Pinion gear, cross shaft
Remove pinion gear (21), cross shaft (22), and
washer (23) as one unit.

Remove bevel gear (24) and thrust plate.
10. Bearing
Remove bearing (26) from case (25).
30-138
FINE
ASSEMBLY
DIFFERENTIAL GEAR
ASSEMBLY
OF
CASE
1. Bearing
Using press fit kit (3) (120 mm inner diameter),
press fit bearing (26) to case (25).

Install thrust and small bevel gear (24) in case.
Align thrust with dowel pin and install.
3.
Pinion gear, cross shaft

Assemble pinion gear (21) and washer (23) with
cross shaft (22).
Align washer groove with dowel pin of case
and install.

Install bevel gear (20) and thrust plate (19).
30-139
5. Bevel gear (large)

Using eye-bolts (2) (thread dia. = 16 mm, Pitch =
2.0 mm), lift and install bevel gear (18).
Align pin hole of thrust and dowel pin on case
side and install.
FINE ASSEMBLY
ASSEMBLY
OF
PINION
6. Bearing
1) Using press fit kit (4) (26 mm inner diameter).
Install pinion bearing (17).
2) Using press fit kit (5) (55mm inner diameter),

install bearing (16).
Rotating surface of bearing:
Engine oil (EO30-CD)
7. Cage
1) Install outer races (14) and (13).
2) lnstall cage (11) to pinion assembly.
30-140
8. Collar
Install collar (27).
9. Bearing
Using press fit kit (4) (76 mm inner diameter),
install bearing (12).
ASSEMBLY OF DIFFERENTIAL
ASSEMBLY
Set differential case on special tools Hl-I, H2-2, and
H2-3.
10. Pinion assembly
1) Assemble shims (5) removed whe n
disassembled.
Standard shims thickness: 2.1 mm.
2) Using eye-bolts (5) (Thread dia.=12mm, Pitch
1.75 mm), install pinion assembly (4).
3) Remove oil seal (3) and dust seal (3A) to case.
Lip of oil seal : Grease (G2-LI)
Rear Lip of dust seal: Grease (G2-LI)
4) Fit O-ring to case, and install case (2).

Mounting bolt:
279.3 29.4 Nm (206.14 21.7 lbf ft)
Mounting bolt: Thread tightener (LT2)
30-141

5) Insert coupling (28), fit O-ring and tighten
holder.
Mounting bolt:
Mounting bolt:
921 98 Nm (607.6 72.3 lbf ft)
Fit the balancer (6) to bolt hole of coupling,
and measure the rotating torque.
Rotating torque: Max. 50.0 N (11.22 lb)
11 Differential gear assembly

Sling differential gear assembly (10) and install
case.
12. Nut, cap

1) Align nut (7) with differential case groove and
install.
2) Install cap (8) and tighten (9).

Mounting bolt:
Mounting bolt:
Check match marks on bearing cup
before installing.
Rotate bevel gear 20 - 30 times to settle in,
then tighten bolt.
30-142
Bearing pre-load adjustment steps are as

follows.
1) Install tool H4-1 and H4-2 to cap on both sides.
2) Measure clearance "a" between tool H4-2 with

tool H4-1.
3) Add 0.26 0.07 mm to measuremen t

dimension and set scale on tool H4-1.
The added dimension becomes the amount of
bending of the case, given before pre-load and
given after pre-load.
4) Tighten adjusting nut with bar until increased
amount becomes 0.26 0.07 mm.
Caution for pre-load adjustment

When adjusting nut is overtightened (in case
the amount of increased bending surpasses
the standard measurement), return adjusting
nut to position before adjusting. Then, while
rotating bevel gear, lightly tap bearing cap and
bevel gear with plastic hammer, and check that
there is no clearance in position b.
30-143

13. Adjusting tooth contact, backlash
Adjust the backlash, and at the same time adjus t
tooth contact.
1) Adjust backlash as follows:
i) Movement of bevel gear is done with
adjusting nut (7). At this time, so as not to
change pre-load pressurization of bearing,
turn nuts on both sides, the same amount
each, in same direction.
ii) Put dial gauge (3) in vertical contact with
forward and reverse sides of outer edge of
bevel gear tooth face, and while turning
adjusting nut, adjust until gauge meter
fluctuation becomes 0.3 - 0.4 mm.
Measure at three or four places, and keep the
pinion gear fixed when measuring.
2) Adjust tooth contact as follows:
i) Adjust bevel pinion by adjusting shims
between differential case and bearing
cage.
ii) Adjusting tooth contact
For details, see ADJUSTING TOOTH
CONTACT.
30-144
3) Adjusting tooth contact

Coat face 7 or 8 teeth of bevel pinion lightly with red lead (minimum). Hold the bevel gear by hand to act as
a brake, rotate the pinion gear forward and backward and inspect the pattern left on the teeth.
When adjusting the driven gear do not change the pre-load of the bearing. Turn the left and right adjusting nut, the
same amount each (check by the number of notches), in the same direction.
30-145

14. Lock
After adjusting tooth contact and backlash, install
lock (6).
Mounting bolt: Thread tightener (LT-2)
30-146
FINAL DRIVE ASSEMBLY
DISASSEMBLY OF FINAL DRIVE

ASSEMBLY
1. Tire assembly
Loosen hub nut, raise chassis with work equipment
or jack, insert support stand under axle, then sling
tire assembly, remove hub nuts, and lift off tire
assembly (1).
Tire assembly: 660 kg (1452 lb)
2. Draining oil
1) Remove drain plug (2) and drain oil.
Set so that the drain plug is at the bottom.
Axle oil: 78
rear)
3. Cover
Remove mounting bolts (3), then remove cover (4).
4. Drive shaft
Screw in bolt (1) (Thread dia.=12 mm, Pitch = 1.75
mm) in drive shaft, then pull out drive shaft
assembly (5) and remove.
5. Planetary carrier assembly

Remove mounting bolts (6), then using eyebolt (2)
(Thread dia.=12 mm, Pitch=1.75 mm), lift of f
planetary carrier assembly (7).
Use a bar to adjust the position of the center of
gravity when removing.
Planetary carrier assembly: 90 kg
(198.42 lb)
30-147

6. Ring gear
1) Using tool H6, secure wheel hub (8) and brake
housing (9).
Install tool H6 at three places at equal
distances.
Do not remove tool H6 until assembly Step 3.
2) Remove mounting bolts (10), then remove

retainer (11) and ring gear (12).
Check the number and thickness of shims on
the inside of the retainer.
Ring gear: 50 kg (110 lb)
7. Disassembly of planetary carrier

Using press, pull out shaft (13), then remove pinion
gear (14).
Lock ball (15) is fitted in the shaft, so be careful
not to lose the ball.
Write the serial number on the case and be
careful not to mix the removed parts with other
parts.
The bearings and other parts have settled as a
set, so make identification marks and be
careful not to mix with other parts.
30-148
8. Disassembly of ring gear

1) Remove lock plates (18) from ring gear hub
(17), then remove ring gear (19)
2) Pull out bearing (20) from ring gear hub (17).
30-149
ASSEMBLY OF FINAL DRIVE

ASSEMBLY
1. Assembly of ring gear
1) Press fit bearing (20) on ring gear hub (17).
After press fitting the bearing, check that there
is not clearance between the rib and bearing.
2) Set ring gear hub (17) on ring gear (19), then
install lock plates (18).
Install the lock plates with the wider ones on
the inside.
Remove all grease and oil from the bolt.
Mounting bolt:
Mounting bolt:
31.4 2.9 Nm (23.1 2.2 lbf ft)
2. Assembly of planetary carrier

Set pinion gear (14) in carrier case, insert ball (15)
in shaft (13), then press fit.
Press fit so that the hole for the lock ball is on
the outside circumference, then stop with the
hole at the front and align the holes.
After press fitting the shaft, check that the gear
rotates smoothly.
30-150
3. Wheel bearing adjustment

1) Insert ring gear assembly (12) in axle housing, fit retainer (11) tighten temporarily with
mounting bolts (10), and remove tool H6.
Measure thickness "b" of retainer before

installing. Do not insert shims in the retainer
when tightening temporarily.
Rotate the wheel hub 20 - 30 times and
tighten the bolts to a uniform torque.
Mounting bolt:
78.4 4.9 Nm (57.9 3.6 lbf ft)
2) Using a depth micrometer or dial gauge,

insert through measuring hole of retainer (21)
and measure clearance "a" from retainer to
face of housing.
ure at two places and take the
average.
0.3 mm added to measured valu e
difference C = a - b, becomes shim thickness.
the smallest number of shims whic h
gives the required thickness.
30-151

3) After installing tool H6 to brake housing and
wheel hub, remove retainer, insert the required number of shims and retainer, then
tighten mounting bolts.
When assembling shims, after installing
tool H6, always tighten the mounting
bolts uniformly to the specified tightening
torque.
Mounting bolt:
Mounting bolt:
279.5 29.4 Nm (206.1 21.7 lbf ft)
4. Planetary carrier
Fit O-ring, using eye-bolts (2) ( Thread dia. = 12
mm, Pitch = 1.75 mm) sling planetary carrier
assembly (7), set in mounting position and
tighten mounting bolts (6).
Because balance is bad, adjust the center of
gravity with a bar and install.
5. Axle shaft
Screw in bolt (D (Thread dia. = 12 mm, Pitch=
1.75 mm) in axle shaft and insert axle shaft assembly (5).
If the position of the sun gear does not match,
rotate the wheel hub to align.
6. Cover
Fit O-ring, install final drive cover (4), then tighten
mounting bolts (3).
Mounting bolt:
68.6 9.8 Nm (50.6 7 lbf ft)
30-152
7. Refilling with oil

Tighten drain plug (2), then remove level plug,
and add oil through oil filter to specified level. Set
the machine so that the level plug of the final drive
is at the bottom when refilling with oil.
Axle oil: Approx. 78
8. Tire assembly
Raise tire assembly (1), set to wheel hub, and
tighten temporarily with wheel nuts. Then jack up
chassis with work equipment and jack, remov e
stand under axle, lower chassis to ground and
tighten wheel nuts to specified torque.
Wheel nut: 470 49.0 Nm (347.4 36.2
lbf ft)
(Width across flats: 30 mm)
30-153
REMOVAL OF ORBIT-ROLL
ASSEMBLY
ground and turn the steering fully to the
right. Then stop the engine and put blocks
under the wheels to prevent the machine
from moving.
1. Remove cover (1) from steering column.
2. Remove joint lock bolt (2).
3. Disconnect four hoses (3).
Mark the hoses and their destinations to facilitate
reassembly.
4. Remove three mounting bolts (4), then remove

Orbit Roll assembly (5).
5. Remove joint lock bolt (6), then remove joint assembly (7).
6. Remove bolt (8), then remove bracket
(9).
INSTALLATION OF ORBIT-ROLL
ASSEMBLY
Joint lock bolt:

55.9 7.8 Nm (41.2 5.8 lbf ft)
Bracket mounting bolt :
51.9 7.8 Nm (38.3 5.8 lbf ft)
30-154
ORBIT-ROLL ASSEMBLY
ORBIT-ROLL ASSEMBLY
DISASSEMBLY OF ORBIT-ROLL
ASSEMBLY
Ensure a clean working environment.
1. Dirt or debris in the hydraulic system will cause
premature wear and erratic operation. Keep all
dirt and dust out of the hydraulic circuit.
2. Use a clean work bench when disassembling or
assembling the equipment.
3. Remove dirt from the exterior of the unit before
disconnecting any piping.
4. Always wipe dirt off the unit before placing it on
the work bench.
After disassembling, wash with a clean petroleum-base solvent, and blow dry with clean air.
Always ensure that there are no impurities in the
solvent or air.
If any other solvent is used, it may lead to
deterioration of the rubber seal. Never wipe
any part with a cloth or apply steam to the
unit.
The solvent is flammable. Keep flames and
sparks away.
PREPARATORY WORK
1) Fit blind plugs in the five ports in the valve
body, clean the outside, then remove the
blind plugs.
2) Install tube nut (1) to one of the ports.
3) Install in a vise (2) with the end cover at the
top.
Do not clamp the valve body directly in the
vise, which could damage or break the unit.
1. Remove 7 mounting bolts (1), insert screwdriver
between end cover assembly (2) and sleeve (3),
then remove end cover assembly (2).
After removing, check that there is no
damage to the edge of the hole in the end
cover.
30-155

2. Remove commutator (5) and washer (6).
Do not remove pin (4).
3. Using two mounting bolts (1), remove commutator

ring (7) and manifold (8).
4. Using two mounting bolts (1), remove rotor set (9)
and wear plate (10) in the same way as commutator ring and manifold.
5. Insert screwdriver between sleeve (3) and valve

body (11), then remove sleeve (3).
6. Remove drive link(12).
7. Remove ball (13).

8. Remove rod (14), roller (15), rod (16), and spring
(17).
30-156
ORBIT-ROLL ASSEMBLY
ORBIT-ROLL ASSEMBLY
9. Install in vise with input shaft (18) at the top, and

make counter marks with a punch in upper cover
(19) and valve body (11).
10. Remove four mounting bolts (20), then grip input
shaft (18), move it up, and remove input shaft,
upper cover, and valve spool assembly (23).
The valve spool is fitted in the body with an

extremely small clearance, so if a horizontal
force is applied, it will be impossible to
remove it. When removing the valve spool
from the housing, never apply any excessive
force.
11. Remove upper cover assembly (22) from input

shaft and valve spool assembly (23), then remove
shim (24) and spacer (25).
shims, and keep in a safe place.
12. Remove seal (26) and snap ring (27), then

remove spacer (28), seal (29), and seal ring
(30) from upper cover (19).
30-157

Seal (29) and seal ring (30) may form one unit.
13. Remove snap ring (31), thrust washer (32),

thrust bearing (33), thrust washer (34), and
wave washer (35) from input shaft (18).
14. Use punch pin (3) (3.0 mm dia, 16 mm length),

to remove needle roller (36) from input shaft
(18).
Cushion the input shaft with a wooden block to

prevent damage when striking with the hammer.
30-158
ORBIT-ROLL ASSEMBLY
ORBIT-ROLL ASSEMBLY
15. Set valve spool (37) facing bottom, then remove
torsion bar (38) and spacer (39) from input shaft
and valve spool assembly.
Do not remove needle roller (40) from the
torsion bar.
16. Set valve spool (37) facing bottom, then rotate

input shaft (18) until drive link (41) comes out.
17. Set valve spool (37) facing bottom, then rotate
input shaft (18) clockwise to a point where ball
comes out.
Ball (42) may come out by itself, so be
careful not to lose it.
Do not remove ball retaining spring (43)

unless it is to be replaced. When removing
it, hold the flat end with pliers and pull up
until it comes completely out from valve
spool (37). When doing this, be careful not
to damage the outside of the valve spool or
the control edge.
30-159
ASSEMBLY OF ORBIT-ROLL
ASSEMBLY
Before assembly, wash all parts with clean
petroleum based solvent and dry with air. Never
wipe with a cloth.
Check carefully that there is no debris or paint
on the edge of the lapped surface.
If there are no special instructions, do not coat
any parts with oil when assembling.
1. Set thrust washer (34), thrust bearing (33), and
thrust washer (32) to input shaft (18), and install
snap ring (31).
2. Install wave washer (35) to thrust bearing (33)
and thrust washer (34).
3. Install ball (42) inside valve spool (37).
4. To mesh the groove and ball, rotate

counterclockwise and insert input shaft (18) into
valve spool (37).
Keep the spool horizontal when doing this.
5. Fit center portion of torsion bar (38) between

thrust washer (34) and valve spool (37).
30-160
ORBIT-ROLL ASSEMBLY
ORBIT-ROLL ASSEMBLY
The positioning of the valve spool and input

shaft is carried out by inserting the torsion bar.
6. Check spline of input shaft (18) and drive link

(41), and align spline of valve spool (37), then
install drive link (41).
If the drive link and input shaft do not mesh,
rotate the input shaft slightly to carry out the
meshing.
When inserting the drive link, make sure that the
torsion bar is securely held in position.
If the drive link is assembled correctly, there will
be a clearance of 8.89 mm between the thrust
washer and valve spool.
If the relationship between the spool, drive link,
and input shaft is not correct, the steering unit
will not work properly.
7. Measure diameter L of pin (40) of torsion bar

(38) at several points and check that the
difference does not exceed 0.025 mm.
8. Set spacer (39) to torsion bar (38), then insert in
valve spool and input shaft assembly (23).
30-161

9. Using pin (3) (outside diameter: 3 mm), align pin
hole of input shaft (18) and torsion bar (38).
10. Using pin (1), knock pin (36) 0.8 mm in from
end face of input shaft.
11. Install spacer (25) on valve spool and input

shaft. If there is a lip at one end inside the
spacer, install so that the lip surface is facing
the wave washer.
12. Install input shaft and valve spool assembly (23)
to valve body (11).
The clearance is extremely small, so if any
sideways pressure is applied during assembly, it
will not work properly.
13. Set shim (24) on top of thrust washer, fit seal,
align counter marks of upper cover (19), then
install and tighten mounting bolts (20)
temporarily.
14. Set tool F1 in position, and install so that valve

body and upper cover are centered.
15. Tighten mounting bolts (20) and remove tool
F1.
Mounting bolt :
27.4 2.5 Nm (19.9 1.8 lbf ft)
30-162
ORBIT-ROLL ASSEMBLY
ORBIT-ROLL ASSEMBLY
16. Measure width

several places and check that the difference
does not exceed 0.025 mm.
17. Pull input shaft down, align drive link (12) with
spline of valve spool, then rotate spool so that
end face of spool and valve body are level with
each other.
18. Align pin (40) and drive link (12) and install.
19. Using depth gauge (6), measure installed height

h of end face of valve body and valve spool.
30-163

h = Within 0.063 mm.....
Not necessary to adjust shim.
If installed height h = 0.064 mm or more, repea t
Steps -12 through 19 to adjust the shim height so
that h = Within 0.063 mm.
20. Install ball (13).

21. Set rod (17) to spring (16), then fit to valve body
(11) and install roller (15) and rod (14).
22. Fit seal to valve body.
23. Before installing rotor, check rotor as follows.

1) Set the pin end of end cover assembly at top
and spline end of rotor assembly (9) at bottom, then check that rotor rotates freely inside
stator.
2) Measure thickness of rotor and stator, and

check that the difference is less than 0.18
mm.
3) Using feeler gauge (7), check that the clearance of the rotor from the stator is less than
0.18 mm.
30-164
ORBIT-ROLL ASSEMBLY
ORBIT-ROLL ASSEMBLY
24. Using guide pin (8), install wear plate (10), rotor
assembly (9), and manifold (8).
25. Fit seal to end cover assembly (2).
26. Set sleeve (3) and end cover assembly (2) in

position, tighten mounting bolts (1) uniformly, then
install sleeve, and remove end cover assembly.
27. Fit washer (6) to end cover assembly (2), and

install commutator (5).
Install the commutator so that the concav e
part is at the end cover assembly end.
Determine the position so that the oval hole of

the commutator is in line with one of the bolt
holes of the end cover assembly.
30-165

28. Install commutator ring (7).
29. Rotate input shaft so that tip of drive shaft is
aligned with oval hole in commutator.
30. Set end cover assembly (2) on sleeve (3), then
tighten five mounting bolts uniformly.
Mounting bolt:
6.9 0.6 Nm (60.7 5.2 lbf in)
31. Set input shaft end facing top, then install seal
ring (30) and seal (29).
Install the seals from the small diameter
end.
Seal ring (30) and seal (29) are stuck
together and are supplied as one unit.
Coat the new seal with oil and install from
the lip end.
When doing this, coat the inside with a
small amount of grease.
32. Using tool F2, install spacer (28) from small diameter end.
33. Install snap ring (27).
34. Fit seal (26) to input shaft, and fit to upper cover.
30-166
ORBIT-ROLL ASSEMBLY
STEERING CYLINDER
REMOVAL OF STEERING
CYLINDER ASSEMBLY
ground, install the safety bar on the
frame, and put blocks under the wheels
to prevent the machine from moving.
1. Remove bolts (1), loosen bolt (2), then rotate

cover (3) carefully towards rear of machine.
Rotate the cover using bolt (2) as the fulcrum.
The operating space is confined, so be
extremely careful when carrying out the operation.
2. Disconnect bottom hose (4).

3. Disconnect grease tube (5).
4. Remove mounting bolt (6), then pull out pin (7).
Note the number and thickness of the shims
to use as a guideline when assembling.
5. Disconnect head hose (8).
30-167

6. Remove mounting bolt (9), then pull out pin
(10).
Note the number and thickness of the shims
to use as a guideline when assembling.
7. Using lever block, lift off steering cylinder (11).
Carry out the removal operation for the
cylinder using two workers.
Be careful not to damage the cylinder rod.
Steering cylinder : 47 kg (103.4 lb)
INSTALLATION OF STEERING
CYLINDER ASSEMBLY
WARNING! When aligning the position of
the pin hole, use a bar. Never insert your
fingers in the pin hole.
Adjust the shims so that the clearance is
specified value.
Clearance a + b = Less than 1.0 mm
(The specified value is the same for both
the rod end and the bottom end.)
30-168
STEERING CYLINDER ASSEMBLY
DISASSEMBLY OF STEERING
CYLINDER ASSEMBLY
1. Set cylinder assembly (1) in tool U1.
2. Raise lock of cylinder head (2), then using tool
U2, remove cylinder head (2) from cylinder.
3. Pull cylinder head and piston rod assembly (3)

out from cylinder (4), then lift off.
Oil will come out when the piston rod
assembly is removed from the cylinder, so
catch it in a container.
4. Remove cylinder (4) from tool U1.
5. Set cylinder head and piston rod assembly in

tool U1, and, using power wrench (1) and
socket U3, loosen nut (5).
Power wrench: x 16
Socket U3: Width across flats: 60 mm
6. Remove nut (5), then remove piston assembly

(6), and cylinder head assembly (7) from rod
(8).
30-169

7. Disassembly of piston assembly
1) Remove wear ring (9).
2) Remove piston ring (10) from piston (11).
8. Disassembly of cylinder head assembly
1) Remove snap ring (16), then remove dust
seal (17).
2)
3)
4)
5)
6)
Remove rod packing (18).

Remove buffer ring (19).
Remove O-ring (20) and backup ring (21).
Remove O-ring (22).
Remove bushing (23) from cylinder head
(24).
30-170
ASSEMBLY OF STEERING
CYLINDER ASSEMBLY
Clean all parts, and check for dirt or damage.
Coat the sliding surfaces of all parts with engine
oil before installing. Be careful not to damage
the rod packing, dust seals or O-ring when
assembling.
1. Assembly of cylinder head assembly
1) Using tool U5, press fit bushing (23) to
cylinder head (24).
Be extremely careful not to deform the
bushing when press fitting.
2) Install buffer ring (19).
3) Install rod packing (18).
Be careful to install rod packing (18)
facing in the correct direction.
4) Using push tool, install dust seal (17) to
cylinder head (24).
6) Install O-ring (22).
7) Install backup ring (21) and O-ring (20).
Do not try to force the backup ring into
position.
Warm it in water (50 - 60
2. Assembly of piston assembly
1) Using tool U6-1, expand piston ring (10).
Place the piston ring on the expander
and turn the handle 8 - 10 times to
expand the ring.
2) Remove piston ring (10) from tooI U6-1, and
assemble on piston (11).
3) Fit tooI U6-2, on piston ring, then using clamp

U6-3, contact piston ring.
4) Assemble wear ring (9).
30-171

3. Set piston rod (8) in tool U1.
4. Assemble cylinder head assembly (7) and piston
assembly (6) no rod, then fit nut (5).
5. Using power wrench (1) and socket U3 tighten nut

(5).
Piston nut:
Power of power wrench (1)
X16
Width across flats of nut (5)
60 mm
Tightening torque of nut
1,765 176 Nm
(1302 132 lbf ft)
6. Remove piston rod and head assembly from tool

U1.
7. Set cylinder (4) in tool U1.
8. Raise piston rod and head assembly (3), and
assemble in cylinder (4).
9. Using tool U2, tighten cylinder head nut (2).

Cylinder head nut:
932.0 93.2 Nm (687.1 68.7 lbf ft)
10. Bend lock into notch on cylinder side.
11. Remove cylinder assembly from tool U1.
30-172
STEERING VALVE
REMOVAL OF STEERING VALVE

ASSEMBLY
ground and turn the steering fully to the
right. Then stop the engine and put
blocks under the wheels to prevent the
machine from moving.
1. Remove bolt (1), Ioosen bolt (2),then rotate cover
(3) carefully towards rear of machine.
Rotate the cover using bolt (2) as the
fulcrum.
extremely careful when carrying out the
operation.
2. Remove side cover (4).
3. Remove mounting bolts (5), and disconnect

bracket (6).
4. Remove mounting bolts (7), and disconnect
bracket (8).
5. Disconnect hose (9) between cut-off valve and

hydraulic tank.
6. Disconnect hoses (10) and (11) between cut-off
valve and loader circuit.
7. Disconnect hose (12) between steering valve and
cut-off valve.
Hose (12) is at the rear of the cut-off valve.
30-173

8. Disconnect tubes (13) between steering valve and
steering cylinder.
9. Disconnect tube, (14) between steering valve and
hydraulic tank.
10. Disconnect hose (15) between stop valve and

steering valve.
11. Disconnect hose (16) between stop valve and
steering valve.
It is connected to both ends of the steering
valve.

steering pump.
13. Disconnect tube (18) between switch pump and
steering valve.
cut-off valve.
15. Remove mounting bolt (20).
16. Using guide bolt (1), pull out steering valve

assembly (21) together with bracket approx. 200
mm to center of machine.
Remove the cut-off valve at this point.
30-174
STEERING VALVE
STEERING VALVE
17. Lift off steering valve assembly (21) together with

bracket.
INSTALLATION OF STEERING
VALVE ASSEMBLY
removal.
Install the cut-off valve after lowering the

steering valve assembly together with the
bracket to the mounting position.
After installing the cut-off valve, use the guide
bolt to move close to the frame and install.
30-175
REMOVAL OF BRAKE VALVE

ASSEMBLY
ground and put blocks under the wheels to
1. Remove clamp (1) at front of brake valve.
2. Disconnect hose (2) between valve and hydraulic
tank.
3. Disconnect hoses (3) and (4) between
accumulator and valve.
Fit a wrench to the joint to stop it from turning.
4. Remove hoses (5) between R.H. brake valve and
slack adjuster.
5. Remove clamp (6).
6. Disconnect hose (7) between R.H. brake valve
and L.H. brake valve.
7. Disconnect hose (8) between valve and hydraulic
tank.
8. Disconnect hose (9) between accumulator and
valve.
9. Remove pedal (10).
10. Pull out snap pin (11), then pull out pin (12).
Be careful not to lose L-shaped pin (13).
30-176
BRAKE VALVE
BRAKE VALVE
11. Remove mounting bolts (14), then remove brake

valve assembly (15).
Carry out the operation with two workers and
remove the valve assembly from under the
floor plate.
INSTALLATION OF BRAKE
VALVE ASSEMBLY
Reverse the removal procedure to install a brake
valve assembly.
30-177
REMOVAL OF SLACK
ADJUSTER ASSEMBLY
1. Remove cover (1) on top of front frame.
2. Disconnect tube (2) between brake valve and

slack adjuster.
3. Disconnect tube (3) between slack adjuster and
left and right brake pistons.
4. Remove mounting bolts, then remove slack
adjuster (4).
operation.
INSTALLATION OF SLACK
ADJUSTER ASSEMBLY
removal.
Tube: 80.9 12.3 Nm (60 9.4 lbf ft)
Tube: 68.6 9.8 Nm (50.6 7.2 lbf ft)
30-178
SLACK ADJUSTER
SLACK ADJUSTER
DISASSEMBLY OF SLACK
ADJUSTER
1. Bleeder
Remove bleeder (2) from body (1).
2. Cylinder
Remove mounting bolts, then disconnect body (1)
and cylinder (4) together with bracket (3).
WARNING! There is spring tension inside the
cylinder, so hold the contact surfaces and be
careful when removing.
3. Piston
1) Remove spring (5) and O-ring (6).
2) Remove piston (7), then remove O-ring
Use a rod of 10 mm diameter and pus h
out the piston slowly.
Be careful not to damage the thread with
the rod.
4. Poppet
Do not disassemble the poppet unless
necessary. If it is disassembled, replace the
whole cylinder assembly.
1) Remove cover (8) from cylinder (4), then
remove plug (9), spring (10) and poppet (11).
When removing the poppet, blow in air
from the oil hole in the cylinder.
Hold the oil port of the cylinder by hand,
and do not pump in air suddenly.
Be careful not to change the combination
of poppet (11) and cylinder (4).
When replacing, replace the poppet and
cylinder as an assembly.
2) Remove O-ring (12) from poppet.
30-179
ASSEMBLY OF SLACK
ADJUSTER
1. Poppet
1) Fit O-ring (12) on poppet (11).
2) Install poppet (11), spring (10), plug (9) and
cover (8), then assemble cylinder (4).
2. Piston
1) Install O-ring (13) on piston (7).
2) Insert piston (7) in cylinder (4).
Check that the piston moves smoothly.
3. Cylinder
1) Install O-ring (6) and spring (5) in cylinder.
Installed load of spring 43.1 Nm (4.4 kg)
(9.68 lb)
2) Install body (1) and cylinder (4) together with
bracket (3).
4. Bleeder
Install bleeder (2).
30-180
SLACK ADJUSTER
BRAKE
REMOVAL OF BRAKE
ASSEMBLY (FRONT, REAR)
1. Remove final drive assembly. For details, see
DISASSEMBLY OF FINAL DRIVE ASSEMBLY.
2. Disconnect brake tube (1).
3. Set tooI H6 in position, and sling brake and wheel
hub assembly, remove mounting bolts (2), then lift
off brake and wheel hub assembly (3).
Brake, wheel hub assembly: 280 kg
(617.3 lb)
4. Remove bearing (5) and retainer (6) from axle (4).
INSTALLATION OF BRAKE

removal.
Brake tube: 68.6 9.8 Nm (50.6 7.2 lbf

ft)
Mounting bolt: Thread tightener (LT-2)

Brake, wheel hub mounting bolt:
548.8 58.8 Nm (405.1 43.4 lbf ft)
30-181
DISASSEMBLY OF BRAKE
1. Cylinder
Using eye-bolt (1) (Thread dia. = 16 mm, Pitch =
2.0 mm), lift out cylinder (1).
Disassemble cylinder with following steps:

1) Screw in eye-bolts (1) (Thread dia.=16 mm,
Pitch 2.0 mm), push in spring with bar (2),
then pull out pin (2).
2) Remove spring (3) and shaft (4).
3)
Remove piston (5).
2. Plate, disc
1) Remove plate (6).
30-182
BRAKE
BRAKE
2) Remove disc (7).

When removing the disc and plates, put
match marks on the inner gear and disc, and
outer gear and plate before removing.
The discs are made of soft material, so b e
careful not to damage them during removal.
Remove discs and plates alternately.
3. Gear assembly
1) Remove tool H6.
2) Using eyebolt (3) (Thread dia.=12 mm, Pitch

=1.75 mm), lift off gear (8).
3) Remove plate (9) from gear (8).
4) Remove floating seal (10) and oil seal (11)

from gear (8).
30-183

4. Floating seal, outer race
1) Remove floating seal (12) from hub (13).
2) Remove outer races (14) and (15) from hub
(13).
30-184
BRAKE
BRAKE
ASSEMBLY OF BRAKE
1. Outer race, floating seal
1) Using push tool (4), press fit outer race (15)
to hub (13).
2) Using push tool (5), press fit outer race (14 )
to hub (13).
3) Using tooI H9, install floating seal (12) to hub

(13).
Seal contact surface:
Engine oil (EO30-CD)
Assemble O-ring (12) to floating seal.
Use alcohol to completely remove any white
blooming from the surface of the O-ring.
Remove all oil and grease from the floating
seal and hub O-ring contact surface.
Tighten tool H9 uniformly to prevent twisting
of the floating seal O-ring. After press fitting,
measure height at four places around the
circumference and check that the difference
in dimension t at all four places is within 1
mm.
2. Gear assembly
1) Using tool H5, install oil seal (11) to gear (8).
Lip of oil seal: Grease (G2-LI)
Mating surface of oil seal hub:
Thread tightener (Loctite #648)
30-185

2) Using tooI H8, install floating seal (10) to gear
(8).
Seal contact surface:
Engine oil (E030-CD)
Assemble O-ring (10) to floating seal.
Use alcohol to completely remove any white
blooming from the surface of the O-ring.
Remove all oil and grease from the floating
seal and retainer O-ring contact surface.
Tighten tool H8 uniformly to prevent twisting
of the floating seal O-ring. After press fitting,
measure height t at four places around the
circumference and check that the difference
in dimension t at all four places is within 1
mm.
3. Assemble plate (9), then using eyebolt (3)

(Thread dia.=12 mm, Pitch= 1.75 mm), raise gear
(8) and install.
4. Install tool H6.
30-186
BRAKE
BRAKE
5. Disc, plate
1) Install disc (7).
2) Install plate (6).

Align notched portion of outer teeth of plate
and assemble.
Align the counter marks on the disc and inner
gear, and plate and outer gear, then
assemble the plates and discs in turn.
6. Cylinder
Assemble cylinder with following steps:
1) Set piston (5) at bottom.
2) Install shaft (4) and spring (3).

3) Screw in eye-bolts (1) (Thread dia. = 6 mm,
Pitch = 2.0 mm), push in spring with bar (2),
then install pin (2).
30-187

4) Fit O-ring and using eye-bolts (1) (Thread dia. =
16 mm, Pitch = 2.0 mm), match with guide bolt (i)
and lift and install cylinder assembly (1).
Mounting bolt:
Mounting bolt:
176.5 19.6 Nm (130.2 14.5
lbf ft)
30-188
BRAKE
HYDRAULIC PUMP
REMOVAL OF HYDRAULIC
PUMP (SWITCH & PPC,
LOADER, TORQUE
CONVERTER-TRANSMISSION,
STEERING) ASSEMBLY
1. Remove engine hood assembly.
For details, see REMOVAL OF ENGINE
HOOD ASSEMBLY.
2. Remove bulkhead assembly.
For details, see REMOVAL OF BULKHEAD
ASSEMBLY.
3. SWITCH+PPC pump assembly
1) Disconnect hose (1) and tube (2).
2) Remove mounting bolt (3).
3) Lift off pump assembly (4).
4. Loader pump assembly

1) Remove bolts (5), and disconnect tube
(6) together with hose.
2) Disconnect hose (7).
3) Remove U-bolts (8), then remove

bracket (9).
4) Remove bolt (10), then remove tube (11).
5) Remove bolt (12), then remove pump
assembly (13).
6) Disconnect tube (14).
30-189

5. Steering pump assembly
1) Remove drive shaft assembly (15).
2) Disconnect tube (16).

3) Remove bolt (17), then remove pump
assembly (18).
6. Transmission, torque converter pump

assembly
1) Disconnect hose (18).
2) Disconnect tube(19).
3) Remove mounting bolt (20), then remove
pump assembly (21).
INSTALLATION OF HYDRAULIC
PUMP (SWITCH & PPC,
LOADER, TORQUE
CONVERTER-TRANSMISSION,
STEERING) ASSEMBLY

removal.
Drive shaft:
110.7 12.7 Nm (81.0 9.4 lbf ft)
30-190
HYDRAULIC PUMP
HYDRAULIC TANK
TANK ASSEMBLY
WARNING! Loosen the oil filler cap slowly to

release the pressure inside the hydraulic
tank. Then operate the steering wheel and
control levers several times to release the
remaining pressure in the hydraulic piping.
Remove cover (1).
Loosen plug (2) on top of the hydraulic tank filter
and bleed the air from tank.
1. Remove plug (3), then loosen valve (4) and drain

hydraulic oil.
Hydraulic oil: 175
2. Sling ladder floor (5), then remove mounting bolts

and lift off.
Be careful of the center of gravity when lifting
off the ladder floor.
Ladder floor: 90 kg (198 lb)
3. Disconnect main suction tube (6).

4. Disconnect return tube (7) from cooler.
5. Disconnect main return tube (8).
30-191

6. Disconnect hose (9) between brake valve and
hydraulic tank.
7. Disconnect stop valve, charge valve, PPC,

Orbit-roll, and drain hoses (10).
8. Sling hydraulic tank, then remove mounting bolts

(11) and (12).
9. Lift off hydraulic tank assembly (13).

Hydraulic tank assembly: 240 kg (308 lb)
TANK ASSEMBLY

removal.
Plug: 11.8 1.0 Nm (8.7 7.2 lbf ft)
Hydraulic tank bolt: 277.3 32.3 Nm

(205 23.9 lbf ft)
30-192
HYDRAULIC TANK
HYDRAULIC FILTER
FILTER ASSEMBLY
tank.
1. Remove cover (1).
2. Loosen plug (2) and bleed air from tank, then
remove mounting bolts, and remove cover (3).
WARNING! The cover is under pressure

from a spring. Remove the cover slowly and
carefully.
3. Remove spring (4).
4. Remove bypass valve (5).
5. Remove filter (6).
FILTER ASSEMBLY

removal.
Plug: 11.8 1.0 Nm (8.7 7.2 lbf ft)
30-193
REMOVAL OF PPC VALVE

ASSEMBLY
and put blocks under the wheels td prevent
Open cover (1).
Loosen plug (2) on top of the hydraulic tank filter
and bleed the air from tank.
1. Remove console box cover (3) on right side of
operator's seat.
2. Disconnect rods (4).
3. Disconnection of hoses from PPC valve
1) Disconnect hoses P1 (5) and P4 (6) for
bucket control
2) Disconnect hoses P3 (7) and P2 (8) for boom
control
3) Disconnect hose (9) from PPC pump
4) Remove eyebolt (10) of return hose leading
to hydraulic tank.
After disconnecting the hoses, fit tags to
distinguish them.
4. Remove mounting bolts (11), then remove PPC
valve assembly (12).
INSTALLATION OF PPC VALVE

ASSEMBLY

removal.
Plug: 11.8 1.0 Nm (8.7 7.2 lbf ft)
30-194
PPC VALVE
PPC VALVE
DISASSEMBLY OF PPC VALVE

ASSEMBLY
1. Remove bolt (1).
2. Remove plate (2).
3. Remove seal (3), then remove collar (4).
4. Remove valve assembly and center spring (7)
from valve body (10).
5. Remove collar (11), then remove retainer (6),
shim (12), and spring (8) from valve (9).
ASSEMBLY OF PPC VALVE

ASSEMBLY
1. Push shim (12), spring (8), and retainer (6) into
valve (9), and install collar (11).
2. Install center spring (7) and valve assembly to
valve body (10).
3. Install spool (5).
4. Fit O-ring and install collar (4).
5. Install seal (3).
6. Fit plate (2) and install bolt (1).
Bolt: 44.1 4.9 Nm (325.5 36.2 lbf ft)
30-195
REMOVAL OF MAIN CONTROL

VALVE ASSEMBLY
1. Open cover (1).
2. Loosen plug (2) on top of the hydraulic tank filter
and bleed air from tank.
3. Remove bucket cylinder assembly. For details,
see REMOVAL OF BUCKET CYLINDER
ASSEMBLY.
4. Remove bolt (3), then remove cover (4).
5. Remove bolt (5), and loosen bolt (6), then rotate

cover (7) carefully to right.
Rotate the cover on the right side of the
chassis to the left.
Rotate the cover using bolt (6) as the fulcrum.
operation.
6. Disconnect hose (13) for bucket spool between

PPC valve (P1) and main control valve (PB1).
30-196
MAIN CONTROL VALVE
MAIN CONTROL VALVE
7. Disconnect hose (14) for boom spool between

PPC valve (P3) and main control valve (PB2).
8. Disconnect hose (15) for bucket spool between
PPC valve (P4) and main control valve (PA1).
9. Disconnect hose (16) for boom spool between
PPC valve (P2) and main control valve (PA2).
Remove the hose clamp.
After disconnecting the hose, move it to the
rear of the machine.
distinguish them.
10. Disconnect hose (17) between main control valve
and hydraulic tank.
11. Remove tube (18) between main control valve

and bucket cylinder together with hose.
and boom cylinder.
13. Disconnect tube (20) from manifold.
14. Remove bracket (21) of tube.

main control valve from main control valve.
16. Disconnect tube (23) between hydraulic tank and
main control valve from main control valve.
30-197

and bucket cylinder together with hose.
18. Disconnect tube (25) between main control valve
and boom cylinder from main control valve.
Loosen the tube clamp.
19. Remove mounting bolts and rotate main control

valve (26) 90
20. Using eyebolts, lift off main control valve.

Be careful of the slack adjuster bleed screw
when removing.
Main valve: 91 kg (200.2 lb)
INSTALLATION OF MAIN
CONTROL VALVE ASSEMBLY
removal.
Plug: 11.8 1.0 Nm (8.68 .7 lbf ft)

To refill with oil (hydraulic tank), add oil
through oil filler to the specified level.
Run the engine to circulate the oil through the
system. Then check the oil level again.
30-198
MAIN CONTROL VALVE
MAIN CONTROL VALVE
DISASSEMBLY OF MAIN CONTROL VALVE
1. Spool assembly
1)
Remove sleeve (1), then remove case (2).
30-199

2)
3)
4)
5)
Remove spring (3) and retainer (4).

Remove spring (5) and retainer (6).
Remove piston (7), spring (8), and spacer (9).
Remove spool assembly (10).
Disassemble spool assembly.
Remove plugs (12) and (13) from spool
(11).
2. Main relief valve

1) Remove main relief valve assembly (14).
Disassemble main relief valve assembly.
i) Loosen nut (15), and pull out adjustment
screw (16), then remove retainer (17),
spring (18), spacer (19), and poppet (20)
Before loosening nut (15), measure
the protrusion of screw (16) from the
end face of the nut.
ii) Loosen nut (21), then remove holder
(22), seat (23), and backup ring (24).
iii) Remove snap ring (25), then remove
retainer (26), valve (27), and spring (28)
from sleeve (29).
iv) Remove backup ring (30) from sleeve.
If there is any abnormality in the
sleeve or valve, replace as an
assembly.
3. Safety valve assembly with suction
Remove safety valve assembly (31).
The safety valve cannot be adjusted when it
is on the machine, so do not disassemble it.
30-200
MAIN CONTROL VALVE
MAIN CONTROL VALVE
4. Suction valve assembly

Remove suction valve assembly (32).
Disassemble suction valve assembly (32).
i) Remove valve (33) together with seal
(34).
ii) Remove seal (34) from valve (33).
iii) Remove spring (35) from sleeve (36).
If there is any abnormality in the sleeve or
valve, replace as an assembly.
5. Selector valve assembly

Remove selector valve assembly (37).
1) Remove sleeve (38) together with seat (39).
Seat (39) is press fitted to sleeve (38)
(press fitting load: 1,177 - 7,845 N (120 800 kg), so if there is any abnormality
replace as an assembly. (The same
applies for the sleeve.)
2) Remove nipple (40), then remove shim (41),
spring (42), and piston (43).
shims, and keep in a safe place.
6. Check valve assembly
1) Remove plate (44), then remove spring (45)
and check valve (46).
2) Remove flange (47), then remove spring (48),
seal (49), and valve (50).
30-201
MAIN CONTROL VALVE
MEMORANDA
30-202
MAIN CONTROL VALVE
ASSEMBLY OF MAIN CONTROL VALVE
30-203

1. Check valve assembly
1) Assemble valve (50), seal (49), and spring
(48) in valve body (51), then fit O-ring and
install flange (47).
Flange surface: Thread tightener (LT-2)
2) Assemble check valve (46) and spring (45) in
valve body, then fit O-ring and install plate
(44).
88.2 9.8 Nm (65.1 7.2 lbf ft)
2. Selector valve assembly
Assemble selector valve assembly.
1) Assemble piston (43), spring (42), and shim
(41) in sleeve (38), then fit O-ring and install
nipple (40).
Nipple: 22.1 2.5 Nm (162.5 18.1 lbf ft)
Fit O-ring and install selector valve assembly (37).
Selector valve
68.6 9.8 Nm (50.6 7.2 lbf ft)
3. Suction valve assembly
Assemble suction valve assembly.
i) Assemble spring (35) in sleeve (36).
ii)
Assemble seal (34) in valve (33), and

install to sleeve (36).
Fit O-ring and install suction valve assembly (32).

Suction valve assembly:
186.2 9.8 Nm (130.2 7.2 lbf ft)
4. Safety valve assembly with suction
Fit O-ring and install safety valve assembly (31).
Safety valve :
186.2 9.8 Nm (130.2 7.2 lbf ft)
30-204
MAIN CONTROL VALVE
MAIN CONTROL VALVE
5. Main relief valve assembly

Assemble main relief valve.
i) Install backup ring (30) and O-ring to
sleeve (29).
ii) Assemble spring (28), valve (27), and
retainer (26) in sleeve (29), and install
snap ring (25).
iii) Fit backup ring (24) and O-ring, and
assemble seat (23) in sleeve.
iv) Screw nut (21) into holder (22), then fit
O-ring and assemble in sleeve, and
tighten nut.
Holder: 39.2 9.8 Nm (28.9 7.2 lbf
ft)
Nut thread Thread tightener (LT-2)
Nut: 152.0 - 24.5 Nm (112.1 18.1
lbf ft)
v)
Assemble poppet (20), spacer (19),

spring (18), and retainer (17), and screw
in adjustment screw (16).
Adjus t
protrusion from end face of nut (15) to
same dimension as at time of
disassembly, then tighten with nut (15).
Nut thread: Thread tightener (LT-2)
Nut: 39.2 4.9 Nm (28.9 3.6 lbf ft)
Fit O-ring and install main relief valve assembly

(14).
Main relief valve assembly:
323.6 44.1 Nm (238.7 32.5 lbf ft)
6. Spool assembly
Assembly of spool assembly.
Install plugs (13) and (12) to spool (11).
Nut thread: Tightener (LT-2)
Nut: 24.5 4.9 Nm (18.1 3.6 lbf ft)
1) Assemble spool assembly (10) in valve body.
2) Assemble spacer (9), spring (8), and piston
(7).
3) Assemble retainer (6), spring (5), retainer (4),
and spring (3), then fit O-ring and install case
(2) and sleeve (1).
30-205
REMOVAL OF BUCKET
CYLINDER ASSEMBLY
WARNING! Pressure in the hydraulic system
must be released. Loosen the oil filler cap
slowly to release pressure inside the hydraulic
tank. Operate steering wheel and control
levers several times to release the remaining
pressure in the hydraulic piping.
1. Disconnect connector (1) for bucket positioner.
2. Disconnect grease tube (2) from bottom pin.
3. Disconnect head hose (3).
4. Disconnect bottom hose (4).
5. Sling cylinder then remove lockbolt, and remove

head pin (5).Sling from two points and be careful
of the center of gravity.
6. Remove lock bolt, then remove bottom pin (6).

If there are shims, check the number and
thickness of the shim.
30-206
BUCKET CYLINDER
BUCKET CYLINDER
7. Remove bucket cylinder assembly (7).

Bucket cylinder assembly: 286 kg
(629.2 lb)
INSTALLATION OF BUCKET
CYLINDER ASSEMBLY
removal.
When aligning the pin hole at the bottom end,

assemble shims so that the total clearance
between the cylinder and frame is within the
specified value, then assemble pin (6) and
lock with the bolt.
WARNING! Align the position of the pin hole

with a bar. Never insert a finger in the pin
hole.
30-207
REMOVAL OF BOOM CYLINDER

ASSEMBLY
1
Lift off fender (1).

Fender: 25 kg (55 lb)
2. Sling boom cylinder, then remove lock bolt,

and remove pin (3).
Start the engine and operate the control
lever to retract the cylinder rod of the
cylinder where the pin has been
removed.
After stopping the engine, release the
remaining pressure from the hydraulic
piping.
3. Disconnect head hose (4) and bottom hose

(5).
4. Fit lifting tool to bottom of boom cylinder (2),

then use lever block (1) to pull out to rear of
machine.
5. Using forcing screws, remove bottom pin (6)
If there are shims, check the number and
thickness of the shim.
30-208
BOOM CYLINDER
BOOM CYLINDER
6. Lift off boom cylinder assembly (2).

Boom cylinder assembly: 272 kg
(598.4 lb)
INSTALLATION OF BOOM
CYLINDER ASSEMBLY
removal.
When aligning the pin hole at the bottom end,

assemble shims so that the total clearance
between the cylinder and frame is within the
specified value, then assemble pin (6) and
lock with the bolt.
WARNING! When aligning the position of the
pin hole, use a bar. Never insert your fingers
in the pin hole.
30-209
DISASSEMBLY OF BOOM AND

BUCKET CYLINDERS
ASSEMBLY
1. Set cylinder assembly (1) tool U1.
2. Remove mounting bolts (2) of cylinder head.
3. Pull cylinder head and piston rod assembly (3) out

from cylinder (4), then lift off.
Oil will come out when the piston rod
assembly is removed from the cylinder, so
catch it in a container.
4. Remove piston bolts (5), then remove spacer (6),

piston assembly (7) and cylinder head assembly
(8).
5. Remove O-ring (10) and backup ring (11) from

piston rod (9).
30-210
BOOM AND BUCKET CYLINDERS
6. Disassembly of piston assembly

Remove wear ring (12) and piston ring (13) from
piston (14).
7. Disassembly of cylinder assembly

1) Remove O-ring (15 )and back up ring(16).
2) Remove snap ring, then remove dust seal
(17).
3) Remove rod packing (18).

4) Remove bushing (19).
30-211
ASSEMBLY OF BOOM AND

BUCKET CYLINDERS
ASSEMBLY
Clean all parts, and check for dirt or damage.
Coat the sliding surfaces of all parts with engine
oil before installing. Be careful not to damage the
U-packings, dust seals or O-ring when
assembling.
1. Assembly of cylinder head assembly

1) Using push tooI U5, press fit bushing (19) on
cylinder head (20).
Be careful not to deform the bushing
when press fitting.
2) Assemble rod packing (18).
Be careful to install the rod packing facing in
the correct direction.
3) Assemble buffer ring (21).
4) Assemble backup ring (16) and O-ring (15) in
order.
Do not try to force the backup ring into
position. Heat the backup ring in warm
water (50
5) Using push tool U4, install dust seal (17) to

cylinder head, then secure with snap ring.
30-212
2. Assembly of piston assembly

1) Using tool U6-1, expand piston ring (13).
Set the piston ring on the expander and
turn the handle 8 - 11 times to expand
the ring.
2) Remove piston ring from tool U6-1, and
assemble on piston (14).
3) Fit tools U6-2, on piston ring, then using
clamp U6-3, compress piston ring.
4) Assemble wear ring (12) on piston.
3. Assemble O-ring (10) and backup ring (11) on

piston rod (9).
4. Assemble cylinder head assembly (8) and piston

assembly (7) on piston rod.
Coat backup ring (11) with grease so that it
does not stick out, and assemble carefully.
5. Assemble spacer (6), then tighten piston bolts (5).
Piston bolt :
176.5 19.6 Nm (130.2 14.5 lbf ft)
Piston bolt: Adhesives (LT-2)
30-213

6. Set cylinder (4) in tool U1, then raise piston rod
and head assembly (3), and assemble in cylinder
(4).
Tighten cylinder head mounting bolts (2).

Cylinder head mounting bolt:
662 74 Nm (501 542.5 lbf ft)
Remove cylinder assembly (1) from tool U1.
30-214
CENTER HINGE PIN
REMOVAL OF CENTER HINGE

PIN
Warning! Stop the machine on level ground,
install the safety bar on the frame, and block
the wheels to prevent the machine from
moving.
Warning! Loosen the oil filler cap slowly to
1. Open cover (1) and loosen plug (2) on top of
hydraulic tank to prevent oil from flowing out from
tank.
2. Remove bolt (3), then remove cover (4).
3. Remove plug (5), then loosen valve (6) and drain

hydraulic oil. When draining thehydraulic oil, drain
to the level of the bottom of each pipe.
Hydraulic oil :
140
piping)
4. Remove covers (7) and (8) at bottom of cab.
30-215

5. Remove left and right steering cylinder pins (9).
If there are shims between the pin and frame,
check the number and thickness.
6. Remove guard (10), then remove center drive
shaft (11).
Center drive shaft assembly: 31 kg (68.2
lb)
7. Disconnect hose (12) between brake valve and
slack adjuster.
8. Disconnect connectors (13) FR1 and (14) FR2.

Disconnect the clamps under the floor.
9. Disconnect hoses (15) and (16) between steering

valve and stop valve at steering valve end.

oil cooler.
11. Disconnect hose (18) between work equipment
control valve and hydraulic tank.
12. Disconnect hose (19) between work equipment
control valve and loader pump.
30-216
CENTER HINGE PIN
CENTER HINGE PIN
13. Disconnect bypass hose (20) from hydraulic

circuit at top of tank.
14. Disconnect hoses P1 (21) and P4 (22) for bucket
control.
15. Disconnect hoses P3 (23) and P2 (24) for boom
control.
Disconnect the clamps at the rear frame end.
16. Using hydraulic jack to rear frame, insert block (1)

while adjusting height.
Put support stands (2) under the left and right
side of the frame.
17. Put support stand (2) under counterweight.
18. Using jack under front frame, insert block (3).
19. Remove mounting bolts, then remove retainer

(25).
If there are shims between the retainer and
frame, check the number and height.
30-217

20. Adjust height carefully so that lower hinge pin (26)
can be removed easily by hand.
21. Remove spacer (27).

(28).
23. Using puller, remove upper hinge pin (29) and

spacer(30).
30-218
CENTER HINGE PIN
CENTER HINGE PIN
24. Remove safety bar, then pull out front frame

towards front and disconnect frame.
Be careful not to let the spacer at the top of
the lower hinge get caught in the rear frame.
Carry out the operation carefully and pay
attention to maintaining the balance.
Move approx. 100 mm (3.9 in) at a time.

(31).
frame, check the number and thickness.
26. Remove dust seal (32) from retainer (31).
27. Remove spacer (33) and dust seal (34) from front
frame.
30-219

28. Remove bearing (35).
29. Remove retainer (36).

frame, check the number and thickness.
30. Remove dust seal (37) from retainer.

Remove dust seal (38) at the frame end.
31. Remove bearing (39).
30-220
CENTER HINGE PIN
CENTER HINGE PIN
INSTALLATION OF CENTER
HINGE PIN
removal.
Plug: 11.8 1.0 Nm (8.68 .7 lbf ft)
Adjust the shims so that the clearance is the

specified value.

110.7 12.7 Nm (752.2 94 lbf ft)
Outer circumference of hinge pin:

Grease (G2-LI)
Measure clearance c between the retainer
and frame at four places on the inside
circumference, and select a shim thickness to
make the value 0.08 - 0.18 mm less than the
measured value.
When adjusting the shim, temporarily tighten
the retainer mounting bolts to act as a
stopper.
When tightening the mounting bolts, first
tighten the retainer mounting bolts to the
specified torque, then tighten the pin
mounting bolts.
After selecting the shim, assemble the
retainer to the specified torque.
Remove all oil and grease from the mounting
bolts and mount holes.
Mounting bolt:
Thread tightener (Loctite 262)
Mounting bolt (48) when adjusting shims:
276.3 29.4 Nm (206 21.7 lbf ft)
Mounting bolt (48):
276.3 29.4 Nm (206 21.7 lbf ft)
Mounting bolt (49) when adjusting shims
382.2 34.3 Nm (282.1 25.3 lbf ft)
30-221
Assemble spacer (30), insert upper hinge

(29), then tap three times with a copper
hammer to settle the parts.
Never coat spacer (30) with grease.
Outer circumference of hinge pin
Grease (G2-LI)
Mounting bolt (46):
Thread tightener (Loctite 262)
Mounting bolt (46):
176.4 19.6 Nm (130.2 14.5 lbf ft)
Mounting bolt (47):
176.4 19.6 Nm (130.2 14.5 lbf ft)
Grease on spacer (28) may prevent the
mounting bolts being tightened to the
specified tightening torque. Remove any
grease and tighten again.
Use tool K2 to press fit the bearing and

spacer to the frame. Make sure the bearing is
not at an angle.
Fill the inside of the bearing with grease.
When assembling the bearing, be sure to
assemble the spacer.
The clearance of the bearing is adjusted, so
do not change the combination of bearing
and spacer.
When replacing, replace as a set.
Press fit so that the lip of the dust seal is
facing the outside.
Measure clearance a between retainer (31)
and hinge at four places on the inside
make the value 0.08 - 0.18 mm less tha n
the measured value.
Mounting bolt (when adjusting shims):
98.0 9.8 Nm (72.3 7.2 lbf ft)
Mounting bolt:
176.4 19.6 Nm (130.2 14.5 lbf ft)
30-222
CENTER HINGE PIN
CENTER HINGE PIN
Using tool K1, press fit the bearing and

spacer to the frame.
When press fitting the bearing, be careful that
the bearing is not at an angle.
Fill the inside of the bearing with grease.
When assembling the bearing, be careful not
to forget to assemble the spacer.
The clearance of the bearing is adjusted, so
do not change the combination of bearing
and spacer.
When replacing, replace as a set.
Press fit so that the lip of the dust seal is
facing the outside.
Measure clearance a between retainer (36)
and the hinge at four places on the inside
make the value 0.08 - 0.18 mm less than the
measured value.
Mounting bolt (when adjusting shims):
58.8 5.9 Nm (43.4 4.3 lbf ft)
Mounting bolt:
176.4 19.6 Nm (130.2 14.5 lf ft)
After completion of mounting the hinge pin, fill
with oil and bleed the air.
1) Tighten the plug on the top of the hydraulic tank
filter, then add hydraulic oil through oil filler to the
specified level.
Plug on top of filter
11.8 1.0 Nm (8.7 .7 lbf ft)
Hydraulic oil: Approx. 140
Run the engine to circulate the oil
through the system. Then check the oil
level again.
2) Bleed the air from the brake system. For details,
see TESTING AND ADJUSTING.
30-223
REMOVAL OF WORK
EQUIPMENT
install the safety bar on the frame, block the
1. Remove mounting pin (1) of bucket link.
Remove cord ring.
Tie the bucket link to the tilt lever with wire.
Mounting pin: 25 kg (55 lb)
2. Remove mounting pin (2) of bucket hinge.
Remove cord ring.
Warning! Use a bar to align the pin
holes. Never use your fingers.
3. Move machine to rear and disconnect bucket.
4. Temporarily sling bucket cylinder (3), pull pin (4),

then disconnect cylinder rod and tilt lever.
Attach lifting tool to bucket cylinder and
secure in the rear.
Bucket cylinder: 285 kg (627 lb)
5. Attach lever block (1) to boom cylinder (5), pull

machine to rear and remove mounting pin (6).
Boom cylinder: 272 kg (598.4 lb)
30-224
WORK EQUIPMENT
WORK EQUIPMENT
6. Temporarily sling bellcrank (7) and bucket link,

remove mounting pin (8), then lift out from boom
(9).
Remove with the bucket link still fitted.
Three technicians are necessary for removal
of mounting pin operation.
Bellcrank and bucket link: 615 kg (1365
lb)
Mounting pin: 59 kg (129.8 lb)
7. Temporarily sling bucket link (10), remove

mounting pin (11), then lift out from bellcrank (7).
Remove cord ring.
Bucket link: 103 kg (226.6 lb)
Note the number of shims at this location for
reference when installing.
8. Remove boom kickout switch (13).
9. Temporarily sling boom (9), pull out mounting pin

of boom, then lift out boom.
Shims are installed at connecting point of
front frame and boom, so check the number
of shims.
Boom: 2,025 kg (4455 lb)
30-225

10. Pull out dust seal (14) and bushing (15) from
boom (9).
bellcrank (7)
30-226
WORK EQUIPMENT
WORK EQUIPMENT
bucket link (10).
After long use, wear can make the pin difficult to

remove. A puller (pin puller jig) such as the one
shown here can be helpful when removing a pin.
30-227
INSTALLATION OF WORK
EQUIPMENT ASSEMBLY
removal.
Clearance g + h = Less than 1.0 mm

Be careful not to get cord ring (22) caught.
Clearance e + f = Less than 1.0 mm

Secure the bucket link and bellcrank with

wire.
Insert shims so that the clearance is equal on
the left and right.
Clearance c + d = Less than 1.0 mm
Align the hole in the boom mount and the

front frame, then insert shims to make th e
clearance equal on the left and right.
After assembling the pin, set the support
stand to the tip of the boom.
Grease each pin.
30-228
WORK EQUIPMENT
BULKHEAD
REMOVAL OF BULKHEAD
ASSEMBLY
Warning! Stop the machine on level ground
1. Remove engine hood assembly (1). For details,
see REMOVAL OF ENGINE HOOD ASSEMBLY.
2. Remove bulkhead left side cover (2).
Disconnect the connector (BR1) at the
bottom at the engine end of the left side of
the bulkhead.
Reach in at the point marked by the arrow,
and disconnect the connector (BR1).
3. Remove bulkhead hood (3).

4. Remove floor plate (4).
5. Remove covers (5) and (6).
6. Disconnect hose (7) at receiver tank end.

7. Disconnect hose (8) at condenser end.
Disconnect the accelerator control cable at
the fuel pump end.
30-229

8. Disconnect brake hoses (9), (10), and (11).
9. Disconnect emergency brake valve connecting
hoses (12), (13), and (14).
10. Disconnect accumulator charge valve connecting

hoses (15), (16), and (17).
11. Disconnect PPC pump connecting hose (18).
12. Disconnect PPC accumulator inlet hose (19).
13. Disconnect window washer hoses (20).
14. Disconnect transmission breather (21).
distinguish them.
15. Remove four mounting bolts (22) and (23).
16. Lift off bulkhead assembly (24).
Bulkhead assembly: 220 kg (484 lb)
INSTALLATION OF BULKHEAD
ASSEMBLY
interference.
When installing the hoses, be careful not to
let dirt, dust, or moisture get inside the hoses.
Using a gas charger (X3), charge with new
freon gas (R134a).
30-230
BULKHEAD
ENGINE HOOD
REMOVAL OF ENGINE HOOD

ASSEMBLY
set the parking brake to the PARKING
position, and block wheels to prevent the
machine from moving.
Open the left and right inspection covers.
1. Remove exhaust tube (1).
2. Remove radiator grille (2).
Remove the baffle plate on both sides of the
radiator.
3. Disconnect head lamp connector (3).
4. Disconnect water level sensor connector (4).
5. Remove six mounting bolts (5) and four mounting
bolts (6).
6. Remove radiator support (7).
7. Lift off engine hood (8).

There are clamps for the air conditioner
hoses at two places inside the engine hood
on the right, so disconnect them.
Use a lever block to maintain the balance
when lifting off.
Engine hood assembly: 470 kg (1034 lb)
INSTALLATION OF ENGINE
HOOD ASSEMBLY
removal.
30-231
REMOVAL OF FLOOR FRAME

ASSEMBLY
moving.
1. Remove cab assembly.
For details, see REMOVAL OF CAB ASSEMBLY.
2. Remove left and right ladders (1) and (2).
Ladder: 90 kg (198 lb)
3. Remove floor plate (4) and cover (3) of bulkhead.
4. Disconnect wiring connectors (5) (TM1, 2, LR16).
5. Disconnect ground connection (6).
6. Disconnect hoses (7) between brake valve and

slack adjuster.
7. Disconnect hose (9) between Orbit-roll (8) and
hydraulic tank.
8. Disconnect hose (10) between Orbit-roll (8) and
accumulator.
9. Disconnect hoses (11) between Orbit-roll (6) and
stop valve.
10. Disconnect return hose (12) between Orbit-roll

valve and hydraulic tank.
11. Disconnect return hose (13) coming from PPC
valve.
12. Disconnect return hose (14) coming from brake
valve.
After disconnecting the hose, install a blind
plug to prevent contamination.
30-232
FLOOR FRAME
FLOOR FRAME
13. Remove mounting bolts (15), then remove brake

hose bracket (16).
14. Disconnect PPC hoses (17).
The hoses are fitted with self-seal couplings.
15. Disconnect hose (18) from accumulator.
16. Disconnect accumulator charge valve connecting

hoses (19) and (20).
17. Disconnect PPC accumulator connecting hose
(21).
18. Disconnect two window washer hoses (22).
19. Disconnect two hoses (23) from brake valve.
20. Disconnect air conditioner compressor hose (24).

There are hose clamps at two places inside
the engine hood. Remove the hose clamps.
21. Remove clamp (25) and joint (26), then remove
accelerator cable (27).
22. Disconnect heater hoses (28) and (29).

Hose (29) is installed under the connector at
the suction end of the water pump.
Drain the coolant.
30-233
FLOOR FRAME
23. Remove floor frame mount mounting nuts (30 )

(four places).
24. Lift off floor frame assembly (31).
Check that all the clamps and wiring
harnesses have been disconnected.
Floor frame assembly: 280 kg (617 lb)
INSTALLATION OF FLOOR
FRAME ASSEMBLY
removal.
Install the hoses

interference.
without
twisting
or
When installing the hoses, be careful to

prevent dirt, dust, or moisture from getting
inside the hoses.
freon gas (R134a).
Mount nut:
277.3 32.3 Nm (202.5 23.9 lbf ft)
Refilling with coolant
Tighten radiator drain valve and add coolant
through water filler to the specified level.
Run the engine to circulate the coolant through
the system. Then check the water level again.
30-234
COUNTERWEIGHT
REMOVAL OF COUNTERWEIGHT
moving.
1. Sling counterweight (19), then remove mounting
bolts, and lift off.
When lifting off the counterweight, be careful

to maintain the balance.
Counterweight: 1,500 kg (3,300 lb)
INSTALLATION OF
COUNTERWEIGHT
removal.
Counterweight mounting bolt:

1,568 196 Nm (1157 144 lbf ft)
30-235
FUEL TANK
REMOVAL OF FUEL TANK

ASSEMBLY
moving.
1. Loosen drain valve (1) and drain fuel.
Check the fuel level before draining.
Fuel (when full): 486
2. Remove engine oil drain valve (2) from fuel tank.

3. Disconnect hose (3) between injection pump and
fuel tank.
4. Disconnect hose (4) between fuel tank and feed
Pump.
5. Disconnect spill hose (5).
6. Disconnect connector (6) for fuel level sensor.

7. Remove hoses (7) of blow-by and muffler.
8. Sling fuel tank assembly (8), then remove

mounting bolts and slowly lower the tank.
Put a pallet under the tank, then be careful to
maintain the balance of the tank assembly,
and lower it on to the pallet.
Fuel tank assembly: 246 kg (541.2
lb)
Before pulling out the fuel tank assembly,
remove breather tube (9).
The bottom surface of the tank is not flat,
and there is danger that it may slip, so be
extremely careful when handling it.
30-236
FUEL TANK
INSTALLATION OF FUEL TANK

ASSEMBLY
removal.
Fuel tank mounting bolt:

931.0 98.0 Nm (686 72 lbf ft)
Be careful of breather tube (9) when raising
the tank.
30-237
REMOVAL OF CAB ASSEMBLY

moving.
1. Remove covers (1) at bottom of floor frame.
2. Remove right cover (2) inside cab.
3. Disconnect electric wiring connectors (3).

4. Disconnect window washer hose (4).
5. Remove two steering post lock bolts (5).
30-238
CAB ASSEMBLY
CAB ASSEMBLY
6. Remove plastic mounting bolts and pull up rubber

boot (6) at bottom of steering post.
7. Remove four bolts (7), then tip steering post over

fully towards operator's seat.
At the same time, set the column tilt lever to
the unlock position and tip the steering
column over fully toward the operator's seat.
8. Remove two cab mounting bolts (8) and four

mounting bolts (9) each at intermediate position
and rear.
9. Raise cab assembly (10) slowly and keep

horizontal when lifting off.
Be careful that there is no interference with
the electric wiring at the rear right of the floor
frame.
Cover the steering post and plastic cover with
a sheet to prevent any damage.
30-239
INSTALLATION OF CAB
ASSEMBLY
removal.
When installing the cab assembly, be sure to

install the seal.
Coat the seal uniformly with adhesive.
Seal: Adhesive (Cemedyne 366E)
30-240
CAB ASSEMBLY
REMOVAL OF AIR CONDITIONER

UNIT ASSEMBLY
moving.
Warning! Disconnect the cable from the
1. Remove cab assembly. For details,
REMOVAL OF CAB ASSEMBLY.
see
2. Remove connector (1)

3. Install freon gas collector and regenerator to plug
(2), and collect refrigerant.
4. Remove operator's seat (3).
Operator's seat assembly: 40 kg (88 lb)
5. Remove rear console box (4).

6. Remove console box cover (5).
7. Remove console box (6).
8. Disconnect connector (7) (CL3).

9. Disconnect connector (8) (CL2).
10. Disconnect tubes (9).
11. Disconnect heater hoses (10).
30-241

11. Remove mounting bolt (11), then remove air
conditioner unit assembly (12).
Pull the unit out to the left and remove it.
INSTALLATION OF AIR
CONDITIONER UNIT ASSEMBLY
removal.
Using a gas charger (X3), charge with new freon
gas (R134a).
30-242

CONDENSER ASSEMBLY
and block the wheels to prevent the machine
from moving.
1. Disconnect connector (1) (E1 2).
2. Install freon gas collector and regenerator to
plugs (2), and collect refrigerant.
3. Remove bulkhead cover (3).
4. Disconnect connectors (4) (B07 and B12).
5. Disconnect hose (5) between condenser and air
conditioner compressor.
Always fit a wrench to the condenser end.
6. Disconnect connectors (6) (B01 and B11).
7. Disconnect hose (7) between top and bottom
condensers.
8. Disconnect hose (8) between receiver tank and
condenser.
9. Remove mounting bolts (9), then remove
condenser assembly (10).
INSTALLATION
OF
AIR
CONDITIONER
CONDENSER
ASSEMBLY
removal.

interference.
When installing the hoses, be careful not
to let dirt, dust, or moisture get inside the
hoses.
Using a gas charger (X3), charge with
new freon gas (R134a).
30-243
REMOVAL OF RECEIVER TANK

from moving.
1. Disconnect connector (1) (E12).
3. Remove bulkhead cover (3).
4. Disconnect hose (4) between air conditioner

compressor and receiver tank
5. Disconnect hose (5) between receiver tank and
condenser.
6. Remove U-bolts (6), then remove receiver tank
assembly (7).
INSTALLATION OF RECEIVER
TANK
interference.
freon gas (R134a).
30-244

COMPRESSOR ASSEMBLY
from moving.
1. Disconnect connector (1) (E12).
3. Loosen adjustment bolt (3) and lock bolt (4), then

remove belt (5) and remove from compressor.
4. Disconnect hoses (6).

5. Remove four mounting bolts (7), then remove air
conditioner compressor assembly (8).
INSTALLATION OF AIR
CONDITIONER COMPRESSOR
ASSEMBLY
removal.

interference.
freon gas (R134a).
30-245
MEMORANDA
30-246
40
Enginemount
MAINTENANCE
mount
TorqueconverterandPTO
..........................................................................
....................................................................................
........................................................................................
Main relief, torque converter

Lubricationreliefvalve
Driveshaft
relief valve.
Differential
...6
...8
..I 0
..I 4
.................................................................
.............................................................................
......................................................................................
Centersupport
........................................................................
.........................................................................................
Transmission
..................................................................................
Torqueconverterchargingpump
Transfer
..............................................................................
Transmission
Damper
STANDARD
...................................................................................
......................................................................................
16
..I
..I
..I
..Z 0
Final drive .......................................................................................
..2 4
Axlemount
..2 6
......................................................................................
Centerhingepin
..................................................................................
..2 8
Steering column
..................................................................................
..3 0
Steering pump
...................................................................................
..3 1
Steeringvalve......................................................................................3
Steeringcylindermount
............................................................................
2
..3 3
Brakevalve........................................................................................3
Slackadjuster..
Brake
..................................................................................
..........................................................................................
Parking brake
....................................................................................
4
..3 8
..4 0
..4 2
Hydraulicpump.....................................................................................4
Switchand
PPCpump
.............................................................................
4
..4 5
PPCvalve..
.....................................................................................
..4 6
Cut-offvalve
.....................................................................................
..4 8
Maincontrolvalve...................................................................................5
Hydrauliccylinders..
Bucketlinkage
..............................................................................
0
..5 4
......................................................................................
Bucket............................................................................................5
Bucketpositionerandboomkick-out
ROPSCab
..................................................................
......................................................................................
8
..5 9
..6 0
40-I
MAINTENANCE
STANDARD
ENGINE MOUNT
ENGINE MOUNT
El
LlZAD066
Unit: mm
No.
1
40-2
Check item
Clearance
between engine mounting
bracket and adjusting
bolt
Criteria
Remedy
3.0 - 7.0
Adjust
MAINTENANCE
STANDARD
TRANSMISSION
TRANSMISSION
MOUNT
MOUNT
B-B
SDW02122
Unit: mm
No
1
Check item
Thickness
of shim for
mounting
Criteria
Shim thickness:
Remedy
0.5mm
(Decide the shim thickness
so that the misalignment
between the
damper output shaft and input shaft is less than 2.0mm).

2
Clearance
between
stopper and bracket
There must be a clearance
of at least 2mm between the stopper and
Adjust
bracket around the whole circumference.
40-3
MAINTENANCE
STANDARD
TORQUE CONVERTER
CHARGING
PUMP
TORQUE CONVERTER CHARGING PUMP
6p-l
277.0 '-31.ONm
(28.25 '-3.25kgmI
SEW02124
Unit: mm
I
No
Check item
Criteria
I I
Clearance
between
gear case and
Standard clearance
side plate, gear
Clearance
Remedy
between
inside diameter
I
Clearance
limit
0.10 - 0.15
0.19
0.06 - 0.149
0.20
of
Replace
plain bearing and outside diameter of

gear shaft
1 Insertion depth of pin

I
14 +o/-0.5
Rotating torque of spline shaft
ti
6.9 - 11.8 Nm (0.7 - 1.2 kgm}

Revolution
Pressure
Standard
Repair limit
(rpm)
MPa
discharge
discharge
{kg/cm?
(P/min)
(Plmin)
2500
3.5 MPA
(35.9)
40-4
192
176
MAINTENANCE
STANDARD
MEMORANDA
40-5
MAINTENANCE
STANDARD
DAMPER
DAMPER
A-A
7
8
SDWO2123
40-6
MAINTENANCE
STANDARD
DAMPER
Unit: mm
No
Check item
Clearance
between
bearing
Criteria
Standard
Tolerance
size
and shaft.
Shaft
40
Clearance
between
bearing
80
and housing.
3
Clearance
betweenbearing
75
and shaft.
4
Clearance
between
bearing
130
and cover.
5
Clearance
between
retainer
135
and cover.
Wear of surface in coupling
95
and oil seal.

7
Wear of surface in shaft and

seal.
Backlash of spline (shaft,
Standard
Clearance
clearanc
e
limit
-0.009
-0.003
-0.034
-0.012
-0.034
-0.03
-0.030
-0.013
+0.012
-0.027
-0.007
-0.015
-0.007
+.018
0.007
-0.018
+.007
0.036
-0.014
+0.04
0.014
-0.054
0.094
Tolerance
0.05
0.035
0
-0.013
Standard size
6
Hole
Remedy
Replace
0.025
0.05
0.13
Repair limit
-0.12
-0.087
105
-0.12
-0.087
0.071 - 0.177
coupling, and body).
40-7
MAINTENANCE
TORQUE CONVERTER
STANDARD
AND PTO
/
,
66 5*7.5Nm
(6. 75* 0. 75kd
SKW02125
Unit:
Standard
1
Remedy
Criteria
Check item
No
inside diameter of seal ring surface of

retainer
Tolerance
Repair limit
Repair
size
120
+0.035
0
120.5
chrome
plating or
replace
Inside diameter
of seal ring surface of sleeve
65
+0.025
65.1
0
Width
3
Width and thickness
3.95
ring
4.6
*O.l
Thickness
4
40-8
3.55
-0.1
of seal
Backlash of PTO gear (Drive gear)
0.18 - 0.49
4.14
Replace
mm
MAINTENANCE
STANDARD
MEMORANDA
40-9
MAINTENANCE
STANDARD
TRANSMISSION
TRANSMISSION
SKW02126
40-I 0
MAINTENANCE
STANDARD
TRANSMISSION
Unit: mm
No
Installation
No. 1 clutch spring (X 10)
load
utch spring (X 10)
No. 4 clutch spring (10

17.5 kg)
each)
5
No. 5 clutch spring (X 10)
39.8
16.4 kg1
101.0 N
32.5
86.3 N
37.4
(10.3 kg}
6
No. 6 clutch spring (10
39.8
(8.8 kg)
77.5 N
34.2
65.7 N
37.4
17.9 kg)
each)
Thickness of 4 discs and 3 plates for No. 1 clutch
Standard
16.7 kg)
Tolerance
Repair limit
35
50.26
31.8
35
kO.26
31.8
25
io.22
22.6
25
*to.22
22.6
Thickness of assembled
No. 5 clutch
2 discs and 1 plates for
15
*0.17
13.4
12
Thickness of assembled
No. 6 clutch
3 discs and 2 plates for
25
rto.22
22.6
13
Thickness of 1 disc
*to.1
4.2
14
Thickness of 1 plate
Zto.1
4.5
size
15
Clearance
between
I
transmission
input shaft bearing and housing
Standard
size
90
16
Clearance
between transmission
72
outout shaft bearina and carrier

17
Clearance
between transmission
output shaft bearing and housing
Replace
100
Tolerance
Standard
Clearance
clearance
Limit
+0.037
Shaft
Hole
+0.016
+0.031
-0.015
-0.006
-0.006
+0.016
+0.026
-0.013
-0.006
-0.006
+0.016
+0.031
-0.015
-0.006
-0.006
+0.031
+0.037
40-I 1
MAINTENANCE
STANDARD
TRANSMISSION
SKW02127
40-12
MAINTENANCE
TRANSMISSION
STANDARD
Unit: mm
No.
1
Check item
Wear of seal ring for input
Criteria
I
Width
I
Standard size
shaft
Remedy
I
Tolerance
I
Reoair limit
-0.01
Thickness
3.0
-0.03
2.6
3.5
*0.1
3.35
-0.01
2
Wear of seal ring for

output shaft
Backlash between
Width
4.0
-0.03
3.5
Thickness
5.1
*0.12
4.95
No. 1 sun gear and planet
0.13 - 0.32
No. 1 planet gear and ring
0.15 - 0.38
0.13 - 0.32
0.15 - 0.38
0.12 - 0.30
0.15 - 0.38
0.13 - 0.32
0.15 - 0.38
0.14 - 0.35
0.15 - 0.38
gear
4
Backlash between
gear inside teeth
Replace
5
Backlash between
gear
Backlash between
gear inside teeth
Backlash between
gear
Backlash between
gear inside teeth
Backlash between
gear
10
Backlash between
gear inside teeth
11
Backlash between
gear
12
Backlash between
gear inside teeth
40-I 3
3
14
45*63Nm
6*8.5bd
10.3* 12.3Nm
1.25* 1.25ka
40-14
MAINTENANCE
STANDARD
TRANSFER
Unit: mm
No
Check item
Criteria
Standard
size
Clearance
between
85
Clearance
Clearance
Clearance
Clearance
between
between
between
between
drive gear bearing and cage
drive gear bearing and cage
150
150
idler gear and bearing
drive gear bearing and case
95
170
(cover)
Clearance
Clearance
Clearance
Clearance
between
between
between
between
80
output shaft and bearing
output shaft bearing and cage
140
spacer and bearing
output shaft bearing and
95
170
housing
10
Coupling oil seal contact surface
Tolerance
Shaft
drive gear and bearing
Standard
Remedy
Standard
Hole
clearance
+0.045
-0.023
+0.023
-0.020
-0.065
-0.012
0.006
-0.018
-0.052
-0.052
0.018
-0.018
-0.040
-0.040
+0.059
-0.037
-0.037
-0.020
-0.079
0.025
-0.025
-0.040
-0.040
+0.039
-0.020
-0.020
-0.015
-0.054
-0.012
0.006
-0.018
-0.052
-0.052
+0.045
-0.023
+0.023
-0.020
-0.065
-0.012
0.013
-0.025
-0.052
-0.052
Tolerance
_ Replace
Repair limit
size
0
95
94.8
-0.087
11
Clearancebetweencageandcase
2 (Shim)
Preload:
0.1 - 1.0 Nm (0.01 - 0.1 kgm}
(Drive gear as individual
12
Clearance
between
cover and case
2 (Shim)
Adjust
part)
Preload:
0.3 - 0.55 Nm (0.03 - 0.055 kgm}
Then add 0.1 mm of shim (idler
gear as individual
13
Clearance
between
cage and cover
0.25
(Shims)
part)
Preload:
0.5 - 1 .O Nm (0.05 - 0.1 kgm}
(Output shaft as individual
14
Backlash between
drive gear and idler gear
0.17 - 0.44
15
Backlash between
idler gear and driven gear
0.17 - 0.44
part)
Replace
40-I 5
MAINTENANCE
STANDARD
MAIN RELIEF, TORQUE CONVERTER
RELIEF VALVE
MAIN RELIEF, TORQUE CONVERTER RELIEF VALVE
A-A
SDWO2129
Unit: mm
No
1
Check item
Clearance
between main
relief valve and valve body
Standard
size
25
Clearance
converter
between torque
Remedv
Criteria
22
relief valve and
Tolerance
Standard
Clearance
clearance
limit
Shaft
Hole
-0.035
+0.013
0.035
-0.045
0.058
-0.035
+0.013
0.035
-0.045
0.058
0.08
0.08
valve body
3
Main relief valve spring

(outer)
Standard
size
Repair limit
Free
Installa-
Installation
Free
Length
tion
load
Length
Installation
Replace
load
length
128
75.3
509 N
(51.9
108
75.3
(inner)
5
402 N
50
42
153N
483 N
(49.3 kg}
104.8
(41 .O kg}
{I 5.6 kg}
40-I 6
124.2
kg}
382 N
(39.0 kg}
48.5
145 N
(14.8 kg}
MAINTENANCE
LUBRICATION
STANDARD
LUBRICATION
RELIEF VALVE
RELIEF VALVE
SDWO2130
Unit: mm
No
Criteria
Check item
Remedv
Repair limit
Standard size
Free Length
1
Lubrication
valve spring
relief
26
Installation
Installation
length
load
23.7
11.8 N
(1.2 kg)
Free Length
Installation
load
Replace
25.2
10.8 N
(1.1 kg}
40-I 7
MAINTENANCE
STANDARD
DRIVE SHAFT
DRIVE SHAFT
_I,
47
~~____yf~Y&-
d\y-
---_-
__-_ _ __-.
40-I 8
MAINTENANCE
STANDARD
CENTER SUPPORT
CENTER SUPPORT
6
SEW02132
Unit: mm
No.
Check item
Criteria
Standard
Tolerance
size
Clearance
between
case
140
and bearing
2
Clearance
between
case
130
and bearing
3
Clearance
between
cou-
80
pling shaft and bearing

4
Clearance
between cou-
75
Standard
Standard
Clearance
clearance
limit
-0.015
Shaft
Hole
-0.036
-0.018
-0.018
-0.061
-0.061
-0.036
-0.018
-0.018
-0.061
-0.061
+0.051
0.032
+0.032
-0.015
0.066
+0.051
0.032
-0.015
0.066
+0.032
pling shaft and bearing
Remedy
size
Tolerance
-0.015
0.029
Replace
0.029
Repair limit
Repair
95
5
Wear of oil seal surface
-0.18
chrome
plating or
-0.087
replace
105
-0.18
-0.087
7
End play of coupling shaft
Preload max. 3.9 Nm (0.4 kgm}
Replace
40-I 9
MAINTENANCE
STANDARD
DIFFERENTIAL
DIFFERENTIAL
13
14
15
i2
40-20
MAINTENANCE
STANDARD
DIFFERENTIAL
Unit: mm
T
No.
Check item
Criteria
Standard
Tolerance
size
1
Clearance
of side bearing (outer race) in
differential
gear assembly
Clearance
of side bearing (inner race) in differ-
120
Clearance
of pinion shaft bearing (outer race)
Clearance
of pinion shaft bearing (inner race)
Clearance
of pinion shaft bearing (inner race)
Clearance
of pilot bearing (outer race)
171.45
of pilot bearing (inner race)
Clearance
between differential
+0.054
0.014
-0.025
+0.014
0.079
+0.045
-0.023
+0.023
-0.020
-0.065
+0.025
+0.026
0.026
-0.014
-0.039
11
120
I
1
Replace
0
-0.015
Clearance
+0.034
1 +0.012
I
1 +0.010
0.012
0.049
carrier and cage

1
clearance
Hole
I
Clearance
Standard
Shaft
180
ential aear assemblv

3
remedy
-0.060
0.106
between spider and differential pinion
bushina
10
Backlash of bevel gear
11
Backlash of differential
12
End olav of pinion aear
13
Free rotating torque of bevel gear
14
Rear face runout of bevel gear
15
G -
Standard thickness
0.30 - 0.41
aear
of shims for stop shaft
0.30 - 0.41
Max. 0.064
Max. 8.34 Nm 10.85 kam\
0.1
Clearance
Replace
a +(O.l f 0.05)
40-2 1
MAINTENANCE
DIFFERENTIAL
STANDARD
r
277*32Nm
:28.25* 3.25kpml
927*
.94.5*
103Nm
10.5koml
-+QV-T-Z
II
_I
SOW02352
40-22
MAINTENANCE
STANDARD
DIFFERENTIAL
Unit: mm
No.
Check item
Thickness
of side gear washer
Criteria
Remedy
Standard size
Tolerance
Repair limit
+0.05
3.8
-0.05
2
Thickness
of pinion gear washer
1.5
100
+O.OQ
1.35
Replace
0
-0.087
40-23
MAINTENANCE
FINAL DRIVE
STANDARD
FINAL DRIVE
SOW02135
Unit: mm
No
Criteria
Check item
Standard
Tolerance
size
Clearance
between
plane-
55
tary shaft and bearing

2
Clearance
ring gear
between
190
hub and bearing
Shaft
Hole
+0.015
+0.002
0
-0.015
Remedy
Standard
Clearance
clearance
limit
-0.002
-0.030
+0.033
-0.004
+0.004
-0.030
-0.063
Standard size
Tolerance
Repair limit
22
+O.l /-0.1
21.5
Thickness of spacer
Backlash between
planet gear and sun gear
0.18 - 0.43
Backlash between
planet gear and ring gear
0.18 - 0.54
Thickness of shim for wheel hub
40-24
Replace
2.0
Replace
MAINTENANCE
STANDARD
MEMORANDA
40-25
MAINTENANCE
STANDARD
AXLE MOUNT
AXLE MOUNT
-.____--
/.
1569*196Nm
~160~20bnl
3
217*32Nm
I28.25*3.25bml
4
I
I
A-A
40-26
__/
/*
.---
ill
-5
P
stlwoz136
MAINTENANCE
STANDARD
AXLE MOUNT
I Init. mm
No.
Check item
Criteria
Standard
Tolerance
size
Clearance
of shaft and hole
310
front support side (after press
Remedy
Standard
Clearance
clearance
limit
1.6
Shaft
Hole
-0.056
+0.489
0.056
-0.137
0.626
+2.300
+0.089
-0.800
-0.056
+0.481
fitting bushing)
2
Clearance
of shaft and hole
320.2
front support side (before

installing bushing)
3
Clearance
of shaft and hole
Replace
260
rear support side (after press

fitting bushing)
4
Clearance
of shaft and hole
270.2
rear support side (before
-0.137
-0.008
+2.300
+0.081
+0.800
0.048
1.6
(see
note)
0.618
installing bushing)
Thickness
of wear plate
Standard size
Tolerance
20
-0.10
Repair limit
-0.25
Thickness
* Note:
of wear plate
+O.l
-0.3
Thickness of rear bushing
*0.1
Thickness of front bushing
*O.l
Replace
The bushings must be in contact with the support at both the front and rear.
40-27
MAINTENANCE
CENTER HINGE PIN
STANDARD
CENTER HINGE PIN
5&6*5.9Nm
(6.0i0.6kra)
(Yhsn
17
m
~$~!~~!$?I,
40-28
277.0*31.9&
(26.25*3.25kaml
(When adjust
(Final
value)
ina
shim)
SDWO2353
MAINTENANCE
STANDARD
CENTER HINGE PIN

Unit: mm
No.
Check item
Criteria
Standard
Remedy
Tolerance
Standard
size
Clearance
between
lower hinge
clearance
100
pin and rear frame

2
Clearance
between
lower hinge
100
pin and spacer (small)

3
Clearance
between
lower hinge
100
pin and bearing

4
Clearance
between
lower hinge
100
pin and spacer (large)

5
Clearance
between
rear frame and
130
spacer (large)
6
Clearance
between front frame
Clearance
between
upper hinge
100
pin and rear frame

8
Clearance
between
upper hinge
100
pin and bearing

9
Clearance
between front frame
Clearance
between
rear frame and
125
bushing
11
Clearance
at press fitted part of
115
seal of upper hinge pin

12
Clearance
at press fitted part of
135
seal of lower hinge pin
13
14
-0.036
+0.054
0.036
-0.058
0.112
-0.036
+0.054
0.036
-0.058
0.112
-0.036
0.016
-0.058
-0.020
0.058
-0.036
+0.054
0.036
-0.058
0.112
-0.043
+0.063
0.043
-0.106
0.169
-0.048
-0.023
-0.025
-0.088
-0.088
-0.036
+0.054
0.036
-0.058
0.112
-0.036
0.016
-0.058
-0.020
0.058
160
and lower hinge bearing

10
Hole
155
and upper hinge bearing

7
Shaft
-0.050
-0.025
-0.025
-0.090
-0.090
-0.043
+0.063
0.043
-0.084
0.146
+0.280
+0.054
-0.126
+0.180
-0.28
+0.310
+0.063
-0.147
+0.210
-0.31
Standard size
Tolerance
Height of lower hinge spacer

(small)
35
*0.1
Height of lower hinge spacer
101.5
*0.1
Replace
(large)
15
Shim thickness for lower hinge and
2.3
retainer
16
Shim thickness for lower hinge and
1.6
Adjust
retainer
17
Shim thickness for upper hinge
1.6
and retainer
40-29
MAINTENANCE
STANDARD
STEERING
COLUMN
STEERING COLUMN
D-D
-__-__-__
----__-__
SDWO2138
Unit: mm
No.
Check item
Criteria
Remedy
I
Standard
Tolerance
Standard
size
1
Clearance
between
and column bushing
40-30
steering shaft
19
Clearance
Shaft
Hole
+0.150
0.05
-0.080
+0.050
0.23
Replace
MAINTENANCE
STANDARD
STEERING
PUMP
STEERING PUMP
A-A
SEW02124
No.
Check item
Criteria
Clearance
between gear case
mm
Remedy
Standard clearance
1
Init.
Clearance
0.10 - 0.15
0.19
0.06 - 0.149
0.20
limit
and side plate, gear

2
Clearance
between
inside diame-
Replace
ter of plain bearing and outside

diameter of gear shaft
3
Insertion depth of pin

Discharge
EOI O-CD
14 +o/-0.5
0.7 - 1.2 kgm
Revolution
Discharge
Standard
Repair limit
(RPM)
pressure
discharge
discharge
(kg/cm)
@/min.)
@/min.)
210
184
170
45 - 55
2500
40-31
MAINTENANCE
STANDARD
STEERING
VALVE
STEERING VALVE
I
No.
SLW01253
Unit: mm
I
Check item
Criteria
Remedy
Standard size
Steering spool return spring
Free
Installed
length
length
37.2
Repair limit
Installed load
32.0
Free
Load
length
limit
56.9 N
45.1 N
15.8 kg1
2
Load check valve spring
20.9
13.2
9.3 i4.9 N
(0.95 kO.5 kg}
Demand spool return spring
Relief valve spring
Check valve return spring
75.2
24.0
21.6
68.5
22.19
17.0
40-32
7.8 N
IO.8 kg)
136.3 N
111.8 N
{I 3.9 kg}
{I 1.4 kg}
182.4 N
145.1 N
(18.6 kg)
(14.8 kg}
2.3 N
1
14.6 kg1
(0.23 kg}
1.8 N
1 (0.18 kg}
Replace
MAINTENANCE
STEERING
STANDARD
CYLINDER
MOUNT
STEERING CYLINDER MOUNT
b'
A-A
SDWO2140
Unit: mm
Remedy
Criteria
Check item
No.
Standard
Tolerance
Standard
clearance
size
Clearance
between
bushing connection
mounting
pin and
60
of steering
Shaft
Hole
+0.200
0.100
-0.074
+O.lOO
0.248
+0.200
0.100
-0.074
+O.lOO
0.248
cylinder rod and frame

2
Clearance
between
mounting
bushing at connection
pin and
60
of steering
Replace
cylinder bottom and frame
Connection
of steering cylinder and
front frame
4
Connection
rear frame
Width of
Width of
boss
hinge
70 +0.8
74 *I
Standard clearance
(Clearance
a + b)
2.2 - 5.0
0
of steering cylinder and
70 -0.5
Max. 1.0
after adjusting shim
74 il
3.0 - 5.5
40-33
MAINTENANCE
STANDARD
BRAKE VALVE
BRAKE VALVE
(RIGHT)
SOW02141
40-34
MAINTENANCE
No
STANDARD
BRAKE VALVE
Unit: mm
Check item
1 Remedv
Criter
Standard
Tolerance
size
1
Clearance
between
Standard
Clearance
clearance
limit
0.25
pedal
mount hole and bracket
Shaft
Hole
-0.025
+O.l
0.175
-0.075
0.025
-0.025
+O.l
0.175
-0.075
0.025
hole
IO
Clearance
between
roller
and pin
IO
0.25
Replace
Standard size
Outside diameter
Tolerance
Repair limit
of roller
30
I
I
Control spring
Return spring
Return spring
16.7 N
28
{I .7 kg}
40-35
MAINTENANCE
STANDARD
BRAKE VALVE
(LEFT)
SDWD2142
40-36
MAINTENANCE
STANDARD
BRAKE VALVE
Unit: mm
No
Check item
Criter
Standard
Remedv
Tolerance
size
1
Clearance
between
Standard
Clearance
clearance
limit
0.25
pedal
mount hole and bracket
Shaft
Hole
-0.025
+O.l
0.175
-0.075
0.025
-0.025
+0.1
0.175
-0.075
0.025
hole
10
Clearance
between
roller
and pin
-I--10
Standard size
Outside diameter
of roller
0.25
Replace
Tolerance
Repair limit
I
29.2
Standard Size
Control spring
Repair limit
Free length
Test height
Test load
Free length
34
21.8
93.2 N
33
Test load
19.5 kg)
5
Control spring
46.3
34.3
459.0 N
45.3
(46.8 kg}
6
Return spring
86.2
58
60.8 N
78
16.2 kg)
7
Spring
17
15
69.6 N
16.2
(7.1 kg)
8
Return spring
31.5
19.5
16.7 N
28
40-37
MAINTENANCE
STANDARD
SLACK ADJUSTER
SLACK ADJUSTER
SEW02143
No.
Criteria
Check item
Standard
Remedy
Tolerance
size
Shaft
1
Clearance
between
Unit: mm
Standard
Clearance
clearance
Limit
Hole
body and
oiston
Replace
Free
Test
Test
Free
Test
length
length
load
length
load
198
38
43.2 N
14.4 kg)
39.2
33
66.7 N
40-38
MAINTENANCE
STANDARD
MEMORANDA
40-39
MAINTENANCE
BRAKE
STANDARD
BRAKE
/I: !
14J
___-_-___-_____________-_I
b_----____-_____-__-____
I+
40-40
--kL/~
---___
__--
7
i.J
MAINTENANCE
STANDARD
BRAKE
Unit: mm
No.
Check item
Criteria
Remedy
Standard size
Return spring
Repair limit
Free
Install
Install
Free
Install
length
length
load
length
load
80.2
69.9
600.2 N
72.2
539.4 N
(61.2 kg}
Standard size
155 kg)
Tolerance
Repair
limit
Thickness
of plate
Thickness
of disc
Total thickness of plates
2.3
kO.08
2.0
3.8
*to.1
4.6
38.8
kO.98
35.0
42.0
+0.097
and discs
5
Wear of piston seal contact

surface
Wear of piston seal contact
38.3
+0.089
surface
7
Replace
Backlash between outer
0.21 - 0.65
gear and plate

8
Backlash between
inner
0.31 - 0.74
gear and disc
40-41
MAINTENANCE
STANDARD
PARKING
BRAKE
PARKING BRAKE
SDWcl2145
Unit: mm
No.
Check item
Criteria
Remedy
Standard size
1
Parking brake spring

(outside)
Repair limit
Free
Install
Install
Free
Install
length
length
load
length
load
77.7
54.0
1425 &22 N
69.9
(145.2 Q.2 kg}

2
Parking brake spring
77.8
54.0
(inside)
535 k5.3 N
70.0
(54.6 55.4 kg}

Standard size
Tolerance
1258 N
(128.3 kg}
482 N
(49.1 kg}
Repair
limit
Separate
Thickness
4.0
of plate
*0.05
3.9
0.15
0.6
3.2
*o. 1
35.0
0.45
+0.175
0.235
Distortion
Thickness
4
Brake
Depth of lining
disc
groove
Thickness
lining
40-42
Load of wave spring
0
if
0.7
+0.075
Replace
MAINTENANCE
STANDARD
MEMORANDA
40-43
MAINTENANCE
HYDRAULIC
STANDARD
PUMP
HYDRAULIC PUMP
SAR(4)-160
.6Nm
sDwo2146
Unit: mm
Remedy
Criteria
Check item
10.
Clearance
Standard size
1
Clearance
between gear case
0.11 - 0.16
0.19
0.06 - 0.140
0.20
limit
and side plate gear

2
Clearance
between
inside
Replace
diameter of plain bearing and

outside diameter of gear shaft
3
14
0
-0.5
9.8 - 14.7 Nm
{I .O - 1.5 kgm}
Discharge:
Revolution
Discharge
Standard
Repair limit
(rpm)
pressure
Discharge
Discharge
MPa {kg/cm)
(PI min.)
@/min.)
328
303
Oil: EOIO-CD
Temperature:
45 - 55C
20.6
2,200
40-44
12101
MAINTENANCE
STANDARD
SWITCH, PPC PUMP
SWITCH, PPC PUMP

SAR(3)-63 + SAR(I)-28
I-
SAR(3)-63
SAR(l)-28
I.
A-A
SOW02147
Unit: mm
UIICZCIR
V.
Clearance
1LsilII
between gear
case and side plate gear
Clearance
between
,LG,
IQ
I\FillEJ
Model
Standard clearance
Clearance
limit
SAR(3) - 63
0.10 - 0.15
0.19
SAR(l)
- 28
0.10 - 0.15
0.19
SAR(3) - 63
0.06 - 0.149
0.20
0.064 - 0.119
0.20
Model
Standard size
Tolerance
SAR(3) - 63
10
inside diameter of plain

bearing and outside
Replace
SAR(l)
- 28
diameter of gear shaft

3
0
-0.5
SAR(l)
- 28
10
0
-0.5
Rotating torque of spline
SAR(3) - 63
6.9 - 11.8 Nm
shaft
(0.7 - 1.2 kgm}

SAR(l)
- 28
2.0 - 4.9 Nm
(0.2 - 0.5 kgm}
Model
Discharge
Oil: EOI O-CD
Temperature:
Revolution
(rpm)
45 - 55C
SAR(3) - 63
2,500
Discharge
Standard
Repair limit
pressure
discharge
discharge
MPa {kg/cm?
(P/min)
(P/min)
20.6
145
134
67
60
1210)
SAR(l)
- 28
2,500
3.7
1381
40-45
MAINTENANCE
STANDARD
PPC VALVE
PPC VALVE
FOR BUCKET, BOOM
SEW02148
Unit: mm
No.
Check item
Criteria
Standard size
Centering
spring
Remedy
Repair limit
Free length
Installed
Installed
X O.D.
length
load
load
52.8 X 12.3
36.0
29.4 N
23.5 N
damaged
(3.0 kg)
12.4 kg}
deformed
39.2 N
31.4 N
14.0 kg)
13.2 kg)
(bucket DUMP, boom
Free length
Installed
LOWER)
2
Centering
pin (bucket
52.8 X 12.3
36.0
TILT, boom RAISE)

3
Metering spring
31.4 x 7.4
29.4
16.7 N
Il.7
40-46
kg)
13.7 N
Il.4
kg)
Replace
spring if
or
MAINTENANCE
PPC VALVE
STANDARD
OPTION
SEW02149
Unit: mm
No.
Remedv
Check item
Repa r limit
Standard size
Centering
Centering
spring
pin
Metering spring
Free length
Installed
Installed
X O.D.
length
load
load
52.8 X 12.3
36.0
29.4 N
31.4 N
damaged
(3.0 kg)
(3.2 kg)
deformed
39.2 N
23.5 N
14.0 kg)
12.4 kg)
16.7 N
13.7 N
52.8 X 12.3
31.4 x 7.4
36.0
29.4
Free length
Installed
Replace
spring if
or
40-47
MAINTENANCE
STANDARD
CUT-OFF VALVE
CUT-OFF VALVE
A-A
Qq
34.3*4.9Nm
(3.5*0.5lmd
L
B-B
SDW02150
Unit: mm
No.
Check item
I
I
I
Criteria
Standard size
Free length
40-48
Unload valve spring
Check valve spring
1
I
36.95
33
Repair limit
Installed
Installed
length
load
load
3.0
35.3 N
26.4 N
(3.6 kg1
(2.9 kg)
16.7 N
1.4 N
(0.17 kg}
(0.14 kg}
2.0
Remedy
Free length
Installed
Replace
MAINTENANCE
STANDARD
MEMORANDA
40-49
MAINTENANCE
MAIN CONTROL VALVE
STANDARD
MAIN CONTROL VALVE

2-SPOOL VALVE
10
-5
-kg.
186.3*
9.8Nm
11
\
SEW02151
40-50
MAINTENANCE
STANDARD
MAIN CONTROL VALVE
Unit: mm
No.
Check item
Criteria
Standard size
T
Bucket spool return
Free length
Installed length
64.4
62.2
spring (Large)
Bucket spool return
14.9
18.6
spring (Small)
Boom spool return
64.4
62.7
spring (Large)
4
Boom spool return
18.6
15.2
spring (Small)
5
Boom spool return
89.2
82.0
spring (Large)
6
Boom spool return
42.0
42.0
82.4
82.0
Remedv
Installed load
Repair limit
Free length
Installed load
190N
152 N
{I9.4 kg)
(15.5 kg}
112.8 N
90 N
{I 1.5 kg}
(9.2 kg)
149 N
119.6 N
(15.2 kg}
(12.2 kg}
104N
83.4 N
(10.6 kg}
(8.5 kg)
616 N
554N
(62.8 kg}
(56.5 kg}
Replace
spring (Small)
7
Bucket spool return

spring (Large)
Bucket spool return
182.4 N
163.8 N
(18.6 kg}
(16.7 kg}
42.0
42.0
52.3
38.0
86.3 N
68.6 N
18.8 kg)
17.0 kg1
spring (Small)
9
10
11
Main valve spring
Check valve spring
Suction valve spring of
78.2
52.0
27.9
18.0
safety valve
12
13
27.9
18.0
53.0
42.1
spring
14
15
Unloader valve spring
Relief valve poppet
82.7
47
49.3
43.3
spring
18.8 N
14.7 N
{I .92 kg}
(1.5 kg)
6.9 N
5.9 N
(0.70 kg}
IO.6 kg)
6.9 N
5.9 N
(0.70 kg)
IO.6 kg1
137 N
123.6 N
(14.0 kg)
(12.6 kg}
49 N
39 N
15.0 kg1
14.0 kg)
209.9
167.7 N
(21.4 kg}
(17.1 kg}
40-51
MAINTENANCE
STANDARD
MAIN CONTROL VALVE
3-SPOOL VALVE
__
17
\
68.6*9.8Nm
,('i'bmt
cv
/
22.1*2.5Nm
(2.25*0.25kpm)
SEW02152
40-52
MAINTENANCE
STANDARD
MAIN CONTROL VALVE

Unit: mm
1 Remedy

Replace
Boom spool return s
16
17
18
19
27.9

spring
53.0
Unloader valve spring
82.7
Relief valve poppet

spring
49.3
18.0
42.1
47
43.3
6.9 N
5.9 N
(0.70 kg}
(0.6 kg)
137N
123.6 N
(14.0 kg}
{I 2.6 kg}
49 N
39 N
16.0 kg1
14.0 kg1
209.9 N
167.7 N
j21.4 kg)
(17.1 kg)
40-53
MAINTENANCE
STANDARD
HYDRAULIC
CYLINDERS
STEERING
HYDRAULIC
CYLINDERS
CYLINDER
(Width across flats: 60 n
BOOM CYLINDER
SOW02154
BUCKET CYLINDER
?
40-54
0
MAINTENANCE
STANDARD
HYDRAULIC
CYLINDERS
Unit: mm
No.
Check item
Criteria
Name of
Std.
cylinder
size
Steering
55
TRemedv
Tolerance
Shaft
Hole
-0.030
Standard
Clearance
Clearance
limit
0.327
-L
Clearance
between rod
and bushing
Boom
110
Bucket
Clearance
between
piston rod mounting

and diameter of hole
120
Steering
+0.151
0.036
-0.076
+0.006
0.227
-0.036
+0.274
0.096
-0.090
+0.060
0.364
-0.043
+0.203
0.091
-0.106
+0.048
0.309
+o. 174
0.100
-0.074
+o. 100
0.248
60
pin
Boom
120
0.469
0.469
Replace
1.0
+o. 1
0
Bucket
120
+0.307
+0.220
Clearance
between
Steering
cylinder bottom
mounting pin and
bushing
+0.174
0.100
-0.074
+O.lOO
0.248
60
Boom
120
1.0
+0.307
+0.220
Bucket
120
+0.307
+0.220
Cylinder bore
Standard size
110
Steering
Tolerance
Repair limit
0
+0.15
Boom
200
0
+0.2
225
0
+0.2
40-55
MAINTENANCE
BUCKET LINKAGE
STANDARD
BUCKET LINKAGE
Section A-A
a
Section D-D
'b
Section E-E
"
Section F-F
Section G-G
40-56
a'
-b
'b
Section H-H
Section J-J
MAINTENANCE
STANDARD
BUCKET LINKAGE
Unit: mm
No.
Check item
Criteria
Tolerance
Standard
size
Clearance between pin and bushing
110
Remedy
Shaft
Hole
-0.036
+0.307
Standard
Clearance
clearance
limit
0.256
1.0
at boss ends and bucket link.

2

at joint of and bucket
Replace,
also if

at joint of and frame
120
at joint of bucket cylinder bottom
-0.090
+0.220
0.397
other
-0.036
+0.307
0.256
parts are
-0.090
+0.220
0.397
biting into
pin.
and frame
5

at joint of bucket cylinder rod and
lever

at joint of tilt lever and

at joint of boom cylinder bottom and
frame
120
at joint of boom cylinder rod and
-0.036
+0.307
0.256
-0.090
+0.220
0.397
1.0
Width between
Width
Standard clearance
bosses
of hinge
(Clearance a + b)
143
140
3.0
153
150
3.0
180
176.8
3.2
Joint of bucket cylinder and frame

9
Insert
10
Joint of and frame
11
Joint of and bucket
shims on
both
sides to
make
12
Joint of bucket link and bucket
145
142
3.0
13
Joint of tilt lever and bucket link
144
142
2.0
on both
240
237
3.0
left and
143
140
3.0
sides less
clearance
14
Joint of tilt lever and
15
Joint of bucket lever and bucket
right
than
cylinder
1.5mm
16
Joint of boom cylinder and boom
17
Joint of boom cylinder and frame
125
122
3.0
40-57
MAINTENANCE
STANDARD
BUCKET
BUCKET
Section
A-A
Section
B-B
2
L17CZO25
Unit: mm
No
Criteria
Wear of bucket tooth
Thickness
of shims for tooth (Clearance
between
tooth and bucket)

3
Tightening
torque of mounting
bolt for bucket tooth
Tightening
torque of mounting
bolt for corner tooth
40-58
Remedy
Standard size
Repair limit
61
23
Replace
MAINTENANCE
STANDARD
BUCKET POSITIONER
BUCKET POSITIONER
AND BOOM KICK-OUT
AND BOOM KICK-OUT
View
Section
A-A
L17DV004
Unit: mm
No
Check item
Clearance
of bucket positioner
Clearance
of boom kick-out switch
Tightening
torque of mounting
bolt for adjuster
Tightening
torque of mounting
bolt for switch
Criteria
Remedy
switch
3-5
Adjust
9.Ok3.5 kgm
1.85.2 kgm
Retighten
40-59
MAINTENANCE
STANDARD
ROPS CAB
ROPS CAB
*
!r
#; ;;
----_
-1--j-K
__LT_
.-__A-
,/
$7
SDWO2159
40-60
Komatsu America International Company

440 North Faitwav Drive
I
Vernon Hills, IL 66061-8112 U.S.A.
1
Attn: Technical Publications
1
Fax No. (847) 970-4186
PROPOSAL
FOR MANUAL REVISION
FOR INTERNAL
NAME OF COMPANY:
USE ONLY
No. PMR
LOCATION:
PHONE NO:
DATE:
DEPARTMENT:
NAME:
VlANUAL NAME:
MANUAL NO:
MACHINE MODEL:
j/N IF APPLICABLE:
AGE NO:
ROBLEM:
Attach photo or sketch.

If more space is needed, use another sheet.
FOR INTERNAL
CORRECTIVE
HPFMRI
081696
USE ONLY
ACTION:

Shop Manual Wa500

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CEBM001202

PRODUCT PUBLICATIONS INFORMATION

PARTS BOOK - PAPER:

PARTS BOOK - MICROFICHE:

OPERATION & MAINTENANCE MANUAL:

REQUISITION FOR TECHNICAL SERVICE PUBLICATIONS AND SERVICE FORMS

Komatsu America International Company

PURCHASE ORDER NO.

CITY, STATE, ZIP CODE

PUBLICATION FORM NO.

CURRENT PRICES WILL BE CHARGED

The affected pages are indicated with the

New pages to be added

LIST OF ORIGINAL, NEW AND REVISED PAGES

LIST OF ORIGINAL, NEW AND REVISED PAGES

LIST OF ORIGINAL, NEW AND REVISED PAGES

LIST OF ORIGINAL, NEW AND REVISED PAGES

LIST OF ORIGINAL, NEW AND REVISED PAGES

LIST OF ORIGINAL, NEW AND REVISED PAGES

IMPORTANT SAFETY NOTICE

7. Before adding oil or making repairs, park the machine on

1. Before carrying out any greasing or repairs, read all the

8. Before starting work, lower blade, ripper, bucket or any

2. When carrying out any operation, always wear safety

9. When disassembling or assembling, support the machine

6. Decide a place in the repair workshop to keep tools and

23. When measuring hydraulic pressure, check that the

18. As a general rule, do not use gasoline to wash parts. In

HOW TO READ THE SHOP MANUAL

HOW TO READ THE SHOP MANUAL

REVISED EDITION MARK

Shop manuals are issued as a guide to carrying out repairs.

When a manual is revised, an edition mark (

These various volumes are designed to avoid duplication of

Consecutive page number for each

Special safety precautions are

Special technical precautions or

Weight of parts or systems.

Places that require special

Places where oil, water or fuel

Places where oil or water must be

Heavy parts (25 kg or more) must be lifted with a

If a part cannot be smoothly removed from the machine by

Slinging with one rope may cause turning of the

Allowable load (tons)

Do not sling a heavy load with ropes forming a wide

The allowable load value is estimated to be 1/6 or 1/7 of

Sling wire ropes from the middle portion of the hook.

Used in places requiring an immediately effective, strong adhesive.

Features: Resistance to heat, chemicals

Used as adhesive or sealant for gaskets and packing of power train

Features: Resistance to heat

Main applications, features

Used as adhesive or sealant for metal, glass or plastic.

Used as sealant for machined holes.

Features: Silicon based, resistant to heat, cold.

Features: Silicon based, quick hardening type.

Used as lubricant for sliding parts (to prevent squeaking).

Used to prevent seizure or scuffing of the thread when press fitting or

General purpose type

Used for normal temperature, light load bearing at places in contact

Used as sealant for various threads, pipe joints, flanges.

Used for places with heavy load.

STANDARD TORQUE REQUIREMENTS